Samson 3731-5, Type 3731-5 Mounting And Operating Instructions

Series 3731
Type 3731-5

Electropneumatic Ex d Positioner

with FOUNDATION™fieldbus communication

Mounting and
Operating Instructions

EB 8387-5 EN

Firmware version R 1.4x

Edition

March 2016

Fig. 1 · Type 3731-5

EB + CD

2 EB 8387-5 EN

DANGER!

indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

WARNING!

indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.

NOTICE

indicates a property damage message.

Note: Supplementary explanations, informa

-

tion and tips

Definitions of the signal words used in these instructions

Contents

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 5

2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 7

3.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . . 9

3.2.2 Configuration using the NI-BUS™ Configurator

. . . . . . . . . . . . . . . . . 9

3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Attachment to the control valve – Mounting parts and accessories . . . 13

4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 20

4.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 22

4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 24

4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26

4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 26

4.6 Required mounting parts and accessories. . . . . . . . . . . . . . . . 28

5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 37

6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 38

6.1 Rotary pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.2 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.3 Readings on display. . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.2 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 40

7.3 Checking the operating range of the positioner . . . . . . . . . . . . . 41

7.4 Determining the fail-safe position. . . . . . . . . . . . . . . . . . . . 42

7.5 Positioner initialization. . . . . . . . . . . . . . . . . . . . . . . . . 43

7.5.1 Initialization based on MAX maximum range . . . . . . . . . . . . . 44

EB 8387-5 EN 3

Contents

7.5.2 Initialization based on NOM nominal range . . . . . . . . . . . . . . 45

7.5.3 Initialization based on MAN manually selected range . . . . . . . . . 47

7.5.4 SUB substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 48

7.6 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.7 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 53

8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 54

8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 55

8.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 56

8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 56

8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 57

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58

11 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

12 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 78

12.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 80

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

13.1 Selecting the valve characteristic . . . . . . . . . . . . . . . . . . . . 82

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4 EB 8387-5 EN

Contents

Note concerning these Mounting and Operating Instructions

These instructions EB 8387-5 describe the mounting, start up and on-site operation of the
Type 3731-5 Positioner.
You can find additional information on the enclosed CD-ROM (CD 8387-5) or on the Internet
at http://www.samson.de.

1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start up and opera

-

tion of the positioner:

4

The positioner may only be mounted, started up or operated by trained and experi

­enced 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.

4

Explosion-protected versions of this positioner 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.

4

Any hazards that could be caused by the process medium, the operating pressure, the
signal pressure or by moving parts of the control valve are to be prevented by means
of the appropriate measures.

4

If inadmissible motions or forces are produced in the actuator as a result of the supply
pressure level, it must be restricted by means of a suitable supply pressure reducing
station.

To avoid damage to any equipment, the following also applies:

4

Proper shipping and appropriate storage are assumed.

4

Do not operate the positioner with the back of the positioner/vent opening facing up

-

wards.

4

Do not ground electric welding equipment near to the positioner.

Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC and
2004/108/EC.
The Declaration of Conformity is included on the enclosed CD-ROM.

EB 8387-5 EN 5

Important safety instructions

Vent opening

2 Article code

Positioner Type 3731 - 5 x x x x x x 0 0 0 x 1 x 0 0 0

With LCD, autotune, F

OUNDATION™ fieldbus

Explosion protection

ATEX:
II 2G Ex d IIC T6,T5,T4 Gb; II 2G Ex de IIC T6,T5,T4 Gb; II 2D Ex tb IIIC T80°C DB IP66
II 2G Ex d IIC T6 Gb; II 2G Ex de IIC T6 Gb; II 2D Ex tb IIIC IP65 T80°C

2 1

FM/CSA:
Class I, Div. 1+2, Groups B, C, D; Class I, Zone 1, Groups IIB+H2;
Class I, Div. 1+2 Groups E, F, G; Class III/
Class I, Zone 1, Group IIB+H2 T4...T6; Class I, Div. 1+2, Groups B, C, D T4...T6;
Class II, Div. 1, Groups E, F, G

2 3

JIS: Ex d IIC T6 2 7

Options (additional equipment)

Without 0 0

Binary input 0 3

Forced venting 0 5

Diagnostics

EXPERT 1

EXPERT+/PST 2

Electrical connections

2x M20 x 1.5 1

2x ½ NPT 2

Explosion-protection certificates

As specified in Explosion protection 0

IECEx: Ex d IIC T6, T5, T4 Gb; Ex d e IIC T6, T5, T4 Gb; Ex tb IIIC T80°C Db IP66 2 1 2

GOST: 1Ex d IIC T6/T5/T4 Gb X; 1Ex d e IIC T6/T5/T4 Gb X; Ex tb IIIC T 80°C Db X 2 1 3

Special applications

Without 0

Positioner compatible with paint (IP 41/NEMA 1) 1

Special version

Without 0 0 0

6 EB 8387-5 EN

Article code

3 Design and principle of

operation

The electropneumatic Ex d positioner is at

­tached to pneumatic control valves. It is used
to assign the valve stem position (controlled
variable x) to the control signal (reference
variable w). The input signal received from
a control system is compared to the travel or
rotational angle of the control valve, and a
signal pressure (output variable y) is pro

-

duced for the pneumatic actuator.

The positioner basically consists of an
electrical travel sensor system (2), an analog
i/p converter (6) with downstream air ca

­pacity booster (7) and the electronic unit
with a microcontroller (5).

In case of a system deviation, the actuator is
either vented or filled with more air. The sig

­nal pressure supplied to the actuator can be
limited to 1.4 bar, 2.4 bar or 3.7 bar by
software or on site at the positioner.

EB 8387-5 EN 7

Design and principle of operation

%

S

mm

%

mm

w

x

G

PD

Serial

Interface

16

22

20

23

2

4

17

5

19

3

6

7

8

1

9

x

y

Fig. 2 · Functional diagram

1 Control valve
2 Travel sensor
3 PD controller
4 IEC 61158-2

interface module
5 Microcontroller
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator

16 Display
17 Forced venting control

(optional)

19 D/A converter
20 Serial interface (SSP)
22 Rotary pushbutton
23 Binary input

(optional)

FOUNDATION

™

fieldbus

IEC 61158-2

A constant air stream to the atmosphere is
created by the flow regulator (9) with a
fixed set point. The air stream is used to
purge the inside of the housing as well as to
optimize the air capacity booster (7). The
i/p converter (6) is supplied with a constant
upstream pressure by the pressure regulator
(8) to make it independent of the supply
pressure.

All parts are enclosed in an Ex d housing.
The electrical cables are connected over a
separate terminal compartment which also
has Ex d protection.

The standard EXPERT diagnostics are inte

-

grated into the positioner. It provides infor

-

mation on the positioner and generates di

­agnostic and status messages, which allow
faults to be pinpointed quickly.

The positioner is suitable for the following
types of attachment using the corresponding
accessories:

4

Direct attachment to SAMSON
Type 3277 Actuator: Section

4.1

4

Attachment to actuators acc. to
IEC 60534-6 (NAMUR): Section 4.2

4

Attachment to Type 3510 Micro-flow
Valve: Section 4.3

4

Attachment to rotary actuators acc. to
VDI/VDE 3845: Section 4.4

3.1 Additional equipment

Binary input

The positioner has an optional binary input.

Connected at terminals A-B:
The binary input for DC voltage signals al

­lows process information to be exchanged
over the FOUNDATION™fieldbus network.

Connected at terminals B-C:
This input connects a floating contact which
is powered by the positioner. The switching
state of the binary input can be indicated
over the F

OUNDATION

™

fieldbus network.

Forced venting

The i/p converter stops working if the oper

­ating voltage supply to the relevant terminals
is interrupted. The positioner can no longer
operate and the control valve moves to the
fail-safe position determined by the actua

-

tor, independent of the reference variable.

Extended EXPERT

+

valve diagnostics

Refer to Table 5 on page 30 for order num­bers.

EXPERT+is an optional diagnostic firmware
integrated in the positioner which allows the
predictive, status-oriented maintenance of
pneumatic control valves. It upgrades the
standard EXPERT diagnostics firmware in­corporated in the positioner. The upgraded
version provides extended functions to pin

­point valve parameters that have worsened,
allowing the user to plan predictive mainte

­nance and service work before malfunctions
can affect the process, causing unscheduled
plant shutdowns.
The extended EXPERT

+

diagnostics can be

activated later at the positioner by purchas

­ing an activation code or using a USB
dongle in conjunction with TROVIS-VIEW
software when

EXPERT

+

is not already acti

-

vated on delivery of the positioner.

8 EB 8387-5 EN

Design and principle of operation

3.2 Communication

The positioner is completely controlled over
the digital signal transmission implemented
according to FOUNDATION™ fieldbus spec

-

ification.

Data are transmitted as bit-synchronous cur

­rent modulation at a rate of 31.25 kbit/s
over twisted-pair cables conforming to
IEC 61158-2.

3.2.1 Configuration using

TROVIS-VIEW software

Refer to Table 5 on page 30 for order num

-

bers.

The positioner can be configured using the
TROVIS-VIEW configuration and operator
interface.
The positioner is equipped with an addi

­tional digital SERIAL INTERFACE to allow a
computer to be connected over an adapter
cable from the RS-232 or USB port 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.

Note: Instructions on how to install and ope

-

rate the TROVIS-VIEW software are inclu

­ded in the Configuration Manual
KH 8387-5 on the CD-ROM.

3.2.2 Configuration using the
NI-BUS™

Configurator

The NI-FBUS™ 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 con

-

nect it to the FOUNDATION™ fieldbus.

The integrated function blocks are linked us

-

ing the NI-FBUS™

Configurator.

EB 8387-5 EN 9

Design and principle of operation

3.3 Technical data

10 EB 8387-5 EN

Design and principle of operation

Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Rated travel Adjustable Direct attachment to Type 3277: 3.6 to 30 mm

Attachment acc. to IEC 60534-6 (NAMUR): 3.6 to 200 mm
Attachment to rotary actuators (VDI/VDE 3845): 24° to 100°

Travel range Adjustable Adjustable within the initialized travel/angle of rotation;

travel can be restricted to

1

5

at the maximum

Bus connection Fieldbus interface acc. to IEC 61158-2 bus-powered

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

Communication

Fieldbus Data transmission as per F

OUNDATION™ fieldbus specification,

Communication Profile Class: 31 PS, 32 L;
Interoperability tested according to Interoperability Test System (ITS) Revision 4.6

Execution time

AO FB: 20 ms DI FB: 40 ms PID: 60 ms

Local communication SAMSON SSP interface and serial interface adapter

Software requirements (SSP): TROVIS-VIEW with database module 3731-5

Permissible operating
voltage

9 to 32 V DC · Powered over bus line
The limits in the test certificate additionally apply.

Max. operating current 15 mA

Additional current in case of fault 0 mA

Supply air Pressure Type 3731-521, Type 3731-527: 1.4 to 7 bar (20 to 105 psi),

Type 3731-523: 1.4 to 6 bar (20 to 90 psi)

Air quality Compliance with ISO 8573-1: 2004

Max. particle size and density: Class 4
Oil content: Class 3
Moisture and water: Class 3
Pressure dew point: At least 10 K beneath the lowest ambient temperature to be
expected

Signal pressure (output) 0 bar up to supply pressure

Characteristic Linear/equal percentage/reverse equal percentage

User-defined (over operating software and communication)
Butterfly valve/Rotary plug valve/Segmented ball valve: linear/equal percentage
Deviation from terminal-based conformity≤1 %

Hysteresis

≤

0.3 %

Sensitivity

≤

0.1 %

Direction of action Reversible

Air consumption Independent from supply pressure 110 l

n

/h

Air output
capacity

to fill actuator

with air

At∆p = 6 bar: 8.5 mn³/h · At∆p = 1.4 bar: 30 mn³/h · K

Vmax(20° C)

= 0.09

to vent actuator

At∆p = 6 bar: 14.0 m

n

³/h · At∆p = 1.4 bar: 4.5 mn³/h · K

Vmax(20° C)

= 0.15

EB 8387-5 EN 11

Design and principle of operation

Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Influences Temperature:≤0.15/10 K · Supply air: None

Vibration:≤0.25 % up to 2000 Hz and 4 g acc. to IEC 770

EMC Complying with requirements of EN 61000-6-2, EN 61000-6-3, EN 61326-1 and NAMUR

Recommendation NE 21

Electrical connections Two threaded connections with ½ NPT thread, optionally with M20 x 1.5

Screw terminals for 2.5 mm² wire cross-section
Degree of protection IP 66/NEMA 4 X
Perm. storage

temperature

–60 to 80 °C

Materials Housing Die-cast aluminum EN AC-AlSi10Mg(Fe) (EN AC-44300) acc. to DIN EN 1706

chromated and powder paint coated

External

parts

Stainless steel 1.4571 and 1.4301

Weight Approx. 2.5 kg
Compliance

·

·

Additional equipment

Option: Binary input, galvanically isolated

Connection Terminals A-B

Voltage input 0 to 30 V DC,
reverse polarity protection

Terminals B-C
for external floating contact

Input Current consumption: 3.5 mA at 24 V

Static destruction limit: 40 V

R < 100Ω; contact loadability: 100 mA
Static destruction limit: 20 V/5.8 mA

Signal “1“ at Ue > 5 V
Signal “0“ at Ue < 3 V

Option: Forced venting, galvanically isolated

Input 0 to 40 V DC/0 to 28 V AC, reverse polarity protection 45 V DC/32 V AC,

input resistance≥7 k

Ω

Signal Fail-safe position at an input voltage≤3 V · Normal operation at an input voltage > 5.5 V

Summary of explosion protection certificates

12 EB 8387-5 EN

Design and principle of operation

Type

3731- Certificate Type of protection/comments

521

EC-type
examination
certificate

Number
Date

PTB11 ATEX 1014 X
2012-07-26

II 2G Ex d IIC T6,T5,T4 Gb;
II 2G Ex de IIC T6,T5,T4 Gb;
II 2D Ex tb IIIC T80°C DB IP66

EC-type
examination
certificate

Number
Date

PTB05 ATEX 1058
2006-07-21

II 2G Exd IIC T6 Gb;
II 2G Exde IIC T6 Gb;
II 2D Ex tb IIIC IP65 T80°C

Number
Date
Valid until

RU C-DE-GB08.B.00697
2014-12-15
2019-12-14

1Exd IIC T6/T5/T4 Gb X;
1Exd e IIC T6/T5/T4 Gb X;
Ex tb IIIC T80°C Db X

Number
Date

IECEx PTB11.0084X
2011-09-14

Exd IIC T6, T5, T4 Gb;
Exd e IIC T6, T5, T4 Gb;
Ex tb IIIC T80°C Db IP66

INMETRO

Number
Date
Valid until

IEx 13.0193X
2013-10-15
2016-10-14

Exd IIC T* Gb;
Exde IIC T* Gb;
* See ambient temperature

KCS

Number
Date
Valid until

13-KB4BO-0036
2013-01-31
2016-01-31

Exd IIC T6/T5/T4

On request

4 Attachment to the control

valve – Mounting parts and
accessories

WARNING!

Attach the positioner, keeping the following
sequence:

1. Mount the positioner on the control valve

2. Connect the supply air

3. Connect the electrical power

4. Perform the start-up settings

The positioner is suitable for the following
types of attachment:

4

Direct attachment to SAMSON
Type 3277 Actuator

4

Attachment to actuators according to
IEC 60534-6 (NAMUR)

4

Attachment to Type 3510 Micro-flow
Valve

4

Attachment to rotary actuators

NOTICE

Attach the positioner to the control valve,
observing the following instructions to avoid
damaging the positioner.

–

Use only the mounting parts/accessories
listed in the Tables 1 to 5 (pages 28 and

30) to mount the positioner. Observe the
type of attachment.

–

The positioner is fitted with pneumatic
connections with ¼ NPT threads. If you
need G ¼ threads, attach the connecting
plate (6) listed in the accessories.

–

Observe the assignment between lever
and pin position (see travel tables on
page

14).

–

Fit a signal pressure restriction (Table 5
on page 30) for actuators with di

-

aphragm areas less than 240 cm².

Lever and pin position

The positioner is adapted to the actuator
and to the rated travel by the lever on the
back of the positioner and the pin inserted
into the lever.

The travel tables on page 14 show the maxi

­mum adjustment range at the positioner. The
travel that can be implemented at the valve
is restricted by the pin position used and ad

­ditionally by the selected fail-safe position
and the required compression of the actua

-

tor springs.

The positioner is standard equipped with the
lever M (pin position 35).

Note: If the standard mounted lever M is re

­placed, 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.

EB 8387-5 EN 13

Attachment to the control valve – Mounting parts and accessories

Fig. 3 · Lever M with pin position 35 (delivered state)

14 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

Travel tables

Note: The lever M is included in the scope of delivery.
Levers S, L, XL for attachment according to IEC 60534-6 (NAMUR) are available as accesso

-

ries (see Table 3 on page 30).

Direct attachment to Type 3277-5 and Type 3277 Actuators

Actuator size Rated travel Adjustment range at positioner

Required

lever

Assigned

pin position

[cm²] [mm] Min. Travel Max.

120 7.5 5.0 to 25.0 M 25

120/175/240/350 15 7.0 to 35.0 M 35

300/355/700 30 10.0 to 50.0 M 50

Attachment according to IEC 60534-6 (NAMUR)

SAMSON valves/Type 3271 Actuator Other valves/actuators

Required

lever

Assigned

pin position

Actuator size Rated travel

[cm²] [mm] Min. Travel Max.

60 and 120 with
Type 3510 Valve

7.5

3.6

to 18.0 S 17

120 7.5 5.0 to 25.0 M 25

120/175/240/350 15

7.0 to 35.0 M 35

700/750 7.5

355/700/750 15 and 30 10.0 to 50.0 M 50

1000/1400/2800 30 14.0 to 70.0 L 70

1000/1400/2800 60 20.0 to 100.0 L 100

1400/2800 120 40.0 to 200.0 XL 200

Attachment to rotary actuators according to VDI/VDE 3845

Rotary actuators

Required

lever

Assigned

pin position

Min. Opening angle Max.

24 to 100° M 90°

4.1 Direct attachment

4.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 28 for required
mounting parts and accessories.

Actuator with 120 cm²

NOTICE

If a solenoid valve or similar is additionally
mounted to the control valve, observe the
following instructions which differ from the
instructions otherwise described:

–

The switchover plate (9) is omitted.

–

The signal pressure must be routed from
the signal pressure output over the con

­necting plate (order no. 1400-6820) to
the actuator.

– Fit the screw-in restriction (accessories,

order no. 1400-6964/item no.
0390-1424) into the signal pressure out­put.

–

Do not remove the screw plug (4) at the
back of the positioner.

Depending on the type of positioner attach

­ment, the signal pressure is routed either left
or right of the yoke through a bore to the
actuator diaphragm.

1.

Refer to Fig. 4 to select the symbol to
match the required fail-safe position
and how the positioner is attached:

Fail-safe position:

“Actuator stem extends“ = Air-to-open
“Actuator stem retracts“ = Air-to-close
Positioner attachment: Left or right with
view looking onto the switchover plate

2. Align the marking of the switchover
plate (9) to the corresponding symbol
and mount the plate on the actuator
yoke.

3. If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are re

-

quired, the connecting plate (6), mak

­ing sure both seal rings (6.1) are
seated properly.

4. Remove screw plug (4) on the back of
the positioner and seal the signal pres

-

sure output "Output 38" on the con

­necting plate (6) or on the pressure
gauge bracket (7) with the stopper (5)
included in the accessories.

5. 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.

6. Press brass restriction (accessories,
order no. 1400-6964/item no.
0390-1423) into the seal of the signal
pressure input at the actuator yoke.

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

8. 15 mm travel: Keep the follower pin
(2) at lever M (1) on the back of the
positioner in the pin position 35 (deliv

-

ered state).

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

EB 8387-5 EN 15

Attachment to the control valve – Mounting parts and accessories

9. Insert formed seal (15) into the groove
of the positioner housing, pressing the
four retaining rings over the housing
screws and both fittings into the hous

-

ing recesses.

10. Thread the bias spring (17) through the
crosspiece underneath the lever (1) and
push into the hole in the housing. Push
the lever (1) until it engages into place.
Place positioner on the cover plate (10)
and fasten it using the three fixing
screws.
Check to make sure that the follower
pin (2) rest on top of the follower clamp
(3). The lever (1) must rest on the fol­lower clamp with spring force.
Make sure that the seal ring (10.1) is
inserted in the borehole of the cover
plate.

11. Mount cover (11) on the other side.
Make sure that the vent plug (11.1)
points downwards when the control
valve is installed to allow any con

-

densed water that collects to drain off.

16 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

EB 8387-5 EN 17

Attachment to the control valve – Mounting parts and accessories

9

11

Supply 9

Output 38

5

6

4

17

7

6

10

10.1

3

2

1

15

6.1

1.1

1.2

14

8

11.1

A

A-A

A

Fig. 4 · Direct attachment for Type 3277-5 Actuator with 120 cm²

Switchover plate (9)

Marking

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower clamp
4 Screw plug
5 Stopper
6 Connecting plate for G ¼

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

for actuator

10 Cover plate

10.1 Seal ring
11 Cover

11.1 Vent plug
14 Gasket
15 Formed seal
17 Bias spring (only with

direct attachment)

Signal pressure input
for right attachment

Symbols

Actuator stem

extends

Left attachment Right attachment

Actuator stem

retracts

Signal pressure
input for left
attachment

Signal pressure input
with brass restriction

Cut-out of
cover plate

4.1.2 Type 3277 Actuator

Refer to Table 2 on page 28 for the required
mounting parts and accessories.

Actuators with 175 to 750 cm²

Mount the positioner on the yoke as shown
in Fig. 5. 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 re

-

tracts" through external piping.

1. Place follower clamp (3) on the actua

­tor 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 the narrow
side of the cut-out opening (Fig. 5, left)
pointing towards the signal pressure
connection. Make sure that the bonded
gasket (14) points towards the actuator
yoke.

3. Actuators with 355, 700 and 750 cm²:
Remove the follower pin (2) at lever M
(1) on the back of the positioner from
pin position 35, reposition it in the hole
for pin position 50 and screw tight.

Actuators with 175 to 350 cm² with
15 mm travel: The follower pin (2) re

­mains in pin position 35 (delivered
state).

4. Insert formed seal (15) into the groove
of the positioner housing, pressing the
four retaining rings over the housing
screws and both fittings into the hous

-

ing recesses.

5. Thread the bias spring (17) through the
crosspiece underneath the lever (1) and

push into the hole in the housing. Push
the lever (1) until it engages into place.
Place positioner on the cover plate (10)
and fasten it using three fixing screws.
Check whether the follower pin (2) rests
on top of the follower clamp (3).
The lever (1) must rest on the follower
clamp with spring force.

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 corre

­sponds with the actuator with fail-safe
action "Actuator stem extends" or "Ac

­tuator stem retracts." If necessary, re­move the three fixing screws and the
cover plate. Then reposition the gasket
(16) turned by 180°. The previous ver­sion of the connection block (Fig. 5,
bottom) requires the switch plate (13) to
be turned such that the corresponding
actuator symbol points to the marking.

7. Actuators with 175 cm²: Unscrew the
filter from the signal pressure input and
first screw the screw restriction (acces

­sories order no. 1400-6964/item no.
0390-1424) into the input and then the
filter.

8. 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 "Ac

-

tuator stem retracts", additionally re

­move the stopper (12.2) and attach the
external signal pressure line.

18 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

EB 8387-5 EN 19

Attachment to the control valve – Mounting parts and accessories

2

17

10 1415

1

2

3

11

SUPPLY

13

B

1.1

1.2

12

12.1

12

12.2

12.11216

1616

12.2

SUPPLY

Ansicht B

Ansicht A

Ansicht C

SUPPLYG

G 3/8

11.1

A

C

Fig. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 175 to 750 cm

2

View A

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower clamp
10 Cover plate G ¼
11 Cover

11.1 Vent plug

Connection block (old)
with switch plate (13)

12 Connection block

12.1 Screw

12.2 Stopper or connection for
external piping

13 Switch plate
14 Gasket
15 Formed seal
16 Gasket
17 Bias spring

(only for direct attachment)

Cut-out of
cover plate (10)

Stem retracts

Stem extends

Marking

View A

View C

View B

Actuator stem

retracts extends

9. Mount cover (11) on the other side.
Make sure that the vent plug (11.1)
points to the back when the control
valve is installed to allow any con

-

densed water that collects to drain off.

4.2 Attachment according to

IEC 60534-6 (NAMUR)

Refer to Table 3 on page 30 for the required
mounting parts and accessories.

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

1. Actuator with 175 cm²:
Unscrew the filter from the signal pres­sure input and first screw the screw re­striction (accessories order no.
1400-6964/item no. 0390-1424) into
the input and then the filter.

2. Actuator sizes 120 to 750 cm²:
Screw the two bolts (14) to the bracket
(9.1) of the stem connector (9), place
the follower plate (3) on top and tighten
it using the screws (14.1).

Actuator size 2800 cm² and 1400 cm²
(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).

3. Mount NAMUR bracket (10) to the con

-

trol 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 (3/3.1) is
centrally aligned with the NAMUR
bracket at mid valve travel.

4. If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are re

­quired, the connecting plate (6), mak­ing sure both seal rings (6.1) are
seated properly.

5. Screw a screw restriction (accessories
order no. 1400-6964/item no.
0390-1424) into the signal pressure
output for actuators with diaphragm ar­eas smaller than 240 cm².

6. Select required lever (1) size M, L or XL
and pin position according to the actu

­ator size and valve travels listed in the
table on page 14.

Lever M with pin position 25 or 50:

6.1 Remove follower pin (2) from pin posi

­tion 35 and screw it into the required
hole.

Lever L or XL:

6.1 Unscrew the standard lever M from the
shaft of the positioner.

6.2 Screw the long follower pin (2) in

­cluded in the mounting kit in the pin
position of the required lever (1) as

-

signed in the table.

20 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

EB 8387-5 EN 21

Attachment to the control valve – Mounting parts and accessories

10

11

1

1

14.1

3

3.1

16

15

14

1

1.2

1.1

2

9.1

9

6

7

8

6.1

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

1 Lever

1.1 Nut

1.2 Disk spring
3 Follower plate

3.1 Follower plate
6 Connecting plate

(only for G ¼)

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

Additional bracket for
actuators with 2800 cm²
and travel≥60 mm

Fit screw-in restriction into output
(38) for actuators smaller than
240 cm²

Attachment to
NAMUR rib

Attachment to rod-type yoke
Rods with 20 to 35 mm Ø

Lever XL and L

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

6.4 Move the lever once all the way as far
as it will go in both directions.

7. Place positioner on the NAMUR
bracket in such a manner that the fol

-

lower pin (2) rests in the slot of the fol

­lower plate (3/3.1). Adjust the lever (1)
correspondingly. Screw the positioner
to the NAMUR bracket using three fix

­ing screws.

4.3 Attachment to Type 3510
Micro-flow Valve

Refer to Table 3 on page 30 for the required
mounting parts and accessories.

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

1.

Mount the travel indication scale (ac­cessories) onto the outer side of the
yoke using the hex screws (12.1), en

­suring that the scale is aligned with the
stem connector.

2. Fasten the bracket (9.1) onto the stem
connector.

3. Fasten the two pins (9.2) to the bracket
(9.1) on the stem connector. Mount the
follower plate (3) and fasten it using the
screws (9.3).

4. Fasten the hex bar (11) onto the outer
side of yoke by screwing the M8 screws
(11.1) directly into the holes on the
yoke.

5. Fasten the bracket (10) to the hex bar
(11) using the hex screw (10.1),
washer and tooth lock washer.

6. If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are re

-

quired, the connecting plate (6), mak

­ing sure both seal rings (6.1) are
seated properly.

7. Screw the restriction (accessories order
no. 1400-6964/item no. 0390-1424)
into the signal pressure output of the
positioner (or output of the pressure
gauge bracket or connecting plate).

8. Unscrew the standard installed lever M
(1) including follower pin (2) from the
positioner shaft.

9. Take lever S (1) and screw follower pin
(2) in the bore for pin position 17.

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

11. 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 screws.

22 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

EB 8387-5 EN 23

Attachment to the control valve – Mounting parts and accessories

10.1

11.1

9

11

12.1

6

2

1

1.2

1.1

7

8

6.1

10

9.1

3

9.2

9.3

Fig. 7 · Attachment to Type 3510 Micro-flow Valve

Fit screw-in restriction into
output (38)

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Follower plate
6 Connecting plate

6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge mounting kit
9 Stem connector

9.1 Bracket

9.2 Pin

9.3 Screws
10 Bracket

10.1 Screw
11 Hex bar

11.1 Screws

12.1 Screws

Lever S

4.4 Attachment to rotary
actuators

Refer to Table 4 on page 30 for the required
mounting parts and accessories.

Both mounting kits contain all the necessary
mounting parts. First select correct actuator
size. Prepare actuator, and mount required
adapter supplied by the actuator manufac

-

turer, if necessary.

1. Mount the housing (10) onto the rotary

actuator. In case of VDI/VDE attach

­ment, place spacers (11) underneath, if
necessary.

2. For SAMSON Type 3278 and VETEC
S160 Rotary Actuator, screw the
adapter (5) onto the free end of the
shaft or place adapter (5.1) onto the
shaft of the VETEC R Actuator.
Place adapter (3) onto Type 3278,
VETEC S160 and VETEC R Actuator. For
VDI/VDE version, this step depends on
the actuator size.

3. Stick adhesive label (4.3) onto the cou

­pling wheel in such a manner that the
yellow part of the sticker is visible in the
window of the housing when the valve
is OPEN. Adhesive labels with explana

­tory symbols are enclosed and can be
stuck on the housing, if required.

4. Screw tight coupling wheel (4) onto the
slotted actuator shaft or adapter (3) us

-

ing screw (4.1) and disk spring (4.2).

5. Undo the standard follower pin (2) on
the lever M (1) of the positioner. Attach
the follower pin (Ø 5) included in the
mounting kit to pin position 90°.

6. If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are re

-

quired, the connecting plate (6), mak

­ing sure both seal rings (6.1) are
seated properly.
For double-acting, springless rotary ac

-

tuators, a reversing amplifier is re

­quired to attach the positioner to the
actuator. Refer to section 4.5.

7. For actuators with a volume of less than
300 cm³, screw the screw restriction
(accessories order no.1400-6964/item
no. 0390-1424) into the signal pres

­sure output of the positioner (or the out­put of the pressure gauge bracket or
connecting plate).

8. Place positioner on the housing (10)
and screw it tight. Considering the ac­tuator's direction of rotation, align lever
(1) so that it engages in the correct slot
of the coupling wheel with its follower
pin (Fig. 8).

24 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

1

10

4

Fig. 8 · Direction of rotation

Counterclockwise

Clockwise

EB 8387-5 EN 25

Attachment to the control valve – Mounting parts and accessories

Counterclockwise

6

6.1
7
8

1

1.1

1.2

2

4.1

3

10.1

10

11

5

4.3

4

4.2

4.1

3

5.1

5

10.1

10

4.3

4

4.2

Fig. 9 · Attachment to rotary actuators

1 Lever

1.1 Nut

1.2 Disk spring
2 Follower pin
3 Adapter
4 Coupling

wheel

4.1 Screw

4.2 Disk spring

4.3 Adhesive label
5 Actuator shaft

or adapter

5.1 Adapter

6 Connecting plate (only for G ¼)

6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge mounting kit
10 Adapter housing

10.1 Screws
11 Spacers

Fit screw-in restriction into signal pressure output
for actuators with < 300 cm³ volume

SAMSON Type 3278
VETEC S160, VETEC R

Attachment acc. to VDI/VDE 3845
(Sept. 2010) level 1, size AA1 to AA4

(see section 12.1)

4.5 Reversing amplifier for
double-acting actuators

For the use with double-acting actuators, the
positioner must be fitted with a reversing
amplifier, e.g. the SAMSON Type 3710 Re

-

versing Amplifier (see Mounting and Oper

-

ating Instructions EB 8392).

If a different reversing amplifier (item no.
1079-1118 or 1079-1119) is used, follow
the mounting instructions described in sec

-

tion 4.5.1.

The following applies to all reversing am

-

plifiers:

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 A2.
The rule A1+ A2= Z applies.

A1: Output A1leading to the signal pressure

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

A

2

: Output A2leading to the signal pressure
connection at the actuator which closes the
valve when the pressure increases

4.5.1 Reversing amplifier

(1079-1118 or 1079-1119)

NOTICE

Do not unscrew sealing plug (1.5) out of the
reversing amplifier.

1. Thread the special nuts (1.3) from the

accessories of the reversing amplifier

into the boreholes of the positioner.
Remove the rubber seal (1.4).

2. Insert the gasket (1.2) into the recess of
the reversing amplifier and push both
the hollowed special screws (1.1) into
the connecting boreholes A1and Z.

3.

Position the reversing amplifier (1) and
screw tight using both the special
screws (1.1).

4. Use a screwdriver (8 mm wide) to
screw the enclosed filters (1.6) into the
connecting boreholes A

1

and Z.

NOTICE

On start up of double-acting actuators, the
following settings as described in section
must be made:

– Pressure limit (Code 16) = OFF
– Fail-safe position (Code 0) = AIR TO

OPEN (AtO)

Pressure gauge attachment

The mounting sequence shown in Fig. 10 re

­mains unchanged. Screw a pressure gauge
bracket onto the connections A1and Z.

Pressure gauge

G ¼ 1400-7106

bracket: ¼ NPT 1400-7107

Pressure gauges for supply air Z and output
A

1

as listed in Tables 1 to 4.

26 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

EB 8387-5 EN 27

Attachment to the control valve – Mounting parts and accessories

A

1

1.5 1.6

1.3 1.2 1.1 1 1.6

Z

A

2

1.4

A

1

A

2

Z

A

1

Output 38 Supply 9

Output 38 Supply 9

1.3 1.21.1

Fig. 10 · Mounting a reversing amplifier (1079-1118 or 1079-1119)

From the positioner

Control signals to

the actuator

1 Reversing amplifier

1.1

Special screws

1.2 Gasket

1.3 Special nuts

1.4 Rubber seal

1.5 Sealing plug

1.6 Filter

4.6 Required mounting parts and accessories

28 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

Table 1 · Direct attachment to Type 3277-5 (Fig. 4)

Order no.

Mounting parts For actuators with 120 cm² effective diaphragm area 1400-7452

Version compatible with paint for actuators 120 cm² or smaller 1402-0940

Accessories for
the actuator

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

Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new)

1)

1400-6822

Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new)1), G

1

8

and

1

8

NPT 1400-6823

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): G

1

8

1400-6820

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old):

1

8

NPT 1400-6821

Accessories for
the positioner

Connecting plate (6) G ¼ 1400-7461

Pressure gauge bracket (7)

G ¼ 1400-7458

¼ NPT 1400-7459

Pressure gauge mounting kit (8) up to max. 6 bar (output/supply)

St. st./Brass 1400-6950

St. st./St. st. 1400-6951

1)

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

Table 2 · Direct attachment to Type 3277 (Fig. 5) Order no.

Mounting
parts

Standard version for actuators with 175, 240, 350, 355, 700, 750 cm² 1400-7453

Version compatible with paint for actuators with 175, 240, 350, 355, 700, 750 cm² 1400-0941

Accessories

Required piping with screw
fitting
– for "Actuator stem retracts"
– with air purging of the top
diaphragm chamber

175 cm²

Steel

G

1

4

/ G

3

8

1402-0970

1

4

NPT /

3

8

NPT

1402-0976

Stainl. steel

G

1

4

/ G

3

8

1402-0971

1

4

NPT /

3

8

NPT

1402-0978

240 cm²

Steel

G

1

4

/ G

3

8

1400-6444

1

4

NPT /

3

8

NPT

1402-0911

Stainl. steel

G

1

4

/ G

3

8

1400-6445

1

4

NPT /

3

8

NPT

1402-0912

350 cm²

Steel

G

1

4

/ G

3

8

1400-6446

1

4

NPT /

3

8

NPT

1402-0913

Stainl. steel

G

1

4

/ G

3

8

1400-6447

1

4

NPT /

3

8

NPT

1402-0914