Series 3730
Electropneumatic Positioner
Type 3730-6
®
with HART communication and pressure sensors
Fig. 1 · Type 3730-6
Mounting and
Operating Instructions
EB 8384-6 EN
Firmware version 1.01
Edition February 2012
Definitions of the signal words used in these instructions
DANGER!
indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
NOTICE
indicates a property damage message.
Note: Supplementary explanations, information and tips
WARNING!
indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
2
EB 8384-6 EN
Contents
Contents
Page
1
Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6
2
Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3
3.1
3.2
3.3
3.4
3.5
3.5.1
3.6
3.7
Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8
Safety function (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flow rate calculation. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Type of application . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Configuration using TROVIS-VIEW 4 . . . . . . . . . . . . . . . . . . 12
Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 13
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4
4.1
4.1.1
4.1.2
4.2
4.3
4.4
4.4.1
4.5
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.7
4.8
4.9
4.10
Attachment to the control valve – Mounting parts and accessories . . .
Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . .
Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . .
Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . .
Attachment to Type 3510 Micro-flow Valve with Type 3271-5 Actuator .
Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . .
Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . .
Reversing amplifier for double-acting actuators . . . . . . . . . . . . .
Attaching an external position sensor. . . . . . . . . . . . . . . . . .
Mounting the position sensor with direct attachment. . . . . . . . . . .
Mounting the position sensor with attachment according to IEC 60534-6
Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . .
Mounting the position sensor to rotary actuators . . . . . . . . . . . .
Mounting the leakage sensor. . . . . . . . . . . . . . . . . . . . . .
Attaching positioners with stainless steel housings . . . . . . . . . . . .
Air purging function for single-acting actuators . . . . . . . . . . . . .
Required mounting parts and accessories . . . . . . . . . . . . . . . .
20
22
22
24
26
28
30
32
34
34
34
36
37
38
39
40
40
41
5
5.1
5.1.1
5.1.2
5.1.3
5.2
5.2.1
Connections . . . . . .
Pneumatic connections .
Signal pressure gauges
Supply pressure . . . .
Signal pressure (output)
Electrical connections .
Switching amplifiers . .
45
45
45
45
46
46
48
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EB 8384-6 EN
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3
Contents
5.2.2
Establishing communication . . . . . . . . . . . . . . . . . . . . . . 49
6
6.1
6.2
6.3
Operator controls and readings
Serial interface . . . . . . . .
HART® communication . . . .
Dynamic HART® variables . . .
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52
54
54
54
7
7.1
7.2
7.3
7.4
7.5
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.7
7.8
7.9
Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . .
Defining the valve closed position . . . . . . . . . . . . . . . .
Setting the volume restriction Q . . . . . . . . . . . . . . . . .
Adapting the display. . . . . . . . . . . . . . . . . . . . . . .
Limiting the signal pressure. . . . . . . . . . . . . . . . . . . .
Checking the operating range of the positioner . . . . . . . . . .
Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAX – Initialization based on maximum range . . . . . . . . . .
NOM – Initialization based on nominal range . . . . . . . . . .
MAN – Initialization based on a manually selected OPEN position
MAN2 – Initialization based on manually selected end positions. .
SUB – Substitute calibration . . . . . . . . . . . . . . . . . . .
Tuning the KP input filter . . . . . . . . . . . . . . . . . . . . .
Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . .
Settings for on/off valves . . . . . . . . . . . . . . . . . . . .
Reset to default values . . . . . . . . . . . . . . . . . . . . . .
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56
56
57
57
57
58
59
60
61
62
64
65
68
68
69
71
8
8.1
8.2
8.2.1
8.2.2
8.3
8.3.1
Operation. . . . . . . . . . . . .
Enabling and selecting parameters
Operating modes . . . . . . . . .
Automatic and manual modes . . .
Fail-safe position (SAFE) . . . . . .
Malfunction/Failure . . . . . . . .
Confirming error messages . . . .
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74
74
75
75
76
76
77
9
9.1
Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 78
Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 80
10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11
Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 81
12
Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 81
13
Maintenance, calibration and work on equipment . . . . . . . . . . . 82
14
Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4
EB 8384-6 EN
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Contents
15
15.1
Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . 110
16
Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 111
Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
EB 8384-6 EN
5
Important safety instructions
1
Important safety instructions
For your own safety, follow these instructions concerning the mounting, start-up and operation of the positioner:
4 The positioner is to be mounted, started up or operated only by trained and
experienced personnel familiar with the product.
According to these Mounting and Operating Instructions, trained personnel refers to
individuals who are able to judge the work they are assigned to and recognize
possible dangers due to their specialized training, their knowledge and experience as
well as their knowledge of the applicable standards.
4 Explosion-protected versions of this 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. Refer to section 11.
4 Any hazards that could be caused by the process medium, the operating pressure, the
signal pressure or by moving parts of the control valve are to be prevented by means
of the appropriate measures.
4 If inadmissible motions or forces are produced in the actuator as a result of the supply
pressure, the supply pressure must be restricted by means of a suitable supply
pressure reducing station.
To avoid damage to any equipment, the following also applies:
4 Do not operate the positioner with the back of the positioner/vent opening facing upwards.
The vent opening must not be sealed when the positioner is installed on site
Vent opening
4 Proper shipping and appropriate storage are assumed.
4 Do not ground electric welding equipment near to the positioner.
Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC
(ATEX) and 89/336/EEC (EMC).
The Declaration of Conformity is available on request.
6
EB 8384-6 EN
Article code
2
Article code
Type 3730-6- x x x x x x x 0 x x 0 x 0 0
Positioner
With HART® communication and pressure sensors
Explosion protection
ATEX:
II 2 G Ex ia IIC/IIB T6; II 2 D Ex tD A21 IP 66 T 80°C
IECEx: Ex ia IIC/IIB T6; Ex d[ia] IIC/IIB T6; Ex tD A21 IP 66 T 80°C
110
111
GOST: 1Ex ia IIC T6 X, DIP A21 Ta80°C, IP 66
113
ATEX:
810
II 3 G Ex nA II T6; II 3 G Ex nL IIC/IIB T6; II 3 D Ex tD A22 IP 66 T 80°C
IECEx: Ex nA II T6; Ex nL IIC/IIB T6; Ex tD A22 IP 66 T 80°C
811
GOST: Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 66
813
Options (additional equipment)
Inductive limit switch
Without
0
With SJ2-SN
With SJ2-S1N
1
2
Venting function
Without
Solenoid valve 24 V DC
Forced venting 24 V DC
Additional equipment
Without
Position transmitter
Leakage sensor
Binary input
External position sensor
Without
Including 10 m connecting cable
Prepared for connection, without sensor
Emergency shutdown
3.8 mA
4.4 mA
0
0
1
2
0
1
2 0
3
0
1
2
1
0
1
Housing material
Standard aluminum
1
Stainless steel 1.4581
2
Special applications
None
0
Compatible with paint
1
Exhaust air connection with ¼–18 NPT thread, back of positioner housing sealed
2
Attachment according to VDI/VDE 3847
6
EB 8384-6 EN
7
Design and principle of operation
3
Design and principle of
operation
The electropneumatic positioner is attached
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
pneumatic signal pressure (output variable
y) is produced.
The positioner basically consists of an electrical travel sensor system (2), an analog i/p
converter (6) with downstream air capacity
booster (7) and the electronics unit with a
microcontroller (5).
The standard positioner is fitted with three
binary contacts: A fault alarm output indicates a fault to a control station and two
configurable software limit switches are
used to indicate the end positions of the
valve.
The valve position (x) is transmitted as a linear travel motion or an angle of rotation by
the pick-up lever and travel sensor (2) to an
analog PD controller (3). Simultaneously, an
A/D converter (4) transmits the position of
the valve to the microcontroller (5). The PD
controller compares this valve position to the
4 to 20 mA DC control signal supplied by
the controller after it has been converted by
the A/D converter (4). In case of a system
deviation, the actuator (1) is either vented or
filled with more air by changes to the i/p
converter (6). This causes the valve plug to
adopt the position corresponding to the reference variable (w).
The supply air is supplied to the air capacity
8
EB 8384-6 EN
booster (7) and the pressure regulator (8).
An intermediate flow regulator (9) with fixed
settings is used to purge the positioner and
also guarantees trouble-free operation of the
air capacity booster. The output signal pressure supplied by the booster can be limited
over the software. Both pressure sensors (23
and 24) monitors the supply pressure ps and
the signal pressure pout.
The volume restriction Q (10) is used to optimize the positioner.
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
4
4
4
4
Design and principle of operation
22
13
mm
%
S
w
1)
x
depending
on version
> 3.8 mA
> 4.4 mA
4
A3
15
5
19
A2
14
A1
x1)
14
&
>12 V
w
24 V DC
17
x
18
PD
G
25
6
10
Control valve
Travel sensor
PD controller
A/D converter
Microcontroller
i/p converter
Air capacity booster
Pressure regulator
Flow regulator
Volume restriction
Inductive limit switch
Solenoid valve
Analog position transmitter or binary input
G
9
24
y
8
23
11
2
3
12
1
2
3
4
5
6
7
8
9
10
11*
12*
13*
BE
16
21 FSK
%
Serial
Interface
mm
20
7
14
15
16
17*
18*
19
20
21
22*
23
24
25*
*
Q
1
x
Software limit switches A1/A2
Fault alarm output A3
LCD
Solenoid valve control
Galvanic isolation
D/A converter
Communication interface
®
HART modulation
Binary input BE
Pressure sensor for supply pressure ps
Pressure sensor for signal pressure pout
Forced venting
Option
Fig. 2 · Functional diagram
EB 8384-6 EN
9
Design and principle of operation
3.1
Safety function (SIL)
The safety function is based on the shutdown
of the i/p converter (6). This causes the
pneumatic actuator to be vented and the
valve to move to its fail-safe position.
3.2
Valve diagnostics
The EXPERTplus valve diagnostics are integrated into the positioner. They provide information on the valve condition (see Table 1) and generate status messages to
quickly pinpoint faults.
Monitoring of the input signal
The i/p converter is switched off when the
input signal of the positioner at terminals
+11/–12 falls below 3.8 mA or 4.4 mA depending on the positioner version (a signal
range of 4 to 20 mA is required). See
Fig. 18 on page 48.
Monitoring the voltage supply
(version with forced venting and solenoid
valve)
The i/p converter and the solenoid valve
(when installed) are shut down whenever the
voltage at terminals +81/–82 falls below
12 V (an input voltage of 24 V DC is required). See Fig. 18 on page 48.
When the i/p converter is switched off by
the monitoring of the input signal or the voltage supply, the fail-safe position S is activated and is indicated on the positioner
display.
If required, the user can check the safety
function using the software.
For more details, refer to the Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
10
EB 8384-6 EN
For more details, refer to the Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
3.3
Flow rate calculation
Due to the differential pressure measurement
Dp out, EXPERTplus is able to calculate the
flow rate in a SAMSON Type 3241 or
Type 3251 Valve, provided all the parameters regarding the medium and the process
have been defined in the positioner.
For more details, refer to the Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
Design and principle of operation
Table 1 · Diagnostic functions and diagnosis,
(refer to the Operating Instructions EB 8389-1 EN on EXPERTplus Valve Diagnostics for more details)
Diagnostic function
Control
valve
On/off
valve Diagnosis
Monitoring
Data logger
•
•
Depending on trigger condition selected
Valve signature
•
Ä
– Friction
– Supply pressure
– Actuator springs
– Pneumatic leakage
On/off valve
–
•
– Breakaway time
– Transit time
Valve position histogram
•
Ä
– Course of the manipulated variable range
Set point deviation
histogram
•
•
– Final travel/angle value
– Manipulated variable range
– Manipulated variable range limitation
– Seat leakage
– Positioner-valve linkage
– Max. set point deviation
Cycle counter histogram
•
•
– Packing leakage
– Dynamic load factor
Leakage sensor
•
•
– Seat leakage
Course of end position
•
•
– Course of end position
– Zero point shift
Dynamic tests
•
Ä
–
Valve dead band
•
•
– Dead band
Partial stroke test
(PST)
•
•
–
–
–
–
Overshooting
Dead time
T86
Full stroke test (FST)
•
•
–
–
–
–
Overshooting
Dead time
T86
Settling time
Settling time
Full scope of functions
Function is performed, but not analyzed
Function is not performed
EB 8384-6 EN
11
Design and principle of operation
3.4
Type of application
There are two different types of application:
Control valve and On/off valve. The automatic mode
(AUTO) and manual mode
(MAN) can be selected in both types of
applications.
Operating
mode
Automatic
Control valve
The positioner
Discrete analysis
follows the refer- of the reference
ence variable (w) variable (w).
continuously.
Reading Valve position x
on dis- in %
play
Manual
On/off valve
Valve position x
in % and O/C
(Open/Close) in
alternating sequence
The positioner follows the manual
set point given over local operation.
The application type is set in Code 49 - h
(see section 7.8).
Note:
– Depending on the application type, certain diagnostic functions cannot be performed or analyzed. See Table 1.
– Section 7.8 contains details on discrete
analysis of on/off valves.
– In manual mode, an on/off valve can be
moved past 100 % of the nominal range
(with the closed position for ATO) or below 0 % of the nominal range (with the
closed position for ATC). See section 7.1
for valve closed position.
12
EB 8384-6 EN
3.5
Communication
The positioner is equipped with an interface
for HART® protocol (Highway Addressable
Remote Transducer) for communication purposes. Data are transmitted in a superimposed frequency (FSK = Frequency Shift
Keying) on the existing signal loop for the 4
to 20 mA reference variable.
Either a HART® capable handheld communicator or a computer with FSK modem can
be used to establish communication and operate the positioner.
3.5.1 Configuration using
TROVIS-VIEW 4
The positioner can be configured using the
TROVIS-VIEW 4 software for configuration
and operation. The positioner is equipped
for this purpose with an additional 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 4 software enables the
user to easily set parameters in the
positioner and view process parameters online.
Note: TROVIS-VIEW 4 is a free software
which can be downloaded from the
SAMSON website (www.samson.de >
Services > Support & Downloads).
Design and principle of operation
3.6
Additional equipment
Inductive limit switch
In the version with inductive limit switch, the
rotary shaft of the positioner carries an adjustable tag which actuates the installed
proximity switch. The optional inductive limit
switch (11) is connected to A1, while the remaining software limit switch is connected to
A2.
Solenoid valve
If the operating voltage for the solenoid
valve (12) falls under 12 V, the supply pressure for the i/p converter (6) is vented to the
atmosphere. The positioner can no longer
operate and the control valve moves to the
fail-safe position determined by the actuator, independent of the reference variable.
In manual mode, the manual set point is
reset to 0 %. A different manual set point
must entered again.
Forced venting
If the voltage signal at terminals +81/–82
falls below 12 V, the i/p converter (6) is
de-energized. The positioner vents the actuator, causing valve to move to the fail-safe
position determined by the actuator, independent of the reference variable.
Analog position transmitter
The position transmitter (13) is a two-wire
transmitter and issues the travel sensor signal as a 4 to 20 mA signal processed by the
microcontroller. Since this signal is issued independent of the positioner’s input signal,
the momentary travel/angle of rotation is
controlled in real-time. Additionally, the position transmitter allows positioner faults to
be indicated over a signal current of
< 2.4 mA or > 21.6 mA.
Leakage sensor
By upgrading the positioner with a leakage
sensor, it is possible to detect seat leakage
when the valve is in the closed position. For
more details, refer to the Operating Instructions EB 8389-1 EN on EXPERTplus Valve
Diagnostics.
Binary input
The optional binary input can be configured:
4 To connect a floating contact
4 To connect a non-floating contact (0 to
24 V DC)
By selecting a certain function, one of the
following actions can be activated:
Transmit switching state
The switching state of the binary input is
logged.
Activate local write protection
After the first initialization, a local write
protection can be activated. While the
binary input is active, no settings can be
changed at the positioner. The positioner
cannot be re-initialized. Configuration
enabling over Code 3 is not active ( ).
Start PST
The positioner start a single partial stroke
test. The test is performed with the settings in Code 49 - d2 to Code 49 - d9
(refer to Operating Instructions
EB 8389-1 EN on EXPERTplus Valve Diagnostics).
Move valve to safety set point
An on/off valve moves to the predeter-
4
4
4
4
EB 8384-6 EN
13
Design and principle of operation
4
4
4
mined safety set point when the
positioner is in automatic mode
(AUTO). This function is not performed in
the manual mode
(MAN) or fail-safe
position mode (SAFE).
Switch AUTO/MANUAL
The positioner changes from the automatic mode
(AUTO) to the manual
mode
(MAN) or vice versa.
This function is not performed if the
positioner is in the fail-safe position
mode (SAFE).
Start data logger
The data logger starts recording when
the binary input is activated (refer to Operating Instructions EB 8389-1 EN on
EXPERTplus Valve Diagnostics).
Reset diagnostics
Active tests and monitoring are stopped
and the diagnostic data is reset once.
Additionally, the external solenoid valve
function can be selected if a non-floating
contact is configured:
External solenoid valve
The voltage for an external solenoid
valve is connected in parallel to terminals
+81/–82. This allows the switching state
of the solenoid valve to be monitored.
4
Note: The optional binary input can only be
configured using the operator software e.g.
TROVIS-VIEW 4. The switching state is
transmitted when the switch is closed by default.
External position sensor
In this version, only the sensor is mounted to
the control valve. The positioner is located
14
EB 8384-6 EN
separately from the valve.
The connection of controlled variable (x) and
output variable (y) signals to the valve is established by cable and piping for air.
Design and principle of operation
3.7
Technical data
Type 3730-6 Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Travel, adjustable
Direct attachment to Type 3277:
Attachment acc. to IEC 60534-6:
Rotary actuators:
Travel range
Adjustable within the initialized travel/angle of rotation
Travel can be restricted to 15 at the maximum
Ref. variable w
3.6 to 30 mm
3.6 to 200 mm
24° to 100°
Signal range
4 to 20 mA · Two-wire unit with reverse polarity protection · Min. span 4 mA
Static destruction limit
30 V
Minimum current
3.6 mA for display · Emergency venting at £ 3.8 mA
Load impedance
£ 9.2 V (corresponding to 460 W at 20 mA)
Supply air
Supply pressure
1.4 to 7 bar (20 to 105 psi)
Air quality
ISO 8573-1
(2001-02)
Max. particle size and density: Class 4 · Oil content: Class 3
pressure dew point: Class 3 or at least 10 K beneath the lowest ambient temperature to
be expected
Signal pressure (output)
0 bar up to the capacity of supply pressure · Limitable between 1.4 and 7.0 bar by software
Character- Adjustable
istic
Linear, equal percentage, reverse equal percentage, user-defined (by software)
Butterfly, rotary plug and segmented ball valves: linear/equal percentage
Deviation
£1%
£ 0.3 %
Hysteresis
Sensitivity
£ 0.1 %
Transit time
Separately adjustable up to 240 seconds for supply air and exhaust air by software
Direction of action
Reversible
Air consumption, steady
state
Independent from supply pressure approx. 110 ln/h
Air output
capacity
Actuator pres- At Dp = 6 bar: 8.5 mn³/h · At Dp = 1.4 bar: 3.0 m n³/h · KVmax (20 °C) = 0.09
surized
Actuator
vented
Permissible ambient
temperature
Influences
At Dp = 6 bar: 14.0 mn³/h · At Dp = 1.4 bar: 4.5 m n³/h · KVmax (20 °C) = 0.15
–20 to +80 °C for all versions
–45 to +80 °C with metal cable gland
–25 to +80 °C with inductive limit switch (SJ2-S1N) and metal cable gland
Limits in test certificate additionally apply for explosion-protected devices
Temperature
£ 0.15 %/10 K
Supply air
None
Vibration
Electromagnetic
compatibility
£ 0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Complying with requirements of EN 61000-6-2, EN 61000-6-3, EN 61326-1 and
NAMUR Recommendation NE 21
EB 8384-6 EN
15
Design and principle of operation
Type 3730-6 Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Electrical connections
One M20 x 1.5 cable gland for 6 to 12 mm clamping range · Additional second M20 x
1.5 threaded hole · Screw terminals for 0.2 to 2.5 mm² wire cross-section
Degree of protection
IP 66/NEMA 4X
Use in safety-instrumented Suitable for use in safety-instrumented systems up to SIL 2
systems in compliance with – triggered by the set point, emergency venting at £ 3.8 mA or £ 4.4 mA depending
IEC 61508/SIL
on the positioner version
– by the optional forced venting, emergency venting at £ 12 V
Suitable for use in safety-instrumented systems up to SIL 3
The current circuit of the set point and the forced venting must both be operated in a
safety-related system
Communi- Local
cation
HART®
SAMSON SSP interface and serial interface adapter
Software requirement (SSP): TROVIS-VIEW with database module 3730-6
HART® field communication protocol
Impedance in HART frequency range: receive 350 to 450 W, send: approx. 155 W
Software requirements (handheld communicator): device description for Type 3730-6
Software requirements (PC): DTM file acc. to Specification 1.2, suitable for integrating
the positioner in frame applications that supports the FDT/DTM concept (e.g. PACTware)
Explosion
protection
ATEX
Type 3730-6-110:
Type 3730-6-810:
II 2 G Ex ia IIC/IIB T6; II 2 D Ex tD A21 IP 66 T 80 °C
II 3 G Ex nA II T6; II 3 G Ex nL IIC/IIB T6;
II 3 D Ex tD A22 IP 66 T 80 °C
IECEx
Type 3730-6-111: Ex ia IIC/IIB T6; Ex d [ia] IIC/IIB T6; Ex tD A21 IP 66 T 80 °C
Type 3730-6-811: Ex nA II T6; Ex nL IIC/IIB T6; Ex tD A22 IP 66 T 80 °C
GOST
Type 3730-6-113: 1Ex ia IIC T6 X, DIP A21 Ta80°C, IP 66
Type 3730-6-813: Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 66
Binary contacts
2 software limit switches, reverse polarity protection, floating, configurable switching characteristics (default settings
according to table)
Signal
status
No response
£ 1.2 mA
Response
³ 2.1 mA
1 fault alarm contact, floating
Signal
status
No response/No
³ 2.1 mA
alarm
Response/Fault
alarm
For connection to
£ 1.2 mA
NAMUR switching amplifier acc. to EN 60947-5-6
Materials
Housing
Die-cast aluminum EN AC-AlSi12(Fe) (EN AC-44300) acc. to DIN EN 1706, chromated
and powder paint coated · Special version: Stainless steel 1.4581
External parts
Stainless steel 1.4571 and 1.4301
Cable gland
Polyamide, black, M20 x 1.5
Weight
Approx. 1.0 kg
16
EB 8384-6 EN
Design and principle of operation
Options for Type 3730-6 Positioner
Inductive limit switch
For connection to switching amplifier acc. to EN 60947-5-6.
Can be used in combination with a software limit switch.
SJ2-SN proximity switch
NAMUR NC contact
SJ2-S1N proximity switch
NAMUR NO contact
Solenoid valve · Approval acc. to IEC 61508/SIL
Input
24 V DC reverse polarity protection, static destruction limit 40 V
U - 5.7 V
(corresponding to 4.8 mA at
Current consumption I =
3840 W
24 V/114 mW)
Signal "0" no pick-up
£ 12 V
Signal "1" safe pick-up
> 19 V
Service life
> 5 x 10 6 switching cycles
Use in safety-instrumented systems in Suitable for use in safety-instrumented systems up to SIL 2
compliance with IEC 61508/SIL
– triggered by the set point, emergency venting at £ 3.8 mA or £ 4.4 mA
depending on the positioner version
– by the optional forced venting, emergency venting at £ 12 V
Suitable for use in safety-instrumented systems up to SIL 3
The current circuit of the set point and the forced venting must both be operated
in a safety-related system
Forced venting· Approval acc. to IEC 61508/SIL
Input
24 V DC reverse polarity protection, static destruction limit 40 V
U - 5.7 V
(corresponding to 4.8 mA at
Current consumption I =
3840 W
24 V/114 mW)
Signal "0" no pick-up
£ 12 V
Signal "1" safe pick-up
> 19 V
Use in safety-instrumented systems in Suitable for use in safety-instrumented systems up to SIL 2
compliance with IEC 61508/SIL
– triggered by the set point, emergency venting at £ 3.8 mA or £ 4.4 mA
depending on the positioner version
– by the optional forced venting, emergency venting at £ 12 V
Suitable for use in safety-instrumented systems up to SIL 3
The current circuit of the set point and the forced venting must both be operated
in a safety-related system
Analog position transmitter
Two-wire transmitter · Galvanically isolated
Supply voltage
12 to 30 V DC · Reverse polarity protection · Static destruction limit 40 V
Output signal
4 to 20 mA
Direction of action
Reversible
Operating range
–10 to +114 %
Characteristic
Linear
Hysteresis and HF influence or other
influences
Same as positioner
Fault indication
Can be issued with current signal 2.4 ±0.1 mA or 21.6 ±0.1 mA
EB 8384-6 EN
17
Design and principle of operation
Options for Type 3730-6 Positioner
Binary input · Galvanically isolated · Switching behavior configured over software
Active switching behavior (default setting)
Connection
For external switch (floating contact) or relay contacts
Electrical data
Open-circuit voltage when contact is open: max. 10 V, pulsed DC current with
peak value of 100 mA and RMS current 0.01mA when the contact is closed
Contact
Closed, R < 20 W Switching state ON (default)
Open, R > 400 W Switching state OFF (default)
Passive switching behavior
Connection
For externally applied DC voltage, reverse polarity protection
Electrical data
3 to 30 V · Destruction limit: 40 V · Current draw at 24 V: 3.7 mA
Voltage
> 6 V Switching state ON (default)
< 1 V Switching state OFF (default)
External position sensor
Travel
Same as positioner
Cable
10 m with M12x1 connector, designed for continuous flexing, flame retardant
acc. to VDE 0472, resistant to oils, lubricants, coolants as well as other corrosive media
Permissible ambient
temperature
–60 to +105 °C · Limits specified in the EC Type Examination Certificate additionally apply for explosion-protected devices.
Vibration immunity
Up to 10 g in the range between 10 and 2000 Hz
Degree of protection
IP 67
18
EB 8384-6 EN
EB 8384-6 EN
19
Attachment to the control valve – Mounting parts and accessories
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:
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 21 show the maximum adjustment range at the positioner. The
travel that can be implemented at the valve
is additionally restricted by the selected
fail-safe position and the required compression of the actuator springs.
The positioner is standard equipped with the
lever M (pin position 35).
4 Direct attachment to SAMSON
Type 3277 Actuator
4 Attachment to actuators according to
IEC 60534-6 (NAMUR)
4 Attachment to Type 3510 Micro-flow
Valve
4 Attachment to rotary actuators
NOTICE
Attach the positioner to the control valve,
observing the following instructions to avoid
damaging the positioner.
– Use only the mounting parts/accessories
listed in the Tables 2 to 6 (pages 41 to
43) to mount the positioner. Observe the
type of attachment!
– Observe the assignment between lever
and pin position (see travel tables on
page 21)!
20
EB 8384-6 EN
Fig. 3 · Lever M with pin position 35
NOTICE
The lever must be held stationary in the mid
position while undoing or fastening the nut
to ensure that the lever does not move to one
of the end stops.
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 accessories (see Table 4 on page 42).
Direct attachment to Type 3277-5 and Type 3277 Actuators
Actuator size
Rated travel
[cm²]
[mm]
Adjustment range at positioner
Min.
Travel
Max.
Required
lever
Assigned
pin position
120
7.5
5.0
to
25.0
M
25
120/240/350
15
7.0
to
35.0
M
35
355/700
30
10.0
to
50.0
M
50
Required
lever
Assigned
pin position
Attachment according to IEC 60534-6 (NAMUR)
SAMSON valves/Type 3271 Actuator
Actuator size
Rated travel
Other valves/actuators
[cm²]
[mm]
min.
Travel
60 and 120 with
Type 3510 Valve
max.
7.5
3.6
to
18.0
S
17
5.0
to
25.0
M
25
7.0
to
35.0
M
35
120
7.5
120/240/350
15
700
7.5
700
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
Min.
24
Opening angle
Max.
Required
lever
Assigned
pin position
to
100°
M
90°
EB 8384-6 EN
21
Attachment to the control valve – Mounting parts and accessories
4.1
Direct attachment
4.1.1 Type 3277-5 Actuator
Refer to Table 2 on page 41 for the required
mounting parts and accessories.
Note the travel table on page 21!
Actuator with 120 cm²
1.
2.
3.
4.
5.
6.
7.
22
Mount connecting plate (9) on the actuator.
Mount connecting plate (6) or pressure
gauge bracket (7) with pressure gauges
onto the positioner, making sure both
seal rings (6.1) are seated properly.
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.
Mount cover plate (10) with 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.
15 mm travel: Keep the follower pin
(2) at lever M (1) on the back of the
positioner in the pin position 35 (delivered state).
7.5 mm travel: Remove the follower pin
(2) from the pin position 35, reposition
it in the bore for pin position 25 and
screw tight.
Insert formed seal (15) in the groove of
the positioner housing.
Place positioner on the cover plate (10)
in such a manner that the follower pin
(2) rests on the top of the follower
EB 8384-6 EN
8.
9.
clamp (3). Adjust the lever (1) correspondingly and open the positioner
cover to hold the positioner shaft in position at the cap or the switch (Fig. 21
on page 53).
The lever (1) must rest on the follower
clamp with spring force.
Mount the positioner on the cover plate
(10) using the two fixing screws.
Mount cover (11) on the other side.
Make sure that the vent plug points
downwards when the control valve is
installed to allow any condensed water
that collects to drain off.
Connect output (38) over the piping/tubing to the connecting plate on
the actuator (9).
NOTICE
The signal pressure output at the back is not
used in the Type 3730-6 (see EB 8384-0 to
-5 EN).
Attachment to the control valve – Mounting parts and accessories
15
14
Lever M
1
2
3
1.1
1.2
Cut-out of cover
plate
6.1
6
5
Supply 9
1
1.1
1.2
2
3
5
6
6.1
Lever
Nut
Disk spring
Follower pin
Follower clamp
Stopper
Connecting plate
Seal rings
10
9
11
6
Note:
Always use the connecting plate (6)
included in the accessories to connect
7 supply and output.
Never screw threaded parts directly
8 into the housing.
Output 38
7
8
9
10
11
14
15
Pressure gauge bracket
Pressure gauge mounting kit
Connecting plate for actuator
Cover plate
Cover
Gasket
Formed seal
Fig. 4 · Direct attachment - Signal pressure connection for Type 3277-5 Actuator with 120 cm²
EB 8384-6 EN
23
Attachment to the control valve – Mounting parts and accessories
4.1.2 Type 3277 Actuator
Refer to Table 3 on page 42 or the required
mounting parts and the accessories.
Note the travel table on page 21!
Actuators with 240 to 700 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 retracts" through external piping.
1.
2.
3.
4.
5.
24
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.
Mount cover plate (10) with narrow
side of the cut-out opening (Fig. 5, on
the left) pointing towards the signal
pressure connection. Make sure that the
bonded gasket (14) points towards the
actuator yoke.
For actuators with 355/700 cm², remove the follower pin (2) at lever M (1)
on the back of the positioner from pin
position 35, reposition it in the bore for
pin position 50 and screw tight.
For actuators 240 and 350 cm² with
15 mm travel, the follower pin (2) remains in pin position 35.
Insert formed seal (15) in the groove of
the positioner housing.
Place positioner on the cover plate in
such a manner that the follower pin (2)
rests on the top of the follower clamp
(3). Adjust the lever (1) correspond-
EB 8384-6 EN
6.
7.
8.
ingly and open the positioner cover to
hold the positioner shaft in position at
the cap or the switch (Fig. 21 on page
53).
The lever (1) must rest on the follower
clamp with spring force.
Mount the positioner on the cover plate
(10) using the two fixing screws.
Make sure that the tip of the gasket
(16) projecting from the side of the
connection block (12) is positioned
above the actuator symbol that corresponds with the actuator with fail-safe
action "Actuator stem extends" or "Actuator stem retracts." If necessary, remove the three fixing screws and the
cover. Then reposition the gasket (16)
turned by 180°. The previous version of
the connection block (Fig. 5, bottom)
requires the switch plate (13) to be
turned such that the corresponding actuator symbol points to the marking.
Place the connection block (12) with the
associated seal rings against the
positioner and the actuator yoke. Screw
it tight using the fixing screw (12.1).
For actuators with fail-safe action "Actuator stem retracts", additionally remove the stopper (12.2) and fit on the
external signal pressure piping.
Mount cover (11) on the other side.
Make sure that the vent plug points
downwards when the control valve is
installed to allow any condensed water
that collects to drain off.
Attachment to the control valve – Mounting parts and accessories
1
Lever
12
1.1
1.2
Nut
Disk spring
12.1 Screw
2
Follower pin
3
Follower clamp
10
11
Cover plate
Cover
11.1 Vent plug
Connection block
12.2 Stopper or connection for
external piping
13 Switch plate
14
Gasket
15
16
Formed seal
Gasket
15
10 14
1
2
3
11 11.1
2
Lever M
1.1
1.2
Cut-out of
cover plate (10)
View C
Ansicht
C
View AA
Ansicht
16
16
G
G 3/8
SUPPLY
C
Actuator stem
retracts
extends
16
12
SUPPLY
12.1
12.2
A
Ansicht
View BB
13
12
SUPPLY
Connection block (old)
with switch plate (13)
B
Stem retracts
Stem extends
12
Marking
12.1
12.2
Fig. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350, 355 and 700 cm²
EB 8384-6 EN
25
Attachment to the control valve – Mounting parts and accessories
4.2
Attachment according to
IEC 60534-6 (NAMUR)
Refer to Table 4 on page 42 for the required
mounting parts and the accessories.
Note the travel table on page 21!
3.
4.
The positioner is attached to the control
valve with a NAMUR bracket (10).
1.
2.
26
Screw the two bolts (14) to the bracket
(9.1) of the stem connector (9), place
the follower plate (3) on top and use
the screws (14.1) to tighten.
Actuator size 2800 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).
Mount NAMUR bracket (10) to the control valve as follows:
– For attachment to the NAMUR rib,
use an M8 screw (11), washer and
toothed lock washer directly in the
existing yoke bore.
– For attachment to valves with
rod-type yokes, use two U-bolts (15)
around the yoke.
Align the NAMUR bracket (10) in
such a way that the slot of the follower plate (3) is centrally aligned with
the NAMUR bracket at mid valve
travel.
EB 8384-6 EN
Mount connecting plate (6) or pressure
gauge bracket (7) with pressure gauges
(8) on the positioner, making sure both
seal rings (6.1) are seated properly.
Select required lever size (1) M, L or XL
and pin position according to the actuator size and valve travels listed in the
table on page 21.
Should you require a pin position other
than position 35 with the standard installed lever M, or require a lever size L
or XL, proceed as follows:
NOTICE
The lever must be held stationary in the mid
position while undoing or fastening the nut
to ensure that the lever does not move to one
of the end stops.
5.
6.
7.
Fasten the follower pin (2) in the assigned lever bore (pin position) as listed
in the table. Only use the longer follower pin (2) included in the mounting
kit.
Place lever (1) on the positioner shaft
and screw tight using the disk spring
(1.2) and nut (1.1).
Place positioner on the NAMUR
bracket in such a manner that the follower pin (2) rests in the slot of the follower plate (3, 3.1). Adjust the lever (1)
correspondingly.
Screw the positioner to the NAMUR
bracket using both fixing screws.
Attachment to the control valve – Mounting parts and accessories
Attachment to rod-type yoke
Rod diameter 20 to 35 mm
15
11
10
Attachment to
NAMUR rib
9
9.1
3.1
16
Additional bracket for
2
actuators with 2800 cm
and travel ³ 60 mm
14
1
Lever L or XL
Lever
1
Nut
Disk spring
Follower pin
Follower plate
2
Follower plate
1.1
6.1
6
7
Connecting plate
1.2
Seal rings
1
Pressure gauge bracket
Pressure gauge
mounting kit
9
Stem connector
9.1 Bracket
10 NAMUR bracket
11 Screw
14 Bolt
14.1 Screw
15 U-bolt
Note: Always use the connecting plate (6) included in the accessories to
16 Bracket
connect supply and output. Never screw threaded parts directly into the housing.
1
1.1
1.2
2
3
3.1
6
6.1
7
8
3
14.1
8
Fig. 6 · Attachment according to IEC 60534-6 (NAMUR)
EB 8384-6 EN
27
Attachment to the control valve – Mounting parts and accessories
4.3
Attachment to Type 3510
Micro-flow Valve with
Type 3271-5 Actuator
Refer to Table 4 on page 42 for the required
mounting parts and accessories.
Note the travel table on page 21!
The positioner is attached to the valve yoke
using a bracket.
1.
2.
3.
Place clamp (3) on the valve stem connector, align at a right angle and screw
tight.
Screw bracket (10) to the valve yoke
using two screws (11).
Mount connecting plate (6) or pressure
gauge bracket (7) with pressure gauges
to the positioner, making sure both seal
rings (6.1) are seated properly.
NOTICE
The lever must be held stationary in the mid
position while undoing or fastening the nut
to ensure that the lever does not move to one
of the end stops.
4.
5.
6.
7.
28
Unscrew the standard installed lever M
(1) including follower pin (2) from the
positioner shaft.
Take lever S (1) and screw follower pin
(2) in the bore for pin position 17.
Place lever S on the positioner shaft
and screw tight using the disk spring
(1.2) and nut (1.1).
Place positioner on the bracket (10) in
such a manner that the follower pin
slides into the groove of the clamp (3).
EB 8384-6 EN
Adjust the lever (1) correspondingly.
Screw the positioner to the bracket (10)
using both screws.
Attachment to the control valve – Mounting parts and accessories
1
Lever
1.1
1.2
Nut
Disk spring
2
Follower pin
3
6
Clamp
Connecting clamp
6.1
Seal rings
7
8
3
10
Pressure gauge bracket
Pressure gauge
mounting kit
Bracket
11
Screw
10
11
Note: Always use the connecting plate
(6) included in the accessories to connect
supply and output.
Never screw threaded parts directly into
the housing.
11
1.2
6
1.1
2 1
6.1
Lever S
8
7
Fig. 7 · Attachment to Type 3510 Micro-flow Valve
EB 8384-6 EN
29
Attachment to the control valve – Mounting parts and accessories
4.4
Attachment to rotary
actuators
Refer to Table 5 on page 43 for the required
mounting parts and accessories.
Note the travel table on page 21!
6.
The positioner is mounted to the rotary actuator using two pairs of brackets.
Prior to attaching the positioner to the
SAMSON Type 3278 Rotary Actuator,
mount the associated adapter (5) to the free
end of the rotary actuator shaft.
7.
Note: On attaching the positioner as described below, it is imperative that the actuator's direction of rotation is observed.
1.
2.
3.
4.
5.
30
Place follower clamp (3) on the slotted
actuator shaft or the adapter (5).
Place coupling wheel (4) with flat side
facing the actuator on the follower
clamp (3). Refer to Fig. 9 to align slot
so that it matches the direction of rotation when the valve is in its closed position.
Screw coupling wheel and follower
clamp tightly onto the actuator shaft using screw (4.1) and disk spring (4.2).
Screw the bottom pair of brackets
(10.1) with the bends pointing either to
the inside or to the outside (depending
on the actuator size) to the actuator
case. Position top pair of brackets (10)
and screw tight.
Mount connecting plate (6) or pressure
gauge bracket (7) with pressure gauges
to the positioner, making sure both
EB 8384-6 EN
8.
O-rings are seated properly.
For double-acting, springless rotary actuators, a reversing amplifier is required to attach the positioner to the
actuator, see section 4.5.
Unscrew the standard follower pin (2)
from the positioner's lever M (1). Use
the metal follower pin (Ø5) included in
the mounting kit and screw tight into
the bore for pin position 90°.
Place positioner on the top pair of
brackets (10) and screw tight. Considering the actuator's direction of rotation, adjust lever (1) so that it engages
in the slot of the coupling wheel (4) with
its follower pin (see Fig. 9). It must be
guaranteed that the lever (1) is parallel
to the long side of the positioner when
the actuator is at half its angle of rotation.
Stick scale plate (4.3) on the coupling
wheel so that the arrow tip indicates the
closed position, and it can be easily
read when the valve is installed.
1
1.2
1.1
4.1
2
4.2
3
5
Actuator flange
Fig. 8 · Mounting the coupling wheel with Type 3278
Attachment to the control valve – Mounting parts and accessories
6.1
1
1.2
1.1
2
4.3
10
10.1
6
(7, 8)
4
5
Note:
Always use the connecting
plate (6) included in the
accessories to connect
supply and output.
Never screw threaded
parts directly into the
housing.
Legends Figs. 8 + 9
1
Lever
1.1 Nut
1.2 Disk spring
2
Follower pin
3
Follower clamp (Fig. 8)
4
Coupling wheel
4.1 Screw
4.2
4.3
4.3
80 mm
130 mm
Slot
Control valve opens counterclockwise
Control valve opens clockwise
Disk spring
Scale plate
Scale plate
5
Actuator shaft
Adapter for Type 3278
6.1 Seal rings
7
Pressure gauge bracket
8
Pressure gauge
mounting kit
10 Top pair of brackets
10.1 Bottom pair of brackets
Slot
Fig. 9 · Attachment to rotary actuators
EB 8384-6 EN
31
Attachment to the control valve – Mounting parts and accessories
4.4.1 Heavy-duty version
6.
Refer to Table 4 on page 42 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 manufacturer, if necessary.
1.
2.
3.
4.
5.
Mount the housing (10) onto the rotary
actuator. In case of VDI/VDE attachment, place spacers (11) underneath, if
necessary.
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.
Stick adhesive label (4.3) onto the coupling 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 explanatory symbols are enclosed and can be
stuck on the housing, if required.
Screw tight coupling wheel (4) onto the
slotted actuator shaft or adapter (3) using screw (4.1) and disk spring (4.2).
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°.
7.
If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are required, the connecting plate (6), making sure both seal rings (6.1) are
seated properly.
For double-acting, springless rotary actuators, a reversing amplifier is required to attach the positioner to the
actuator. Refer to section 4.5.
Place positioner on 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. 10).
Counterclockwise
1
10
4
Clockwise
Fig. 10 · Direction of rotation
32
EB 8384-6 EN
Attachment to the control valve – Mounting parts and accessories
1 Lever
1.1 Nut
1.2 Disk spring
Connecting plate
(only for G ¼)
6.1 Seal rings
2
Follower pin
7
3
4
Adapter
Coupling wheel
Pressure gauge
bracket
8
Pressure gauge
mounting kit
10
Adapter housing
4.1 Screw
4.2 Disk spring
4.3 Adhesive label
5
Actuator shaft
or adapter
6
10.1 Screws
11 Spacers
6
6.1
7
8
1
1.1
1.2
5.1 Adapter
2
4.1
4.2
4
4.3
4.1
4.2
4
4.3
3
3
5.1
10.1
5
10.1
10
11
10
5
SAMSON Type 3278
VETEC S160, VETEC R
Attachment acc. to VDI/VDE 3845
(Sept. 2010) level 1, size AA1 to AA4
(see section 15.1)
Fig. 11 · Attachment to rotary actuators (heavy-duty version)
EB 8384-6 EN
33
Attachment to the control valve – Mounting parts and accessories
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 Reversing Amplifier (see Mounting and Operating Instructions EB 8392 EN).
4.6
Attaching an external
position sensor
Refer to Table 7 on page 44 for the required
mounting parts and accessories.
In the positioner version with an external position sensor, the sensor placed in a separate housing is attached over a plate or
bracket to the control valve. The travel
pick-off corresponds to that of a standard
device.
The positioner unit can be mounted as required to a wall or a pipe.
For the electrical connection a 10 meter
connecting lead with M12x1 connectors is
included in the scope of delivery.
Note:
– In addition, the instructions in sections
5.1 and 5.2 apply for the pneumatic and
electrical connection.
Operation and setting are described in
sections 7 and 8.
– Since 2009, the back of the position sensor (20) is fitted with two pins acting as
mechanical stops for the lever (1). If this
position sensor is mounted using old
mounting parts, two corresponding
Ø 8 mm holes must be drilled into the
mounting plate/bracket (21).
4.6.1 Mounting the position sensor with direct attachment
Type 3277-5 Actuator with 120 cm²
The signal pressure from the positioner is
routed over the signal pressure connection
of the connecting plate (9, Fig. 13 left) to the
actuator diaphragm chamber. To proceed,
first screw the connecting plate (9) included
in the accessories onto the actuator yoke.
Turn the connecting plate (9) so that the
correct symbol for the fail-safe position
"Actuator stem extends" or "Actuator
stem retracts" is aligned with the marking
(Fig. 13, below).
Make sure that the gasket for the connecting plate (9) is correctly inserted.
The connecting plate has boreholes with
NPT and G threads.
Seal the threaded connection that is not
used with the rubber seal and square plug.
4
Fig. 12 · Positioner unit with sensor mounted on a
micro-flow valve
For the pneumatic connection either a connecting plate (6) or a pressure gauge
bracket (7) must be fixed to the housing, depending on the accessories chosen. Make
sure the seal rings (6.1) are correctly inserted (see Fig. 6 on page 27, bottom right).
34
EB 8384-6 EN
4
4
Attachment to the control valve – Mounting parts and accessories
Type 3277 Actuator with 240 to 700 cm²
2.
The signal pressure is routed to the connection at the side of the actuator yoke for the
version "Actuator stem extends".
For the fail-safe position "Actuator stem retracts" the connection on the top diaphragm
case is used. The connection at the side of
the yoke must be fitted with a venting plug
(accessories).
3.
Mounting the position sensor
1.
Place the lever (1) on the sensor in
mid-position and hold it in place.
Unthread the nut (1.1) and remove the
lever together with the disk spring (1.2)
from the sensor shaft.
4.
Screw the position sensor (20) onto the
mounting plate (21).
Depending on the actuator size and
rated valve travel, determine the required lever and position of the follower pin (2) from the travel table on
page 21.
The positioner is delivered with lever M
in pin position 35 on the sensor. If necessary, remove the follower pin (2)
from its pin position and move it to the
borehole for the recommended pin position and screw tight.
Place the lever (1) and disk spring (1.2)
on the sensor shaft.
1
2
3
11
1.1
1.2
20
21
9
Signal pressure
Vent plug
Signal pressure
Symbol
Actuator stem
extends
retracts
Marking
1
1.1
1.2
2
3
9
11
20
21
Lever
Nut
Disk spring
Follower pin
Follower clamp
Connecting plate
Cover
Position sensor
Mounting plate
Fig. 13 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)
EB 8384-6 EN
35
Attachment to the control valve – Mounting parts and accessories
5.
6.
7.
Place the lever (1) in mid-position and
hold it in place. Screw on the nut (1.1).
Place the follower clamp (3) on the actuator stem, align and fasten it, making
sure that the fastening screw rests in the
groove of the actuator stem.
Place the mounting plate (21) together
with the sensor onto the actuator yoke
so that the follower pin (2) rests on the
top of the follower clamp (3). It must
rest on it with spring force.
Screw tight the mounting plate (21)
onto the actuator yoke using both fixing
screws.
Mount cover (11) on the other side.
Make sure that the vent plug points
downwards when the control valve is
installed to allow any condensed water
that collects to drain off.
20
21
1.1, 1.2
14.1
3 14
9.1
4.6.2 Mounting the position sensor with attachment according to IEC 60534-6
For the required mounting parts and accessories, refer to Table 7 on page 44.
1.
Place the lever (1) on the sensor in
mid-position and hold it in place.
Unthread the nut (1.1) and remove the
lever together with the disk spring (1.2)
from the sensor shaft.
2.
Screw the position sensor (20) onto the
bracket (21).
The standard attached lever M with the follower pin (2) at position 35 is designed for
120, 240 and 350 cm² actuators with
15 mm rated travel.
9
1
1.1
1.2
2
3
9
9.1
14
14.1
20
21
2
Fig. 14 · Mounting according to IEC 60534-6 (NAMUR)
36
EB 8384-6 EN
Lever
Nut
Disk spring
Follower pin
Follower plate
Stem connector
Bracket
Bolt
Screws
Position sensor
Bracket
Attachment to the control valve – Mounting parts and accessories
For other actuator sizes or travels, select the
lever and pin position from the travel table
on page 21. Lever L and XL are included in
the mounting kit.
4.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve
3.
For the required mounting parts and accessories, refer to Table 7 on page 44.
4.
5.
Place the lever (1) and disk spring (1.2)
on the sensor shaft.
Place the lever (1) in mid-position and
hold it in place. Screw on the nut (1.1).
Screw both bolts (14) to the bracket
(9.1) of the stem connector (9). Attach
the follower plate (3) and fix with the
screws (14.1).
Place the bracket with the sensor at the
NAMUR rib in such a manner that the
follower pin (2) rests in the slot of the
follower plate (3), then screw the
bracket using its fixing screws onto the
valve.
20
21
1.
2.
3.
Place the lever (1) in mid-position and
hold it in place. Unscrew the nut (1.1)
and remove the standard attached lever
M (1) together with the disk spring
(1.2) from the sensor shaft.
Screw the position sensor (20) onto the
bracket (21).
Select the lever S (1) from the accessories and screw the follower pin (2) into
the hole for pin position 17.
Place the lever (1) and disk spring (1.2)
on the sensor shaft.
1.1
1.2
1
2
1
1.1
1.2
2
3
20
21
Lever
Nut
Disk spring
Follower pin
Follower clamp
Position sensor
Bracket
3
Fig. 15 · Mounting on a micro-flow valve
EB 8384-6 EN
37
Attachment to the control valve – Mounting parts and accessories
4.
5.
Place the lever (1) in mid-position and
hold it in place. Screw on the nut (1.1).
Place the follower clamp (3) on the stem
connector, align it at a right angle and
screw tight.
Position the bracket (21) with the position sensor on the valve yoke and screw
tight, making sure the follower pin (2)
slides into the groove of the follower
clamp (3).
2.
3.
4.
4.6.4 Mounting the position sensor to rotary actuators
For the required mounting parts and accessories, refer to Table 7 on page 44.
1.
Place the lever (1) in mid-position and
hold it in place. Unscrew the nut (1.1)
and remove the standard attached lever
M (1) together with the disk spring
(1.2) from the sensor shaft.
Screw the position sensor (20) onto the
mounting plate (21).
Replace the follower pin (2) normally
attached to the lever (1) with the metal
follower pin (Ø 5) from the accessories
and screw it into the hole for pin position 90°.
Place the lever (1) and disk spring (1.2)
on the sensor shaft.
Place the lever (1) in mid-position and
hold it in place. Screw on the nut (1.1).
Follow the instructions describing attachment
to the standard positioner in section 4.4
Instead of the positioner, attach the position
sensor (20) with its mounting plate (21).
20
21
1
1.1
1.2
2
20
21
2
1
1.1, 1.2
Fig. 16 · Positioner unit with sensor mounted on rotary actuators
38
EB 8384-6 EN
Lever
Nut
Disk spring
Follower pin
Position sensor
Mounting plate
Attachment to the control valve – Mounting parts and accessories
4.7
Mounting the leakage
sensor
Normally, the control valve is delivered with
positioner and leakage sensor already
mounted.
If the leakage sensor is mounted after the
valve has been installed or it is mounted
onto another control valve, proceed as described in following.
NOTICE
Fasten the leakage sensor using a torque of
20 ±5 Nm.
3
2
The hole with M8 thread on the NAMUR rib
should preferably be used to mount the sensor (Fig. 17).
Note: If the positioner was mounted directly
onto the actuator (integral attachment), the
NAMUR interfaces on either side of the
valve yoke can be used to mount the leakage sensor.
The start-up of the leakage sensor is described in detail in the Operating Instructions
EB 8389-1 EN on EXPERTplus Valve Diagnostics.
1
1
2
3
Leakage sensor
Screw
Plug-type connection
Fig. 17 · Mounting the leakage sensor
EB 8384-6 EN
39
Attachment to the control valve – Mounting parts and accessories
4.8
Attaching positioners with
stainless steel housings
Positioners with stainless steel housings require mounting parts that are completely
made of stainless steel or free of aluminum.
Note: The pneumatic connecting plate, pressure gauge bracket and Type 3710 Pneumatic Reversing Amplifier are available in
stainless steel (see Table 6 for order numbers).
The Tables 2 to 6 (pages 41 to 43) apply for
attaching positioners with stainless steel
housings with the following restrictions:
Direct attachment
All mounting kits from Tables 2 and 3
can be used. The connection block is not
required. The stainless steel version of the
pneumatic connecting plate routes the air
internally to the actuator.
4
4 Attachment according to IEC 60534-6
(NAMUR rib or attachment to rod-type
yokes)
All mounting kits from Table 4 can be
used. Connecting plate in stainless steel.
4 Attachment to rotary actuators
All mounting kits from Table 5 can be
used except for the heavy-duty version.
Connecting plate in stainless steel.
4.9
Air purging function for
single-acting actuators
The exhaust air from the positioner is diverted to the actuator spring chamber to
40
EB 8384-6 EN
provide corrosion protection inside the actuator. The following must be observed:
Direct attachment to Type 3277-5 (stem
extends FA/stem retracts FE)
The air purging function is automatically
provided.
4
4 Direct attachment to Type 3277, 240 to
2
700 cm
FA: Remove the stopper 12.2 (Fig. 5
on page 25) at the connection
block and make a pneumatic connection to the spring chamber on
the vented side.
NOTICE
The method described does not apply to
old connection blocks in powder-paintcoated aluminum.
In this case, follow the instructions for attachment described below in “Attachment acc. to IEC 60534-6 (NAMUR rib
or attachment to rod-type yokes) and to
rotary actuators”.
FE:
The air purging function is automatically provided.
4 Attachment acc. to IEC 60534-6
(NAMUR rib or attachment to rod-type
yokes) and to rotary actuators
The positioner requires an additional
port for the exhaust air that can be connected over piping. An adapter available
as an accessory is used for this purpose.
See Table 6.
Attachment to the control valve – Mounting parts and accessories
NOTICE
The adapter uses one of the M20 x 1.5 connections in the housing which means just
one cable gland can be installed.
Should other valve accessories be used
which vent the actuator (e.g. solenoid valve,
volume booster, quick exhaust valve), this
exhaust air must also be included in the
purging function. The connection over the
adapter at the positioner must be protected
with a check valve, e.g. check valve G ¼
(order no. 8502-0597) mounted in the piping. Otherwise the pressure in the positioner
housing would rise above the ambient pressure and damage the positioner when the
exhausting components respond suddenly.
4.10
Required mounting parts and accessories
Order no.
Table 2 · Direct attachment to Type 3277-5 Actuator (Fig. 4)
Mounting parts
Accessories for
the actuator
Mounting parts for actuators 120 cm² or smaller
1400-7452
Connecting plate (9) (new) for Actuator Type 3277-5xxxxxx.01 (new) 1),
G ¼ and ¼ NPT
1400-6823
Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old): G ¼
1400-6820
Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old): G ¼
Connecting plate (6)
Accessories for
the positioner
Pressure gauge bracket (7)
Pressure gauge mounting kit (8) up to max. 6 bar (output/supply)
1)
1400-6821
G
1
4
4
1400-7461
4
NPT
G
1
1
1
1400-7462
1400-7458
4
NPT
1400-7459
St. steel/brass
1400-6950
St. steel/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.
EB 8384-6 EN
41
Attachment to the control valve – Mounting parts and accessories
Order no.
Table 3 · Direct attachment to Type 3277 (Fig. 5)
Mounting parts
For actuators with 240, 350, 355 and 700 cm²
1400-7453
240 cm²
Required piping with screw fitting
– for "Actuator stem retracts"
– with air purging of the top diaphragm chamber
350 cm²
355 cm²/
700 cm²
Accessories
Connection block with seals and screw
Pressure gauge mounting kit (8) up to max. 6 bar (output/supply)
Steel
1400-6444
Stainless steel
1400-6445
Steel
1400-6446
Stainless steel
1400-6447
Steel
1400-6448
Stainless steel
1400-6449
G¼
1400-8819
¼ NPT
1400-8820
St. st./Brass
1400-6950
St. st./St. st.
1400-6951
Table 4 · 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
Order no.
For actuators
7.5
S
Type 3271-5 Actuator with 60/120 cm² on Type 3510 Valve (Fig. 7)
1400-7457
5 to 50
M 1)
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
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
30 or 60
L
Connecting plate (6)
Accessories
Pressure gauge bracket (7)
Pressure gauge mounting kit (8) up to max. 6 bar (output/supply)
1)
Lever M is mounted on the standard positioner (included in the scope of delivery)
42
EB 8384-6 EN
G¼
1400-7461
¼ NPT
1400-7462
G¼
1400-7458
¼ NPT
1400-7459
St. st./Brass
1400-6950
St. steel/St. st.
1400-6951
Attachment to the control valve – Mounting parts and accessories
Order no.
Table 5 · Attachment to rotary actuators (Figs. 8 and 9)
Attachment acc. to VDI/VDE 3845 (September 2010), refer to section 15.1 for details
Actuator surface corresponds to level 1
Size AA1 to AA4, version with CrNiMo steel bracket
Size AA1 to AA4, heavy-duty version
1400-7448
1400-9244
Heavy-duty version (e.g. Air Torque 10 000)
Mounting
parts
1400-9542
Bracket surface corresponds to level 2, heavy-duty version
1400-9526
Attachment for SAMSON Type 3278 with 160/320 cm², CrNiMo steel bracket
1400-7614
Attachment for SAMSON Type 3278 with 160 cm² and for VETEC Type S160, Type
R and Type R, 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
G
Connecting plate (6)
Accessories
1
4
1
Pressure gauge mounting kit up to max. 6 bar (output/supply)
4
1
1400-7459
St. steel/brass
1400-6950
St. steel/st. steel
1400-6951
Order no.
Pneumatic reversing amplifier for double-acting actuators
Type 3710
Cable gland M20 x 1.5, nickel-plated brass
1890-4875
Adapter M 20 x 1.5 to ½ NPT, aluminum
0310-2149
Retrofit kit for inductive limit switch 1x SJ 2-SN
1400-7460
Cover plate with list of parameters
and operating instructions
1990-0761
English/Spanish
1990-3100
English/French
1990-3142
TROVIS-VIEW with device module 3730-3 (order no. 6661-1056)
Air purging
function
1400-7458
4
German/English (standard)
Positioner
with stainless steel
housing
1400-7462
NPT
Table 6 · General accessories
Accessories
1400-7461
4
NPT
G
Pressure gauge bracket (7)
1
1043732
Serial interface adapter (SAMSON SSP interface - RS-232 port on computer)
1400-7700
Isolated USB interface adapter (SAMSON SSP interface - USB port on computer)
including TROVIS-VIEW CD-ROM
1400-9740
Connecting plate (stainless steel)
Pressure gauge bracket (stainless steel)
Adapter with threaded bushing (M20 x 1.5) for attachment acc. to IEC 60534-6 (NAMUR rib or attachment to rod-type yoke) and to rotary actuators
G¼
1400-7476
¼ NPT
1400-7477
Only in ¼ NPT
1400-7108
G¼
0310-2619
¼ NPT
0310-2550
EB 8384-6 EN
43
Attachment to the control valve – Mounting parts and accessories
Order no.
Table 7 · Attachment of external position sensor
1400-7472
Mounting parts for actuators with 120 cm² see Fig. 13 left
Direct attachment
Connecting plate (9, old) for Actuator Type 3277-5xxxxxx.00
Connecting plate (new) for Actuator Type 3277-5xxxxxx.01
G
1
8
1400-6820
1
8
NPT
1400-6821
1400-6823
(new) 1)
Mounting parts for actuators with 240, 350, 355 and 700 cm², see Fig. 13 right
1400-7471
NAMUR attachmt.
Mounting parts for attachment to NAMUR rib with lever L and XL, see Fig. 14
1400-7468
Micro-flow valve
Mounting parts for Type 3510 Micro-flow Valve, see Fig. 15
1400-7469
VDI/VDE 3845 (September 2010), refer to section x for details
Actuator surface corresponds to level 1
Size AA1 to AA4 with follower clamp and coupling wheel, version with
CrNiMo steel bracket, see Fig. 16
Size AA1 to AA4, heavy-duty version
Attachment to
rotary actuators
Size AA5, heavy-duty version (e.g. Air Torque 10 000)
1400-9992
Bracket surface corresponds to level 2, heavy-duty version
1400-9974
SAMSON Type 3278 with 160 cm² (also for VETEC Type S160 and Type R),
heavy-duty version
1400-9385
SAMSON Type 3278 with 320 cm² and for VETEC Type S320, heavy-duty
version
1400-5891
and
1400-9974
Connecting plate (6)
Pressure gauge bracket (7)
Accessories for
positioner
Pressure gauge mounting kit up to max. 6 bar
(output/supply)
G
1
1
4
NPT
1400-7462
1
1400-7458
1
NPT
4
4
4
1400-6950
St. steel/st. steel
1400-6951
Only new switchover and connecting plates can be used with new actuators (Index 01).
Old and new plates are not interchangeable.
EB 8384-6 EN
1400-7459
St. steel/brass
Note: The other fastening parts are to be provided at the site of installation as
wall foundations vary from site to site.
44
1400-7461
G
Bracket to mount the positioner on a wall
1)
1400-7473
1400-9384
0309-0111
Connections
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 auxiliary
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
NOTICE
Follow the instructions below to avoid damaging the positioner.
– The threaded connections in the
positioner housing are not designed direct air connection!
– The screw glands must be screwed into
the connecting plate, the pressure gauge
mounting block or the connection block
from the accessories.
The air connections are optionally designed as a bore with ¼ NPT or G ¼
thread.
The customary fittings for metal and copper pipes or plastic hoses can be used.
– The supply air must be dry and free from
oil and dust.
The maintenance instructions for upstream pressure reducing stations must
be observed.
If the positioner is attached directly to the
Type 3277 Actuator, the connection of the
positioner's output pressure to the actuator is
fixed. For attachment according to
IEC 60534-6 (NAMUR), the signal pressure
can be routed to either the top or bottom diaphragm chamber of the actuator, depending on the actuator's fail-safe action "Actuator stem extends" or "Actuator stem retracts".
For rotary actuators, the manufacturer's
specifications for connection apply.
5.1.1 Signal pressure gauges
To monitor the supply air (Supply) and signal pressure (Output), we recommend that
pressure gauges be attached (see accessories in Tables 2 to 6).
5.1.2 Supply pressure
The required supply air pressure depends on
the bench range and the actuator's operating direction (fail-safe action).
The bench range is registered on the nameplate either as spring range or signal pressure range depending on the actuator. The
direction of action is marked FA or FE, or by
a symbol.
Note: If the supply pressure ps is lower than
the upper spring range value detected during plotting of the valve signature, PLOW is
indicated under Code 0.
EB 8384-6 EN
45
Connections
Actuator stem extends FA (air to open)
Fail-safe position "Valve closed"
(for globe and angle valves):
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 pstmax is roughly estimated as follows:
pstmax = F +
d2 × p × Dp
[bar]
4×A
d = Seat diameter [cm]
Dp = Differential pressure across the valve
[bar]
A = Actuator diaphragm area [cm²]
F = Upper bench range value [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 (Output
38) of the positioner can be limited in steps
of 0.1 bar to a pressure between 1.4 and
7.0 bar in Code 16.
The limitations is not activated [7.0 bar] by
default.
46
EB 8384-6 EN
5.2
Electrical connections
DANGER!
Risk of electric shock and/or
the formation of an explosive
atmosphere!
– For electrical installation, observe the relevant electrotechnical regulations and
the accident prevention regulations that
apply in the country of use.
NOTICE
– Adhere to the terminal assignment!
– Switching the assignment of the electrical
terminals may cause the explosion protection to become ineffective!
– Do not loosen enameled screws in or on
the housing.
– The maximum permissible values specified in the national EC type examination
certificates apply when interconnecting
intrinsically safe electrical equipment (Ui
or Uo; Ii or Io; Pi or Po; Ci or Co, and Li or
Lo).
Selecting cables and wires:
For installing intrinsically safe circuits, observe Paragraph 12 in EN 60079-14: 2008
(VDE 0165 Part 1).
To install and select cables and wires as well
as to run several intrinsically safe circuits in
one multi-core cable, observe the installation
regulations valid in the country of use. The
diameter of an individual wire in a
fine-stranded conductor must not be smaller
than 0.1 mm. Protect the conductor ends
against splicing, e.g. by using wire-end ferrules.
When two separate cables are used for con-
Connections
nection, an additional cable gland can be
installed.
Seal cable entries left unused with plugs.
Devices used at ambient temperatures below –20 °C must be fitted with metal cable
glands.
Equipment for use in zone 2/zone 22
In equipment operated with type of protection EEx nA II (non-sparking equipment) according to EN 60079-15 (2003), circuits
may be connected, interrupted or switched
while energized only during installation,
maintenance or repair.
Equipment connected to energy-limited circuits with type of protection Ex nL (energy-limited equipment) according to EN
60079-15 (2003) may be switched under
normal operating conditions.
The maximum permissible values specified
in the national explosion protection certificates also apply when interconnecting the
equipment with energy-limited circuits in
type of protection Ex nL IIC/IIB.
Only use a current source!
³ 3.6 mA: Microprocessor and display active
< 3.7 mA: LOW on display
£ 3.8 mA: Emergency shutdown
> 3.9 mA: Actuator can be filled with air
> 22 mA: OVERLOAD on display
In general, it is not necessary to connect the
positioner to a bonding conductor. Should
this be required, however, this conductor
can be connected inside the device.
Depending on the version, the positioner is
equipped with inductive limit switches
and/or a solenoid valve.
The position transmitter is operated on a
two-wire circuit. The usual supply voltage is
24 V DC. Considering the resistance of the
supply leads, the voltage at the position
transmitter terminals can be between 12 V
and 30 V DC.
Refer to Fig. 18 or the label on the terminal
strip for terminal assignment.
Cable entries
The cable entry with M20 x 1.5 cable gland,
6 to 12 mm clamping range.
There is a second M20 x 1.5 threaded bore
in the housing that can be used for additional connection, when required.
The screw terminals are designed for wire
cross-sections of 0.2 to 2.5 mm². Tighten by
at least 0.5 Nm.
The wires for the reference variable must be
connected to the terminals 11 and 12 located in the housing.
EB 8384-6 EN
47
Connections
Accessories:
Plastic cable gland M20 x 1.5:
– black
Order no. 8808-1011
– blue
Order no. 8808-1012
– Brass, nickel-pl. Order no. 1890-4875
– St. steel 1.4305 Order no. 8808-0160
Adapter M20 x 1.5 to ½ NPT
– Aluminum, powder-coated
Order no. 0310-2149
– Stainless steel
Order no. 1400-7114
5.2.1 Switching amplifiers
For operation of the limit switches, switching
amplifiers must be connected in the output
circuit. To ensure the operational reliability
of the positioner, the amplifiers should comply with the limit values of the output circuits
conforming to EN 60947-5-6.
If the positioner is to be installed in hazardous areas, the relevant regulations must be
observed.
Optional
Optional
A3
+81
-82
+11 -12
+83
-84
A2
+51 -52
A1
+41 -42
G
+31 -32
Optional
Optional
G
+31 -32
+31 -32
A
24 V DC
Forced venting/solenoid
valve
(optional)
mA
control signal
Fig. 18 · Electrical connections
48
EB 8384-6 EN
Switching amplifier acc. to
EN 60947-5-6
A3
Fault
indication
Limit switches
A2
Software
A1
Software
optionally
inductive
Two-wire
transmitter
supply unit
for optional
position
transmitter
Leakage
sensor
Binary
input
Connections
5.2.2 Establishing communication
Communication between PC and positioner
(via FSK modem or handheld communicator,
if necessary, using an isolation amplifier) is
based on the HART® protocol.
Type Viator FSK modem
RS 232
not ex. Order no. 8812-0130
PCMCIA not ex
Order no. 8812-0131
USB
not ex
Order no. 8812-0132
If the supply voltage of the controller or control station becomes too low because it has
been reduced by the load in the circuit, an
isolation amplifier is to be connected between controller and positioner (interfacing
as for positioner connected in hazardous areas, see Fig. 19).
If the positioner is used in hazardous areas,
an explosion-protected isolating amplifier is
to be used.
By means of the HART® protocol, all control
room and field devices connected in the
loop are individually accessible through
their address via point-to-point or standard
bus (multidrop).
Point-to-point:
The bus address/polling address must always be set to zero (0).
Standard bus (multidrop):
In the standard bus (multidrop) mode, the
positioner follows the analog current signal
(reference variable) as for point-to-point
communication. This operating mode is, for
example, suitable for split-range operation
of positioners (series connection). The bus
Handheld communicator
or second FSK modem
Connection in safe area
3730-6
4 to 20 mA
Controller/control station
Safe area
Connection in hazardous area
Hazardous area
3730-6
Controller/control station
Explosion-protected isolating amplifier
Handheld communicator
or second FSK modem (explosion-protected)
Fig. 19 · Connection with FSK modem
EB 8384-6 EN
49
Connections
address/polling address has to be within a
range of 1 to 15.
Note:
Communication errors may occur when the
process controller/control station output is
not HART-compatible.
For adaptation, the Z box (order no.
1170-2374) can be installed between output and communication interface.
At the Z box a voltage of 330 mV is released (16.5 W at 20 mA).
Alternatively, a 250-W resistor can be connected in series and a 22-mF capacitor can
be connected in parallel to the analog output.
Note:
– The load for the controller output will increase as a result.
– The insertion of a capacitor is not permissible for intrinsically safe circuits (Ex
ia), energy-limited circuits (Ex nL) and for
the type of protection Ex nA.
50
EB 8384-6 EN
250 W
22 mF
Controller/control station
Fig. 20 · Adapting the output signal
EB 8384-6 EN
51
Operator controls and readings
6
Operator controls and
readings
Rotary pushbutton
The rotary pushbutton is located underneath
the front protective cover.
The positioner is operated on site using the
rotary pushbutton:
Turn
to select codes and values.
Press
to confirm setting.
Readings on display
Icons appear on the display that are assigned to parameters, codes and functions.
Operating mode:
– Manual mode (see section 8.2.1)
– Automatic mode (see section 8.2.1)
S – SAFE (see section 8.2.2)
4 Bar elements:
Slide switch AIR TO OPEN or AIR TO CLOSE
4 AIR TO OPEN applies when the increasing signal pressure opens the valve
4 AIR TO CLOSE applies when the increasing signal pressure closes the valve
The signal pressure is the air pressure at the
output of the positioner which is transferred
to the actuator.
For positioners with an attached reversing
amplifier for double-acting rotary actuators
(section 4.5): switch position AIR TO OPEN.
Volume restriction Q
4
The volume restriction is used to adapt the
air delivery to the actuator size. Two fixed
settings are possible depending on how the
air is routed at the actuator:
For actuators smaller than 240 cm² with
a loading pressure connection at the side
(Type 3271-5) ® MIN SIDE.
For actuators 240 cm² and larger, select
MAX SIDE for a side connection.
4
4
4
52
EB 8384-6 EN
In
manual and
automatic modes,
the bars indicate the system deviation
that depends on the sign (+/–) and the
value. One bar element appears per 1 %
system deviation.
If the device has not yet been initialized
( blinks on the display), the lever position in degrees in relation to the longitudinal axis is indicated. One bar element
corresponds 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
: Failure
: Maintenance required/Maintenance
demanded
blinks: Out of specification
These icons indicate that an error has occurred.
A classified status can be assigned to
each error. Classifications include 'No
message', 'Maintenance required',
'Maintenance demanded' and 'Failure'
(see section 14).
Configuration enabled
Indicates that codes marked with an asterisk (*) in the code list (section 14) are
enabled for configuration (section 8.1).
Operator controls and readings
Automatic
Clockwise
Counterclockwise
Error
Escape
ix ³ 21.6 mA
ix £ 2.4 mA
w £ 3.7 mA
Manual
Maximum range
Not available/
Not active
NOM Nominal travel
AUTO
CL
CCL
Err
ESC
HI
LO
LOW
MAN
MAX
No
Fail-safe position
active
Limit switch
Alarm 2
Displays and their meaning
OVERLOAD w > 22 mA
PLOW
ps lower than upper spring
range value
RES
Reset
SAFE
Fail-safe position
SUB
Substitute calibration
TUNE
Initialization in progress
YES
Available/Active
ZP
Zero calibration
0 bar
No supply air
ää
Increasing/increasing
äæ
Increasing/decreasing
Maintenance required/demanded
Blinking: Out of specification
Configuration enabled
S
%
Units
blinks Emergency mode
(see Code 62)
blinks Not initialized
S
Valve in mechanical
fail-safe position
Failure
Maintenance
required/demanded
blinks Out of specification
blinks Write protection active
(over binary input option or
HART®communication)
O/C and PST in alternating sequence:
Write protection active
(time-controlled PST)
mm
Limit switch
Alarm 1
mm
%
Designation
Position
Parameter
Bar elements for
set point deviation
or lever position
Code
Closed-loop operation Manual mode Fault
Initialization key
Cap or rotary switch
Metal tag of proximity switch
SSP interface
CLOSE
AIR TO
OPEN
SERIAL
INTERFACE
CAUTION
VALVE
ACTUATES
INIT
S
Switch for
AIR TO OPEN
AIR TO CLOSE
mm
%
%
mm
Volume restriction
Q
MAX BACK
MIN SIDE
MIN BACK
MAX SIDE
Rotary pushbutton
Fig. 21 · Display and operator controls
EB 8384-6 EN
53
Operator controls and readings
6.1
Serial interface
The positioner must be supplied with at least
3.8 mA.
The positioner can be connected directly to
the PC via the local serial interface and the
serial interface adapter.
The operator software is TROVIS-VIEW 4
with installed device module 3730-6.
6.2
®
HART communication
The positioner must be supplied with at least
3.6 mA. The FSK modem must be connected
in parallel to the current loop.
A DTM file (Device Type Manager) conforming to the Specification 1.2 is available for
communication. This allows the device, for
example, to be run with the PACTware operator interface. All the positioner's parameters are then accessible over the DTM and
the operator interface.
For start-up and settings, proceed as described in section 7.1 to 7.4. Refer to the
code list in section 14 for the parameters
necessary for the operator interface.
NOTICE
The write access for HART® communication
can be disabled over Code 47. You can
only disable or enable this function locally at
the positioner.
The write access is enabled by default. The
on-site operation including the INIT key can
be locked over HART®communication. The
word 'HART' then blinks on the display
when Code 3 is selected. This locking function can only be disabled over HART® com-
54
EB 8384-6 EN
munication. On-site operation is enabled by
default.
Note: In the case, complex functions are
started in the positioner, which require a
long calculation time or lead to a large
quantity of data being stored in the volatile
memory of the positioner, the alert 'busy' is
issued by the DTM file.
This alert is not an error message and can
simply be confirmed.
6.3
®
Dynamic HART variables
The HART® specification defines four dynamic variables consisting of a value and an
engineering unit. These variables can be assigned to device parameters as required.
The universal HART® command 3 reads the
dynamic variables out of the device. This allows manufacturer-specific parameters to
also be transferred using a universal command.
The dynamic variables of Type 3730-6 can
be assigned as follows in TROVIS-VIEW
[Device settings > Positioner > HART® communication]:
Operator controls and readings
®
Table 8 · Assignment of dynamic HART variables
Variable
Meaning
Unit
Set point
Set point
%
Direction of action set point Direction of action set point
%
Set point after transit time
specification
Set point after transit time specification
%
Valve position
Valve position
%
Set point deviation e
Set point deviation e
%
Absolute total valve travel
Absolute total valve travel
–
Binary input status
0 = Not active
–
1 = Active
255 = –/–
Internal solenoid
valve/forced venting status
0 = De-energized
–
1 = Energized
2 = Not installed
Condensed state
Temperature
0 = No message
3 = Failure
1 = Maintenance required
4 = Out of specification
2 = Maintenance demanded
7 = Function check
Temperature
–
°C
Leakage sensor sound level Sound pressure level (leakage sensor)
dB
Ambient pressure
Ambient pressure
mbar
Signal pressure p out
Signal pressure pout
bar
Supply pressure
Supply pressure
bar
Flow rate
Flow rate
m³/h
Differential pressure
Differential pressure
bar
EB 8384-6 EN
55
Start-up – Settings
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:
4 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
4 If 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.
56
EB 8384-6 EN
NOTICE
Perform the start-up settings in the same sequence as listed (section 7.1 to section 7.6).
Note: The positioner performs a test in the
start-up phase while following its automation task at the same time. During the
start-up phase, operation on site is unrestricted, yet write access is limited.
7.1
Defining the valve closed
position
Taking into account the valve type and actuator's direction of action, assign the closed
position (0 %) by positioning the AIR TO
OPEN/CLOSE slide switch:
AIR TO OPEN (ATO) position
Signal pressure opens the valve, e.g. for
valve with fail-close
AIR TO CLOSE (ATC) position
Signal pressure closes the valve, e.g. for
valve with fail-open
4
4
NOTICE
The AIR TO OPEN (ATO) setting always applies to double-acting actuators.
For checking purposes:
After successfully completing initialization,
the positioner display should read 0 % when
the valve is closed and 100 % when the
valve is open. If this is not the case, change
the slide switch position and re-initialize the
positioner.
Start-up – Settings
Note: The switch position is prompted prior
to an initialization. After an initialization has
been completed, changing the switch position does not have any effect on the operation of the positioner.
7.2
7.3
Adapting the display
The data representation on the positioner
display can be turned by 180° to adapt it to
how the positioner is mounted.
Reading direction for right
attachment of pneumatic
connections
Setting the volume
restriction Q
MAX BACK
MIN SIDE
MIN BACK
MAX SIDE
Reading direction for left attachment of pneumatic connections
Q
Fig. 22 · Volume restriction Q
MAX BACK/MIN SIDE setting
The volume restriction Q is used to adapt the
air delivery to the size of the actuator:
4
MAX BACK/MIN SIDE position for actuators with a transit time < 1 s, e.g. linear
actuators with an effective area smaller
than 240 cm², require a restricted air
flow rate (MIN).
MIN BACK/MAX SIDE position for actuators with a transit time ³ 1 s (the air
flow rate does not need to be restricted.)
Intermediate positions are not permitted
4
NOTICE
The positioner needs to be initialized again
after the position of the restriction has been
changed.
If the displayed data appear upside down,
proceed as follows:
Turn
® Code 2
Press
, Code 2 blinks
Turn
® Required direction
Press
to confirm reading direction.
7.4
Limiting the signal pressure
If the maximum actuator force may cause
damage to the valve, the signal pressure
pout must be limited.
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.
EB 8384-6 EN
57
Start-up – Settings
Selecting
manual operating mode:
Configuration enabled
Default: No
Operating mode
Default MAN
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® Code 0
Turn
® YES
Press
, Code 0 blinks
Press
, display
Turn
® MAN
Limiting the signal pressure:
Pressure limit
Default: No
Checking the operating range:
Manual set point
(current angle of rotation is
indicated)
® Code 16
Turn
Press
, Code 16 blinks
Turn
until the required pressure limit appears.
Press
to confirm the pressure limit setting.
7.5
Checking the operating
range of the positioner
To check the mechanical attachment and the
proper functioning, the valve should be
moved through the operating range of the
positioner in the
manual operating mode
with the manual set point.
58
Press
. The positioner changes to the
manual operating mode .
EB 8384-6 EN
Turn
® Code 1
Press
, Code 1 and
blink
Turn
until the pressure in the positioner
builds up, and the control valve moves to its
final positions so that the travel/angle of rotation can be checked.
The angle of rotation of the lever on the
back of the positioner is indicated. A horizontal lever (mid position) is equal to 0°.
To ensure the positioner is working properly, the outer bar elements may not blink
while the valve is moving through the operating range.
Exit Code 1 by pressing the rotary
pushbutton ( ).
Start-up – Settings
WARNING!
To avoid personal injury or property damage caused by the supply air or electrical
auxiliary power, disconnect the supply air
and electrical auxiliary power before exchanging the lever or changing the pin position.
7.6
During initialization the positioner adapts itself optimally to the friction conditions and
the signal pressure demand of the control
valve. The type and extent of self-adaptation
depends on the set initialization mode:
4 Maximum range (MAX)
Initialization
WARNING!
During initialization, the control valve moves
through its entire travel/angle of rotation
range. Therefore, do not start the initialization procedure while a process is running,
but only during start-up when all shut-off
valves are closed.
Before starting initialization, check the maximum permissible signal pressure of the control valve. During initialization, the
positioner issues an output signal pressure
up to the maximum supply pressure supplied. If necessary, limit the signal pressure
by connecting an upstream pressure reducing valve.
NOTICE
After the positioner has been mounted on to
another actuator or its mounting location
has been changed and prior to
re-initializing the positioner, the positioner
needs to be reset to its basic setting (default
values). Refer to section 7.9.
Note: When the write protection
is activated, the initialization cannot be started.
4
4
4
4
(standard
range)
Initialization mode for simple start-up of
valves with two clearly defined mechanical end positions, e.g. three-way valves
(see section 7.6.1)
Nominal range (NOM)
Initialization mode for all globe valves
(see section 7.6.2)
Manually selected OPEN position
(MAN)
Initialization mode for globe valves with
manual entry of the OPEN position (see
section 7.6.3)
Manually selected end positions
(MAN2)
Initialization mode for globe valves with
manual entry of both positions (see section 7.6.4)
Substitute calibration (SUB)
This mode allows a positioner to be replaced while the plant is running, with
the least amount of disruption to the
plant (see section 7.6.5)
Alternating displays
Initialization running
Icon depending on initialization mode selected
Bar graph display
indicating the progress of
the initialization
EB 8384-6 EN
59
Start-up – Settings
After the basic initialization, the reference
curve for the valve signature is recorded
(Code 48 - h0 = YES).
Reading in alternating
sequence:
TEST/D1
Bar graph display
indicating the progress of
the initialization
%
Initialization successful,
positioner in automatic
operating mode
The time required for an initialization process depends on the transit time of the actuator and may take several minutes.
After a successful initialization, the
positioner runs in closed-loop operation indicated by .
A malfunctioning leads to the process being
canceled. The initialization error appears on
the display according to how it has been
classified by the condensed state. See section 8.3.
Note: An error during the recording of the
valve signature is indicated by Code 81. The
valve signature does not affect closed-loop
operation.
Valve closed position AIR TO CLOSE
If the slide switch is set to AIR TO CLOSE,
the positioner automatically switches to the
direction of action increasing/decreasing
(äæ) on successful completion of initialization.
This results in the following assignment between reference variable and valve closed
position:
Valve closed
position
Direction of
action
Reference variable w
Valve
CLOSED
OPEN
AIR TO OPEN
ää
w=0%
AIR TO CLOSE
äæ
w = 100 % w = 0 %
w = 100 %
The tight-closing function is activated.
NOTICE
Set Code 15 (final position w>) to 99 % for
three-way valves.
Canceling an initialization process
The initialization procedure can be canceled
while running by pressing the rotary
pushbutton ( ). STOP appears three seconds long and the positioner then changes
to the fail-safe position (SAFE).
Exit the fail-safe position again over Code 0
(see section 8.2.2).
7.6.1 MAX – Initialization based
on maximum range
The positioner determines travel/angle of
rotation of the closing member from the
CLOSED position to the opposite side and
60
EB 8384-6 EN
Start-up – Settings
adopts this travel/angle of rotation as the
operating range from 0 to 100 %.
Select the initialization mode:
Enable configuration:
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
Default MAX
Turn
® Code 6
Press
Turn
Default No
Press
mode.
® MAX
to confirm MAX as the initialization
Start initialization:
Turn
Press
Turn
Press
® Code 3, display: No
, Code 3 blinks
® YES
, display
4 Press INIT key to start initialization!
After initialization, the maximum travel/angle of rotation (Code 5) which was detected
during initialization is indicated.
Enter the pin position:
mm
Pin position
Default No
Turn
® Code 4
Press
, Code 4 blinks
Turn ® Pin position on lever (see relevant
section on attachment)
Press
Turn ® Skip nominal range (Code 5) and
go to Code 6.
7.6.2 NOM – Initialization based
on 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 lower travel/angle range value
(Code 8) and upper travel/angle range
value (Code 9) as the operating range.
EB 8384-6 EN
61
Start-up – Settings
Enable configuration:
Press
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
Select the initialization mode:
Default No
Initialization mode
Default MAX
Turn
® Code 6
Press
, Code 6 blinks
® NOM
Turn
® Code 3, display: No
Turn
Press
, Code 3 blinks
Turn
® YES
Press
to confirm the NOM as the initialization mode.
Press
, display
Start initialization:
Enter pin position and nominal range:
mm
mm
Pin position
Default No
Nominal range
(locked with Code 4 = No)
Turn
® Code 4
Press
, Code 4 blinks
Turn
® Pin position on lever (read relevant section on attachment)
Press
® Code 5
Turn
Press
Turn
62
, Code 5 blinks
® Nominal travel/angle
EB 8384-6 EN
4 Press INIT key to start initialization!
Note: If the nominal range determined during initialization is smaller than the range
entered in Code 5, initialization is canceled
and an error message (Code 52) is generated.
After initialization, check the direction of
action and, if necessary, change it (Code
7).
7.6.3 MAN – Initialization based
on a manually selected
OPEN position
Before starting initialization, move the control valve manually to the OPEN position.
The positioner calculates the differential
travel/angle from the OPEN and CLOSED
Start-up – Settings
positions and adopts it as the operating
range with limits of lower travel/angle
range value (Code 8) and upper travel/angle range value (Code 9).
Select the initialization mode:
Initialization mode
Default MAX
Enable configuration:
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
Turn
® Code 6
Press
, Code 6 blinks
Turn
® MAN
Press
to confirm the MAN as the initialization mode.
Enable configuration
Default No
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
Enter the pin position:
mm
Enter OPEN position:
Manual set point
(the current angle of rotation
is displayed)
Turn
® Code 0
Press
, Code 0 blinks
Turn
® MAN
Press
Pin position
Default No
Turn
® Code 4
Press
, Code 4 blinks
Turn
® Pin position on lever (see relevant
section on attachment)
Press
Turn
® Skip nominal range (Code 5)
and go to Code 6.
Turn
® Code 1
Press
, Code 1 blinks
Turn
clockwise in small steps until the required valve position is reached. The valve
must be moved with a monotonically increasing signal pressure.
Press
to confirm the OPEN position.
Start initialization:
4 Press INIT key to start initialization!
EB 8384-6 EN
63
Start-up – Settings
After initialization, the maximum travel is indicated in mm or the maximum angle in ° in
Code 5.
Turn
® YES
Press
, display
Enter the pin position:
7.6.4 MAN2 – Initialization based
on manually selected end
positions
Before starting initialization, move the control valve manually to the end positions. The
positioner calculates the travel/angle difference from the positions that the valve moved
to and adopts it as the operating range with
limits of lower travel/angle range value
(Code 8) and upper travel/angle range
value (Code 9).
Note: This initialization mode can only be
started when the valve position differs in the
end positions and the positioner has not yet
been initialized.
mm
Pin position
Default No
Turn
® Code 4
Press
, Code 4 blinks
Turn ® Pin position on lever (see relevant
section on attachment
Press
Turn ® Skip nominal range (Code 5) and
go to Code 6.
Select the initialization mode and enter end
positions:
Enable configuration:
Initialization mode
Default MAX
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
POS1 (end position 1)
Enable configuration
Default No
Turn
® Code 3, display: No
Press
, Code 3 blinks
64
EB 8384-6 EN
POS2 (end position 2)
Turn
® Code 6
Press
, Code 6 blinks
Start-up – Settings
Turn
® MAN2
Press
to adopt the initialization mode
MAN2 ® POS1 and the current angle position of the lever are indicated on the display
in alternating sequence.
Turn
clockwise in small steps until the required valve position is reached. The valve
must be moved with a monotonically increasing signal pressure.
Press
to confirm the valve position ®
WAIT. The valve position is adopted after
the pressure settles ® POS2 and the current
angle position of the lever are indicated on
the display in alternating sequence.
Turn
until the required OPEN position of
the valve is reached.
Press
to confirm the valve position ®
WAIT. Initialization can be started as soon
as MAN2 is indicated again on the display.
Start initialization:
4 Press INIT key to start initialization!
After initialization, the tight-closing function
(Code 14) is deactivated.
expected. You should always select a different initialization mode if the plant allows it.
The SUB initialization mode is used to replace a positioner while the process is running. For this purpose, the control valve is
usually fixed mechanically in a certain position, or pneumatically by means of a pressure signal which is routed to the actuator
externally. The blocking position ensures
that the plant continues to operate with this
valve position.
The blocking position can also be the
fail-safe position when this condition is beneficial for the temporary phase.
NOTICE
Perform a reset before re-initializing the
positioner if the substitute positioner has already been initialized. Refer to section 7.9.
Enable configuration:
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
7.6.5 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 determined by an initialization procedure. As a
result, a high level of accuracy cannot be
Enable configuration
Default No
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
EB 8384-6 EN
65
Start-up – Settings
Enter the pin position and nominal range:
mm
mm
Enter the direction of action:
Pin position
Default No
Nominal range
(locked with Code 4 = No)
Direction of action
Default ää
Turn
® Code 7
Press
, Code 7 blinks
Turn
® Direction of action (ää/äæ)
Press
Turn
® Code 4
Press
, Code 4 blinks
Deactivate travel limit:
Turn
® Pin position on lever (see relevant
section on attachment)
Travel limit
Default 100.0
Press
Turn
® Code 5
Press
, Code 5 blinks
Turn
® Code 11
Press
, Code 11 blinks
Press
Turn
® No
Select the initialization mode:
Press
® Nominal travel/angle
Turn
Initialization mode
Default MAX
® Code 6
Turn
Press
® SUB
Turn
Press
mode.
66
to confirm SUB as the initialization
EB 8384-6 EN
Change pressure limit and control parameters:
Note: Do not change the pressure limit
(Code 16). Only change the control parameters KP (Code 17) and TV (Code 18) if the
settings of the replaced positioner are
known.
Start-up – Settings
Press
Pressure limit
Default No
KP level
Default 7
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).
Define the valve closed position:
4 Set switch for valve closed position AIR
TV level
Default
Turn
® Code 16/17/18
Press
, Code 16/17/18 blinks
Turn
to set the control parameter selected
Press
to confirm the setting.
Enter closing direction and blocking position:
Closing direction
Direction of rotation causing
the valve to move to the
CLOSED position (view onto
positioner display)
Default: CCL (counterclockwise)
mm
Turn
Press
Blocking position
Default: 0
® Code 34
, Code 34 blinks
Turn
® Closing direction (CCL counterclockwise/CL clockwise)
4
TO OPEN or AIR TO CLOSE as described in section 7.1 on page 56.
Set volume restriction as described in
section 7.2 on page 57.
Start initialization:
4 Press INIT key!
The operating mode is changed to automatic mode .
Note:
– As initialization has not been carried out
completely, the error code 76 (no emergency mode) and possibly also error
code 57 (control loop) may appear on
the display.
These alarms do not influence the
positioner’s readiness for operation.
– If the positioner shows a tendency to oscillate in automatic operating mode, the
parameters KP and TV must be slightly
corrected. Proceed as follows:
Set TV to 4 (Code 18).
If the positioner still oscillates, the gain
KP (Code 17) must be decreased until the
positioner shows a stable behavior.
EB 8384-6 EN
67
Start-up – Settings
Zero point calibration
7.7
If the process allows it (valve move once to
the closed position), perform a zero point
calibration according to section 7.7.
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.
7.6.6 Tuning the KP input filter
Changing the KP level (Code 17) affects the
set point deviation. This effect can be compensated for by tuning the input filter without having to re-initialize the positioner.
Enable configuration:
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
Zero calibration
NOTICE
The valve briefly moves from the current
travel/angle position to the closed position.
Note:
– The positioner must be connected to the
supply air to perform the zero calibration.
– A zero calibration is not possible if there
is zero point shift of more than 5 %. In
this case, Code 54 is activated. The
positioner must be re-initialized.
Tuning the input filter:
Enable configuration:
Tuning the input filter
Standard MAX
Turn
® Code 6
Press
, Code 6 blinks
Turn
® KP
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
Perform zero calibration:
4 Press INIT key to start initialization!
The tuning is started. During the tuning,
the valve moves through its whole range
and the input filter is recalibrated.
68
EB 8384-6 EN
Zero calibration
Default MAX
Turn
® Code 6
Press
, Code 6 blinks
Start-up – Settings
Turn
® ZP
4 Press INIT key!
Zero calibration is started, the positioner
moves the control valve to the CLOSED
position and readjusts the internal electrical zero point.
7.8
Settings for on/off valves
If the valve is to be operated using the
on/off valve as the type of application, the
operating point, test limits and limits for the
discrete analysis must be defined.
Note: The travel range of on/off valves is
defined using the fail-safe position and the
given Operating point. As a result, the following parameters to define the operating
range and the range of the reference variable (set point) cannot be changed or analyzed:
Lower travel/angle range value (Code 8)
Upper travel/angle range value (Code 9)
Lower travel/angle limit (Code 10)
Upper travel/angle limit (Code 11)
Set point, lower range value (Code 12)
Set point, upper range value (Code 13)
and falls below the Fail-safe action limit
(Code 49 - h2).
Travel [%]
100
Code 49 - h1
80
Code 49 - h5
60
40
20
Code 49 - h2
Δt < 6 s
Time [s]
If the reference variable (w
) is above
the Operating point limit (Code 49 - h5)
when automatic mode starts, the valve
(
) moves to the Operating point
(Code 49 - h1). The valve moves back to the
fail-safe position if the reference variable
continues and falls below the Fail-safe action limit (Code 49 - h2).
Travel [%]
100
Code 49 - h1
80
Code 49 - h5
60
40
Discrete analysis
If the reference variable (w
) is below
Operating point limit (Code 49 - h5) at the
start of automatic operation, the valve
(
) moves to the fail-safe position. If
the reference variable increases and exceeds the Operating point limit, the valve
moves to the Operating point (Code 49 h1). The valve moves back to the fail-safe
position if the reference variable continues
20
Code 49 - h2
Δt < 6 s
Time [s]
EB 8384-6 EN
69
Start-up – Settings
Triggering the partial stroke test (PST)
Canceling the partial stroke test (PST)
A partial stroke test is started when the reference (w
) moves from the Operating point into the range between 25 and
50 % travel and remains there for longer
than six seconds. The valve (
) moves
from the last defined position to the Lower
range value (of step) (Code 49 - d2).
The partial stroke test is canceled whenever
the reference variable changes and falls below the Fail-safe action limit. The valve
moves back to fail-safe position.
After the partial stroke test is completed, the
valve moves back to its previous position
(fail-safe position or Operating point).
Enable configuration:
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
Select on/off valve as type of application:
Travel [%]
100
Code 49 - h1
80
Code 49 - h5
60
40
Code 49 - h4
20
Code 49 - h3
Code 49 - h2
Code 49 - d2
Time [s]
Δt > 6 s
Start PST
Turn
® Code 49
Press
, Code 49 blinks
Turn
® Code h0
Press
, Code h0 blinks
Turn
® YES
Press
End PST
Enter operating point, test limits and limits
for discrete analysis:
Travel [%]
Start PST
100
80
End PST
Code 49 - h1 =
Code 49 - d2
Code 49 - h5
60
Code 49 - h4
40
20
Code 49 - h3
Code 49 - h2
Δt > 6 s
70
EB 8384-6 EN
Time [s]
Turn
® Code h1/h2/h3/h4/h5
Press
, Code h1/h2/h3/h4/h5 blinks
Turn
to adjust the parameter selected
Press
to confirm the setting.
Start-up – Settings
7.9
Reset to default values
A reset allows the positioner to be reset to
the default settings. To reset the positioner,
the options Diag, Std and DS are available
in Code 36. Table 8 lists the reset functions.
Note: Code 36 – DS is usually selected
when the valve is mounted in another position or when the positioner is to be mounted
to another valve.
Performing a reset does not necessarily
mean the positioner must be re-initialized.
Enable configuration:
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display
Reset start-up parameters:
Reset
Default No
Turn
® Code 36, display: – – –
Press
, Code 36 blinks
Turn
® DIAG/STD/DS
Press . The parameters are reset depending on the option selected. Refer to Table 9.
EB 8384-6 EN
71
Start-up – Settings
Table 9 · Reset functions
Initialization
Reset Code 36
Diag
Std
DS
NO
YES
YES
Fail-safe behavior
Air supply failure
NO
NO
YES
Power supply failure of positioner
NO
NO
YES
Power supply failure of external solenoid valve
YES
NO
NO
Emergency mode
NO
NO
NO
Operating hours counter
NO
NO
NO
Device in operation
NO
YES
YES
Device switched on since initialization
NO
YES
YES
Device in operation since initialization
NO
YES
YES
NO
YES
YES
YES
Logging
Code
no.
Parameter
2
Reading direction
NO
YES
4
Pin position
NO
YES
YES
5
Nominal range
NO
YES
YES
6
Initialization mode
NO
YES
YES
7
Direction of action
NO
YES
YES
8
Lower travel/angle range value
NO
YES
YES
9
Upper travel/angle range value
NO
YES
YES
10
Lower travel/angle range limit
NO
YES
YES
11
Upper travel/angle range limit
NO
YES
YES
12
Set point, lower range value
NO
YES
YES
13
Set point, upper range value
NO
YES
YES
14
CLOSED end position
NO
YES
YES
15
OPEN end position
NO
YES
YES
16
Pressure limit
NO
YES
YES
17
Proportional-action coefficient Kp level
NO
NO
NO
18
Derivative-action time Tv level
NO
NO
NO
19
Tolerance band
NO
YES
YES
20
Select characteristic
NO
YES
YES
21
Enter transit time OPEN
NO
YES
YES
22
Enter transit time CLOSED
NO
YES
YES
24
Total valve travel limit
NO
YES
YES
25
Alarm mode
NO
YES
YES
72
EB 8384-6 EN
Start-up – Settings
Table 9 · Reset functions
Reset Code 36
Diag
Std
DS
NO
YES
YES
26
Limit A1
27
Limit A2
NO
YES
YES
32
Error message in case of 'Function check' condensed state
NO
YES
YES
33
Error message in case of 'Maintenance required' and 'Out of
specification' condensed state
NO
YES
YES
38
Inductive limit switch
NO
NO
NO
46
Bus address
NO
NO
YES
48 d5
Diagnosis
Zero point limit
Principle of operation (actuator)
NO
NO
YES
h0
Initialization including valve signature
NO
YES
YES
h3
Desired time until 'Reset diagnostic measured data'
NO
NO
YES
d11
49 -
Partial stroke test (PST)
A2
Test start
NO
NO
NO
A3
Enter test interval
NO
YES
YES
A8
Activate Dp out monitoring
NO
YES
YES
A9
Dp out monitoring value
NO
YES
YES
d2
Lower range value
NO
YES
YES
d3
Upper range value
NO
YES
YES
d4
Activate ramp function
NO
YES
YES
d5
Ramp time (increasing)
NO
YES
YES
d6
Ramp time (decreasing)
NO
YES
YES
d7
Settling time before starting test
NO
YES
YES
d8
Waiting time after step change
NO
YES
YES
d9
Sampling time
YES
YES
YES
E0
Activate x monitoring
NO
YES
YES
E1
x monitoring value
NO
YES
YES
E5
Activate PST tolerance band monitoring
NO
YES
YES
E6
PST tolerance band
NO
YES
YES
E7
Max. test duration
YES
YES
YES
h0
Type of application
NO
YES
YES
h1
Operating point
NO
YES
YES
h2
Fail-safe action limit
NO
YES
YES
h5
Operating point limit
NO
YES
YES
EB 8384-6 EN
73
Operation
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
The code list in section 14 on page 83 onwards contains all codes with their meaning
and default settings.
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 3
Configuration
not enabled
Configuration
enabled
Turn
® Code 3, display: No
Press , Code 3 blinks.
Change the setting of Code 3.
Turn
® YES
Press , display:
Configuration is enabled.
You can now configure codes one after the
other:
74
EB 8384-6 EN
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 changes to
Code 0.
Canceling a value before it is confirmed
Canceling the reading
To cancel a value before it is confirmed (by
pressing ) proceed as follows:
Turn
® ESC
Press
. The entered value is not adopted.
Operation
8.2
Turn
Operating modes
8.2.1 Automatic and manual modes
After initialization has been completed successfully, the positioner is in the automatic
mode
(AUTO).
%
Automatic mode
® Code 0
Press
, display: AUTO, Code 0 blinks
Turn
® MAN
, Code 1 blinks
Turn
until sufficient pressure has been
built up in the positioner and the control
valve moves to the required position.
Note: The positioner automatically returns to
Code 0 if no settings are made within 120
seconds. The positioner remains in the manual mode.
Switch to automatic operating mode
(AUTO)
Switch to manual operating mode
Turn
Press
® Code 1
Turn
® Code 0
Press
, Code 0 blinks
Turn
® AUTO
Press . The positioner changes to automatic operating mode.
Press
to change to the manual operating
mode .
The switchover is smooth since the manual
mode starts up with the set point last used
during automatic mode. The current position
is displayed in %.
Adjust the manual set point
%
%
EB 8384-6 EN
75
Operation
8.2.2 Fail-safe position (SAFE)
8.3
If you want to move the valve to fail-safe position determined during start-up (see section 7.1), proceed as follows:
All status and error messages are classified
according to a status in the positioner. The
default settings of the status classification are
listed in the code list.
® Code 0
Turn
Press , display: current operating mode
(AUTO or MAN), Code 0 blinks
® SAFE
Turn
Press , display: S
The valve moves to the fail-safe position.
Once the positioner is initialized, the current
valve position is indicated on the display in
%.
Note: The status classification can only be
changed in the operator software, e.g.
TROVIS-VIEW 4. For more details, refer to
the Operating Instructions EB 8389-1 EN on
EXPERTplus Valve Diagnostics.
To provide a better overview, the classified
messages are summarized in a condensed
state. The following status messages are
available:
4 Failure
Exit the fail-safe position
Turn
® Code 0
Press
, Code 0 blinks
4
Turn
and select the required operating
mode AUTO or MAN.
Press .
The positioner switches to the operating
mode selected.
76
EB 8384-6 EN
Malfunction/Failure
4
The positioner cannot perform its control
task due to a functional fault in the device or in one of its peripherals or an initialization 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
faster rate than expected. Maintenance is
necessary in the short term.
Operation
4 Out of specification
Fault alarm output
The positioner is operated outside the
specified operating conditions.
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 appears on the display
with the following icons:
Function check
Positioner
display
Priority
Text, e.g. TUNE or
TEST
Failure
Out of specification
4 The 'Function check' condensed state can
4
Condensed state
Condensed state
The 'Failure' as the condensed state causes
the optional fault alarm output to be
switched.
blinking
Maintenance required/ Maintenance demanded
The message with the highest priority determines the condensed state in the positioner.
If error messages exist, the possible source
of error is displayed in Code 49 onwards. In
this case, ERR appears on the display.
S
Example:
Error caused by pin
position
also activate the fault alarm contact in
Code 32.
The 'Maintenance required/ Maintenance demanded' condensed state and
'Out of specification' can also activate
the fault alarm contact in Code 33.
8.3.1 Confirming error messages
Enable configuration:
Note: If no settings are entered within
120 seconds, the enabled configuration
function becomes invalid.
Turn
® Code 3, display: No
Press
, Code 3 blinks
Turn
® YES
Press
, display:
Confirm error messages:
Turn
® Error code which you want to
confirm.
Press
to confirm the error message.
The cause and recommended action are
listed in the code list (section 14).
EB 8384-6 EN
77
Adjusting the limit switch
9
Adjusting the limit switch
The positioner version with inductive limit
switch has one adjustable tag (1) mounted
on the shaft which operates the proximity
switch (3).
For operation of the inductive limit switch,
the corresponding switching amplifier according to EN 60947-5-6 (see section
5.2.1) must be connected to the output.
If the tag (1) is inside the field of the switch,
the switch assumes a high resistance. If the
tag is outside of the field, the switch assumes
a low resistance.
Normally, the limit switch is adjusted such
that it will provide a signal in both end positions of the valve. The switch, however, can
also be adjusted to indicate intermediate
valve positions.
Adjustment screw (2)
Fig. 23 · Adjustment of the limit switch
78
EB 8384-6 EN
Note: The inductive limit switch replaces the
software limit switch A1 with terminal assignment +41/–42.
Each switching position can optionally be set
to indicate when the tag has entered the
field, or when it has left the field.
The second software limit switch remains effective, the function of the software limit
switch A1 is disabled.
Software adaptation
Code 38 (inductive alarm is set to YES).
The inductive limit switch is connected to the
terminals +41/–42.
The device is set up accordingly in the delivered state.
Tag (1) Proximity switch (3)
Adjusting the limit switch
Setting the switching point:
NOTICE
During adjustment or testing, the switching
point must always be approached from
mid-position (50 %).
Contact function:
4 Tag leaving the field > Contact is made.
4 Tag entering the field > Contact is
opened.
To ensure safe switching under any ambient
conditions, the switching point should be adjusted to a value of approx. 5 % before the
mechanical stop (OPEN – CLOSED).
For CLOSED position:
1.
2.
3.
Initialize positioner.
Use the MAN function to move the
positioner to 5 % (see LC display).
Adjust the tag using the yellow adjustment screw (2) until the tag enters or
leaves the field and the switching amplifier responds. You can measure the
switching voltage as an indicator.
Contact function:
4 Tag leaving the field > contact is made
4 Tag entering the field > contact is
opened.
For OPEN position:
1.
2.
3.
Initialize positioner.
Use the MAN function to move the
positioner to 95 % (see LC display).
Adjust the tag (1) using the yellow adjustment screw (2) until the tag enters or
leaves the field of the proximity switch
(3).
You can measure the switching voltage
as an indicator.
EB 8384-6 EN
79
Adjusting the limit switch
9.1
Retrofitting an inductive
limit switch
1
2
Required retrofit kit:
Limit switch Order no. 1400-7460
4
Note: For explosion-protected devices, the
requirements in section 11 need to be kept.
1.
2.
3.
4.
5.
6.
7.
Take off the rotary pushbutton (3) and
cap (1), unthread the five fixing screws
(2) and lift off the plastic cover (9).
Use a knife to cut an opening at the
marked location (4).
Push the connector (11) with cable
through the opening and secure the
proximity switch (7) on the cover with a
dot of glue.
Remove the jumper (item no.
8801-2267) at the socket X7 of the top
board and insert the cable connector
(11).
Guide the cable in such a manner that
the plastic cover can be placed back
onto the positioner. Insert the fixing
screws (2) and screw tight. Attach the
clamping plate (8) onto the proximity
switch.
Attach the rotary switch (5). Make sure
the flattened side of the positioner shaft
is turned so that the rotary switch (5)
can be attached with the metal tag next
to the proximity switch.
Note: On start-up of the positioner, set
the option 'inductive alarm' under Code
38 from No to YES.
3
5
8
7
6
9
7
Socket X7 (11)
1
2
3
4
5
Cap
Screws
Rotary pushbutton
Marking
Rotary switch
6
7
8
9
11
Metal tag
Proximity switch
Clamping plate
Plastic cover
Connector
Fig. 24 · Retrofitting an inductive limit switch
80
EB 8384-6 EN
Maintenance
10
Maintenance
The positioner does not require any maintenance.
There are filters with a 100 µm mesh size in
the pneumatic connections for supply and
output which can be removed and cleaned,
if required.
The maintenance instructions of any upstream supply air pressure reducing stations
must be observed.
tended for future use inside hazardous areas must comply with the safety requirements placed on serviced devices. Before
being used inside hazardous areas, test the
devices according to the specifications for
servicing explosion-protected devices.
Refer to section 13 for maintenance, calibration and settings within and outside potentially explosive areas.
12
11
Servicing
explosion-protected devices
If a part of the device on which the explosion protection is based needs to be serviced, the device must not be put back into
operation until a qualified inspector has assessed it according to explosion protection
requirements, has issued an inspection certificate or given the device a mark of conformity.
Inspection by a qualified inspector is not required if the manufacturer performs a routine test on the device prior to putting it back
into operation. The passing of the routine
test must be documented by attaching a
mark of conformity to the device. Replace
explosion-protected components only by
original, routine-tested components from the
manufacturer.
Devices that have already been in operation outside hazardous areas and are in-
Firmware update (serial
interface)
Firmware updates on positioners currently in
operation can be performed as follows:
When updates are performed by a service
employee appointed by SAMSON, the update is confirmed on the positioner by the
test mark assigned by SAMSON’s Quality
Assurance.
In all other cases, only persons from the
plant operator with written approval may
perform updates. This person must confirm
the update on the positioner.
Laptops and PCs connected to the power
supply must use an additional safety barrier.
This does not apply to laptops in battery operation. In this case, it is assumed that a battery-powered laptop runs briefly for software programming or for testing purposes.
a) Updates outside hazardous area:
Remove the positioners from the plant
and update them outside the hazardous
area.
EB 8384-6 EN
81
Maintenance, calibration and work on equipment
b.) Updates on site:
Updates on site are only permitted after
the plant operator has presented a signed hot work permit.
After updating has been completed, add the
current firmware to the nameplate; this can
be done using labels.
13
Maintenance, calibration
and work on equipment
The interconnection with intrinsically safe
circuits to check or calibrate the apparatus
must only be performed with intrinsically
safe current/voltage calibrators and measuring instruments to rule out any damage
to components relevant for explosion protection.
The maximum values for intrinsically safe
circuits specified in the approvals must be
kept.
82
EB 8384-6 EN
Code list
14
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
0
Operating mode
Switchover from automatic to manual mode is smooth.
[MAN] Manual mode
AUtO
Automatic mode
Automatic mode is only possible after the positioner has been initialized.
SAFE
Fail-safe position
Refer to section 6 for reading under Code 0
ESC
Escape
1
Manual set point (manual w) Adjust the manual set point with the rotary pushbutton, the
current travel/angle is displayed in % when the positioner is ini0 to 100 [0] %
tialized, otherwise the position of the lever in relation to the cenof the nominal range
tral axis is indicated in degrees °.
An on/off valve can be
Note: Can only be selected when Code 0 = MAN
moved past 100 % of the
nominal range (with the
closed position for ATO) or
below 0 % of the nominal
range (with the closed position for ATC).
2
Reading direction
Normal or upside down
The reading direction of the positioner display, depending on the
location of the pneumatic connection
ESC
3
Enable configuration
[No] · YES · ESC
Enables the option to modify data (automatically deactivated when
the rotary pushbutton has not been operated for 120 s.)
Codes marked with an asterisk (*) can only be read and not
overwritten.
HART blinks on the display when the on-site operation is locked
over HART® communication.
PST appears on the display when the on-site operation is locked
by the time-controlled partial stroke test.
In these cases, codes can only read over the SSP interface.
EB 8384-6 EN
83
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
4*
Pin position
[No] · 17, 25, 35, 50, 70,
100, 200 mm · 90° with rotary actuators · 300 mm with
piston actuators · ESC
The follower pin must be inserted into the correct pin position according to the valve travel/angle of rotation.
For initialization using NOM (nominal range) or SUB (substitute
calibration), the pin position must be entered.
For initialization using MAX, MAN and MAN2, the pin position
is not required, however, it is required under Code 5 to display
NOTICE If you select a pin
position in Code 4 that is too the nominal range.
small, the positioner switches
to SAFE mode for reasons of
Pin position
Default
Adjustment range
safety
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
300
200.0
60.0 to 300.0
5*
Nominal range
[15.0] mm or angle °
ESC
For initialization using NOM (nominal range) or SUB (substitute
calibration), the nominal range must be entered. The possible adjustment range depends on the pin position from the table for
Code 4.
After initialization to the maximum range (MAX), the maximum
nominal travel/angle reached on initialization is displayed.
6*
Initialization mode (init
mode)
[MAX] · NOM · MAN
MAN2 · SUB
KP · ZP
ESC
MAX:
Maximum range · For simple start-up of valves with two
clearly defined mechanical end positions · The positioner
determines travel/angle of rotation of the closing
member from the CLOSED position to the opposite stop
in the actuator
NOM: Nominal range · For all globe valves · The positioner determines travel/angle of rotation of the closing member
from the CLOSED position to the specified nominal
range
MAN: Manual setting 1 · For all globe valves with unknown
nominal range (OPEN position) · The positioner determines travel/angle of rotation from the manually selected OPEN position (100 %) to the CLOSED position
84
EB 8384-6 EN
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
6*
Initialization mode (init
mode)
- continued -
MAN2: Manual setting 2 · For all globe valves with unknown
nominal range (OPEN and CLOSED position) · The
positioner determines travel/angle of rotation between
the manually selected OPEN (100 %) and the manually
selected CLOSED position (0 %)
SUB:
Substitute calibration · To replace a positioner while the
plant is running, with the least amount of disruption to
the plant
KP:
Fine tuning of the input filter · The valve moves through
its entire valve range.
NP:
Zero calibration · The zero point is recalibrated.
NOTICE The valve moves briefly from the operating point
to the closed position!
7*
Direction of action (w/x)
Direction of action of the set point in relation to the valve position
[ää] · äæ · ESC
ää:
Increasing/increasing: a globe valve opens as the set
point increases.
äæ:
Increasing/decreasing: a globe valve closes as the set
point increases.
The direction of action is adapted to the change in closed direction as follows:
8*
ATO:
AIR TO OPEN · After initialization, the direction of action remains increasing/increasing (ää), a globe valve
opens as the mA signal increases.
ATC:
AIR TO CLOSE · After initialization, the direction of action changes to increasing/decreasing (äæ ), a globe
valve opens as the mA signal increases.
Lower travel/angle range
value (lower x-range value)
Lower range value for the travel/angle of rotation in the operating range.
[0.0] to 80.0 % of the nominal range · ESC
Nominal range and characteristic are automatically adapted.
Specified in mm or angle°,
provided Code 4 is activated.
The operating range is the actual travel/angle of the valve and is
limited by the lower travel/angle range value (Code 8) and the
upper travel/angle range value (Code 9).
Usually, the operating range and the nominal range are identical. The nominal range can be limited to the operating range
by the lower and upper x-range values. Value is displayed or
must be entered.
See also the example in Code 9!
EB 8384-6 EN
85
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
Upper range value for the travel/angle of rotation in the operUpper travel/angle range
value (upper x-range value) ating range.
9*
20.0 to [100.0] % of the
nominal range · ESC
10*
11*
Nominal range and characteristic are automatically adapted.
Specified in mm or angle°,
provided Code 4 is activated.
Example: The operating range is modified, for example, to limit
the range of a valve which has been sized too large. For this
function, the entire resolution range of the set point is converted
to the new limits. 0 % on the display corresponds to the adjusted
lower limit and 100 % to the adjusted upper limit.
Lower travel/angle limit
(lower x-limit)
Lower limitation of the travel/angle of rotation to the entered
value.
[No] · 0.0 to 49.9 % of the
operating range · ESC
The characteristic is not adapted.
Upper travel/angle limit
(upper x-limit)
Upper limitation of the travel/angle of rotation to the entered
value.
No · 50.0 to120.0 % of the
operating range · ESC,
[100.0]
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!
When set to 'No', the valve can be opened past the nominal
travel with a set point outside of the 4 to 20 mA range.
86
EB 8384-6 EN
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
12*
Set point, lower range value Lower range value (0 % = 4 mA) of the valid set point range
(w-start)
This value must be smaller than the upper range value (w-end).
[0.0] to 75.0 % · ESC
The set point range is the difference between Set point, upper
range value – Set point, lower range value. The difference must
be larger or equal to 25 % (= 4 mA).
When the set point range of 0 to 100 % = 4 to 20 mA, the valve
moves through its entire operating range from 0 to 100 %
travel/angle of rotation.
In split-range operation, the valves operate with smaller set
points. The control signal of the control unit to control two valves
is divided such, for instance, that the valves move through their
full travel/angle of rotation at only half the input signal (first
valve set to 0 to 50 % = 4 to 12 mA and second valve set to 50
to 100 % =12 to 20 mA).
13*
Set point, upper range
value (w-end)
Upper range value (100 % = 20 mA) of the valid set point range
This value must be greater than the lower range value (w-start).
25.0 to [100.0] % · ESC
14*
CLOSED end position
(end position w <)
No · 0.0 to 49.9 % of the
span set over Code 12/13
ESC, [1.0]
Limit of the set point w
When the set point falls below the limit, an actuator with ATO is
completely vented and an actuator with ATC is filled with air.
This action always lead to the 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*
OPEN end position
(end position w >)
[No] · 50.0 to 100.0 % of
the span set over Code
12/13 · ESC
Limit of the set point w
When the set point falls below the limit, an actuator with ATO is
filled with air and an actuator with ATC is completely vented.
This action always lead to the maximum opening of the valve.
Codes 14/15 have priority over Codes 8/9/10/11.
NOTICE For double-acting
Codes 21/22 have priority over Codes 14/15.
actuators (ATO) the pressure limit must not be active! Example: Set the end position w > to 99 % for three-way valves.
16*
Pressure limit
The signal pressure to the actuator can be limited.
[No] · 1.4 to 7.0 bar · ESC
After changing the pressure limit setting, the actuator must be
vented once (e.g. by selecting the fail-safe position).
EB 8384-6 EN
87
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
17*
During the initialization of the positioner, the K P and TV values
are optimized. If the value for the KP level is below 3, the error
code 61 is activated.
0 to 17 · ESC, [7]
Should the positioner show a tendency for impermissibly high
NOTICE Changing the KP
post-pulse oscillation due to additional interference, the K P and
level influences the system
TV levels can be adapted after the initialization.
deviation. This influence can
For this, either the TV level can be increased in increments until
be balanced out by tuning
the desired response behavior is reached or, when the maximum
the input filter in Code 6.
value of 4 is reached, the KP level can be decreased in increSee section 7.6.6.
ments.
18*
Derivative-action time Tv
level
Proportional-action
coefficient Kp level
No · 1 to 4 · ESC, [2]
19*
Tolerance band
See Code 19.
A change of the TV level has no effect on the set point deviation.
Used for error monitoring.
0.1 to 10.0 % of the
If the system deviation is greater than selected tolerance band for
operating range · ESC, [5.0] a time longer than the lag time [30 s], this causes the error code
57 (control loop) to be activated.
Note: The lag time can only be set using the operator software.
20*
88
Select characteristic
Select the characteristic. See section 16
[0] to 9 · ESC
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 in operator software)
EB 8384-6 EN
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
21*
22*
Transit time OPEN
(w ramp OPEN)
The time required to pass through the operating range when the
valve opens.
[0] to 240 s · ESC
NOTICE
The transit time entered in
this code does not apply
when the safety function is
triggered, the solenoid
valve/forced venting is activated or when the auxiliary
power fails.
This parameter can be used to increase the Min. transit time
OPEN (Code 40).
Transit time CLOSED
(w ramp CLOSED)
Limitation of the transit time (Code 21 and 22): For some applications it is advisable to limit the transit time of the actuator to
prevent it from engaging too fast in the running process.
Code 21 has priority over Code 15.
The time required to pass through the operating range when the
valve closes.
[0] to 240 s · ESC
This parameter can be used to increase the Min. transit time
CLOSED (Code 41).
NOTICE
The transit time entered in
Code 22 has priority over Code 14.
this code does not apply
when the safety function is
triggered, the solenoid
valve/forced venting is activated or when the auxiliary
power fails.
23*
Absolute total valve travel
YES · [0] to 99 · 107 · ESC
24*
Totaled double valve travel
Can be reset to 0 in Code 36 – STD and – DS.
Exponential reading after value
reaches 9999
Note: The value is saved in a non-volatile memory every 24
hours.
Total valve travel limit
Limit of total valve travel.
1000 to 99 · 107 · ESC,
[1 000 000]
A 'Total valve travel exceeded' message is issued with the selected status classification when the limit is exceeded.
Note: The 'Total valve travel exceeded' message has the default
status classification 'Maintenance required'. This classification
can only be changed in the operator software (e.g. TROVISVIEW 4).
Exponential reading after value
reaches 9999
EB 8384-6 EN
89
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
25*
Alarm mode
0 to 3 · ESC, [2]
Switching mode of software limit switches alarm A1 and A2 in
responding state (when positioner has been initialized).
Explosion-protected version according to EN 60947-5-6
0: A1 ³ 2.1 mA
1: A1 £ 1.2 mA
2: A1 ³ 2.1 mA
3: A1 £ 1.2 mA
A2 £ 1.2 mA
A2 £ 1.2 mA
A2 ³ 2.1 mA
A2 ³ 2.1 mA
Version without explosion protection
0: A1 R = 348 W
A2 Non-conducting
1: A1 Non-conducting A2 Non-conducting
2: A1 R = 348 W
A2 R = 348 W
3: A1 Non-conducting A2 R = 348 W
When a positioner has not been initialized, the software limit
switches always register the signal as in the state of no response.
If there is no mA signal at the terminals 11/12, the software limit
switches both switch to £ 1.2 mA signal (Ex) or non-conducting
(without explosion protection).
Note: The fault alarm output always switches to £ 1.2 mA/
non-conducting in case of a fault. It has ³ 1.2 mA® = 348 W
when there is no fault.
26*
Limit A1
Valve position limit in relation to the operating range
No · 0.0 to 100.0 % of the
Alarm A1 responds when the value falls below the limit.
operating range · ESC, [2.0]
NOTICE
The setting has no effect
when an inductive limit
switch has been installed.
27*
90
Limit A2
Valve position limit in relation to the operating range
No · 0.0 to 100.0 % of the
operating range · ESC,
[98.0]
Alarm A2 responds when the value falls below the limit.
EB 8384-6 EN
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
28*
Alarm test
Reading direction:
29*
Standard
[No]
RUN 1
RUN 2
RUN 3
Turned
[No]
1 RUN
2 RUN
3 RUN
ESC
ESC
Position transmitter x/ix 3)
[ää] · äæ · ESC
30*
Fault alarm ix 3)
[No] · HI · LO · ESC
31*
Position transmitter test 3)
–10.0 to 110.0 % of the operating range · ESC,
[default value is last indicated
value of the position transmitter]
3)
32*
Test Testing the software limit switches alarm A1 and A2 as well
as the fault alarm contact A3.
On activating the test, the contacts switch five times.
RUN1/1 RUN: Software limit switch A1 to ³ 2.1mA
RUN2/2 RUN: Software limit switch A2 to ³ 2.1 mA
RUN3/3 RUN: Fault alarm contact A3 to £ 1.2 mA
Operating direction of the position transmitter. This indicates how
the travel/angle position is assigned to the output signal I, based
on the closed position. The operating range (see Code 8) of the
valve is represented by the 4 to 20 mA signal. Values exceeding
or falling below the limits 2.4 to 21.6 mA can be represented.
When a positioner has not been connected (set point less than
3.6 mA), the signal is 0.9 mA and 3.8 mA or 4.4 mA when the
positioner has not been initialized.
When Code 32 = YES, the position transmitter issues the value as
set in Code 30 during initialization or zero calibration.
When Code 32 = No, 4 mA is issued during a running self-adaptation.
Used to select whether faults causing the fault alarm contact to
switch should also be indicated by the position transmitter output
and how they should be signaled
HI ix = 21.6 ±0.1mA or LO ix = 2.4 ±0.1mA
Testing the position transmitter. Values can be entered in relation
to the operating range.
The momentary valve position is used in initialized positioners locally as the start value (bumpless changeover to the test mode).
On testing over software, the entered simulation value is issued
as the position feedback signal for 30 seconds.
Analog position transmitter: Code 29/30/31 can only be selected if the position transmitter (optional) is installed.
Error message in case of
YES:
'Function check' condensed
state
No:
[YES] · No · ESC
'Failure' and 'Function check' condensed state cause an
error message to be generated.
Only 'Failure' condensed state causes an error message
to be generated.
EB 8384-6 EN
91
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
33*
34*
YES:
Error message in case of
'Maintenance required' and
'Out of specification' condensed states
No:
[YES] · No · ESC
'Failure', 'Maintenance required' and 'Out of specification' condensed state cause an error message to be generated.
Only 'Failure' condensed state causes an error message
to be generated.
Closing direction
CL :
Clockwise
CL · [CCL] · ESC
CCL:
Counterclockwise
Turning direction in which the valve is moved to the CLOSED position (view onto the rotary switch motion when the positioner
cover is open).
Note: Only needs to be entered when the SUB initialization mode
(Code 6) is selected.
35*
36*
Blocking position
Distance up to CLOSED position
[0] mm/° /% · ESC
Note: Only needs to be entered when the SUB initialization mode
(Code 6) is selected.
Reset
STD:
STD · DIAG · DS · ESC
92
EB 8384-6 EN
Reset start-up
– Parameters are reset to their default settings
– Diagnosis data are reset
– Information parameters (read only) remain unchanged
– Positioner must be re-initialized
DIAG: Reset diagnosis data
– Parameter settings, reference data and logging remain unchanged
– Re-initialization not required
DS:
Reset positioner to default settings
– Parameters are reset to their default settings
– Diagnosis data are reset
– Information parameters (read only) are deleted
– Positioner must be re-initialized
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
37
Options
Read only
Indicates which option (connected to terminals 31 and 32,
Fig. 18) is installed:
No:
No option installed
POS:
Analog position transmitter
dI:
Binary input
LS:
Leakage sensor
When the binary input is used, DI and HIGH or LOW status are
displayed in alternating sequence.
When the leakage sensor is used, LS and the detected sound
level in dB are displayed in alternating sequence.
38*
Inductive limit switch
Indicates whether the inductive contact option is installed.
[No] · YES · ESC
39
Set point deviation e
Shows the set point deviation (e = w – x)
Read only
40
Min. transit time OPEN
Minimum opening time determined during initialization
Read only
41
Min. transit time CLOSED
Minimum closing time determined during initialization
Read only
42
43
Set point
Set point w applied for automatic mode
Read only
4 to 20 mA corresponds with 0 to 100 %
Firmware version
Device type and current firmware version (displayed in alternating sequence)
Read only
44
Info y
Read only
Control signal y in %, in relation to the travel range determined
during initialization
MAX:
The positioner builds up its maximum output pressure.
See description for Code 14, 15.
0 P:
The positioner vents completely. See description for Code
14, 15.
– – –:
The positioner is not initialized.
EB 8384-6 EN
93
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
45
Internal solenoid valve/
forced venting
Read only
46*
Bus address
[0] to 15 · ESC
Indicates whether a solenoid valve/forced venting is installed.
If a voltage supply is connected at the terminals +81/–82, YES
and HIGH appear on the display in alternating sequence. If a
voltage supply is not connected (actuator vented, fail-safe position indicated on the display by the S icon), YES and LOW appear on the display in alternating sequence.
Using the HART® protocol, all connected control room devices
and field devices can be addressed individually using a
point-to-point connection or the standard (multidrop) bus.
Point-to-point: HART® master drive connected on HART® field
device. With this connection, the positioner address must
always be set to '0'.
Standard (multidrop) bus: A maximum of 15 field devices can be
connected in parallel to a single pair of wires. The
HART® master drive tells them apart by their addresses
in the range from 1 to 15.
47*
HART® write protection
[No] · YES · ESC
When the write protection function is activated, device data can
only be read, but not overwritten over HART® communication.
48 - Diagnosis
Note: For more details, refer to the Operating Instructions EB 8389-1 EN on EXPERTplus Valve
Diagnostics.
d0
Temperature
Read only
d1
Minimum Temperature
Read only
d2
Maximum temperature
Read only
d3
Current operating temperature [°C] inside the positioner
(accuracy ±3 %)
Lowest temperature [°C] inside the positioner since the operating
hours counter started counting
Highest temperature [°C] inside the positioner since the operating
hours counter started counting
Number of zero calibrations The number of zero calibrations performed since the last initialization.
Read only
d4
Number of initializations
Read only
94
EB 8384-6 EN
The number of initializations that have been performed since the
last start with default settings.
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
d5*
Zero point limit
Valve position limit in relation to the nominal range
0.0 to 100.0 % of the nominal range · ESC, [5.0]
When the limit is exceeded, a 'Zero point' message (Code 58) is
generated according to the status classification selected.
Note: The 'Zero point' message (Code 58) has the default status
classification 'Maintenance required'. This classification can only
be changed in the operator software (e.g. TROVIS-VIEW 4) .
d6
Condensed state
Read only
d7
Supply pressure ps
Summary of all the classified status messages according to the
NAMUR Recommendation NE 107
OK:
No message
C:
Maintenance required
CR:
Maintenance demanded
S:
Out of specification
B:
Failure
I:
Function check
Current supply pressure [bar]
Read only
d8
Signal pressure pout
Current signal pressure [bar]
Read only
d9
Flow rate
Current flow rate through the valve
Read only
Note: – – – – appears on the display when the flow rate calculation is not active or has failed.
d10 Differential pressure
Read only
Current differential pressure [bar]
d11* Direction of action (actuator) Indicates the actuator's direction of action
[-/-] · SA · DA · ELSE · ESC SA:
Single-acting
DA:
Double-acting
ELSE:
Other
EB 8384-6 EN
95
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
h0*
Initialization including valve Initialization with [YES] or without [No] plotting the valve signasignature
ture
No · [YES] · ESC
The valve signature involves the signal pressure pout being plotted
in relation to the valve position.
The valve signature is plotted during initialization of an
uninitialized positioner (e.g. after initialization has been reset
(Code 36 - STD and Code 36 - DS)). The valve signature is also
plotted during each further initialization when one of the settings
in Initialization mode (Code 6), Pin position (Code 4), Direction
of action (Code 7), Pressure limit (Code 16), Proportional-action
coefficient Kp level (Code 17) or Derivative-action time Tv level
(Code 18) is changed as well as when the switch position
(ATO/ATC) has been changed.
Note: The valve signature is required to perform diagnostic functions. For more details, refer to the Operating Instructions
EB 8389-1 EN on EXPERTplus Valve Diagnostics.
h1
– Unassigned –
h2
– Unassigned –
h3*
Desired time until 'Reset di- Time interval between scheduled reset of diagnosis data
agnostic measured data'
[0] to 365 days · ESC
h4
Remaining time until 'Reset
diagnostic measured data'
Read only
49
Partial stroke test (PST)
Note: The Operating Instructions EB 8389-1 EN on EXPERTplus Valve Diagnostics contain further details on the partial stroke test (PST).
A0* Start test
[No] · YES · ESC
Remaining time (time and unit of time displayed in alternating sequence) until the next scheduled reset of the diagnosis data
Start partial stroke test (Test D4).
The valve moves through the test range (Lower range value (Code
49 - d2) to Upper range value (Code 49 - d3)) and back again
in a ramp or in steps.
The time, set point, valve position, set point deviation and the
control signal are recorded.
A1
Time until next test
Read only
96
EB 8384-6 EN
Remaining time (time and unit of time displayed in alternating sequence) until the next time-controlled test starts
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
A2* Test
AUTO · [MAN] · ESC
Activates (AUTO) or deactivates (MAN) the time-controlled partial stroke test.
NOTICE
The write protection is active
in the AUTO setting (local
operation and operation
over software locked)
A3* Test interval
A4
– Unassigned –
A5
Recommended min. sampling time
Test interval (time and unit of time displayed in alternating sequence) until starting the time-controlled test
Sampling time [s] used to record entire step response in the
graph of the partial stroke test.
Read only
A6
– Unassigned –
A7
Dp_out reference value
Read only
The valve moves to the lower range value (Code 49 - d2) and
upper range value (Code 49 - d3) with a certain signal pressure.
The Dp_out reference value [bar] is calculated from the two
signal pressures.
Note: The reference value only applies to the adjusted step and
ramp values.
A8* Activate Dp_out monitoring
Activates (YES) or deactivates (No) the Dp_out monitoring.
[No] · YES · ESC
A9* Dp_out monitoring value
0.00 to 7.00 bar · ESC,
[1.00]
The test is canceled whenever the signal pressure change falls
below and exceeds the reference value. The reference value is
made up of Dp out reference value (Code 49 - A7) and the
Dp_out monitoring value.
d0
– Unassigned –
d1
– Unassigned –
d2*
Lower range value
Start value of the test
0.0 to [100.0] % · ESC
Note: To perform the partial stroke test, the Lower range value
must be within the range of the current operating point ± Tolerance limit.
The Tolerance limit is 2.0 % by default. It can be changed in the
operator software, e.g. TROVIS-VIEW 4.
EB 8384-6 EN
97
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
d3*
Upper range value
Final value of the test
0.0 to 100.0 % · ESC, [90.0]
d4*
Activate ramp function
YES:
The valve is ramped through the test range within the
adjusted ramp time.
No:
The valve is moved in steps through the test range (step
response).
No · [YES]
d5*
Ramp time (decreasing)
0 to 9999 s · ESC, [45]
Time period in which the valve moves through the operating
range from the closed to the open position
The time to move from Lower range value (Code 49 - d2) to
Upper range value (Code 49 - d3) is calculated:
Upper range value – Lower range value / 100 x Ramp time (increasing)
d6*
Ramp time (increasing)
0 to 9999 s · ESC, [45]
Time period in which the valve moves through the operating
range from the open to the closed position
The time to move from Upper range value (Code 49 - d3) to
Lower range value (Code 49 - d2) is calculated:
Lower range value – Upper range value / 100 x Ramp time (decreasing)
d7*
Settling time before starting Settling time between reaching the upper range value (Code 49 test
d3) and the valve moving through the test range in the reverse
direction
1 to 240 s · ESC, [10]
d8*
Waiting time after step
change
d9*
1.0 to 240.0 s · ESC, [2.0]
Waiting time between step change from Lower range value
(Code 49 - d2) to Upper range value (Code 49 - d3) and vice
versa
Sampling time
Time interval between measuring data
[0.2] to 250.0 s · ESC
E0*
Activate x monitoring
Activates x monitoring (YES) or deactivates it (No)
No · [YES]
The test is canceled when the valve moves below the adjusted
–10.0 to 110.0 % of the en- value.
tire travel · ESC, [85.0]
E1*
x monitoring value
E2
– Unassigned –
E3
– Unassigned –
98
EB 8384-6 EN
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
E4
– Unassigned –
E5*
Activate PST tolerance band Activates PST tolerance band monitoring (YES) or deactivates it
monitoring
(No)
[No] · YES
E6*
E7*
0.1 to 100.0 % · ESC, [5.0]
The test is canceled when the deviation in valve position (in relation to the upper range value of the step) exceeds the adjusted
value.
Max. test duration
The test is canceled when the maximum test duration is reached.
PST tolerance band
30 to 25000 s · ESC [30]
E8
– Unassigned –
E9*
Reset 'Partial stroke test pa- Resets partial stroke test parameters
rameters'
F0
No test available
F1
– Unassigned –
F2
x cancelation
The test was canceled.
The valve position fell below the x monitoring value (Code 49 E1).
F3
Dp_out cancelation
The test was canceled.
The change in signal pressure (Dp_out) fell below or exceeded
the reference value (Code 49 - A9).
F4
Tolerance band exceeded
The deviation of the valve position exceeded the adjusted PST tolerance band (Code 49 - E6).
F5
Max. test duration exceeded
The test was canceled.
The Max. test duration (Code 49 - E7) was reached.
F6
Test canceled manually
F7
Measured data memory full The Sampling time (Code 49 - d9) is too low. After recording
100 data points per variable, logging is stopped, but the test
continues until it is completed.
F8
Cancelled by internal solenoid valve/forced venting
The test was canceled.
The internal solenoid valve has been energized/the forced
venting has been activated.
EB 8384-6 EN
99
Code list
Code Parameter – Readings,
no. values [default setting]
Description
Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
F9
Canceled by control loop
error
The test was canceled.
A control loop error has occurred.
Type of application
Note: Section 7.8 contains details on the on/off valve.
h0
Type of application
No:
Control valve
[No] · YES · ESC
YES:
On/off valve
Depending on the selected type of application, the positioner behaves differently in automatic mode and has different diagnostic
functions. Refer to section 3.4.
Valve position when
0.0 to [100.0] % valve posi- set point w > Operating point limit (Code 49 - h5)
tion · ESC
h1
Operating point
h2
Fail-safe action limit
Limit of set point w
0.0 to 20.0 % set point ·
ESC, [12.5]
A limit violation causes the valve to move to the fail-safe position.
Lower limit to start test
If the set point is between Lower limit to start test (25 %) and
Fail-safe action limit (Code 49 - h2), the valve remains in its last
valid position.
h3
[25.0 % set point]
If the set point remains between Lower limit to start test (25 %)
and Upper limit to start test (50 %) for six seconds, a partial
stroke starts. After the partial stroke test is completed, the valve
moves back to the last valid position.
h4
Upper limit to start test
[50.0 % set point]
If the set point is between Operating point limit and Upper limit
to start test (50 %), the valve remains in its last valid position.
If the set point remains between Lower limit to start test (25 %)
and Upper limit to start test (50 %) for six seconds, a partial
stroke starts. After the partial stroke test is completed, the valve
moves back to the last valid position.
h5
100
Operating point limit
Limit of set point w
55.0 to 100.0 % set point ·
ESC, [75.0]
A limit violation causes the valve to move to the Operating point
(Code 49 - h1).
EB 8384-6 EN
Code list
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:
, Out of specification:
blinking, Failure 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 in an operator software, e.g.
TROVIS-VIEW 4.
EB 8384-6 EN
101
Code list
Initialization errors
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When error messages exist, they are displayed here.
50
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
– NAMUR attachment: bracket slipped or follower pin is not in
the slot of the follower plate
– Follower plate incorrectly attached
Status classification [Maintenance required]
Recommended action – Check attachment and pin position.
– Re-initialize the positioner.
51
Dx < range
The measuring span of the sensor is too low.
– Pin positioned incorrectly
– Incorrect lever installed
– Pressure limit selected too low
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 [Out of specification]
Recommended action – Check attachment and pressure limit.
– Re-initialize the positioner.
52
Attachment
– The nominal range could not be achieved during initialization
with NOM initialization mode (the maximum travel/angle
reached is indicated on the display).
– Incorrect lever installed
– Supply pressure too low. The valve cannot move to the required position.
Status classification [Maintenance required]
Recommended action – Check attachment and supply pressure.
– Re-initialize the positioner.
102
EB 8384-6 EN
Code list
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When error messages exist, they are displayed here.
53
Initialization time exceeded The initialization routine lasts too long.
(Init time >)
– The valve opens after a considerable delay.
– The valve does not have fixed end stops (possible with a lined
control butterfly).
– The valve has a strong tendency to hunt.
Status classification [Maintenance required]
Recommended action – Check supply pressure. If necessary, install a pneumatic
booster.
– Adjust end stops.
– Reduce tendency to hunt (e.g. restrict or open booster bypass).
Then re-initialize the positioner.
54
Initialization - internal sole- 1) Internal solenoid valve/forced venting not connected or
noid valve/forced venting
incorrectly connected.
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 solenoid
valve/ forced venting
– Re-initialize the positioner.
Re. 2) – Switch to MAN operating mode.
– Re-initialize the positioner.
55
Transit time too short
(transit time <)
The actuator positioning rates determined during the initialization are so short (< 0.3 s) that the positioner cannot adapt itself
optimally.
Status classification [Out of specification]
Recommended action – Activate the volume restriction in the positioner output.
– Re-initialize the positioner.
56
Pin position/switch position 1) The pin position was not entered for the initialization modes
NOM and SUB.
2) The switch (ATO/ATC) is defective
Status classification [Maintenance required]
Recommended action Re. 1) – Enter pin position and nominal range.
– Re-initialize the positioner.
Re. 2) – Return the positioner to SAMSON for repair.
EB 8384-6 EN
103
Code list
Operational errors
Error codes – Recommended
action
57
Control loop
Additional indication at the
fault alarm contact!
Condensed state alarm active, when prompted, ERR appears.
When fault alarms exist, they are displayed here.
Control loop error: the control valve does not react within the tolerable times of the controlled variable (tolerance band alarm Code
19).
– Actuator is mechanically blocked.
– Attachment of the positioner has subsequently shifted.
– Supply pressure not sufficient.
Status classification [Maintenance required]
Recommended action – Check attachment.
– Check supply pressure.
58
Zero point
– Mounting position or linkage of the positioner has moved.
– Valve seat trim is worn, especially with soft-sealed plugs.
Status classification [Maintenance required]
Recommended action – Check valve and the attachment of the positioner.
– Perform a zero calibration.
A reinitialization is recommended for deviations of the zero point
over 5 %.
59
Inconsistent data
memory
The error is automatically recognized by the self-monitoring function
and corrected.
Status classification Failure (status classification change not possible)
60
Internal device error
The positioner changes to the fail-safe position (SAFE).
Additional indication at the
fault alarm contact!
Status classification Failure (status classification change not possible)
Recommended action Return the positioner to SAMSON AG for repair.
61
KP too small
A proportional-action coefficient Kp level smaller than 3 has been
detected during initialization.
Note: A Kp level < 3 does not cause the initialization process to be
canceled.
Status classification [Maintenance required]
Recommended action – Activate the volume restriction in the outlet of the positioner.
– Increase the bypass restriction setting of booster (if installed).
104
EB 8384-6 EN
Code list
Hardware errors
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When fault alarms exist, they are displayed here.
62
x signal
Additional indication at the fault
alarm contact!
– Measured data recording for actuator has failed.
– Conductive plastic element is defective.
The emergency mode on the display is indicated by a blinking
closed-loop operation icon and 4 dashes instead of the position
indication.
Open-loop operation:
If the measuring system has failed, the positioner is still in a reliable 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.
63
SIL shutdown/w too small
1)
Emergency shutdown of the i/p block is implemented by
3.8 mA or 4.4 mA (depending on the positioner version)
2)
The set point w is smaller than 3.7 mA.
This state is indicated on the positioner display by a
blinking LOW
Status classification [No message]
Recommended action Re. 1)
Re. 2)
64
i/p converter
Raise the current (depending on version) above the limit.
Check set point.
If necessary, limit the current source downwards so that
no values below 3.7 mA can be issued.
– The circuit of the i/p converter has been interrupted.
Status classification Failure (status classification change not possible)
Recommended action – Return the positioner to SAMSON AG for repair.
EB 8384-6 EN
105
Code list
Error appendix
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When fault alarms exist, they are displayed here.
65
Hardware
Additional indication at the fault
alarm contact!
A hardware error has occurred, the positioner changes to the
fail-safe position (SAFE).
As long as the error exists, no EXPERTplus diagnostic messages
are logged.
Status classification [Failure]
Recommended action Confirm error and return to the automatic operating mode, or
perform a reset and re-initialize the device. If this is not successful, return device to SAMSON AG for repair.
66
67
– Unassigned –
Test calculation
Additional indication at the fault
alarm contact!
The hardware controller is monitored by means of a test calculation.
Status classification [Failure]
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.
68
to
75
– Unassigned –
76
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 vents the output when a measuring error occurs or A1
with double-acting actuators. 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.
106
EB 8384-6 EN
Code list
Diagnostic errors
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When fault alarms exist, they are displayed here.
77
– Unassigned –
78
– Unassigned –
79
Collective error
Messages generated by EXPERTplus exist.
The error does not have any direct effect on the positioner's functioning.
Refer to Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics
Status classification Maintenance required (status classification change not possible)
80
– Unassigned –
81
Valve signature canceled
Error during automatic plotting of the valve signature
Error messages are saved in a non-volatile memory. They cannot
be reset.
Status classification [Maintenance required]
Recommended action Restart plotting of the valve signature or start initialization including valve signature.
83
– Unassigned –
84
Partial stroke test (PST)/full
stroke test (FST)
A partial stroke test or full stroke test cannot be started or has
been canceled.
Refer to Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
Status classification No message
Recommended action Read out test status (only in the operator software)
85
On/off valve
The transit time and breakaway time or the final travel/angle
value of the on/off valve has changed.
Status classification No message
Recommended action Check valve and actuator.
EB 8384-6 EN
107
Code list
Error codes – Recommended action Condensed state alarm active, when prompted, ERR appears.
When fault alarms exist, they are displayed here.
86
SIL tests
The SIL operator test has failed.
Refer to Operating Instructions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
Status classification Failure (status classification change not possible)
Recommended action Return the positioner to SAMSON AG for repair.
108
EB 8384-6 EN
Dimensions in mm
Dimensions in mm
Pressure
gauge
or connecting plate
Attachment acc. to IEC 60534-6
Lever mm
S = 17
M = 50
L = 100
XL = 200
External position
sensor
Schild
28
15
58
46
70
70
15
34
70
210
Direct attachment
14
34
80
M20 x 1.5
40
28
58
Output (38) Supply (9)
86
164
Fig. 23a · NAMUR and direct attachment
EB 8384-6 EN
109
Dimensions in mm
Output Y1
Output Y1
Supply (9)
86
56
80
52
Output Y2
80
130
166
30
86
Ø 101
Output Y2
Type 3710
Reversing
Amplifier
Fig. 23b · Attachment to rotary actuators VDI/VDE 3845 (Sept. 2010), level 1, size AA1 to AA4
15.1
Fixing levels according to VDI/VDE 3845 (September 2010)
Mmin
Level 2 (bracket surface)
25
M6
C
Level 1 (actuator surface)
Actuator
Dimensions in mm
Ød
B
ØD
A
Size
A
B
C
Æd
Mmin
ÆD*
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
110
EB 8384-6 EN
Valve characteristic selection
16
Valve characteristic selection
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 the operator
software (e.g. TROVIS-VIEW 4).
Linear (select characteristic: 0)
Travel/ angle of rotation [%]
100
50
Reference variable [%]
0
0
50
100
Equal percentage (select characteristic: 1)
Travel/ angle of rotation [%]
Rev. equal percentage (select characteristic: 2)
Travel/ angle of rotation [%]
100
100
50
50
Reference variable [%]
0
0
50
100
Reference variable [%]
0
0
50
100
EB 8384-6 EN
111
SAMSON butterfly valve, linear
(select characteristic: 3)
SAMSON butterfly valve, equal percentage
(select characteristic: 4)
Travel/ angle of rotation [%]
Travel/ angle of rotation [%]
100
100
50
50
Reference variable [%]
0
0
50
Reference variable [%]
0
0
100
VETEC rotary plug valve, linear
(select characteristic: 5)
Travel/ angle of rotation [%]
50
100
VETEC rotary plug valve, equal percentage
(select characteristic: 6)
Travel/ angle of rotation [%]
100
100
50
50
Reference variable [%]
0
0
50
100
Segmented ball valve, linear
(select characteristic: 7)
Reference variable [%]
0
0
50
100
Segmented ball valve, equal percentage
(select characteristic: 7)
Travel/ angle of rotation [%]
Travel/ angle of rotation [%]
100
100
50
50
Reference variable [%]
0
0
50
100
Reference variable [%]
0
0
50
100
EB 8384-6 EN
113
114
EB 8384-6 EN
EB 8384-6 EN
115
116
EB 8384-6 EN
EB 8384-6 EN
117
118
EB 8384-6 EN
EB 8384-6 EN
119
120
EB 8384-6 EN
Index
Index
E
A
Electrical connection . . . . . . . . 46, 50
Error messages
confirming . . . . . . . . . . . . . 77
data errors . . . . . . . . . . . . 106
diagnostic errors . . . . . . . . . 107
error appendix . . . . . . . . . . 106
hardware errors . . . . . . . . . 105
initialization errors . . . . . . . . 102
operational errors . . . . . . . . . 104
External position sensor . . . . . . . . 14
attachment
acc. to IEC 60534-6 (NAMUR) . 36
direct attachment . . . . . . . . 34
to rotary actuators . . . . . . . 38
to Type 3510 Micro-flow Valve . 37
electrical connection . . . . . . . . 34
pneumatic connection. . . . . . . . 34
technical data . . . . . . . . . . . 18
Accessories . . . . . . . . . . . . . . 42
Application, type of . . . . . . . . 12, 69
Article code . . . . . . . . . . . . . . . 7
Attachment
acc. to IEC 60534-6 (NAMUR) . . . 26
direct attachment
to Type 3277 Actuator . . . . . 24
to Type 3277-5 Actuator . . . . 22
reversing amplifier . . . . . . . . . 34
to rotary actuators . . . . . . . . . 30
to Type 3510 Micro-flow Valve . . . 28
Automatic mode . . . . . . . . . . 52, 75
B
Bar element . . . . . .
Binary input . . . . . .
electrical connection
technical data . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
52
13
48
18
C
Cable entry . . . . . . . . . . . . . . 47
Closed position of valve . . . . . . . . 56
Communication
HART . . . . . . . . . . . . . 12, 54
TROVIS-VIEW 4 . . . . . . . . . . 12
Condensed state . . . . . . . . . . . . 77
Configuration enabled . . . . . . . 52, 74
Connection
electrical . . . . . . . . . . . 48 - 50
pneumatic . . . . . . . . . . . 45 - 46
D
Default setting . . . . . . . . . . . . . 72
Diagnostic functions . . . . . . . . . . 11
Dimensions . . . . . . . . . . . 109 - 110
Display . . . . . . . . . . . . . . 52 - 53
turning by 180° . . . . . . . . . . 57
F
Fail-safe position (SAFE) . . . . . . . . 76
Failure . . . . . . . . . . . . . . 76 - 77
Firmware update . . . . . . . . . . . . 81
Flow rate calculation . . . . . . . . . . 10
Forced venting . . . . . . . . . . . . . 13
electrical connection . . . . . . . . 48
technical data . . . . . . . . . . . 17
H
HART communication . . . . . . . . . 54
HART protocol . . . . . . . . . . . . . 49
I
Initialization
manually selected end positions (MAN2)
. . . . . . . . . . . . . . . . 59, 64
manually selected OPEN position (MAN)
. . . . . . . . . . . . . . . . 62, 64
maximum range (MAX) . . . . 59 - 60
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Index
substitute calibration (SUB) . . . . . 65
KP input filter . . . . . . . . . . . . . 68
Pneumatic connections . . . . .
Position transmitter . . . . . . .
technical data . . . . . . .
Principle of operation, positioner
L
R
Leakage sensor . . . . . . . . . . . . 13
electrical connection . . . . . . . . 48
mounting. . . . . . . . . . . . . . 39
Limit switch . . . . . . . . . . . . . . 13
adjusting . . . . . . . . . . . 78 - 80
electrical connection . . . . . . . . 48
retrofitting . . . . . . . . . . . . . 80
technical data . . . . . . . . . . . 17
Reset . . . . . . . . . . . . . . . . . 72
Reversing amplifier. . . . . . . . . . . 34
Rotary pushbutton . . . . . . . . . . . 52
K
M
Maintenance. . . . . . . . . . . . . . 81
Malfunction . . . . . . . . . . . . . . 76
Manual mode . . . . . . . . . . . 52, 75
Mounting parts . . . . . . . . . . 41 - 44
O
On/off valve . . . . . . . . . 12, 69 - 70
Operating modes . . . . . . . 52, 75 - 76
Operating range
manually selected end positions
(MAN2) . . . . . . . . . . . . 59, 64
manually selected OPEN position
(MAN) . . . . . . . . . . . . . . . 59
manually selected OPEN position
(MAN) . . . . . . . . . . . . . . . 62
maximum range (MAX) . . . . 59 - 60
nominal range (NOM) . . . . . 59, 61
Operation. . . . . . . . . . . . . 74 - 77
Operator controls . . . . . . . . . 52 - 55
Output
(signal pressure) . . . . . . . . . . 46
P
Parameters, enabling. . . . . . . . . . 74
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8 - 18
S
Safety function SIL . . . . . . . . . . . 10
Serial interface. . . . . . . . . . . 12, 54
Servicing . . . . . . . . . . . . . . . 81
Signal pressure . . . . . . . . . . . . 46
indication . . . . . . . . . . . . . 45
limiting. . . . . . . . . . . . . . . 57
Slide switch AIR TO OPEN/CLOSE. . . 56
Software update . . . . . . . . . . . . 81
Solenoid valve . . . . . . . . . . . . . 13
electrical connection . . . . . . . . 48
technical data . . . . . . . . . . . 17
Start-up . . . . . . . . . . . . . . . . 56
Status classification . . . . . 76, 102 - 108
Status messages . . . . . . . . . . . . 52
Substitute calibration (SUB) . . . . . 59, 65
Supply pressure . . . . . . . . . . . . 45
T
Technical data . . .
options. . . . .
Travel tables . . . .
Type of application.
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15
17
21
12
U
Update . . . . . . . . . . . . . . . . 81
V
Valve characteristic, selecting . . . . . 111
Valve diagnostics . . . . . . . . . 10, 14
Index
diagnostic functions . . . . . . . . 11
Z
Zero calibration . . . . . . . . . . . . 68
EB 8384-6 EN
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EB 8384-6 EN
2012-02
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