Series 3730 Type 3730-4 Electropneumatic Positioner with PROFIBUS-PA communication Fig. 1 · Type 3730-4 Mounting and Operating Instructions EB 8384-4 EN (1300-1613) Firmware version 1.
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.
Contents Contents Page 1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6 2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3 3.1 3.2 3.2.1 3.3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . .
Contents 7.3 7.4 7.5 7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.7 7.8 7.9 7.10 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 range . SUb substitute calibration . . . . .
Revisions of the positioner firmware Revisions of the positioner firmware compared to the previous version – Control R Control R 1.43 R 1.44 Internal revisions R 1.45 Internal revisions R 1.46 Internal revisions R 1.52 Diagnosis Codes 48 extended All EXPERTplus diagnostic functions are available without having to activate them in the positioner (see EB 8389 EN on EXPERTplus Valve Diagnostics).
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.
Article code 2 Article code Positioner Type 3730-4 x x x 0 x 0 x x 1 x 0 0 x 0 x x With LCD and autotune, PROFIBUS-PA Explosion protection ohne 0 ATEX: II 2G Ex ia IIC T6; II 2D Ex tb IIIC T80°C IP66 1 3 CSA: Ex ia IIC T6; Class I, II, Div.1, Groups A, B, C, D, E, F, G; Ex nA II T6; Ex nL IIC T6; Class I, Div.2, Groups A, B, C, D; Class II, Div.1, Groups E, F, G FM: Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A, B, C, D, E, F, G; Class I, Div.2, Groups A, B, C, D; Class II, Div.
Design and principle of operation 3 Design and operation principle When a set point deviation occurs, the actuator is pressurized or vented. If required, the changes in the signal pressure can be slowed down by a connectable Q restriction. The signal pressure supplied to the actuator can be limited by software or on site to 1.4, 2.4 or 3.7 bar. of The electropneumatic positioner is attached to pneumatic control valves.
Design and principle of operation The positioner communicates and is powered using IEC 61158-2 transmission technology conforming to the PROFIBUS-PA specification. 3.1 Additional equipment Solenoid valve As a standard feature, the positioner comes with a binary input for DC voltage signals to signalize process information over the PROFIBUS-PA. If the operating voltage for the solenoid valve (12) fails, the supply pressure for the booster is vented to the atmosphere.
Design and principle of operation 3.2 Communication The positioner is completely controlled over the digital signal transmission implemented complying with PROFIBUS-PA Profile B as per DIN EN 50170 and DIN 19245 Part 4. Data are transmitted as bit-synchronous current modulation at a rate of 31.25 kbit/s over twisted-pair cables conforming to IEC 61158-2.
Design and principle of operation 3.3 Technical data Type 3730-4 Positioner (technical data in test certificates additionally apply for explosion-protected devices) Rated travel, adjustable Direct attachment to Type 3277 Actuator: 3.6 to 30 mm Attachment acc. to IEC 60534-6-1: 3.6 to 300 mm Attachment acc. to VDI/VDE 3847: 3.
Design and principle of operation Type 3730-4 Positioner (technical data in test certificates additionally apply for explosion-protected devices) –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 The limits in test certificate additionally apply for explosion-protected devices. Permissible ambient temperature Temperature ≤ 0.15 %/10 K Influences Supply air None Vibration ≤ 0.25 % up to 2000 Hz and 4 g acc.
Design and principle of operation 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 Black polyamide, M20x1.5 Weight Approx. 1 kg Options for Type 3730-4 Binary input 2 for floating contact Switching input R < 100 Ω, contact loadability 100 mA, static destruction limit 20 V / 5.
Attachment to the control valve – Mounting parts and accessories 4 Attachment to the control valve – Mounting parts and accessories – Observe the assignment between lever and pin position (see travel tables on page 15). WARNING! Mount the positioner, keeping the following sequence: 1. Remove protective film from pneumatic connections. 2. Mount the positioner on the control valve 3. Connect the supply air 4. Connect the electrical power 5.
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 3 on page 44). Direct attachment to Type 3277-5 and Type 3277 Actuators Adjustment range at positioner 1) Actuator size Rated travel [cm²] [mm] Min. Travel Max. Required lever Assigned pin position 120 7.5 5.0 to 25.0 M 25 120/240/175/350 15 7.
Attachment to the control valve – Mounting parts and accessories 4.1 Direct attachment 4.1.1 Type 3277-5 Actuator Refer to Table 1 on page 42 for the required mounting parts as well as the accessories. Note the travel table on page 15. Actuator with 120 cm² Depending on the type of positioner attachment, the signal pressure is routed either left or right of the yoke through a bore to the actuator diaphragm.
Attachment to the control valve – Mounting parts and accessories Symbols 1 1.1 1.2 2 3 4 5 6 6.1 7 8 9 Switchover plate (9) Actuator stem extends Attachment left Attachment right Actuator stem retracts Signal pressure input for left attachment Marking Signal pressure input for right attachment 15 14 Lever Nut Disk spring Follower pin Follower clamp Screw plug Stopper Connecting plate Seal rings Pressure gauge bracket Press. gauge mounting kit Switchover plate for actuator 10 Cover plate 10.
Attachment to the control valve – Mounting parts and accessories 4.1.2 Type 3277 Actuator Refer to Table 2 on page 43 or the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 15. Actuators with 175 to 750 cm² Mount the positioner on the yoke as shown in Fig. 5.
Attachment to the control valve – Mounting parts and accessories 1 1.1 1.2 2 3 10 11 11.1 Lever Nut Disk spring Follower pin Follower clamp Cover plate Cover Vent plug 12 Connection block 12.1 Screw 12.2 Stopper or connection for external piping 13 Switch plate 14 Gasket 15 Formed seal 16 Gasket 15 10 14 1 2 3 11 11.1 2 Lever M 1.1 1.2 Cut-out of cover plate (10) View AA Ansicht 16 View C Ansicht C 16 G G 3/8 SUPPLY C Actuator stem retracts extends 16 12 SUPPLY 12.1 12.
Attachment to the control valve – Mounting parts and accessories 4.2 Attachment according to IEC 60534-6 (NAMUR) Refer to Table 3 on page 44 for the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 15. The positioner is attached to the control valve with a NAMUR bracket (10). 1. Screw the two bolts (14) to the bracket (9.1) of the stem connector (9), place the follower plate (3) on top and use the screws (14.1) to tighten.
Attachment to the control valve – Mounting parts and accessories Attachment to rod-type yoke Rod diameter 20 to 35 mm 15 11 10 9 Attachment to NAMUR rib 9.1 3.1 16 Additional bracket for actuators with 2800 cm2 and travel ≥ 60 mm 1 Lever Lever XL and L Nut 1 Disk spring Follower pin Follower plate 2 Follower plate 1.1 Connecting plate 6.1 6 7 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.
Attachment to the control valve – Mounting parts and accessories 4.3 Attachment according to VDI/VDE 3847 Type 3730-4xxxxxxxx0x0060xx and Type 3730-4xxxxxxxx0x0070xx Positioners with air purging of the actuator's spring chamber can be attached according to VDI/VDE 3847. Type 3730-4xxxxxxxx0x0000xx Positioner without air purging of the actuator's spring chamber can be attached according to VDI/VDE 3847.
Attachment to the control valve – Mounting parts and accessories View from below 1.1 1.2 13.1 17.1 17 17.2 18 18.1 13 11 1 11.1 3 12 12.1 Exh. 20 2 19 1.1 1.2 6 1 6.2 6.1 4 1 1.1 1.2 2 3 4 5 6 6.1 6.2 6.3 11 11.1 Lever Nut Disk spring Follower pin Follower clamp Screw plug Stopper Adapter bracket Screws Formed seal Screws Cover Vent plug 12 Connecting plate 12.1 Seal 13 Adapter block 13.1 Screws 17 Turnboard 17.1 Formed seal 17.2 Screws 18 Blank plate 18.
Attachment to the control valve – Mounting parts and accessories 7. Insert screws (13.1) through the middle holes of the adapter block (13). 8. Place the connecting plate (12) together with the seal (12.1) onto the screws (13.1) corresponding to the fail-safe action "actuator stem extends" or "actuator stem retracts". The fail-safe action that applies is determined by aligning the groove of the adapter block (13) with the groove of the connecting plate (12) (Fig. 8).
Attachment to the control valve – Mounting parts and accessories Attachment to NAMUR rib (see Fig. 9) Refer to Table 4 on page 44 for the required mounting parts as well as the accessories. Note the travel table on page 15. 1. Series 240 Valves, actuator size up to 1400-60 cm²: Screw the two bolts (14) to the bracket of the stem connector or directly to the stem connector (depending on the version), place the follower plate (3) on top and use the screws (14.1) to fasten it.
Attachment to the control valve – Mounting parts and accessories 7. Mount the blank plate (18) to the turnboard (17) using the screws (18.1) Make sure that the seals are correctly seated. Note: A solenoid valve can also be mounted in place of the blank plate (18). The orientation of the turnboard (17) determine the mounting position of the solenoid valve. Alternatively, a restrictor plate can be mounted (see AB 11 EN). 8. Mount the adapter block (13) to the NAMUR connection block using the screws (13.1).
Attachment to the control valve – Mounting parts and accessories View from below 13 13.1 17.1 17 17.2 18 18.1 11 10 3 16 15 20 Exh. 1 1.1 1.2 2 3 3.1 4 5 6 6.1 6.2 6.3 10 Lever Nut Spring disk Follower pin Follower plate Follower plate Screw plug Stopper Adapter bracket Screws Formed seal Screws NAMUR connection block 11 Screw with toothed lock washer 13 13.1 14 14.1 15 16 17 17.1 17.2 18 18.
Attachment to the control valve – Mounting parts and accessories 4.4 Attachment to Type 3510 Micro-flow Valve Refer to Table 3 on page 44 for the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 15. 1. Screw bracket (9.1) to the stem connector (9). 2. Fasten the two pins (9.2) to the bracket (9.1) on the stem connector. Mount the follower plate (3) and fasten it using the screws (9.3). 3.
Attachment to the control valve – Mounting parts and accessories 12.1 11 11.1 10.1 10 9 9.1 3 9.2 9.3 Note: Always use the connecting plate (6) included in the accessories to connect supply and output. Never screw threaded parts directly into the housing. 1.1 2 1.2 1 6 Lever S 1 1.1 1.2 2 3 6 6.1 7 8 9 9.1 Lever Nut Disk spring Follower pin Follower plate Connecting clamp Seal rings Pressure gauge bracket Pressure gauge mounting kit Stem connector Bracket 9.2 9.3 10 10.1 11 11.1 12.
Attachment to the control valve – Mounting parts and accessories 4.5 Attachment to rotary actuators Refer to Table 5 on page 45 for the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 15. The positioner is mounted to the rotary actuator using two pairs of double 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.
Attachment to the control valve – Mounting parts and accessories 6.1 1 1.2 1.1 2 4.3 10 10.1 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. 11 + 12 1 Lever 1.1 Nut 1.2 Disk spring 2 Follower pin 3 Follower clamp (Fig. 11) 4 Coupling wheel 4.1 Screw 4.2 Disk spring 4.3 Scale plate 4.3 Scale plate 5 Actuator shaft Adapter for Type 3278 6.
Attachment to the control valve – Mounting parts and accessories 4.5.1 Heavy-duty version Refer to Table 5 on page 45 for the required mounting parts as well as the accessories with their order numbers. 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. Mount the housing (10) onto the rotary actuator.
Attachment to the control valve – Mounting parts and accessories 1 1.1 1.2 2 3 4 4.1 4.2 4.3 5 Lever Nut Disk spring Follower pin Adapter Coupling wheel Screw Disk spring Adhesive label Actuator shaft or adapter 5.1 Adapter 6 6.1 7 8 10 10.1 11 Connecting plate (only for G ¼) Seal rings Pressure gauge bracket Pressure gauge mounting kit Adapter housing Screws Spacers Fit screw-in restriction into signal pressure output for actuators with < 300 cm³ volume 6 6.1 7 8 1 1.1 1.2 2 4.1 4.2 4 4.3 4.1 4.
Attachment to the control valve – Mounting parts and accessories 4.6 Reversing amplifier for double-acting actuators The following applies to all reversing amplifiers: 2. Thread the special nuts (1.3) from the accessories of the reversing amplifier into the boreholes of the connecting plate. 3. Insert the gasket (1.2) into the recess of the reversing amplifier and push both the hollowed special screws (1.1) into the connecting boreholes A1 and Z. 4.
Attachment to the control valve – Mounting parts and accessories From the positioner Output 38 A1 Supply 9 Z A2 Control signals to the actuator A1 1.1 1.2 1 1.1 1.2 1.3 1.4 1.5 1.6 6.2 1.5 1.6 Reversing amplifier Special screws Gasket Special nuts Rubber seal Sealing plug Filter 6 Connecting plate 6.1 O-rings 6.2 Screws Supply 9 6 1.4 Z Output 38 6.1 1.3 A2 A1 1.3 1.2 1.1 1 1.6 Fig.
Attachment to the control valve – Mounting parts and accessories 4.7 Attaching an external position sensor Refer to Table 7 on page 46 for the mounting parts and accessories required. 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.
Attachment to the control valve – Mounting parts and accessories 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). pin (2) from the travel table on page 15. The positioner is delivered with lever M in pin position 35 on the sensor.
Attachment to the control valve – Mounting parts and accessories 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. 7. 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. 4.7.
Attachment to the control valve – Mounting parts and accessories the follower plate (3) and fix with the screws (14.1). 5. 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. 2. Screw the position sensor (20) onto the bracket (21). 3. Select the lever S (1) from the accessories and screw the follower pin (2) into the hole for pin position 17.
Attachment to the control valve – Mounting parts and accessories 4.7.4 Mounting the position sensor to rotary actuators For the required mounting parts and the accessories, refer to Table 7 on page 46. 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. 2. Screw the position sensor (20) onto the mounting plate (21). 3.
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 and a pressure gauge bracket made of stainless steel are available (order numbers listed below). The Type 3710 Pneumatic Reversing Amplifier is also available in stainless steel.
Attachment to the control valve – Mounting parts and accessories over piping. An adapter available as an accessory is used for this purpose: Threaded bushing G ¼ (M20 x 1.5): ¼ NPT 0310-2619 0310-2550 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.
Attachment to the control valve – Mounting parts and accessories Table 2 · Direct attachment to Type 3277 (Fig. 5) Mounting parts Order no. Standard version for actuators with 175, 240, 350, 355, 700, 750 cm² 1400-7453 Version compatible with paint for actuators with 175, 240, 350, 355, 700, 750 cm² Steel 175 cm² Stainl. steel Steel 240 cm² Stainl. steel Steel 350 cm² Stainl.
Attachment to the control valve – Mounting parts and accessories Table 3 · Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter) according to IEC 60534-6 (Figs. 6 and 10) Travel in mm Lever For actuators 7.5 Type 3271-5 with 60/120 cm² on Type 3510 Valve (Fig. 10) S 5 to 50 Order no.
Attachment to the control valve – Mounting parts and accessories Order no. Table 5 · Attachment to rotary actuators (Figs. 11 and 12) Attachment acc. to VDI/VDE 3845 (September 2010), refer to section 15.1 for details Mounting parts Actuator surface corresponds to level 1 Size AA1 to AA4, version with CrNiMo steel bracket Size AA1 to AA4, heavy-duty version Size AA5, heavy-duty version (e.g.
Attachment to the control valve – Mounting parts and accessories Order no. Table 7 · Attachment of external position sensor Template for mounting position sensor on older mounting parts. See note on page 32. 1060-0784 Mounting parts for actuators with 120 cm² see Fig. 17 left Direct attachment Connecting plate (9, old) for Actuator Type 3277-5xxxxxx.00 1400-7472 G 18 1400-6820 1 1400-6821 8 NPT Connecting plate (new) for Actuator Type 3277-5xxxxxx.
Connections 5 Connections WARNING! Mount the positioner, keeping the following sequence: 1. Remove protective film from pneumatic connections. 2. Mount the positioner on the control valve 3. Connect the supply air 4. Connect the electrical power 5. 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. observed.
Connections Actuator stem retracts FE (AIR TO CLOSE) Fail-open (for globe and angle valves): For tight-closing valves, the maximum signal pressure pstmax is roughly estimated as follows: pstmax = F + d 2 ⋅ π ⋅ ∆p [bar] 4⋅A d = Seat diameter [cm] ∆p = Differential pressure across the valve [bar] A = Actuator diaphragm area [cm²] If there are no specifications, calculate as follows: Required supply pressure = Upper bench range value + 1 bar. 5.1.
Connections In particular, the radial thickness of the conductor insulation for common insulation materials, such as polyethylene, must have a minimum radial thickness of 0.2 mm. 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 connection, an additional cable gland can be installed. Seal cable entries left unused with plugs.
Connections Bus line Limit switch Route the two-wire bus line to the screw terminals marked "IEC 1158-2", whereby no polarity has to be observed. For operation of the limit switches, switching amplifiers have to be connected in the output circuit. Their function is to control the limit values of the control circuit according to EN 60947-5-6, thus ensuring operational reliability of the positioner. If the positioner is installed in hazardous areas, the relevant regulations must be observed.
Connections Solenoid valve (forced venting function) 5.2.1 Establishing communication For positioners fitted with the optional solenoid valve for the forced venting function, a voltage of 24 V DC must be connected to the relevant terminals +81 and –82. The communication structure between the controller, logic solvers (PLC) or automation system, or between a PC or work station and the positioner(s) is implemented by a segment coupler (see Fig. 22) conforming to PROFIBUS directives.
Connections Controller/PLC/Control system PROFIBUS-DP(E) RS 485 PROFIBUS-DP(E) RS 485 Display and operating elements Bus termination Segment coupler PROFIBUS-PA IEC 61158-2 Bus termination 3730-40 3730-40 3730-40 3730-40 Controller/PLC/Control system PROFIBUS-DP RS 485 PROFIBUS-DP RS 485 Display and operating elements Bus termination Expl.-protected segment coupler Hazardous area PROFIBUS-PA IEC 61158-2 3730-41 3730-41 3730-41 3730-41 Bus termination Fig.
Operator controls and readings 6 For positioners with an attached reversing amplifier for double-acting rotary actuators (section 4.6): switch position AIR TO OPEN. 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 Press to select codes and values. to confirm setting.
Operator controls and readings Readings on display Icons appear on the display that are assigned to parameters, codes and functions. Operating modes: 4 4 4 Manual mode (MAN), section 8.2.1 The positioner follows the manual set point (Code 1) and not the set point provided by the process control system. blinks: The positioner has not yet been initialized. Operation only possible over manual set point (Code 1). Automatic mode (AUTO), section 8.2.
Operator controls and readings Maintenance alarm/fault Manual mode Closed-loop operation Bar graph for system deviation or lever position Designation Position Parameter % mm mm Binary contact 1 Units % S Configuration enabled Code Binary contact 2 Maintenance required Maintenance demanded Fail-safe position active Readings in display Automatic mode ää äæ Clockwise Counterclockwise Error Escape w too small Manual mode Maximum range Not available/ S not active NOM Nominal travel RES Reset RUN S
Start-up – Settings 7 Start-up – Settings WARNING! Mount the positioner, keeping the following sequence: 1. Remove protective film from pneumatic connections. 2. Mount the positioner on the control valve 3. Connect the supply air 4. Connect the electrical power 5.
Start-up – Settings 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. 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. The positioner only needs to be initialized again after the fail-safe action of the actuator has been changed. 7.
Start-up – Settings Limiting the signal pressure: Reading direction for left attachment of pneumatic connections Pressure limit Default: No If the displayed data appear upside down, proceed as follows: Turn → Code 16 Turn → Code 2 Press → Code 16 blinks. Press → Code 2 blinks. Turn → Required direction Turn until the required pressure limit (1.4/2.4/3.7 bar) appears. Press 7.4 to confirm reading direction.
Start-up – Settings Checking the operating range: Manual reference variable w (current angle of rotation is indicated) Turn → Code 1 Press → Code 1 and 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 (bus line) before exchanging the lever or changing the pin position. blink.
Start-up – Settings 7.6 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.
Start-up – Settings The time required for an initialization process depends on the transit time of the actuator and 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.
Start-up – Settings Turn → Code 3, display: No Press → Code 3 blinks Turn → YES Press , display mm Select the initialization mode: Initialization mode Default MAX Turn → Code 6 Press Turn → MAX Press to confirm the MAX as the initialization mode. Start initialization: 4 Press INIT key to start initialization! The nominal travel/angle of rotation is indicated in % after initialization. Code 5 (nominal range) remains locked.
Start-up – Settings Enable configuration: Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid. Turn → Nominal travel/angle Press . Select the initialization mode: Initialization mode Default MAX Default No Turn → Code 3, display: No Press , Code 3 blinks Turn → YES Press , display Turn → Code 6 Press , Code 6 blinks Turn → NOM Press to confirm the NOM as the initialization mode.
Start-up – Settings (Code 8) and travel/angle range end (Code 9). Select the initialization mode: Enable configuration: Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid. Default No Initialization mode Default MAX Turn → Code 6 Press , Code 6 blinks Turn → MAN Press to confirm the MAN as the initialization mode.
Start-up – Settings 7.6.4 SUb substitute calibration A complete initialization procedure takes several minutes and requires the valve to move through its entire travel range several times. This initialization mode, however, is an emergency mode, in which the control parameters are estimated and not determined by an initialization procedure. As a result, a high level of accuracy cannot be expected. You should always select a different initialization mode if the plant allows it.
Start-up – Settings Select the initialization mode: Initialization mode Default MAX Turn → Code 6 Press , Code 6 blinks Turn → SUb 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 the replaced positioner are known. Press to confirm the SUb as the initialization mode.
Start-up – Settings 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 Blocking position Default: 0 Turn → Code 34 Press , Code 34 blinks Turn → Closing direction (CCL counterclockwise/CL clockwise) Press . Turn → Code 35 Press , Code 35 blinks Start initialization: 4 Press INIT key. The positioner switches to MAN mode.
Start-up – Settings Note: 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.
Start-up – Settings Press , Code 36 blinks Turn → Std Press . All start-up parameters and the diagnosis are reset to their default values. Note: – Code 36 - diAG allows just the diagnosis data (EXPERTplus) to be reset. Refer to EB 8389 EN on EXPERTplus valve diagnostics. – Reset the control and identification parameters as well as the bus address with the FACTORY_RESET parameter (refer to Configuration Manual KH 8384-4 EN). 7.
Operation Note: The bus address can only be implemented by the PROFIBUS command SET_ADRESS when the bus address is set to the default setting [126]. Refer to Configuration Manual KH 8384-4 EN. 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.
Operation Press to access the selected code. The code number starts to blink. 8.2 Turn and select the setting. Press to confirm the selected setting. 8.2.1 Automatic and manual modes Note: If no settings are entered within 120 seconds, the enabled configuration function becomes invalid and the display changes to Code 0. Operating modes After initialization has been completed successfully, the positioner is in automatic mode (AUTO).
Operation Adjust the manual set point 8.2.2 SAFE – Fail-safe position % Turn → Code 1 Press , 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 manual mode with Code 0 if no settings are made within 120 seconds. Switch to automatic operating mode Turn → Code 0 Press , Code 0 blinks. Turn → AUtO Press . The positioner changes to tomatic operating mode.
Operation 8.3 Malfunction/maintenance alarm All status and fault alarms are assigned to a classified status in the positioner. The default settings of the status classification are listed in the code list. Note: The status classification can be changed in TROVIS-VIEW and over the PROFIBUS-PA parameters. Refer to the Configuration Manual KH 8384-4 EN on the supplied CD-ROM (CD 8384-4) for more details.
Operation The cause and recommended action are listed in the code list (section 14). Example Error caused by pin position S 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 74 to confirm the error message.
Adjusting the limit switch 9 Adjusting the limit switch The positioner version with an 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 (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.
Adjusting the limit switch For CLOSED position: 1. Initialize positioner. 2. Use the MAN function to move the positioner to 5 % (see LC display). 3. 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: Tag leaving the field > contact is made. Tag entering the field > contact is opened. For OPEN position: 1. Initialize positioner. 2.
Adjusting the limit switch is turned so that the rotary switch (5) can be attached with the metal tag next to the proximity switch. 7. Note: On start-up of the positioner, set the option inductive alarm under Code 38 from No to YES. 1 2 4 3 5 8 7 6 9 7 Socket X7 (11) 1 2 3 4 5 Cap Screws Rotary pushbutton Marking Rotary switch 6 7 Metal tag Proximity switch 8 Clamping plate 9 Plastic cover 11 Connector Fig.
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.
Maintenance, calibration and work on equipment a) Updates outside the hazardous area: Remove the positioners from the plant and update them outside the hazardous area. 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.
Code list 14 Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. Operating mode 0 [MAN] AUtO SAFE ESC Manual mode Automatic mode Fail-safe position Escape Manual w 1 0 to 100 [0] % of the nominal range Switchover from automatic to manual mode is smooth. In fail-safe mode, the symbol S appears on the display.
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 5* Nominal range mm or angle ° ESC For initialization using NOM or SUb, the nominal travel/angle of rotation of the valve must be entered. The permissible adjustment range depends on the pin position according to the table for Code 4. Code 5 is generally locked until Code 4 is set to No, i.e.
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 9* Travel/angle range end (upper x-range value) 20.0 to 100.0 [100.0] % of the nominal range ESC Note: Specified in mm or angle ° provided Code 4 is set 10* Travel/angle lower limit (lower x-limit) 0.0 to 49.9 % of the operating range 11* Upper range value for the travel/angle of rotation in the nominal or operating range.
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 15* Set point range end (w-end) 50.0 to 100.0 % of the span adjusted via Code 12/13 [No], ESC If w approaches the percentage adjusted at the final value that causes the valve to open, the actuator is immediately completely filled with air (with AIR TO OPEN) or vented (with AIR TO CLOSE).
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 19* 20* Tolerance band Used for error monitoring 0.1 to 10.0 [5] % of the operating range ESC Determination of the tolerance band in relation to the operating range. Associated lag time [30] s is a reset criterion.
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 23* Total valve travel Can be reset to 0 by RES. Exponential reading from 9999 travel cycles onwards Note: The total valve travel is saved in a non-volatile memory after every 1000 double travel. RES, ESC 24* Totaled double valve travel.
Code list Code Parameter – Display, values no. [default setting] Description Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. 42 Auto-w/manual-w info 0.0 to 100.0 % of the span Read only, Auto mode: indicates the supplied automatic set point Man mode: indicates the supplied manual set point 43 Firmware info control Read only, indicates the positioner type and current firmware version in alternating sequence. 44 y info Read only.
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: , Maintenance alarm: ). If “No message” is assigned to the error code as the status classification, the error is not included in the condensed state. A status classification is assigned to every error code in the default setting.
Code list Initialization errors Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms 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. • Bracket slipped in case of NAMUR attachment or positioner is not central. • Follower plate incorrectly attached.
Code list Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms exist, they are displayed here. 53 Initialization time exceeded The initialization routine lasts too long. (Init time >) • No pressure on the supply line or there is a leak. • Supply air failure during initialization. Status classification [Maintenance required] Recommended action Check attachment and supply pressure. Re-initialize the positioner.
Code list Operational errors Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms exist, they are displayed here. 57 Control loop Control loop error, the control valve does not react within the tolerable times of the controlled variable (tolerance band alarm Code 19). • Actuator mechanically blocked. • Attachment of the positioner subsequently shifted. • Supply pressure not sufficient.
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 Determination of the measured data for the actuator has failed. Conductive plastic element is defective. The positioner continues to run in emergency mode, but should be replaced as soon as possible. The emergency mode on the display is indicated by a blinking closed-loop operation icon and 4 dashes instead of the position indication.
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 Initialization key jammed A hardware error has occurred, the positioner changes to the fail-safe position (SAFE). Status classification Maintenance alarm (cannot be classified) Recommended action Confirm error and return to the automatic operating mode, or perform a reset and re-initialize the device.
Code list Data errors Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms exist, they are displayed here. 68 Control parameter Control parameter error Status classification [Maintenance required] Recommended action Confirm error, perform reset and re-initialize the positioner. 69 Poti parameter Parameter error of the digital potentiometer.
Code list Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms exist, they are displayed here. 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 changes to the fail-safe position (SAFE) when a measuring error occurs.
Code list Diagnosis errors Error codes – Recommended action Condensed state alarm active, when prompted, Err appears. When fault alarms exist, they are displayed here. 79 Diagnostic alarms Alarms are generated by the extended EXPERTplus diagnostics Status classification Maintenance required (cannot be classified) 80 Diagnostic parameters Errors that are not critical for control.
Dimensions in mm Dimensions in mm Pressure gauge bracket or connection plate Attachment acc. to IEC 60534-6 External position sensor Lever in mm S = 17 M = 50 L = 100 XL = 200 Schild 28 15 58 46 70 70 15 34 70 210 Direct attachment 14 34 80 M20 x 1.5 40 28 58 86 164 Fig.
Dimensions in mm Attachment according to VDI/VDE 3847 to Type 3277 62 24 164 200 13 164 Attachment according to VDI/VDE 3847 on NAMUR rib 62 83 164 Fig.
Dimensions in mm Heavy-duty version Output Y1 Output Y1 Supply (9) 86 56 80 52 Output Y2 Reversing amplifier (optional)* 80 130 166 30 86 Ø 101 Output Y2 Light version Output A1 Supply (9) 50 Z 76 A1 79 59 49 A2 50 Connecting plate G ¼ or ¼ NPT 58 80 130 150 Reversing amplifier (optional)* Output A2 * Reversing amplifier – Type 3710 (see drawing of heavy-duty version for dimensions) – 1079-1118/1079-1119, no longer available (see drawing of light version for dimensions) Fig.
Dimensions in mm 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 ∅d Mmin ∅D* AA0 50 25 15 5.5 for M5 66 50 AA1 80 30 20 5.5 for M5 96 50 AA2 80 30 30 5.5 for M5 96 50 AA3 130 30 30 5.5 for M5 146 50 AA4 130 30 50 5.5 for M5 146 50 AA5 200 50 80 6.
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 a workstation/ operating software (e.g. TROVIS-VIEW). 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.
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
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The FISCO Concept allows interconnection of intrinsically safe apparatus to associated apparatus not specifically examined in Intrinsically safe if installed as specified in manufacturer’s installation manual. CSA- certified for hazardous locations Type 4 Enclosure Ex ia IIC T6 Class I, Division 1, Groups A, B, C and D; Class II, Division 1, Groups E, F + G; Class III. such combination.
Addendum Page 3 Addendum Page 4 Table 1: Intrinsic Safety Parameters Table 2: CSA – certified barrier parameters of circuit 4 Profibus Limitswitches inductive Forced ventingfunction Circuit No. 1 1 2 Terminal No.
Addendum Page 6 Installation drawing Control Relay KHA5-OTI/Ex2, KHA6-OTI/Ex1 or KHA6-OTI/Ex2 with Model SJ-b-N Proximity Sensors Ex nA II T6 / Ex nL IIC T6 Class I, Div. 2; Groups A, B, C, D; Class II, Div.
Addendum Page 7 Installation Manual for apparatus approved by FM for use in hazardous locations. TM Communication is optionally either according to the FOUNDATION Fieldbus Specification or according to PROFIBUS PA in compliance FISCO-Concept The FISCO Concept allows interconnection of intrinsically safe apparatus to associated apparatus not specifically examined in such combination.
Table 2: FM – approved barrier parameters of circuit 4 Table 1: Maximum values Supply barrier Fieldbus Foundation Circuit No. Terminal No.
Addendum Page 11 FM approved for hazardous locations: Ex nA II T6; Ex nL IIC T6 Zone 2. Class I, II, Div. 2 Groups A, B, C, D, E+F. Field enclosure NEMA 4X FM-approved associated apparatus suitable for Profibus PA or FOUNDATION FF FIELDBUS Serial interface, FM-approved Model 3730-43/3730-53 Positioners 12- 41+ SAFE LOCATION LOCATION Fieldbus Isolating amplifier 1 or 2 channels circuit 1 Limit switch circuit 2 or 3730-53 . HAZARDOUS Ex nA II T6; Ex nL IIC T6 Zone 2. Class I, II, Div.
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EB 8384-4 EN S/Z 2015-02 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.
