Samson I-P Positioner

7/29/2019 Samson I-P Positioner

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Series 3730Electropneumatic PositionerType 3730-1

Mounting andOperating Instructions

EB 8384-1 EN (1300-1610)Firmware version 2.12

Edition November 2010

Fig. 1 Type 3730-1


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Contents Page

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6

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

3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8

3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Attachment to the control valve mounting parts and accessories . . . 12

4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 18

4.3 Attachment to Type 3510 Micro-flow Valve . . . . . . . . . . . . . . . 20

4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 22

4.4.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26

4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 26

4.6 Attaching positioners with stainless steel housings. . . . . . . . . . . . 28

4.7 Air purging function for single-acting actuators . . . . . . . . . . . . . 28

4.8 Mounting parts and accessories . . . . . . . . . . . . . . . . . . . . 295 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 32

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

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

5.2.1 Switching amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.1 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Setting the volume restriction Q. . . . . . . . . . . . . . . . . . . . . . 38

7.2 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.3 Entering the opening direction . . . . . . . . . . . . . . . . . . . . . 38

7.4 Setting other parameters . . . . . . . . . . . . . . . . . . . . . . . 39

7.5 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.6 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2 EB 8384-1 EN

Contents


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7.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.8 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.9 Manual adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 428 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

10 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 47

11 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 50

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

EB 8384-1 EN 3

Contents


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4 EB 8384-1 EN


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Revision in positioner firmware compared to the previous version

Previous version New 2.02 2.10

New reset function in Code P0, refer to section 7.8

New manual adjustment function in Code P14, refer to section 7.9

2.10 2.11

Internal modifications

2.11 2.12

Internal modifications

EB 8384-1 EN 5

Revision in positioner firmware


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1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start-up and opera-tion of the positioner:

4 The positioner is to be mounted, started up or operated only by trained andexperienced personnel familiar with the product.

According to these Mounting and Operating Instructions, trained personnel refers toindividuals who are able to judge the work they are assigned to and recognizepossible dangers due to their specialized training, their knowledge and experience as

well as their knowledge of the applicable standards.

4 Explosion-protected versions of this positioner may only be operated by personnel

who have undergone special training or instructions or who are authorized to workon explosion-protected devices in hazardous areas. Refer to section 10.

4 Any hazards that could be caused by the process medium, the operating pressure, thesignal pressure or by moving parts of the control valve are to be prevented by meansof the appropriate measures.

4 If inadmissible motions or forces are produced in the actuator as a result of the supplypressure, the supply pressure must be restricted by means of a suitable supply pres-sure reducing station.

To avoid damage to any equipment, the following also applies:4 Do not operate the positioner with the back of the positioner/vent opening facing up-

wards. The vent opening must not be sealed when the positioner is installed on site.

4 Proper shipping and appropriate storage are assumed.

4 Do not ground electric welding equipment near to the positioner.

Note:The device with a CE marking fulfils the requirements of the Directives 94/9/EC(ATEX) and 89/336/EEC (EMC). The declaration of conformity is available on request.

6 EB 8384-1 EN

Important safety instructions

Vent opening


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2 Article code

EB 8384-1 EN 7

Article code

Article code Type 3730-1 x x 0 0 0 0 0 0 0 x 0 0 x 0 0 0

With LCD, autotune4 to 20 mA reference variable, two software limit switches

Explosion protection

Without 0

ATEX: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80 C IP 66 1

FM/CSA:Class I, Zone 0 AEx ia IIC; Class I, II, III; Div.1, Groups AG;Class I, Div.2, Groups AD; Class II, Div.2, Groups F, G/Ex ia IIC T6; Class I, Zone 0; Class II, Groups EG; Ex nA II T6; Class I, Zone 2;Class I Div.2, Groups AD; Class II, Div.2, Groups EG

3

ATEX: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T 80 C IP 66 8

Option: Inductive limit switch

Without 0

With SJ2-SN proximity switch 1

With SJ2-S1N proximity switch 2

Housing material

Standard aluminum 0

Stainless steel 1.4581 1

Special applicationsWithout 0

Compatible with paint 1

Exhaust air with NPT connection, back of positioner housing sealed 2

Special version

Without 0 0 0


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3 Design and principle ofoperation

The electropneumatic positioner is mountedto pneumatic control valves and is used toassign the valve position (controlled

variable 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 direct attach-ment to Type 3277 Actuators or for attach-ment to actuators according to IEC 60534-6(NAMUR).

Additionally, a coupling wheel included inthe accessories is required to transfer the ro-tary motion for rotary actuators according to

VDI/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 toresistance, an analog i/p module withdownstream booster as well as the electronicunit with a microcontroller. The positioner isfitted with two adjustable software limit

switches as standard to indicate the valve'send 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, an

A/D converter (4) transmits the position ofthe valve to the microcontroller (5). The PDcontroller compares this actual position to

the 4 to 20 mA DC control signal (referencevariable) after it has been converted by the

A/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 control

valve to move to the position determined bythe reference variable.The pneumatic air capacity booster (7) andthe pressure regulator (8) are provided with

supply air. An intermediate flow regulator(9) with fixed settings is used to purge thepositioner and also guarantees trouble-freeoperation of the pneumatic booster.The output signal pressure supplied by thebooster can be limited to 2.4 bar by activat-ing the parameter P9.The volume restriction Q (10) is used to opti-mize the positioner by adapting it to the ac-

tuator size.Tight-closing function:The pneumatic actuator is completely filled

with air or vented as soon as the referencevariable falls below 1 % or exceeds 99 %(see end positions set over parameters P10and P11).

8 EB 8384-1 EN

Design and principle of operation


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EB 8384-1 EN 9


Fig. 2 Functional diagram

%

Smm

%

mm

w

x

Q

PD

A2

A1

4 5

3

11

12

6

7

8

10

1

w

9

x

y

2

7 Air capacity booster

8 Pressure regulator

9 Flow regulator

10 Volume restriction

11 Limit switches

12 Display

1 Control valve

2 Travel sensor

3 PD controller

4 A/D converter

5 Microcontroller

6 i/p converter


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3.1 Technical data

10 EB 8384-1 EN


Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Travel, adjustableDirect attachment to Type 3277: 3.6 to 30 mm

Attachment acc. to IEC 60534-6: 3.6 to 200 mm or 24 to 100 with rotaryactuators

Travel rangeAdjustable within the initialized travel/angle of rotation;travel can be restricted to 15 at the maximum

Reference variable wSignal range 4 to 20 mA Two-wire device, reverse polarity protection,split-range 4 to 11.9 mA and 12.1 to 20 mA, static destruction limit 100 mA.

Minimum current 3.7 mA

Load impedance 6 V (corresponding to 300 W at 20 mA)

Supply airAir quality acc.to ISO 8573-1

Supply pressure from 1.4 to 7 bar (20 to 105 psi),Max. particle size and density: Class 4 Oil content: Class 3, pressure dew point:Class 3 or at least 10 K beneath the lowest ambient temperature to be expected

Signal pressure (output) 0 bar up to supply pressure, limitable to approx. 2.4 bar via software

Characteristic Optionally 1 characteristic for globe valves, 8 characteristics for opening angle

Hysteresis 1 %

Sensitivity 0.1 %

Transit time < 0.5 s for initialization not permissible, adaptation over volume restriction Q

Direction of action w/x reversible

Air consumption, steadystate

Independent from supply pressure approx. 110 ln/h

Air output capacityActuator pressurizedActuator vented

AtDp = 6 bar: 8.5 mn3/h, atDp = 1.4 bar: 3.0 mn3/h KVmax(20 C) = 0.09atDp = 6 bar: 14.0 mn3/h, atDp = 1.4 bar: 4.5 mn3/h KVmax(20 C) = 0.15

Permissible ambienttemperature

20 to +80 C in all versions45 to +80 C with metal cable gland25 to +80 C with inductive limit switches (SJ2-S1N) and metal cable glandLimits in test certificate also apply for explosion-protected devices.

InfluencesTemperature: 0.15 %/10 K Supply air: None

Vibration:

0.25 % up to 2000 Hz and 4 g acc. to IEC 770Electromagneticcompatibility

Complying with requirements specified in EN 61000-6-2, EN 61000-6-3,EN 61326-1 and NAMUR Recommendation NE 21

Electrical connectionsOne M20 x 1.5 cable gland for 6 to 12 mm clamping range Additional second M20

x 1.5 threaded hole Screw terminals for 0.2 to 2.5 mm wire cross-section

Explosionprotection

ATEX

FM

CSA

Type 3730-11: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80 C IP 66

Type 3730-18: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T 80 C IP 66

Type 3730-13:Class I, Zone 0 AEx ia IIC; Class I, II, III; Div.1, Groups AG;Class I, Div.2, Groups AD; Class II, Div.2, Groups F, G

Type 3730-13:Ex ia IIC T6; Class I, Zone 0; Class II, Groups EG; Ex nA II T6; Class I,Zone 2; Class I Div.2, Groups AD; Class II, Div.2, Groups EG


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EB 8384-1 EN 11


Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Degree of protection IP 66 / NEMA 4X

Use in safety-instrumentedsystems in compliancewith IEC 61508

Suitable for use in safety-relevant applications up to SIL 2 (single device) and SIL 3(with redundant configuration), safety shutdown at a reference variable of 0 mA.

Weight Approx. 1 kg

Materials

HousingDie-cast aluminum EN AC-Al Si12(Fe) (EN AC-44300) acc. to DIN EN 1706,chromated and plastic coated Special version: Stainless steel 1.4581

External parts Stainless steel 1.4571 and 1.4301

Cable gland M20x1.5, black polyamide

Binary contactsTwo software limit switches with configurable limits (0.5 % steps), reverse polarityprotection, floating

Signal statusNo response:

Response:

Without explosion protectionConductive ( R = 348 W)Non-conducting

Explosion-protected version 2.1 mA 1.2 mA

Operating voltage

- Binary input of the PLC acc. toIEC 61131-2, Pmax= 400 mW

- NAMUR switching amplifier acc. toEN 60947-5-6

Only for connection to NAMURsignal converter acc. to EN 60947-5-6

Option:Inductive limit switch

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

SJ2-SN proximity switch NAMUR NC contact

SJ2-S1N proximity switch NAMUR NO contact


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4 Attachment to the controlvalve mounting parts and

accessoriesThe 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 to

VDI/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 actual valve travel that can be achievedis restricted by the pin position used and ad-ditionally by the actuator spring compres-sion required.

The travel range listed in the travel tablesopposite can only achieved if the nominalrange is set to MAX.

The positioner is standard equipped with theleverM (pin position 35).

Note:If the standard mounted lever M (pinposition 35) is replaced, the newly mountedlever must be moved once all the way as faras it will go in both directions to adapt it tothe internal measuring lever.

12 EB 8384-1 EN

Attachment to the control valve mounting parts and accessories

Fig. 3 Lever M (set pin position 35)


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EB 8384-1 EN 13


Travel tables

Note:The leverM is included in the scope of delivery.Levers S, L,XLfor attachment according to IEC 60534-6 (NAMUR) are available as accesso-ries (Table 3, page 30).

Direct attachment to Type 3277-5 and Type 3277 Actuators

Actuator size Rated travel Adjustment range at positioner Requiredlever

Assignedpin position[cm] [mm] Min. Travel Max.

120 7.5 5.0 to 25.0 M 25

120/240/350 15 7.0 to 35.0 M 35355/700 30 10.0 to 50.0 M 50

Attachment according to IEC 60534-6 (NAMUR attachment)

SAMSON valves/Type 3271 Actuator Other valves/actuatorsRequired

leverAssignedpin position

Actuator size Rated travel

[cm] [mm] Min. Travel Max.

60 and 120with Type 3510

7.5 3.6 to 18.0 S 17

120 7.5 5.0 to 25.0 M 25

120/240/350 157.0 to 35.0 M 35

700 7.5

700 15 and 30 10.0 to 50.0 M 50

1000/1400/2800 30 14.0 to 70.0 L 70

1000/1400/2800 60 20.0 to 100.0 L 100

1400/2800 120 40.0 to 200.0 XL 200

Attachment to rotary actuators according to VDI/VDE 3845

Rotary actuators Requiredlever

Assignedpin positionMin. Opening angle Max.

24 to 100 M 90


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4.1 Direct attachment

4.1.1 Type 3277-5 ActuatorRefer to Table 1 on page 29 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!

Actuator with 120 cm

Depending on the type of positioner attach-ment, the signal pressure is routed either left

or 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 according

to 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 bonded

gasket (14) points towards the actuatoryoke.

5. 15 mm travel: Keep the follower pin (2)at leverM (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 and

screw tight.6. Insert formed seal (15) in the groove of

the 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. 14). The lever (1) mustrest on the follower clamp with springforce. Mount the positioner on the coverplate (10) using the two fixing screws.During the installation make sure that theseal ring (10.1) is inserted in the bore ofthe intermediate 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.

14 EB 8384-1 EN



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EB 8384-1 EN 15


9 11

Supply 9 Output 38

56

4

7

6

10

10.1

3

2

1

15

6.1

1.11.2

14

8

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

1 Lever 1.1 Nut 1.2 Disk spring

2 Follower pin3 Follower clamp4 Screw plug5 Stopper 6 Connecting plate6.1 Seal rings7 Pressure gauge bracket 8 Press. gauge mounting kit 9 Switchover plate f. actuator10 Cover plate10.1 Seal ring

11 Cover 14 Gasket 15 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

Actuator stemextends

Attachment left Attachment right

Actuator stemretracts

Switchover plate (9)

Signal pressureinput for right

attachment

Marking

Cut-out of coverplate

Signal pressureinput for leftattachment

Lever M


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4.1.2 Type 3277 Actuator

Refer to Table 2 on page 30 for the requiredmounting parts as well as the accessorieswith their order numbers.Note the travel table on page 13!

Actuators with 240 to 700 cm

Mount the positioner on the yoke as shownin Fig. 5. The signal pressure is routed to theactuator over the connection block (12), foractuators with fail-safe action "Actuator

stem extends" internally through a bore inthe valve yoke and for "Actuator stem re-tracts" through external 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 the left)pointing towards the signal pressureconnection. Make sure that the bondedgasket (14) points towards the actuator

yoke.3. For actuators with 355/700 cm, re-

move the follower pin (2) at leverM (1)on the back of the positioner from pinposition 35, reposition it in the bore for

pin position 50 and screw tight.For actuators 240 and 350 cm 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 hold

the positioner shaft in position at the capor the switch (Fig. 14). 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 with

the actuator with fail-safe action"Actuator stem extends" or "Actuatorstem retracts." If necessary, remove thethree fixing screws and the cover. Thenreposition the gasket (16) turned by180. The previous version of the con-nection block (Fig. 5, bottom) requiresthe switch plate (13) to be turned suchthat the corresponding actuator symbolpoints to the marking.

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 external

signal pressure piping.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 8384-1 EN



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EB 8384-1 EN 17


2

10 1415

1 2 3 11 11.1

SUPPLY

13B

C

1.11.2

12

12.1

12

12.2

12.11216

16 16

12.2SUPPLY

Ansicht A

Ansicht B

Ansicht C

SUPPLY

G

G3/8

A

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

Lever M

1 Lever

1.1 Nut

1.2 Disk spring2 Follower pin

3 Follower clamp

10 Cover plate

11 Cover

11.1 Vent plug

12 Connection block

12.1 Screw

12.2 Stopper or connection forexternal piping

13 Switch plate

14 Gasket

15 Formed seal

16 Gasket

View A

View C

View B

Cut-out ofcover plate (10)

Actuator stemretracts extends

Actuator stem retracts

Actuator stem extends

Marking

Connection block (old)with switch plate (13)


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4.2 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 cm and 1400 cm with120 mm travel: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 and

then 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 lock

washer directly in the yoke bore.For attachment to valves with rod-type

yokes, use two U-bolts (15) around theyoke.Align the NAMUR bracket (10) accord-ing to the embossed scale so that the slotof the follower plate (3) is centrallyaligned with the NAMUR bracket at mid

valve travel.3. Mount connecting plate (6) or pressure

gauge 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, LorXLand pin position according to the actua-tor size and valve travels listed in the ta-ble below.Should you require a pin position otherthan position 35with the standard in-stalled leverM, or require a lever size LorXL, 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),you must move it once all the way as far asit will 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 NAMUR

bracket using both its fixing screws.

18 EB 8384-1 EN



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EB 8384-1 EN 19


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

10

11

1

1 14.1

3

3.1

16

15

14

1

1.2

1.1

2

9.1

9

6.1 6 7 8

1 Lever 1.1 Nut 1.2 Disk spring2 Follower pin3 Follower plate3.1 Follower plate6 Connecting plate6.1 Seal rings7 Pressure gauge bracket 8 Pressure gauge

mounting kit9 Stem connector 9.1 Bracket 10 NAMUR bracket 11 Screw 14 Bolt 14.1 Screw15 U-bolt 16 Bracket

Note:Always use the connecting plate (6) included in the accessories toconnect supply and output. Never screw threaded parts directly into thehousing.

Attachment toNAMUR rib

Additional bracket foractuators with 2800 cm2

and travel 60 mm

Attachment to rod-type yokeRods with 20 to 35 mm

Lever XL and L


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4.3 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 leverM

(1) including follower pin (2) from thepositioner shaft.5. Take leverS (1) and screw follower pin

(2) in the bore for pin position 17.6. Place leverS on the positioner shaft and

screw tight using the disk spring (1.2)and nut (1.1).Move lever once all the way as far as it

will 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.

20 EB 8384-1 EN



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EB 8384-1 EN 21


Fig. 7 Attachment to Type 3510 Micro-flow Valve

3

10

11

11

6

121.2 1.1

78

6.1

1 Lever 1.1 Nut

1.2 Disk spring

2 Follower pin

3 Clamp

6 Connecting plate

6.1 Seal rings

7 Pressure gauge bracket

8 Pressure gaugemounting kit

10 Bracket

11 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


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4.4 Attachment to rotaryactuators

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

Refer to Table 4 on page 31 for the requiredmounting parts as well as the accessorieswith their order numbers.

Prior mounting the positioner to theSAMSON Type 3278 Rotary Actuator, youhave to mount the associated adapter (5) to

the free end of the rotary actuator shaft.

NOTICEDuring 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 slotted

actuator shaft or the adapter (5).2. Place coupling wheel (4) with flat side

facing the actuator on the followerclamp (3). Refer to Fig. 9 to align slot sothat it matches the direction of rotation

when the valve is in its closed position.3. Screw coupling wheel and follower

clamp tightly onto the actuator shaft us-ing the 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 gauges

to the positioner, making sure bothO-rings are seated properly.

Fordouble-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator,see section 4.5.

6. Unscrew the standard follower pin (2)from the positioner's leverM (1). Use themetal follower pin ( 5) included in theaccessories and screw tight into the borefor 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.

22 EB 8384-1 EN


1.2

1.11

2

4.1

4.2

53

Fig. 8 Mounting the coupling wheel with Type 3278

Actuator flange


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EB 8384-1 EN 23


10

10.1

6(7, 8)

1.124.3

5

6.1

4

1.21

130 mm

80 mmNote:

Always use the connectingplate (6) included in theaccessories to connectsupply and output.Never screw threaded partsdirectly into the housing.

Control valve opens clockwise

Control valve opens counterclockwise

Slot

Slot

Legends Figs. 8 and 9

1 Lever 1.1 Nut 1.2 Disk spring2 Follower pin3 Follower clamp (Fig. 8)4 Coupling wheel4.1 Screw

4.2 Disk spring4.3 Scale plate5 Actuator shaft

Adapter for Type 32786.1 Seal rings7 Pressure gauge bracket 8 Pressure gauge

mounting kit10 Top pair of brackets10. Bottom pair of brackets

Fig. 9 Attachment to rotary actuators


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4.4.1 Heavy-duty version

Refer to Table 4 on page 31 for the requiredmounting parts as well as the accessorieswith their order numbers.

Both mounting kits contain all the necessarymounting parts. First select correct actuatorsize. Prepare actuator, and mount requiredadapter supplied by the actuator manufac-turer, if necessary.

1. Mount the housing (10) onto the rotary

actuator. In case of VDI/VDE attach-ment, place spacers (11) underneath, ifnecessary.

2. For SAMSON Type 3278 and VETECS160 Rotary Actuator, screw the adapter(5) onto the free end of the shaft orplace adapter (5.1) onto the shaft of the

VETEC R Actuator.Place adapter (3) onto Type 3278, VETECS160 and VETEC R Actuator. For

VDI/VDE version, this step depends onthe actuator size.

3. Stick adhesive label (4.3) onto the cou-pling wheel in such a manner that the

yellow part of the sticker is visible in thewindow of the housing when the valve isOPEN. Adhesive labels with explanatory

symbols are enclosed and can be stuckon the housing, if required.4. Screw tight coupling wheel (4) onto the

slotted actuator shaft or adapter (3) us-ing screw (4.1) and disk spring (4.2).

5. Undo the standard follower pin (2) onthe lever M (1) of the positioner. Attachthe follower pin ( 5) included in themounting kit to pin position 90.

6. If applicable, mount pressure gaugebracket (7) with pressure gauges or, in

case G threaded connections are re-quired, the connecting plate (6), makingsure both seal rings (6.1) are seatedproperly.For double-acting, springless rotary ac-tuators, a reversing amplifier is requiredto attach the positioner to the actuator.Refer to section 4.5.

7. For actuators with a volume of less than

300 cm, fit the screw-in restriction (or-der no.1400-6964) into the signal pres-sure output of the positioner (or the out-put of the pressure gauge bracket orconnecting plate).

8. Place positioner on housing (10) andscrew it tight. Considering the actuator'sdirection of rotation, align lever (1) sothat it engages in the correct slot of thecoupling wheel with its follower pin (Fig.10).

24 EB 8384-1 EN


1

10

4

Fig. 10 Direction of rotation

Counterclockwise

Clockwise


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EB 8384-1 EN 25


66.178

11.11.2

2

4.1

3

10.1

10

11

5

4.344.2

4.1

3

5.1

5

10.1

10

4.344.2

Fig. 11 Attachment to rotary actuators (heavy-duty version)

1 Lever

1.1 Nut

1.2 Disk spring2 Follower pin

3 Adapter

4 Coupling wheel

4.1 Screw

4.2 Disk spring

4.3 Adhesive label

5 Actuator shaft or adapter

5.1 Adapter

6 Connecting plate (only for G )

6.1 Seal rings

7 Pressure gauge bracket8 Pressure gauge mounting kit

10 Adapter housing

10.1 Screws

11 Spacers

Fit screw-in restriction into signal pressure outputfor actuators with < 300 cm volume

Attachment acc. to VDE/VDI 3845(Sept. 2010), level 1, size AA1 to AA4,refer to section 11.1

SAMSON Type 3278VETEC S160, VETEC R


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4.5 Reversing amplifier fordouble-acting actuators

For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier, e.g. the SAMSON Type 3710Reversing Amplifier (see Mounting and Op-erating Instructions EB 8392 EN).

If a different reversing amplifier (item no.1079-1118 or 1079-1119) is used, followthe mounting instructions described in sec-

tion 4.5.1.

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

The output signal pressure of the positioneris supplied at the outputA1 of the reversingamplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure atA1, is applied atoutputA2.The ruleA1 +A2 = Z applies.

Mounting

1. Mount the connecting plate (6) from theaccessories in Table 4 to the positioner.Make sure that both O-rings (6.1) areseated correctly.

2. Thread the special nuts (1.3) from the

accessories of the reversing amplifierinto the boreholes of the connectingplate.

3. Insert the gasket (1.2) into the recess ofthe reversing amplifier and push boththe special hollow screws (1.1) into theconnecting boreholesA1 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 screw

the enclosed filters (1.6) into the con-necting boreholesA1 and Z.

NOTICEThe sealing plug (1.5) should not be un-screwed out of the reversing amplifier.The rubber seal (1.4) is not required and

can be removed when the sealing plug isused.

Signal pressure connections

A1: OutputA1 leading to the signal pressureconnection at the actuator which opens the

valve when the pressure increases

A2: OutputA2 leading to the signal pressureconnection at the actuator which closes the

valve when the pressure increases

Pressure gauge attachment

The mounting sequence shown in Fig. 12 re-mains unchanged. Screw a pressure gaugebracket onto the connectionsA1 and Z.

Pressure gauge G 1400-7106

bracket: NPT 1400-7107 Pressure gauges for supply air Z and output

A1 as listed in Tables 1 to 4.

26 EB 8384-1 EN



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EB 8384-1 EN 27


Fig. 12 Mounting a reversing amplifier (1079-1118 or 1079-1119)

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

Output38

Supp

ly9

1.3 1.21.1

1 Reversing amplifier

1.1 Special screws

1.2 Gasket1.3 Special nuts

1.4 Rubber seal

1.5 Sealing plug

1.6 Filter

6 Connecting plate

6.1 O-rings

6.2 Screws

From the positioner

Control signals tothe actuator


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4.6 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 andpressure gauge bracket are available madeof stainless steel (order numbers listed be-low). The Type 3710 Pneumatic Reversing

Amplifier is also available in stainless steel.

Connecting plate(stainless steel):

G NPT

1400-74761400-7477

Pressure gaugebracket (st. steel):

Only in NPT 1400-7108

The Tables 1 to 5 (pages 29 to 31) apply for

attaching positioners with stainless steelhousings with the following restrictions:

Direct attachment

All 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

yokes)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.

4.7 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 cmFA: Remove the stopper 12.2 (Fig. 5 on

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

NOTICE

The method described does not apply toold connection blocks in pow-der-paint-coated aluminum. In this case,follow the instructions for attachmentdescribed below in Attachment acc. toIEC 60534-6 (NAMUR rib or attach-ment to rod-type yokes) and to rotaryactuators.

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 connected

28 EB 8384-1 EN



29/68

over piping. An adapter available as an ac-cessory is used for this purpose:

Threaded bushing(M20 x 1.5):

G NPT

0310-26190310-2550

NOTICEThe adapter uses one of the M20x1.5 con-nections in the housing which means justonecable gland can be installed.

4.8 Mounting parts andaccessories

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 thepurging function. The connection over theadapter at the positioner must be protected

with a check valve, e.g. check valve G (order no. 8502-0597) mounted in the pip-ing. Otherwise the pressure in the positionerhousing would rise above the ambient pres-sure and damage the positioner when theexhausting components respond suddenly.

EB 8384-1 EN 29


Table 1 Direct attachment to Type 3277-5 Actuator (Fig. 4) Order no.

Mounting parts Mounting parts for actuators up to 120 cm 1400-7452

Accessoriesfor theactuator

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

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

Connecting plate newfor Actuator Type 3277-5xxxxxx.01 (new) 1):G and NPT

1400-6823

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): G 1400-6820

Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): NPT 1400-6821

Accessoriesfor thepositioner

Connecting plate (6)G 1400-7461

NPT 1400-7462

Pressure gauge bracket (7)G 1400-7458

NPT 1400-7459

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

Stainless steel/brass 1400-6950

Stainless steel/st. steel 1400-6951

1) Only new switchover and connecting plates can be used with new actuators (Index 01).Old and new plates are notinterchangeable.


30/68

EB 8384-1 EN 30


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

Mounting parts Mounted to actuators 240, 350, 355, 700 cm 1400-7453

Accessories

Required piping with screw fitting for fail-safe action "Actuator stem retracts" for air purging of the top diaphragm

chamber

240 cmSteel 1400-6444

Stainless steel 1400-6445

350 cmSteel 1400-6446

Stainless steel 1400-6447

355 cm/700 cm

Steel 1400-6448

Stainless s teel 1400-6449

Connection block with seals and screwG 1 4 1400-8819

14 NPT 1400-8820

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


St. steel/st. steel 1400-6951

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

Travel in mm Lever For actuator Order no.

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

5 to 50 M1)

Actuators from other manufacturers and Type 3271 with 120 to 700 cm 1400-745414 to 100 L Actuators from other manufacturers and Type 3271, 1400-60 version 1400-7455

40 to 200XL Actuators from other manufacturers and Type 3271, versions 1400-120 and

2800 cm with 120 mm travel1400-7456

30 or 60 L

Type 3271 Actuator, versions 1400-120 and 2800 cm with 30 or 60 mmtravel

1400-7466

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

1400-6771

Accessories

Connecting plate (6)

G 1 4 1400-74611

4 NPT 1400-7462

Pressure gauge bracket (7)G 1 4 1400-7458

14 NPT 1400-7459

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



1) Lever M is mounted on basic model (included in the scope of delivery of the positioner)


31/68

EB 8384-1 EN 31


Table 4 Attachment to rotary actuators (Figs. 8 and 9) Order no.

Mountingparts

Attachment acc. to VDI/VDE 3845 (September 2010), refer to section 11.1 for details

Actuator surface corresponds to level 1Size AA1 to AA4, version with CrNiMo steel bracket

Size AA1 to AA4, heavy-duty version

Heavy-duty version (e.g. Air Torque 10 000)

1400-7448

1400-9244

1400-9542

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

Attachment for SAMSON Type 3278 with 160/320 cm, CrNiMo steel bracket 1400-7614

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

1400-9245

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

1400-5891and

1400-9526Attachment to Camflex II 1400-9120

Accessories

Connecting plate (6)G 1 4 1400-7461

14 NPT 1400-7462

Pressure gauge bracket (7)G 1 4 1400-7458

14 NPT 1400-7459

Pressure gauge mounting kit up to max. 6 bar (output/supply)St. steel/brass 1400-6950


Table 5 General accessories Order no.

Accessories

Pneumatic reversing amplifier for double-acting actuators Type 3710

Cable gland M20 x 1.5, nickel-plated brass 1890-4875

Adapter M20 x 1.5 to NPT, aluminum 0310-2149

Retrofit kit for inductive limit switch 1 x SJ2-SN 1400-9735

Cover plate with list of parametersand operating instructions

DE/EN (delivery state) 1990-7930

EN/ES 1990-8212

EN/FR 1990-8132


32/68

5 Connections

WARNING!Mount the positioner, keeping the followingsequence:1. Remove protective film from pneumatic

connections.2. Mount the positioner on the control valve3. Connect the supply air4. Connect the electrical power5. Perform the start-up settings

The connection of the electrical auxiliarypower may cause the actuator stem to move,depending on the operating mode.Do not touch the actuator stem or obstruct itto avoid risk of injury to hands or fingers.

5.1 Pneumatic connections

NOTICEThe 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 NPT or G thread.The customary fittings for metal and copperpipes or plastic hoses can be used.

Note:The supply air must be dry and freefrom oil and dust. The maintenance instruc-tions for upstream pressure reducing stationsmust be observed.

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 actuator isfixed. 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.

32 EB 8384-1 EN

Connections


33/68

5.1.1 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).

5.1.2 Supply pressure

The required supply air pressure depends onthe bench range and the actuator's operat-ing direction (fail-safe action). The bench

range is registered on the nameplate eitheras spring range or signal pressure range.The direction of action is marked FAorFE,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 signal

pressure pstmaxis roughly estimated as fol-lows:

pstmax= F +d p

A

2

4

p D[bar]

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

[bar]A = Actuator diaphragm area [cm]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 toapprox. 2.4 bar by setting the parameterP9= ON.

EB 8384-1 EN 33

Connections


34/68

5.2 Electrical connections

DANGER!Risk of electric shock and/or theformation of an explosive atmo-sphere!

For electrical installation, observe the rel-evant electrotechnical regulations andthe accident prevention regulations thatapply in the country of use.

The following regulations apply to

mounting and installation in hazardousareas: EN 60079-14: 2008Explosiveatmospheres Part 14: Electrical instal-lations design, selection and erection(orVDE 0165 Part 1).

NOTICE Adhere to the terminal assignment! Switching the assignment of the electrical

terminals may cause the explosion pro-tection to become ineffective! Do not loosen enameled screws in or on

the housing. The maximum permissible values speci-

fied in the national EC type examinationcertificates apply when interconnectingintrinsically safe electrical equipment (Uior Uo; Iior Io; Pior Po; Cior Co, and LiorLo).

Selecting cables and wires:

ObserveClause 12 of EN 60079-14: 2008(VDE 0165 Part 1) when installing intrinsi-cally safe circuits. The Subclause 12.2.2.7applies when running multi-core cables con-taining more than one intrinsically safe cir-cuit.

In particular, the radial thickness of the con-ductor insulation for common insulation ma-

terials, such as polyethylene, must have aminimum radial thickness of 0.2 mm.

The diameter of an individual wire in afine-stranded conductor must not be smallerthan 0.1 mm. Protect the conductor endsagainst splicing, e.g. by using wire-end fer-rules.

When two separate cables are used for con-nection, an additional cable gland can be

installed.Seal cable entries left unused with plugs.

Devices used at ambient temperatures be-low 20 Cmust be fitted with metal cableglands.

Equipment for use in zone 2/zone 22

In equipment operated with type of protec-

tion Ex nA II (non-sparking equipment) ac-cording to EN 60097-15: 2003, circuitsmay be connected, interrupted or switchedwhile energized only during installation,maintenance or repair.

Equipment connected to energy-limited cir-cuits with type of protection Ex nL (en-ergy-limited equipment) according toEN 60097-15: 2003 may be switched un-

der normal operating conditions.The maximum permissible values specifiedin the Statement of Conformity or its ad-denda apply when interconnecting theequipment with energy-limited circuits intype of protection Ex nL IIC.

34 EB 8384-1 EN

Connections


35/68

Cable entries

Cable entry with M20x1.5 cable gland, 6 to

12 mm clamping area.There is a second M20x1.5 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 mm. Tighten byat least 0.5 Nm.

The wires for the reference variable must beconnected to the terminals 11 and 12 lo-

cated in the housing. Only use a currentsource!

NOTICE The incorrect connection of a voltage

source of just around 7 V (or around 2 Vwhen connected to the wrong pole) bymistake can damage the positioner.

The minimum current for the positioner is3.7 mA. It should not be unnecessarilyinterrupted for less than two minutes.

In general, it is not necessary to connect thepositioner to a bonding conductor. Shouldthis be required, however, this conductorcan be connected inside the device.

For operation of the limit switches inType 3730-11/-13/-18 Positioners, switch-ing amplifiers which comply withEN 60947-5-6 must be connected to termi-nals 41/42 and 51/52 in the output circuit.If the positioner is to be installed in hazard-ous areas, the relevant regulations must beobserved.

EB 8384-1 EN 35

Connections


36/68

Refer to Fig. 13 for the terminal assignment.

NOTICEThe minimum permissible reference variablemust not fall below 3.7 mA for the operationof the positioner.

Accessories:Plastic cable gland M20x1.5: Black Order no. 8808-1011 Blue Order no. 8808-1012

Ni-plated brass Order no. 1890-4875 Stainless steel 1.4305

Order no. 8808-0160

Adapter M20 x 1.5 to NPT: Aluminum, powder-coated

Order no. 0310-2149 Stainless steel Order no. 1400-7114

5.2.1 Switching amplifier

For operation of the limit switches, switchingamplifiers must be connected in the outputcircuit. To ensure the operating reliability ofthe positioner, the amplifiers should comply

with 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.

For applications in safe areas (non-hazard-ous areas), limit switches can be directly in-terconnected to the binary input of the PLCin accordance with IEC 61131. This appliesto the standard operating range for digitalinputs according to Clause 5.2.1.2 ofIEC 61131-2 with the rated voltage of24 V DC.

36 EB 8384-1 EN

Connections

+11 -12 +51 -52 +41 -42

(A2) (A1)

+45 -44

Fig. 13 Electrical connections

mA control signal

Explosion-protected versionConnection for

switching amplifiers acc. to EN 60947-5-6

Version without explosion protectionConnection to

PLC binary input acc. to IEC 61131-2

Limit switches

Connection forswitching amplifiers acc.

to EN 60947-5-6

Inductivelimit switch

Option


37/68

6 Operation

The positioner is mainly operated with therotary pushbutton.The volume restriction must be set first toadapt the air delivery.

6.1 Operator controls

Rotary pushbutton

Turn the button to select a parameter

code (P0to P16) and then press it to confirmthe parameter code selected.If you want to change a parameter value,turn the button to select the required

valve. Then press the button to confirmthe value.

NOTICEParameter codes that have been changed

are first saved in the EEPROM (protectedagainst power failure) when the display re-turns to the status indication mode. Turnbutton to CodeP0or wait three minutes untilthe display returns automatically.The parameter code is not saved perma-nently as long as the icon appears at thetop of the display.

Note:The positioner must be re-initializedafter the parameter codes P2, P3, P4andP8have been changed.

EB 8384-1 EN 37

Operation

Volumerestriction

Actuatorsymbol

Rotary pushbutton

Limit switch Fail-safe position Values not yet saved in EEPROM

Closed loopoperation

Parameter/error code

Cap/Positioner shaftFault

Fig. 14 Operator controls and display


38/68

Volume restriction Q

The volume restriction is used to adapt the

air delivery to the actuator size. Two fixedsettings are possible depending on how theair is routed at the actuator. See section 7.1for more details.

Display

The LC display indicates icons that are as-signed to codes and functions. The bargraph indicates the system deviation that de-pends on the sign (+/) and the value. Onebar graph element appears per 1 % systemdeviation.If the positioner is not initialized, the leverposition in degrees in relation to the longitu-dinal axis is indicated instead of the systemdeviation. One bar graph element corre-sponds to approximately a 5 angle.

If the fault icon appears on the display,turn the button until ERRappears to viewthe error code(s) E0to E15. Refer to section7.6 for details.

7 Start-up

WARNING!Attach the positioner, keeping the followingsequence:1. Remove protective film from pneumatic

connections2. Mount the positioner on the control valve3. Connect the supply air4. Connect the electrical power5. Perform the start-up settings

For most applications, the positioner isready for operation with its default settings,provided it is attached properly.The positioner just needs to be initialized af-ter the volume restriction has been set andthe fail-safe position has been determined.

WARNING!

Do not perform a start-up while the processis running.On applying supply air and the electric con-trol signal, the control valve may movethrough its entire travel range/rotational an-gle range depending on the setting.

Note:The positioner has a function to moni-tor the working range.If the lever moves too close to the mechani-cal stops (risk of mechanical damage), thepositioner vents the actuator and the valvemoves to its fail-safe position (Sdisplayedtogether with error codeE8orE9).In this case, check the positioner attachment.Reset the displayed error code usingRST(see section 7.6.)

38 EB 8384-1 EN

Start-up


39/68

7.1 Setting the volume restriction Q

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

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

4 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:

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

4 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 appliesforactuators from other manufacturers.

Overview Position of the volume restriction*

Signal

pressure

Transit

time

< 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.

7.2 Adapting the display

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

Turn the button until Code P1 appears,

press button to confirm the selectedcode. P1 blinks.

Reading direction for rightattachment of pneumaticconnections

Turn button until the display is adjustedto the desired direction, then confirm rea-ding direction by pressing the button.

7.3 Entering the openingdirection

4 AIR TO OPEN/ATO applies to a valveopening as the signal pressure increases.

4 AIR TO CLOSE/ATC applies to a valveclosing as the signal pressure increases.

EB 8384-1 EN 39

Start-up

MAX BACKMIN SIDE

MIN BACKMAX SIDE

Q

Fig. 15 Volume restriction QMAX BACK/MIN SIDE setting


40/68

The signal pressure is the air pressure at theoutput of the positioner, which is applied to

the actuator.AIR TO OPEN/ATO is always used withpositioners fitted with a reversing amplifierfor double-acting actuators (connections de-scribed in section 4.5)

DefaultATO

Turn until Code P2appears.

Press to confirm P2. P2blinks.

Turn until the required fail-safe positionappears.

Press to confirm the setting.

7.4 Setting other parametersThe following table lists all the parametercodes and their default settings.

If you want to change the default setting of aparameter, proceed in the same manner as

previously described.More details concerning the parametercodes can be found in section 8.

7.5 Initialization

During initialization the positioner adapts it-self optimally to the friction conditions andthe signal pressure demand of the control

valve.The type and extent of self-adaptation de-pends on the preset parameters.MAXis the default setting for the nominalrange (Code P4). During the initializationprocess, the positioner determines thetravel/rotational angle of the closing ele-ment from the CLOSED position as far as it

will go in the other direction.

40 EB 8384-1 EN

Start-up

Parameter codes Codes marked with * can be changed without having to re-initialize the positioner[...] Default setting

P0 Display with status indication P9* Pressure limit 2.4 bar [OFF]

P1 * Reading direction P10* End position w < [ON]

P2 Fail-safe position [ATO] / ATC P11 * End position w > [OFF]

P3 Pin position [35] P12* Limit value A1 switching threshold [2 %]

P4 Nominal range [MAX] P13* Limit value A2 switching threshold [98 %]

P5* Characteristic [1] P14 Display of reference variable w

P6* Reference variable [4...20 mA] P15 INIT Start initialization

P7* w/x direction of action [>>] P16* ZERO Start zero calibration

P8 Gain KP [50]


41/68

Note:For standard operation, after thepositioner is mounted on the valve and the

volume restriction has been set and thefail-safe position has been checked overCodeP2, start initialization over CodeP15to ensure the optimal functioning of thepositioner.The positioner works with its standard set-tings (default settings).

WARNING!

During the initialization, the control valvemoves through its entire travel/angle of ro-tation range. Therefore, do not start initial-ization while a process is running, but onlyduring start-up, when all shut-off valves areclosed.

Start initialization by activating Code P15as follows:

Turn until Code P15appears

Press button six seconds long,6-5-4-3-2-1- is counted down on the display.

Initialization has started, the displayblinks!

Note:The time required for the initializationprocedure depends on the actuator transittime and can take a few minutes.

Initialization successfullycompleted, positioner runsin closed loop operation

After a successful initialization, thepositioner runs in closed loop operation in-dicated by the closed-loop operationicon and control position in % predeter-mined by the reference variable on the dis-play.

A malfunctioning leads to the process beinginterrupted. The fault icon appears onthe display. See section 7.6 for details.

Canceling initialization

The initialization can be canceled by pressing. The positioner then moves to the fail-safe

position (indicated bySon display).

First initialization:A new zero calibrationcan be started directly afterwards.

Initialization following the first initializa-tion: Cancel the fail-safe position and returnto original operating mode.

To cancel the fail-safe position, proceed asfollows:

When P0status indication mode of the dis-play is selected:

Press , ESCappears.

Turn , RSTappears.

Press to reset the fail-safe position.

The positioner runs again using its originalsettings.

EB 8384-1 EN 41

Start-up

%


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7.6 Faults

On the occurrence of a fault, the fault iconappears at the bottom of the display.

By turning the button past Code P0orP16, the respective error code E0to E15to-gether with ERRappear on the display.Refer to the code list in section 8 for thecause of the errors and the recommendedaction.

Example:

If, for instance, a travel has been enteredover Code P4(nominal range) which islarger than the maximum valve travel possi-ble, the initialization process would be inter-rupted (error code E2) because the ratedtravel would not have been reached (errorcode E6). The valve moves to the fail-safeposition (Sindicated on the display).

Display of the faultindication

The nominal range (Code P4) must bechanged and the positioner re-initialized toremedy this problem.

Reset error codes

The error codes E0, E1, E8and E9can bereset as follows:

Turn button until the error code appears,

press button, ESCappears,turn button, RSTappears,

press button to reset error.

The resetting procedure can be canceled bypressing button when ESCappears.

7.7 Zero calibration

In case of inconsistencies in the closing posi-tion of the valve, e.g. with soft-sealed plugs,it may necessary to recalibrate zero.

Start the zero calibration by activatingCode P16as follows:

Turn button until Code P16appears.

Press button six seconds long,6-5-4-3-2-1 is counted down on the display.

42 EB 8384-1 EN

Start-up

S

S S


43/68

Zero calibration has started, the displayblinks!

The positioner moves the control valve to theCLOSED position and recalibrates the inter-nal electric zero point.

When the zero calibration has been suc-cessfully completed, the positioner returns toclosed loop operation (status indication).

Canceling zero calibration

The zero calibration can be canceled bypressing . The positioner then moves tothe fail-safe position (indicated bySon thedisplay).

A new zero calibration can be started di-rectly afterwards.

7.8 Reset

The positioner is in closed-loop operationafter the initialization has been successfullycompleted.

A reset causes an initialization to be can-celed and all parameters settings are reset tothe default settings (refer to section 8).

When P0status indication mode of the dis-play is selected:

Press down for six seconds, the displaycounts down 6-5-4-3-2-1 and ESCappearson the display.

Turn , RSTappears on the display.

Press to reset parameters to their defaultsettings.

7.9 Manual adjustment

The valve position can be moved as followsusing the Manual adjustmentfunction:

Turn until Code P14appears.

Press down for six seconds, the displaycounts down 6-5-4-3-2-1.

The manual set point (w man) is indicatedon the display of an initialized positioner.

The lever position in degrees in relation to

the longitudinal axis is indicated on thedisplay of a positioner that has not beeninitialized.

Turn .

Initialized positioner:The manual set point is adjusted in stepsof 0.1 %. You can move the valve con-trolled within its range.

Positioner that has not been initialized:By adjusting the manual set point, thevalve is only moved in one direction un-controlled.

Press to deactivate the manual adjust-ment function.

Note:TheManual adjustmentfunction canonly be exited as described. The positioner

does not automaticallyexit this function andreturn the display to the status indicationmode after the positioner has not been oper-ated for three minutes.

EB 8384-1 EN 43

Start-up


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8 Code list

Code Display, values[default setting]

Description

Parameter codes Codes marked with * can be changed without having to re-initialize the positioner

P0 Status indication mode of the display showing basic information.Reset, refer to section 7.8.

The reading indicates the valve position or the angle of rotation in %when the positioner is initialized, otherwise the position of the leverin relation to the mid-axis is indicated in degrees ().

P1 * Reading direction The reading direction of the display is turned by 180.P2 ATO/ATC Parameter to adapt the positioner to how the control valve functions:

ATO Air to open (valve CLOSED in fail-safe position)ATC Air to close (valve OPEN in fail-safe position)

P3 Pin position17/25/[35]/50/70/100/200 mm/90

The follower pin must be inserted into the correct pin positionaccording to the valve travel/angle of rotation (select as per traveltables on page 13).

P4 Nominal range[MAX]

Values withdefault setting [35]:e.g.7.5/8.92/10.6/12.6/15.0/17.8/21.2 mm

The possible adjustment range can be selected in stages dependingon the selected pin position

17 from 3.75 to 10.625 from 5.3 to 15.035 from 7.5 to 21.250 from 10.6 to 30.070 from 15.0 to 42.4100 from 21.2 to 60.0200 from 42.4 to 120

For90 Maximum range only, ifP3= 90MAX Maximum possible travel

P5 * Characteristic1 to 8[1]

Characteristic selection: Characteristic 1 for globe valves,Characteristic 1 to 8 with rotary actuators (P3= 90)

1: Linear 5: Butterfly valve linear2: Equal percentage 6: Butterfly valve eq. percentage3: Rotary plug linear 7: Segmented ball linear4: Rotary plug eq. percentage 8: Segmented ball eq. percentage

P6 * Reference variable[4...20 mA]SRLO/SRHI

For split-range operationSRLO low range 4 to 11.9 mASRHI high range 12.1 to 20 mA

44 EB 8384-1 EN

Code list


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P7* w/x>> / [>>]

Direction of action of the reference variable w to the travel/rotationalangle x (increasing/increasing or increasing/decreasing).

P8 Gain KP30/[50]

On initializing the positioner, the gain is set to the selected value.

P9 * Pressure limitON/[OFF]

The signal pressure can take on the same pressure as the supply airat the maximum [OFF] or, in the case that the maximum actuatorforce can damage the valve, the pressure is limited to approx.2.4 bar.

P10 * End position w ON/ [OFF]

Tight-closing function:If w reaches up to 99 % towards the final value that causes the valveto open, the actuator is immediately completely filled with air (with

ATO- Air to open) or vented (withATC- Air to close).This action always lead to the valve being completely opened.

P12 * Switching point A10 to 100 % [2 %]

Software limit value A1 is displayed or can be changed in relation tothe operating range (steps of 0.5 %).

P13* Switching point A20 to 100 % [98 %]

Software limit value A2 is displayed or can be changed in relation tothe operating range (steps of 0.5 %).

P14 Info w/Man w Display only, indicates the reference variable applied in 0 to 100 %corresponding 4 to 20 mA.Manual adjustment, refer to section 7.9.

P15 Startinitialization

The initialization process can be interrupted by pressing the rotarypushbutton. The control valve moves to its fail-safe position.Over parameter code P0, the fail-safe position can be canceledagain and the positioner then starts with the original setting.

Also after a power supply failure, the positioner starts with its orig-inal setting.

P16 * Startzero calibration

The zero calibration process can be interrupted by pressing the ro-tary pushbutton. The control valve moves to its fail-safe position.Over parameter code P0, the fail-safe position can be canceledagain and the positioner then starts with the original setting.

Also after a power supply failure, the positioner starts with itsoriginal setting.

EB 8384-1 EN 45

Code list


46/68

Error codes

E0 Zero error Only with tight-closing function P10w < set to ON

The zero point has shifted by more than 5 % compared to initializa-tion. The erro may arise when the mounting position/linkage of thepositioner moves or when the valve seat trim is worn, especially withsoft-sealed plugs.

Recommended action Check valve and mounting of the positioner. If OK, perform a zerocalibration over Code P16(see section 7.7)or select the error code and reset with RST.

E1 Displayed and INITvalues are not identical

Parameter codes were changed after the initialization had been com-pleted.

Recommended action Select the error code and reset with RST.

E2 Positioner has not beeninitialized

Recommended action Set parameter and initialize the positioner over Code P15.

E3 KP setting Positioner hunts.Volume restriction set incorrectly, too much gain.

Recommended action Check the volume restriction setting as described in section 7.1.

Limit gain KP over Code P8. Re-initialize the positioner.E4 Transit time is too fast The transit times of the actuator determined during initialization are

so short (under 0.5 second) that the positioner cannot adapt itselfwell enough.

Recommended action Check the volume restriction setting as described in section 7.1.Re-initialize the positioner.

E5 Standstill detection isnot possible

Supply pressure is too low or varies. Mounting incorrect.

Recommended action Check supply air and positioner mounting.Re-initialize the positioner.

E6 Travel is not achieved Supply pressure is too low, actuator leaks, incorrect travel adjustedor pressure limit function activated.

Recommended action Check supply air, positioner mounting and setting.Re-initialize the positioner.

46 EB 8384-1 EN

Code list


47/68

E7 Actuator does not move No supply air, mounting blocked.No input signal or input signal below 3.7 mA

Recommended action Check supply air, positioner mounting and mA input signal.Re-initialize the positioner.

E8 Travel signalat lower limit

Wrong pin position, wrong lever, wrong attachment direction whenNAMUR attachment is used.

Recommended action Check positioner mounting and re-initialize the positioner.

E9 Travel signalat upper limit

Wrong pin position, wrong lever, wrong attachment direction whenNAMUR attachment is used.

Recommended action Check positioner mounting and re-initialize the positioner.

E10 Not assigned

E11 Hardware Defective ceramic oscillator, positioner continues to run with an in-ternal RC oscillator, but it should be replaced as soon as possible.

Recommended action Return positioner to SAMSON AG for repair.

E12 No factory calibration No factory calibration performed, memory defective.


E13 Memory fault Fault in the memory management


E14 Checksum errordata memory

Data memory defective


E15 Checksum errorcalibration data

Data memory defective


EB 8384-1 EN 47

Code list


48/68

9 Maintenance

The positioner does not require any mainte-nance.

There are filters with a 100 mm 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.

10 Servicing explosion-protecteddevices

If a part of the device on which the explo-sion protection is based needs to be ser-

viced, the device must not be put back intooperation until a qualified inspector has as-sessed it according to explosion protectionrequirements, has issued an inspection cer-tificate or given the device a mark of confor-mity.

Inspection by a qualified inspector is not re-quired if the manufacturer performs a rou-tine test on the device prior to putting it backinto operation. The passing of the routinetest must be documented by attaching amark of conformity to the device. Replaceexplosion-protected components only byoriginal, routine-tested components from themanufacturer.

Devices that have already been operatedoutside hazardous areas and are intendedfor future use inside hazardous areas mustcomply with the safety requirements placedon serviced devices. Before being used in-side hazardous areas, test the devices ac-cording to the specifications for servicingexplosion-protected devices.

48 EB 8384-1 EN

Maintenance


49/68

11 Dimensions in mm

EB 8384-1 EN 49

Dimensions in mm

40

34

210

2814

80

164 Output (38) Supply (9)

86

70

15

46

34

58

58

Fig. 16a NAMUR and direct attachment

or connecting plate NAMUR attachmentPressure gaugebracket

Lever mmS = 17 M = 50L = 100XL = 200

Direct attachment M20 x 1.5


50/68

50 EB 8384-1 EN

Dimensions in mm

56

86

13080

166

3086

101

80

52 Output Y1

Output Y2

Supply (9)

Output Y1

Output Y2

Fig. 16b Attachment to rotary actuators VDI/VDE 3845 (Sept. 2010), level 1, size AA1 to AA4

A1 Z

A2

Output A1

Output A2

Supply (9)

50 80130

49

59

79

76

50

58

150

Connecting plateG or NPT

Reversingamplifier (optional)*

Reversingamplifier (optional)*

* Reversing amplifier

Type 3710 (see drawing of heavy-duty versionfor dimensions)

1079-1118/1079-1119, no longer available(see drawing of light version for dimensions)

Heavy-duty version

Light version


51/68

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

EB 8384-1 EN 51

Dimensions in mm

A

M6

C

B

25

Mmin

d

D

Level 2 (bracket surface)

Level 1 (actuator surface)

Actuator

Dimensions in mm

Size A B C d Mmin D*

AA0 50 25 15 5.5 for M5 66 50

AA1 80 30 20 5.5 for M5 96 50

AA2 80 30 30 5.5 for M5 96 50

AA3 130 30 30 5.5 for M5 146 50

AA4 130 30 50 5.5 for M5 146 50

AA5 200 50 80 6.5 for M6 220 50

* Flange type F05 according to DIN EN ISO 5211


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52 EB 8384-1 EN


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Samson I-P Positioner

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