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

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Page 1

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

Page 2

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

Page 3

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

Page 4

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.

Page 5

1 Important safety instructions

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

tion of the positioner:

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.

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.

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.

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:

Proper shipping and appropriate storage are assumed.

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

wards.

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

Page 6

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

Page 7

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

Serial

Interface

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

Page 8

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:

Direct attachment to SAMSON Type 3277 Actuator: Section

4.1

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

Attachment to Type 3510 Micro-flow Valve: Section 4.3

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

Page 9

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

Page 10

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

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

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

³/h · At∆p = 1.4 bar: 4.5 mn³/h · K

Vmax(20° C)

= 0.15

Page 11

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

Page 12

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

Page 13

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:

Direct attachment to SAMSON Type 3277 Actuator

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

Attachment to Type 3510 Micro-flow Valve

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)

Page 14

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°

Page 15

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.

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

Page 16

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

Page 17

EB 8387-5 EN 17

Attachment to the control valve – Mounting parts and accessories

Supply 9

Output 38

10.1

6.1

1.1

1.2

11.1

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

Page 18

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

Page 19

EB 8387-5 EN 19

Attachment to the control valve – Mounting parts and accessories

10 1415

SUPPLY

1.1

1.2

12.1

12.2

12.11216

1616

12.2

SUPPLY

Ansicht B

Ansicht A

Ansicht C

SUPPLYG

G 3/8

11.1

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

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

Page 20

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

Page 21

EB 8387-5 EN 21

Attachment to the control valve – Mounting parts and accessories

14.1

3.1

1.2

1.1

9.1

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

Page 22

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.

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

Page 23

EB 8387-5 EN 23

Attachment to the control valve – Mounting parts and accessories

10.1

11.1

12.1

1.2

1.1

6.1

9.1

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

Page 24

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

Fig. 8 · Direction of rotation

Counterclockwise

Clockwise

Page 25

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

4.1

10.1

4.3

4.2

4.1

5.1

10.1

4.3

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)

Page 26

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

of the reversing amplifier. An opposing pressure, which equals the required supply pressure when added to the pressure at A

, 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

: 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.

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

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

as listed in Tables 1 to 4.

26 EB 8387-5 EN

Attachment to the control valve – Mounting parts and accessories

Page 27

EB 8387-5 EN 27

Attachment to the control valve – Mounting parts and accessories

1.5 1.6

1.3 1.2 1.1 1 1.6

1.4

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

Page 28

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)

1400-6822

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

and

NPT 1400-6823

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

1400-6820

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

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

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

1402-0970

NPT /

NPT

1402-0976

Stainl. steel

/ G

1402-0971

NPT /

NPT

1402-0978

240 cm²

Steel

/ G

1400-6444

NPT /

NPT

1402-0911

Stainl. steel

/ G

1400-6445

NPT /

NPT

1402-0912

350 cm²

Steel

/ G

1400-6446

NPT /

NPT

1402-0913

Stainl. steel

/ G

1400-6447

NPT /

NPT

1402-0914

Page 29

EB 8387-5 EN 29

Attachment to the control valve – Mounting parts and accessories

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

Accessories

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

phragm chamber

355 cm²

Steel

/ G

1402-0972

NPT /

NPT

1402-0979

Stainl. steel

/ G

1402-0973

NPT /

NPT

1402-0980

700 cm²

Steel

/ G

1400-6448

NPT /

NPT

1402-0915

Stainl. steel

/ G

1400-6449

NPT /

NPT

1402-0916

750 cm²

Steel

/ G

1402-0974

NPT /

NPT

1402-0981

Stainl. steel

/ G

1402-0975

NPT /

NPT

1402-0982

Connection block with seals and screw

1400-8819

NPT 1402-0901

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

Steel/brass 1400-6950

St. steel/St. steel 1400-6951

Table 3 · Attachment to NAMUR ribs or control valves with rod-type yokes

(20 to 35 mm rod diameter) according to IEC 60534-6 (Figs. 6 and 7)

Travel in mm Lever For actuators Order no.

7.5 S Type 3271-5 Actuator w. 60/120 cm² on Type 3510 Valve (Fig. 7) 1400-7457

5 to 50 M1)Actuators from other manufacturers and Type 3271with 120 to 700 cm² 1400-7454

14 to 100 L Actuators from other manufacturers and Type 3271, versions 1000 and

1400-60

1400-7455

40 to 200 XL

Actuators from other manufacturers and Type 3271, versions 1400-120 and 2800 cm² with 120 mm travel

1400-7456

30 or 60 L

Type 3271, versions 1400-120 and 2800 cm² (30 or 60 mm travel) 1400-7466

Mounting bracket for Emerson and Masoneilan linear actuators; a mounting kit acc. to IEC 60534-6 is necessary depending on the travel (see above)

1400-6771

Valtek Type 25/50 1400-9554

Page 30

EB 8387-5 EN 30

Attachment to the control valve – Mounting parts and accessories

Table 3 · Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter) according to IEC 60534-6 (Figs. 6 and 7)

Travel in mm Lever For actuators Order no.

Accessories

Connecting plate 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

Lever M is attached to basic positioner (included in the scope of delivery)

Table 4 · Attachment to rotary actuators (Figs. 8 and 9)

Order no.

Mounting parts

Attachment acc. to VDI/VDE 3845 (September 2010), see section 12.1 for details

Actuator surface corresponds to level 1

Size AA1 to AA4, heavy-duty version Size AA5, heavy-duty version (e.g. Air Torque 10 000)

1400-9244 1400-9542

Bracket surface corresponds to level 2, heavy-duty version 1400-9526

Attachment for SAMSON Type 3278 with 160 cm² and for VETEC Type S160, R and M, heavy-duty version

1400-9245

Attachment for SAMSON Type 3278 with 320 cm² and for VETEC Type S320, heavy-duty version

1400-5891

and

1400-9526

Attachment to Camflex II

1400-9120

Accessories

Connecting plate (6)

1400-7461

NPT 1400-7462

Pressure gauge bracket (7)

1400-7458

NPT 1400-7459

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

St. steel/brass 1400-6950

St. steel/st. steel 1400-6951

Table 5 · General accessories

Order no.

Accessories

Reversing amplifier for double-acting actuators Type 3710

Signal pressure restrictions (screw restriction (item no. 0390-1424) and brass restric

tion (item no. 0390-1423))

1400-6964

Activation code for EXPERT+for Type 3731-5 Positioner 1400-9318

USB dongle for EXPERT+ (specify the number of activations) Only can be used in combination with TROVIS-VIEW 6661-1065

1400-9555

TROVIS-VIEW with database module 3731-5 6661-1065

Serial interface adapter (SAMSON SSP interface – RS-232 port of computer)

1400-7700

Isolated USB interface adapter (SAMSON SSP interface – USB port on computer) including TROVIS-VIEW CD-ROM

1400-9740

Page 31

5 Connections

WARNING!

Mount 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 connection of the electrical auxilary power may cause the actuator stem to move, depending on the operating mode. Do not touch the actuator stem or obstruct it to avoid risk of injury to hands or fingers.

5.1 Pneumatic connections

The maximum supply pressure at the input is: – 7 bar for Types 3731-521 and 3731-527 – 6 bar for Type 3731-523

DANGER! Danger from the formation of an explosive atmosphere!

The operator of the apparatus must ensure that the working medium cannot form an ex

plosive atmosphere, i.e. only such gases may be used which are free from substances whose presence in the medium might lead to the formation of an explosive atmosphere (e.g. do not use flammable gases, oxygen or oxygen-enriched gases).

Follow the instructions below to avoid dam

aging the positioner.

–

Do not exceed the maximum supply pressure at the input.

–

The screw fittings with ¼ NPT thread can be screwed directly into the positioner. In case G ¼ threaded connections are required, the fittings must be screwed into the connecting plate (6) or pressure gauge mounting block or connection block available from the accessories. Customary screw-in fittings for metal and copper pipes or plastic hoses can be used.

– 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 pipes and hoses thoroughly prior to connecting them.

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 di

aphragm chamber of the actuator, depend

ing on the actuator's fail-safe action "Actua

tor stem extends" or "Actuator stem re

tracts". For rotary actuators, the manufacturer's specifications for connection apply.

EB 8387-5 EN 31

Connections

Page 32

5.1.1 Signal pressure gauges

To monitor the supply air (Supply) and sig

nal pressure (Output), we recommend that pressure gauges be attached (see accesso

ries in Tables 1 to 5).

5.1.2 Supply pressure

The required supply pressure (of supply air) depends on the bench range and the actua

tor's operating direction (fail-safe action). The bench range is registered on the name

plate either as spring range or signal pres

sure range depending on the actuator. The direction of action is marked FA or FE, or by a symbol.

Actuator stem extends FA (AIR TO OPEN)

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)

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

max

is roughly estimated as fol

lows:

pst

max

= F +

d p

⋅ ⋅⋅π ∆

[bar]

d = Seat diameter [cm]

∆

p = Differential pressure across the valve

[bar] A = Actuator diaphragm area [cm²] 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

5.1.3 Signal pressure (output)

The signal pressure at the output (Out

put 38) of the positioner can be limited to

1.4, 2.4 or 3.7 bar in Code 16.

The limitation is not activated [OFF] by de

fault.

32 EB 8387-5 EN

Connections

Page 33

5.2 Electrical connections

EB 8387-5 EN 33

Connections

DANGER! Risk of electric shock and/or the formation of an explosive atmosphere!

For electrical installation, you are required to observe the relevant electrotechnical regulations and the accident prevention regulations that ap

ply in the country of use.

The following standard applies for assembly and installation in hazardous areas: EN 60079-14 (VDE 0165 Part 1) Explosive atmospheres - Electrical installations design, selection and erection.

Connection to conform with the type of protection Ex d (EN 60079-1):

The Type 3731-521 Positioner must be connected over the appropriate cable glands or conduit systems which meet the requirements of EN 60079-1 (Electri

cal apparatus for explosive gas atmospheres - Part 1: Flameproof enclosures "d") Clauses 13.1 and 13.2 and for which a special test certificate exists. Do not use simple types of cable glands or blanking plugs.

Seal any cable entries that are not used using blanking plugs approved for this purpose for installations according to the type of protection Ex db.

Install the connecting line rigidly and ensure it is protected adequately from being damaged. In case the temperature exceeds 70 °C at the cable entries, use appropriate temperature-resistant connecting cables.

Integrate the positioner into the equipotential bonding system on site.

Connection to conform with the type of protection Ex e (EN 60079-7):

The cable and cable entries or blanking plugs must be certified according to the type of protection Ex e (ATEX) and for which a special test certificate exists.

Devices used at ambient temperatures below –20 °C must have metal cable en

tries.

In cases where more than one cable core is connected to the same terminal, make sure that each cable core is clamped adequately.

Two cables with varying cross-sections may only be connected to one terminal, if this is not explicitly allowed in the documentation related to the electrical ap

paratus, when the two cables are secured with a common crimp sleeve before

hand.

Page 34

34 EB 8387-5 EN

Connections

Table 6 · Accessories Order no.

Cable gland M20 x 1.5; Ex e, black plastic 8808-0178

Blanking plugs; Ex de; stainless steel (approvals: CENELEC, CSA, GOST, IECEx)

M20 x 1.5 8323-1203

½ NPT 8323-1204

Cable entry for unarmored cables; Ex e, Ex d, Ex tD A21 (approvals: CENELEC, IECEx)

M20 x 1.5 8808-0200

½ NPT 8808-2010

Connection to conform with the type of protection Ex i (EN 60079-11):

For connection to a certified, external instrinsically safe circuit, the terminal compartment of the positioner may be opened within the hazardous area.

Only the terminal compartment is to be opened within the hazardous area to connect it to a certified instrinsically safe circuit.

Positioners that are connected to non-intrinsically safe circuits are no longer permitted to be used as instrinsically safe equipment.

The IP rating of the cable, cable entries and blanking plugs must be the same as the positioner's degree of protection.

Page 35

Cable entry

The threaded connections for the terminal compartment are designed with ½ NPT or M20x1.5 threads.

The electrical connections are screw terminals for wire cross-sections of 0.2 to

2.5 mm² using a tightening torque of at least

0.5 Nm.

Note: The positioner is powered either over the connection to the fieldbus segment or over a DC voltage source (9 to 32 V) con

nected to the bus terminals in the positioner.

You are required to observe the relevant regulations for use in hazardous areas!

EB 8387-5 EN 35

Connections

Power supply unit

Ex-fieldbus barrier/isolator

 Hazardous area

Power conditioner

Control system

3731-52

IEC 61158-2



Bus termination

FOUNDATIONTM fieldbus

Fig. 11 · Connection according to FOUNDATIONTMfieldbus for hazardous areas

Fig. 12 · Location of the terminals

(lid unscrewed)

Page 36

Electrical auxiliary power supplied over the bus line

Route the two-wire bus line to the screw terminals marked “Signal”. Polarity does not have to be observed. Refer to Fig. 13 or the nameplate for the terminal assignment. After connecting the electrical auxiliary power,

tEStinG runs across the display of

the positioner.

Note: Just one binary input is available (either version 1 or version 2).

Version 1 of binary input (terminals A–B)

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

Version 2 of binary input (terminals B–C)

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

36 EB 8387-5 EN

Connections

A B C

Option

A B C

Option

IEC 61158-2

Signal

A B C

Option

L/+

0...40 V DC

0...28 V AC



Fig. 13 · Electrical connections

Forced venting

Version 1 Version 2

Binary input

Page 37

EB 8387-5 EN 37

Connections

NOTICE

The demanded degree of protection might not be met because the terminal compart

ment is not sealed tightly. Only operate the positioner with sealed cable entries and with the lid screwed on properly.

NOTICE

Loss of explosion protection due to damaged lid thread and/or connecting thread. Do not open the flameproof enclosure when the positioner is in the energized state. Ob

serve explosion protection regulations.

1. Unscrew lid.

Guide the wires through the side cable entry to the terminal compartment using a cable gland or conduit system.

3. Connect wires to the terminals as

shown in the wiring diagram (Fig. 13).

4. Check O-ring for damage and replace

it with a new one, if necessary.

5. Screw on the lid as far as it will go.

Turn it back to first safety position (notch).

6. Unscrew the cap screw to lock the lid.

5.2.1 Establishing communication

Communication between the controller or automation system, or between a computer or work station and the positioner(s) is im

plemented to conform with

EN 61158-2.

Note: Refer to the Configuration Manual KH 8387-5 for more information.

Page 38

6 Operator controls and

readings

6.1 Rotary pushbutton

The rotary pushbutton ( ) is located under

neath the front protective cover.

The positioner is operated on site using the rotary pushbutton:

Turn to select codes and values. Press to confirm setting.

6.2 Serial interface

The serial interface connection is located un

derneath the display lid: Unscrew and re

move retaining screw and then unscrew display lid.

NOTICE

The explosion protection is ineffective as soon as the display lid is opened!

To use the TROVIS-VIEW software, connect the positioner over an adapter to the RS-232 or USB port of the computer.

6.3 Readings on display

Icons appear on the display that are as

signed to parameters, codes and functions.

Operating modes

– Manual mode (MAN), see sec

tion 8.2.1 The positioner follows the manual set point (Code 1) instead of the set point of the Analog Ouput Block

– Automatic mode (AUTO), see

section

8.2.1

The positioner is in closed-loop operation and follows the the set point of the Ana

log Output Block.

– SAFE, see section

8.2.2 The positioner vents the output. The valve moves to the mechanical fail-safe position.

Bar elements

In manual and automatic operating modes, the bars indicate the system devia

tion that depends on the sign (+/–) and the value. One bar element appears per 1 % system deviation. If the device has not yet been initialized, the icon appears on the display and the lever position in degrees in relation to the longitudinal axis is indicated. One bar element cor

responds to approximately a 5° angle of rotation. If the fifth bar element blinks (reading > 30°), the permissible angle of rotation has been exceeded. Lever and pin position must be checked.

Status messages

Maintenance alarm

Maintenance required/Maintenance

demanded

hese icons indicate that an error has occurred. A classified status can be assigned to each error. Classifications include “No message”, “Maintenance required”, “Maintenance de

manded” or “Maintenance alarm“ (see sec

tion 8.3).

Configuration enabled

This indicates that the codes marked with an asterisk (*) in the code list (section

11)

are enabled for configuration (see sec

tion 8.1).

38 EB 8387-5 EN

Operator controls and readings

Page 39

EB 8387-5 EN 39

Operator controls and readings

Retaining screw

Protective cover Rotary pushbutton LC display Serial interface

and together:

AO Transducer Block is in MAN operating mode

blinks Emergency mode,

see Code 62 blinks Not initialized blinks Valve in mechanical

fail-safe position

Fail-safe position

active

Code

Bar elements for system deviation or lever position

Units

Condensed state:

Maintenance alarm

Designation

Position

Parameter

Binary input

Configuration

enabled

Manual operation Closed-loop operation

Condensed state:

Maintenance required

Main

RES Reset RUN Start SAFE Fail-safe position SUb Substitute calibration TunE Initialization in progress YES Exists ZP Zero calibration

tEStinG Self-test tESt Test function active

ää Increasing/increasing äæ Increasing/decreasing

AUtO Automatic mode CL Clockwise CCL Counterclockwise Err Error ESC Escape MAN Manual setting

MAX Maximum range

NO Not available NOM Nominal travel ON On OFF Off

Readings and their meanings

Fig. 14 · Readings and operator controls

Page 40

7 Start-up – Settings

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

Reading on display after connecting the electrical auxiliary power:

tEStinG runs across the display and then the fault alarm icon

appears and blinks on the display when the positioner has not yet been initialized. The reading indicates the lever position in degrees in relation to the longitudinal axis.

Reading when the positioner has not yet been initialized

Code 0 appears on the display when a positioner has been initialized. The positioner is in the last active operating mode.

WARNING!

The actuator stem moves while the start-up settings are being performed. Do not touch the actuator stem or obstruct it to avoid risk of injury to hands or fingers.

NOTICE

Perform the start-up settings in the same se

quence as listed (section 7.1 to section 7.5).

7.1 Adapting the display

The reading on the display can be turned by 180° to adapt it to how the positioner is at

tached.

Reading direction for right attachment of pneumatic connections

Reading direction for left attachment of pneumatic connections

If the display appears upside down, proceed as follows:

Turn

→

Code 2

Press , Code 2 blinks.

Turn

→

Desired reading direction.

Press

to confirm the reading direction.

7.2 Limiting the signal pressure

If the maximum actuator force may cause damage to the valve, the signal pressure must be limited.

40 EB 8387-5 EN

Start-up – Settings

Page 41

NOTICE

Do not activate the pressure limit function in actuators with fail-safe action AIR TO OPEN (AtO), e.g. double-acting actuators (OFF = default).

Enable configuration at the positioner before activating the pressure limit function:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

Configuration enabled

Default: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Pressure limit function:

Pressure limit

Default: OFF

Turn

→

Code 16

Press , Code 16 blinks.

Turn

until the required pressure limit

(1.4/2.4/3.7 bar) appears.

Press to confirm the pressure limit.

7.3 Checking the operating range of the positioner

To check the mechanical attachment, the valve should be moved through the operat

ing range of the positioner in the

manual operating mode using the manual reference variable w.

Select manual operating mode:

Mode Default: MAN

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

MAN

Press to change the positioner to

manual mode.

Checking the operating range:

Manual reference variable (the current opening angle appears)

Turn

→

Code 1

Press , Code 1 and blink.

Turn

until the pressure builds up in the positioner, and the control valve moves to its end positions to check the travel range/an

gle of rotation.

EB 8387-5 EN 41

Start-up – Settings

Page 42

The angle of the lever on the back of the positioner is indicated on the display. A horizontal lever (mid-position) is equal to 0°.

To ensure the positioner is working prop

erly, the outer bar elements may not blink

while the valve is moving through the oper

ating range. The manual operating mode can be exited by pressing the rotary pushbutton ( ).

The permissible range has been exceeded

when the displayed angle is greater than 30°, and the outer right or left bar element blinks. The positioner changes to the fail-safe position

SAFE.

fter canceling the fail-safe position SAFE (see section 8.2.2) it is absolutely necessary to check the lever and pin position as described in section 4.

WARNING!

To avoid personal injury or property dam

age caused by the supply air or electrical auxiliary power, disconnect the supply air and electrical auxiliary power (bus line) be

fore exchanging the lever or changing the pin position.

7.4 Determining the fail-safe position

To adapt the positioner to the operating di

rection of the actuator, the fail-safe position of the positioner must be determined:

AIR TO OPEN (AtO) Signal pressure opens the valve. Fail-safe position: Valve CLOSED

AIR TO CLOSE (AtC) S

ignal pressure closes the valve.

Fail-safe position: Valve OPEN

NOTICE

Double-acting actuators must always be set to AIR TO OPEN (AtO).

Note: The fail-safe position setting remains set even when the positioner is started up again after the power supply has been disconnected.

Initialization

Fail-safe position AIR TO OPEN

Fail-safe position AIR TO CLOSE

42 EB 8387-5 EN

Start-up – Settings

Page 43

Turn

→

Code 0

Press , display: MAN Code 0 blinks.

Turn

→

Init

Press .

Turn until the required fail-safe position appears on the display.

Press to confirm the fail-safe position.

Turn

→

ESC

Press to exit or:

Start initialization as described in sec

tion

7.5.

For checking purposes: After the positioner has been initialized successfully, the valve closed position is indicated on the positioner display as 0 %, whereas the valve open position is indicated by 100 %. If this is not the case, the closing direction has to be adapted correspondingly and the positioner needs to be re-initialized.

7.5 Positioner initialization

WARNING!

During initialization, the control valve moves through its entire travel/angle of rotation range. Therefore, do not start the initializa

tion procedure while a process is running, but only during start-up when all shut-off valves are closed.

Before starting initialization, check the maxi

mum permissible signal pressure of the con

trol valve. During initialization, the positioner issues an output signal pressure up to the maximum supply pressure sup

plied. If necessary, limit the signal pressure by connecting an upstream pressure reduc

ing valve.

NOTICE

If the positioner is mounted onto another ac

tuator or its mounting position is changed, reset the positioner to its default settings be

fore re-initializing it. Refer to section 7.7.

During initialization the positioner adapts it

self optimally to the friction conditions and the signal pressure requirements of the con

trol valve. The type and extent of self-adaptation depends on the initialization mode selected:

MAX maximum range (standard range) Initialization mode for simple start-up of valves with two clearly defined mechani

cal end positions, e.g. three-way valves (see section 7.5.1)

NOM nominal range

Initialization mode for all globe valves (see section 7.5.2)

MAN manually selected range

Initialization mode for globe valves with an unknown nominal range (see section

7.5.3)

SUB substitute calibration (emergency mode) This mode allows a positioner to be re

placed while the plant is running, with the least amount of disruption to the plant (see section 7.5.4)

EB 8387-5 EN 43

Start-up – Settings

Page 44

Note: The initialization procedure can be in

terrupted while running by pressing the rota

ry pushbutton ( ). StOP appears three se

conds long and the positioner then moves to the fail-safe position. The fail-safe position can be canceled again over Code 0.

Alternating displays: Initialization running

Initialization progress indicated

(MAX, NOM, MAN or SUB appears, depending on the initialization mode selected)

Initialization successful Positioner in automatic

operating mode

The time required for an initialization process depends on the stroking speed of the actuator

and may take several minutes.

After a successful initialization, the positioner runs in automatic mode indicated by the closed-loop operation icon.

A malfunctioning leads to the process being interrupted. The initialization error appears on the display according to how it has been classified by the condensed state. See sec

tion 8.3 on page 56).

Note: Positioner with extended EXPERT+di

agnostics automatically start to plot the refe

rence graphs (drive signal y d1 and hystere

sis d2) after initialization has been comple

ted. tESt d1 and d2 appear on the display in alternating sequence. An unsuccessful plotting of the reference graphs is indicated on the display by Code

81. The positioner still works properly, even though the reference graph plotting has not been completed successfully.

7.5.1 Initialization based on MAX

maximum range

The positioner determines travel/angle of rotation of the closing member from the CLOSED position to the opposite side and adopts this travel/angle of rotation as the operating range from 0 to 100 %.

Enable configuration:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

Configuration enabled Default: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

44 EB 8387-5 EN

Start-up – Settings

Page 45

Press , display:

Select initialization mode:

Init mode Default: MAX

Turn

→

Code 6

Press

Turn

→

MAX

Press to confirm the MAX initialization mode.

Start initialization:

Initialization

Fail-safe position setting

Progress indicated until initialization starts

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

Init

Press . The setting of the fail-safe position AtO or AtC appears.

Keep

pressed down for 6 seconds.

Initialization starts after the progress indica

tion has stopped.

The nominal travel/angle of rotation is indi

cated in % after initialization. Code

5 (nomi

nal range) remains locked. The parameters for travel/angle range start (Code

8) and travel/angle range end (Code 9) can also only be displayed and modified in %.

For a reading in mm/°, enter the pin posi

tion (Code 4).

Enter pin position:

Pin position Default: OFF

Turn

→

Code 4

Press , Code 4 blinks.

Turn

→

Pin position on lever (see sec

tions on attachment)

Press . The reading of the nominal range appears in mm/°.

7.5.2 Initialization based on NOM

nominal range

The calibrated sensor allows the effective valve travel to be set very accurately. During the initialization process, the positioner checks whether the control valve can move through the indicated nominal range (travel or angle) without collision. If this is the case, the indicated nominal range is adopted with the limits of

EB 8387-5 EN 45

Start-up – Settings

Page 46

travel/angle range start (Code 8) and travel/angle range end (Code 9) as the op

erating range.

Note: The maximum possible travel must al

ways be greater than the nominal travel en

tered. If this is not the case, initialization is interrupted (error message Code 52) becau

se the nominal travel is not achieved.

Enable configuration:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

Configuration enabled Default: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Enter pin position and nominal travel:

Pin position Default: OFF

Nominal range (with Code 4 = OFF locked)

Turn

→

Code 4

Press , Code 4 blinks.

Turn

→

Pin position on lever (see sec

tions on attachment)

Press

Turn

→

Code 5

Press , Code 5 blinks.

Turn

→

Nominal valve travel

Press

Select initialization mode:

Initialization mode Default: MAX

Turn

→

Code 6

Press , Code 6 blinks.

Turn

→

NOM

Press to confirm the NOM initialization mode.

46 EB 8387-5 EN

Start-up – Settings

Page 47

Start initialization:

Initialization

Fail-safe position setting

Progress indicated until initialization starts

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

Init

Press . The setting of the fail-safe position AtO or AtC appears.

Keep

pressed down for 6 seconds.

Initialization starts after the progress indica

tion has stopped.

Note: After initialization, check the direction of action and, if necessary, change it (Code 7).

7.5.3 Initialization based on MAN manually selected range

Before starting initialization, move the con

trol valve manually to the OPEN position by turning

in small steps. The valve must

move to the required valve position with a

monotonically increasing signal pressure. The positioner calculates the differential travel/angle using the OPEN and CLOSED positions and adopts it as the operating range with limits of travel/angle range start (Code

8) and travel/angle range end

(Code 9).

Enter OPEN position:

Manual reference variable (the current angle of rotation is displayed)

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

MAN

Press .

Turn

→

Code 1

Press , Code 1 blinks.

Turn

until the OPEN position of the valve

is reached.

Press to confirm the OPEN position.

Enable configuration:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

EB 8387-5 EN 47

Start-up – Settings

Page 48

Configuration enabled Default: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Enter pin position:

Pin position Default: OFF

Turn

→

Code 4

Press , Code 4 blinks.

Turn

→

Pin position on lever (see sec

tions on attachment).

Press .

Select initialization mode:

Initialization mode Default: MAX

Turn

→

Code 6

Press , Code 6 blinks.

Turn

→

MAN

Press to confirm the MAN initialization mode.

Start initialization:

Initialization

Fail-safe position setting

Progress indicated until initialization starts

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

Init

Press . The setting of the fail-safe position AtO or AtC appears.

Keep pressed down for 6 seconds. Initialization starts after the progress indica

tion has stopped.

7.5.4 SUB substitute calibration

A complete initialization procedure takes several minutes and requires the valve to move through its entire travel range several times. This initialization mode, however, is an emergency mode, in which the control parameters are estimated and not deter

mined by an initialization procedure. As a result, a high level of accuracy cannot be expected.

48 EB 8387-5 EN

Start-up – Settings

Page 49

You should always select a different initial

ization mode if the plant allows it.

The SUB initialization mode is used to re

place a positioner while the process is running. For this purpose, the control valve is usually fixed mechanically in a certain po

sition, or pneumatically by means of a pres

sure signal which is routed to the actuator externally. The blocking position ensures that the plant continues to operate with this valve position.

By entering the blocking position (Code

35), closing direction (Code 34), pin position (Code 4), nominal range (Code 5) and di

rection of action (Code 7), the positioner can calculate the positioner configuration.

NOTICE

Perform a reset before re-initializing the positioner if the substitute positioner has already been initialized. Refer to section .

Enable configuration:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

Configuration enabled Default: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Enter pin position and nominal travel:

Pin position Default: OFF

Nominal range (with Code 4 = OFF locked)

Turn

→

Code 4

Press , Code 4 blinks.

Turn

→

Pin position on lever (see sec-

tions on attachment).

Press .

Turn

→

Code 5

Press , Code 5 blinks.

Turn

→

Nominal travel of the valve

Press .

Select initialization mode:

Initialization mode Default: MAX

Turn

→

Code 6

Press .

Turn

→

SUB

EB 8387-5 EN 49

Start-up – Settings

Page 50

Press to confirm the SUB initialization mode.

Enter direction of action:

Direction of action Default: ää

Turn

→

Code 7

Press , Code 7 blinks.

Turn

→

Direction of action (ää/äæ)

Press .

Deactivate travel limit:

Travel limit Default: 100.0

Turn

→

Code 11

Press , Code 11 blinks.

Turn

→

OFF

Press .

Change pressure limit and control parame

ters:

Note: Do not change the pressure limit (Code 16). Only change the control para

meters KP(Code 17) and TV(Code 18) if the settings of the replaced positioner are known.

Pressure limit Default: OFF

KP stage Default: 7

TV stage Default: 2

Turn

→

Code 16/17/18

Press , Code16/17/18 blinks.

Turn

and set the selected control param-

eter.

Press to confirm setting.

Enter closing direction and blocking position:

Closing position Direction of rotation causing the valve to move to the CLOSED position (view onto positioner display) Default: CCL (counterclockwise)

Blocking position Default: 0

Turn

→

Code 34

Press , Code 34 blinks.

50 EB 8387-5 EN

Start-up – Settings

Page 51

Turn

→

Closing direction (CCL counter

clockwise/CL clockwise)

Press .

Turn

→

Code 35

Press , Code 35 blinks.

Turn

→

Blocking position, e.g. 5 mm (read off at travel indicator scale of the blocked valve or measure with a ruler)

Press .

Start initialization:

Initialization

Fail-safe position setting

Progress indicated until initialization starts

Blocking position

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

Init

Press . The setting of the fail-safe position AtO or AtC appears.

Keep

pressed down for 6 seconds.

Initialization starts after the progress indica

tion has stopped. The operating mode changes to MAN. The blocking position appears.

Note: As initialization has not been carried out completely, the error code 76 (no emer

gency mode) and possibly also error code 57 (control loop) may appear on the dis

play. These messages do not influence the positio

ner’s readiness for operation.

Cancel the blocking position and change to automatic operating mode:

For the positioner to follow its reference variable again, the blocking position must be canceled and the positioner must be set to

automatic operating mode.

Turn

→

Code 1

Press , Code 1 and blink.

Turn until the pressure in the positioner builds up and the valve moves slightly past the blocking position.

Press to cancel the blocking position.

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

AUtO

EB 8387-5 EN 51

Start-up – Settings

Page 52

Press . The positioner changes to the au

tomatic operating mode. The current valve position is indicated in % on the display.

Note: If the positioner shows a tendency to hunt in automatic operating mode, the pa

rameters KPand TVmust be slightly cor

rected. Proceed as follows:

–

Set TV(Code 18) to 4.

–

Reduce KP(Code 17) until the positioner shows a stable behavior.

Zero point correction

Finally, if process operations allow it, the zero point must be calibrated as described in section

7.6.

7.6 Zero calibration

In case of discrepancies with the closing position of the valve, e.g. with soft-sealed plugs, it may become necessary to recalibrate the zero point.

NOTICE

The valve briefly moves from the current travel/angle of rotation position to the closed position.

Note: The supply air must be connected to peform a zero calibration.

Enable configuration:

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Perform zero calibration:

Initialization mode Default: MAX

Turn

→

Code 6

Press , Code 6 blinks.

Turn

→

Press .

Turn

→

Code 0

Press . Display: MAN, Code 0 blinks.

Turn

→

Init

Press . The setting of the fail-safe position AtO or AtC appears.

Keep

pressed down for 6 seconds. Zero calibration is started, the positioner moves the control valve to the CLOSED posi

tion and recalibrates the internal electrical zero point.

52 EB 8387-5 EN

Start-up – Settings

Page 53

7.7 Reset to default values

This function resets all parameters to the fac

tory default values (see code list in section 11).

Enable configuration:

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Reset start-up parameters:

Reset Default: OFF

Turn

→

Code 36, display: OFF

Press , Code 3 blinks.

Turn

→

RUN

Press . All start-up parameters are reset to their default values.

EB 8387-5 EN 53

Start-up – Settings

Page 54

8 Operation

WARNING!

The actuator stem moves while the positioner is being operated. Do not touch the actuator stem or obstruct it to avoid risk of injury to hands or fingers.

8.1 Enabling and selecting parameters

All codes with their meanings and default settings are listed in the code list in sec

tion 11 on page 59 onwards. The codes which are marked with an asterisk (*) must be enabled with Code 3 before the associated parameters can be configured as described below.

Code

Configuration not enabled

Configuration enabled

Turn

→

Code 3, display: OFF

Press , Code 3 blinks Change the setting of Code 3.

Turn

→

Press , display: The configuration is enabled.

You can now configure codes one after the other:

Turn

and select the required code.

Press to access the selected code. The code number starts to blink.

Turn and select the setting.

Press to confirm the selected setting.

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid and the display resets to Code 0.

Canceling the setting

To cancel a value before it is confirmed (rotary pushbutton

) without the value you

have just selected being adopted:

Turn

→

ESC

Press to confirm the cancelation. The entry is completed without the value you have just selected being adopted.

54 EB 8387-5 EN

Operation

Page 55

8.2 Operating modes

8.2.1 Automatic and manual operating modes

After initialization has been completed suc

cessfully for the first time, the positioner is automatically in automatic operating mode.

automatic operating

mode

Switching to manual operating mode

Turn

→

Code 0

Press , display: AUtO, Code 0 blinks.

Turn

→

MAN

Press to switchover to manual operat

ing mode. The switchover is smooth since the manual operating mode starts up with the set point last used during automatic operating mode. The current position is displayed in %.

Adjust the manual reference variable

Turn

→

Code

Press , Code 1 blinks.

Turn until the positioner has built up enough pressure and the control valve moves to the required position.

Note: If no settings are entered within approx. two minutes, the positioner auto

matically returns to Code 0, but remains in

manual operating mode.

Switching to automatic operating mode:

Turn

→

Code 0

Press , Code 0 blinks.

Turn

→

AUtO

Press to switchover to the automatic operating mode.

EB 8387-5 EN 55

Operation

Page 56

8.2.2 SAFE – Fail-safe position

If you want to move the valve to fail-safe po

sition determined during start-up (see sec

tion 7.4), proceed as follows:

Turn

→

Code 0

Press , display: current operating mode (AUtO or MAN), Code 0 blinks.

Turn

→

SAFE

Press , display: S The valve moves to the fail-safe position. If the positioner is initialized, the current valve position is indicated on the display in %.

Exit the fail-safe position

Turn

→

Code 0

Press , Code 0 blinks.

Turn

and select the required operating

mode AUtO or MAN.

Press . The positioner switches to the operating mode selected.

8.3 Malfunction/maintenance alarm

All status messages and fault alarms are as

signed to a classified status in the positioner. The default settings of the status classifica

tion are listed in the code list.

Note: The classification of the status messages can be changed in TROVIS-VIEW and over the parameters in the DD file. Refer to the Configuration Manual KH 8387-5 on the supplied CD-ROM (CD 8387-5) for more information.

To provide a better overview, the classified alarms are summarized in a condensed state. The following status messages are available:

Maintenance alarm

The positioner cannot perform its control task due to a functional fault in the de

vice or in one of its peripherals or an ini

tialization has not yet been successfully completed.

Maintenance required

The positioner still performs its control task (with restrictions). A maintenance requirement or above average wear has been determined. The wear tolerance will soon be exhausted or is reducing at a faster rate than expected. Maintenance is necessary in the medium term.

Maintenance demanded

The positioner still performs its control task (with restrictions). A maintenance demand or above average wear has been determined. The wear tolerance will soon be exhausted or is reducing at a

56 EB 8387-5 EN

Operation

Page 57

faster rate than expected. Maintenance is necessary in the short term.

Function check

Test or calibration procedures are being performed. The positioner is temporarily unable to perform its control task until this procedure is completed

Note: If an event is assigned to the “No message” status, this event does not have any effect on the condensed state.

The condensed state is represented by the following icons:

Condensed state

Positioner

display

Maintenance alarm

Maintenance required/ Maintenance demanded

Function check

tESting, TunE or

tESt

If the positioner has not been initialized, the maintenance alarm icon ( ) appears on the display as the positioner cannot follow its reference variable.

If fault alarms exist, the possible source of error is displayed in Code 49 onwards. In this case, Err appears on the display.

The cause and recommended action are listed in the code list (section 11).

Error: Pin position

Note: The optional EXPERT+valve diagnos

tics generate further diagnostic messages which are included in the condensed state according on how they have been classified. A diagnostic alarm generated by the ex

tended EXPERT

diagnostics is issued by

Code 79.

8.3.1 Confirming error messages

Enable configuration:

Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid.

Configuration enabled Standard: OFF

Turn

→

Code 3, display: OFF

Press , Code 3 blinks.

Turn

→

Press , display:

Confirming alarm:

Turn

→

Error code that is to be con

firmed.

Press

to confirm the errror message.

EB 8387-5 EN 57

Operation

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9 Maintenance

The positioner does not require any mainte

nance. There are filters with a 100µm mesh size in the pneumatic connections for supply and output which can be removed and cleaned, if required. The maintenance instructions of any up

stream supply air pressure reducing stations must be observed.

10 Servicing explosion-protected

devices

If a part of the positioner on which the ex

plosion protection is based needs to be ser

viced, the positioner must not be put back into operation until an expert has inspected the device according to explosion protection requirements, has issued a certificate stating this or given the device a mark of confor

mity. Inspection by an expert is not required if the manufacturer performs a routine test on the device prior to putting it back into opera

tion. The passing of the routine test must be documented by attaching a mark of confor

mity to the device.

58 EB 8387-5 EN

Maintenance

Page 59

11 Code list

Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

Operating mode

[MAN] AUtO · SAFE ESC

AUtO Automatic mode MAN Manual mode SAFE Fail-safe position ESC Escape In MAN and AUtO mode, the system deviation is represented by

bar elements on the display. If the positioner has been initialized, the numerical reading indi

cates the valve position or the angle of rotation in %, otherwise the position of the lever in relation to the central axis is displayed in degrees °.

Switchover from automatic to manual mode is smooth. In fail-safe position, the S icon appears on the display.

Init AtO · AtC

Init Start initialization Determine fail-safe position:

AtO: AIR TO OPEN (valve CLOSED in fail-safe position) or AtC: AIR TO CLOSE (valve OPEN in fail-safe position)

Manual reference variable w

0 to 100 [0] % of the nominal range

Setting the manual reference variable w The current travel/angle is displayed in % when the positioner

has been initialized, otherwise the position of the lever in relation to the central axis is indicated in degrees °.

Can only be selected when Code 0 = MAN.

Reading direction

[Normal] or upside down ESC

The reading direction of the display is turned by 180°.

Enable configuration

[OFF] ON ESC

Enables the option to modify data (automatically deactivated when the rotary pushbutton has not been operated for 120 s.)

FF blinks on the display when the on-site operation is locked over the FF network.

Codes marked with an asterisk (*) can only be read and not overwritten. Codes can also only be read over the SSP interface.

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

Pin position

[OFF] 17, 25, 35, 50, 70, 100,

200 mm 90° with rotary actuators ESC

Note! If you select a pin position in Code 4 that is too small, the positioner switches to the fail-safe position (SAFE mode) for reasons of safety.

The follower pin must be inserted into the correct pin position ac

cording to the valve travel/angle of rotation. The pin position must be entered for initialization using NOM or

SUb.

Pin position Standard Adjustment range Code 4 Code 5 Code 5

17 7.5 3.6 to 17.7 25 7.5 5.0 to 25.0 35 15.0 7.0 to 35.4 50 30.0 10.0 to 50.0 70 40.0 14.0 to 70.7 100 60.0 20.0 to 100.0 200 120.0 40.0 to 200.0 90° 90.0 24.0 to 100.0

Nominal range

mm or angle ° ESC

For initialization using NOM or SUb, the nominal travel/angle of rotation of the valve must be entered. The permissible adjustment range depends on the pin position according to the table for Code 4.

Code 5 is generally locked until Code 4 is set to OFF, i.e. after a pin position has been entered, Code 5 can be configured.

After initialization has been successfully completed, the max

imum nominal travel/angle reached on initialization is dis

played.

Initialization mode

[MAX] NOM · MAN · SUb · ZP ESC

Select the initialization mode MAX: Maximum range of the control valve, the travel/angle of

the closure member from the CLOSED position to the op

posite stop in the actuator.

NOM: Nominal range of the control valve, the travel/angle of

the closure member measured from the CLOSED position

to the indicated OPEN position. MAN: Manually selected range SUb: Substitute calibration (emergency mode) ZP: Zero calibration

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

Direction of action

[ää]

äæ

ESC

Direction of action of the reference variable w in relation to the travel/angle of rotation x (increasing/increasing or in

creasing/decreasing).

Automatic adaptation:

AIR TO OPEN: After initialization, the direction of action remains

increasing/increasing (ää), a globe valve opens as the reference variable increases.

AIR TO CLOSE: After initialization, the direction of action

changes to increasing/decreasing (äæ), a globe valve closes as the reference variable increases.

Travel/angle range start (lower x-range value)

0.0 to 80.0 [0.0] % of the nominal range

Specified in mm or angle ° provided Code 4 is set

ESC

Starting value for the travel/angle of rotation in the nominal or operating range.

The operating range is the actual travel/angle of the control valve and is limited by the travel/angle range start (Code 8) and the travel/angle range end (Code 9). Usually, the operating range and the nominal range are identical. The nominal range can be limited to the operating range by the travel/angle range start and end. Value is displayed or must be entered.

The characteristic is adapted. See also the example in Code 9.

Travel/angle range end (upper x-range value)

20.0 to 100.0 [100.0] % of the nominal range

Specified in mm or angle ° provided Code 4 is set

ESC

End value for the travel/angle of rotation in the nominal or oper

ating range. Value is displayed or must be entered. The characteristic is adapted. Example: The operating range is modified, for example, to limit

the range of a control valve which has been sized too large. For this function, the entire resolution range of the reference variable is converted to the new limits. 0 % on the display corresponds to the adjusted lower limit and 100 % to the adjusted upper limit.

10*

Travel/angle lower limit (lower x-limit)

[OFF]

0.0 to 49.9 % of the operating range

ESC

Limitation of the travel/angle of rotation downwards to the en

tered value. The characteristic is not adapted. See also example in Code 11.

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

11*

Travel/angle upper limit (upper x-limit)

50.0 to 120.0 [100] % of the operating range

OFF · ESC

Limitation of the travel/angle of rotation upwards to the entered value.

When set to OFF, the valve can be opened past the nominal travel with a reference variable outside of the 0 to 100 % range.

The characteristic is not adapted. Example: In some applications, it is better to limit the valve

travel, e.g. if a certain minimum medium flow is required or a maximum flow must not be reached. The lower limit must be adjusted with Code 10, and the upper limit with Code 11. If a tight-closing function has been set up, it has priority over the travel limitation.

14*

Setpoint cutoff decrease (final position w <)

0.0 to 49.9 [1.0] % OFF · ESC

If reference variable w reaches the percentage adjusted that causes the valve to close, the actuator is immediately completely vented (with AIR TO OPEN) or filled with air (with AIR TO CLOSE). This action always lead to maximum tight-closing of the valve.

Codes 14/15 have priority over Codes 8/9/10/11. Codes 21/22 have priority over Codes 14/15.

15*

Setpoint cutoff increase (final position w >)

[OFF]

50.0 to 100.0 % ESC

If reference variable w reaches the percentage adjusted that causes the valve to open, the actuator is immediately completely filled with air (with AIR TO OPEN) or vented (with AIR TO CLOSE). This action always lead to the valve being completely opened. A signal pressure limit is possible over Code 16.

Codes 14/15 have priority over Codes 8/9/10/11. Codes 21/22 have priority over Codes 14/15.

Example: Set the cutoff to 99 % for three-way valves.

16*

Pressure limit

[OFF] P 1.4 2.4 3.7 ESC

The pressure limit determined during initialization is displayed in bar. The pressure limit can be changed for fail-safe position AIR TO OPEN (AtO).

After changing a pressure limit already set, the actuator must be vented once (e.g. by selecting the fail-safe position over Code 0).

NOTICE

Do not activate the pressure limit for actuators with fail-safe posi

tion AIR TO OPEN (AtO), e.g. double-acting actuators.

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

17*

Proportional-action coeffi

cient KP (step)

0 to 17 [7] ESC

Displaying or changing the KPand TVsteps:

During initialization, the KPand TVvalues are optimized. Should the positioner show a tendency for impermissibly high post-pulse oscillation due to additional interference, the KPand TVsteps can be adapted after initialization. For this, either the TVstep can be increased in increments until the desired response behavior is reached or, when the maximum value of 4 is reached, the K

step can be decreased in increments. Note: Changing the K

step influences the system deviation.

18*

Rate time TV (step)

[2] 1 3 4 OFF ESC

Changing TV, see Code 17. Note: Changing the TVstep has no effect on the system devia

tion.

19*

Tolerance band

0.1 to 10.0 [5] % of the operating range

ESC

Used for error monitoring Determination of the tolerance band in relation to the operating

range. Associated lag time [30] s is a reset criterion. If a lag time is determined during initialization which is six times > 30 s, the six-fold lag time is accepted as the lag time.

20*

Characteristic

0 to 9 [0] ESC

Select the characteristic: 0 Linear 1 Equal percentage 2 Reverse equal percentage 3 SAMSON butterfly valve linear 4 SAMSON butterfly valve equal percentage 5 VETEC rotary plug valve linear 6 VETEC rotary plug valve equal percentage 7 Segmented ball valve linear 8 Segmented ball valve equal percentage 9 User-defined (defined over operating software) Note: The various characteristics are listed in the Appendix

(section 13.1).

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

21*

Required transit time OPEN (w ramp open)

0 to 240 s [0] ESC

The time required to pass through the operating range when the valve opens.

Limitation of the transit time (Code 21 and 22): For some applications it is better to limit the actuating speed of the actuator to prevent it from engaging too fast in the running process.

Code 21 has priority over Code 15.

22*

Required transit time CLOSED (w ramp closed)

0 to 240 s [0] ESC

The time required to pass through the operating range when the valve closes.

Code 22 has priority over Code 14.

23*

Total valve travel

0 to 99 · 107[0]

Exponential reading from 9999 travel cycles onwards

RES · ESC

Totaled double valve travel. Can be reset to 0 via

RES.

Note: The number of travel cycles (in steps of 1000) is saved in a non-volatile memory.

24*

Limit of total valve travel

1000 to 99 · 10

[1 000 000]

Exponential reading from 9999 travel cycles onwards

ESC

Limit value of total valve travel. If the limit is exceeded, the fault alarm and the wrench icons appear on the display.

34*

Closing direction

[CCL] Counterclockwise CL Clockwise ESC

Turning direction of the lever in which the valve is moved to the CLOSED position (view onto the display of the positioner).

Needs only be entered in SUb initialization mode.

35*

Blocking position

[0] mm/° /% ESC

Distance up to the CLOSED position (0 % position). Only needs to be entered in SUb initialization mode.

36*

Reset

[OFF] RUN · ESC

Resets all parameters to default settings. Note: After setting

RUN, the positioner must be re-initialized.

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

System deviation e

–99.9 to 999.9 %

Deviation from the target position (e = w – x) Display only

Minimum transit time OPEN

0 to 240 s [0]

Time [s] needed by the system (positioner, actuator and valve) to move through the nominal travel/angle to open the valve (100 % position).

Display only

Minimum transit time CLOSED

0 to 240 s [0]

Time [s] needed by the system (positioner, actuator and valve) to move through the nominal travel/angle to close the valve (0 % position).

Display only

Auto-w/manual-w

0.0 to 100.0 % of the span

Supplied manual and automatic reference variable Display only

Firmware version control

Xxxx

Positioner type and current firmware version (in alternating sequence)

Display only

y info

0 to 100 %, [0 %]

Control signal y [%] based on the travel range determined on initialization · Display only

MAX: The positioner builds up its maximum output pressure,

see description in Code 14 and 15.

0 P: The positioner vents completely, see description in

Code 14 and 15.

– – –: The positioner has not been initialized.

Forced venting status

YES · HIGH/LOW · NO

Indicates whether the option is installed or not · Display only NO No forced venting installed YES Forced venting installed If a voltage supply is connected at the terminals of the forced

venting option, YES and HIGH appear on the display in alter

nating sequence. If a voltage supply is not applied (actuator vented, fail-safe position indicated on the display by the S icon), YES and LOW appear on the display in alternating sequence.

46*

Bus address

ESC

Display only

EB 8387-5 EN 65

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

47*

Status of write protection switch

[NO] YES · ESC

When the write protection function is activated, device data can only be read, but not overwritten over FF communication.

48*

Diagnostics

Diagnostic parameters d

d0 Temperature

–55 to 125 °C

Current operating temperature [°C] inside the positioner (accuracy±3 %)

Display only

d1 Minimum temperature

[20]

The lowest temperature below 20 °C that has ever occurred. Display only

d2 Maximum temperature

[20]

The highest temperature above 20 °C that has ever occurred. Display only

d3 Number of zero

calibrations

[0]

The number of zero calibrations since the last initialization. Display only

d4 Number of

initializations

[0]

The number of initializations that have been performed since the last reset.

Display only

d5 Zero point limit

[5 %]

0.0 to 100.0 % of the nominal range

User-defined zero point monitoring Used for error monitoring of the zero point shift.

d6 Condensed state Condensed state, made up from the individual states · Display

only OK Okay C Maintenance required CR Maintenance demanded B Maintenance alarm I Function check

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

48*

d7 Start reference test

[OFF] ON · ESC

Starting of a reference test (for the EXPERT+functions: Drive signal y steady-state (d1) and drive signal y hysteresis (d2).

The reference test can only be activated in manual operating mode as the valve moves through its entire working range.

If EXPERT+is activated at later point in time, the reference graphs must be plotted in order to activate the diagnostic functions.

d8 EXPERT

activation Enter the activation code for EXPERT+.

After the activation procedure has been successfully completed, YES appears under d8.

FF parameters

F0 Firmware Rev.

Communication

Display only

F1 Binary input Display only

1 Active · 2 Inactive

F3 Simulate PV Activation of simulation mode

Positioner (AO)

A0 Target Mode Target operating mode

A1 Actual Mode Actual operating mode · Display only

A2 CAS_IN Value Analog reference variable adopted from an upstream function

block (value) · Display only

A3 CAS_IN Status Analog reference variable adopted from an upstream function

block (status) · Display only

A4 SP Value Reference variable w (value) · Display only

A5 SP Status Reference variable w (status) · Display only

A6 OUT Value Manipulated variable (value) · Display only

A7 OUT Status Manipulated variable (status) · Display only

A8 BLOCK ERR Active block error · Display only

EB 8387-5 EN 67

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

48*

Process controller (PID)

P0 Target Mode Target operating mode

P1 Actual Mode Actual operating mode · Display only

P2 CAS_IN Value Analog reference variable adopted from an upstream function

block (value) · Display only

P3 CAS_IN Status Analog reference variable adopted from an upstream function

block (status) · Display only

P4 SP Value Reference variable w (value) · Display only

P5 SP Status Reference variable w (status) · Display only

P6 OUT Value Manipulated variable (value) · Display only

P7 OUT Status Manipulated variable (status) · Display only

P8 BLOCK ERR Active block error · Display only

Positioner (AO TRD), binary input (DI1 TRD, DI2 TRD)

t0 Target Mode (AO TRD) Target operating mode

t1 Actual Mode (AO TRD) Actual operating mode · Display only

t2 Transducer State State of the Transducer Block · Display only

t3 BLOCK ERR AO TRD Active block error · Display only

t4 Target Mode (DI1 TRD) Target operating mode

t5 Actual Mode (DI1 TRD) Actual operating mode · Display only

t6 BLOCK ERR DI1 TRD Active block error · Display only

t7 Target Mode (DI2 TRD) Target operating mode

t8 Actual Mode (DI2 TRD) Actual operating mode · Display only

t9 BLOCK ERR DI2 Active block error · Display only

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

48*

Operating unit (RES)

S0 Target Mode (RES) Target operating mode

S1 Actual Mode (RES) Actual operating mode · Display only

S2 BLOCK ERR (RES) Active block error · Display only

Binary input (DI1)

I0 Target Mode (DI1) Target operating mode

I1 Actual Mode (DI1) Actual operating mode · Display only

I2 Field_Val_D Value Discrete process variable field hardware (value) · Display only

I3 Field_Val_D Status Discrete process variable field hardware (status) · Display only

I4 OUT_D Value Discrete output variable (value) · Display only

I5 OUT_D Status Discrete output variable (status) · Display only

I6 BLOCK ERR Active block error · Display only

Binary input DI2

L0 Target Mode (DI2) Target operating mode

L1 Actual Mode (DI2) Actual operating mode · Display only

L2 Field_Val_D Value Discrete process variable field hardware (value) · Display only

L3 Field_Val_D Status Discrete process variable field hardware (status) · Display only

L4 OUT_D Value Discrete output variable (value) · Display only

L5 OUT_D Status Discrete output variable (status) · Display only

L6 BLOCK ERR Active block error · Display only

D2 Function Block L

L0 Target Mode DI2 Required operating mode

L1 Actual Mode DI2 Actual operating mode

L2 Field_Val_D Value Displays the discrete input variable

EB 8387-5 EN 69

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Code

no.

Parameter – Display, values [default setting]

Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.

48*

L3 Field_Val_D Status and its status

L4 OUT_D Value Displays the discrete output variable

L5 OUT_D Status and its status

L6 BLOCK ERR Displays the current block error

49*

PST Description of partial stroke test function (refer to EB 8388-5 EN)

Note: The error codes listed in following appear in the display corresponding to their status classification set over the condensed state (Maintenance required/Maintenance demanded:

, Maintenance alarm: ). If “No message” is assigned to the error code as the status

classification, the error is not included in the condensed state.

A status classification is assigned to every error code in the default setting. The status classification of error codes can also be changed as required using an operating software (e.g. TROVIS-VIEW). Refer to the Configuration Manual KH 8387-5.

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Initialization errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

x > range The value supplied by the measuring signal is either too high or

too low, the measuring sensor is close to its mechanical limit.

• Pin positioned incorrectly.

• Bracket slipped in case of NAMUR attachment or positioner is

not central.

• Follower plate incorrectly attached.

Status classification [Maintenance required]

Recommended action Check attachment and pin position, set operating mode from

SAFE to MAN and re-initialize the positioner.

∆

x < range The measuring span of the sensor is too low.

• Pin positioned incorrectly.

• Wrong lever. A rotational angle smaller than 16° at the positioner shaft creates

just an alarm. An angle below 9° leads to the initialization being canceled.

Status classification [Maintenance required]

Recommended action Check attachment and re-initialize the positioner.

Attachment • Positioner attachment incorrect.

• Nominal travel/angle (Code 5) could not be achieved on

initialization under NOM or SUb (no tolerance downwards permissible).

• Mechanical or pneumatic fault, e.g. wrong lever selected or

supply pressure too low to move to the required position.

Status classification [Maintenance required]

Recommended action Check attachment and supply pressure. Re-initialize the

positioner. Under certain circumstances, it may be possible to check the maximum travel/angle by entering the actual pin position and then performing an initialization under MAX. After initialization has been completed, the Code 5 indicates the maximum achieved travel or angle.

EB 8387-5 EN 71

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Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Initialization time exceeded (Init time >)

The initialization routine lasts too long. The positioner returns to its previous operating mode.

• No pressure on the supply line or there is a leak.

• Supply air failure during initialization.

Status classification [Maintenance required]

Recommended action Check attachment and supply pressure.

Re-initialize the positioner.

Initialization/forced venting 1) A solenoid valve is installed (Code 45 = YES) and was

not or not properly connected so that an actuator pressure could not be built up. The alarm is generated when you attempt to initialize the positioner.

2) If you attempt to initialize the device from the fail-safe position (SAFE).

Status classification [Maintenance required]

Recommended action Re. 1) Check connection and supply voltage of the forced venting

Code 45 HIGH/LOW

Re. 2) Set the MAN operating mode over Code 0. Then initialize

the positioner.

Transit time too short (transit time <)

The actuator positioning rates determined during the initialization are so short that the positioner cannot adapt itself optimally.

Status classification [Maintenance required]

Recommended action Check the volume restriction setting as described in section 4,

re-initialize the positioner.

Pin position Initialization was canceled because you are required to enter the

pin position for the selected initialization modes NOM and SUb.

Status classification [Maintenance required]

Recommended action Enter pin position over Code 4 and nominal travel/angle over

Code 5. Re-initialize the positioner.

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Operational errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Control loop Control loop error, the control valve does not react within the to

lerable times of the controlled variable (tolerance band alarm Code 19).

• Actuator mechanically blocked.

• Attachment of the positioner subsequently shifted.

• Supply pressure not sufficient.

Status classification [Maintenance required]

Recommended action Check attachment.

Zero point Zero point incorrect.

Error may arise when the mounting position/linkage of the posi

tioner moves or when the valve seat trim is worn, especially with soft-sealed plugs.

Status classification [Maintenance required]

Recommended action Check valve and mounting of the positioner. If OK, perform a

zero calibration over Code 6 (see section 7.6 on page 52). If the lever position on the back of the positioner has been changed (e.g. while exchanging the lever), move the lever as far as it will go in both directions to adapt it to the internal measuring lever. We recommend re-initializing the positioner if the zero point de

viates by more than 5 %.

Autocorrection Should an error occur in the data range of the positioner, the

self-monitoring function recognizes it and automatically corrects it.

Status classification [No message]

Recommended action Automatic

Fatal error An error was detected in the data relevant for safety,

autocorrection is not possible. This may be due to EMC disturbances.

The control valve moves to its fail-safe position.

Status classification Maintenance alarm (cannot be classified)

Recommended action Reset over Code 36.

Re-initialize the positioner (see sections 7.7 and 7.5).

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Hardware errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

x signal Determination of the measured data for the actuator has failed.

Conductive plastic element is defective. The positioner continues to run in emergency mode, but should be replaced as soon as possible. The emergency mode on the display is indicated by a blinking closed-loop control icon and 4 dashes instead of the position in

dication.

Note on the control:

If the measuring system has failed, the positioner is still in a reli

able state. The positioner switches to emergency mode where the position cannot be accurately controlled anymore. However, the positioner continues operation according to its reference variable signal so that the process remains in a safe state.

Status classification [Maintenance required]

Recommended action Return the positioner to SAMSON AG for repair.

i/p converter The circuit of the i/p converter has been interrupted.

Status classification Maintenance alarm (cannot be classified)

Recommended action Cannot be remedied.

Return the positioner to SAMSON AG for repair.

Hardware A hardware error has occurred, the positioner moves to the

fail-safe position SAFE.

Status classification Maintenance alarm (cannot be classified)

Recommended action Confirm error and return to the automatic operating mode, or

perform a reset and re-initialize the device. If this is not success

ful, return device to SAMSON AG for repair.

Data memory The writing of data to the data memory does not work anymore,

e.g. when the written data deviate from the read data. Valve moves to the fail-safe position.

Status classification Maintenance alarm (cannot be classified)

Recommended action Return the positioner to SAMSON AG for repair.

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Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Test calculation The hardware controller is monitored by means of a test

calculation.

Status classification Maintenance alarm (cannot be classified)

Recommended action Confirm error. If this is not possible, return the positioner to

SAMSON AG for repair.

Data errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Control parameter Control parameter error

Status classification [Maintenance required]

Recommended action Confirm error, perform reset and re-initialize the positioner.

Poti parameter Parameter error of the digital potentiometer.

Status classification [Maintenance required]

Recommended action Confirm error, perform reset and re-initialize the positioner.

Calibration Error in the production calibration data. Subsequently, the device

runs on default values.

Status classification [Maintenance required]

Recommended action Return the positioner to SAMSON AG for repair.

General parameters Parameter errors that are not critical for the control.

Status classification [Maintenance required]

Recommended action Confirm error.

Check and, if necessary, reset required parameters.

Start-up parameters Start-up parameter error

Status classification [Maintenance required]

Recommended action Confirm error, perform reset and re-initialize the positioner.

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Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Internal device error 1 Internal device error

Status classification [Maintenance required]

Recommended action Return the positioner to SAMSON AG for repair.

FF parameters Parameter errors that are not critical for the control.

Status classification [Maintenance required]

Recommended action Confirm error and perform reset.

Info parameters Info parameter errors that are not critical for the control.

Status classification [Maintenance required]

Recommended action Confirm error.

Check and, if necessary, reset required parameters.

No emergency mode The travel measuring system of the positioner has a

self-monitoring function (see Code 62). An emergency mode (open-loop control) is not available for certain actuators, such as double-acting actuators. In this case, the positioner moves to the fail-safe position when a measuring error occurs. During the initialization, the positioner checks whether the actuator has such a function or not.

Status classification [No message]

Recommended action Merely information, confirm, if necessary.

No further action necessary.

Program loading error

Additional alarm at the fault alarm contact

When the positioner starts operation for the first time after the in

put signal has been applied, it carries out a self-test (

tEStinG runs across the display). If the positioner loads the wrong program, the valve moves to the fail-safe position. It is not possible to make the valve leave this fail-safe position again.

Status classification

Maintenance alarm (cannot be classified)

Recommended action Interrupt current and restart positioner.

Otherwise, return the positioner to SAMSON AG for repair.

Options parameter Errors in options parameters

Status classification [Maintenance required]

Recommended action Return the positioner to SAMSON AG for repair.

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Diagnosis errors

Error codes – Recommended action Condensed state alarm active, when prompted, Err appears.

When fault alarms exist, they are displayed here.

Extended diagnostics Error messages are generated in the extended EXPERT+diagnos

tics if EXPERT+has been successfully activated in Code 48.

Status classification

Maintenance required (cannot be classified)

Diagnostic parameters Errors that are not critical for control.

Status classification Maintenance required (cannot be classified)

Reference test canceled The reference graphs were not plotted or an error occurred

during plotting the reference graphs for drive signal y steady-state or drive signal y hysteresis.

• Reference test was interrupted

• Reference line y steady-state or y hysteresis was not adopted. Error messages are saved in EEPROM. They cannot be reset.

Status classification [Maintenance required]

Recommended action Check and, if necessary, perform a new reference test

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12 Dimensions in mm

78 EB 8387-5 EN

Dimensions in mm

122

NPT ½, ¼

236

Output Supply

Fig. 15a · Attachment according to IEC 60534-6 and direct attachment

Attachment acc. to IEC 60534-6

→

Direct attachment

→

Pressure gauge bracket

or connecting plate (G ¼ only)

Electrical connections: 2 x female thread

½ NPT or M20 x 1.5

Lever in mm

S = 17 M = 50 L = 100 XL = 200

¼ NPT

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EB 8387-5 EN 79

Dimensions in mm

Output Y

Supply (9)

Output Y

130

166

30 86

Ø 101

Fig. 15b · Attachment to rotary actuators VDI/VDE 3845 (Sept. 2010), level 1, size AA1 to AA4

Type 3710 Reversing Amplifier (option)

A1Z

130

166

30 86

Ø 101

Output A2

Output A1

Supply (9)

Reversing amplifier 1079-1118 or 1079-1119 (option)

Page 80

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

80 EB 8387-5 EN

Dimensions in mm

min

Ød

ØD

Level 2 (bracket surface)

Level 1 (actuator surface)

Actuator

Dimensions in mm

Size A B C

∅

d M

min

∅

D* AA0 50 25 15 5.5 for M5 66 50 AA1 80 30 20 5.5 for M5 96 50 AA2 80 30 30 5.5 for M5 96 50 AA3 130 30 30 5.5 for M5 146 50 AA4 130 30 50 5.5 for M5 146 50 AA5 200 50 80 6.5 for M6 220 50

* Flange type F05 according to DIN EN ISO 5211

Page 81

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Page 82

13 Appendix

13.1 Selecting the valve characteristic

The characteristics that can be selected in Code 20 are shown in following in graph form.

Note: A characteristic can only be defined (user-defined characteristic) using a workstation/ operating software (e.g. TROVIS-VIEW).

Linear (select characteristic: 0)

Equal percentage (select characteristic: 1) Rev. equal percentage (select characteristic: 2)

82 EB 8387-5 EN

Appendix

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

Page 83

SAMSON butterfly valve linear

(select characteristic: 3)

SAMSON butterfly valve equal percentage

(select characteristic: 4)

VETEC rotary plug valve linear

(select characteristic: 5)

VETEC rotary plug valve equal percentage

(select characteristic: 6)

Segmented valve ball linear

(select characteristic: 7)

Segmented ball valve equal percentage

(select characteristic: 8)

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

100

0 50 100

Travel/ angle of rotation [%]

Reference variable [%]

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Page 90

Index

Accessories . . . . . . . . . . . . . . . . . . 28 - 29

Additional equipment

binary input. . . . . . . . . . . . . . . . . . . . 9

electrical connection . . . . . . 36

technical data . . . . . . . . . 12

extended EXPERT+ valve diagnostics . . 9

forced venting . . . . . . . . . . . . . . . . . . 9

electrical connection . . . . . . 36

technical data . . . . . . . . . 12

Article code . . . . . . . . . . . . . . . . . . . . . . 7

Attachment

acc. to IEC 60534-6 (NAMUR). . . . . 20

direct attachment

to Type 3277 Actuator . . . . . 18

to Type 3277-5 Actuator . . . . 15

reversing amplifier. . . . . . . . . . . . . . 26

to rotary actuators . . . . . . . . . . . . . . 24

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

Bar elements . . . . . . . . . . . . . . . . . . . . . 38

Blocking position

canceling . . . . . . . . . . . . . . . . . . . . 51

Bus line. . . . . . . . . . . . . . . . . . . . . . . . . 36

Cable entry. . . . . . . . . . . . . . . . . . . . . . 35

Characteristic

selecting . . . . . . . . . . . . . . . . . . 63, 82

Code list . . . . . . . . . . . . . . . . . . . . 59 - 77

Communication . . . . . . . . . . . . . . . 10 - 11

Configuration

using NI-BUS Configurator . . . . . . . . 10

using TROVIS-VIEW. . . . . . . . . . . . . 10

Connections

electrical . . . . . . . . . . . . . . . . . . . . . 33

pneumatic . . . . . . . . . . . . . . . . . . . . 31

Default values . . . . . . . . . . . . . . . . . . . . 53

Design, positioner . . . . . . . . . . . . . . . . . . 8

Display . . . . . . . . . . . . . . . . . . . . . 38 - 39

turned by 180° . . . . . . . . . . . . . . . . 40

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

Enable configuration . . . . . . . . . . . . 38, 54

Error messages

confirming. . . . . . . . . . . . . . . . . . . . 57

data errors . . . . . . . . . . . . . . . . . . . 75

diagnosis errors. . . . . . . . . . . . . . . . 77

initialization errors. . . . . . . . . . . . . . 71

operational errors . . . . . . . . . . . . . . 73

Explosion protection . . . . . . . . . . . . . . . 12

Fail-safe position. . . . . . . . . . . . . . . . . . 56

determining. . . . . . . . . . . . . . . . . . . 42

Initialization

MAN manually selected range . . 43, 47

MAX maximum range. . . . . . . . 43 - 44

NOM nominal range . . . . . . . . . 43, 45

SUB substitute calibration . . . . . . 43, 48

Maintenance. . . . . . . . . . . . . . . . . . . . . 58

Malfunction. . . . . . . . . . . . . . . . . . . . . . 56

Mounting parts . . . . . . . . . . . . . . . 28 - 29

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Index

Page 91

Operating modes . . . . . . . . . . . . . . 38, 55

Operating range

checking . . . . . . . . . . . . . . . . . . . . . 41

MAN manually selected range . . 43, 47

MAX maximum range. . . . . . . . 43 - 44

NOM nominal range . . . . . . . . . 43, 45

Operation . . . . . . . . . . . . . . . . . . . 54 - 57

Operator controls . . . . . . . . . . . . . . . . . 39

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

Principle of operation, positioner . . . . . . . 8

Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Reversing amplifier . . . . . . . . . . . . . . . . 26

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

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

Signal pressure . . . . . . . . . . . . . . . . . . . 32

limiting . . . . . . . . . . . . . . . . . . . . . . 40

Start-up . . . . . . . . . . . . . . . . . . . . . 40, 53

Status messages . . . . . . . . . . . . . . . . . . 38

Function check. . . . . . . . . . . . . . . . . 57

Maintenance alarm . . . . . . . . . . . . . 56

Maintenance demanded. . . . . . . . . . 56

Maintenance required . . . . . . . . . . . 56

Substitute calibration . . . . . . . . . . . . 43, 48

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

Technical data. . . . . . . . . . . . . . . . . . . . 11

Travel tables . . . . . . . . . . . . . . . . . . . . . 14

Valve characteristic, selecting. . . . . . . . . 82

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

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Index

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SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 Internet: http://www.samson.de EB 8387-5 EN

2016-04