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.
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 3.3 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. . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 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
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.
Design and principle of operation 22 13 mm % S w 1) x depending on version > 3.8 mA > 4.
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.
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 manipul
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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).
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.
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.
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.
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.
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.
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 spec
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.
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.
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.
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.
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.
Operator controls and readings Automatic Clockwise Counterclockwise Error Escape ix ³ 21.6 mA ix £ 2.4 mA w £ 3.
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.
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 v
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
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 signa
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 [%]
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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 . . . .
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 . . . . . . . . .
Index diagnostic functions . . . . . . . . 11 Z Zero calibration . . . . . . . . . . . .
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.
