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Pneumatic ActuatorType 3271

Mounting andOperating Instructions

EB 8310 ENEdition October 2004

Fig. 1 · Type 3271 Actuators

Type 3271

Type 3271-5

Type 3271-52

Type 3271 with handwheel

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 3

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1 Reversing the operating direction (fail-safe action) . . . . . . . . . . . . 62.1.1 Type 3271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1.2 Actuator with handwheel . . . . . . . . . . . . . . . . . . . . . . . . 82.2 Replacing the diaphragm and stem seal . . . . . . . . . . . . . . . . 102.3 Adjusting the travel stop . . . . . . . . . . . . . . . . . . . . . . . . 112.4 Manual operation of Type 3271 with side-mounted handwheel . . . . . 122.4.1 Normal operation with the handwheel locked . . . . . . . . . . . . . 122.4.2 Actuator stem extends upon air supply failure . . . . . . . . . . . . . 122.4.3 Actuator stem retracts upon air supply failure. . . . . . . . . . . . . . 122.4.4 Actuator stem extends when supply air is applied . . . . . . . . . . . . 132.4.5 Actuator stem retracts when supply air is applied . . . . . . . . . . . . 13

3 Description of nameplate . . . . . . . . . . . . . . . . . . . . . . . 14

4 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 EB 8310 EN

Contents Safety instructions

General safety instructions

Assembly, start-up and operation of the device may only be performed bytrained and experienced personnel familiar with this product.According to these mounting and operating instructions, trained personnel isreferred to individuals who are able to judge the work they are assigned toand recognize possible hazards due to their specialized training, theirknowledge and experience as well as their knowledge of the relevantstandards.

Any hazards which could be caused by the signal pressure and movingparts of the actuator are to be prevented by means of appropriatemeasures.

Proper shipping and appropriate storage are assumed.

1 Design and principle ofoperation

The Type 3271 Actuators are primarily usedfor attachment to Series 240, 250, 260 and280 Valves.

Type 3271-5 with a die-cast aluminumcasing and effective diaphragm areas of 60and 120 cm2, is mounted to Type 3510Valves and Series 240 Valves.The Type 3271 Actuator is made up of twodiaphragm cases, a rolling diaphragm andsprings.Actuators with manual override additionally

have a handwheel mounted on the top dia-phragm case or mounted on the side of thevalve yoke. The handwheel moves the actua-tor stem over a spindle. The Type 3271 Ac-tuator can be equipped in a special versionwith a mechanically adjustable travel stop(Fig. 7).

The signal pressure creates a force at the di-aphragm surface which is balanced by thesprings (6) arranged in the actuator. Thenumber of springs and their compressiondetermine the bench range (signal pressurerange) while taking the rated travel into ac-count which is directly proportional to thesignal pressure.

EB 8310 EN 3

Design and principle of operation

Fig. 2 · Sectional diagram of Type 3271

4

3

2 1 1.156

8.1

8

9

71011

1212.1

15

1316

a

9

31 Nut1.1 Nut2 Actuator stem3 Vent plug4 Loading pressure

connection5 Top diaphragm

case

6 Springs7 Diaphragm plate8 Diaphgram8.1 Hose clamp

9 Nuts and bolts10 Bottom diaphragm case11 Loading pressure connection12 Stem seal12.1 Dry bearing13 Wiper15 Ring nut16 Stem connector

Actuator stemretracts FE

Actuator stemextends FA

A maximum of 30 springs can be installed,partly fitted inside one another.

In an actuator with the fail-safe action"Actuator stem extends FA", the loadingpressure is connected to the loading pres-sure connection (11) to fill the bottom dia-phragm chamber with air which causes theactuator stem to move upwards.In an actuator with the fail-safe action"Actuator stem retracts FE", the loadingpressure is connected to the loading pres-

sure connection (4) to fill the top diaphragmchamber with air which causes the actuatorstem to move downwards.The stem connector (16) connects the actua-tor stem (2) to the plug stem of the valve.

Fail-safe action

When the signal pressure fails, the fail-safeaction of the actuator depends on whetherthe springs are installed in the top or bottomdiaphragm chamber.

4 EB 8310 EN


Fig. 3 · Type 3271-5 Actuators with 120 cm2 (top) and 60 cm2 (bottom) effective diaphragm area

4

81177.1

1615 13

12.112

3

52

20 21 22

1 1.1 6 9

10 2.1

2122

16

1 Nut1.1 Nut2 Actuator stem2.1 Bushing3 Vent plug3.1 Vent plug4 Loading press. connection

Actuator stem retracts5 Top diaphragm case6 Springs

7 Diaphragm plate7.1 Metal plate8 Diaphragm9 Nuts and bolts10 Bottom diaphragm case11 Loading press. connection

Actuator stem extends12 Stem seal12.1 Dry bearing

13 Wiper15 Ring nut16 Stem connector20 Screw (60 cm2)21 Washer (60 cm2)22 Sleeve (60 cm2)

Actuator stem extendsWhen the signal pressure is reduced or theair supply fails, the springs move the actua-tor stem downwards and close the valve.The valve opens when the signal pressure isincreased enough to overcome the force ex-erted by the springs.

Actuator stem retractsWhen the signal pressure is reduced or theair supply fails, the springs move the actua-tor stem upwards and open the valve. Thevalve closes when the signal pressure is in-

creased enough to overcome the force ex-erted by the springs.

The tandem actuator (Fig. 4) has two dia-phragms connected to each other. The sig-nal pressure produces an actuating forcedouble to that of an actuator with just onediaphragm.

Actuators with an additional manual over-ride (Fig. 5) have a handwheel that movesthe actuator stem over a spindle after thelocking mechanism (lock nut) has been dis-engaged. A side-mounted handwheel (Fig.8) moves the stem over a bevel or wormgear.

Note!Refer to the attached valve’s Mounting andOperating Instructions to mount or removethe actuator from the valve.Actuators with 2800 cm2 diaphragm areaweigh 450 kg and cannot be mounted ontothe valve on site.Important!The pneumatic actuators are designed for amaximum supply pressure of 6 bar.To prevent the actuator from being dam-aged, do not let the supply pressure exceedthe upper spring range value by more than3 bar when the actuator is used forflow-switching service (on-off valve) with thefail-safe action "Actuator stem retracts".Label actuators that have a reduced supplypressure with a sticker "max. supply pres-sure limited to ... bar".The maximum supply pressure for actuatorswith fail-safe action “Actuator stem extends”and mechanical travel stops should not ex-ceed the upper spring range value by morethan 1.5 bar.

EB 8310 EN 5


Fig. 4 · Tandem actuator

3.1

3

4

4

4.1

4.115

16

3.1

3

7

3 Loading pressure connection3.1 Vent plug4 Loading pressure connection4.1 Vent plug15 Ring nut16 Stem connector

Actuator stemretracts

Actuator stemextends

2 Operation

Note! Only apply the loading pressure tothe diaphragm chamber that does not con-tain the springs. It is important for atroublefree operation of the actuator that thevent plug (3) is not blocked. Make sure inversions with a handwheel that the plugstem can move freely when the valve is be-ing positioned by the pneumatic actuator bymoving the handwheel into a neutral posi-tion (Fig. 5 for 240 to 700 cm2 and Fig. 8for 1400 and 2800 cm2) .

2.1 Reversing the operatingdirection (fail-safe action)

The operating direction, i.e. fail-safe action,of pneumatic actuators can be changed.Prior to proceeding, you must remove theactuator from the valve.

The fail-safe action "Actuator stem extends"or "Actuator stem retracts" is specified onthe nameplate with the initials FA and FE onType 3271 Actuator or by a symbol onType 3271-5 Actuator.

Caution!To disassemble an actuator withpreloaded actuator springs (recog-nizable by the long bolts on the dia-phragm chambers), always undo theshort bolts first and then unthreadthe long bolts slowly and evenly untilthe actuator springs are fully decom-pressed.

2.1.1 Type 3271

Reversing the fail-safe action "Actuatorstem extends" to "Actuator stem retracts"(Fig. 2)

1. Unthread nuts and remove the bolts (9)from the diaphragm cases.

2. Lift off the top diaphragm case (5) andremove the springs (6).

3. Pull the actuator stem (2) with dia-phragm plate (7) and diaphragm (8) outof the bottom diaphragm case (10).

4. Unscrew nut (1), while holding the nut(1.1) stationary with a suitable tool.Caution! Proceed carefully to avoiddamaging the seals of the actuator stem.

Caution!Do not loosen the nut (1.1) on the actuatorstem. It is painted over to protect it.If, however, it does become loose, it is es-sential that the dimension "a" from the topof the nut to the bottom of the actuator stemis kept as shown in Fig. 2 and the tablebelow.

Actuator cm2 Dimension a in mm (Fig. 2)

120 100.5, or 89 with threaded end

240 98.25

350 107.25

700

125 for 15 mm rated travel(0.4-1.2 bar)

144 for 30 mm and 40 mmrated travel

1400 230

2800 430

6 EB 8310 EN

Operation

5. Lift off the diaphragm plate with dia-phragm and replace them in reverse or-der. Tighten nut (1).

6. Apply lubricant/sealant (order no.8152-0043) to the actuator stem.

7. Place the diaphragm plate with dia-phragm in the top diaphragm case. In-sert the springs (6) and slide the lowerdiaphragm case over the actuator stem.

8. Screw tight the nuts and bolts of the dia-phragm cases.

9. Remove vent plug (3) from top dia-phragm case and screw it into the load-ing pressure connection on the bottomdiaphragm case.

The actuator springs now press against thediaphragm plate from below and cause theactuator stem to retract. The loading pres-sure is connected over the connection (4) tothe top diaphragm chamber. The actuatorstem starts to extend when the signal pres-sure overcomes the force of the springs.

10.Record the changed fail-safe action onthe nameplate!

Proceed in the same manner for the Type3271-5 Actuator, but additionally install themetal plate (7.1).For the version intended for attachment tomicro-flow valves, additionally install thebushing (2.1) for the mechanical travel stop.In Type 3271-52 Actuator with 60 cm2 dia-phragm area, unthread the screw (20) andthen remove the washer (21) and sleeve(22).

Reversing the fail-safe action "Actuatorstem retracts" to "Actuator stem extends"(Fig. 2)

1. Unthread nuts and remove the bolts (9)and lift off the top diaphragm case (5).

2. Pull the diaphragm plate (7) and dia-phragm with the actuator stem (2) out ofthe bottom diaphragm case (10). Re-move the springs (6).

3. Unscrew nut (1), while holding the nut(1.1) stationary with a suitable tool.Caution! Proceed carefully to avoiddamaging the seals of the actuator stem.

4. Remove the diaphragm plate with dia-phragm and replace them in reverse or-der. Screw tight nut (1).

5. Coat the actuator stem with sealant/lu-bricant (order no. 8152-0043) and in-sert it into the bottom diaphragm cham-ber along with the diaphragm plate anddiaphragm.

6. Insert springs (6) and place the top dia-phragm case back on.

7. Screw tight the nuts and bolts of the dia-phragm cases.

8. Remove the vent plug (3) from the bot-tom loading pressure connection andplace it in the top connection.

The springs which are now pressed from thetop against the diaphragm plate cause theactuator stem to extend.The signal pressure is connected via the con-nection (11) to the bottom diaphragm cham-ber. The actuator stem starts to retract whenthe signal pressure overcomes the force ofthe springs.

EB 8310 EN 7

Operation

9. Record the changed fail-safe action onthe nameplate!

Proceed in the same manner for the Type3271-5 Actuator, but additionally install themetal plate (7.1).For an actuator intended for a micro-flowvalve, install the bushing (2.1) for the travelstop.

For Type 3271-52 Actuator with 60 cm2

undo the screw (20) and then remove thewasher (21) and sleeve (22).

2.1.2 Actuator with handwheel

240, 350 and 700 cm2 (Fig. 5) only

1. Undo lock nut (20) and relieve thesprings (6) by turning the handwheel(17).

2. Loosen threaded pin (26) and unscrewcoupling nut (25) from the coupling(22).

3. Knock out the clamping sleeve (23) andremove the ring (24).

4. Unthread the ring nut (28) and lift off theflange part (21).

Reversing the fail-safe action "Actuatorstem extends" to "Actuator stem retracts"

Proceed as described in section 2.1.1.However, use the word "spindle with nut(27)" in place of "nut (1)".

After reversing the operating direction:

1. Place the flange part (21) and couplingnut (25). Then fasten the flange part (21)with the ring nut (28).

2. Attach the ring (24) with clampingsleeve (23).

3. Screw coupling nut (25) as far as it willgo onto the coupling (22) and securewith threaded pins (26).

Reversing the fail-safe action "Actuatorstem retracts" to "Actuator stem extends"


8 EB 8310 EN

Operation


1. Place the flange part (21) and the cou-pling nut (25) and then secure flangepart (21) with ring nut (28).

2. Attach the ring (24) with clampingsleeve (23).


EB 8310 EN 9

Operation

Fig. 5 · Actuators 240, 350 und 700 cm2 with handwheel

17

20

21

22

23

2425

34567

86.110

11216

26

2728

8.1

9

2 Actuator stem3 Vent plug4 Loading press. connection5 Top diaphragm case6 Springs6.1 Additional springs7 Diaphragm plate8 Diaphragm9 Nuts and bolts8.1 Hose clip10 Bottom diaphragm case11 Loading press. connection16 Stem connector17 Handwheel20 Lock nut21 Flange part22 Coupling23 Clamping sleeve24 Ring25 Coupling nut26 Threaded pin27 Spindle with nut28 Ring nut

Actuator stem retracts Actuator stem extends

Neutral positionPointer points to groove incoupling (22)

2.2 Replacing the diaphragmand stem seal

Diaphragm (Fig. 2)

1. Remove the diaphragm plate (7) to-gether with diaphragm (8) and actuatorstem (2) from the diaphragm case as de-scribed in section 2.1.

2. Remove the hose clamp (8.1) and pull ittogether with the diaphragm (8) off thediaphragm plate (7) (not necessary withType 3271-5 as the diaphragm is heldin place by the metal plate (7.1)).

3. Stretch the new diaphragm onto the dia-phragm plate. Fit the hose clamp (8.1)evenly into the groove intended for itand tighten. Insert a piece of protectivewear-resistant rubber between the dia-phragm and the worm screw of the hoseclamp (jubilee clip) to protect the dia-phragm.

4. Reassemble actuator as described insection 2.1.

Stem seal (Fig. 6)

1. Remove the diaphragm plate (7) to-gether with the actuator stem (2) fromthe diaphragm case as described insection 2.1.

2. Coat the new stem seal (12) with lubri-cant/sealant (order no. 8152-0043)and insert it.

3. If necessary, replace the dry bearing (12.1)and wiper (13) with new ones as well.

4. Reassemble the actuator as described insection 2.1.

10 EB 8310 EN

Operation

Fig. 6 · Actuator stem seal

12

12.1

2

13

2.3 Adjusting the travel stop

(Type 3271 in special version only)

The travel stop can be adjusted upwards ordownwards to 50 % of the travel.

Downward travel stop(actuator stem extends)

1. Undo the lock nut (34) and unscrew thecap (33).

2. Undo the lock nut (31) and adjust thenut (32) to set required travel stop.

3. Tighten the lock nut (31) again.

Upward travel stop(actuator stem retracts)

1. Undo the lock nut (34) and adjust thecap (33) to set the required travel stop.


EB 8310 EN 11

Operation

Fig. 7 · Travel stop

33

31

32

34

5

7

2

2 Actuator stem7 Diaphragm plate31 Lock nut32 Nut33 Cap34 Lock nut



2.4 Manual operation of Type3271 with side-mountedhandwheel

Note! To operate the handwheel on actua-tors with 1400 and 2800 cm2 diaphragmareas, do not use any additional tools suchas a lever or wrench.

2.4.1 Normal operation with thehandwheel locked

The handwheel is not used. The valve is po-sitioned by the pneumatic signal pressureapplied to the valve.To achieve this, the pin next to the actuatorstem must be in the neutral position:The pin must sink into the flange so far thatits groove is aligned with the top of theflange.

If this is not case:

Pull the locking knob on the side all theway out and turn it to unlock thehandwheel.

Turn the handwheel until the pin reachesthe neutral position.

Turn the locking knob until it engages tolock the handwheel again.

The easiest way to adjust the handwheel iswith the valve in the fail-safe position.

2.4.2 Actuator stem extends uponair supply failure

The manual override must overcome theforce of the actuator springs to open thevalve.


Turn the handwheel counterclockwise(direction Auf/Open/Ouvert), the pinsinks into the flange.Initially, the handwheel is easy to turnand after a certain point of pressure isreached, the valve starts to open.

On reaching the final position at thestop, do not turn the handwheel any fur-ther by force.Caution! Risk of damage.

After finishing manual operation, turnthe handwheel to bring the pin back intothe neutral position again.


2.4.3 Actuator stem retracts uponair supply failure

The manual override must overcome theforce of the actuator springs to close thevalve.


Turn the handwheel clockwise (directionZu/Close/Fermé), the pin emerges fromthe flange.Initially, the handwheel is easy to turnand after a certain point of pressure isreached, the valve starts to close.


12 EB 8310 EN

Operation



2.4.4 Actuator stem extends whensupply air is applied

The manual override must overcome theforce of the actuator springs to open thevalve.Do not close the valve any further than be-fore unlocking the handwheel.


Turn the handwheel counterclockwise(direction Auf/ Open/Ouvert), the pinsinks into the flange.Initially, the handwheel is easy to turnand the pin’s position does not moveanymore. After a certain point of pres-sure is reached (how long depends onthe valve travel), the valve starts to open.




2.4.5 Actuator stem retracts whensupply air is applied

The manual override must overcome theforce of the actuator springs to close thevalve.Do not open the valve any further than be-fore unlocking the handwheel.

EB 8310 EN 13

Operation

Fig. 8 · Side-mounted handwheel

Pin with groove

Neutralposition

Locking knob(locked)

Version in this drawingfor 80 mm travel


Turn the handwheel clockwise (directionZu/Close/Fermé), the pin emerges fromthe flange.After a certain point of pressure isreached, the valve starts to close.




3 Description of nameplate

14 EB 8310 EN

Description of nameplate

Fig. 9 · Nameplate

1 Type designation2 Modification index3 Effective diaphragm area4 Operating direction:

Actuator stem extends FAActuator stem retracts FE

5 Travel6 Bench range (spring range)7 Bench range with preloaded springs

SAMSON 165 7VFH

2 3 4

4 Customer inquiries

Please specify the following details on mak-ing inquires:

Type and model number Effective diaphragm area Bench range (spring range) in bar Actuator version and its operating direc-

tion

Dimensions and weightsRefer to the Data Sheets T 8310-1 EN orT 8310-2 EN for the different actuator ver-sions.

EB 8310 EN 15

Customer inquiries

SAMSON AG ⋅ MESS- UND REGELTECHNIKWeismüllerstraße 3 ⋅ 60314 Frankfurt am Main ⋅ GermanyPhone +49 69 4009-0 ⋅ Fax +49 69 4009-1507Internet: http://www.samson.de EB 8310 EN S/

Z20

04-1

1

Pneumatic ActuatorType 3277


EB 8311 ENEdition July 2006

Fig. 1 · Type 3277 Pneumatic Actuator Fig. 2 · Type 3277-5 Pneumatic Actuator


The Type 3277 Pneumatic Actuators with aneffective diaphragm area of 240, 350 or700 cm² are primarily mounted to controlvalves from the Series 240, 250 and 280.

Type 3277-5 with a die-cast aluminum caseand an effective diaphragm area of120 cm², is mounted to Type 3510 and Se-ries 240 Valves.

The actuator is made up of two diaphragmcases, a rolling diaphragm and springs. Thelower diaphragm case is permanently fixedto the yoke which allows the direct attach-ment of either a pneumatic or electropneu-matic positioner or a limit switch.

Actuators with manual override (Fig. 5) ad-ditionally have a handwheel mounted on thediaphragm case. The handwheel moves the

actuator stem over a spindle after the lock-ing mechanism (lock nut) has been disen-gaged. In addition, the actuator can beequipped in a special version with a me-chanically adjustable travel stop.

The signal pressure creates a force at the di-aphragm surface which is balanced by thesprings (6) arranged in the actuator. Thenumber of springs and their compressiondetermine the bench range (signal pressurerange) while taking the rated travel into ac-count which is directly proportional to thesignal pressure. A maximum of 30 springscan be installed, partly fitted inside one an-other.

The stem connector (16) connects the actua-tor stem (2) with the plug stem of the controlvalve.

2 EB 8311 EN


Assembly, start-up and operation of the device may only be performed bytrained and experienced personnel familiar with this product.According to these mounting and operating instructions, trained personnel isreferred to individuals who are able to judge the work they are assigned toand recognize possible hazards due to their specialized training, theirknowledge and experience as well as their knowledge of the relevantstandards.

Any hazards which could be caused by the signal pressure and movingparts of the actuator are to be prevented by means of appropriatemeasures.


Fail-safe action

When the signal pressure fails, the fail-safeaction of the actuator depends on whetherthe springs are installed in the top or bottomdiaphragm chamber.

Actuator stem extendsWhen the signal pressure is reduced or theair supply fails, the springs move the actua-tor stem downwards and close the valve.The valve opens when the signal pressure isincreased enough to overcome the force ex-erted by the springs.

Actuator stem retractsWhen the signal pressure is reduced or theair supply fails, the springs move the actua-tor stem upwards and open the valve. Thevalve closes when the signal pressure is in-creased enough to overcome the force ex-erted by the springs.

EB 8311 EN 3


Fig. 3 · Sectional diagram of Type 3277 with 240, 350 and 700 cm² effective diaphragm area

5 1.1 1 6 6.1 3

8

12

12.1

11

10

12.1

13

2

15

16

4

7

a

9

1 Nut1.1 Nut2 Actuator stem3 Vent plug4 Loading pressure

connection5 Top diaphragm

case6 Springs7 Diaphragm plate8 Diaphragm9 Nuts and bolts10 Yoke with bottom

diaphragm case11 Loading pressure

connection12 Stem seal12.1Dry bearing13 Wiper15 Ring nut16 Stem connector

Dimension a350 cm² = 209 mm700 cm² = 246 mm

Loading pressure connectionType 3277 Actuator (Fig. 3)In the Type 3277 Actuator with fail-safe ac-tion "Actuator stem extends", the loadingpressure is connected to the loading pres-sure connection (11) at the side of the yoketo fill the bottom diaphragm chamber whichcauses the actuator stem (2) to move up-wards. In an actuator with the fail-safe ac-tion "Actuator stem retracts", the loadingpressure is connected the loading pressureconnection (4) to fill the top diaphragmchamber which causes the actuator stem tomove downwards.

Type 3277-5 Actuator (Fig. 4)In the Type 3277-5 Actuator, the loadingpressure is connected to a borehole either atthe left or right of the yoke. A switchoverplate (14, accessories) directs the air to oneof the diaphragm chambers, depending onthe fail-safe action of the actuator ("Actuatorstem extends" or "Actuator stem retracts"),which is determined by how the plate isaligned with the mark (14.4).

Turn the switchover plate to align thesymbol (14.3) for the appropriatefail-safe action with the mark (14.4). SeeFig. 4, bottom left. The operating direc-tion (>>) or (<>) of the positioner deter-mines whether the left or right attach-ment is to be used.

A connecting plate (accessories) is requiredinstead of the switchover plate if the actua-tor is operated without a positioner. Theloading pressure is directly connected to theloading pressure connection (14.8) of theconnecting plate to fill the diaphragm cham-ber.

Turn the connecting plate to align thesymbol (14.3) for the appropriatefail-safe action "Actuator stem extends"or "Actuator stem retracts" with the mark(14.4). See Fig. 4, bottom right.

Make sure that the flat gasket of the con-necting plate is correctly inserted.

The connecting plate has both NPT andG threaded bores. Seal the bore not re-quired with a rubber gasket and squareplug.

Accessories: The switchover plate or con-necting plate must be ordered separately.Please note that actuators with modificationindex 01 e.g. 3277-531xxx20.01 (old =.00) are equipped with new plates.

Old and new plates are not interchangeable.

In-dex Order no.

Switch-over plate

NewOld

0100

1400-68221400-6819

Con-nectingplate

NewOld: G thread

Old NPT thread

010000

1400-68231400-68201400-6821

Note! The pneumatic actuators are designedfor a maximum supply pressure of 6 bar.To prevent the actuator from being dam-aged, do not let the supply pressure exceedthe upper spring range value by more than3 bar when the actuator is used forflow-switching service (on-off valve) with thefail-safe position "Actuator stem retracts".Label actuators that have a reduced supplypressure with a sticker "max. supply pres-sure limited to … bar".Note! Refer to the operating instructions ofthe corresponding valve on how to mountand remove the actuator from the valve.

4 EB 8311 EN


EB 8311 EN 5


14

2.1 2

7.1

14.1

14.214

16

1315

14.3

14.4

14.8

14.3

14.4

14.5

14.6

14.7

a a

8

10

16

12.112

6 1 2 1.19

7

Fig. 4 · Type 3277-5 Actuators with 120 cm2 effective diaphragm area

Connecting plate

Actuator stem extendsLeft attachment Right attachment

1 Nut1.1 Nut2.1 Bushing5 Diaphragm case6 Springs7 Diaphragm plate7.1 Metal plate8 Diaphragm9 Nuts and bolts10 Yoke12 Stem seal

12.1 Dry bearing13 Wiper14 Switchover or connecting

plateAir routing:

14.1 for actuator stem extends14.2 for actuator stem retracts15 Ring nut16 Stem connector

Actuator stem retractsLeft attachment Right attachment Actuator stem

extends retracts

Switchover plate

14.3 Symbol14.4 Marking for signal

pressure input14.5 For left attachment14.6 For right attachment14.7 Seal with filter14.8 Loading pressure

connection

Actuator with threadedconnection for amicro-flow valve

Dimension a = 188.5 with 15 mm traveland 185.5 with 20 mm travel

2 Operation

Note!It is important for a trouble-free operation ofthe Type 3277 Actuator that the vent plug(3) is not blocked.Make sure in versions with a handwheel thatthe plug stem can move freely when thevalve is being positioned by the pneumaticactuator by moving the handwheel into aneutral position.

2.1 Reversing the operatingdirection (fail-safe action)

The operating direction, i.e. fail-safe action,of pneumatic actuators can be changed.Prior to proceeding, you must remove theactuator from the valve.

The fail-safe action is represented by a sym-bol on the nameplate.

"Actuator stem extends"

"Actuator stem retracts"

Caution!To disassemble an actuator with pre-loaded actuator springs (recogniza-ble by the long bolts on the di-aphragm chambers), always undothe short bolts first and then unthre-ad the long bolts slowly and evenlyuntil the actuator springs are fullydecompressed.

2.1.1 Standard actuator


Note!Actuators with 700 cm² (travel = 30 mm)that are mounted to valves with 15 mmtravel, are preloaded by approx. 75 % onmounting them to the valve.The signal pressure range is recorded on thenameplate when the actuators have beenpreloaded on mounting them to the valve.

1. Unthread nuts and remove the bolts (9)from the diaphragm cases.

2. Lift off the top diaphragm case (5) andremove the springs (6).

3. Pull the actuator stem (2) with dia-phragm plate (7) and diaphragm (8) outof the yoke (10).

4. Unscrew nut (1), while holding the nut(1.1) stationary or clamping the actuatorstem with a suitable tool.Caution! Proceed carefully to avoiddamaging the seals of the actuator stem.

6 EB 8311 EN

Operation

Caution!Do not loosen the nut (1.1) on the actuatorstem. It is painted over to protect it.If, however, it has been loosened, it is essen-tial that the dimension a (Figs. 3 and 4)measured from the top of the nut to the bot-tom of the actuator stem is kept.

5. Apply lubricant/sealant (order no.8152-0043) to the sealing places on theactuator stem.

6. Turn over top diaphragm case (5). Placethe actuator stem with diaphragm plate,diaphragm and metal plate (7.1), if ap-plicable in the case.

7. Insert the springs (6) and slide the yokewith bottom diaphragm case over theactuator stem.

8. Screw tight the nuts and bolts of the dia-phragm cases. Remove vent plug (3) inType 3277 Actuator.

Proceed in the same manner for theType 3277-5 Actuator intended for the mi-cro-valve, but additionally attach the bush-ing (2.1) for the mechanical travel stop.

The springs now press from below againstthe diaphragm plate and cause the actuatorstem to retract (fail-safe action). The actuatorstem only starts to extend when the signalpressure overcomes the force of the springs.



1. Unthread nuts and remove the bolts (9)and lift off the top diaphragm case (5).

2. Pull the actuator stem with diaphragmplate, diaphragm and metal plate (7.1),if applicablethe diaphragm plate (7) outof the yoke and bottom diaphragm case(10).

3. Unscrew nut (1), while holding the nut(1.1) stationary or clamping the actuatorstem with a suitable tool.Caution! Proceed carefully to avoiddamaging the seals of the actuator stem.

4. Remove the diaphragm plate with dia-phragm and replace them in reverse or-der. Screw tight nut (1).

5. Coat the sealing parts of the actuatorstem with sealant/lubricant (order no.8152-0043).

6. Insert the actuator stem with diaphragmplate, diaphragm and metal plate (7.1),if applicable, into the bottom diaphragmcase with yoke.

7. Insert springs (6) and place the top dia-phragm case back on. Screw tight thenuts and bolts of the diaphragm cases.

8. Screw the vent plug (3) into the top load-ing pressure connection of theType 3277 Actuator.

Proceed in the same manner for theType 3277-5 Actuator intended for the mi-cro-valve, but additionally attach the bush-ing (2.1) for mechanical travel stop.

The springs now press from the top againstthe diaphragm plate and cause the actuatorstem to extend (fail-safe action). The actua-

EB 8311 EN 7

Reversing the operating direction (fail-safe action)

tor stem only starts to retract when the signalpressure overcomes the force of the springs.


2.1.2 Actuator with handwheel

Type 3277 (Fig. 5) only

1. Undo lock nut (20) and relieve thesprings (6) by turning the handwheel(17).

2. Loosen threaded pin (26) and unscrewcoupling nut (25) from the coupling(22).

3. Knock out the clamping sleeve (23) andremove the ring (24).

4. Unthread the ring nut (15) and lift off theflange part (21) together with the cou-pling nut (25).




1. Replace the flange part (21) with ringnut (15) and coupling nut (25).

2. Tighten ring nut (15). Attach the ring(24) with clamping sleeve (23).





1. Replace the flange part (21) with ringnut (15) and coupling nut (25).

2. Tighten ring nut (15). Attach the ring(24) with clamping sleeve (23). Attachthe ring (24) with clamping sleeve (23).


8 EB 8311 EN


EB 8311 EN 9


17

20

21

2224

1513

346

96.1

7

11

12.1

13

23

2625

12

527

8

1012

Fig. 5 · Type 3277 Actuator with additional handwheel

2 Actuator stem3 Vent plug4 Loading press. connection5 Top diaphragm case6 Springs6.1 Additional springs7 Diaphragm plate8 Diaphragm9 Nuts and bolts10 Bottom diaphragm case11 Loading press. connection15 Ring nut12 Stem seal12.1 Dry bearing13 Wiper17 Handwheel20 Lock nut21 Flange part22 Coupling23 Clamping sleeve24 Ring25 Coupling nut26 Threaded pin27 Spindle with nut

Neutral positionPointer points to groovein coupling (22)

2.2 Adjusting the travel stop

(with Type 3277 in special version only)

The travel stop can be adjusted upwards ordownwards to 50% of the travel.

Downward travel stop(actuator stem extends)

1. Undo the lock nut (34) and unscrew thecap (33).

2. Undo the lock nut (31) and adjust thenut (32) to set required travel stop.


Upward travel stop(actuator stem retracts)

1. Undo the lock nut (34) and adjust thecap (33) to set the required travel stop.


10 EB 8311 EN

Adjusting the travel stop

Fig. 6 · Travel stop

33

31

32

34

5

7

2

2 Actuator stem5 Top diaphragm case7 Diaphragm plate31 Lock nut32 Nut33 Cap



3 Replacing the diaphragm andstem seal

3.1 Diaphragm

(Fig. 3)

1. Remove the diaphragm plate (7) to-gether with diaphragm (8) and actuatorstem (2) from the diaphragm case as de-scribed in section 2.1.1.

2. Remove the hose clamp and pull it to-gether with the diaphragm (8) off the di-aphragm plate (7) (not necessary withType 3277-5 as the diaphragm is heldin place by the metal plate (7.1)).

3. Stretch the new diaphragm onto the dia-phragm plate. Fit the hose clamp evenlyinto the groove intended for it andtighten.

4. Reassemble actuator as described insection 2.1.1.

3.2 Stem seal

1. Remove the diaphragm plate (7) to-gether with the actuator stem (2) fromthe diaphragm case as described insection 2.1.1.

2. Coat the new stem seal (12) with lubri-cant/sealant (order no. 8152-0043)and insert it.

3. If necessary, replace the dry bearing(12.1) and wiper (13) with new ones aswell.

4. Reassemble the actuator as described insection 2.1.1.

4 Customer inquiries

Please specify the following details on mak-ing inquires:

Type and model number Effective diaphragm area Bench range (spring range) in bar Actuator version and its operating direc-

tion

Dimensions and weightsRefer to the Data Sheet T 8310-1 EN dimen-sions and weights of the different actuatorversions.

EB 8311 EN 11

Replacing the diaphragm and stem seal

Fig. 7 · Actuator stem seal

12

12.12

13

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de EB 8311 EN S/

Z20

06-0

8

Certificate Registration No.12 100/104 4269

Electric multi-turn actuators

Operation instructions

SAExC 07.1 – SAExC 16.1SARExC 07.1 – SARExC 16.1

AUMA NORM

2

Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1AUMA NORM Operation instructions

Scope of these instructions: These instructions are valid for multi-turn actuators of the type rangeSA(R)ExC 07.1 – SA(R)ExC 16.1 in version AUMA NORM.These operation instructions are only valid for “clockwise closing”, i.e.driven shaft turns clockwise to close the valve

Table of contents Page

1. Safety instructions 41.1 Range of application 41.2 Commissioning (electrical connection) 41.3 Maintenance 41.4 Warnings and notes 4

2. Short description 4

3. Technical data 5

4. Transport and storage 7

5. Packaging 7

6. Mounting to valve/ gearbox 8

7. Manual operation 10

8. Electrical connection 118.1 Ex-plug/socket connector with terminal board 118.2 Ex-plug-in terminal connection 128.3 Delay time 138.4 Heater 138.5 Motor protection 138.6 Remote position transmitter 138.7 Limit and torque switches 148.8 Fitting of the cover 14

9. Opening the switch compartment 159.1 Removal of the switch compartment cover 159.2 Pulling off the indicator disc (option) 15

10. Setting of the limit switching 1610.1 Setting for end position CLOSED (black section) 1610.2 Setting for end position OPEN (white section) 1610.3 Checking the switches 16

11. Setting of the DUO limit switching (option) 1711.1 Setting for direction CLOSE (black section) 1711.2 Setting for direction OPEN (white section) 17

12. Setting of the torque switching 1812.1 Programming 1812.2 Checking the switches for torque and DUO limit switching 18

13. Test run 1913.1 Check direction of rotation: 1913.2 Check limit switching: 19

14. Setting of the potentiometer (option) 20

15. Setting of electronic position transmitter RWG (option) 2115.1 Setting for 2-wire system 4 – 20 mA and 3- /4-wire system 0 – 20 mA 2215.2 Setting for 3- / 4- wire system 4 – 20 mA 23

16. Setting of the mechanical position indicator (option) 24

17. Closing the switch compartment 24

3

Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1Operation instructions AUMA NORM

Page

18. Maintenance 25

19. Lubrication 26

20. Disposal and recycling 26

21. Service 26

22. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with plug/ socket connector 28

23. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with terminal connection 30

24. PTB certificate 32

25. Declaration of Conformity and Declaration of Incorporation 34

Index 35

Addresses of AUMA offices and representatives 36

1. Safety instructions1.1 Range of application AUMA actuators are designed for the operation of industrial valves, e.g.

globe valves, gate valves, butterfly valves and ball valves.For other applications, please consult us. The manufacturer is not liable forany possible damage resulting from use in other than the designated appli-cations. Such risk lies entirely with the user.Observance of these operation instructions is considered as part of theactuators’ designated use.

1.2 Commissioning(electrical connection)

For work carried out in hazardous areas, special regulations (StandardEN 60079-17) must be observed.Work at the open actuator under voltage must only be performed if it isassured that for the duration of the work there is no danger of explosion.Pay attention to additional national regulations.During electrical operation certain parts inevitably carry lethal voltages.Work on the electrical system or equipment must only be carried out by askilled electrician himself or by specially instructed personnel under thecontrol and supervision of such an electrician and in accordance with theapplicable electrical engineering rules.

1.3 Maintenance The maintenance instructions (refer to page 25) must be observed, other-wise a safe operation of the actuator is no longer guaranteed.

1.4 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries ordamage. Qualified personnel must be thoroughly familiar with all warningsand notes in these operation instructions.Correct transport, proper storage, mounting and installation, as well ascareful commissioning are essential to ensure a trouble-free and safeoperation.The following references draw special attention to safety-relevant proce-dures in these operation instructions. Each is marked by the appropriatepictograph.This pictograph means: Note!“Note” marks activities or procedures which have major influence on thecorrect operation. Non-observance of these notes may lead to consequen-tial damage.This pictograph means: Electrostatically endangered parts!If this pictograph is attached to a printed circuit board, it contains partswhich may be damaged or destroyed by electrostatic discharges. If theboards need to be touched during setting, measurement or for exchange, itmust be assured that immediately before a discharge through contact withan earthed metallic surface (e.g. the housing) has taken place.This pictograph means: Warning!“Warning” marks activities or procedures, which, if not carried out correctly,can affect the safety of persons or material.

2. Short description AUMA multi-turn actuators type SA(R)ExC 07.1 – SA(R)ExC 16.1 have amodular design. The limitation of travel is realised via limit switches in bothend positions. Torque seating is also possible in both end positions. The typeof seating is determined by the valve manufacturer.

4


3. Technical data

5


ApplicationMulti-turn actuators AUMA NORM require external controls. AUMA offers the controls AMExC 01.1 or ACExC 01.1. These canalso easily be mounted to the actuator at a later date.Features and functionsExplosion protection Standard: II2G EEx de IIC T4

II2G c IIC T4Options: II2G EEx d IIC T4

II2G IIC T4Protection types Motor compartment: d flameproof enclosure EEx d

Switch compartment: d flameproof enclosure EEx dTerminal compartment: e increased safety EEx e

d (Option) flameproof enclosure EEx dGear housing : c constructional safety

EC type examination certificate PTB 01 ATEX 1087Type of duty 1) Standard: SAExC Short-time duty S2 - 15 min

SARExC Intermittent duty S4 - 25 %Option: SAExC Short time duty S2 - 30 min

SARExC Intermittent duty S4 - 50 %Motors 3-ph AC asynchronous motor, type IM B9 according to IEC 34Insulation class F, tropicalizedMotor protection Standard: SAExC 3 PTC thermistors (according to DIN 44081)2)

SARExC 3 PTC thermistors (according to DIN 44082)2)

Option: SAExC 3 thermoswitches (NC)3)

Self-locking yes (for output speeds from 4 to 90 rpm)Limit switching Counter gear mechanism for end positions CLOSED and OPEN

for 1 to 500 turns per stroke (optional for 1 to 5,000 turns per stroke)Standard: Single switch (1 NC and 1 NO) for each end position:Options: Tandem switch (2 NC and 2 NO) for each end position,

switches galvanically isolatedTriple switch (3 NC and 3 NO) for each end position, switches galvanically isolatedIntermediate position switch (DUO limit switching), availablefor any intermediate position

Torque switching adjustable torque switching for direction OPEN and CLOSEStandard: Single switch (1 NC and 1 NO) for each directionOptions: Tandem switch (2 NC and 2 NO) for each direction, switches galvanically isolated

Non-intrusive setting (option) Magnetic limit and torque transmitter MWG(only possible in combination with actuator controls ACExC 01.1)for 1 to 500 turns per stroke or for 10 to 5,000 turns per stroke

Position feedback signal,analogue (options)

Potentiometer or 0/4 – 20 mAFor further details see separate data sheet

Torque feedback signal, analogue(option)

Only available in connection with magnetic limit and torque transmitter MWG and theactuator controls ACExC 01.1

Mechanical position indicator(option)

Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED

Running indication Blinker transmitterHeater in switch compartment Standard: self-regulating PTC heater, 5 – 20 W

110 – 250 V DC/ACOptions: 24 – 48 V DC/ACA resistance type heater (5 W, 24 V DC) is installed in the actuator in combination with theactuator controls AMExC or ACExC .

Manual operation Manual drive for setting and emergency operation, handwheel does not rotate duringelectric operation.Option: Handwheel lockable

Electrical connection Standard: Ex-plug/socket connector with terminal board (screw type connection)Options: Ex-plug-in terminal connection

Threads for cable glands Standard: Metric threadOptions: Pg thread, NPT thread, G thread

1) Based on 20 °C ambient temperature and at an average load with running torque according to Technical data SA(R)ExC.The type of duty must not be exceeded

2) PTC thermistors require additionally a suitable tripping device in the controls3) According to EN 60079-14 a thermal overload relay (e.g. motor protection switch) must be installed for explosion-proof actuators in addition to the

thermoswitches.

Table 1: Technical data multi-turn actuator SA(R)ExC 07.1 – SA(R)ExC 16.1

6


Terminal plan SAExC: KMS TP 210/001 (basic version)SARExC: KMS TP 200/001 (basic version)

Output drive types A, B1, B2, B3, B4 according to EN ISO 5210A, B, D, E according to DIN 3210C according to DIN 3338Special output drives: AF, AK, AG, IB1, IB3

Service conditionsEnclosure protection according toEN 60 529

Standard: IP 67Option: IP 68For both enclosure protections (IP 67 and IP 68) the terminal compartment ist additionallysealed against the interior - double sealed

Corrosion protection Standard: KN Suitable for installation in industrial units, in water- or power plantswith a low pollutant concentration4)

Options: KS Suitable for installation in occasionally or permanently aggressiveatmosphere with a moderate pollutant concentration (e.g. inwastewater treatment plants, chemical industry)

KX Suitable for installation in extremely aggressive atmosphere withhigh humidity and high pollutant concentration

KX-G same as KX, however aluminium-free version (outer parts)Finish coating Standard: two-component iron-mica combinationStandard colour Standard: silver-grey (DB 701, similar to RAL 9007)

Option: Other colours are possible on requestAmbient temperature5) Standard: – 20 °C to + 40 °C

Optionen: – 40 °C to + 40 °C (low temperature)– 50 °C to + 40 °C (extreme low temperature)

Vibration resistance6)

according to EN 60068-2-62 g, from 10 Hz to 200 Hz (without controls)

Lifetime

Other informationEC directives ATEX directive: (94/9/EC)

Electromagnetic Compatibility (EMC): (89/336/EEC)Low Voltage Directive: (73/23/EEC)Machinery Directive: (98/37/EC)

Reference documents Product description “Electric multi-turn actuators SA/SAR”Information “Electric actuators and valve gearboxes according to ATEX”Dimension sheets SA(R)ExCElectrical data sheets SA(R)ExCTechnical data SAExC

4) If occasionally or permanently exposed to aggressive substances, we recommend a higher corrosion protection KS or KX.5) Under certain conditions (special sizing) up to + 60 °C possible6) For standard version with Ex-plug/socket connector with terminal board

Type Operating cycles (OPEN-CLOSE-OPEN)with 30 turns per stroke

SAExC 07.1 – SAExC 10.1 20,000SAExC 14.1 – SAExC 16.1 15,000SAExC 25.1 – SAExC 30.1 10,000SAExC 35.1 – SAExC 48.1 5,000

Typ Starts inmillions

Number of starts based on S4 - 25 %, for anexpected lifetime of a minimum of operation hours

min. 5,000 h 10,000 h 20,000 hSARExC 07.1 – SARExC 10.1 5.0 1,000 500 250SARExC 14.1 – SARExC 14.5 3.5 700 350 175SARExC 16.1 3.5 600 300 150

4. Transport and storage .Transport to place of installation in sturdy packing..Do not attach ropes or hooks to the handwheel for the purpose of lifting byhoist.. If multi-turn actuator is mounted on valve, attach ropes or hooks for thepurpose of lifting by hoist to valve and not to multi-turn actuator..Store in well-ventilated, dry room..Protect against floor dampness by storage on a shelf or on a woodenpallet..Cover to protect against dust and dirt..Apply suitable corrosion protection agent to bright surfaces.

If multi-turn actuators are to be stored for a long time (more than 6 months),the following points must be observed additionally:.Prior to storage: Protect bright surfaces, in particular the output drive parts

and mounting surface, with long-term corrosion protection agent..Check for corrosion approximately every 6 months. If first signs of corro-sion show, apply new corrosion protection.

After mounting, connect actuator immediately to electricalsystem, so that condensation is prevented by the heater.

5. Packaging Our products are protected by special packaging for the transport ex works.The packaging consists of environmentally friendly materials which caneasily be separated and recycled.For the disposal of the packaging material we recommend recycling andcollection centres.We use the following packaging materials: wood, cardboard, paper and PEfoil.

7


6. Mounting to valve/ gearbox .Prior to mounting the multi-turn actuator must be checkedfor damage. Damaged parts must be replaced by originalspare parts..After mounting to valve/ gearbox, touch up any possibledamage to paint finish.. Increased temperatures at the valve flange or valve stem:If temperatures > 40 °C are to be expected at the valve mount-ing flange or the valve stem (e.g. due to hot media), pleaseconsult AUMA. Temperatures > 40 °C are not considered withregards to the non-electrical explosion protection.

Mounting is most easily done with the valve shaft/gearbox shaft pointingvertically upward. But mounting can be done in any other position as well.The multi-turn actuator leaves the factory in position CLOSED (limit switchCLOSED tripped)..Check if mounting flange fits the valve/ gearbox.

Spigot at flanges should be loose fit!

The output drive types B1, B2, B3 or B4 (figure A) are delivered with boreand keyway (usually according to ISO 5210).

For output drive type A (figure B-1), the internal thread of the stem nut mustmatch the thread of the valve stem. If not ordered explicitly with thread, thestem nut is unbored or with pilot bore when delivered. For finish machiningof stem nut refer to next page..Check whether bore and keyway match the input shaft of valve/gearbox..Thoroughly degrease mounting faces at multi-turn actuator and valve/

gearbox..Apply a small quantity of grease to input shaft of valve/gearbox..Place actuator on valve/ gearbox and fasten. Fasten bolts (at least quality8.8, refer to table 2) evenly crosswise.

8


Figure AOutput drive type B1/B2

Plug sleeveOutput drive type B3/B4

Bore with keyway

Strength class 8.8 TA (Nm)M 8 25M 10 50M 12 87M 16 220

Table 2: Fastening torque for bolts

Finish machining of stem nut (output drive type A):

The output drive flange does not have to be removed from the actuator..Remove spigot ring (80.2, figure B-1) from mounting flange..Take off stem nut (80.3) together with thrust bearing (80.01) and thrustbearing races (80.02)..Remove thrust bearing and thrust bearing races from stem nut..Drill and bore stem nut and cut thread.When fixing in the chuck, make sure stem nut runs true!.Clean the machined stem nut..Apply ball bearing grease to thrust bearing and races, then place them onstem nut..Re-insert stem nut with thrust bearings into the mounting flange. Ensurethat dogs are placed correctly in the slots of the hollow shaft..Screw in spigot ring until it is firm against the shoulder..Press Lithium soap EP multi-purpose grease on mineral oil base, quanti-ties see table, into the grease nipple with a grease gun:

Protection tube for rising valve stem.Protection tubes may be supplied loose. Seal thread with hemp, Teflontape or thread sealing material..Screw protection tube (1) into thread (figure B-2) and tighten it firmly..For corrosion protection KS/ KX, push down the seal (2) to the housing..Check, whether cap (3) is available and without damage.

9


Figure B-1

80.3

80.2

Output drive type AStem nut

80.01/ 80.02

Figure B-2: Protection tube for rising valve stem

3

1

2

Outputdrive

A 07.2 A 10.2 A 14.2 A 16.2 A 25.2 A 30.2 A 35.2 A 40.2 A 48.2

Qty1) 1.5 g 2 g 3 g 5 g 10 g 14 g 20 g 25 g 30 g1) For grease with a density ρ = 0.9 kg/dm³

Table 3: Grease quantities for output drive A

7. Manual operation The actuator may be operated manually for purposes of setting andcommissioning, and in case of motor failure or power failure.Manual operation is engaged by an internal change-over mechanism.

Engaging manual operation: .Lift change-over lever in the centre of the handwheel up to approx. 85°,while slightly turning the handwheel back and forth until manual driveengages (figure C).

Manual force is sufficient for operating the change-overlever. It is not necessary to use an extension. Excessiveforce may damage the change-over mechanism.

.Release change-over lever (should snap back into initial position by springaction, figure D), if necessary push it back manually.

Operating the change-over lever while the motor is running(figure E) can lead to increased wear at the change-overmechanism.

.Turn handwheel into desired direction (figure F).

Disengaging manual operation: Manual operation is automatically disengaged when motor is started again.The handwheel does not rotate during motor operation.

10


Figure DFigure C

Figure E Figure F

8. Electrical connection When working in potentially explosive areas, observe theEuropean Standards EN 60079-14 “Electrical Installations inHazardous Areas” and EN 60079-17 “Inspection and Mainte-nance of Electrical Installations in Hazardous Areas”.Work on the electrical system or equipment must only becarried out by a skilled electrician himself or by speciallyinstructed personnel under the control and supervision ofsuch an electrician and in accordance with the applicableelectrical engineering rules.

8.1 Ex-plug/socket connector with terminal board

For the Ex-plug/socket connector (figure G-1), the electrical mains connec-tion is made after removing the plug cover (50.0) at the EEx e terminals ofthe terminal board (51.0). The flameproof compartment (type of protectionEEx d) remains hereby closed..Check whether type of current, supply voltage and frequency correspond

to motor data (refer to name plate at motor)..Loosen bolts (50.01) (figure G-1) and remove plug cover.. Insert cable glands with “EEx e” approval and of size suit-able for connecting cables..Enclosure protection IP 67 or IP 68 is only ensured if suit-able cable glands are used..Seal cable entries which are not used with suitable plugs.

.Remove cable sheathing in a length of 120 –140 mm.Strip wires: Controls max. 8 mm, motor max. 12 mm.For stranded wires use end-sleeves according to DIN 46228..2 wires for each connection permitted..Connect cables according to order related terminal plan KMS TP . . .The terminal plan applicable to the actuator KMS TP . . . is attached tothe handwheel in a weather-proof bag, together with the operation instruc-tions. In case the terminal plan is not available, it can be obtained fromAUMA (state commission no., refer to name plate) or downloaded directlyfrom the Internet (www.auma.com).

If the actuator must be taken from the valve, e.g. for service purposes, it canbe separated from the mains without having to remove the wiring(figure G-2). For that the screws (51.02) are removed and the plug/ socketconnector is pulled off. Plug cover (50.0) and terminal board (51.0) remaintogether.

Flameproof enclosure! Before opening, ensure that there isno explosive gas and no voltage.

A special parking frame (figure G-3) for protection against touching the barecontacts and against environmental influences is available.

11


Figure G-1: Connection

50.0

50.01

51.0

Figure G-2: Disconnection from themains

50.0

51.0

51.02

Figure G-3: Parking frame(accessory)

Parking frame

8.2 Ex-plug-in terminal connection

The electrical connection to the mains is on terminals (figure G-4). Theterminal compartment is designed for explosion protection “EEx e”(increased safety). The separation between the terminal compartment(increased safety) and the switch compartment (flameproof enclosure) isrealised via a flameproof line bushing with integral plug/ socket connector..Check whether type of current, supply voltage and frequency correspond

to motor data (refer to name plate at motor)..Loosen bolts (51.01) (figure G-4) and remove terminal cover (50.1).. Insert cable glands with “EEx e” approval and of size suit-able for connecting cables..Enclosure protection IP 67 or IP 68 is only ensured if suit-able cable glands are used..Seal cable entries which are not used with suitable plugs.

.Connect cables according to order related terminal plan KMS TP . . . ..The terminal plan applicable to the actuator KMS TP . . . is attached to thehandwheel in a weather-proof bag, together with the operation instruc-tions. In case the terminal plan is not available, it can be obtained fromAUMA (state commission no., refer to name plate) or downloaded directlyfrom the Internet (www.auma.com).

If the actuator must be taken from the valve, e.g. for service purposes, it canbe separated from the mains without removing the wiring (figure G-5). Forthat the screws (51.02) are removed and the frame assly. with the integralplug/ socket connector is pulled off. Terminal cover (50.1) and frame assly.(51.16) remain together.


12


Figure G-4: Connection

50.1

51.16

51.01

Technical data Motor power connections1) Protective earth Control pinsNo. of contacts max. 3 1 (leading contact) 38 pins / sockets

Marking U1, V1, W1 according to VDE 1 to 24, 31 to 40, 47 to 50

Voltage max. 550 V – 250 VCurrent max. 25 A – 10 AType of customer connection Screws Screws ScrewsCross section max. 6 mm2 6 mm2 1.5 mm2

Material: Pin / socket carrier Araldite / Polyamide Araldite / Polyamide Araldite / PolyamideContacts Brass (Ms) Brass (Ms) Brass (Ms) tin-plated1) Suitable for copper wires. For aluminium wires contact AUMA.

Table 4: Technical data Ex-plug/ socket connector with terminal board for explosion-proof actuators

Figure G-5: Disconnection from themains

50.1

51.16 51.02

A special parking frame (figure G-6) for protection against touching the barecontacts and against environmental influences is available.

8.3 Delay time The delay time is the time from the tripping of the limit or torque switches tothe motor power being removed. To protect the valve, we recommend adelay time < 50 ms. Longer delay times are possible provided the outputspeed, output drive type, valve type and the type of installation are takeninto consideration.We recommend to switch off the corresponding contactor directly by the limitor torque switch.

8.4 Heater AUMA multi-turn actuators have a heater installed as standard. To preventcondensation, the heater must be connected.

8.5 Motor protection In order to protect against overheating and impermissibly high temperaturesat the actuator, PTC thermistors or thermoswitches are embedded in themotor winding. The thermoswitch is tripped as soon as the max. permissiblewinding temperature has been reached.

PTC thermistors and PTC tripping device or thermoswitches and thermaloverload relay have to be connected, otherwise the guarantee for the motorwill lapse.

8.6 Remote position transmitter For the connection of remote position transmitters (potentiometer, RWG)screened cables must be used.

13


Technical data Motor power connections1) Protective earth Control terminals

Terminals max. 3 1 48

Marking U1, V1, W1 according to VDE 1 to 48

Voltage max. 750 V – 250 V

Current max. 25 A 16 A

Type of connection Screws Screws Cage clamp2)

Cross section max. 10 mm2 up to SA 16.1 10 mm2 2.5 mm2 flexible, 4 mm2 solid1) Suitable for copper wires. For aluminium wires contact AUMA.2) Optional with screw connections

Table 5: Technical data Ex-plug-in terminal connection for explosion-proof actuators

Figure G-6: Parking frame (accessory)

Parking frame

8.7 Limit and torque switches

Only the same potential can be switched on the two circuits (NC/ NOcontact) of a limit or torque switch. If different potentials are to be switchedsimultaneously, tandem switches are required.For correct signalisation, the leading contacts must be connected at thetandem switch.Use the lagging contacts for switching off.

8.8 Fitting of the cover After connection:.Clean sealing faces at the plug cover or terminal cover and the housing..Check whether O-ring is in good condition..Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces..Preserve joint surfaces with an acid-free corrosion protection agent.

Flameproof enclosure! Handle cover and housing parts withcare. Joint surfaces must not be damaged or soiled in anyway. Do not jam cover during fitting.

.Replace cover (50.0 figure G-1 or 50.1 figure G-4) and fasten 4 boltsevenly crosswise..Fasten cable glands with the specified torque to ensure the requiredenclosure protection.

14


Mechanicallife time = 2 x 106 starts

Type of current Switch rating Imax

30 V 125 V 250 V1-phase AC(ind. load) cos phi = 0.8

5 A 5 A 5 A

DC(resistive load)

2 A 0.5 A 0.4 A

with gold platedcontacts

min. 5 V, max. 50 V

Current min. 4 mA, max. 400 mA

Table 6: Technical data limit and torque switches

RD

BK

RD

BK

BK

2

RD

2

BK

RD

BK

2

RD

2

BK

RD

DSR 1 / DÖL 1WSR 1 / WÖL 1

DSR / DÖLWSR / WÖL

Figure G-7

I Single switch

II Tandem switchNO NCNC NO

9. Opening the switchcompartment

To be able to make the following settings (clause 10. to 16.) the switchcompartment must be opened and, if installed, the indicator disc must beremoved.

These settings are only valid for “clockwise closing”, i.e. driven shaft turnsclockwise to close the valve.

When working in potentially explosive areas, observe theEuropean Standards EN 60079-14 “Electrical Installations inHazardous Areas” and EN 60079-17 “Inspection and Mainte-nance of Electrical Installations in Hazardous Areas”.Work on the electrical system or equipment must only becarried out by a skilled electrician himself or by speciallyinstructed personnel under the control and supervision ofsuch an electrician and in accordance with the applicableelectrical engineering rules.

9.1 Removal of the switch compartment cover


.Remove 4 bolts and take off the cover at the switch compartment(figure H) .

9.2 Pulling off the indicator disc (option). If installed, pull off indicator disc (figure J). Open end spanner (approx.14 mm) may be used as lever.

15


DSR

WDR

Figure J: Pulling off the indicator disc

Indicator disc

Figure H-1: Cover with indicator glass Figure H-2: Cover without indicator glass

Bolts

10. Setting of the limit switching

10.1 Setting for end position CLOSED (black section).Turn handwheel clockwise until valve is closed..After having reached the end position, turn back handwheel approximately1/2 a turn (overrun). During test run (page 17) check overrun and, ifnecessary, correct setting of the limit switching..Press down and turn setting spindle A (figure K-1) with screw driver(5 mm) in direction of arrow, thereby observe pointer B.While a ratchet is felt and heard, the pointer B moves 90° every time.When pointer B is 90° from mark C, continue turning slowly. When pointerB has reached the mark C, stop turning and release setting spindle. If youoverride the tripping point inadvertently (ratchet is heard after the pointerhas snapped), continue turning the setting spindle in the same directionand repeat setting process.

10.2 Setting for end position OPEN (white section).Turn handwheel counterclockwise until valve is open, then turn backapproximately 1/2 a turn..Press down and turn setting spindle D (figure K-1) with screw driver(5 mm) in direction of arrow, thereby observe pointer E.While a ratchet is felt and heard, the pointer E moves 90° every time.When pointer E is 90° from mark F, continue turning slowly. When pointerE has reached the mark F, stop turning and release setting spindle. If youoverride the tripping point inadvertently (ratchet is heard after the pointerhas snapped), continue turning the setting spindle in the same directionand repeat setting process.

10.3 Checking the switches The red test buttons T and P (figure K-1) serve for operating the limitswitches manually..Turning T in direction of the arrow LSC (WSR) triggers limit switch

CLOSED..Turning P in direction of the arrow LSO (WÖL) triggers limit switch OPEN.

16


Figure K-1: Control unit

A

T

B

C

D

P

E

F

11. Setting of the DUO limit switching (option)

Any application can be switched on or off via the two intermediate positionswitches.

For setting, the switching point (intermediate position) mustbe approached from the same direction as afterwards inelectrical operation.

11.1 Setting for direction CLOSE (black section).Move valve to desired intermediate position..Press down and turn setting spindle G (figure K-2) with screw driver(5 mm) in direction of arrow, thereby observe pointer H.While a ratchet is felt and heard, the pointer H moves 90° every time.When pointer H is 90° from mark C, continue turning slowly. When pointerH has reached the mark C, stop turning and release setting spindle. If youoverride the tripping point inadvertently (ratchet is heard after the pointerhas snapped), continue turning the setting spindle in the same directionand repeat setting process.

11.2 Setting for direction OPEN (white section).Move valve to desired intermediate position..Press down and turn setting spindle K (figure K-2) with screw driver(5 mm) in direction of arrow, thereby observe pointer L.While a ratchet is felt and heard, the pointer L moves 90° every time.When pointer L is 90° from mark F, continue turning slowly. When pointerL has reached the mark F, stop turning and release setting spindle. If youoverride the tripping point inadvertently (ratchet is heard after the pointerhas snapped), continue turning the setting spindle in the same directionand repeat setting process.

17


Figure K-2: Control unit

G

T

H

C

K

P

L

F

12. Setting of the torque switching

12.1 Programming .The set torque must suit the valve!.This setting should only be changed with the consent ofthe valve manufacturer!

.Loosen both lock screws O at the torque dial (figure L)..Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm).Example:Figure J shows the following setting:3.5 da Nm = 35 Nm for direction CLOSE4.5 da Nm = 45 Nm for direction OPEN.Tighten lock screws O again.The torque switches can also be operated in manual

operation..The torque switching acts as overload protection over fulltravel, also when stopping in the end positions by limitswitching.

12.2 Checking the switches for torque and DUO limit switching

The red test buttons T and P (figure K-2) serve for operating the torqueswitches manually:.Turning T in direction of the arrow TSC (DSR) triggers torque switch

CLOSED..Turning P in direction of the arrow TSO (DÖL) triggers torque switchOPEN.. If a DUO limit switching (optional) is installed in the actuator, the interme-diate position switches will be operated at the same time.

18


Figure L: Torque switching headsSetting CLOSED Setting OPEN

O OP P

13. Test run Work at the open actuator under voltage must only beperformed if it is assured that for the duration of the workthere is no danger of explosion.

13.1 Check direction of rotation: . If provided, place indicator disc on shaft.The direction of rotation of the indicator disc (figure M-1) indicates thedirection of rotation of the output drive.. If there is no indicator disc, the direction of rotation can also be observedon the hollow shaft. To this end, remove screw plug (no. 27) (figure M-2).

.Move actuator manually to intermediate position or to sufficient distancefrom end position..Switch on actuator in direction CLOSE and observe the direction of rotation:

If the direction of rotation is wrong switch off immediatelyCorrect phase sequence at motor connection. Repeat test run.

13.2 Check limit switching: .Move actuator manually into both end positions of the valve..Check whether limit switching is set correctly. Hereby observe that theappropriate switch is tripped in each end position and released again afterthe direction of rotation is changed. If this is not the case, the limitswitching must first be set, as described from page 15.

If no other options (clauses 14. to 16.) require setting:.Close switch compartment (see page 24, clause 17.).

19


Figure M-1: Indicator disc

CLOSED OPENFigure M-2: Opening the hollow shaft

27

S1/S2

Direction of rotation of the indicator disc:counterclockwise correctDirection of rotation of the hollow shaft:clockwise correct

Table 7:

14. Setting of the potentiometer (option)

– For remote indication –.Move valve to end position CLOSED.. If installed, pull off indicator disc..Turn potentiometer (E2) clockwise until stop is felt.End position CLOSED corresponds to 0 %, end position OPEN to 100 %..Turn potentiometer (E2) back a little.

Due to the ratio of the reduction gearings for the positiontransmitter the complete resistance range is not alwaysutilized for the whole travel. Therefore an external possibilityfor adjustment (setting potentiometer) must be provided.

.Perform fine-tuning of the zero point at external setting potentiometer (forremote indication).

20


Figure N: Control unit

E2

15. Setting of electronic position transmitter RWG (option)

– For remote indication or external control –

After mounting the multi-turn actuator to the valve, check setting bymeasuring the output current (see subclause 15.1 or 15.2) and re-adjust, ifnecessary.

The position transmitter board (figure P-1) is located under the cover plate(figure P-2).

21


Terminal plans KMS TP_ _ 4 / _ _ _

for 3- or 4- wire system

KMS TP _ 4 _ / _ _ _KMS TP _ 5 _ / _ _ _

for 2-wire systemOutput current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA

Voltage supply Uv24 V DC, ±15 %

smoothed14 V DC + (I x RB),

max. 30 V

Max. input currentI 24 mA at 20 mA

output current20 mA

Max. load RB 600 Ω (Uv - 14 V) / 20 mA

Table 8: Technical data RWG 4020

Figure P-1: Position transmitter board

15.1 Setting for 2-wire system 4 – 20 mA and 3- /4-wire system 0 – 20 mA.Connect voltage for electronic position transmitter..Move valve to end position CLOSED.. If installed, pull off indicator disc..Connect ammeter for 0 – 20 mA to measuring points (figure P-2).

The circuit (external load) must be connected (max. loadRB), or the appropriate poles at the terminals (refer toterminal plan) must be linked, otherwise no value can bemeasured.

.Turn potentiometer (E2) clockwise until stop is felt..Turn potentiometer (E2) back a little.

.Turn potentiometer “0” clockwise until output current starts to increase..Turn potentiometer “0” back until the following value is reached:for 3- or 4-wire system: approx. 0.1 mAfor 2-wire system: approx. 4.1 mA.This ensures that the signal remains above the dead and live zero point..Move valve to end position OPEN..Set potentiometer “max.” to end value 20 mA..Approach end position CLOSED anew and check minimum value (0.1 mAor 4.1 mA). If necessary, correct the setting.

If the maximum value can not be reached, the selection ofthe reduction gearing must be checked.

22


Figure P-2 “0” (0/4 mA) “max.” (20 mA)

Measuring point(+)0/4 – 20 mA

Measuring point(–)0/4 – 20 mA

Cover plate

E2

15.2 Setting for 3- / 4- wire system 4 – 20 mA.Connect voltage for electronic position transmitter..Move valve to end position CLOSED.. If installed, pull off indicator disc..Connect ammeter for 0 – 20 mA to measuring points (figure P-2).

The circuit (external load) must be connected (max. loadRB), or the appropriate poles at the terminals (refer toterminal plan) must be linked, otherwise no value can bemeasured.

.Turn potentiometer (E2) clockwise until stop is felt..Turn potentiometer (E2) back a little.

.Turn potentiometer “0” clockwise until output current starts to increase..Turn back potentiometer “0” until a residual current of approx. 0.1 mA isreached..Move valve to end position OPEN..Set potentiometer “max.” to end value 16 mA..Move valve to end position CLOSED..Set potentiometer “0” from 0.1 mA to initial value 4 mA.This results in a simultaneous shift of the end value by 4 mA, so that therange is now 4 – 20 mA..Approach both end positions anew and check setting. If necessary, correctthe setting.

If the maximum value can not be reached, the selection ofthe reduction gearing must be checked.

23


Figure P-2

Cover plate

Measuring point(+)0/4 – 20 mA

“0” (0/4 mA) “max.” (20 mA)

E2

Measuring point(–)0/4 mA – 20 mA

16. Setting of the mechanical position indicator (option)

.Place indicator disc on shaft..Move valve to end position CLOSED..Turn lower indicator disc (figure Q1) until symbol CLOSED is in align-ment with the mark on the cover (figure Q-2)..Move actuator to end position OPEN..Hold lower indicator disc CLOSED in position and turn upper disc withsymbol OPEN until it is in alignment with the mark on the cover.

Indicator disc rotates approximately 180° to 230° at full travel from OPEN toCLOSED or vice versa. A suitable reduction gearing was installed in ourworks.If the turns per stroke are changed at a later date, the reduction gearingmay have to be exchanged, too.

17. Closing the switch compartment

.Clean sealing faces of housing and cover.Check whether O-ring is in good condition..Apply a thin film of non-acidic grease to the sealing faces..Preserve joint surfaces with an acid-free corrosion protection agent.

Flameproof enclosure! Handle cover and housing parts withcare. Joint surfaces must not be damaged or soiled in anyway. Do not jam cover during fitting.

.Replace cover on switch compartment and fasten bolts evenly crosswise.

Touch up possible defects to paint finish after commis-sioning.

24


Figure Q-1:

Indicator disc

Figure Q-2:

Mark

18. Maintenance For any maintenance work, the following should be observed:

.Regular inspection and maintenance (in 3 year intervals)performed by qualified and trained personnel according tothe European standard EN 60079-17 “Inspection and Main-tenance of Electrical Installations in Hazardous Areas” isrequired..When working in potentially explosive areas, observe thestandard EN 60079-17 “Inspection and Maintenance ofElectrical Installations in Hazardous Areas”..Work at the open actuator under voltage must only be per-formed if it is assured that for the duration of the workthere is no danger of explosion..Pay attention to national regulations.

.Check actuator visually. Ensure that no outside damage or changes arevisible.The electric connecting cables must be without damage and wiredcorrectly.Do a thorough touch-up of possible damage to paint finish to preventcorrosion. Original paint in small quantities can be supplied by AUMA..Cable entries, cable glands, plugs etc. have to be checked for correcttightness and sealing. Observe torques according to manufacturer’sdetails. If required, replace the components. Only use components whichhave a test certificate..Check whether Ex-connections are fastened correctly..Take care of possible discolouration of the terminals and wires. This wouldindicate an increased temperature..For Ex housings, take care especially of a possible collection of water.This may originate from ‘breathing’ due to severe temperature variations(e. g. change of night and day), from damaged seals etc. Remove anywater immediately..Check the flame path gaps of flameproof enclosures for dirt and corro-sion.Since the dimensions of all flameproof joints are strictly defined andinspected, no mechanical work (such as grinding) shall be performed onthem. The joint surfaces have to be cleaned chemically (e. g. withEsso-Varsol)..Before fitting, the joint surfaces have to be preserved with an acid-freecorrosion protection agent (e. g. Esso Rust BAN 397)..Ensure that all housing covers are handled carefully and that the seals arechecked..All cable and motor protection components have to be checked.. If defects which affect the safety are detected during maintenance, repairmeasures have to be initiated without delay..Any kind of surface coating for the joint surfaces is not permitted..When exchanging parts, seals etc. only original spare parts shall be used..Flameproof enclosure! Before opening, ensure that there

is no explosive gas and no voltage..Flameproof enclosure! Handle cover and housing partswith care. Joint surfaces must not be damaged or soiled inany way. Housing parts and joint surfaces in particularmust not be processed mechanically. Do not jam coverduring fitting.

25


We recommend additionally:. If operated seldom, perform a test run about every 6 months. This ensuresthat the actuator is always ready to operate..Approximately six months after commissioning and then every year checkbolts between actuator and valve/gearbox for tightness. If required, tightenapplying the torques given in table 2, page 8..For multi-turn actuators with output drive type A: at intervals of approx.6 months from commissioning press in Lithium soap EP multi-purposegrease on mineral oil base at the grease nipple with grease gun (quantitysee table 3, page 9).

19. Lubrication .The gear housing is filled with lubricant in the factory..A grease change is recommended after the following operation time:. If operated seldom after 10 – 12 years. If operated frequently after 6 – 8 years

Lubrication of the valve stem must be done separately.

20. Disposal and recyclingAUMA actuators have an extremely long lifetime. However, there will come atime when you have to replace them.The actuators have a modular design and may therefore easily be disas-sembled, separated and sorted according to materials, i.e.:.electronic scrap.various metals.plastics.greases and oils

The following generally applies:.Collect greases and oils during disassembly. As a rule, these substancesare hazardous to water and must not be released into the environment..See disassembled material to a sound disposal or to separate recyclingaccording to materials..Observe the national regulations for waste disposal.

21. Service AUMA offers extensive services such as maintenance and inspection foractuators. Addresses of AUMA offices and representatives can be found onpage 36 and on the Internet (www.auma.com).

26


Notes

27


22. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with plug/ socket connector

28


152.

2

152.

1

80.0

5.37

DB

3/ B

4/ E

9.0

10.0

S2

90.0

85.0

30.0

14

012

90.0

01

90.0

01

85.0

01

85.0

01

S2

153.

5

153.

3

155.

0

153.

1

153.

2

153.

0

SA

ExC

07.1

SA

ExC

10.1

–S

AR

ExC

07.1

SA

RE

xC10

.1–

SA

ExC

14.1

–S

AE

xC16

.1S

AR

ExC

14.1

SA

RE

xC16

.1–

70.0

79.0

-279

.0-3 58

.0 52.3

S2

S2

S2

79.0

-1

20.0

49.0

70.1

S1

/ S2 59

.0

156.

0

105.

0S

1/ S

2

24.0

/ 23.

0

106.

0

61.0

60.0

15.0

5.0

27 S1

/ S2

S1

/ S2 39

020

019

25.0

24S

2 17.0

19.0

5.7

5.12

151.

0

160.

1

160.

2

S2

56.0

57.0

52.0

3.0

107

100

053

18

22.0

S2

1.0

6

80.0

01

80.0

01

80.3

5.8

5.32

B1

/ CA

2.0

S2

S2

S2

51.2

51.1

51.0

S1

/ S2

50.0

S1

/ S2

51.3

51.4

Sam

ple

nam

epl

ate

-A

ctua

tor

type

-C

omm

issi

onnu

mbe

r-

Wor

ksnu

mbe

r-

Pro

tect

ion

type

Torq

uera

nge

inC

LOS

E/O

PE

N-

Lubr

ican

t-

Tem

pera

ture

rang

e

29


Note:When placing orders for spare parts, it is essential to mention type of actuator and our commission number(refer to actuator name plate).

1) SAExC 16.1 with output speeds of 32 to 180 rpm or SARExC 16.1 with output speeds of 32 and 45 rpm withoutplug/ socket connector; motor directly wired to pin carrier (No. 52.0).

2) only required for some output speeds3) not included in basic equipment

No. Type Designation

012 E Notched pin

019 E Cheese head screw

020 E Clamping washer

053 E Countersunk screw

1.0 B Housing assly.

2.0 B Flange, bottom assly.

3.0 B Hollow shaft assly. (without worm wheel)

5.0 B Worm shaft assly.

5.12 E Grub screw

5.32 E Coupling pin

5.37 B Pull rod assly.

5.7 E Motor coupling

5.8 B Manual drive coupling assly.

6 E Worm wheel

9.0 B Planetary gear for manual drive assly.

10.0 B Retaining flange assly.

14 E Change-over lever

15.0 B Cover for switch compartment assly.

17.0 B Torque lever assly.

18 E Gear segment

19.0 B Crown wheel assly.

20.0 B Swing lever assly.

22.0 B Drive pinion II for torque switching assly.

23.0 B Drive wheel for limit switching assly.

24 E Drive wheel for limit switching

24.0 B Intermediate wheel for limit switching assly.

25.0 E Locking plate

27 E Screw plug

30.0 B Handwheel with ball handle assly.

39 E Screw plug

49.0 1) B Motor plug, socket assly.

50.0 B Cover assly.

51.0 B Terminal board assly.

51.1 E Screw - Control terminal

51.2 E Washer - Control terminal

51.3 E Screw - Power terminal

51.4 E Washer - Power terminal

52.0 B Pin carrier (without pins)

52.3 E Circlip

56.0 B Pin for control

57.0 B Pin for motor

Type B = sub-assembly Type E = component


58.0 B Wire for protective earth

59.0 1) BPin for motor and thermoswitchin motor plug

60.0 BControl unit assly. (but without torque head,without switches)

61.0 B Torque switching head

70.0 B Motor

70.1 1) BMotor pin carrier(without pins)

79.0-1 2) B Planetary gearing for motor drive assly.


79.0-3 2) B Ex-motor mounting flange

80.0 3) BOutput drive Form A assly.(without thread in stem nut)

80.0013) E Thrust bearing set

80.3 3) E Stem nut Form A (without thread)

85.0 3) B Output drive B3

85.0013) E Snap ring

90.0 3) B Output drive D


100 BSwitch for limit / torque switching(including pins at wires)

105.0 BBlinker transmitter including pins at wires(without impulse disc and insulation plate)

106.0 B Stud bolt for switches

107 E Spacer

151.0 B Space heater

152.1 3) B Potentiometer (without slip clutch)

152.2 3) B Slip clutch for potentiometer

153.0 3) B RWG assly.

153.1 3) BPotentiometer for RWG(without slip clutch)

153.2 3) B Slip clutch for RWG

153.3 3) B Electronic board RWG

153.5 3) B Wires for RWG

155.0 3) B Reduction gearing

156.0 3) B Mechanical position indicator

160.1 3) E Protection tube (without cap)

160.2 3) E Cap for stem protection tube

S1 S Seal-kit, small

S2 S Seal-kit, large

Type S = set assly. = assly.

23. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with terminal connection

30


20.0

49.0

70.1

70.0

S1

/ S2

5.0

9.0

80.0

90.0

2.0

S2

S2

3.0

27 S1

/ S2 S

1/ S

2

39

59.0

156.

0

106.

0

105.

0

107

100

61.0

60.0

15.0

S1

/ S2

053

18

22.0

24.0

/ 23.

002

001

925

.0

24S

2

S2

17.0

19.0

51.1

6

50.0

2050

.023

1.0

5.37

6

80.0

01

80.0

01

80.3

S2

90.0

01

90.0

01

5.7

5.12

5.8

160.

1

S2

5.32

S1

/ S2

50.1

50.0

16

50.0

2150

.024

S1

/ S2

50.2

54.0

160.

2

56.0

57.0

52.0S2

54.2

54.2

153.

5

153.

3

153.

1

153.

2

152.

2

152.

115

1.0

79.0

-279

.0-3

S2

S2

S2

79.0

-1

10.0

S2

S2

SA

ExC

14.1

–S

AE

xC16

.1S

AR

ExC

14.1

–S

AR

ExC

16.1

SA

ExC

07.1

–S

AE

xC10

.1S

AR

ExC

07.1

–S

AR

ExC

10.1

B1

/ CA

DB

3/ B

4/ E

85.0

85.0

01

85.0

01

153.

015

5.0

30.0

14012

-A

ctua

tor

type

-C

omm

issi

onnu

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r-

Wor

ksnu

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N-

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ican

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Sam

ple

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ate

31


Note:When placing orders for spare parts, it is essential to mention type of actuator and our commission number(refer to actuator name plate)

1) SAExC 16.1 with output speeds of 32 to 180 rpm or SARExC 16.1 with output speeds of 32 and 45 rpm withoutplug/ socket connector; motor directly wired to pin carrier (No. 52.0).

2) only required for some output speeds3) not included in basic equipment


012 E Notched pin

019 E Cheese head screw

020 E Clamping washer

053 E Countersunk screw

1.0 B Housing assly.

2.0 B Flange, bottom assly.3.0 B Hollow shaft assly. (without worm wheel))5.0 B Worm shaft assly.

5.12 E Grub screw5.32 E Coupling pin5.37 B Pull rod assly.5.7 E Motor coupling5.8 B Manual drive coupling assly.6 E Worm wheel

9.0 B Planetary gear for manual drive assly.

10.0 B Retaining flange assly.

14 E Change-over lever

15.0 B Cover for switch compartment assly.

17.0 B Torque lever assly.

18 E Gear segment

19.0 B Crown wheel assly.

20.0 B Swing lever assly.

22.0 B Drive pinion II for torque switching assly.

23.0 B Drive wheel for limit switching assly.

24 E Drive wheel for limit switching

24.0 B Intermediate wheel for limit switching assly.

25.0 E Locking plate

27 E Screw plug

30.0 B Handwheel with ball handle assly.

39 E Screw plug49.0 1) B Motor plug, socket assly.50.016 E End piece

50.020 E Terminal for controls

50.021 E Terminal for motor

50.023 E Terminal cover for controls

50.024 E Terminal cover for motor

50.1 B Cover assly.

50.2 BTerminal carrier-frame assly.(without terminals)

51.16 B Frame extension assly.

52.0 B Pin carrier (without pins)

54.0-1 B Cable conduit assly. (cust. connection)54.2 E Circlip

Type B = sub-assembly Type E = component


56.0 B Pin for controls

57.0 B Pin for motor

59.0 1) BPin for motor and thermoswitchin motor plug

60.0 BControl unit assly. (but without torque head,without switches)

61.0 B Torque switching head70.0 B Motor

70.1 1) BMotor pin carrier(without pins)


79.0-2 2) B Planetary gearing for motor drive assly. (SA 16.1)79.0-3 2) B Ex-motor mounting flange

80.0 3) BOutput drive form A assly.(without thread in stem nut)

80.0013) E Thrust bearing set

80.3 3) E Stem nut Form A (without thread)

85.0 3) B Output drive B3


90.0 3) B Output drive D


100 BSwitch for limit / torque switching(including pins at wires)

105.0 3) BBlinker transmitter including pins at wires(without impulse disc and insulation plate)

106.0 B Stud bolt for switches

107 E Spacer

151.0 B Space heater

152.1 3) B Potentiometer (without slip clutch)

152.2 3) B Slip clutch for potentiometer153.0 3) B RWG assly.

153.1 3) BPotentiometer for RWG(without slip clutch)

153.2 3) B Slip clutch for RWG

153.3 3) B Electronic board RWG

153.5 3) B Wires for RWG

155.0 3) B Reduction gearing

156.0 3) B Mechanical position indicator160.1 3) E Protection tube (without cap)160.2 3) E Cap for stem protection tube

S1 S Seal-kit, smallS2 S Seal-kit, large

Type S = set assly. = assly.

24. PTB certificate

32


33


25. Declaration of Conformity and Declaration of Incorporation

34


35


IndexCCorrosion protection 7

DDeclaration of Conformity 34Declaration of Incorporation 34DUO limit switching 17

EElectrical connection 11Electronic position transmitterRWG 21

2-wire system 223-/ 4-wire system 23

FFinish machining of stem nut 9

HHandwheel 10Heater 13

IIndicator disc 24Internet 35

LLimit switches 14Limit switching 16,17Lubrication 26

MMaintenance 4Manual operation 10Mechanical position indicator 24Motor protection 13Mounting to valve/ gearbox 8

NName plate 28

OOutput drive types 8

PParking frame 11Position indicator 24Position transmitter RWG 21Potentiometer 20Protection tube 9PTB certificate 32PTC thermistors 13

RRemote indication 20,21

SSafety instructions 4Service 26Spare parts list 28

Actuator 28Spare parts list SA(R)ExC withterminal connection 31Storage 7

TTandem switch 14Technical data 5Test run 19Thermoswitches 13Torque setting 18Transport 7Tripping torque 18

Information also availableon the Internet:

Terminal plan, inspection records and further actuator informationcan be downloaded directly from the internet by entering the order no.or comm no. (refer to name plate).Our homepage: http://www.auma.com

Certificate Registration No.12 100/104 4269

AUMA Riester GmbH & Co. KGP. O. Box 1362D - 79373 Mü[email protected]

+49 (0)7631/809-0+49 (0)7631/809 250

+49 (0)711 / 34803 0+49 (0)711 / 34803 34

AUMA Riester GmbH & Co. KGP. O. Box 1151D - 73747 [email protected]

For detailed information about AUMA products refer to the Internet:

www.auma.com Y002.775/003/en/1.05

EuropeAUMA Riester GmbH & Co. KGFactory MüllheimDE-79373 MüllheimTel +49 7631 809 - 0Fax +49 7631 809 - [email protected] Ostfildern-NellingenDE-73747 OstfildernTel +49 711 34803 - 3000Fax +49 711 34803 - [email protected] Centre CologneDE-50858 KölnTel +49 2234 20379 - 00Fax +49 2234 20379 - [email protected] Centre MagdeburgDE-39167 NiederndodelebenTel +49 39204 759 - 0Fax +49 39204 759 - [email protected] Centre BavariaDE-85386 EchingTel +49 81 65 9017-0Fax +49 81 65 [email protected] Office, Ship building sectorDE-21079 HamburgTel +49 40 791 40285Fax +49 40 791 [email protected] Office, IndustryDE-29664 WalsrodeTel +49 5167 504Fax +49 5167 [email protected] OfficeDE-39167 NiederndodelebenTel +49 39204 75980Fax +49 39204 [email protected] OfficeDE-45549 SprockhövelTel +49 2339 9212 - 0Fax +49 2339 9212 - [email protected]ürttemberg OfficeDE-73747 OstfildernTel +49 711 34803 80Fax +49 711 34803 [email protected] OfficeDE-74937 SpechbachTel +49 6226 786141Fax +49 6226 [email protected] OfficeDE-76764 RheinzabernTel +49 7272 76 07 - 23Fax +49 7272 76 07 - [email protected] plant sectorDE-79373 MüllheimTel +49 7631 809 192Fax +49 7631 809 [email protected]üro BavariaDE-93356 Teugn/NiederbayernTel +49 9405 9410 24Fax +49 9405 9410 [email protected] Armaturenantriebe GmbHAT-2512 TribuswinkelTel +43 2252 82540Fax +43 2252 [email protected]

AUMA (Schweiz) AGCH-8965 BerikonTel +41 566 400945Fax +41 566 [email protected] Servopohony spol. s.r.o.CZ-10200 Praha 10Tel +420 272 700056Fax +420 272 [email protected] AUMATOR ABFI-02270 EspooTel +35 895 84022Fax +35 895 [email protected] FranceFR-95157 Taverny CédexTel +33 1 39327272Fax +33 1 [email protected] ACTUATORS Ltd.GB- Clevedon North Somerset BS21 6QHTel +44 1275 871141Fax +44 1275 [email protected] ITALIANA S.R.L.IT-20023 Cerro Maggiore MilanoTel +39 0331-51351Fax +39 [email protected] BENELUX B.V.NL-2314 XT LeidenTel +31 71 581 40 40Fax +31 71 581 40 [email protected] Polska Sp. z o.o.PL-41-310 Dabrowa GórniczaTel +48 32 26156 68Fax +48 32 26148 [email protected] Priwody AUMARU-141400 Moscow region for mail:124365 Moscow a/ya 11Tel +7 495 221 64 28Fax +7 495 221 64 [email protected] ARMATUR ABSE-20039 MalmöTel +46 40 311550Fax +46 40 [email protected]ØNBECH & SØNNER A/SDK-2450 København SVTel +45 33 26 63 00Fax +45 33 26 63 [email protected] S.A.ES-28027 MadridTel +34 91 3717130Fax +34 91 [email protected]. G. Bellos & Co. O.E.GR-13671 Acharnai AthensTel +30 210 2409485Fax +30 210 [email protected] SØRUM A. S.NO-1301 SandvikaTel +47 67572600Fax +47 [email protected]

INDUSTRAPT-2710-297 SintraTel +351 2 1910 95 00Fax +351 2 1910 95 [email protected] Endüstri Kontrol Sistemieri Tic. Ltd.Sti.TR-06460 Övecler AnkaraTel +90 312 472 62 70Fax +90 312 472 62 [email protected] Control Limited Liability CompanyUA-02099 KiyivTel +38 044 566-9971, -8427Fax +38 044 [email protected]

AfricaAUMA South Africa (Pty) Ltd.ZA-1560 SpringsTel +27 11 3632880Fax +27 11 [email protected] CairoTel +20 2 3599680 - 3590861Fax +20 2 [email protected]

AmericaAUMA ACTUATORS INC.US-PA 15317 CanonsburgTel +1 724-743-AUMA (2862)Fax +1 [email protected] Chile Respresentative OfficeCL- BuinTel +56 2 821 4108Fax +56 2 281 [email protected] S. A.AR-C1140ABP Buenos AiresTel +54 11 4307 2141Fax +54 11 4307 [email protected] Termoindustrial Ltda.BR-13190-000 Monte Mor/ SP.Tel +55 19 3879 8735Fax +55 19 3879 [email protected] Inc.CA-L4N 5E9 Barrie OntarioTel +1 705 721-8246Fax +1 705 [email protected] Ferrostaal de Colombia Ltda.CO- Bogotá D.C.Tel +57 1 401 1300Fax +57 1 416 5489dorian.hernandez@manferrostaal.comwww.manferrostaal.comPROCONTIC Procesos y Control AutomáticoEC- QuitoTel +593 2 292 0431Fax +593 2 292 [email protected] DE MEXICO S. A. de C. V.MX-C.P. 02900 Mexico D.F.Tel +52 55 55 561 701Fax +52 55 53 563 [email protected] S.A.C.PE- Miralflores - LimaTel 00511444-1200 / 0044 / 2321Fax [email protected] Inc.PR-00936-4153 San JuanTel +18 09 78 77 20 87 85Fax +18 09 78 77 31 72 [email protected]

SuplibarcaVE- Maracaibo Estado, ZuliaTel +58 261 7 555 667Fax +58 261 7 532 [email protected]

AsiaAUMA Actuators (Tianjin) Co., Ltd.CN-300457 Tianjin Teda DistrictTel +86 22 6625 1310Fax +86 22 6625 [email protected] (INDIA) PRIVATE LIMITEDIN-560 058 BangaloreTel +91 80 2839 4655Fax +91 80 2839 [email protected] JAPAN Co., Ltd.JP-210-0848 Kawasaki-ku,Kawasaki-shi KanagawaTel +81 44 329 1061Fax +81 44 366 [email protected] ACTUATORS (Singapore) Pte Ltd.SG-569551 SingaporeTel +65 6 4818750Fax +65 6 [email protected] Middle East Rep. OfficeAE- DubaiTel +971 4 3682720Fax +971 4 [email protected] CONTROLS Ltd.HK- Tsuen Wan, KowloonTel +852 2493 7726Fax +852 2416 [email protected] Controls Co., Ltd.KR-153-803 Seoul KoreaTel +82 2 2113 1100Fax +82 2 2113 1088/[email protected] Eng. Company W. L. L.KW-22004 SalmiyahTel +965 4817448Fax +965 [email protected] Trading EnterprisesQA- DohaTel +974 4433 236Fax +974 4433 [email protected] Valves and Intertrade Corp. Ltd.TH-10120 Yannawa BangkokTel +66 2 2400656Fax +66 2 [email protected]/Top Advance Enterprises Ltd.TW- Jhonghe City Taipei Hsien (235)Tel +886 2 2225 1718Fax +886 2 8228 [email protected]

AustraliaBARRON GJM Pty. Ltd.AU-NSW 1570 ArtarmonTel +61 294361088Fax +61 [email protected]

2006-03-08

Series 3730Electropneumatic PositionerType 3730-3

With HART® communication


EB 8384-3 ENFirmware version 1.4xEdition March 2007

Fig. 1 · Type 3730-3

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 81.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 91.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Attachment to the control valve – Mounting parts and accessories . . . 132.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.1.1 Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . 162.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 182.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 202.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 222.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 242.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 262.5.1 Pressure gauge attachment . . . . . . . . . . . . . . . . . . . . . . 262.6 Attaching an external position sensor . . . . . . . . . . . . . . . . . 282.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 282.6.2 Mounting the position sensor with attachment according to IEC 60534-6 302.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 312.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 322.7 Attaching positioners with stainless steel housings. . . . . . . . . . . . 342.8 Air purging function for single-acting actuators . . . . . . . . . . . . . 34

3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 363.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 363.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 383.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 403.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 40

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424.1 Operator controls and display . . . . . . . . . . . . . . . . . . . . . 424.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 444.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 454.3.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 46

5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 465.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 475.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . 475.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 47

2 EB 8384-3 EN

Contents

5.4 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 485.5 Checking the operating range of the positioner . . . . . . . . . . . . . 485.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.6.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 515.7 Fault/failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575.8 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 595.10 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 595.11 Start-up over HART® communication . . . . . . . . . . . . . . . . . . 59

6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 606.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 606.2 Extended EXPERT+ diagnostics . . . . . . . . . . . . . . . . . . . . . 616.3 Classification of the status alarms and the condensed status . . . . . . . 61

7 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 64

8 Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . 668.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678.3 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688.3.1 Simplest method (MAX) . . . . . . . . . . . . . . . . . . . . . . . . 688.3.2 Precise method (NOM) . . . . . . . . . . . . . . . . . . . . . . . . 688.3.3 Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . 68

9 Upgrading options . . . . . . . . . . . . . . . . . . . . . . . . . . 699.1 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 699.2 Activation of optional EXPERT+ diagnostics . . . . . . . . . . . . . . . 70

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 70

12 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

13 Setting with TROVIS-VIEW software – Parameter list . . . . . . . . . . 8713.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8713.2 Starting TROVIS-VIEW and performing basic settings . . . . . . . . . . 8813.3 Setting the parameters. . . . . . . . . . . . . . . . . . . . . . . . . 9113.4 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

14 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

EB 8384-3 EN 3

Contents

4 EB 8384-3 EN

Safety instructions

General safety instructions

The positioner may only be assembled, started up or operated by trainedand experienced personnel familiar with the product.According to these mounting and operating instructions, trained personnel isreferred to as individuals who are able to judge the work they are assignedto and recognize possible dangers due to their specialized training, theirknowledge and experience as well as their knowledge of the relevantstandards.

Explosion-protected versions of this positioner may only be operated bypersonnel who have undergone special training or instructions or who areauthorized to work on explosion-protected devices in hazardous areas.Refer to section 11 on Servicing explosion-protected versions.

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

If inadmissible motions or forces are produced in the actuator as a result ofthe supply pressure level, it must be restricted by means of a suitable supplypressure reducing station.Do not operate the positioner with the back of the positioner/exhaust airopening facing upwards. The exhaust air opening must not be sealed whenthe positioner is installed on site.


Note! The device with a CE marking fulfils the requirements of the Directives94/9/EC (ATEX) and 89/336/EEC (EMC).The declaration of conformity is available on request.

EB 8384-3 EN 5

Versions

Article code Type 3730-3 X X X X X 0 0 X 0 X 0 0 X 0 X X

Explosion protectionWithout

II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °Cacc. to ATEXCSA/FM intrinsically safe/non incendive

II 3 G EEx na II T6 / II 3 D IP 65 T 80 °Cacc. to ATEX

01

38

Additional equipment

Inductivelimit switch

WithoutWith Type SJ 2-SN

01 0

Solenoid valveSIL 4

Without24 V DC

04

Analogposition transmitter

WithoutWith

01

ExternalPosition sensor

WithoutWith 0

01

Diagnostics EXPERTEXPERT+ (extended)

12

Housing material AluminumStainless steel 1.4581 0

01

Positioner forspecialapplications

Without

Free of substances thatimpair painted surfaces

Exhaust air with ¼ NPTconnection

0

1

2

Special versions Without

IECEx 1

0

0

0

1

0

2

6 EB 8384-3 EN

Firmware modification

Modifications of positioner firmware in comparison to previous versions

Previous New

1.00 1.10

The HART protocol as per HART specification Revision 5 is supported by de-fault setting.The setting can be changed to HART Revision 6 over TROVIS-VIEW. HARTtools as well as AMS or handheld communicators are currently not supportedby the Revision 6 version.

The following additional status indications were implemented:Code 76 - No emergency modeCode 77 - Program loading errorDisplays number of zero calibrations performed since the last initialization.

For initialization of "AIR TO CLOSE" actuators, the direction of action (Code7) is automatically set to increasing/decreasing.

Code 3, the activation period of the enabled configuration function wasextended to 120 s.

1.10 1.20

Electronics changed, no new functions added.

1.20 1.30

New EXPERT+ diagnostics functions (Code 48) addedPositioner in EXPERT+ version with extended diagnostics features.

A running initialization can be canceled by pressing the pushbutton.

The position transmitter (Code 37) and solenoid valve (Code 45) options areautomatically recognized.

1.30 1.40

All EXPERT+ functions can be used over HART® communication in this firm-ware version and higher.

EB 8384-3 EN 7

Firmware modification

The fault alarm contact is triggered by the condensed status of the positioner.It is always active with “Maintenance alarm” condensed status.

If Code 32 is set to Yes: Also active with “Function check” condensed statusIf Code 33 is set to Yes: Also active with “Maintenance required/Mainte-nance demanded” condensed status

The “Function check” condensed status is additionally set for Test A1, A2,fault alarm output and position transmitter.

The min./max. values of the temperature monitoring can be reset.

1.40 1.41

Internal modifications

1.41 1.42

Internal modifications


The electropneumatic positioner is mountedto pneumatic control valves and is used toassign the valve position (controlledvariable x) to the control signal (referencevariable w). The DC control signal receivedfrom a control unit is compared to the travelor rotational angle of the control valve andissues a signal pressure (output variable y).

The positioner is designed depending on thecorresponding accessories for directattachment to Type 3277 Actuators or forattachment to actuators according toIEC 60534-6 (NAMUR).

Additionally, a coupling wheel included inthe accessories is required to transfer the ro-tary motion for rotary actuators according toVDI/VDE 3845.Springless rotary actuators require an ac-cessory reversing amplifier to permit thepowered operation in either direction.

The positioner basically consists of a travelsensor system that functions proportional tothe resistance, an analog i/p module withdownstream booster as well as the electronicunit with a microcontroller.The positioner is fitted with three binary con-tacts as standard: A fault alarm output isused to indicate a fault to the control stationand two configurable software limit switchesto indicate the valve’s end positions.The position of the valve is transmitted aslinear travel motion or angle of rotation viapick-up lever and travel sensor (2) to an an-alog PD controller (3). Simultaneously, anA/D converter (4) transmits the position ofthe valve to the microcontroller (5). The PD

controller compares this actual position tothe 4 to 20 mA DC control signal (referencevariable) after it has been converted by theA/D converter (4).In case of a system deviation, the operationof the i/p converter (6) is changed so thatthe actuator (1) is filled or vented via thedownstream air capacity booster (7). Thiscauses the closure member of the controlvalve to move to the position determined bythe reference variable.The pneumatic air capacity booster (7) andthe pressure regulator (8) are provided withsupply air. An intermediate flow regulator(9) with fixed settings is used to purge thepositioner and also guarantees trouble-freeoperation of the pneumatic booster. The out-put signal pressure supplied by the boostercan be limited over the software.The volume restriction Q (10) is used to opti-mize the positioner by adapting it to the ac-tuator size.

Serial interface

The positioner is equipped with an interfaceto allow the SAMSON TROVIS-VIEW Con-figuration and Operator Interface softwareto transmit data and parameters over anadapter cable from the RS-232 interface ofa computer to the positioner. Refer to sec-tion 13.To detect any valve faults at an early stage,the positioner can optionally be equippedwith EXPERT+ valve diagnostics. You can ac-cess the functions provided by EXPERT+

valve diagnostics over TROVIS-VIEW soft-ware and over the DTM file of the device.Refer to Data Sheet T 8388 EN for more de-tails on EXPERT+ valve diagnostics. Instruc-tions on how to operate the software can befound in Operating Instructions EB 8388 EN.

8 EB 8384-3 EN


1.1 Communication

The positioner is equipped with an interfacefor HART® protocol (Highway AddressableRemote Transducer) for communication pur-poses. Data are transmitted in a superim-posed frequency (FSK = Frequency ShiftKeying) on the existing signal loop for the 4to 20 mA reference variable.

Either a HART capable handheld communi-cator or a PC with FSK modem can be usedto establish communication and operate thepositioner.

1.2 Additional equipment

As an option, the device can be additionallyequipped with a solenoid valve for forcedventing, an analog position transmitter, aninductive limit switch or an external positionsensor.

Version with solenoid valve

If the operating voltage for the solenoidvalve (12) fails, the supply pressure for thei/p module is vented to the atmosphere. Thepositioner can no longer operate and thecontrol valve moves to the fail-safe positiondetermined by the actuator, independent ofthe reference variable.

EB 8384-3 EN 9


Fig. 2 · Functional diagram

1 Control valve2 Travel sensor3 PD controller4 A/D converter5 Microcontroller6 i/p converter7 Air capacity booster8 Pressure regulator9 Flow regulator10 Volume restriction11* Inductive limit switch12* Solenoid valve13* Analog position transmitter14 Software limit switches

Alarm 1/215 Fault alarm output

Alarm 316 Display17* Solenoid valve control18* Galvanic isolation19 D/A converter20 Communication interface21 HART modulation* Optional

w

x

Q

%S

mm

GG

PD

SerialInterface 16

13

15

A2

A3

A1

112

4

21 FSK

20

195

3

12

6

7

8

10

1

14

14

w

xy

24V DC

9

17 18

Positioner with position transmitter

The position transmitter (13) is a two-wiretransmitter and issues the travel sensor sig-nal as a 4 to 20 mA signal processed by themicrocontroller.Since this signal is issued independent of thepositioner’s input signal (min. current3.8 mA), the actual travel/angle of rotationis controlled in real-time. Additionally, theposition transmitter provides the possibilityof signaling a positioner fault over a signalcurrent of <2.4 mA or >21.6 mA.

1.3 Technical data

Version with inductive limit switch

The rotary shaft of the positioner carries anadjustable tag which actuates the installedproximity switch.The optional inductive limit switch (11) leadsto A1 and the software limit switch, whichkeeps its function, leads to A2.

Version with external position sensor

In this version, only the sensor is mounted tothe control valve. The positioner is locatedseparately from the valve.The connection of x and y signals to thevalve is established via cable and piping forair (only without inductive limit switch).

10 EB 8384-3 EN


Positioner

Travel, adjustable Direct attachment to Type 3277: 3.6 to 30 mmAttachment acc. to IEC 60534-6: 3.6 to 200 mm or 24° to 100° with rotary actuators

Travel range Adjustable within the initialized travel/angle of rotation;travel can be restricted to 1

5 at the maximum

Reference variable w Signal range 4 to 20 mA, 2-wire unit, reverse polarity protection,min. span 4 mA, static destruction limit 100 mA

Minimum current 3.6 mA for display, 3.8 mA for operation

Load impedance ≤ 8.2 V (corresponding to 410 Ω at 20 mA)

Supply air

Supply pressure from 1.4 to 7 bar (20 to 105 psi),Air quality acc. to ISO 8573-1 (2001): Max. particle size and density: Class 4Oil content: Class 3, pressure dew point: Class 3 or at least 10 K beneath the lowestambient temperature to be expected

Signal pressure (output) 0 bar up to the capacity of supply pressure, limitable to 1.4/2.4/3.7 ±0.2 bar viasoftware

Characteristic,user-defined adjustableover operating software

Linear/equal percentage/reverse equal percentage/butterfly valve linear/butterfly valve eq. percentage/rotary plug valve linear/rotary plug valve eq. percent-age/segmented ball valve linear/segmented ball valve eq.percentageDeviation from terminal-based conformity ≤ 1 %

Hysteresis ≤ 0.3 %

Sensitivity ≤ 0.1 %

EB 8384-3 EN 11


Transit time Separately adjustable up to 240 seconds for supply air and exhaust air

Direction of action Reversible

Air consumption, steadystate

Independent from supply pressure approx. 110 ln/h

Air output capacityActuator pressurizedActuator vented

At Δp = 6 bar: 8.5 mn3/h, at Δp = 1.4 bar: 3.0 mn

3/h KVmax (20 °C) = 0.09at Δp = 6 bar: 14.0 mn

3/h, at Δp = 1.4 bar: 4.5 mn3/h KVmax (20 °C) = 0.15

Permissible ambienttemperature

–20 to +80 °C, with metal cable gland –45 to +80 °CThe limits specified in the EC Type Examination Certificate additionally apply forexplosion-protected devices.

Influences Temperature: ≤ 0.15 %/10 K Supply air: NoneVibration: ≤ 0.25 % up to 2000 Hz and 4 g acc. to IEC 770

Electromagneticcompatability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21

Explosion protection

II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 °C orII 3 G EEx nA II T6 / II 3 D IP 65 T 80 °C

IECEx ia IIC T6 / IP 54 and IP 65 T 80 °CFM/CSA intrinsically safe Class I, II, III, Division 1, Group A, B, C, D, E, F, G, T6FM/CSA non incendive Class I, Division 2, Group A, B, C, D, T6

Degree of protection IP 66 / NEMA 4X

Communication (local) SAMSON SSP interface and serial interface adapter

Software requirements TROVIS-VIEW with database module 3730-3

Communication (HART)HART® field communication protocolImpedance in the HART frequency range: receive 350 to 450 Ω,send: approx. 155 Ω

Software requirements(HART®)

For handheld communicator: device description for 3730-3,For PC: DTM file acc. to Specification 1.2, suitable for integrating the positioner inframe applications that supports the FDT/DTM concept (e.g. PACTware);other integration options (e.g. AMS, PDM) available.

Binary contacts2 software limit switches, reverse polarity protection, configurable switching characteristics,default settings as per tableSignal status:

No response:Response:

Without explosion protection:Non-conductingConductive (R = 348 Ω )

Exp.-protected version:≤ 1.2 mA≥ 2.1 mA

1 fault alarm contact

Signal status:No response/No alarm

Response/Fault alarm

Without explosion protection:Conductive R = 348 ΩNon-conducting

Exp.-protected version:≥ 2.1 mA≤ 1.2 mA

Operating voltage

Positioners with model no. ../9000 only for connection tosignal converter acc. to EN 60947-5-6.All other versions also for connection to binary input ofthe PLC acc. to EN 61131, Pmax = 400 mW

Only for connection tosignal converter acc. toEN 60957-5-6

12 EB 8384-3 EN


Solenoid valve SIL 4 approval acc. to IEC 61508

Input

24 V DC reverse polarity protection, static destruction limit 40 V;

Current consumption I =U 5.6 V4020−

Ω(corresponding to 4.5 mA at 24 V)

Signal Signal "0" no pick-up ≤ 15 V Signal "1" safe pick-up > 19 V

Service life > 5 x 106 switching cycles

Implementation insafety-relevant systems incompliance withIEC 61508

Probability of failure on demand of safety functions PFD < 2.8 x 10–7 for a confidencelevel of 95 %.The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater orequal to 0.99. The valves are therefore suitable for implementation in safety-relatedsystems with a hardware fault tolerance of 1 or 2 up to and including SIL 4.

Analog position transmitter Two-wire transmitter

Supply voltage 12 to 30 V DC, reverse polarity protection, static destruction limit 40 V

Output signal 4 to 20 mA

Direction of action Reversible

Operating range 0 to 100 % of the travel range, optional also for fault indication over 2.4 or 21.6 mA

Characteristic Linear

Hysteresis andHF influence Same as positioner

Other influences Same as positioner

Fault indication Can be issued with current signal < 2.4 mA or > 21.6 mA

Inductive limit switch Type SJ 2SN Proximity Switch

For connection to switching amplifier acc. to EN 60947-5-6. Can be used in combination with a software limit switch.

External position sensor

Nominal travel Adjustable same as positioner

Cable 10 m with M12x1 connector, designed for continuous flexing, flame retardant acc. toVDE 0472, reistant to oils, lubricants, coolants as well as other corrosive media

Ambient conditionsPermissible temperature: –60 to +105 °C, the limits specified in the EC Type Examina-tion Certificate additionally apply for explosion-protected devices.Vibration immunity: up to 10 g in the range between 10 and 2000 Hz

Degree of protection IP 67

Materials

Housing: Die-cast aluminum EN AC-AlSi12(Fe) (EN AC 44300) acc. toDIN EN 1706, chromated and powder paint coatedSpecial version: Stainless steel 1.4581External parts: Stainless steel 1.4571 and 1.4301Cable gland M20x1.5, black polyamide

Weight Approx. 1.0 kg

2 Attachment to the controlvalve – Mounting parts andaccessories

The positioner can be attached either di-rectly to a SAMSON Type 3277 Actuator oraccording to IEC 60534-6 (NAMUR) to con-trol valves with cast yokes or rod-type yokesas well as to rotary actuators according toVDI/VDE 3845.

For attachment to the various actuators, cor-responding mounting parts and accessoriesare required. These are listed with their or-der numbers in Tables 1 to 5.

On attaching the positioner, it is importantto observe the assignment between leverand pin position according to the travelslisted in the travel tables.The tables show the maximum adjustmentrange at the positioner. The travel that canbe implemented at the valve is restricted bythe pin position used and additionally by theactuator spring compression required.The positioner is standard equipped with thelever M (pin position 35).

Note!If the standard mounted lever M (pin posi-tion 35) is replaced, the newly mounted le-ver must be moved once all the way as faras it will go in both directions to adapt it tothe internal measuring lever.

EB 8384-3 EN 13

Attachment to the control valve – Mounting parts and accessories

Travel table for direct attachment to Type 3277 Actuator

Type3277-5

and3277

Actuators

Actuator sizecm²

Rated travelmm

Adjustment range at positionerMin. Travel Max.

Requiredlever

Assignedpin position

120 7.5 5.0 25.0 M 25

120/240/350 15 7.0 35.4 M 35

700 30 10.0 50.0 M 50

Fig. 3 · Lever M with pin position 35

14 EB 8384-3 EN


Table 1 Direct attachment to Type 3277-5 Actuator, see Fig. 4

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

Accessoriesfor theactuator

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

Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6822

Connecting plate for additional attachment of a solenoid valve G 1/8Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1/8 NPT

1400-68201400-6821

Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6823

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

Accessoriesfor thepositioner

Connecting plate (6) G ¼: 1400-7461 ¼ NPT: 1400-7462

or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459

Pressure gauge mounting kit (8) up tomax. 6 bar (output/supply) St. st./Bs: 1400-6950 St. st./St. st.: 1400-6951

Table 2 Direct attachment to Type 3277 Actuator, see Fig. 5

Accessories

Mounting parts for actuators with 240, 350 and 700 cm² 1400-7453

Required piping with screw fittings for "Actuatorstem retracts" or when the top diaphragmchamber is filled with air

cm2 Steel Stainless steel240 1400-6444 1400-6445350 1400-6446 1400-6447700 1400-6448 1400-6449

Connection block with seals and screw G ¼: 1400-8811 ¼ NPT: 1400-8812

Pressure gauge mounting kit up to max. 6 bar(output and supply) St.st./Bs: 1400-6950 St.st/St.st.: 1400-6951

Travel table for attachment according to IEC 60534-6 (NAMUR)

SAMSON valves Other valves/actuators Requiredlever

Assignedpin position

Type 3271Actuator

cm² Rated travel mm Min. Travel Max.

60 and 120 withType 3510 Valve 7.5 3.6 17.7 S 17

120 7.5 5.0 25.0 M 25

120/240/350 15 7.0 35.4 M 35

700/1400/2800 15 and 30/30 10.0 50.0 M 50

1400/2800 60 14.0 70.7 L 70

1400/2800 60 20.0 100.0 L 100

1400/2800 120 40.0 200.0 XL 200

Rotary actuators Opening angle 24° to 100° M 90°

EB 8384-3 EN 15


Table 4 Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 8 and 9

Mountingparts

With follower clampand coupling wheel,CrNiMo steel bracket

VDI/VDE 3845 for all sizes of fixing level 2for Type 3278 Actuator with 160/320 cm2

for Camflex II

1400-74481400-76141400-9120

VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty versionMounting parts for rotary actuators VDI/VDE 3845 (level 1), heavy-duty version

1400-92441400-9526

SAMSON Type 3278 160 cm² / VETEC Type S160 and Type R 1400-9245

Accessories

Connecting plate G ¼: 1400-7461 ¼ NPT: 1400-7462


Pressure gauge mounting kit up to max. 6 bar(output/supply) St.st./Bs: 1400-6950 St.st./St.st: 1400-6951

Table 5 General accessories

Accessories

Pneumatic reversing amplifier for double-actingactuators

G ¼¼ NPT

1079-11181079-1119

Cable gland M20 x 1.5 Nickel-plated brass 1890-4875

Adapter M 20 x 1.5 to ½ NPT, aluminum 0310-2149

Retrofit kit for inductive limit switch 1x SJ 2-SN 1400-7460

Cover plate with list of parametersand operating instructions

German/English (standard)English/SpanishEnglish/French

1990-07611990-31001990-3142

EXPERT+ activation code(specify the serial number of the positioner on ordering this option) 1400-9318

Table 3 Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter)according to IEC 60534-6, see Fig. 6

Travel in mm Lever For actuators Order no.

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

5 to 50 Without (lever M onbasic model)

Actuators from other manufacturers and Type 3271 with120 to 700 cm² 1400-7454

14 to 100 L Actuators f. other manufacturers and Type 3271, 1400-60version 1400-7455

40 to 200 XL Actuators from other manufacturers and Type 3271, versions1400-120 and 2800 cm² with 120 mm travel 1400-7456

30 or 60 L Type 3271, versions 1400-120 and 2800 cm² with30/60 mm travel 1400-7466

Mounting brackets for Emerson and Masoneilan linear actuatorsIn addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above. 1400-6771

Accessories

Connecting plate G ¼: 1400-7461 ¼ NPT : 1400-7462


Pressure gauge mounting kit up to max. 6 bar(output/supply) St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951

2.1 Direct attachment

2.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 14 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!

Actuator with 120 cm²

Depending on the type of positioner attach-ment, the signal pressure is routed either leftor right of the yoke through a bore to theactuator diaphragm. Depending on thefail-safe action of the actuator "Actuatorstem extends" or "Actuator stem retracts"(valve closes or opens if the supply air fails),the switchover plate (9) must first be at-tached to the actuator yoke. Align theswitchover plate with the correspondingsymbol for left or right attachment accordingto the marking (view looking onto theswitchover plate).

1. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesonto the positioner, making sure bothseal rings (6.1) are seated properly.

2. Remove screw plug (4) on the back ofthe positioner and close the signal pres-sure output "Output 38" on the connect-ing plate (6) or on the pressure gaugebracket (7) with the stopper (5) includedin the accessories.

3. Place follower clamp (3) on the actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.

4. Mount cover plate (10) with narrow sideof the cut-out opening (Fig. 4, on the

left) pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.

5. 15 mm travel: Keep the follower pin (2)at lever M (1) on the back of thepositioner in the pin position 35 (deliv-ered state).7.5 mm travel: Remove the follower pin(2) from the pin position 35, reposition itin the bore for pin position 25 andscrew tight.

6. Insert formed seal (15) in the groove ofthe positioner casing.

7. Place positioner on the cover plate (10)in such a manner that the follower pin(2) rests on the top of the follower clamp(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch (Fig. 19).The lever (1) must rest on the followerclamp with spring force.Mount the positioner on the cover plate(10) using the two fixing screws. Duringthe installation make sure that the sealring (10.1) is inserted in the bore of theintermediate plate.

8. Mount cover (11) on the other side.Make sure that the vent plug pointsdownwards when the control valve is in-stalled to allow any condensed waterthat collects to drain off.

16 EB 8384-3 EN


EB 8384-3 EN 17


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

9 11

Supply 9 Output 38

56

4

7

6

1010.1

3

2

1

15

6.1

1.11.2

14

8

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp4 Screw plug5 Stopper6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Press. gauge mounting kit9 Switchover plate

for actuator10 Cover plate10.1Seal ring11 Cover14 Gasket15 Formed seal

Note!Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.

Symbols


Attachment left Attachment right


Switchover plate (9)

Signal pressureinput for right

attachmentMarking

Cut-out of coverplate

Signal pressureinput for leftattachment

Lever M

2.1.2 Type 3277 Actuator

Refer to Table 2 on page 14 or the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!

Actuators with 240 to 700 cm²

The positioner can be mounted either on theleft or on the right side of the yoke. The sig-nal pressure is routed to the actuator overthe connection block (12), for actuators withfail-safe action "Actuator stem extends" in-ternally through a bore in the valve yokeand for "Actuator stem retracts" through ex-ternal piping.

1. Place follower clamp (3) on the actuatorstem, align and screw tight so that themounting screw is located in the grooveof the actuator stem.

2. Mount cover plate (10) with narrow sideof the cut-out opening (Fig. 5, on theleft) pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuatoryoke.

3. For actuators with 700 cm², remove thefollower pin (2) at lever M (1) on theback of the positioner from pin position35, reposition it in the bore for pin posi-tion 50 and screw tight.For actuators 240 and 350 cm² with15 mm travel, the follower pin (2) re-mains in pin position 35.

4. Insert formed seal (15) in the groove ofthe positioner casing.

5. Place positioner on the cover plate insuch a manner that the follower pin (2)

rests on the top of the follower clamp(3). Adjust the lever (1) correspondinglyand open the positioner cover to holdthe positioner shaft in position at the capor the switch (Fig. 19). The lever (1) mustrest on the follower clamp with springforce. Mount the positioner on the coverplate (10) using the two fixing screws.

6. Make sure that the tip of the gasket (16)projecting from the side of the connec-tion block (12) is positioned above theactuator symbol that corresponds withthe actuator with fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts." If necessary, remove the threefixing screws and the cover. Then repo-sition the gasket (16) turned by 180°.The previous version of the connectionblock (Fig. 5, bottom) requires the switchplate (13) to be turned such that the cor-responding actuator symbol points to themarking.

7. Place the connection block (12) with theassociated seal rings against thepositioner and the actuator yoke. Screwit tight using the fixing screw (12.1). Foractuators with fail-safe action "Actuatorstem retracts", additionally remove thestopper (12.2) and fit on the externalsignal pressure piping.


18 EB 8384-3 EN


EB 8384-3 EN 19


Fig. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm²

2

10 1415

1 2 3 11

SUPPLY

13

16

B

1.11.2

12

12.1

12

12.1

12.2

A

1216 12.2SUPPLY

Cut-out ofcover plate (10)

Actuator stemretracts extends

Stem retracts

Stem extends

Marking

Connection block (old)with switch plate (13)

Lever M

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp10 Cover plate11 Cover12 Connection block

12.1 Screw12.2 Stopper or connection for

external piping13 Switch plate14 Gasket15 Formed seal16 Gasket

2.2 Attachment according toIEC 60534-6

The positioner is attached to the controlvalve with a NAMUR bracket (10).


1. Screw the two bolts (14) to the bracket(9.1) of the stem connector (9), place thefollower plate (3) on top and use thescrews (14.1) to tighten.

Actuator size 2800 cm² and 1400 cm²(120 mm travel) only:For a travel of 60 mm or smaller, screw thelonger follower plate (3.1) directly to thestem connector (9). For a travel exceeding60 mm, mount the bracket (16) first andthen the follower plate (3) to the bracket to-gether with the bolts (14) and screws (14.1).

2. Mount NAMUR bracket (10) to the con-trol valve as follows:For attachment to the NAMUR rib, usean M8 screw (11) and toothed lockwasher directly in the yoke bore.For attachment to valves with rod-typeyokes, use two U-bolts (15) around theyoke.Align the NAMUR bracket (10) in such away that the slot of the follower plate (3)is centrally aligned with the NAMURbracket at mid valve travel.

3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gauges

(8) on the positioner, making sure bothseal rings (6.1) are seated properly.

4. Select required lever size (1) M, L or XLand pin position according to the actua-tor size and valve travels listed in the ta-ble on page 14.Should you require a pin position otherthan position 35 with the standard in-stalled lever M, or require a lever size Lor XL, proceed as follows:

5. Screw the follower pin (2) in the as-signed lever bore (pin position) as listedin the table. Only use the longer followerpin (2) included in the mounting kit.

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

Note!If you have mounted a new lever (1), youmust move it once all the way as far as itwill go in both directions.

7. Place positioner on the NAMUR bracketin such a manner that the follower pin(2) rests in the slot of the follower plate(3, 3.1). Adjust the lever (1) correspond-ingly.Screw the positioner to the NAMURbracket using both its fixing screws.

20 EB 8384-3 EN


EB 8384-3 EN 21


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

10

11

1

1 14.1

3

3.1

16

15

14

11.21.12

9.1

9

6.1 6 7 8

Attachment toNAMUR rib

Additional bracket foractuators with 2800 cm2

and travel ≥ 60 mm

Attachment to rod-type yokeRods with 20 to 35 mm Ø

Lever XL and L

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower plate3.1 Follower plate6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit9 Stem connector9.1 Bracket10 NAMUR bracket11 Screw14 Bolt14.1 Screw15 U-bolt16 Bracket

Note!Always use the connecting plate (6) included in the accessories to connectsupply and output. Never screw threaded parts directly into the housing.

2.3 Attachment to Type 3510Micro-flow Valve

The positioner is attached to the valve yokeusing a bracket.


1. Place clamp (3) on the valve stem con-nector, align at a right angle and screwtight.

2. Screw bracket (10) to the valve yoke us-ing two screws (11).

3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure both sealrings (6.1) are seated properly.

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

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

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

7. Place positioner on the bracket (10) insuch a manner that the follower pinslides into the groove of the clamp (3).Adjust the lever (1) correspondingly.Screw the positioner to the bracket (10)using both its screws.

22 EB 8384-3 EN


EB 8384-3 EN 23


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

3

10

11

11

6

121.2 1.1

78

6.1

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Clamp6 Connecting plate6.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit10 Bracket11 Screw

Note!Always use the connecting plate (6)included in the accessories to connectsupply and output.Never screw threaded parts directlyinto the housing.

Lever S

2.4 Attachment to rotaryactuators

The positioner is mounted to the rotary actu-ator using two pairs of double brackets.

Refer to Table 4 on page 15 for the requiredmounting parts as well as the accessorieswith their order numbers.

Prior to the attachment of the positioner tothe SAMSON Type 3278 Rotary Actuator,you have to mount the associated adapter(5) to the free end of the rotary actuatorshaft.

Note!During the installation of the positioner asdescribed below, it is imperative that the ac-tuator's direction of rotation be observed.

1. Place follower clamp (3) on the slottedactuator shaft or the adapter (5).

2. Place coupling wheel (4) with flat sidefacing the actuator on the followerclamp (3). Refer to Fig. 9 to align slot sothat it matches the direction of rotationwhen the valve is in its closed position.

3. Screw coupling wheel and followerclamp tightly onto the actuator shaftusing screw (4.1) and disk spring (4.2).

4. Screw the bottom pair of brackets (10.1)with the bends pointing either to the in-side or to the outside (depending on theactuator size) to the actuator case. Posi-tion top pair of brackets (10) and screwtight.

5. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gaugesto the positioner, making sure bothO-rings are seated properly.For double-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator,see section 2.5.

6. Unscrew the standard follower pin (2)from the positioner's lever M (1). Use themetal follower pin (Ø5) included in themounting kit and screw tight into thebore for pin position 90°.

7. Place positioner on the top pair ofbrackets (10) and screw tight. Con-sidering the actuator's direction of rota-tion, adjust lever (1) so that it engages inthe slot of the coupling wheel (4) with itsfollower pin (see Fig. 9). It must be guar-anteed that the lever (1) is parallel to thelong side of the positioner when the ac-tuator is at half its angle of rotation.

8. Stick scale plate (4.3) on the couplingwheel so that the arrow tip indicates theclosed position, and it can be easilyread when the valve is installed.

24 EB 8384-3 EN


Fig. 8 · Mounting the coupling wheel with Type 3278

1.21.1

1

2

4.1

4.2

53

Actuator flange

EB 8384-3 EN 25


Fig. 9 · Attachment to rotary actuators

Slot

10

10.1

6(7, 8)

1.124.3

5

6.1

4

1.21

Control valve opens clockwise

Control valve opens counterclockwise

Slot

Note!Always use the connectingplate (6) included in theaccessories to connectsupply and output.Never screw threadedparts directly into thehousing.

Legends Figs. 8 + 91 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp (Fig. 8)4 Coupling wheel4.1 Screw4.2 Disk spring4.3 Scale plate4.3 Scale plate5 Actuator shaft

Adapter for Type 32786.1 Seal rings7 Pressure gauge bracket8 Pressure gauge

mounting kit10 Top pair of brackets10.1 Bottom pair of brackets

2.5 Reversing amplifier fordouble-acting actuators

For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier. The reversing amplifier is listed asan accessory in the Table 5 on page 15.

The output signal pressure of the positioneris supplied at the output A1 of the reversingamplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure at A1, is applied atoutput A2.The rule A1 + A2 = Z applies.

Mounting

1. Mount the connecting plate (6) from theaccessories in Table 5 to the positioner.Make sure that both O-rings (6.1) areseated correctly.

2. Thread the special nuts (1.3) from theaccessories of the reversing amplifierinto the boreholes of the connectingplate.

3. Insert the gasket (1.2) into the recess ofthe reversing amplifier and push boththe hollowed special screws (1.1) intothe connecting boreholes A1 and Z.

4. Place the reversing amplifier onto theconnecting plate (6) and screw tight us-ing both the special screws (1.1).

5. Use a screwdriver (8 mm wide) to screwthe enclosed filters (1.6) into the con-necting boreholes A1 and Z.

Note!The sealing plug (1.5) in the Type 3730Positioner should not be unscrewed out ofthe reversing amplifier.The rubber seal (1.4) is not required andcan be removed when the sealing plug isused.

Signal pressure connections

A1: Output A1 leading to the signal pressureconnection at the actuator which opens thevalve when the pressure increases

A2: Output A2 leading to the signal pressureconnection at the actuator which closes thevalve when the pressure increases

Set slide switch on positioner toAIR TO OPEN.

6. After the initialization is completed, setCode 16 (Pressure limit) to OFF.

2.5.1 Pressure gauge attachment

The mounting sequence shown in Fig. 10 re-mains unchanged. Screw a pressure gaugebracket onto the connections A1 and Z.

Pressure gauge G ¼ 1400-7106bracket: ¼ NPT 1400-7107

Pressure gauges for supply air Z and outputA1 as listed in Tables 1 to 4.

26 EB 8384-3 EN


EB 8384-3 EN 27


Fig. 10 · Mounting a reversing amplifier

A1

1.5 1.6

1.3

6.266.1

1.2 1.1 1 1.6

Z

A2

1.4

A1 A2

Z

A1

Output 38 Supply 9

Out

put 3

8Su

pply

9

1.3 1.21.1

1 Reversing amplifer1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubber seal1.5 Sealing plug1.6 Filter

6 Connecting plate6.1 O-rings6.2 Screws

From the positioner

Control signals tothe actuator

2.6 Attaching an externalposition sensor

Refer to Table 6 on page 33 for a list of themounting parts as well as the accessories re-quired for mounting the position sensor.Accessories for the pneumatic connection tothe positioner housing can be found in Ta-ble 7.

In the positioner version with an externalposition sensor, the sensor placed in a sepa-rate housing is attached over a plate orbracket to the control valve. The travelpick-off corresponds to that of a standarddevice.The positioner unit can be mounted as re-quired to a wall or a pipe.

For the pneumatic connection either a con-necting plate (6) or a pressure gaugebracket (7) must be fixed to the housing, de-pending on the accessory chosen. Makesure the seal rings (6.1) are correctly in-serted (see Fig. 6, bottom right).

For the electrical connection a 10 m con-necting lead with M12x1 connectors plug isincluded.

Note! In addition, the instructions in section3.1 and 3.2 apply for the pneumatic andelectrical connection.Operation and setting are described in sec-tions 4 and 5.

2.6.1 Mounting the position sensorwith direct attachment

Type 3277-5 Actuator with 120 cm²

The signal pressure from the positioner isrouted over the signal pressure connectionof the connecting plate (9, Fig. 12 left) to theactuator diaphragm chamber. To proceed,first screw the connecting plate (9) includedin the accessories onto the actuator yoke.

Turn the connecting plate (9) so that thecorrect symbol for the fail-safe position"Actuator stem extends" or "Actuatorstem retracts" is aligned with the mark-ing (Fig. 12, below).

Make sure that the gasket for the con-necting plate (9) is correctly inserted.

The connecting plate has boreholes withNPT and G threads.Seal the threaded connection that is notused with the rubber seal and squareplug.

28 EB 8384-3 EN


Fig. 11 · Positioner unit with sensor mounted on amicro-flow valve

Type 3277 Actuator with 240 to 700 cm²:

The signal pressure is routed to the connec-tion at the side of the actuator yoke for theversion "Actuator stem extends".For the fail-safe position "Actuator stem re-tracts" the connection on the top diaphragmcase is used. The connection at the side ofthe yoke must be fitted with a venting plug(accessories).

Mounting the position sensor

1. Place the lever (1) on the sensor inmid-position and hold it in place.Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto themounting plate (21).

3. Depending on the actuator size andrated travel of the valve, determine therequired lever and position of the fol-lower pin (2) from the travel table onpage 14.The positioner is delivered with lever Min pin position 35 on the sensor. If nec-essary, remove the follower pin (2) fromits pin position and move it to the bore-hole for the recommended pin positionand screw tight.

4. Place the lever (1) and disk spring (1.2)on the sensor shaft.

EB 8384-3 EN 29


Fig. 12 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)

2021

9

11

1.11.2

3

2

1

Signal pressure

Vent plug

Actuator stemextends retractsSymbol

Marking

Signal pressure

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp9 Connecting plate11 Cover20 Position sensor21 Mounting plate

Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

5. Place the follower clamp (3) on the actu-ator stem, align and fasten it, makingsure that the fastening screw rests in thegroove of the actuator stem.

6. Place the mounting plate (21) togetherwith the sensor onto the actuator yoke sothat the follower pin (2) rests on the topof the follower clamp (3). It must rest onit with spring force.Screw tight the mounting plate (21) ontothe actuator yoke using both fixingscrews.


2.6.2 Mounting the position sensorwith attachment according toIEC 60534-6

For the required mounting parts as well asthe accessories, refer to the order numberslisted in Tables 6 and 7 on page 33.

1. Place the lever (1) on the sensor inmid-position and hold it in place.Unthread the nut (1.1) and remove thelever together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto thebracket (21).

The standard attached lever M with the fol-lower pin (2) at position 35 is designed for120, 240 and 350 cm² actuators with15 mm rated travel.

30 EB 8384-3 EN


Fig. 13 · Mounting according to IEC 60534-6 (NAMUR)

20 21

2

1.1, 1.2 14.1 3 14 99.1

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower plate9 Stem connector9.1 Bracket14 Bolt14.1 Screws20 Position sensor21 Bracket

For other actuator sizes or travels, select thelever and pin position from the travel tableon page 14. Lever L and XL are included inthe mounting kit.

3. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

4. Screw both bolts (14) to the bracket(9.1) of the stem connector (9). Attachthe follower plate (3) and fix with thescrews (14.1).

5. Place the bracket with the sensor at theNAMUR rib in such a manner that thefollower pin (2) rests in the slot of the fol-lower plate (3), then screw the bracketusing its fixing screws onto the valve.

2.6.3 Mounting the position sensorto Type 3510 Micro-flowValve


1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto thebracket (21).

3. Select the lever S (1) from the accesso-ries and screw the follower pin (2) intothe hole for pin position 17.Place the lever (1) and disk spring (1.2)on the sensor shaft.

Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

4. Place the follower clamp (3) on the stemconnector, align it at a right angle andscrew tight.

5. Position the bracket (21) with the posi-tion sensor on the valve yoke and screwtight, making sure the follower pin (2)slides into the groove of the followerclamp (3).

EB 8384-3 EN 31


Fig. 14 · Mounting a micro-flow valve

20 211.11.2

1

3

2

1 Lever1.1 Nut1.2 Disk spring2 Follower pin3 Follower clamp20 Position sensor21 Bracket

2.6.4 Mounting the position sensorto rotary actuators


1. Place the lever (1) in mid-position andhold it in place. Unscrew the nut (1.1)and remove the standard attached leverM (1) together with the disk spring (1.2)from the sensor shaft.

2. Screw the position sensor (20) onto themounting plate (21).

3. Replace the follower pin (2) normally at-tached to the lever (1) with the metal fol-lower pin (Ø 5) from the accessoriesand screw it into the hole for pin posi-tion 90°.

4. Place the lever (1) and disk spring (1.2)on the sensor shaft.Place the lever (1) in mid-position andhold it in place. Screw on the nut (1.1).

Follow the instructions describing attachmentto the standard positioner in section 2.4Instead of the positioner, attach the positionsensor (20) with its mounting plate (21).

32 EB 8384-3 EN


Fig. 15 · Positioner unit with sensor mounted on rotary actuators

2021

2 1 1.1, 1.2

1 Lever1.1 Nut1.2 Disk spring2 Follower pin20 Position sensor21 Mounting plate

EB 8384-3 EN 33


Table 6 Mounting parts for position sensor Order no.

Direct attachment Mounting parts for actuators with 120 cm² see Fig. 12 left 1400-7472

Accessories foractuator 120 cm²

Connecting plate (9, old) for ActuatorType 3277-5xxxxxx.00

G 1/81/8 NPT

1400-68201400-6821

Connecting plate (new) for Actuator Type 3277-5xxxxxx.01 (new) 1400-6823

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

Direct attachment Mounting parts for actuators with 240, 350 and 700 cm², see Fig. 12 right 1400-7471

NAMUR attachment Mounting parts for attachment to NAMUR rib w. lever L and XL, see Fig. 13 1400-7468

Attachment tomicro-flow valves Mounting parts for Type 3510 Micro-flow Valve, see Fig. 14 1400-7469

Attachment to rotaryactuators

VDI/VDE 3845 for all sizes of fixing level 2Mounting parts with follower clamp and coupling wheelCrNiMo steel bracket, see Fig. 15

1400-7473

VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty version 1400-9384

SAMSON Type 3278 160 cm2 / VETEC Type S160 and Type R,heavy-duty version 1400-9385

Table 7 Postioner accessories Order no.

Accessories

Connecting plate (6)G ¼¼ NPT

1400-74611400-7462

or pressure gauge bracket (7)G ¼¼ NPT

1400-74581400-7459

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

St. steel/BrassSt.st./St. steel

1400-69501400-6951

Bracket to mount the positioner on a wallNote! The other fastening parts are to be provided at the site ofinstallation as wall foundations vary from site to site.

0309-0111

2.7 Attaching positioners withstainless steel housings

Positioners with stainless steel housings re-quire mounting parts that are completelymade of stainless steel or free of aluminum.

Note!The pneumatic connecting plate and pres-sure gauge bracket are available made ofstainless steel (order numbers listed below).A stainless steel version of the pneumatic re-versing amplifier is not available.

Connecting plate(stainless steel):

G ¼¼ NPT

1400-74761400-7477

Pressure gaugebracket (st. steel):

Only in¼ NPT 1400-7108

The Tables 1 to 5 (pages 14 and 15) applyfor attaching positioners with stainless steelhousings with the following restrictions:

Direct attachmentAll mounting kits from Tables 1 and 2 canbe used. The connection block is not re-quired. The stainless steel version of thepneumatic connecting plate routes the air in-ternally to the actuator.

Attachment according to IEC 60534-6(NAMUR rib or attachment to rod-type yo-kes)All mounting kits from Table 3 can be used.Connecting plate in stainless steel.

Attachment to rotary actuatorsAll mounting kits from Table 4 can be usedexcept for the heavy-duty version. Con-necting plate in stainless steel.

2.8 Air purging function forsingle-acting actuators

The exhaust air from the positioner is di-verted to the actuator spring chamber toprovide corrosion protection inside the actu-ator. The following must be observed:

Direct attachment to Type 3277-5 (stem ex-tends FA/stem retracts FE)The air purging function is automaticallyprovided.

Direct attachment to Type 3277, 240 to700 cm²FA: Remove the stopper 12.2 (Fig. 5 on

page 19) at the connection block andmake a pneumatic connection to thespring chamber on the vented side.

FE: The air purging function is automati-cally provided.

Attachment acc. to IEC 60534-6 (NAMURrib or attachment to rod-type yokes) and torotary actuatorsThe positioner requires an additional portfor the exhaust air that can be connectedover piping. An adapter available as an ac-cessory is used for this purpose:

Threaded bushing(M20 x 1.5):

G ¼¼ NPT

0310-26190310-2550

Note!The adapter uses one of the M20 x 1.5 con-nections in the housing which means justone cable gland can be installed.

34 EB 8384-3 EN


Should other valve accessories be usedwhich vent the actuator (e.g. solenoid valve,volume booster, quick exhaust valve), thisexhaust air must also be included in the pur-ging function. The connection over theadapter at the positioner must be protectedwith a check valve mounted in the piping.Otherwise the pressure in the positionerhousing would rise above the ambient pres-sure and damage the positioner when theexhausting components respond suddenly.

EB 8384-3 EN 35


3 Connections

3.1 Pneumatic connections

Caution!The threads in the positioner housing are notdesigned for direct air connection!

The screw glands must be screwed into theconnecting plate, the pressure gauge mount-ing block or the connection block from theaccessories. The air connections are option-ally designed as a bore with ¼ NPT or G ¼thread.The customary fittings for metal and copperpipes or plastic hoses can be used.

Note!The supply air must be dry and free from oiland dust. The maintenance instructions forupstream pressure reducing stations must beobserved.Blow through all air tubes and hoses thor-oughly prior to connecting them.

If the positioner is attached directly to theType 3277 Actuator, the connection of thepositioner's output pressure to the actuatoris fixed. For attachment according toIEC 60534-6 (NAMUR), the signal pressurecan be routed to either the top or bottom di-aphragm chamber of the actuator, depend-ing on the actuator's fail-safe action "Actua-tor stem extends" or "Actuator stem re-tracts".For rotary actuators, the manufacturer'sspecifications for connection apply.

3.1.1 Signal pressure gauges

To monitor the supply air (Supply) and sig-nal pressure (Output), we recommend thatpressure gauges be attached (see accesso-ries in Tables 1 to 5).

3.1.2 Supply pressure

The required supply air pressure dependson the bench range and the actuator's oper-ating direction (fail-safe action).The bench range is registered on the name-plate either as spring range or signal pres-sure range depending on the actuator. dieThe direction of action is marked FA or FE,or by a symbol.

Actuator stem extends FA (Air to openATO)

Fail-safe position "Valve Closed"(for globe and angle valves):

Required supply pressure = Upper benchrange value + 0.2 bar, minimum 1.4 bar.

Actuator stem retracts FE (Air to close ATC)

Fail-safe position "Valve Open"(for globe and angle valves):For tight-closing valves, the maximum signalpressure pstmax is roughly estimated as fol-lows:

pstmax = F +d p

A

2

4⋅ ⋅

⋅π Δ

[bar]

36 EB 8384-3 EN

Connections

d = Seat diameter [cm]Δp = Differential pressure across the valve

[bar]A = Actuator diaphragm area [cm²]F = Upper bench range of the actuator

[bar]

If there are no specifications, calculate asfollows:

Required supply pressure =Upper bench range value + 1 bar

Note!The signal pressure at the output (Out-put 38) of the positioner can be limited to1.4, 2.4 or 3.7 bar over Code 16 or thepressure limit can be deactivated (MAX).

EB 8384-3 EN 37

Connections

3.2 Electrical connections

For electrical installation, you are re-quired to observe the relevantelectrotechnical regulations and theaccident prevention regulations thatapply in the country of use. In Ger-many, these are the VDE regulationsand the accident prevention regula-tions of the employers' liability insur-ance association.

The following standards apply for assemblyand installation in hazardous areas:EN 60079-14: 2003 (VDE 0165 Part 1/8.98) "Electrical apparatus for explosive gasatmospheres" and EN 50281-1-2: 1999(VDE 0165 Part 2/11.99) "Electrical appa-ratus for use in the presence of combustibledust".For the interconnection of intrinsically safeelectrical equipment, the permissible maxi-mum values specified in the EC type exami-nation certificate apply (Ui or Uo; Ii or Io; Pior Po; Ci or Co, and Li or Lo).

The following applies for equipment withtype of protection EEx nA (non-sparking ap-paratus) according to the standard EN50021 (1999): Connecting, interrupting, orswitching circuits while energized is only al-lowed during installation, maintenance orrepair work.The following applies for equipment con-nected to energy-limited circuits with type ofprotection EEx nL (energy-limited apparatus)according to the standard EN 50021(1999): This type of equipment may beswitched under normal operating conditions.

For the interconnection of equipment to en-ergy-limited circuits with type of protectionEEx nL IIC, the permissible maximum valuesspecified in the statement of conformity orthe addenda to the statement of conformityapply.Caution!The terminal assignment specified in the cer-tificate must be adhered to. Reversing theassignment of the electrical terminals maycause the explosion protection to become in-effective!Do not tamper with enameled screws insideor on the housing.

Note on the selection of cables and wires:To install intrinsically safe circuits, observesection 12 of the standard EN 60079-14:2003 (VDE 0165 Part 1). To run multi-corecables or lines with more than one intrinsi-cally safe circuit, section 12.2.2.7 of thisstandard applies.An additional cable gland can be installedwhen connecting the device over two sepa-rate cables. Cable entries left unused mustbe sealed with blanking plugs. Devices usedat ambient temperatures down to –20 °Cmust have metal cable entries.

Cable entries

The cable entry with M20 x 1.5 cablegland, 6 to 12 mm clamping range.There is a second M20 x 1.5 threaded borein the housing that can be used for addi-tional connection, when required.The screw terminals are designed for wirecross-sections of 0.2 to 2.5 mm². Tighten byat least 0.5 Nm.

38 EB 8384-3 EN

Connections

The wires for the reference variable must beconnected to the terminals 11 and 12 lo-cated in the housing. Only use a currentsource!If the reference variable exceeds 22 mA,OVERLOAD appears on the LC display towarn the user.

Caution! The erroneous connection of a volt-age source of just around 7 V (or around2 V when connected to the wrong pole) candamage the positioner.

In general, it is not necessary to connect thepositioner to a bonding conductor. Shouldthis be required, however, this conductorcan be connected inside the device.Depending on the version, the positioner isequipped with inductive limit switchesand/or a solenoid valve.

The position transmitter is operated on atwo-wire circuit. The usual supply voltage is24 V DC. Considering the resistance of thesupply leads, the voltage at the positiontransmitter terminals can be between 12 Vand 30 V DC.Refer to Fig. 16 or the label on the terminalstrip for terminal assignment.Note! The minimum permissible referencevariable should not fall below 3.8 mA foroperating the positioner.

Accessories:Plastic cable gland M20 x 1.5:Black Order no. 8808-1011Blue Order no. 8808-1012Nickel-plated brass Order no. 1890-4875Adapter M20 x 1.5 to ½ NPTAluminum, powder-coated

Order no. 0310-2149

EB 8384-3 EN 39

Connections

Fig. 16 · Electric connections

G

+81 -82 +11 -12 +83 -84 +51 -52

A2A3 A1

+41 -42 +31 -32

ASwitching amplifieracc. to EN 60947-5-6

24 V DCsolenoid

valve

mAControl signal

A3Fault

indication

Limit switchesA2 A1

Software Softwareor inductive

2-wire transmittersupply unit for optionalposition transmitter only

Optional Optional

3.2.1 Switching amplifiers

For operation of the limit switches, switchingamplifiers must be connected in the outputcircuit. To ensure the operating reliability ofthe positioner, the amplifiers should complywith the limit values of the output circuitsconforming to EN 60947-5-6.If the positioner is to be installed in hazard-ous areas, the relevant regulations must beobserved.

3.2.2 Establishing communication

Communication between PC and positioner(via FSK modem or handheld communica-tor, if necessary, using an isolation ampli-fier) is based on the HART protocol.

Type Viator FSK modemRS 232 EExia Order no. 8812-0129RS 232 not ex Order no. 8812-0130PCMCIA not ex Order no. 8812-0131USB not ex Order no. 8812-0132

If the supply voltage of the controller or con-trol station becomes too low because it hasbeen reduced by the load in the circuit, anisolation amplifier is to be connected be-tween controller and positioner (interfacing

40 EB 8384-3 EN

Connections

Fig. 17 · Connection with a FSK modem

3730-30

3730-31

Connection in non-hazardous area Handheld communicatoror second FSK modem

Handheld communicatoror second FSK modem (explosion-protected)

Ex isolating amplifier

4 to 20 mA

Safe area

Hazardous area

Controller/control station


Connection in hazardous area

as for positioner connected in hazardous ar-eas, see Fig. 17).

If the positioner is used in hazardous areas,an explosion-protected isolation amplifier isto be used.

By means of the HART protocol, all controlroom and field devices connected in theloop are individually accessible throughtheir address via point-to-point or standardbus (Multidrop).

Point-to-point:The bus address/polling address must al-ways be set to zero (0).

Standard bus (Multidrop):In the standard bus (Multidrop) mode, thepositioner follows the analog current signal(reference variable) as for point-to-pointcommunication. This operating mode is, forexample, suitable for split-range operationof positioners (series connection). The busaddress/polling address has to be within arange of 1 to 15.

Note:Communication errors may occur when theprocess controller/control station output isnot HART-compatible.

For adaptation, the Z box (order no.1170-2374) can be installed between out-put and communication interface.

At the Z box a voltage of 330 mV is re-leased (16.5 Ωat 20 mA).

Alternatively, a 250-Ω resistor can be con-nected in series and a 22-μF capacitor canbe connected in parallel to the analog out-put. Note that in this case, the controller out-put load will increase.

EB 8384-3 EN 41

Connections

22 μF

250 Ω

Fig. 18 · Adapting the output signal


4 Operation

Note!A summary about operating and start upcan be found in section 8 on page 66. Aleaflet including the same summary is alsoenclosed with the positioner.

4.1 Operator controls anddisplay

Rotary pushbutton

The positioner is mainly operated with therotary pushbutton.

Turn the button to select and set codes,parameter and values. Press it to confirmthem.

Slide switch AIR TO OPEN or AIR TOCLOSE

AIR TO OPEN applies when the increas-ing signal pressure opens the valve

AIR TO CLOSE applies when the increas-ing signal pressure closes the valve

The signal pressure is the air pressure at theoutput of the positioner which is transferredto the actuator.

For positioners with an attached reversingamplifier for double-acting rotary actuators(section 2.5): switch position AIR TO OPEN.

For checking purposes:After successfully completing initialization,the positioner display should read 0 % whenthe valve is closed and 100 % when thevalve is open. If this is not the case, changethe slide switch position and re-initialize thepositioner.

The switch position is prompted prior to aninitialization. After an initialization has beencompleted, changing the switch positiondoes not have any effect on the operation ofthe positioner.

Volume restriction Q

The volume restriction is used to adapt theair delivery to the actuator size. Two fixedsettings are possible depending on how theair is routed at the actuator (section 5.2 inpage 47).

Displays

A self test is performed automatically(tEStinG runs across the display) when thepositioner starts up for the first time after theelectrical auxiliary power has been con-nected.

Symbols appear on the LC display that areassigned to parameters, codes, and func-tions.The bar graph in the operating modes Man-ual and Automatic indicates the sys-tem deviation that depends on the sign (+/–)and the value. One bar graph element ap-pears per 1 % system deviation.

If the device has not yet been initialized (seesection 4.3.1), the lever position in degreesin relation to the longitudinal axis is indi-cated instead of the system deviation. Onebar graph element corresponds to approxi-mately a 5° angle of rotation.

If the fifth element blinks (value displayed> 30°), the permissible angle of rotation hasbeen exceeded. Lever and pin position mustbe checked.

42 EB 8384-3 EN

Operation

EB 8384-3 EN 43

Operation

Fig. 19 · Display and controls

AUO Automatic modeCL ClockwiseCCL CounterclockwiseErr ErrorESC EscapeHI ix greater than 21.6 mALO ix smaller than 2.4 mALOW w too lowMAN Manual mode

MAX Maximum rangeNO Not availableNOM Nominal travelON ONOVERLOAD w > 22 mAOFF OFFRES ResetRUN StartSAFE Fail-safe position

SUb Substitute calibrationtEStinG Test function activeTunE Initialization in progressYES AvailableZP Zero calibration Increasing/increasing Increasing/decreasing

Blinking Controlled operationBlinking Not initialized

Displays and their meaning

%mm

AIR TOO

PEN

CLO

SE

INIT C

AU

TION

VA

LVE

AC

TUA

TES

MIN

SIDE

MA

X BAC

K

MIN

BAC

KM

AX SID

E Q

%S

mm

%S

mm

SERIAL

INTERFA

CE

%mm

Failure/fault Manual operation Control operation Code

Configurationenabled

Maintenance required/Maintenance demanded

Fail-safe positionactive

Bar graph forsystem deviationor lever position

Units

Limit switchAlarm 2

DesignationPositionParameter

Limit switchAlarm 1

Initialization key Cap or rotary switch Metal tag of proximity switch

SSP interface

Switch forfail-safe actionof the actuator

Volume restriction

Rotary pushbutton

4.2 Enabling and selectingparameters

The codes which are marked with an aster-isk (*) in section 12 on page 71 onwardsmust be enabled with Code 3 before the as-sociated parameters can be configured asdescribed below.

Code 3Configurationnot enabled

Configurationenabled

From the current display, turn the rotarypushbutton until Code 3 and OFF ap-pear on the display.Confirm Code 3 by pressing the but-ton, the code number blinks.

Turn button until ON appears.Confirm setting by pressing the but-ton.

Configuration is enabled and is indicated bysymbol appearing on the display.

Now you can adjust the codes, parametersand values for the control valve in any de-sired order by turning the button. Con-firm settings by pressing the button.

Note!To cancel a value that you have just enteredunder a code, turn the button until ESCappears on the display and press to con-firm.

Canceling the setting

Note! If no settings are entered within 120seconds, the enabled configuration functionbecomes invalid and the display resets toCode 0.

The code list on page 71 onwards in section12 shows all parameters that can be ad-justed, including their description and theirdefault settings.

Note!After attaching the positioner to the valve aswell as setting the fail-safe position and thevolume restriction, it is sufficient for standardoperation to press the initialization key inorder to ensure optimum positioner opera-tion (section 5.6 on page 49).For this purpose, the positioner must be op-erated with its default values. If necessary, areset must be carried out (section 5.9 onpage 59).

44 EB 8384-3 EN

Operation

4.3 Operating modes

4.3.1 Automatic and manualoperating modes

Prior to initialization:

If the positioner has not been initialized yet,the automatic operating AUtO cannot be se-lected.The valve can only be positioned manuallywith the positioner.

To proceed, turn button clockwise untilCode 1 appears, then confirm Code 1 bypressing the button.

If both the code number and the hand sym-bol are blinking, the valve can be manuallypositioned by turning the button.

After initialization:

After successful initialization in the MAX,NOM or MAN mode (section 5.6.1), thepositioner is in the automatic controloperation mode .

Default

Switching to manual operating mode

Over Code 0, press the button, AUtOappears in the display, Code 0 blinks.

Turn button until MAN appears.

Press button to switchover to the manualoperating mode .

The switchover is smooth since the manualoperating mode starts up with the set pointlast used during automatic operating mode.The current position is displayed in %.

Adjusting the manual set point

Turn button until Code 1 appears.

Press button to confirm, Code 1 blinks.While Code 1 is blinking, you can move thevalve to the position required by turning thebutton. To proceed, turn the button untilenough the positioner has built up enoughpressure and the control valve starts to react.The positioner automatically returns to man-ual mode with Code 0 if the button is notactivated within two minutes.Switching from manual to automatic oper-ating mode works in the same manner.First, you must reset the positioner to Code 0and set it to automatic mode AUtO and con-firm.

EB 8384-3 EN 45

Operation

%

% %

4.3.2 SAFE – Fail-safe position

If you want to move the valve to fail-safe po-sition, proceed as follows:

Select Code 0, press the button, AUtO orMAN appears on the display, Code 0blinks.

Turn the button until SAFE appears.

Press the button to confirm this setting.

Operating mode SAFE has been selected,symbol S for the fail-safe position appears.

Caution!The valve moves to the fail-safe position.

Once the positioner is initialized, the currentvalve position is indicated on the digital dis-play in %.

If you want to return the valve from thefail-safe position to the operating modeAUtO or MAN, the button must bepressed while Code 0 is active.

When the code number blinks, turn thebutton to switch to the desired operatingmode.Press the button to confirm.

5 Start-up and settings

Note!A summary about start-up and operationcan be found in section 8 on page 66. Aleaflet including the same summary is alsoenclosed with the positioner.

Connect pneumatic supply air(Supply 9), making sure the pressure iscorrect as described in section 3.1.

Apply an electrical reference variable of4 to 20 mA (terminals 11 and 12).

The voltage supply >19 V DC for versionwith a solenoid valve must be connectedat terminals 81 (+) und 82 (–).

Warning!The signal pressure supplied maycause the actuator stem to move.Risk of injury!

Note!The positioner performs a test in the start-upphase while following its automation task atthe same time. During the start-up phase,operation on site is unrestricted, yet writeaccess is restricted.

46 EB 8384-3 EN

Start-up and settings

S

5.1 Determining the fail-safeposition

To adapt the positioner to the operating di-rection of the actuator, set slide switch toAIR TO OPEN or AIR TO CLOSE.

AIR TO OPEN = Signal pressure opens thevalve, for fail-safe position: actuator stemextends/valve closed

AIR TO CLOSE = Signal pressure closes thevalve, for fail-safe position: actuator stemretracts/valve open.

The switch position is prompted prior to aninitialization. After an initialization has beencompleted, changing the switch positiondoes not have any effect on the operation ofthe positioner.

5.2 Setting the volume restriction Q

The volume restriction Q is used to adapt theair delivery to the size of the actuator:

Actuators with a transit time < 1 s, e.g.linear actuators with an effective areasmaller than 240 cm², require a re-stricted air flow rate (MIN).

Actuators with a transit time ≥ 1 s do notrequire the air flow rate to be restricted(MAX).

The position of volume restriction Q also de-pends on how the signal pressure is routedat the actuator in SAMSON actuators:

The “SIDE“ position applies for actuatorswith a loading pressure connection at theside, e.g. Type 3271-5.

The “BACK“ position applies for actua-tors with a loading pressure connectionat the back, e.g. in Type 3277-5.

The “SIDE”restriction position always appliesfor actuators from other manufacturers.

Overview · Position of the volume restriction Q*

Signalpressure

Transittime

< 1 s ≥ 1 s

Connection at the side MIN SIDE MAX SIDE

Connection at the back MIN BACK MAX BACK

* Intermediate positions are not permitted.

Note! The positioner needs to be initializedagain after the position of the restriction hasbeen changed.

5.3 Adapting the display

The data representation on the positionerdisplay can be turned by 180°.If the displayed data appear upside down,proceed as follows:

Reading direction for rightattachment of pneumaticconnections

Reading direction for leftattachment of pneumaticconnections

Turn the button until Code 2 appears,and press the button to confirm Code2, Code 2 blinks.

Turn button until the display is ad-justed to the desired direction, then con-firm reading direction by pressing the

button.

EB 8384-3 EN 47


5.4 Limiting the signal pressure

If the maximum actuator force may causedamage to the valve, the signal pressuremust be limited. Select Code 3 to enableconfiguration and then access Code 16 toset the pressure limit to 1.4, 2.4 or 3.7 bar.

The required signal pressure limit is only au-tomatically recognized on initializationwhen the fail-safe position AIR TO OPEN isset.

5.5 Checking the operatingrange of the positioner

To check the mechanical attachment and theproper functioning, the valve should bemoved through the operating range of thepositioner in the manual operating modewith the manual reference variable.

Code 0Selectmanual operationDefault MAN

Code 1Position valve using therotary pushbutton, thecurrent angle of rotation isindicated

1. Turn the button until Code 0 appears,then confirm Code 0 by pressing the

button.2. Turn the button until MAN appears in

the display, i.e. manual operating mode,confirm selected operating mode bypressing the button.

3. Turn the button until Code 1 appears,confirm Code 1 by pressing button.The hand symbol and Code 1 blink.

4. Position control valve by turning thebutton several times until pressure buildsup, and the control valve moves to its fi-nal positions so that the travel/angle ofrotation can be checked.The permissible range has been ex-ceeded when the displayed angle ishigher than 30°, and the outer right orleft bar graph element blinks.If this is the case, it is absolutely neces-sary to check lever and pin position asdescribed in section 2.

Note!If the selected pin position is smaller than in-tended for the respective travel range, thepositioner switches to the SAFE mode, thevalve moves to the fail-safe position (seesection 4.3.2 on page 44).

5. Initialize positioner as described in sec-tion 5.6.

48 EB 8384-3 EN


5.6 Initialization

During initialization the positioner adapts it-self optimally to the friction conditions andthe signal pressure demand of the controlvalve.The type and extent of self-adaptation de-pends on the set initialization mode (seesection 5.6.1).MAX is the default setting for initializationbased on the maximum nominal range.

If configuration is enabled via Code 3,Code 6 can be used to change to other ini-tialization modes.

If the positioner has been initialized once al-ready, it will automatically go to the operat-ing mode used last after the electrical refer-ence variable is applied, Code 0 appearson the display.

On initializing the positioner for the firsttime, the hand symbol appears on thedisplay.

Note!Every time you re-initialize the positioner, itshould be reset to its basic setting includingthe default values. Refer to section 5.9 onpage 59.

Start the initialization process by press-ing the INIT key with a suitable tool.

The time required for an initialization pro-cess depends on the transit time of the actu-ator and take several minutes.Positioners with EXPERT+ diagnostic func-tions start plotting the reference graphs after

EB 8384-3 EN 49


Simplified start-up!For most applications, the positioner with its default settings is ready for operation,provided it has been properly attached.After the fail-safe position and the volume restriction have been set, the positioner onlyneeds to be initialized by pressing the INIT key.

Caution!Prior to starting the initialization procedure, check the maximum permissible supplypressure of the control valve to prevent the valve from being damaged. On initialization,the positioner supplies the maximum available supply pressure. If necessary, restrict thesignal pressure by using a pressure reducing valve upstream of the control valve.Initialization is run in default mode MAX (section 5.6.1). During this process, thepositioner adapts itself optimally to the maximum travel/angle of rotation range.The only parameter that must be checked is the direction of action, i.e. whether the defaultsetting (Code 7 to = increasing/increasing) matches the application or whether itmust be changed.The initialization modes described in following serve to individually adapt and optimizethe positioner to the way it is attached to the valve.

the initialization process has been com-pleted. See note at the end of this section.

Warning!During the initialization, the controlvalve moves through its entiretravel/angle of rotation range.Therefore, do not start initializationwhile a process is running, but onlyduring start-up, when all shut-offvalves are closed.Note!The initialization procedure can beinterrupted while running by press-ing . StOP appears three secondslong and the positioner then movesto the fail-safe position.

Alternating displaysInitialization running

Bar graph displayindicating the progress ofthe initialization

Initialization successful,positioner in automaticoperating mode

After a successful initialization, thepositioner runs in control operation indi-cated by the control symbol.

The control position in % predetermined bythe reference variable appears on the dis-play.

A malfunctioning leads to the process beinginterrupted. The initialization error appearson the display according to how it has beenclassified by the condensed status. See sec-tion 5.7 on page 57.

If the slide switch is set to AIR TO CLOSE,the positioner automatically switches to thedirection of action increasing/decreasing() on successful completion of initializa-tion. This results in the following assignmentbetween reference variable and valve posi-tion:

Fail-safeposition

Direction ofaction

ValveClosed at Open at

Actuator stemextends FA

AIR TO OPEN 4 mA 20 mA

Actuator stemretracts FE

AIR TO CLOSE 20 mA 4 mA

The tight-closing function is activated.Set Code 15 (final position w>) to 99 % forthree-way valves.Further settings relevant for the valve can beentered subsequently.

Note!Positioner with integrated EXPERT+ diagnos-tics automatically start to plot the referencegraphs (drive signal y d1 and hysteresis d2)after initialization has been completed. TESTd1 and d2 appear on the display in an al-ternating sequence.An unsuccessful plotting of the referencegraphs is indicated on the display by Code81 (see error code list).

50 EB 8384-3 EN


%

After the initialization has been successfullycompleted, the positioner still works prop-erly, even though the reference graph plot-ting has not been completed successfully.The reference graphs are required for theextended diagnostic functions of EXPERT+.

5.6.1 Initialization modes

After enabling configuration with Code 3and accessing Code 6, you can choose oneof the initialization modes MAX, NOM,MAN or SUb to start initialization.ZP, the zero calibration is described in sec-tion 5.8 on page 58.

MAX – Initialization based on maximumrange

Initialization mode for simplified start-up forvalves with two clearly defined mechanicaltravel stops, e.g. three-way valves.

The positioner determines travel/angle ofrotation of the closing member from theCLOSED position to the opposite side andadopts this travel/angle of rotation as theoperating range from 0 to 100 %.

Enable configuration:

Default OFF

Turn →Code 3, press ,

turn → ON, press .

After enabling:

Default MAX


turn →MAX, press .

Press INIT key to start initialization!

The initialization procedure maytake several minutes, depending onthe actuator size, as the valve movesthrough its entire travel/angle of ro-tation range.

Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See the note on page50.

Note!For MAX initialization, the positioner cannotindicate nominal travel/angle of rotation inmm/°, Code 5 remains disabled.

In addition, the lower (Code 8) and the up-per (Code 9) x-range value can only be dis-played and modified in %.During MAX initialization, an increased sys-tem deviation (undefined final position of theactuator) in the upper control range may oc-cur with some control valves due to thepneumatic actuator design.

EB 8384-3 EN 51


If you want the display to indicate mm/°,proceed as follows after configuration hasbeen enabled:


turn →Select pin position entered duringinstallation, press .

If you now switch to Code 5, the nominalrange appears in mm/°.The lower and upper x-range values forCode 8 and 9 are displayed in mm/° andcan be adapted accordingly.

NOM – Initialization based on nominalrange

Initialization mode for globe valves, espe-cially for valves with maximum ranges thatare clearly greater than the required nomi-nal range.For this initialization mode, the followingparameters must be entered: pin position(Code 4), nominal travel/angle (Code 5)and, if required, the direction of action(Code 7).

The calibrated sensor enables the effectivevalve travel to be preset very accurately.During the initialization procedure, thepositioner checks whether the control valvecan move through the indicated nominalrange (travel or angle) without collision.In case of a positive result, the indicatednominal range is adopted with the limits oflower x-range and upper x-range values asthe operating range.

Note!The maximum possible travel must alwaysbe greater than the nominal travel entered.If this is not the case, the initialization isinterrupted (error indication Code 52) be-cause the nominal travel is not achieved.


Default OFF


turn →ON, press .

After enabling:

Default OFF

Turn → Code 4, press ,


Default 15


turn →Enter nominal valve travel,

press .

52 EB 8384-3 EN


mm

mm

Default MAX


turn →NOM, press .



Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See note on page 50.

MAN – Initialization based on a manuallyselected range

(with default upper x-range value by meansof manual adjustment).Initialization mode just as NOM, however,for starting up valves with unknown nominalrange.In this mode, the positioner expects the con-trol valve to be moved manually to the de-sired OPEN position prior to enabling theinitialization procedure.The upper range travel/angle of rotationvalue is adjusted using the rotarypushbutton. The positioner uses this OPENposition and the CLOSED position to calcu-late the differential travel/angle and accepts

it as the operating range with the lowerx-range value and upper x-range value be-ing the limits.


Default OFF


turn →ON, press .

After enabling:



Turn →Code 6 , press ,

turn →MAN, press .

Default MAX


turn →MAN, press .

Default MAN

Turn →Code 1, press ,Code 1 blinks.

EB 8384-3 EN 53


Turn until the valve reaches its OPEN po-sition, press .



Positioners with EXPERT+ diagnostic func-tions automatically start plotting the refer-ence graphs after the initialization processhas been completed. See note on page 50.

SUb

(substitute configuration, without initializa-tion)

This initialization mode is an emergencymode. The positioner parameters are esti-mated and not determined by an initializa-tion procedure, so that a high stationary ac-curacy cannot be expected.You should always select a different initial-ization mode if the plant allows it.

The initialization mode SUb is used to re-place a positioner while the process is in op-eration. For this purpose, the control valve isusually fixed mechanically in a certain posi-tion, or pneumatically by means of a pres-

sure signal which is routed to the actuatorexternally. The blocking position ensuresthat the plant continues to operate with thisvalve position.

The spare positioner should not be initial-ized. If necessary, reset the spare positionerusing Code 36.

After the old positioner has been replacedwith a new one, the following parametersmust be entered: pin position (Code 4),nominal range (Code 5), direction of action(Code 7) and closing direction (Code 34).The default travel limit of 100 % (Code 11)must be disabled with OFF.In addition, the blocking position (Code 35)must be adjusted with the button so thatit matches the position of the previouslyblocked valve.

The parameters KP (Code 17), TV (Code 18)and the pressure limit (Code 16) should re-main set to their default values. If the config-uration data of the new positioner areknown, it is recommended to accept its KPand TV values.

After setting the AIR TO OPEN/CLOSEswitch for the fail-safe position, setting thevolume restriction and pressing the INIT key,the positioner calculates its configurationdata on the basis of the blocking positionand the closing direction as well as the otherentered data.The positioner switches to manual operation,subsequently the blocking position should becanceled as described on page 56.

54 EB 8384-3 EN



Default OFF


turn →ON, press .

After enabling:

Default OFF


press →Select pin position entered dur-ing installation,press .

Default 15


turn →Enter nominal travel/angle,

press .

Default MAX


turn →SUb, press .

Default


turn →Retain direction of action orselect .

Press .

Default 100.0


turn →Deactivate travel limit,

press .

Default OFF

Turn →Code 16,

Retain default value for pressure limit,change value only if necessary.

Default 7

Turn →Code 17

Retain default. Proceed as follows only ifknown:

Press ,

EB 8384-3 EN 55


mm

mm

turn →Select KP,

press .

Default 2

Turn →Code 18,

Retain default TV, change only if known.

Default CCL


turn →Select closing direction.

CCL = counterclockwise and CL = clockwise.

Direction of rotation which causes the valveto move to the CLOSED position (view ontothe rotary switch movement while positionercover is open).

Press .

Default 0.0


turn →Enter blocking position, e.g.5 mm (read off at travel indicator scale ofthe blocked valve or measure with a ruler).

Press .

Set switch for fail-safe position AIR TOOPEN or AIR TO CLOSE as described insection 5.1 on page 44.

Set volume restriction as described insection 5.2 on page 45.

Press INIT key!

The positioner switches to manual operat-ing mode!

The adjusted blockingposition is indicated

As initialization has not been carried outcompletely, the error code 76 (no emer-gency mode) and possibly also error code57 may appear on the display.These alarms do not influence thepositioner’s readiness for operation.

Canceling the blocking position

For the positioner to follow its referencevariable again, the blocking position mustbe canceled and the positioner must be setto automatic operation AUtO as follows:

Press →Code 1, press ,

turn in order to move the valve slightlypast the blocking position, then cancel me-chanical blocking.

Press .

Turn →Code 0, press ,Code 0 blinks.

56 EB 8384-3 EN


mm

mm

Turn until AUtO appears on the display.

Press to confirm the operating mode.

The positioner switches to automatic oper-ating mode!

The current valve position is indicated in %.

Note!If the positioner shows a tendency to oscil-late in automatic operating mode, the pa-rameters KP and TV must be slightly cor-rected. Proceed as follows:Set TV to 4 (Code 18).If the positioner still oscillates, the gain KP(Code 17) must be decreased until thepositioner shows a stable behavior.

Zero point correction

Finally, if process operations allow it, thezero point must be adjusted according tosection 5.8 on page 58.

Caution!The positioner automatically moves to zeropoint.

5.7 Fault/failure

All status and fault alarms are assigned aclassified status in the positioner.

To provide a better overview, the classifiedalarms are summarized in a condensed sta-tus for the positioner (see section 6).

The condensed status appears on the dis-play with the following symbols:

Condensed status Display

Maintenance alarm

Maintenancerequested/Mainte-nance demanded

Function check Text

No alarm

If the positioner has not been initialized, thefault symbol appears on the display asthe positioner cannot follows its referencevariable.Additionally, a signal is issued over the faultalarm contact when certain faults occur (seeerror code list).

To access the error codes, turn the buttonpast the Code 50.Err appears on the display with the respec-tive error code.For the cause of the fault and its remedy, re-fer to the codes listed in section 12 onpage 71 onwards.

EB 8384-3 EN 57


Display indicating anerror code

After an error code has occurred, youshould first try to confirm it as follows:


Turn →Code 3 , press ,

turn →ON, press .

Turn until the error code number ap-pears, then press to confirm it.

Should the error occur again, read the rem-edy instructions in the error code list.

Occurrences such as when the total valvetravel is exceeded or when the temperatureleaves the permissible temperature range af-fect the condensed state and cause a faultalarm to be displayed depending on its clas-sification.

The optional EXPERT+ diagnostics generatesadditional diagnostic alarms which are in-cluded in the condensed status with theircorresponding status classification.When a diagnostic alarm is issued byEXPERT+, this is displayed by Code 79 (seeerror code list).

5.8 Zero calibration

In case of discrepancies with the closing po-sition of the valve, e.g. with soft-sealedplugs, it may become necessary torecalibrate the zero point.


Default OFF


turn →ON, press .

After enabling:

Default MAX


turn →ZP, press .

Press INIT key!

Zero calibration is started, the positionermoves the control valve to the CLOSED posi-tion and readjusts the internal electrical zeropoint.

The valve briefly moves from the cur-rent travel/angle of rotation positionto the closed position.

58 EB 8384-3 EN


S

5.9 Reset to default values

This function resets all parameters to the fac-tory default values (see code list in sec-tion 12).


Default OFF


turn →ON, press .

After enabling:

Default OFF


turn →RUN, press .

All parameters are reset and can be recon-figured.

5.10 Start-up via local interface(SSP)

The positioner must be supplied with at least4 mA.The positioner can be connected directly tothe PC via the local serial interface and theserial interface adapter.

Use the TROVIS-VIEW software with 3730-3device module installed. Refer to section 13for more details.

For start-up and settings, proceed as de-scribed in section 5, 5.1 to 5.4 and thenproceed as described in section 13.

Note!Depending on the firmware installed in thepositioner, a certain minimum version of theTROVIS-VIEW device module is required forcommunication.If you have already installed the software,you can download updates atwww.samson.de (Support & Downloads -TROVIS VIEW Updates).

5.11 Start-up over HART®

communication

The positioner must be supplied with at least4 mA current. The FSK modem must be con-nected in parallel to the current loop.

A DTM file (Device Type Manager) conform-ing to the Specification 1.2 is available forcommunication. This allows the device, forexample, to be run with the PACTware op-erator interface. All the positioner's parame-ters are then accessible over the DTM andthe operator interface.

EB 8384-3 EN 59


For start-up and settings, proceed as de-scribed in section 5, 5.1 to 5.4. Refer to thecode list in section 12 as well as section13.4 for the parameters necessary for theoperator interface.

Note!The write access for HART® communicationcan be disabled over Code 47. You canonly disable or enable this function locally atthe positioner.The write access is enabled by default. Theon-site operation including the INIT key canbe locked over HART®communication. Theword "HART" then blinks on the displaywhen Code 3 is selected. This locking func-tion can only be disabled over HART® com-munication. On-site operation is enabled bydefault.

Note!In the case, complex functions are started inthe positioner, which require a long calcula-tion time or lead to a large quantity of databeing stored in the volatile memory of thepositioner, the alert “busy” is issued by theDTM file.

This alert is not a fault alarm and can sim-ply be confirmed.

6 Status and diagnostic alarms

The Type 3730-3 Positioner contains an in-tegrated diagnostic approach to generateclassified status and diagnostic alarms.

There are two different on-board diagnosticsavailable: the standard integrated diagnos-tics (EXPERT) and the optional extendedEXPERT+ diagnostics.

6.1 Standard EXPERT diagnostics

The standard EXPERT diagnostics providesinformation about positioner states such asoperating hours counter, process monitor-ing, number of zero calibrations andinitializations, total valve travel, tempera-ture, initialization diagnostics, zero/controlloop errors, logging of the last 30 alarms,etc.

In addition, the standard EXPERT diagnosticsgenerates diagnostic and status alarmswhich allow faults to be pinpointed quicklywhen a fault occurs.

Alarms are classified in the following maingroups:

Status

Operation

Hardware

Initialization

Data memory

Temperature

60 EB 8384-3 EN

Status and diagnostic alarms

6.2 Extended EXPERT+

diagnostics

In addition to the standard EXPERT diagnos-tic features, the optional EXPERT+ extendeddiagnostics provides the following onlineand offline test functions which enable sig-nificant statements on the condition of theentire control valve.

Online test functions (monitoring functions)

Data logger

Histogram

Cycle counter

Valve end position trend

Y = f (X) diagram (drive signal)

Hysteresis test

Offline test functions (manual functions)

Y = f (X) diagram over the entire valvetravel range

Hysteresis test over the entire valve travelrange

Static characteristic

Step response test

The diagnostic tests are completely inte-grated in the positioner. Further statusalarms are generated from the extensive in-formation gained in the diagnostic tests ofEXPERT+ which provide the user with infor-mation covering the whole control valve.The required reference curves are automati-cally plotted after initialization and saved inthe positioner if EXPERT+ is activated.The optional diagnostic functions providedby EXPERT+ can be selected when ordering

the positioner. Additionally, it is possible toactivate EXPERT+ at a later point in time inan existing positioner.For this purpose, an activation code can beordered, specifying the serial number of thepositioner.

6.3 Classification of the statusalarms and the condensedstatus

The alarms are assigned a classification sta-tus in the positioner. The following states aredifferentiated between:

Maintenance alarmThe positioner cannot perform its controltask due to a functional fault in the device orin one of its peripherals or an initializationhas not yet been successfully completed.

Maintenance requiredThe positioner still performs its control task(with restrictions). A maintenance demandor above average wear has been deter-mined. The wear tolerance will soon be ex-hausted or is reducing at a faster rate thanexpected. Maintenance is necessary in themedium term.

Maintenance demandedThe positioner still performs its control task(with restrictions). A maintenance demandor above average wear has been deter-mined. The wear tolerance will soon be ex-hausted or is reducing at a faster rate thanexpected. Maintenance is necessary in theshort term.

EB 8384-3 EN 61


Function checkTest or calibration procedures are beingperformed. The positioner is temporarily un-able to perform its control task until this pro-cedure is completed.

Classification process in the positionerAn alarm is assigned to one of followingclassified states in the table:

Condensed status

To provide a better overview, the state of thepositioner is summarized in a condensedstatus which is made up from a summary ofall classified positioner alarms.

If an event is classified as “No alarm”, thisevent does not have any affect on the con-densed status of the positioner.

The condensed status is displayed in the en-gineering tool as well as on the positionerdisplay as in the following table:

62 EB 8384-3 EN


Status alarm Engineering tool

Alarm inactive

Alarm activeClassified as “No alarm”

Alarm activeClassified as “Maintenance

required”/”Maintenance demanded”

Alarm activeClassified as “Function

check”

Alarm activeClassified as “Maintenance

alarm”

Status alarm Enginee-ring tool

Positionerdisplay

“Maintenance alarm”

“Maintenance required”"Maintenance

demanded”

“Function check”Text

“No alarm”

Status modification

The classification of the status alarms can bechanged as required.They can be modified using TROVIS-VIEWsoftware over the local SSP interface.

In addition, the classification can be modi-fied over the parameters in DD or easily en-tered over the DTM.

Note!All additional alarms generated by EXPERT+

have the status “No alarm” by default.

Logging and displaying diagnosticfunctions/alarms

The last 30 alarms are logged in thepositioner. However, it is important to notethat the same alarm is only logged oncewhen it first occurs.The alarms and the condensed states ap-pear on the display as described in the codelist (section 12).In addition, the diagnostic parameters areissued over the communication interface ofthe positioner.

The diagnostic functions can easily be dis-played and configured using theTROVIS-VIEW software connected over thelocal interface (SSP) or over the DTM.

EB 8384-3 EN 63


7 Adjusting the limit switch

The positioner version with inductive limitswitch has one adjustable tag (1) mountedon the shaft which operates the proximityswitch (3).

For operation of the inductive limit switch,the corresponding switching amplifier (seesection 3.2.1) must be connected to the out-put.

If the tag (1) is inside the field of the switch,the switch assumes a high resistance. If thetag is outside of the field, the switch assumesa low resistance.

Normally, the limit switch is adjusted suchthat it will provide a signal in both end posi-tions of the valve. The switch, however, canalso be adjusted to indicate intermediatevalve positions.

The desired switching function, i.e. whetherthe output relay shall be picked up or re-leased when the tag has entered the field,has to be determined, if necessary, at theswitching amplifier.

Note!The inductive limit switch replaces the soft-ware limit switch A1 with terminal assign-ment +41/–42.Each switching position can optionally beset to indicate when the tag has entered thefield, or when it has left the field.The second software limit switch remains ef-fective, the function of the software limitswitch A1 is disabled.

Fig. 20 · Adjustment of the limit switch

64 EB 8384-3 EN

Adjusting the limit switch

Adjustment screw (2) Tag (1) Proximity switch (3)

Software adaptation

Code 38 (inductive alarm is set to YES).The inductive limit switch is connected to theterminals +41/–42.The device is set up accordingly when deliv-ered ex works SAMSON.

Setting the switching point:

Note!During adjustment or testing, the switchingpoint must always be approached frommid-position (50 %).

To ensure safe switching under any ambientconditions, the switching point should beadjusted to a value of approx. 5 % beforethe mechanical stop (OPEN – CLOSED).

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 adjust-

ment screw (2) until the tag enters orleaves the field and the switching ampli-fier responds. You can measure theswitching 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. Use the MAN function to move the

positioner to 95 % (see LC display).3. Adjust the tag (1) using the yellow ad-

justment screw (2) until the tag enters orleaves the field of the proximity switch(3).You can measure the switching voltageas an indicator.

Contact function:

Tag leaving the field > Contact is made.Tag entering the field > Contact is opened.

EB 8384-3 EN 65

Adjusting the limit switch

8 Quick start-up guide

8.1 Mounting

Direct attachment

to SAMSON Type 3277 Actuator

Travel mm Actuator cm² Pin position

7.5 120 25

15 120/240/350 35

15/30 700 50

Note!Standard delivery includes lever M readyassembled with the follower pin on 35 mmpin position for 15 mm travel!

To mount the positioner, lift the lever so thatthe follower pin rests on the follower clampof the actuator stem.

NAMUR attachment

Determine the maximum travel range ofthe control valve from the closed positionto as far it will go in the other direction.

Select the lever to match the maximumtravel range as well the next largest pinposition and screw onto the shaft of thepositioner.

Lever option/pin distance:see pin position table (Code 4) or coverplate on the positioner.

Screw the NAMUR bracket onto thevalve yoke so that it is aligned centrallyto the slot of the follower plate when thetravel position is at 50 %.

Secure the positioner to the NAMURbracket, making sure that the followerpin is in the slot of the follower plate.Make sure the lever can still move.

Attachment to rotary actuators

Lever M pin position 90° Put the valve into the closed position, de-

termine the opening direction. Place the follower plate on the slotted ac-

tuator shaft and fasten it to the couplingwheel. Attach the top pair of bracketsand the bottom pair of brackets to theactuator.

Place the positioner on the brackets andscrew tight, making sure that the leverwith its follower pin engages the slot ofthe coupling wheel, while taking into ac-count the opening direction.It is important to make sure that the le-ver's mid position corresponds to the midtravel of the valve (lever's mid position =the lever is parallel to the long side of thepositioner casing).

Pneumatic connections

Screw the threaded connections only intothe attached connection block, connect-ing plate or pressure gauge block fromthe accessories.

66 EB 8384-3 EN

Quick start-up guide

8.2 Start-up

Connect pneumatic supply air (1.4 to6 bar).

Apply an electrical reference variable (4 to20 mA).

Set the fail-safe position

Position the slide switch according tofail-safe position of the control valve:AIR TO OPEN or AIR TO CLOSE.

Adapt the volume restriction Q to theactuator size

Only set the restriction for actuators< 240 cm² to:MIN SIDE for connection at the side orMIN BACK for connection at the back.

Note!After each change of the volume restrictionsetting, the positioner must be re-initialized.

Changing the reading direction of thedisplay

(if necessary)


turn →Display ok, press .

Operation

Selecting the parameters or values

Each parameter has a code number whichis shown in the display. Use the button toselect.Turn the button to select parameters orvalues and then push to confirm.

Select and confirm ESC to prevent an en-tered value from being accepted.

Enabling parameters

Parameters that have a code marked withan asterisk (*) can only be changed whenthey are enabled beforehand using Code 3.

The configuration mode is shown in the dis-play with the symbol.

See the code list on page 71 onwards orcover plate of the positioner for a descrip-tion of the menu codes.

EB 8384-3 EN 67


8.3 Initialization

Note!Perform a reset (Code 36) prior to each ini-tialization

Turn →Code 3, ↵

turn →ON, ↵

turn →Code 36, ↵

select RUN, ↵

Caution!During initialization, the valve runs throughits whole range of travel/angle of rotation.

8.3.1 Simplest method (MAX)

Mount and start up the positioner andpress the INIT key!READY!The positioner adapts itself automatically tothe maximum travel/angle of rotationrange of the control valve.

8.3.2 Precise method (NOM)

Positioner adapts itself precisely to the nomi-nal travel/rotational angle of the controlvalve!

Mount and start up the positioner, then pro-ceed as follows:

Turn →Code 3, ↵

turn →ON, ↵

turn →Code 4, ↵Select pin position, ↵

turn →Code 5, ↵

Enter nominal travel/range, ↵

turn →Code 6, ↵

select NOM, ↵

Press INIT key!

8.3.3 Manual method (MAN)

Initialization mode same as NOM, but forstart-up of control valves with unknownnominal ranges. The final position oftravel/angle of rotation (valve open) is en-tered manually.

Mount and start up the positioner, then pro-ceed as follows:

Turn →Code 0, ↵ ,

turn →select MAN, ↵

turn →Code 1, ↵ ,

turn →valve open position, ↵

turn →Code 3, ↵ ,

turn →ON, ↵

turn →Code 6, ↵ , select MAN, ↵

Press INIT key!

Note!After imposing the electrical reference vari-able, the positioner is in the last used oper-ating mode. Code 0 appears in the display.If the positioner has not yet been initialized,the fault symbol appears on the displayand the symbol blinks.

68 EB 8384-3 EN


9 Upgrading options

9.1 Retrofitting an inductive limitswitch

Required retrofit kit:Limit switch Order no. 1400-7460

Note! For explosion-protected devices, therequirements in section 11 need to be kept.

1. Take off the rotary pushbutton (3) andcap (1), unthread the five fixing screws(2) and lift off the plastic cover (9).

2. Use a knife to cut an opening at themarked location (4).

3. Push the connector (11) with cablethrough the opening and secure theproximity switch (7) on the cover with adot of glue.

4. Remove the jumper at the socket ST1 ofthe top board and insert the cable con-nector (11).

5. Guide the cable in such a manner thatthe plastic cover can be placed back ontothe positioner. Insert the fixing screws (2)and screw tight. Attach the clampingplate (8) onto the proximity switch.

6. Attach the rotary switch (5). Make surethe flattened side of the positioner shaftis turned so that the rotary switch (5) canbe attached with the metal tag next tothe proximity switch.

7. Note!On start-up of the positioner, set the op-tion "inductive alarm" under Code 38from NO to YES.

EB 8384-3 EN 69

Upgrading options

Fig. 21 · Retrofitting an inductive limit switch

1

2

4

3

5

8

7

6

9 7

Socket ST1(11)

1 Cap2 Screws3 Rotary pushbutton4 Marking5 Rotary switch

6 Metal tag7 Proximity switch8 Clamping plate9 Plastic cover11 Connector

9.2 Activation of optionalEXPERT+ diagnostics

The optional extended EXPERT+ diagnosticscan be activated subsequently.

The required activation code is order num-ber 1400-9318.On ordering this option, specify the serialnumber of the positioner (see nameplate orin the software).

Enter the activation code in Code 48 →d8EXPERT+ activation.Plot reference curve with Code 48 →d7Start reference run (see also Code 48 incode list).

10 Maintenance

The positioner does not require any mainte-nance.

There are filters with a 100 μm mesh size inthe pneumatic connections for supply andoutput which can be removed and cleaned,if required.

The maintenance instructions of any up-stream supply air pressure reducing stationsmust be observed.

11 Servicing explosion-protecteddevices

If a part of the positioner on which the ex-plosion protection is based needs to be ser-viced, the positioner must not be put backinto operation until an expert has inspectedthe device according to explosion protectionrequirements, has issued a certificate statingthis or given the device a mark of confor-mity.

Inspection by an expert is not required if themanufacturer performs a routine test on thedevice prior to putting it back into opera-tion. The passing of the routine test must bedocumented by attaching a mark of confor-mity to the device.

Explosion-protected components may onlybe replaced by original, checked compo-nents from the manufacturer.

Devices that have already been used outsideof hazardous areas and are intended foruse in hazardous areas in future must com-ply with the safety demands placed on re-paired devices. Prior to operation, they mustbe tested according to the specifications sti-pulated for "Repairing explosion-protecteddevices".

70 EB 8384-3 EN

Maintenance

12 Code list

Codeno.

Parameter – Display, values[default setting] Description

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

0 Operating mode[MAN]AUtOSAFEESC

AUtO = Automatic mode MAN = Manual modeSAFE = Fail-safe position ESC = EscapeSwitchover from automatic to manual mode is smooth.In fail-safe mode, the symbol S appears on the display.In MAN and AUtO mode, the system deviation is represented bythe bar graph elements.When the positioner is initialized, the numerical display indicatesthe valve position or the angle of rotation in %, otherwise the po-sition of the sensor in relation to the central axis is displayed indegrees °.

1 Manual w0 to 100 [0] %of the nominal range

Adjust the manual set point with the rotary pushbutton, thecurrent travel/angle is displayed in % when the positioner is ini-tialized, otherwise the sensor position in relation to the centralaxis is indicated in degrees °.

2 Reading directionNormal or upside downESC

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

3 Enable configuration[OFF] ON ESC

Enables the option to modify data(automatically deactivated when the rotary pushbutton has not beenoperated for 120 s.)HART blinks on the display when the on-site operation is locked.Codes marked with an asterisk (*) can only be read and notoverwritten.Likewise, codes can only read over the SSP interface.

EB 8384-3 EN 71

Code list

4* Pin position[OFF]17, 25, 35, 50 mm70, 100, 200 mm,90° with rotary actuatorsESC

Note!If you select a pin position inCode 4 that is too small, thepositioner switches to SAFEmode for reasons of safety

For initialization using NOM or SUb, the follower pin must be in-serted into the correct pin position according to the valvetravel/angle of rotation.Pin position Standard Adjustment rangeCode 4 Code 5 Code 517 7.5 3.6 to 17.725 7.5 5.0 to 25.035 15.0 7.0 to 35.450 30.0 10.0 to 50.070 40.0 14.0 to 70.7100 60.0 20.0 to 100.0200 120.0 40.0 to 200.090° 90.0 24.0 to 110.0

5* Nominal range[15.0] mm or angle °ESC

For initialization using NOM or SUb, the nominal travel/angle ofrotation of the valve must be entered.The permissible adjustment range depends on the pin positionaccording to the table.After initialization has been successfully completed, the maximumnominal travel/angle reached on initialization is displayed.

6* Init mode[MAX]NOMMANSubZPESC

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

the closure member from the CLOSED position to theopposite stop in the actuator.

NOM: Nominal range of the control valve, the travel/angle ofthe closure member measured from the CLOSED positionto the indicated OPEN position.

MAN: Manual adjustment: upper x-range valueSUb: No self-adjustment (emergency mode)ZP: Zero calibration

7* w/x[]

ESC

Direction of action of the reference variable w in relation to thetravel/angle of rotation x (increasing/increasing or in-creasing/decreasing)Automatic adaptation:AIR TO OPEN:On completing initialization, the direction of action remains in-creasing/increasing (), a globe valve opens as the mA signalincreases.AIR TO CLOSE:On completing initialization, the direction of action changes toincreasing/decreasing ( ), a globe valve closes as the mAsignal increases.

72 EB 8384-3 EN

Code list

8* Lower x-range value0.0 to 80.0 [0.0] % of thenominal range,Specified in mm or angle ° providedCode 4 is set

ESC

Lower range value for the travel/angle of rotation in the nominalor operating range.The operating range is the actual travel/angle of the controlvalve and is limited by the lower x-range value (Code 8) and theupper x-range value (Code 9).Usually, the operating range and the nominal range are iden-tical. The nominal range can be limited to the operating range bythe lower and upper x-range values.Value is displayed or must be entered.The characteristic is adapted. See also the example in Code 9!

9* Upper x-range value20.0 to 100.0 [100.0] %nominal range,Specified in mm or angle ° provided

Code 4 is set

ESC

Upper range value for the travel/angle of rotation in the nominalor operating range. Value is displayed or must be entered.The characteristic is adapted.Example: The operating range is modified, for example, to limitthe range of a control valve which has been sized too large. Forthis function, the entire resolution range of the reference variableis converted to the new limits. 0 % on the display corresponds tothe set lower limit and 100 % to the set upper limit.

10* Lower x-limit[OFF]0.0 to 49.9 % of theoperating rangeESC

Limitation of the travel/angle of rotation downwards to the en-tered value, the characteristic is not adapted.

The characteristic is not adapted to the reduced range. See alsoexample in Code 11.

11* Upper x-limit[100 %]50.0 to 120.0 [100] % ofthe operating rangeor OFFESC

Limitation of the travel/angle of rotation upwards to the enteredvalue, the characteristic is not adapted.Example: In some applications, it makes sense to limit the valvetravel, e.g. if a certain minimum medium flow is required or amaximum flow must not be reached.The lower limit must be adjusted with Code 10, and the upperlimit with Code 11. If a tight-closing function has been set up, ithas priority over the travel limitation!When set to OFF, the valve can be opened past the nominaltravel with a reference variable outside of the 4 to 20 mA range.

EB 8384-3 EN 73

Code list

12* w-start0.0 to 75.0 [0.0] % of thereference variable rangeESC

Lower range value of the applicable reference variable rangemust be smaller than the final value w-end, 0 % = 4 mAThe reference variable range is the difference between w-endand w-start, and must be Δw ≥ 25 % = 4 mA.For an adjusted reference variable range of 0 to 100 % = 4 to20 mA, the control valve must move through its entire operatingrange from 0 to 100 % travel/angle of rotation.In split-range operation, the valves operate with smaller refer-ence variables. The control signal of the control unit to controltwo valves is divided such, for instance, that the valves movethrough their full travel/angle of rotation at only half the inputsignal (first valve set to 0 to 50 % = 4 to 12 mA and second valveset to 50 to 100 % =12 to 20 mA reference variable).

13* w-end25.0 to 100.0 [100.0] % ofthe reference variable rangeESC

Upper range value of the applicable reference variable range,must be greater than w-start.100 % = 20 mA

14* Final position w <0.0 to [1.0] %of the span adjusted viaCode 12/13OFFESC

If w approaches the percentage adjusted towards the final valuethat causes the valve to close, the actuator is immediately com-pletely vented (with AIR TO OPEN) or filled with air (with AIR TOCLOSE).This action always lead to maximum tight-closing of the valve.

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

15* Final position w >[OFF]50.0 to 100.0 %of the span adjusted viaCode 12/13ESC

If w approaches the percentage adjusted towards the final valuethat causes the valve to open, the actuator is immediately com-pletely filled with air (with AIR TO OPEN) or vented (with AIR TOCLOSE).This action always lead to the valve being completely opened.Codes 14/15 have priority over Codes 8/9/10/11.Example: Set the final position w > to 99 % for three-way valves.

16* Pressure limit[OFF]1.4 2.4 3.7 barESC

The signal pressure can adopt the value of the applied supplypressure at the maximum [OFF] or it can be limited in stages of1.4, 2.4 or 3.7 bar. This pressure limitation is already effectiveduring the initialization.Note: After changing a pressure limit already set, the actuatormust be vented once (e.g. by selecting the fail-safe position overCode 0).The pressure limit of double-acting actuators must always be setto OFF after initialization is completed.

74 EB 8384-3 EN

Code list

17* KP step0 to 17 [7]ESC

Displaying or changing KP

Note on changing the KP and TV steps:During the initialization of the positioner, the KP and TV values areoptimized.Should the positioner show a tendency for impermissibly highpost-pulse oscillation due to additional interference, the KP andTV steps can be adapted after the initialization.For this, either the TV step can be increased in increments untilthe desired response behavior is reached or, when the maximumvalue of 4 is reached, the KP step can be decreased in incre-ments.

CAUTION! Changing the KP step influences the system deviation.This effect decreases as the KP step increases.

18* TV step[2]1 2 3 4 OFFESC

Displaying or changing TV,See note under KP stepA change of the TV step has no effect on the system deviation.

19* Tolerance band0.1 to 10.0 [5] % of theoperating rangeESC

Used for error monitoringDetermination of the tolerance band in relation to the operatingrange.Associated lag time [30] s is a reset criterion.If, during initialization, a transit time is determined which is6 times > 30 s, the 6fold transit time is accepted as lag time.

20* Characteristic0 to 9 [0]ESC

Select the characteristic:0: Linear 5: Rotary plug valve linear1: Equal percentage 6: Rotary plug valve eq. perc.2: Reverse equal percentage 7: Segmented ball valve linear3: Butterfly valve linear 8: Segmented ball valve eq. p.4: Butterfly valve eq. percentage 9: User-defined ** Definition over SAMSON TROVIS-VIEW software or HART® communication

21* w-ramp Open0 to 240 s [0]ESC

The time required to pass through the operating range when thevalve opens.Limitation of the transit time (Code 21 and 22):For some applications it is recommendable to limit the transit timeof the actuator to prevent it from engaging too fast in the runningprocess.

EB 8384-3 EN 75

Code list

22* w-ramp Closed0 to 240 s [0]ESC

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

23* Total valve travel0 to 99 · 107 [0]Exponential reading from 9999 travelcycles onwards

RESESC

Totaled double valve travel.Can be reset to 0 by Code 36 RUN.

24* LV total valve travel1000 to 99 · 107

[1 000 000]Exponential reading from 9999 travelcycles onwards

ESC

Limit value of total valve travel. If the limit value is exceeded, thefault symbol and the wrench symbol appear.

25* Alarm mode0 to 3 [2]ESC

Switching mode of software limit switches alarm A1 and A2 inresponding state (when positioner has been initialized).

1) Explosion-protected version according to EN 60947-5-60: A1 ≥ 2.1 mA A2 ≤ 1.2 mA1: A1 ≤ 1.2 mA A2 ≤ 1.2 mA2: A1 ≥ 2.1 mA A2 ≥ 2.1 mA3: A1 ≤ 1.2 mA A2 ≥ 2.1 mA

2) Version without explosion protection0: A1 R = 348 Ω A2 Non-conducting1: A1 Non-conducting A2 Non-conducting2: A1 R = 348 Ω A2 R = 348 Ω3: A1 Non-conducting A2 R = 348 ΩWhen a positioner has not been initialized, the software limitswitches always register the signal as in the state of no response.If there is no mA signal at the terminals 11/12, the software limitswitches both switch to ≤ 1.2 mA signal (Ex) or non-conducting(without explosion protection).Note! The fault alarm output always switches to ≤ 1.2 mA/non-conducting in case of fault arises; it has ≥ 1.2 mA/R = 348 Ωwhen there is no fault.

76 EB 8384-3 EN

Code list

26* Limit value A1OFF0.0 to 100.0 [2.0] % of theoperating rangeESC

Alarm A1 goes into the state of response when the value exceedsthe limit.Displaying or changing the software limit value A1 in relation tothe operating range.Setting has no effect when an inductive limit switch has been in-stalled.

27* Limit value A2OFF0.0 to 100.0 [98.0] % of theoperating rangeESC

Alarm A2 goes into the state of response when the value fallsbelow the limit.Displaying or changing the software limit value A2 in relation tothe operating range.

28* Alarm testReading direction:Standard Turned[OFF] [OFF]RUN 1 1 RUNRUN 2 2 RUNRUN 3 3 RUNESC ESC

Testing the software limit switches alarm A1 and A2 in additionto the fault alarm contact A3.If the test is activated, the respective limit switches five times.RUN1/1 RUN: Software limit switch A1 to ≥ 2.1 mARUN2/2 RUN: Software limit switch A2 to ≥ 2.1 mARUN3/3 RUN: Fault alarm contact A3 to ≤ 1.2 mA

29* Position transmitter x/ix 3)

[]

ESC

Operating direction of the position transmitter; indicates how thetravel/angle position is assigned to the output signal i, based onthe closed position.The operating range (see Code 8) of the valve is represented bythe 4 to 20 mA signal. Values exceeding or falling below thelimits 2.4 to 21.6 mA can be represented.When a positioner has not been initialized (reference variableless than 3.6 mA), the power consumption of the feedback signalis effective (current approx. 1.8 mA).When YES is set in Code 32 , the position transmitter issues thevalue as per Code 30 during initialization or zero calibration.When NO is set in Code 32, 4 mA is issued during a runningself-adaptation.

30* Fault alarm ix 3)

[OFF] HI LOESC

Used to select whether faults causing the fault alarm contact toswitch should also be signaled by the position transmitter outputand how they should be signaledHI ix > 21.6 mA or LO ix < 2.4 mA

EB 8384-3 EN 77

Code list

31* Position transmitter test 3)

–10.0 to 110.0 [defaultvalue is last indicated valueof the position transmitter]% of the operating rangeESC

Testing the position transmitter. Values can be entered in relationto the operating range.The current actual value is used in initialized positioners locallyas the start value (bumpless changeover to the test mode). Ontesting over software, the entered simulation value is issued asthe position feedback signal for 30 seconds.

3)Analog position transmitter: Code 29/30/31 can only be selected if the position transmitter (optional) is installed.

32* Fault alarm with “Functioncheck” condensed statusNO [YES]ESC

Determines whether a fault alarm is to be issued when “Functioncheck” condensed status occurs.

33* Fault alarm with “Mainte-nance alarm” or “Mainte-nance required” condensedstatusNO [YES]ESC

NO: Fault alarm only with “Maintenance alarm” condensedstatusYES: Fault alarm only with “Maintenance alarm” condensedstatus and with “Maintenance required” condensed status

34* Closing directionCL [CCL]ESC

CL: Clockwise, CCL: CounterclockwiseTurning direction in which the valve is moved to the CLOSED po-sition (view onto the rotary switch motion when the positionercover is open).Needs only be entered in initialization mode SUb (Code 6).

35* Blocking position[0] mm/° /%ESC

Entering the blocking position.Distance up to the CLOSED position.Only necessary in initialization mode SUb.

36* Reset[OFF] RUNESC

Resets all start-up parameters to default (factory setting).Note: After setting RUN, the positioner must be re-initialized.

37 Position transmitterYes No

Display only,indicates whether the position transmitter option is installed.

38* Inductive alarm[NO] YESESC

Indicates whether the inductive limit switch option is installed ornot.

39 System deviation e info–99.9 to 999.9 % ,

Display only,indicates the deviation from the set point position (e = w–x).

78 EB 8384-3 EN

Code list

40 Transit time Open info0 to 240 s [0]

Display only,minimum opening time is determined during initialization

41 Transit time Closed info0 to 240 s [0]

Display only,minimum closing time is determined during initialization

42 Auto-w info0.0 to 100.0 % of the span4 to 20 mA

Display only,indicates the supplied automatic reference variable corre-sponding 4 to 20 mA.

43 Firmware infoXxxx

Display only,indicates the device type and the current firmware version of thepositioner in alternating sequence.

44 y info[0] OP0 to 100 %MAX

Display only.The control signal y is displayed in % in relation to the travelrange determined on initialization.MAX: The positioner builds up its maximum output pressure(refer to description for Codes 14 and 15).0 P: The positioner vents the actuator completely(refer to description for Codes 14 and 15).– – –: The positioner has not been initialized.

45 Solenoid valve infoYesNo

Display only,indicates whether a solenoid valve is installed.If a voltage supply is connected at the terminals of the installedsolenoid valve, YES and HIGH appear on the display in alter-nating sequence. If a voltage supply is not connected (actuatorvented, fail-safe position indicated on the display by the Ssymbol), YES and LOW appear on the display in alternating se-quence.

46* Polling address0 to 63 [0]ESC

Select bus address

47* Write protection HART®

YES [NO]ESC

When the write protection function is activated, device data canonly be read, but not overwritten over HART® communication.

EB 8384-3 EN 79

Code list

48 Diagnostics

d Diagnostic parameters

d0 Current temperature–55 to 125

Operating temperature [°C] inside the positioner

d1 Minimum temperature[20]

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

d2 Maximum temperature[20]

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

d3 Number of zerocalibrations

The number of zero calibrations since the last initialization.

d4 Number of initializations The number of initializations that have been performed.

d5 Zero point limit[5 %]0.0 to 100.0 %

Limit for the zero point monitoring.

d6 Condensed status Condensed status, made up from the individual states.OK: Okay, C: Maintenance required, CR: Maintenance de-manded, B: Maintenance alarm, I: Function check.

d7 Start reference run[OFF]ONESC 1

Triggering of a reference run for the functions: Drive signal ysteady-state and drive signal y hysteresis.The reference run can only be activated in manual operation asthe valve moves through its entire travel range.If EXPERT+ is activated at later point in time, the reference graphsmust be plotted in order to activate the diagnostic functions.

d8 EXPERT+ activation Enter the activation code for EXPERT+.After the activation procedure has been successfully completed,YES appears under d8.

80 EB 8384-3 EN

Code list

Error codes – Remedy Condensed status alarm active, when prompted, Err appears.

Initialization error(indicated on the display by the condensed status with the corresponding classification)

50 x < range The value supplied by the measuring signal is either too high ortoo 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.

Remedy Check attachment and pin position, set operating mode fromSAFE to MAN and re-initialize the positioner.

51 Δx > range The measuring span of the sensor is too low.• Pin positioned incorrectly.• Wrong lever.A rotational angle smaller than 11° at the positioner shaft createsjust an alarm. An angle below 6° leads to the initialization beingcanceled.

Remedy Check attachment and re-initialize the positioner.

52 Attachment • Positioner attachment incorrect.• Nominal travel/angle (Code 5) could not be achieved on

initialization under NOM or SUB (no tolerance downwardspermissible)

• Mechanical or pneumatic error, e.g. wrong lever selected orsupply pressure too low to move to the required position orpneumatic fault

Remedy Check attachment and supply pressure. Re-initialize thepositioner.Under certain circumstances, it may be possible to check themaximum travel/angle by entering the actual pin position andthen performing an initialization under MAX.After initialization has been completed, the Code 5 indicates themaximum achieved travel or angle.

53 Init time > The initialization routine lasts too long. The positioner returns toits previous operating mode.• No pressure on the supply line or there is a leak.• Supply air failure during initialization.

Remedy Check attachment and supply pressure.Re-initialize the positioner.

EB 8384-3 EN 81

Code list

54 Init – Solenoid valve 1) A solenoid valve is installed (Code 45 = YES) and wasnot or not properly connected so that an actuator pressurecould not be built up. The message appears when youattempt to initialize the positioner.

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

Remedy Re. 1) Check connection and supply voltage of the solenoidvalve. Code 45 High/Low

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

55 Transit time < The actuator transit times determined during the initialization areso short that the positioner cannot adapt itself optimally.

Remedy Check the volume restriction setting as described in section 5.2,re-initialize the positioner.

56 Pin pos. Initialization was canceled because you are required to enter thepin position for the selected initialization modes NOM and SUb.

Remedy Enter pin position over Code 4 and nominal travel/angle overCode 5. Re-initialize the positioner.

Operational error(indicated on the display by the condensed status with the corresponding classification)

57 Control loop

Additional alarm at the faultalarm contact!

Control loop error, the control valve does not react within the tol-erable times of the controlled variable (tolerance band alarmCode 19).• Actuator mechanically blocked.• Attachment of the positioner subsequently postponed.• Supply pressure not sufficient.

Remedy Check attachment.

58 Zero point Zero point incorrect. Error may arise when the mounting posi-tion/linkage of the positioner moves or when the valve seat trimis worn, especially with soft-sealed plugs.

Remedy Check valve and mounting of the positioner. If OK, perform azero calibration over Code 6 (see section 5.8 on page 58).

59 Autocorrection Should an error occur in the data range of the positioner, theself-monitoring function recognizes it and automatically correctsit.

Remedy Automatic

82 EB 8384-3 EN

Code list

60 Fatal error


An error was detected in the data relevant for safety,autocorrection is not possible. This may be due to EMC distur-bances.The control valve moves to its fail-safe position.

Remedy Reset over Code 36.Re-initialize the positioner.

Hardware error (indicated on the display by the condensed status with the corresponding classification)

62 x signal


Determination of the measured value for the actuator has failed.Conductive plastic element is defective.The positioner continues to run in emergency mode, but shouldbe replaced as soon as possible.The emergency mode on the display is indicated by a blinkingcontrol symbol and 4 dashes instead of the position indication.

Note on the control:If the measuring system has failed, the positioner is still in a reli-able state. The positioner switches to emergency mode where theposition cannot be accurately controlled anymore. However, thepositioner continues operation according to its reference variablesignal so that the process remains in a safe state.

Remedy Return the positioner to SAMSON AG for repair.

63 w too small The reference variable is much smaller than 4 mA (0 %); occurs ifthe power source that drives the positioner does not comply withthe standard.This state is indicated on the positioner display by a blinkingLOW.

Remedy Check reference variable.If necessary, limit the current source downwards so that no valuesbelow 4 mA can be issued.

64 i/p converter (y) The circuit of the i/p converter has been interrupted.

Remedy Cannot be remedied.Return the positioner to SAMSON AG for repair.

EB 8384-3 EN 83

Code list

Error appendix

65 Hardware


A hardware error has occurred, the positioner moves to thefail-safe position SAFE.

Remedy Confirm error and return to the automatic operating mode, orperform a reset and re-initialize the device. If this is not suc-cessful, return device to SAMSON AG for repair.

66 Data memoryAdditional alarm at the faultalarm contact!

The writing of data to the data memory does not work anymore,e.g. when the written data deviate from the read data.Valve moves to the fail-safe position.


67 Test calculationAdditional alarm at the faultalarm contact!

The hardware positioner is monitored by means of a test calcula-tion.

Remedy Confirm error. If this is not possible, return the positioner toSAMSON AG for repair.

Data error

68 Control parameterAdditional alarm at the faultalarm contact!

Control parameter error.

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

69 Poti parameterAdditional alarm at the faultalarm contact!

Parameter error of the digital potentiometer.


70 CalibrationAdditional alarm at the faultalarm contact!

Error in the production calibration data. Subsequently, the deviceruns on default values


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

Remedy Confirm error.Check and, if necessary, reset required parameters.

84 EB 8384-3 EN

Code list

72 Start-up parameters Start-up parameter errors


73 Internal device error 1 Internal device error


74 HART parameters Error in the HART® parameters that are not critical for the controlfunction.


75 Info parameters Error in the info parameters that are not critical for the controlfunction.


76 No emergency mode The travel measuring system of the positioner has a self-moni-toring function (see Code 62).A controlled emergency mode is not available on certain actua-tors, such as double-acting actuators. For this reason, thepositioner moves to the fail-safe position when a measuring erroroccurs. During the initialization, the positioner checks whetherthe actuator has such a function or not.

Remedy Merely information, confirm, if necessary.No further action necessary.

77 Program loading errorAdditional alarm at the faultalarm contact!

When the device starts operation for the first time after the inputsignal has been applied, it carries out a self-test (tEStinG runsacross the display).If the device loads a program that does not correspond to that ofthe positioner, the valve moves to the fail-safe position. It is notpossible to make the valve leave this fail-safe position again byoperating the positioner.

Remedy Interrupt current and restart positioner. Otherwise, return thepositioner to SAMSON AG for repair.

78 Options parameter Errors in options parameters.

79 Diagnostic alarms Alarms are generated in the EXPERT+ extended diagnostics ifEXPERT+ has been successfully activated in Code 48.

EB 8384-3 EN 85

Code list

80 Diagnostic parameters Error which is not critical for control.

Remedy Confirm error.Check and, if necessary, start new reference run.

81 Reference graphs Error on plotting the reference graphs of drive signal ysteady-state or drive signal y hysteresis.• Reference run was interrupted• Reference line y steady-state or y hysteresis was not adopted.

86 EB 8384-3 EN

Code list

13 Setting with TROVIS-VIEWsoftware – Parameter list

13.1 General

A CD-ROM containing the program for in-stalling the TROVIS-VIEW Configurationand Operator Interface is provided bySAMSON.

Insert the installation CD-ROM to start theinstallation program. Once inserted, theCD-ROM usually starts the installation pro-gram automatically depending on the con-figuration of the operating system.If the program does not start automatically,double-click setup.exe in the root directoryof the CD-ROM in order to installTROVIS-VIEW.Follow the on-screen prompts and instruc-tions of the installation program.

The system requirements are specified in thereadme.txt file in the root directory of theCD-ROM.

The TROVIS-VIEW Operator Interface canbe used for different SAMSON devices.Note that the installation program also of-fers you the option of installing a demomodule. To use the software without restric-tions, the software needs to be activated asdescribed below:

After installation, a dialog box will appear,prompting you to enter the CD key, whichyou will find on the cover of the originalCD-ROM. Once you have entered the cor-rect CD key and initiated the activation pro-cess, a request code will be automaticallygenerated. The Activation dialog box willcome up displaying the generated requestcode and an Internet link to SAMSON’s ac-

tivation server where a unique activationcode will then be generated and displayed.Enter this activation code intoTROVIS-VIEW’s Activation dialog box. Thesoftware is now ready for use without anyrestrictions in the purchased scope.

To enable communication with the PC, con-nect the serial interface to the serial interface(5-pole female socket) of the positioner us-ing a SAMSON connecting cable with serialinterface adapter (order no. 1400-7700).

The positioner settings configured inTROVIS-VIEW can be directly transferredover the SAMSON connecting cable to thepositioner on site. This online connection en-ables you to read any entered settings aswell as providing a diagnostic function.

EB 8384-3 EN 87

Setting with TROVIS-VIEW software – Parameter list

13.2 Starting TROVIS-VIEW andperforming basic settings

Settings may be entered into theTROVIS-VIEW operator interface when ei-ther the positioner is connected or not con-nected. When the positioner is connected,the data uploaded from the positioner canbe overwritten.

When the positioner is not connected, thedefault settings appear on the operator in-terface display or, alternatively, a storedTROVIS-VIEW file (*.tro) can be loaded andwritten over in the File menu by selectingOpen.

Connection to the positioner is establishedby clicking the symbols on top right on thebutton bar:

Upload data from the positioner anddisplayed in the operator interface

Download the complete set of datafrom the operator interface onto thepositioner.To download individual parametersonto the positioner, open thecorresponding drop-down menu.Select Write to just download theselected parameter (see section 13.3)

The positioner is in online mode,indicated by the TROVIS-VIEW 3logo on the top right in the blue bar

The positioner is in offline mode.

You can also activate the listed functions inthe Device menu.

88 EB 8384-3 EN


1. Start TROVIS-VIEW

Make required settings in View menu by activating or deactivating functions.

When the Trend Viewer is activated, all operating data are uploaded cyclically from thepositioner in online mode and shown in the form of graphs.Right-click on the graph to edit the graph format or to copy the logged data to a file.

2. Select required language in Options menu.The selected language can be changed at any time except in online mode.

EB 8384-3 EN 89


3. Select Communication fromthe Options menu and choose.communication settings.

4. Click on Port settings and select port as well asserver setting.

5. Select Convert in the File menu to selectthe firmware version of the positioner.It must match the version specified in thebar at the top.

6. Enter more details about the plant,if necessary, in Customer Data in theEdit menu.

7. Select Load Factory Defaults in Edit menu to upload default settings to the operator inter-face.

90 EB 8384-3 EN


13.3 Setting the parameters

Click on one of the folders listed in the left column to open a window listing the settings of thecorresponding parameters. Place the mouse arrow on the parameter name to open a tool tipproviding information about that particular parameter.

Double-click on a parameter to open a window to enable the parameter to be modified.

Right-click on the parameter to open a drop-down menuproviding further editing options.

The parameters in all the folders are listed in the following parameter list.

EB 8384-3 EN 91


13.4 Parameter list

Parameter Values Defaultsetting

DescriptionRefer to section 12 for the description of thecodes

Identification – Operation unit

TAG Max. 32 charac-ters

Tag identification of operation unit

Long TAG

Bus address 0 Code 46

Description Freely available text fields

Message

Text field 1 to 5

Positioner serialnumber

Serial number of the positioner

Positioner productnumber

3730-3 xxx Manufacturer model number of the positioner

Firmware version x.xx Current firmware version of device, Code 43

Diagnosis level EXPERT

Final assemblynumber

0...16777215 0 Any number assignable to clearly identify theentire field device

Date (day) 1...31 1Date that can be entered. Stored in thepositioner

Date (month) January

Date (year) 1900...2155 2003

Certification Indicates whether the positioner can be used inhazardous area

Number of pream-bles

5 Number of required synchronization bytes

Required number ofpreambles

5...20 5

HART revision 5 Designates the version of the HART specifica-tion which is supported by the positioner

92 EB 8384-3 EN


Identification – Positioner

Device type 3730-3 Indicates exact model designation

Identification – Positioner – Actuator

Type identificationactuator

Manufacturer ID number of the actuator that thepositioner is mounted upon

Actuator type Single-actingDouble-acting

Single-acting Actuator with or without spring return mecha-nism

Attachment Integral/NAMUR

Integral Defines the attachment of the positioner on thecontrol valve

Booster Not present/present

Not present Pneumatic volume booster

Actuator size 60...5600 240 cm² Effective diaphragm or piston area of the actu-ator

Signal pressurelower value

0.0...6 0.2 bar Initial value of the actuator bench range

Signal pressureupper value

0.0...6 1.0 bar Final value of the actuator bench range

Supply pressure 0.0...6 6.0 bar Supply pressure of compressed air network

Identification – Positioner – Valve

Type identificationvalve

Manufacturer ID number of the valve that thepositioner is mounted upon

Direction of flow Flow-to-open(FTO)/Flow-to-close(FTC)

Flow-to-open(FTO)

Indicates in which direction the process mediumflows to the valve plug.

Packing Adjustable/Self-adjusting/Bellows seal

Self-adjusting

Sealing of the plug stem to the atmosphere

Seating surface(leakage class)

Metal sealing/Lapped-in metal/Soft sealing/Nickel sealing

Metal sealing Type of sealing between seat and plug

Pressure balancing Without/With (PTFE)/With (graphite)

Without Plug with pressure balancing to compensate forforces

EB 8384-3 EN 93


Flow characteristic Linear 30:1/Eq. perc. 30:1/Linear 50:1/Eq. perc. 50:1/Other

Linear 50:1 Valve characteristic: Flow to valve travel

Valve dimensionsstandard

DIN/ANSI DIN Valve dimensions according to DIN or ANSI

Nominal size DN 8...2100 50 Nominal size in mm (DIN) or inch (ANSI)

Kvs coefficient 0.0001...20000.0000

1.0000 Kv Valve flow coefficient

Kvs unit Kv/cv Kv Flow coefficient, metric unit (Kvs) or US Amer-ican units (cv)

Seat diameter of thevalve

2.0...500.0 6.0 mm Diameter of valve seat bore

Identification – Positioner – Additional components

Solenoid valveNotinstalled

Code 45

Position transmitter Code 37

Inductive limitswitch

Installed/Not installed

Code 38

Operation unit

HART write protec-tion

Not writeprotected

Code 47

Start with defaultsettings

Code 36

Positioner – Operating mode

Current operatingmode

Indicated the current operating mode used bythe device

Target operatingmode

Automatic/Manual/Fail-safeposition

Automatic Code 0

Positioner – Process data

Reference variable w

Displays currentprocess variables

Code 42

Controlled variable x Current position

System deviation e Deviation from target position (e = w–x)

Manipulatedvariable y

Indicates the control signal y in % in relation tothe travel range found on initialization after thedevice has been initialized.

94 EB 8384-3 EN


Status

Condensed state Summarized state of the positioner.The condensed status is made up from the var-ious states.The condensed status can take on the followingstates:

No alarm

Maintenance required

Maintenance demanded

Maintenance alarm

Function check

The condensed states “Maintenance required”and “Maintenance demanded” are also indi-cated on the positioner display by .The condensed status “Maintenance alarm”causes the fault alarm symbol to appear onthe display.

Fault exists(fault alarm contact)

Display and alarm

Status of the fault alarm contact

Status of limit switchA1

Status of the switching output for limit switch A1

x falls below A1 Indicates whether the controlled variable x hasfallen below the limit for A1

Status of limit switchA2

Status of the switching output for limit switch A2

x exceeds A2 Indicates whether the controlled variable x hasexceeded the limit for A2

Operational status Indicates the current operational status of theinternal control

Temperature Current temperature in the positioner

EB 8384-3 EN 95


Positioner – Reference variable

Direction of action Increasing/increasing >>Incr./decr. <>

Increasing/increasing >>

Code 7

Lower referencerange value

0.0...75.0 % 0.0 % Code 12

Upper referencerange value

25.0...100.0 % 100.0 % Code 13

Enable final posi-tion smaller than w

On/Off On Code 14

Final position whenw is smaller

0.0...49.9 % 1.0 % Code 14

Enable final posi-tion greater than w

On/Off Off Code 15

Final position whenw is greater

50.0...100.0 % 100.0 % Code 15

Required transittime OPEN

0...240 s 0 s Code 21

Required transittime CLOSED

0...240 s 0 s Code 22

Positioner – Working range

Initial value oftravel range/angleof rotation range

0.0...12.0 mm 0.0 % Code 8

Final value of travelrange/angle ofrotation range

3.0...15.0 mm 100.0 % Code 9

Enable travel/angleof rotation lowerlimit

On/Off Off Code 10

Travel/angle ofrotation lower limit

0.0...49.9 % 0.0 % Code 10

Enable travel/angleof rotation upperlimit

On/Off On Code 11

Travel/angle ofrotation upper limit

50.0...120.0 % 100.0 % Code 11

96 EB 8384-3 EN


Positioner – Characteristic

Characteristicselection

LinearEqual percentageEq. perc. reverse

SAMSONbutterfly valves

lineareq. perc.

VETEC rotaryplug valves

lineareq. perc.

Segmented ballvalves

lineareq. perc.

User defined

Linear Code 20

Graphs of the user-defined characteristics,loading and saving characteristics.See example on the next page.

Characteristic type Free text for describing the user-defined char-acteristic

EB 8384-3 EN 97


Example for user-defined characteristic

• Select User defined characteristic in Characteristic selection parameter.• Double-click on Edit, open or save characteristic to open a window where the characteristic can be

edited.Click on Characteristic button on the bottom right to open and save a characteristic.

98 EB 8384-3 EN


Parameter Values Default Description

Positioner – Performance characteristics

Required propor-tional-action coeffi-cient KP (step)

0...17 7 Code 17

Proportional-actioncoefficient KP (step)

Code 17

Required deriva-tive-action time TV(step)

Off/1/2/3/4 2 Code 18

Derivative-actiontime TV (step)

Code 18

Positioner – Fail-safe action

Fail-safe position Closing Fail-safe action of the actuator upon air/auxil-iary power failure or device start-up.Determined during initialization by the positionof the slide switch (see section 5.1).In double-acting actuators, the fail-safe positionrelates only to the failure of the auxiliary powersupply. There is no defined position when thesupply air fails.

Positioner – Error control

Tolerance band 0.1...10.0 % 5.0 % Code 19

Delay time 0...9999 s 30 s Reset criterion for running control loop moni-toring.A control loop error is issued when the delaytime is exceeded and the system deviation is notwithin the tolerance band.

Total valve travel 1 Code 23

Limit of the totalvalve travel

1000...990 000 000

1 000 000 Code 24

Alarm mode A1 Conducting/highA2 Non-conduc./low

A1 Non-conduc./lowA2 Non-conduc./low

A1 Conducting/highA2 Conduc./high

A1 Non-conduc./lowA2 Conducting/high

A1Conducting/highA2Conducting/high

Code 25

EB 8384-3 EN 99


Enable limit valueA1

On/Off On Code 26

Limit value A1 0.0...100.0 % 2.0 % Code 26

Enable limit valueA2

On/Off On Code 27

Limit value A2 0.0...100.0 % 98.0 % Code 27

Fault alarm with“Function check”condensed status

Yes/No No Code 32

Fault alarm with“Maintenancealarm” or“Maintenance re-quired” condensedstatus

Maintenancealarm only andMaintenancerequired only

Maintenancealarm

Code 33

Zero point limit 0.0...100.0 % 5.0 % Limit for zero point monitoring

Positioner – Error control – Classification report

Condensed status error alarms

Note!Each fault alarm has a status assigned to it.The possible states are placed in order starting with the lowest priority:

Maintenance required Lowest

Maintenance demanded

Maintenance alarm

Function check Highest priority

No alarm Alarm is not added to the condensed status

The fault alarm present in the device with the highest priority determines which condensed status is dis-played.The condensed states “Maintenance required” and “Maintenance demanded” are also indicated on thepositioner display by .The condensed status “Maintenance alarm” causes the fault alarm symbol to appear on the dis-play.

100 EB 8384-3 EN


x > range

Determines the individual statusfor each alarm

with symbol

an alarm is not added tothe condensed status

Symbol

for maintenance requiredand

maintenance demanded

Symbol

for maintenance alarm

or symbol

for function check

Code 50

Delta x < range Code 51

Attachment Code 52

Initialization timeexceeded

Code 53

Initialization/solenoid valve

Code 54

Transit time notachieved

Code 55

Pin position Code 56

Control loop Code 57

Zero point Code 58

Autocorrection Code 59

x signal Code 62

w too small Code 63

Control parameter Code 68

Poti parameter Code 69

Calibration param-eter

Code 70

General parameters Code 71

Internaldevice error 1

Code 73

HART parameter Code 74

Parameter info Code 75

No emergencymode

Code 76

Options parameter Code 78

Total valve travelexceeded

Determines the condensed status when a faultoccurs

Temperature< –40 °C

Temperature fell below –40 °C duringoperation

Temperature> 80 °C

Temperature exceeded +80 °C duringoperation

EB 8384-3 EN 101


Positioner – Start-up

Reading direction Pneumaticconnectionright/left

Pneumaticconnectionright

Code 2

Pin position Off17/25/35/50/70/100/200 mm90°

Off Code 4

Initialization mode Nominal rangeMaximum rangeManual adjust-mentSubstitution

Maximumrange

Code 6

Pressure limit Off /2.4/3.7/1.4 bar

Off Code 16

Determined nom-inal range

Code 5

Minimum transittime OPEN

Code 40

Minimum transittime CLOSED

Code 41

Fail-safe action Fail-safe action of the actuator upon air/auxil-iary power failure or device start-up.Determined during initialization by the positionof the slide switch (see section 5.1).In double-acting actuators, the fail-safe positionrelates only to the failure of the auxiliary powersupply. There is no defined position when thesupply air fails.

Positioner – Start-up – Initialization

Initialization mode Nominal rangeMaximum rangeManual adjust-mentSubstitution

Maximumrange

Code 6

Device initialized Status of device initialization

Initialization Starting of initialization procedure.The initialization mode parameter must be firstset to the required initialization procedure.

EB 8384-3 EN 102


Initialization status Status of the running initialization procedure

Initialization can-celed

Running initialization procedure has been can-celed. The control valve moves to its fail-safeposition.


AutomaticManualSAFE

Automatic Code 0


Indicates current operating mode of positioner

Initialization error

x > range

Alarm

Code 50


Attachment Code 52


Code 53

Initialization/sole-noid valve

Code 54

Transit time too short Code 55


No emergencymode

Code 76

Positioner – Start-up – Substitution

Initialized in Submode

Indicates whether the substitute configuration(sub mode) has been performed

Closing direction Counter-clockwise

Code 34

Blocking position 0.0 % Code 35

Positioner – Maintenance

Start zero calibration

Zero calibration Starts zero calibration

Initialization status Status of running initialization procedure

Initialization can-celed

Running initialization procedure has been can-celed. The valve moves to fail-safe position.


AutomaticManualSAFE

Automatic Code 0


Indicates current operating mode of positioner

EB 8384-3 EN 103


Positioner – Simulation

Alarm test A1 Code 28

Alarm test A2 Code 28

Alarm test A3(alarm fault output)

Code 28

Diagnosis

Diagnosis levelsetting

Expert


Automatic Indicates current operating mode of positioner

Diagnosis – Status alarms

Status

Condensed status Alarm symbol Summarized condensed status.Made up from various states.

Operating hourscounter

Display or status

Time elapsed since first initialization

Device in closedloop

Time elapsed in closed loop since first initializa-tion

Device switched onsince lastinitialization

Time elapsed since last initialization

Device in closedloop since lastinitialization

Time elapsed in closed loop since last initializa-tion

Error occurred(fault alarm output)

Status of fault alarm output

Solenoid valvestatus

Status of optional solenoid valve

Fail-safe position Fail-safe action of actuator upon airsupply/auxiliary power failure or devicestart-up.Determined during initialization.

Device initialized Status of device initialization

Start performedwith default settings

Indicates whether a start has been performedwith default settings.

Local operationactive

Local operation is active

Configurationchanged

Status of device status bit configurationchanged.

104 EB 8384-3 EN


Number of zerocalibrations

Number of zero calibrations performed sincelast initialization

Number ofinitializations

Number of initializations performed

Zero point limit Limit for zero point monitoring

Operation

Control loop

Alarm

Code 57

Zero point Code 58

Autocorrection Code 59

Fatal error Code 60

w too small Code 63

Total valve travelexceeded

Status of total valve travel limit

Temperatureexceeded

Status alarm resulting from diagnosis analysis

Hardware

x-signal

Alarm

Code 62

i/p converter Code 64

Hardware Code 65

Data memory Code 66

Control calculation Code 67

Program load error Code 77

Initialization

x range

Alarm

Code 50


Attachment Code 52


Code 53

Initialization/solenoid valve

Code 54

Transit time tooshort

Code 55


No emergencymode

Code 76

EB 8384-3 EN 105


Data memory

Control parameter

Alarm

Code 68

Poti parameter Code 69

Calibrationparameter

Code 70

General parameters Code 71

Internal deviceerror 1

Code 73


Info parameter Code 75

Option parameter Code 78

Diagnosticparameters

Code 80

Temperature

Min. temperature

Display

Lowest temperature recorded in the positioner

Max. temperature Highest temperature recorded in the positioner

Min. temperature(time)

Operating hours counter logging when thelowest temperature was recorded in thepositioner

Max. temperature(time)

Operating hours counter logging when thehighest temperature was recorded in thepositioner

Diagnosis – Status messages – Data logger

Alarms(1) to (30)

Alarm

Recorded alarms issued by the positioner

Operating hours counter logging of each alarmOperating hourssince first initializa-tion

Diagnosis – Status alarms – Reset

Reset absolute totaltravel

Resetting correspondingalarms

Reset counter for absolute total valve travelback to 0

Resetdefault values flag

Set back default values flag to 0

Reset device settingchanged

Reset device status bitdevice setting changed.

106 EB 8384-3 EN


Reset initialization error

Resetx > range


Code 50

ResetDelta x < range

Code 51

Reset attachment Code 52

Resetinitializationexceeded

Code 53

Resetinitialization/solenoid valve

Code 54

Resettransit time tooshort

Code 55

Reset pin position Code 56

Reset operational error

Reset zero point Resetting correspondingalarms

Code 58

Reset autocorrection Code 59

Reset hardware error

Reset hardwareResetting corresponding

alarms

Code 65

Reset controlcalculation

Code 67

Reset data error

Reset controlparameter


Code 68

Reset poti param-eter

Code 69

Resetgeneral parameters

Code 71


Reset options pa-rameter

Code 78

Reset diagnosticparameters

Code 80

Reset statistical information

Reset data logger Measured data in the data logger buffermemory are deleted

EB 8384-3 EN 107


108 EB 8384-3 EN

14 Dimensions in mm

EB 8384-3 EN 109

Dimensions in mm

M20 x 1.5

Direct attachment

Reversing amplifier(option)

A1 Z

A2

40

34

210

28

1480

164 Output (38) Supply (9)

86

70

15

46

3470

7028

Schild

Output A1

Output A2

Supply (9)

50 80

58

58

58

130

495979

76

50

Attachment acc. to IEC 60534-6Pressure gaugebracket

or connecting plate

Lever mmS = 17M = 50L = 100XL = 200

External position sensor

Attachment to rotary actuatorsVDI/VDE 3845

for all sizes of fixing level 2

ConnectingplateG ¼ or¼ NPT

110 EB 8384-3 EN

EB 8384-3 EN 111

112 EB 8384-3 EN

EB 8384-3 EN 113

114 EB 8384-3 EN

EB 8384-3 EN 115

116 EB 8384-3 EN

EB 8384-3 EN 117

118 EB 8384-3 EN

EB 8384-3 EN 119

120 EB 8384-3 EN

EB 8384-3 EN 121

122 EB 8384-3 EN

EB 8384-3 EN 123

124 EB 8384-3 EN

EB 8384-3 EN 125

NEM

A4x

126 EB 8384-3 EN

EB 8384-3 EN 127

SAMSON AG · MESS- UND REGELTECHNIKWeismüllerstraße 3 · 60314 Frankfurt am Main · GermanyPhone: +49 69 4009-0 · Fax: +49 69 4009-1507Internet: http://www.samson.de EB 8384-3 EN S/

Z20

07-0

5

Inductive Limit SwitchType 3768


EB 8356 ENEdition April 2004

Fig. 1 ⋅ Type 3768

Contents Page

1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 41.1 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Attachment to control valve . . . . . . . . . . . . . . . . . . . . . . . . . 62.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . . . . 82.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2.2 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . . . . 102.3.1 Mounting the follower roll lever . . . . . . . . . . . . . . . . . . . . . . . . 102.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . . . . 102.3.3 Adjusting the cam disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . . . . 14

3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.1 Pneumatic connections for versions with solenoid valve . . . . . . . . . . . . 19

4 Operation – Adjusting the limit contacts . . . . . . . . . . . . . . . . . . . 20

5 Servicing explosion-protected versions . . . . . . . . . . . . . . . . . . . . 22

6 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Contents

2 EB 8356 EN

Safety instructions

Assembly, start-up and operation of the device may only be performed bytrained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnelis referred to individuals who are able to judge the work they are assignedto and recognize possible hazards due to their specialized training, theirknowledge and experience as well as their knowledge of the applicablestandards.

Explosion-protected versions of this device may only be operated by person-nel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas (for more details, refer to section 5).

Any hazards which could be caused by the process medium, the signalpressure and moving parts of the control valve are to be prevented bymeans of appropriate measures. If inadmissible motions or forces are produced in the pneumatic actuator asa result of the level of the supply air pressure, this must be restricted bymeans of a suitable pressure reducing station.


Note! The device with a CE marking fulfils the requirements of the Directives 94/9/EC (ATEX) and 89/336/EEC.The declaration of conformity can be viewed and downloaded on theInternet at http://www.samson.de.

EB 8356 EN 3

1 Design and principle of operation

The Type 3768 Limit Switch is designed forattachment to pneumatic control valves. It isequipped with inductive switching elementsthat issue a limit signal whenever the valvetravel exceeds or falls below a certainpreset limit, especially when the valve hasreached one of its end positions. The limitsignal is transmitted to an alarm or indicat-ing unit.The limit switch is also available with a sole-noid valve which is used to move the controlvalve to fail-safe position.The limit switch is designed for either directattachment to SAMSON Type 3277 Actua-tors or for attachment to control valves com-plying with IEC 60534-6 (NAMUR) bymeans of an adapter housing.The valve travel and, hence, the valve posi-tion is transmitted via the pin (1.1) to thelever (1), thus converting the linear travelinto a rotary motion. The shaft (2) transmits

the rotary motion to two adjustable tags (4)which, in return, operate the associatedproximity switches (5).The operation of the inductive limit switchesrequires that switching amplifiers be con-nected in the output circuit (see section 3).

Version with solenoid valve

The solenoid valve is used to move the con-trol valve to its fail-safe position regardlessof the output signal issued by the controlunit. When a control signal which corre-sponds to the binary signal 0 (OFF) is ap-plied to the input, the signal pressure pst isshut off and the actuator vented. As a result,the springs installed in the actuator force thevalve to move to its fail-safe position.Whereas a control signal corresponding tothe binary signal 1 (ON) causes the signalpressure pst to be transmitted to the actua-tor, resulting in activation of the controlvalve.

Fig. 2 ⋅ Functional diagram

46 5

3 2 1 1.1

7

supply

u[V]

pst

4 Tag5 Proximity switch6 Adjustment screw 7 Pressure regulator

1 Lever1.1 Pin2 Shaft3 Spring

4 EB 8356 EN


1.1 Versions

1.2 Technical data

Model 3768- 2 0 0Explosion protection Without

Ex II 2 G EEx ia IIC T6 acc. ATEXEx ia FM/CSAEx II 3 G EEx nA II T6 acc. ATEX

0138

Solenoid valve Without6 V DC12 V DC24 V DC

0234

Pneumatic connections Without1/4-NPTISO 288/1-G 1/4

012

Electrical connections M20 x 1.5 blueM20 x 1.5 blackPlug connector HAN 7D (not with CSA/FM)

124

Travel range Direct attachment: 7.5 to 30 mm; Attachment acc. to IEC 60534-6: 5.5 to 120 mm; angle of rotation: 0-90°

2 proximity switches Type SJ 2-SN; Control circuit: values must match the downstream switching amplifiers

Differential gap ≤1% at rated travel

Degree of protection IP 65 w/o solenoid valve, IP 54 with solenoid valve (special version IP 65 w. filter check valve)

Perm. ambient temp. –20 to +80 °C

EMC Requirements as per EN 50081/50082 are met

Solenoid valve InputAir supply

Binary DC signalSupply air 1.4 to 6 bar (20 to 90 psi)

Nominal signal 6 V DC 12 V DC 24 V DC

Signal 0 (no pick-up) , DC signal at –25 °C ≤1.2 V ≤2.4 V ≤4.7 V

Signal 1 (safe pick-up), DC signal at +80 °C ≥5.4 V ≥9.6 V ≥18 V

Maximum permissible signal 28 V 25 V 32 V

Coil resistance Ri at 20 °C 2909 Ω 5832 Ω 11714 Ω

Air consumption in steady state, Kvs= 0.14 m3/h "Off" ≤60 ln/h; "On" ≤10 ln/h

Closing time for

For rated travel andsignal pressure range

Type 3277 Actuator cm2 120 240 350 700

0.2 to 1 bar

≤0.5 s

≤1 s ≤1.5 s ≤4 s

0.4 to 2 bar ≤2 s ≤2.5 s ≤8 s

0.6 to 3 bar ≤1 s ≤1.5 s ≤5 s

EB 8356 EN 5

Technical data

2 Attachment to control valve

The limit switch can be attached either directlyto a SAMSON Type 3277 Actuator or to con-trol valves with cast yokes or rod-type yokesaccording to IEC 60534-6 (NAMUR).Combined with an intermediate piece, thelimit switch can also be mounted on rotaryactuators.The standard limit switch is delivered with-out accessories. The additionally requiredmounting parts are listed together with theirorder numbers in the tables on pages 16and 17.The limit switch may be mounted on the left-hand or right-hand side of the control valve.Any subsequent changes of the mountingposition change the switching function ofthe limit switch. Please also note the instruc-tions in section 4.

2.1 Direct attachment

1. Screw the clamp (1.2) to the actuatorstem. Make sure the fastening screwrests in the groove of the actuator stem.

2. Screw the associated lever D1 or D2 tothe lever of the limit switch.

3. Secure the distance plate (15) togetherwith the gasket facing towards the actu-ator yoke.

4. Position the limit switch such that thelever D1 or D2 slides in line over thepin (1.1) of the clamp (1.2).

5. Mount cover (18).

Attachment of versions with solenoid valve

To establish the signal pressure connectionto the actuator, use an adapter block or aswitchover plate. Both are listed in Table 2and 3 (page 16).240 to 700 cm2 actuators1. Make sure that the tip of the gasket (16)

projecting from the side of the adapterblock (Fig. 3, middle) is positioned tomatch the actuator symbol for the actua-tor’s fail-safe action "Actuator stem ex-tends" or "Actuator stem retracts".If this is not the case, remove the threefixing screws and the cover. Repositionthe gasket (16) turned by 180°. The old connection block version re-quires the switch plate (13) to be turnedsuch that the corresponding actuatorsymbol points to the marking.

2. Place the adapter block with its O-ringsbetween the limit switch and the actua-tor yoke and secure using the fasteningscrew.For versions "Actuator stem retracts",the ready-to-use signal pressure linemust be additionally mounted.

120 cm2 actuatorsThe signal pressure is transmitted to the dia-phragm chamber via the switchover plate.1. Remove the M3 screw plug at the back

of the limit switch and insert the plug in-cluded in the accessories in the lateralsignal pressure output ("output 38").

2. Mount the limit switch so that the borein the distance plate (15) covers theseal in the bore of the actuator yoke.

3. Align the switchover plate with thecorresponding actuator symbol andscrew tight.

6 EB 8356 EN

Attachment to control valve

Fig. 3 ⋅ Direct attachment – Mounting of bracket, signal pressure connection

SUPPLY

1.218

D2D1

15

15

Signal pressure inputfor right attachment

Marking

Type 3277-5 with 120 cm2

Side view ofadapter blockwith gasket (new)

Tip of gasket(16)

Cover plate

Signal pressureinput for left attachment

Marking

Clamp

Symbol foractuator stemextends

retracts

Switchover plateonly for version with solenoid valve

Actuator stem < extends retracts >

Actuator stem retracts

extends

Switch plate (13)

With switch plate (old)

Symbol foractuator stemretracts

View onto the signal pressure connection< Attachment left Attachment right>

Signal pressure connection< internal over pipe connection >

extends

Adapter blockonly for version with

solenoid valve

Type 3277

EB 8356 EN 7


2.2 Attachment according toIEC 60534-6

For limit switch attachment according toNAMUR, you require an adapter housing.The valve travel is transmitted via the lever(18) and shaft (25) to the bracket (28) ofthe adapter housing and then passed on tothe pin (27a) located on the limit switchlever.For the limit switch attachment you requirethe mounting parts listed in Table 4. Therated travel of the control valve determineswhich lever must be used.You can attach the limit switch either to theleft or to the right of the control valve.

2.2.1 Mounting sequence

Choose the required mounting parts fromTables 4 and 5 on pages 16 and 17.

Control valve with cast yoke:

1. Screw the plate (20) to the stem connec-tor of the actuator and plug stem usingthe countersunk screws. For 2100 and 2800 cm2 actuator ver-sions, use an additional mountingbracket (32).

2. Remove the rubber plug from inside theadapter housing and fasten the housingto the left or right side of the Namur ribusing a hexagon screw.

Control valve with rod-type yoke:

1. Screw the plate (20) to the carrier of theplug stem.

2. Screw the studs (29) into the adapterhousing.

3. Place the housing with the mountingplate (30) on either the right or left sideof the valve stem and screw tight usingnuts (31). Make sure that the lever (18)to be mounted subsequently is in hori-zontal position when the valve is at mid-travel.

4. Screw the pin (19) into the center rowof holes on the plate (20) and lock it ina position above the correct lever mark-ing (1 to 2), as indicated in Table 5.

5. Clamp the clip (21) onto the lever (18).Only when connecting versions withsolenoid valve and air connection point-ing to the front, must the clip beclamped onto the lever with the openside pointing downwards.

6. Attach the lever (18) including clamp-ing plate (22) to the shaft (25). The clipmust clasp the pin (19).

2.2.2 Presetting the travel

1. Move the valve to 50 % travel.2. Adjust the shaft (25) in the adapter

housing so that the black pointer (24)meets the cast mark on the adapterhousing.

3. Screw the clamping plate (22) tight inthis position using the screw (23).

4. Screw in the pin (27a) at the limitswitch lever on the side of the press nutand lock with a hex nut (27b) on theother side. Observe the mounting posi-

8 EB 8356 EN


Fig. 4 ⋅ Attachment according to NAMUR (shown for attachment to the left side)

21,51

2826

A B

24 25 22

32

31

20 19

19 21 2023 18

27b

27a

2930

Mounting position

18 Lever N1, N219 Pin20 Plate21 Clip22 Clamping plate23 Screw24 Pointer25 Shaft26 Lever positioner27a Pin27b Lock nut28 Bracket29 Studs30 Plate31 Nuts32 Mounting bracket

Attachment to rods

Attachment to NAMUR rib

EB 8356 EN 9


tion A or B according to Table 5 andFig. 4.

5. Place the limit switch on the adapterhousing, observing the operating direc-tion. Make sure that the pin (27a) restsagainst the bracket (28).

Caution!The pin must not slip out of the bracket onceinstalled.

2.3 Attachment to rotary actuators

You have the possibility of attaching thelimit switch to rotary actuators according toVDI/VDE 3845. For this purpose, you re-quire the accessories and mounting partslisted in Table 6 on page 17. The rotary mo-tion of these actuators is transferred to themetal tags via the cam disk installed on theactuator shaft and a follower roll on thelimit switch lever.

2.3.1 Mounting the follower rolllever

1. Place the follower roll lever (35) on theside where the transmission lever (37) islocated (opposite of the press nuts). Se-cure with the supplied screws (38) andwashers.

2.3.2 Mounting the intermediatepiece

SAMSON Type 3278 Actuator

1. Screw the adapter (36) to the free endof the rotary actuator’s shaft.

2. Screw intermediate piece (34) with twoscrews to the actuator case. For versions with solenoid valve, makesure that you place the intermediatepiece in such a manner that the air con-nections of the limit switch point to-wards the side of the diaphragm case.

3. Align the cam disk and scale as de-scribed in section 2.3.3, and fastenwith screws.

Actuators according to VDI/VDE 3845

1. Place the entire intermediate piece (34,42, 44 and 45) onto the mountingbracket included in the scope of actua-tor delivery (fixing level 1 acc. toVDI/VDE 3845) and screw tight.

2. Align the cam disk (40) and scale as de-scribed in section 2.3.3 and fasten withscrews.

10 EB 8356 EN


Fig. 5 ⋅ Attachment to rotary actuators

33

3835

39

39

40

34

36

40

34

44

45

42

43

37

Vent plug or filter check valve

33 Limit switch34 Intermediate piece35 Lever with follower roll36 Adapter37 Transmission lever38 Screws39 Scale40 Cam disk41 Actuator shaft42 Disk43 Mounting bracket 44 Coupling45 Seal

Attachment acc. toVDI/VDE 3845

Attachment toSAMSON Type 3278

EB 8356 EN 11


2.3.3 Adjusting the cam disk

The adjustment of the cam disk depends onthe valve’s direction of rotation, i.e. whetherit opens clockwise or counterclockwise.

Important!Starting position is the closed valve.The starting point (bore) of the cam must bepositioned so that the fulcrum of the camdisk and the 0°-position on the scale as wellas the arrow on the inspection glass form ahorizontal line.When aligning the cam disk, the double-sided scale disk must be clipped on the camdisk in such a way that the value on the sca-le matches the control valve’s direction of ro-tation. Secure the cam disk using the faste-ning screw.

Securing the aligned cam disk

To additionally prevent the cam disk frombeing turned, drill a hole into the adapter(36) or the coupling (44) and install a 2 mmdowel pin.Four bore holes are available on the camdisk, and they are located centricallyaround the center bore hole. Select the suit-able bore to secure.

12 EB 8356 EN


Fig. 6 ⋅ Adjusting the cam disk

90˚60˚

30˚ 0˚ 0˚

90˚

60˚

30˚

Starting pointFollower roll

Starting point

Control valve opens counterclockwise Control valve opens clockwise

Insert clip and press the tongues outwards

EB 8356 EN 13


2.3.4 Reversing amplifier fordouble-acting actuators

Limit switches fitted with solenoid valveswhich are intended for use with double-ac-ting actuators must be equipped with a re-versing amplifier. The reversing amplifier is listed as an acces-sory in Table 7 on page 21.The output signal pressure of the solenoidvalve is supplied at output A1 of the revers-ing amplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure at A1, is supplied atoutput A2. A1 + A2 = Z applies.

Assembly

Important! Remove the sealing plug (1.5) before instal-ling the reversing amplifier. The rubberseal (1.4) must remain installed.

1. Screw the special nuts (1.3) included inthe accessories of the reversing ampli-fier into the threaded connections of thelimit switch.

2. Insert the gasket (1.2) into the recess ofthe reversing amplifier and push thetwo hollowed special screws (1.1) intothe connecting bore holes A1 and Z.

3. Place the reversing amplifier onto thelimit switch and screw tight using thetwo special screws (1.1).

Signal pressure connections

A1: Connect output A1 to the signal press-ure connection on the actuator that opensthe valve when the pressure increases.A2 : Connect output A2 to the signal press-ure connection on the actuator that closesthe valve when the pressure increases.

14 EB 8356 EN

Reversing amplifier for double-acting actuators

Vent plug or filter check valve

Fig. 7 ⋅ Mounting a reversing amplifier

A1

1.5

1.3 1.2 1.1

1.3 1.21.1

1

Z

A2

1.4A1 A2

Z

A1

Output 38 Supply 9O

utpu

t 38

Supp

ly 9

1 Reversing amplifier1.1 Special screws1.2 Gasket1.3 Special nuts1.4 Rubber seal1.5 Sealing plug

From the limit switch

To the actuator

EB 8356 EN 15

Reversing amplifier for double-acting actuators

Table 1 Direct attachment (Fig. 3) Actuator size Attachment kit

Required lever with associated clamp and distance plate cm2 Order no.

D1 with sealing plug for output (38) for version with solenoid valve

G 1/41/4 NPT

120 1400-67901400-6791

D1 (33 mm long with 17-mm high bracket) 240 and 350 1400-6370

D2 (44 mm long with 13-mm high bracket) 700 1400-6371

Table 2 (only for versions with solenoid valve) Order no.

Switchover plate for 120 cm2 actuators Actuator Type 3277-5xxxxxx. 00 (old) 1400-6819

Switchover plate new Actuator with index . 01or higher (new) 1400-6822

Connection plate for additional attachmentof, e.g. a solenoid valve

3277-5xxxxxxxx. 00(old)

G 1/81/8 NPT

1400-68201400-6821

Connection plate new Actuator with index .01or higher (new) 1400-6823

Note! Only new switchover and connecting plates can be used for new actuators (index 01). Old and new plates are notinterchangeable.

Required connection block for 240, 350 and 700 cm2 actuator(including seals and mounting screws)

G 1/4 1400-8811

1/4 NPT 1400-8812

Table 3 (only for version with solenoid valve) Actuator size in cm2 Material Order no.

Required tube connection including screw joint

For actuator:Actuator stem retracts or when filling the top diaphragm chamberwith air

240 Steel 1400-6444

240 Stainless steel 1400-6445

350 Steel 1400-6446


700 Steel 1400-6448


Accessories Stainless steel/Br 1400-6950

Pressure gauge mounting kit for supply air and signal pressure SS/SS 1400-6951

Filter check valve, replaces the vent plug and raises the degree of protection to IP 65 1790-7408

Mounting parts table

16 EB 8356 EN

Table 4 Attachment IEC 60534-6 (Fig. 4)

Control valve Travel in mm With lever Order no.

NAMUR attachment kit

Parts, see Fig. 4

Valve with cast yoke 7.5 to 60 N1 (125mm) 1400-6787

22.5 to 120 N2 (212 mm) 1400-6789

Valve with rod-type yoke

withrod

diametermm

20 to 25 N1 1400-6436

20 to 25 N2 1400-6437

25 to 30 N1 1400-6438

25 to 30 N2 1400-6439

30 to 35 N1 1400-6440

30 to 35 N2 1400-6441

Attachment to Fisher and Masoneilan linear actuators(one each of both attachment kits are required per actuator)

1400-6771and 1400-6787

Accessories (w. sol. valve) Press. gauge mount. block G 1/4: 1400-7098 1/4 NPT: 1400-7099

Press. gauge mount. kit for supply and signal pressure St. steel/brass: 1400-6950 St. st./st. st.: 1400-6951


Table 5 Attachment acc. to IEC 60534-6

Travel in mm *) 7.5 15 15 30 30 60 30 60 60 120

Pin on lever marking *) 1 2 1 2 1 2 1 2 1 2

Distance between pin/lever fulcrum 42 84 42 84 42 84 84 168 84 168

With lever N1 (125 mm long) N2 (212 mm long)

Transmission pin (27a) in position A A B A B

*) Interpolate intermediate values

Table 6 Rotary actuator for mounting parts (Fig. 5)

SAMSON Type 3278 Actuator 160 cm2 320 cm2 VDI/VDE 3845

Order no. 1400-7103 1400-7104 1400-7105

Attachment Masoneilan Camflex IDN 25...100

Camflex IDN 125...250

Camflex II

Order no. 1400-7118 1400-7119 1400-7120

Cam disk with accessoriescam disk, linear characteristics (0050-0072) angle of rotation 0 to 90° 1400-6664

Reversing amplifier (Fig. 7) for double-acting springless actuatorsG threaded connectionNPT threaded connection

1079-11181079-1119

Accessories (only for versions with solenoid valves) Stainless steel/brass 1400-6950

Press. gauge mount. kit for supply air and signal pressure Stainless steel/st. steel 1400-6951


Mounting parts table

EB 8356 EN 17

3 Electrical connections

As far as the electrical installation ofthe device is concerned, the relevantnational regulations governing theinstallation of electrical equipmentand the national accident preventionregulations of the country of destina-tion must be adhered to.In Germany, these are the VDE regu-lations and accident prevention regu-lations of the employer’s liability in-surance.For installation in hazardous areas,the following standards apply: EN60079-14: 1997; VDE 0165 Part1/8.98 "Electrical apparatus for ex-plosive gas areas" and EN 50281-1-2: VDE 0165 Part 2/11.99 "Electri-cal apparatus for use in the presen-ce of combustible dust". For intrinsically safe electrical appa-ratus that are certified according tothe Directive 79/196/EEC, the dataspecified in the certificate of con-formity apply for connection of in-trinsically safe circuits.For intrinsically safe electrical appa-ratus that are certified according tothe Directive 94/9/EC, the data spe-cified in the EC type examinationcertificate apply for connection of in-trinsically safe circuits.Note: It is absolutely necessary tokeep to the terminal plan specifiedin the certificate. Reversal of the elec-trical connections may cause the ex-plosion protection to be ineffective!Do not tamper with any paintedscrews inside or on the case.

Switching amplifier

To operate the inductive limit switches,switching amplifiers complying withEN 60947-5-6 must be connected in theoutput circuit.When the limit switch is installed in hazard-ous areas, you are required to observe therelevant regulations.

Note on the selection of cables and wires! To run several intrinsically-safe circuits in amulti-core cable, observe paragraph 12 ofEN 60079-14; VDE 0165/8.98 standards.Note especially that for commonly used insu-lating materials, such as polyethylene, theradial thickness of the conductor insulationmust be minimum 0.2 mm. The diameter ofa single wire of a flexible conductor mustnot be smaller than 0.1 mm.The conductor ends must be protectedagainst unlaying, e.g. by using wire end fer-rules. Any unused openings on the limitswitch must be closed with plugs.Devices used in ambient temperatures downto −40 °C must be fitted with metal cableglands.

For the terminal assignment, refer to Fig. 8or to the label on the terminal strip.

18 EB 8356 EN

Electrical connections

Accessories:Model code 3768-x...x. 03 and lowerCable gland PG 13.5:Black Order no. 1400-6781Blue Order no. 1400-6782Adapter PG 13.5 on 1/2" NPT:Metallic Order no. 1400-7109Blue finish Order no. 1400-7110Model code 3768-x...x. 04 and higherCable gland M20 x 1.5:Black Order no. 1400-6985Blue Order no. 1400-6986Nickel-plated brass

Order no. 1400-4875Adapter M20 x 1.5 on 1/2" NPT:Aluminum powder-coated

Order no. 0310-2149

3.1 Pneumatic connections for ver-sions with solenoid valve

The air connections are either 1/4 NPT orG 1/4 tapped holes. The customary screwjoints for metal and copper tubes or plastichoses can be used.

Important! Make sure that the supply air isdehumidified and free of oil and dust. Youare required to observe the maintenance in-structions for upstream pressure reducingstations.Thoroughly flush the pneumatic lines priorto installation.

When attaching the Type 3277 Actuator di-rectly, the signal pressure connection isfixed. When using NAMUR attachment, thesignal pressure line is connected to eitherthe upper or lower diaphragm chamber ofthe actuator, depending on the actuator’sfail-safe action, i.e. "Actuator stem retracts"or "Actuator stem extends".Exhaust air:Models with the index 3768-x...x. 03 andhigher are equipped with a hinged coverwithout a venting hole. The exhaust air con-nections for these models are included inthe mounting accessories. For direct attach-ment, the vent plug is located on the plasticcover of the actuator, whereas for NAMURattachment, it is located on the adapterhousing and for attachment to rotary actua-tors on the intermediate piece.

Note! If you intend to replace older modelswith model indices 3768-x...x. 02 or lower,the mounting parts need replacing, too.Fig. 8 ⋅ Electrical connections

+41 –42 +51 –52 +81 –82

+ –

(B)A

(A)B

Rear connections

Switching amplifieracc. to EN 60947-5-6

6 to 24 V DCsolenoid valve(optional)

EB 8356 EN 19

Pneumatic connections for versions with solenoid valve

4 Operation – Adjusting the limitcontacts

On the rotary axis, there are two adjustabletags (51) which operate the associatedproximity switches (50).To operate the inductive limit switches,corresponding switching amplifiers must beconnected in the output circuit (see section3).When the tag (4) is in the inductive field ofthe switch, the switch assumes a high resist-ance. When it is no longer in the field, theswitch assumes a low resistance.The limit contacts are usually adjusted toissue a signal for both limit positions. Theswitches, however, can also be adjusted tosignalize intermediate positions.The assignment of the switches A and Bmust be determined according to Tables 7and 8. It depends on the mounting position

of the limit switch and the limit position ofthe valve (either valve Open or Closed).The switches A and B are optionally as-signed to the terminal pairs 41/42 and51/52 by turning the associated nameplate on the terminal block (see also Fig. 8).

Important!Since the tags of the limit switches cannotbe turned by 360°, correct assignment ofthe switches A and B to the valve positionsOpen and Closed must be observed, especi-ally when the limit switches are to be con-nected in fail-safe circuits.

The desired switching function, i.e. whetherthe output relay must be picked up or re-leased when the tag has entered the field,must be determined by means of jumpersfor either working current or closed circuitcurrent at the switching amplifier.

Fig. 9 ⋅ Limit contacts

20 EB 8356 EN

Operation – Adjusting the limit contacts

Setting the switching point

Move the valve to the switching positionand adjust the tag by turning the adjustmentscrew (53) so that the switching point isreached and indicated by the LED on theswitching amplifier.To ensure safe switching under any condi-tion, the switching point should be adjustedto stop approx. 2 % before the mechanicalstop (Open – Closed) is reached.

Table 7 Direct attachment to Type 3277 Actuator (Fig. 3)


Switch

Valve position Tag OUT Tag IN Tag OUT Tag IN

Closed B A A B

Open A B B A

Table 8 NAMUR attachment (Fig. 4) Mounting position of adapter housing when looking onto the lever (18)


Cable glandpoints

towardsValve

position

SwitchTag

Cable glandpoints

towardsValve

position

SwitchTag

OUT IN OUT IN

Front ClosedOpen

BA

AB

Front ClosedOpen

AB

BA

Back ClosedOpen

AB

BA

Back ClosedOpen

BA

AB

EB 8356 EN 21

Operation – Adjusting the limit contacts

5 Servicing explosion-protectedversions

In the event that a part of the limit switch onwhich the explosion protection is basedmust be serviced, the limit switch must notbe operated again, unless an expert has in-spected the device according to the explo-sion protection requirements, issued a certifi-cate stating this, or equipped the devicewith his mark of conformity.The inspection by an expert does not haveto be carried out, if the manufacturer per-forms a routine check test on the deviceprior to taking it into operation again, andthe success of the routine check test is do-cumented by attaching a mark of conform-ity to the device.Parts used in explosion-protected versionsshould only be exchanged for original de-tail inspected parts from the manufacturer.

22 EB 8356 EN

Servicing explosion-protected versions

6 Dimensions in mm

44

19.5

3539

164

4676 50

36N

1=11

3 N

2=20

0

5856

68

28

1429

150

16419.5

37

6818

5

76

Ø110

82

5666

50

M20 x 1.5

28.5

28.5

Output 1 (A1)

Output 2 (A2) Supply (Z)

50

Output (38)

Supply (9)

Reversing amplifier(optional)

Fulcrum of theactuator shaft

Pneumatic connectionreversing amplifier

EB 8356 EN 23

Dimensions in mm

24 EB 8356 EN

EB 8356 EN 25

26 EB 8356 EN

EB 8356 EN 27

28 EB 8356 EN

EB 8356 EN 29

30 EB 8356 EN

EB 8356 EN 31

SAMSON AG ⋅ MESS- UND REGELTECHNIKWeismüllerstraße 3 ⋅ 60314 Frankfurt ⋅ GermanyPhone: +49 69 4009-0 ⋅ Fax: +49 69 4009-1507Internet: http://www.samson.de S/

Z 20

04-0

5

EB 8356 EN

B73GInstallation & Maintenance

Instructions

ADJUSTMENT1. Before applying inlet pressure to filter/regulator, turn

adjustment (1 or 7) counterclockwise to remove all forceon regulating spring (12).

2. Apply inlet pressure, then turn adjustment (1 or 7)clockwise to increase and counterclockwise to decreasepressure setting.

3. Always approach the desired pressure from a lowerpressure. When reducing from a higher to a lowersetting, first reduce to some pressure less than thatdesired, then bring up to the desired pressure.

NOTEWith non-relieving filter/regulators, make pressurereductions with some air flow in the system. Ifmade under no flow (dead-end) conditions, thefilter/regulator will trap the over-pressure in thedownstream line.

4. KNOB ADJUSTMENT. Push knob down to lock pressuresetting. Pull knob up to release. Install tamper resistantcover (see Replacement Items) to make setting tamperresistant.

5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lockpressure setting.

SERVICING1. Open manual drain to expel accumulated liquids. Keep

liquids below baffle (49).2. Clean or replace filter element when dirty.

DISASSEMBLY1. Filter/regulator can be disassembled without removal

from air line.2. Shut off inlet pressure. Reduce pressure in inlet and

outlet lines to zero. 3. Turn adjustment (1 or 7) fully counterclockwise.4. Remove bowl - push into body and turn

counterclockwise.5. Disassemble in general accordance with the item

numbers on exploded view. Do not remove the drainsunless replacement is necessary. Remove and replacedrains only if they malfunction.

CLEANING1. Clean plastic bowl (25, 35) with warm water only. Clean

other parts with warm water and soap.2. Rinse and dry parts. Blow out internal passages in body

(16) with clean, dry compressed air. Blow air throughfilter element (50) from inside to outside to removesurface contaminants.

3. Inspect parts. Replace those found to be damaged.Replace plastic bowl with a metal bowl if plastic bowlshows signs of cracking or cloudiness.

ASSEMBLY1. Lubricate the following items with o-ring grease.

4 (Thrust washer) - outer circumference and both sides.5, 7 (Adjusting screw) - threads and tip.18, 28, 37 (Manual drain body) - the portion of the

body that contacts the bowl, and the hole that accommodates the stem of drain valve (19, 29, 38).53 (Valve) - stem.26, 34, 47, 54 (O-rings)

2. Assemble the unit as shown on the exploded view. Pushbowl, or bowl with guard, into body and turn fullyclockwise.

3. Torque TableItem Torque in Nm (Inch-Pounds)2, 9 (Screw) 2,3 to 3,4 (20 to 30)22, 32, 41 (Nut) 2,3 to 2,8 (20 to 25)43 (Screw) 1,7 to 3,4 (15 to 30)49 (Baffle), 51 (Louver) 1,1 to 2,2 (10 to 20)

TECHNICAL DATAFluid: Compressed airMaximum pressure:

Transparent bowl: 10 bar (150 psig)Metal bowl: 17 bar (250 psig)

Operating temperature*: Transparent bowl: -20° to +50°C (0° to +125°F)Metal bowl: -20° to +80°C (0° to +175°F)

* Air supply must be dry enough to avoid ice formation attemperatures below +2°C (+35°F).

Particle removal: 5 µm, 25 µm, or 40 µm filter elementAir quality: Within ISO 8573-1, Class 3 and Class 5

(particulates)Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar

(90 psig) set pressure and 1 bar (15 psig) droop from set: 50 dm3/s (106 scfm)

Nominal bowl size: 0,1 litre (3.5 fluid ounce)Manual drain connection: 1/8"Automatic drain connection: 1/8"Automatic drain operating conditions (float operated):

Bowl pressure required to close drain: Greater than 0,3 bar (5 psig)

Bowl pressure required to open drain: Less than 0,2 bar (3 psig)

Minimum air flow required to close drain: 0,1 dm3/s (0.2 scfm) Manual operation: Depress pin inside drain outlet to

drain bowlGauge ports:

1⁄4 PTF with PTF main portsRc1/4 with ISO Rc main portsRc1/8 with ISO G main ports

Materials:Body: AluminumBonnet: AluminumValve: BrassBowl:

Transparent: PolycarbonateTransparent with guard: Polycarbonate, steel guardMetal: AluminumMetal bowl liquid level indicator lens: Transparent nylon

Element: Sintered polypropyleneElastomers: Neoprene and nitrile

REPLACEMENT ITEMSService Kit (includes items circled on exploded view):

Relieving.............................................................4383-600Nonrelieving .......................................................4383-601

Liquid level lens kit (43, 45, 46, 47) ......................4380-020Filter element, 5µm (50) ..........................................4438-01Filter element, 25µm (50) ........................................4438-02Filter element, 40µm (50) ........................................4438-03Manual drain (18, 19, 20) ..........................................619-50Automatic drain (21, 22, 23) .................................4000-51RTamper resistant cover (knob adjustment only).......4455-51

PANEL MOUNTING DIMENSIONSPanel mounting hole diameter: 48 mm (1.89")Panel thickness: 2 to 6 mm (0.06" to 0.24")

INSTALLATION1. Shut off air pressure. Install filter/regulator in air line -

vertically (bowl down), with air flow in direction of arrow on body, upstream of lubricators and cycling valves, as close as possible to the device being serviced.

2. Connect piping to proper ports using pipe thread sealanton male threads only. Do not allow sealant to enterinterior of unit.

3. Push bowl, or bowl with guard, into body and turn fullyclockwise before pressurizing.

4. Install a pressure gauge or plug the gauge ports. Gaugeports can also be used as additional outlets for regulated air.

Filter/RegulatorB73G - - -

Thread FormA....PTFB....ISO Rc taperG....ISO G parallel

Port2 ....1/4"3 ....3/8"4 ....1/2"* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.

Spring (Outlet Pressure Range) *F ....0,3 to 4 bar (5 to 60 psig)M...0,3 to 10 bar (5 to 150 psig)S....0,7 to 17 bar (10 to 250 psig)

GaugeG....WithN....Without

DiaphragmN....Non-relievingR....Relieving

AdjustmentK....KnobT ....T-bar

DrainA....AutomaticQ....Manual, 1/4 turn

BowlD....Metal with liquid level indicatorP....Transparent with guardT ....Transparent

Element1 ....5 µm2 ....25 µm3....40 µm

5

4

3

2

1

11

9

78

10

6

12

16

14

52

54

53

13

51

50

49

15

17

27

3646

44

43

47

3938

41

42

3029

32

2831

33

34

35

2019

22

1821

23

45

24

25

26

4837 40

IM-180.300.01 (4/98)Supersedes 12/97a subsidiary of IMI plc

© Norgren 1998

CAUTIONWater vapor will pass through these units and couldcondense into liquid form downstream as air temperaturedrops. Install an air dryer if water condensation could havea detrimental effect on the application.

WARNINGThese products are intended for use in industrial

compressed air systems only. Do not use these productswhere pressures and temperatures can exceed those listedunder Technical Data.

Polycarbonate plastic bowls can be damaged andpossibly burst if exposed to such substances as certainsolvents, strong alkalies, compressor oils containing ester-based additives or synthetic oils. Fumes of thesesubstances in contact with the polycarbonate bowl,externally or internally, can also result in damage. Cleanwith warm water only.

Use metal bowl in applications where a plastic bowlmight be exposed to substances that are incompatible withpolycarbonate.

If outlet pressure in excess of the filter/regulatorpressure setting could cause downstream equipment torupture or malfunction, install a pressure relief devicedownstream of the filter/regulator. The relief pressure andflow capacity of the relief device must satisfy systemrequirements.

The accuracy of the indication of pressure gauges canchange, both during shipment (despite care in packaging)and during the service life. If a pressure gauge is to beused with these products and if inaccurate indications maybe hazardous to personnel or property, the gauge should becalibrated before initial installation and at regular intervalsduring use.

Before using these products with fluids other than air,for non industrial applications, or for life-support systemsconsult Norgren.

B73GInstallation & Maintenance

Instructions

IM-180.300.02 (4/98)Supersedes 12/97a subsidiary of IMI plc

© Norgren 1998

OPERATION MANUAL

BOOSTER RELAY

ＩＬ１００

ＳＭＣ CORPORATION

No.：IL01－OM00006

ﾌｫｰﾏｯﾄ No：FSM027-1

0

CONTENTS

Instructions for your safety 1～2

1. Outline 3

2. Specification 3

3. Structure and the Operation Principle 3～4

4. Transportation and Storage 5

5. Precautions in Using 6

6. Maintenance 7～8

7. Countermeasures for Failure 9

8. Spare Parts List 10

Drawings 11～12

IL100－※※

Page

1

Instructions for your safety Please read thoroughly this operation manual before using the product. Please keep this manual so that you will be able to refer to it anytime, and ensure to give it to end users. These instructions are intended to prevent a hazardous situation and / or equipment damage. These instructions indicate the level of potential hazard by label of “Caution” “Warning”, or “Danger”. To ensure safety, be sure to observe ISO 4414 (Note 1), JIS B 8370 (Note 2) and other safety practices.

Caution : Operator error could result in injury or equipment damage.

Warning : Operator error could result in serious injury or loss of life.

Danger : In extreme conditions, there is a possibility of serious injury or loss of

life

(Note 1) ISO 4414 Pneumatic fluid power-Recommendations for the application of equipment to

transmission and control system. (Note 2) JIS B 8370 Pneumatic system axiom

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2

Warning 1. The compatibility of pneumatic equipment is the responsibility of the person who designs the

pneumatic system or decides its specifications. Since the products specified here are used in various operating conditions, their

compatibility for the specific pneumatic system must be based on specifications or after analyses and/or tests to meet your specific requirements.

2. Only trained personal should operate pneumatically operated machinery and equipment. Compressed air can be dangerous if an operator is unfamiliar with it. Assembly, handling or

repair of pneumatic systems should be performed by trained and experienced operator.

3. Do not service machinery / equipment or attempt to remove component until safety is confirmed.

1. Inspection and maintenance of machinery / equipment should only be performed after confirmation of safe locked-out control positions.

2. When equipment is removed, confirm the safety process as mentioned above.

Cut the supply pressure for this equipment and exhaust all residual compressed air in the system.

3. Before machinery / equipment is restarted, take measures to prevent shooting out of

cylinder piston rod etc. 4. Contact SMC if the product is to be used in any of the following conditions .

1. Conditions and environments beyond the given specifications, or if product is used outdoors.

2. Installation on equipment in conjunction with atomic energy, railway, air navigation,

vehicles, medical equipment, food and beverage, recreation equipment, emergency stop circuits, press applications, or safety equipment.

3. An application which has the possibility of having negative effects on people, property,

or animals requiring special safety analysis.

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3

1. Outline

Increase the operating speed of controlling part when the piping between the instruments and the controlling part is very long, or the controlling part capacity is large.

2. Specification

Supply pressure MAX.1.0MPa

Input・Output pressure MAX.0.7MPa

Output flow Max. 1MPa (Note 1)

Air consumption 0.14～0.7MPa (Note 1)

Linearity Within ±1%

Hysteresis Within 1%

Effective orifice (Cv factor) 1.1 Ambient temperature and

operating fluid temperature －5～60

Port size PT 1/4・3/8

Mass 560g 3. Structure and the operation principle

Input force from the instrument enters to the input chamber and act to diaphragm A. This works against the force generated by diaphragm B. When the force generated by the input is strong, the internal valve is pressed down and the supply air flows to the output side. When not strong, the internal valve is closed and the exhaust port opens for exhaust. This is how the force generated by diaphragm A and B is balanced. Opening of the needle valve connect the air path of the input and the output. The adjustment of the throttle valve, the stability of the closed loop including the booster relay is improved.

5

4. Transportation and Storage

Warning

(1) Handle the product with care.

(2) Do not expose to rain.

(3) The product is packed in a vinyl bag for shipment to prevent from dust. Avoid taking out of the bag just before piping even after unpacking.

(4) If the product is kept unpacking for a certain period, select a place where there is no

moisture nor corrosive gas. While the product shipped has been applied specified paint and surface treatment, take care that inappropriate storing environment may cause generating rust.

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6

5. Precautions in using Warning Operation

(1) Do not operate the booster relay out of the specifications, because it causes malfunction.

(2) If booster relay failure affecting the system is expected, provide a safety circuit for the

system to avoid danger.

Warning Handling (1) Excess vibration and impact on the booster relay cause failure, may cause failure, so

that take care in handling during transportation and operation. (2) Mount the filter to the pressure supply line. Use the mist separator when the oil mist

and carbon are contained. (3) Flush the air piping before connecting the booster relay. (4) Mind the arrow direction of the air flow when piping. (5) The needle valve is opened for 3/4 turn and locked. No adjustment is necessary except

when the control system is unstable. (6) Opening the needle valve delays the response, closing quickens the response.

Warning Air supply (1) Please use the filter to the supply line. Where contained oil mist and carbon, please use

the mist separator.

(2) Avoid using compressed air compressed air containing chemicals, synthetic fluid including organic solvent, salinity, and corrosive gas as it may cause malfunction.

Warning Environment

(1) Do not use in environment where the product is exposed to corrosive gas, chemicals, salt water, water or steam.

(2) Do not operate the product in a location where it is subject to strong vibration and/or

shock. For vibration, it should be within IG 60Hz.

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7

6. Maintenance

Warning

(1) To handle compressed air, person that has experienced and has knowledge about instrumentation machine is suitable. That kind of person should operate unit replacement and maintenance with keeping product specification.

(2) To remove booster relay or to replace unit with product set, please exhaust residual

pressure within piping with supply air stopped. (3) After mounting, maintenance and disassemble, please test leakage and function with

compressed air supplied. When louder breed sound than initial, or when machine do not operate properly, please confirm correct mounting.

Caution

(1) Periodical check (recommended : once / year) Please check once per year on this product. To check, disassemble product following disassemble drawing, and check following item. When disassemble, pay attention in order not to damage diaphragm, in the case of diaphragm stick to body.

To re-assemble, ensure no foreign matter inside product and pay attention for air path position of each part.

(2) Product replacement (recommended : once / 3 years) This product rubber part is recommended to replace once per 3 years. Part replacement adjustment (valve seat centering, main valve length adjustment etc.) make effects on property. Product replacement is recommended by whole product per 3 years if it is used on extremely important point.

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Part description Check items Confirmation Countermeasure

Diaphragm (2,10) No crack or flaw on the surface Visual inspection

“O”ring (11,12) No crack or flaw on the surface Visual inspection

Valve stem spring (6) No crack due to hold Visual inspection

Part replacement if abnormality is found.

Main valve (3) Without lock nut loosen Hand or tool If loosen, retighten.

*( ) shows booster relay disassemble drawing part no.

8

Warning

(Adjustment on Part replacement)

Diaphragm replacement and product disassemble & re-assemble may change in/output

characteristics. For that circumstances, adjust main valve length. Main valve, as shown below, is adjusted the length by screw and fixed with lock nut. To adjust length, loose lock nut. For the main valve length adjustment, make longer when output is low to input signal. Make shorter when output is high to input signal. Main valve total length is basically 25±1mm.

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9

7. Countermeasures for failure

Warning

Avoid use when failure is not solved.

!

Phenomenon Cause Countermeasures

Dust attach supply port or exaust port

Disassemble and clean. (If flawed, replace the part.)

Too much flow from exaust port

Broken diaphragm Replace diaphragm Pressure leak due to loosen screw Tighten screw

Restrictor open too much Decrease open degrees of restrictor, and lock.

No signal even if input signal is applied

Broken diaphragm Replace diaphragm

Valve stem length is changed due to loosen lock nut

Readjust into optimum valve, and lock.

Plugged restrictor Disassemble and clean Bad characteristic

Deformed diaphragm Replace diaphragm

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