Series 250 Pneumatic Control Valves Type 3259-1 and Type 3259-7

Fig. 1 ⋅ Type 3259-7 Control Valve according to the IG standard

Mounting and Operating Instructions EB 8059 EN
Edition May 2006

Contents

Contents 1. 2. 3. 3.1 3.2 3.3 3.4 4. 5. 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.3 6. 7. Assembling valve and actuator Installation . . . . . . . Mounting position . . . . Signal pressure line . . . Shut-off valves and bypass Test connection . . . . . . . . . . . . . . . . . . . .

Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 7 7 7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting - replacing parts . . . . . . Replacing parts of standard valves . . . . . . Packing . . . . . . . . . . . . . . . . . . . Seat and/or plug . . . . . . . . . . . . . . Replacing parts in valve with bellows seal . . . Packing . . . . . . . . . . . . . . . . . . . Metal bellows . . . . . . . . . . . . . . . . Replacing parts in valve with insulating section Description of nameplate . 8 . 8 . 8 . 10 . 10 . 10 . 10 . 10

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Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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EB 8059 EN

Safety instructions

General safety instructions 

The control valve may only be mounted, started up or serviced by fully trained  

For appropriate operation, make sure that the control valve is only used in

and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger. All safety instructions and warnings in these instructions, particularly those concerning installation, start-up and maintenance, must be observed. The control valve fulfills the requirements of the European Pressure Equipment Directive 97/23/EC. Valves with a CE marking have a declaration of con formity that includes information on the applied conformity assessment proce dure. The declaration can be viewed and downloaded on the Internet at http://www.samson.de. areas where the operating pressure and temperatures do not exceed the oper ating values based on the valve sizing data submitted in the order. The manu facturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the control valve by the process me dium, operating pressure, signal pressure or by moving parts are to be prevented by means of the appropriate measures. 

Proper shipping and appropriate storage are assumed.
Caution! 

For installation and maintenance work on the valve, make sure the relevant 

When working on the valve, make sure that the supply lines for the air supply
as well as the control signal are disconnected to prevent any hazards that could be caused by moving parts.

section of the pipeline is depressurized and, depending on the process me dium used, drained as well. If necessary, allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve.

EB 8059 EN

3

Design and principle of operation

1. Design and principle of operation
The Type 3259-1 and Type 3259-7 Control Valves consist of the single-seated Type 3259 Angle Valve and either the Type 3271 or Type 3277 Pneumatic Actuator. The process medium flows through the valve in the direction indicated by the arrow. The position of the plug (3) is changed by the signal pressure acting on the diaphragm in the actuator (8). The plug stem (6) and plug are connected to the actuator stem (8.1) by the stem connector (7). The plug stem is sealed by spring-loaded PTFE V-ring packing (4.2) or by an adjustable high-temperature packing. The control valve can be equipped with an extension bonnet with metal bellows which functions as an additional seal to comply with stringent regulations.

Fail-safe action: Depending on the arrangement of the compression springs (8.3) in the actuator, the control valve provides two different types of fail-safe action: Actuator stem extends: When the signal pressure is reduced or the air supply fails, the springs force the actuator stem to move downward and close the valve. When the signal pressure rises, the valve opens while acting against the force of the springs. Actuator stem retracts: When the signal pressure is reduced or the air supply fails, the springs force the actuator stem to move upward and open the valve. When the signal pressure rises, the valve closes while acting against the force of the springs.

4

EB 8059 EN

Design and principle of operation

Type 3271 Actuator
8 8.3 8.6

Type 3277 Actuator

8.4 8.2 8.1 7 6.1 6.2 6 4.2 8.5 5.5 8.5

5.2 5.3 5 5.1

1.1

3 1 2

1 1.1 2 3 4.2 5 5.1

Valve body Lens ring gasket Seat Plug Packing Valve bonnet Nuts and expansion bolts 5.2 Threaded bushing 5.3 Yoke 5.5 Travel indicator scale

6 6.1 6.2 7 8 8.1 8.2 8.3 8.4 8.5 8.6

Plug stem Stem connector nut Lock nut Stem connector Actuator Actuator stem Ring nut Springs Diaphragm Signal air connection Vent

Tightening torques Nominal size DN 16, 24, 30 45, 58 70, 90 Expansion bolts (5.1) Seat thread 150 Nm + 10 % 300 Nm + 10 % 900 Nm + 10 % M36 x 1.5 M58 x 1.5 M100 x 2 Seat (2) Reduced seat bore 400 Nm 1000 Nm 2700 Nm

Fig. 2 ⋅ Sectional drawing of Type 3259-1 (Type 3259-7)

EB 8059 EN

5

8 to 2. and with a symbol on the Type 3277 Actuator.1).1) by hand until it contacts the actuator stem (8. first apply a loading pressure slightly higher than the lower bench range value (see nameplate on actuator) to the signal press ure connection before unscrewing the ring nut (8).4 bar) to the lower diaphragm chamber connection.1) on the valve.g. Loosen the lock nut (6. 3.8 when the range is between 0. then thread the stem connector nut and the lock nut down 2. Turn it another 1/4 turn and secure this position with the lock nut (6. The fail-safe action "actuator stem extends" or "actuator stem retracts" is marked with the letters "FA" or "FE" respectively on the Type 3271 Actuator. proceed as follows: 1.5) with the tip of the stem connector. Align the travel indicator scale (5. Place the actuator on the yoke (5.g. Slide the ring nut over the plug stem of the valve.2) and the stem connector nut (6. apply a signal pressure that corresponds to the upper bench range value (e.2) from the actuator. The lower bench range value corresponds to the initial value of the bench range to be set and the upper bench range value corresponds to the final value of the bench range. Attach the stem connector parts (7) and screw tight.Assembling valve and actuator 2. apply a signal pressure that corresponds to the lower bench range value (e. For actuators with actuator stem retracts. Assembling valve and actuator If the valve and the actuator were not assembled by the manufacturer or if the original actuator attached to the valve is to be exchanged for an actuator of another type or size. 4. 6.2).3) and secure with the ring nut (8. For actuators with actuator stem extends. 0. 6 EB 8059 EN . Note on disassembly: When disassembling an actuator. Turn the stem connector nut (6. 5. Unscrew the connector stem parts (7) and the ring nut (8.2).4 to 2 bar) to the upper diaphragm chamber connection. Read the bench range and fail-safe action of the actuator stated on the nameplate. Press the plug and plug stem firmly into the seat ring. 2 bar when the range is be- tween 0.

Thoroughly flush the pipeline before install ing the valve. large valves should preferably be installed in horizontal pipelines with the actuator pointing upwards to help make any maintenance work easier. connect it to the upper diaphragm case.g. 3.1 Mounting position The valve and actuator can be mounted in any position. Note! The valve must be installed free of stress and with the least amount of vibrations possible. 4. EB 8059 EN 7 . Especially for liquids and vapors. Operation (e. For valves with insulating section or bellows seal or with for actuators that weigh more than 50 kg. the actuator must be fitted with a suitable support or suspended. Installation 3.1) located on the upper flange for checking any leakage from the bellows. The Type 3277 Actuator’s connection for the lower diaphragm case is located on the side of the yoke underneath the lower case. 3.4 Test connection Versions with metal bellows (Fig. reversing the operating direction) Please refer to the Mounting and operating instructions EB 8310 EN for Type 3271 Pneumatic Actuator and EB 8311 EN for Type 3277 Actuator. connect the signal pressure line to the lower diaphragm case.3 Shut-off valves and bypass We recommend that you install hand-operated shut-off valves both upstream and downstream of the control valve as well as to make a bypass so that it is not necessary to shut down the plant for maintenance routines. however.g. outlet into an open receptacle or sight-glass) at the test connection. 3. 4) include a test connection (11. we recommend connecting a suitable leakage indicator (e.2 Signal pressure line For valves with fail-safe action "actuator stem extends".Installation 3. and for valves with fail-safe action "actuator stem retracts". contact pressure gauge.

if necessary. apply a signal pressure that is slightly higher that the lower bench range (see nameplate) to the actuator. first relieve the corresponding plant section of pressure and. Before proceeding with actuators with "actuator stem extends" and especially for actuators with pre-tensioned springs. the packing may be leaking. this may be because tight shut-off is prevented by dirt or other impurities between the seat and plug or because the seating surfaces have been damaged. disconnect the signal pressure. 5.1). The appropriate seat wrenches can be found in EB 029 EN (formerly WA 029 EN). Unscrew the stem connector nut and lock nut (6. its packing (4.1 Packing If the stuffing box leaks.2) from the plug 8 EB 8059 EN . disconnect the loading pressure again. thoroughly cleaning them and.1. the valve must be inspected at appropriately scheduled intervals to prevent any problems before they occur.Troubleshooting – replacing parts 5. 2.samson. Remove nuts (5.1) and bolts and lift the valve bonnet (5) together with plug stem and plug out of the valve body (1. plug and packing. remove the signal pressure line and dismount the actuator. Also available at http://www. Depending of the application conditions that prevail. Let the plant section cool down to reach ambient temperature. Troubleshooting – replacing parts The control valve is subject to natural wear especially at the seat.5 and 4. if necessary.de/pdf_en/e00290en. If any leaks occur to the atmosphere. We recommend removing the parts. 2.6) must be replaced as described below: Disassembly 1. drain it as well.1 Replacing parts of standard valves 5. This applies particularly to valves with a bellows seal or an insulating section.1 and 6. Lift the actuator off the valve yoke.2) and sealing parts (4.2) and remove the stem connector (7) . replacing them with new parts. After unscrewing the ring nut. We recommend removing the valve from the pipeline. Note: The tightening torques required for assembling the valve are listed in the table on page 5. As the process medium cannot drain completely out of the valve.pdf Disassembling the actuator: 1. Prior to performing any work on the valve body. Important! If you intend carrying out maintenance work on the valve. depending on the pro cess medium. be aware that the some of the process medium could still be in the valve. Unscrew the ring nut (8. If the valve does not seal properly.

In case of leakage. (See table on page 5 for tightening torques used for expansion bolts). Do not apply lubricant to graphite packing! 2. 6.3 4. also only tighten slightly. 9.2 4. Assembly 1.6 4.2 Threaded bushing Fig. Do not tighten.3 4. Insert a new lens ring gasket (1. 4.3) may vary.2). the number of bushings (4.1 4. 3 ⋅ Packing EB 8059 EN 9 .5 4. Screw tight the threaded bushing (5.2) over the plug stem into the valve bonnet. Carefully slide the packing parts over the plug stem into the packing chamber.2 4. Push the plug stem into the valve bonnet (5). compressed 5.2) and stem connector nut (6.5 4. Screw the lock nut (6.6 4. 4.4 4.4 Spring V-ring packing Spacer(s) Washer(s) 4.4 4. 5. Screw threaded bushing (5. 3.2 4. Attach expansion bolts with nuts (5. 5.3 Standard High-temperature 4.2) from the stuffing box. Apply lubricant (order no.5 Carbon bushing(s) 4. 3. 7. only slightly tighten the threaded bushing. Thoroughly clean the packing chamber.6 Graphite.Troubleshooting – replacing parts stem. Take all the stuffing box parts out of the packing chamber using a suitable tool. Attach the actuator as described in section 2 and adjust the lower and upper bench range according to section 2. Unthread the threaded nut (5.1) into the valve body and carefully push the whole valve bonnet into the valve body.2 4. Depending on the nominal size of the valve. 8.1) and fasten the valve bonnet in the valve body. Replace damaged parts. With high-temperature packings. Make sure you keep the correct order. Pull the plug and plug stem out of the valve bonnet (5).1 4.1) onto the plug stem without tightening them. 8150-0111) to all parts as well as to the plug stem (6).

2 Seat and/or plug When replacing the seat or plug. Reassemble as described in section 5. However. Apply lubricant (order no.2. Pull the valve bonnet (5) together with plug stem and plug out of the valve body. 5.1.2. Plug: 1. To do this.1) and bolts. 3. Replace gaskets (9. 5.1.2). 4.1. 5. Separating the bonnet and the intermediate piece is only necessary when the packing needs to be replaced. proceed as described in section 5. no torque should be transferred to the metal bellows.3 Replacing parts in valve with insulating section Replace packing as described in section 5.2 Metal bellows The metal bellows (10) can only be replaced as a whole bellows seal together with the plug stem. Pull the plug out of the valve bonnet. Seat: 1.2) and threaded bushing (5. Replace the seat and plug as described for standard valves in section 5.1. we recommend to replace the packing (4.2 or 4.2 Replacing parts in valve with bellows seal Caution! On disassembling and assembling the bellows seal. 5. Remove nuts (5.1. 10 EB 8059 EN .1. Unscrew nuts (6. 3. 2. 6. Unscrew the seat (2) using the appropriate seat wrench (see sheet WA 029). Replace the used plug with a new plug (3) and plug stem (6).2) and bolts.2. The tightening torques for the seats are listed in the table on page 5.1.1. 5.1) and bolts.Troubleshooting – replacing parts 5.1) with new ones.5 and 4.1. remove nuts (11.1 Packing Replace parts as described for standard valves in chapter 5. 8150-0119) to the thread and sealing cone of the new seat (or the old one after it has been cleaned or reworked) and screw it in. 8150-0119) to the plug stem (6) and insert it.2.1. Remove nuts (5. Then separate the bonnet (11) and intermediate piece (9). 2. Apply lubricant (order no.6) as well. Lift the valve bonnet (5) together with the plug stem (6) and plug out of the valve body (1).

2 Intermediate piece Gaskets Metal bellows Bonnet Test connection Nuts and expansion bolts 9.Troubleshooting – replacing parts 11 11.1 11.1 10 11 11.2 9. 4 ⋅ Valve with bellows seal EB 8059 EN 11 .1 9 10 Fig.1 9 9.1 11.

ANSI: R in psi Bench range with pre-tensioned springs DIN: V in bar. ANSI: CL Order number with modification index Item position in the order Flow coefficient: DIN: K85 value. Serial . Description of nameplates Type 3259 Valve Type 3271 Actuator 5 8 13 14 15 Made in Germany SAMSON 1 2 3 -4 7 9 11 12 10 6 SAMSON H 5 F 1 6 2 V 3 7 4 Type 3277 Actuator 1 2 3 4 5 6 7 8 9 10 11 12 CE marking or Art.monteur pneum. ANSI: Cv value Characteristic: % equal percentage. where applicable Ident. ANSI: Size Permissible excess operating pressure at room temperature: DIN: PN. actuator Servo . Stellantrieb 3 Pneum. 3. 3 (see article 3. ANSI: O Actuator stem retracts Travel DIN: H in mm. ANSI: S in mm Bench range (spring range) DIN: F in bar.No. number of notified body. Pneum. Ni nickel-plated PT soft sealing with PTFE.No. where applicable Type designation Modification index of the valve Material Year of manufacture Nominal size: DIN: DN. 6 bar Begrenzt auf Air supply 90 psi Up to Air d' alimentation Limité à Made in France bar 13 1 2 3 4 14 5 6 7 Type designation Modification index Effective diaphragm area cm Fail-safe action: DIN: FA. fluid group and category. ANSI: B SAMSON Model . ST stellited. § 3 of PED). Federbereich Spring range Plage des ressorts Stelldruckbereich Signal pressure range Plage avec précontrainte Hub cm² Stroke Course mm bar bar 1 Zuluft max.Description of nameplates 6. 5 ⋅ Nameplates 12 EB 8059 EN . Lin linear. DIN: A/Z quick opening. ANSI: O/C Sealing: ME metal. ANSI: C Actuator stem extends DIN: FE. PK soft sealing with PEEK Pressure balancing: DIN: D. Abs. ANSI: R in psi Fig.

Customer inquiries Should you have any questions regarding the control valve. nominal size and valve version Pressure and temperature of the process medium Flow rate in m3/h Direction of flow through the valve Bench rate (e.2 to 1 bar) of the mounted actuator Has a strainer been installed? Installation drawing         Refer to Data Sheet T 8059 EN for dimensions and weights of the different valve ver sions.g. product number.Customer inquiries 7. EB 8059 EN 13 . 0. please submit the following details (see also nameplate): Order number Type.

de EB 8059 EN S/Z 2006-05 .SAMSON AG ⋅ MESS.UND REGELTECHNIK Weismüllerstraße 3 ⋅ 60314 Frankfurt ⋅ Germany Phone +49 69 4009-0 ⋅ Fax +49 69 4009-1507 Internet: http://www.samson.

1 · Type 3271 Actuators Mounting and Operating Instructions EB 8310 EN Edition October 2004 .Pneumatic Actuator Type 3271 Type 3271 Type 3271-5 Type 3271 with handwheel Type 3271-52 Fig.

12 Normal operation with the handwheel locked . . . 2 EB 8310 EN . . . 3 Operation .4. . . . . . . . . . Any hazards which could be caused by the signal pressure and moving parts of the actuator are to be prevented by means of appropriate measures. . 14 Customer inquiries . . . . 6 Reversing the operating direction (fail-safe action) . . . . . . . . . . . . . . . . . . . . . . . . . . . start-up and operation of the device may only be performed by 4 4 trained and experienced personnel familiar with this product. . . . . . According to these mounting and operating instructions. .4. . 12 Actuator stem extends upon air supply failure . . 6 Actuator with handwheel . . . . . . . .Contents Safety instructions Contents 1 2 2. . . . .3 2. . . . .4 2. . . . . . 12 Actuator stem retracts upon air supply failure.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. . . . . .1 2. . . . .4 2. . . . . . .2 2. . . . . . . . . . . . .2 2. . . 6 Type 3271 . . . . . . . . . . . . . . .2 2. 13 Description of nameplate . . . . . . . . Proper shipping and appropriate storage are assumed. . . . . . . . . . . 10 Adjusting the travel stop . . . . . . . . . . trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training. . . . . . . . . . . . .1. . . . . . . . . . . . their knowledge and experience as well as their knowledge of the relevant standards. . . . . . . .5 3 4 Page Design and principle of operation . . . . . .1 2. . . . . 12 Actuator stem extends when supply air is applied . . . . . . . . . . . . . . . . . . .3 2. 8 Replacing the diaphragm and stem seal . . . . 11 Manual operation of Type 3271 with side-mounted handwheel .4. . . . . . . . . . . . . . . . 15 General safety instructions 4 Assembly. . .4. . .4. . . . . 13 Actuator stem retracts when supply air is applied . . . .

1 9 a 3 1 1. The Type 3271 Actuator can be equipped in a special version with a mechanically adjustable travel stop (Fig. The signal pressure creates a force at the diaphragm surface which is balanced by the springs (6) arranged in the actuator. 260 and 280 Valves. is mounted to Type 3510 Valves and Series 240 Valves. 7). Actuators with manual override additionally have a handwheel mounted on the top diaphragm case or mounted on the side of the valve yoke. 250.Design and principle of operation 1 Design and operation principle of The Type 3271 Actuators are primarily used for attachment to Series 240. The handwheel moves the actuator stem over a spindle. Actuator stem extends FA Actuator stem retracts FE 3 5 6 8 9 4 2 1 1. Type 3271-5 with a die-cast aluminum casing and effective diaphragm areas of 60 and 120 cm2. The number of springs and their compression determine the bench range (signal pressure range) while taking the rated travel into account which is directly proportional to the signal pressure.1 2 3 4 Nut Nut Actuator stem 6 Springs Vent plug Loading pressure 7 Diaphragm plate 8 Diaphgram connection 5 Top diaphragm 8.1 7 10 11 Nuts and bolts Bottom diaphragm case Loading pressure connection Stem seal Dry bearing Wiper Ring nut Stem connector EB 8310 EN 3 .1 15 13 16 9 10 11 12 12.1 13 15 16 8. a rolling diaphragm and springs. The Type 3271 Actuator is made up of two diaphragm cases. 2 · Sectional diagram of Type 3271 12 12.1 Hose clamp case Fig.

the fail-safe action of the actuator depends on whether the springs are installed in the top or bottom diaphragm chamber.1 6 sure connection (4) to fill the top diaphragm chamber with air which causes the actuator stem to move downwards.Design and principle of operation A maximum of 30 springs can be installed. In an actuator with the fail-safe action "Actuator stem extends FA". the loading pressure is connected to the loading pressure connection (11) to fill the bottom diaphragm chamber with air which causes the actuator stem to move upwards.1 3 3. 9 5 3 4 8 11 7 7. the loading pressure is connected to the loading pres2 1 1.1 12 12. connection Actuator stem retracts Top diaphragm case Springs 21 Diaphragm plate 22 Metal plate Diaphragm Nuts and bolts Bottom diaphragm case Loading press. In an actuator with the fail-safe action "Actuator stem retracts FE".1 15 13 16 10 20 21 22 2.1 2 2.1 Dry bearing 7 7. 3 · Type 3271-5 Actuators with 120 cm2 (top) and 60 cm2 (bottom) effective diaphragm area 4 EB 8310 EN . The stem connector (16) connects the actuator stem (2) to the plug stem of the valve. connection Actuator stem extends 12 Stem seal 12.1 8 9 10 11 16 13 Wiper 15 Ring nut 16 20 21 22 Stem connector 2 Screw (60 cm ) 2 Washer (60 cm ) 2 Sleeve (60 cm ) Fig. partly fitted inside one another.1 4 5 6 Nut Nut Actuator stem Bushing Vent plug Vent plug Loading press. Fail-safe action When the signal pressure fails.1 1 1.

8) moves the stem over a bevel or worm gear. To prevent the actuator from being damaged. The tandem actuator (Fig.5 bar. Actuators with an additional manual override (Fig..1 4. 4 · Tandem actuator Note! Refer to the attached valve’s Mounting and Operating Instructions to mount or remove the actuator from the valve. Important! The pneumatic actuators are designed for a maximum supply pressure of 6 bar. do not let the supply pressure exceed the upper spring range value by more than 3 bar when the actuator is used for flow-switching service (on-off valve) with the fail-safe action "Actuator stem retracts". 5) have a handwheel that moves the actuator stem over a spindle after the locking mechanism (lock nut) has been disengaged.1 15 16 3 7 Actuator stem extends Loading pressure connection Vent plug Loading pressure connection Vent plug Ring nut Stem connector Fig. EB 8310 EN 5 .. A side-mounted handwheel (Fig. Actuator stem retracts When the signal pressure is reduced or the air supply fails.1 4 3 3. 4 3. the springs move the actuator stem downwards and close the valve. The maximum supply pressure for actuators with fail-safe action “Actuator stem extends” and mechanical travel stops should not exceed the upper spring range value by more than 1. supply pressure limited to . The valve opens when the signal pressure is increased enough to overcome the force exerted by the springs. bar". 4) has two diaphragms connected to each other. Actuators with 2800 cm2 diaphragm area weigh 450 kg and cannot be mounted onto the valve on site. The signal pressure produces an actuating force double to that of an actuator with just one diaphragm.1 4 4. The valve closes when the signal pressure is in- creased enough to overcome the force exerted by the springs. Label actuators that have a reduced supply pressure with a sticker "max. the springs move the actuator stem upwards and open the valve.1 4.1 15 16 Actuator stem retracts 3 3.Design and principle of operation Actuator stem extends When the signal pressure is reduced or the air supply fails.

4-1. Lift off the top diaphragm case (5) and remove the springs (6). 3. 2. always undo the short bolts first and then unthread the long bolts slowly and evenly until the actuator springs are fully decompressed. 240 350 700 1400 2800 6 EB 8310 EN .1 Reversing the operating direction (fail-safe action) The operating direction.5.1) on the actuator stem. 2. It is important for a troublefree operation of the actuator that the vent plug (3) is not blocked. fail-safe action. 8 for 1400 and 2800 cm2) . i.1 Type 3271 Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts" (Fig. Caution! Proceed carefully to avoid damaging the seals of the actuator stem. Pull the actuator stem (2) with diaphragm plate (7) and diaphragm (8) out of the bottom diaphragm case (10). it is essential that the dimension "a" from the top of the nut to the bottom of the actuator stem is kept as shown in Fig. or 89 with threaded end 98.2 bar) 144 for 30 mm and 40 mm rated travel 230 430 Caution! To disassemble an actuator with preloaded actuator springs (recognizable by the long bolts on the diaphragm chambers). while holding the nut (1. 5 for 240 to 700 cm2 and Fig. The fail-safe action "Actuator stem extends" or "Actuator stem retracts" is specified on the nameplate with the initials FA and FE on Type 3271 Actuator or by a symbol on Type 3271-5 Actuator. If.e. 2 and the table below. 2) 1. you must remove the actuator from the valve.25 125 for 15 mm rated travel (0. it does become loose. 4. Make sure in versions with a handwheel that the plug stem can move freely when the valve is being positioned by the pneumatic actuator by moving the handwheel into a neutral position (Fig. Note! Only apply the loading pressure to the diaphragm chamber that does not contain the springs.1) stationary with a suitable tool.25 107. 2) 100. Unscrew nut (1). of pneumatic actuators can be changed. however. Prior to proceeding.Operation 2 Operation 2.1. Caution! Do not loosen the nut (1. It is painted over to protect it. Unthread nuts and remove the bolts (9) from the diaphragm cases. Actuator cm 120 2 Dimension a in mm (Fig.

Coat the actuator stem with sealant/lubricant (order no. EB 8310 EN 7 . The loading pressure is connected over the connection (4) to the top diaphragm chamber. 8152-0043) and insert it into the bottom diaphragm chamber along with the diaphragm plate and diaphragm. Screw tight nut (1). 4. Caution! Proceed carefully to avoid damaging the seals of the actuator stem. For the version intended for attachment to micro-flow valves. Place the diaphragm plate with diaphragm in the top diaphragm case. 6. Unthread nuts and remove the bolts (9) and lift off the top diaphragm case (5). Record the changed fail-safe action on the nameplate! Proceed in the same manner for the Type 3271-5 Actuator. Lift off the diaphragm plate with diaphragm and replace them in reverse order. Screw tight the nuts and bolts of the diaphragm cases. 7. 8. Insert springs (6) and place the top diaphragm case back on. 3. Remove vent plug (3) from top diaphragm case and screw it into the loading pressure connection on the bottom diaphragm case. unthread the screw (20) and then remove the washer (21) and sleeve (22). The actuator stem starts to extend when the signal pressure overcomes the force of the springs.1) stationary with a suitable tool. 9. while holding the nut (1. Tighten nut (1).1). The signal pressure is connected via the connection (11) to the bottom diaphragm chamber. Screw tight the nuts and bolts of the diaphragm cases. Apply lubricant/sealant (order no.Operation 5.1) for the mechanical travel stop. 5. Remove the springs (6). 2) 1. 10. Pull the diaphragm plate (7) and diaphragm with the actuator stem (2) out of the bottom diaphragm case (10). additionally install the bushing (2. The springs which are now pressed from the top against the diaphragm plate cause the actuator stem to extend. 8. Remove the diaphragm plate with diaphragm and replace them in reverse order. 6. 8152-0043) to the actuator stem. but additionally install the metal plate (7. The actuator springs now press against the diaphragm plate from below and cause the actuator stem to retract. Remove the vent plug (3) from the bottom loading pressure connection and place it in the top connection. In Type 3271-52 Actuator with 60 cm2 diaphragm area. Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" (Fig. 7. Unscrew nut (1). 2. The actuator stem starts to retract when the signal pressure overcomes the force of the springs. Insert the springs (6) and slide the lower diaphragm case over the actuator stem.

1. 2. 1. However. 4. 3. Record the changed fail-safe action on the nameplate! Proceed in the same manner for the Type 3271-5 Actuator. Place the flange part (21) and coupling nut (25).1. Then fasten the flange part (21) with the ring nut (28). Attach the ring (24) with clamping sleeve (23).1). Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" 4 Proceed as described in section 2. 8 EB 8310 EN . Loosen threaded pin (26) and unscrew coupling nut (25) from the coupling (22). use the word "spindle with nut (27)" in place of "nut (1)". 350 and 700 cm2 (Fig. For Type 3271-52 Actuator with 60 cm2 undo the screw (20) and then remove the washer (21) and sleeve (22).1. 2. but additionally install the metal plate (7.1.Operation 9. Knock out the clamping sleeve (23) and remove the ring (24). install the bushing (2. Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts" 4 Proceed as described in section 2. use the word "spindle with nut (27)" in place of "nut (1)".1) for the travel stop. Unthread the ring nut (28) and lift off the flange part (21).2 Actuator with handwheel 240. Undo lock nut (20) and relieve the springs (6) by turning the handwheel (17).1. After reversing the operating direction: However. 2. 3. 5) only 1. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26). For an actuator intended for a micro-flow valve.

350 und 700 cm2 with handwheel EB 8310 EN 9 .Operation After reversing the operating direction: 1. 5 · Actuators 240. Place the flange part (21) and the coupling nut (25) and then secure flange part (21) with ring nut (28). Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26).1 9 8 6. connection Top diaphragm case Springs Additional springs Diaphragm plate Diaphragm Nuts and bolts Hose clip Bottom diaphragm case Loading press.1 10 2 16 Actuator stem retracts Actuator stem extends 11 Fig. 3. 2. 2 Actuator stem Vent plug Loading press.1 7 8 9 8. connection Stem connector Handwheel Lock nut Flange part Coupling Clamping sleeve Ring Coupling nut Threaded pin Spindle with nut Ring nut 17 20 21 Neutral position Pointer points to groove in coupling (22) 3 4 5 6 6. Attach the ring (24) with clamping sleeve (23).1 10 11 16 17 20 21 22 23 24 25 26 27 28 22 23 24 25 3 4 5 6 7 26 28 27 8.

Operation 2. Remove the diaphragm plate (7) together with diaphragm (8) and actuator stem (2) from the diaphragm case as described in section 2.1) evenly into the groove intended for it and tighten. Coat the new stem seal (12) with lubricant/sealant (order no.1) and wiper (13) with new ones as well. Reassemble the actuator as described in section 2. Insert a piece of protective wear-resistant rubber between the diaphragm and the worm screw of the hose clamp (jubilee clip) to protect the diaphragm. 6 · Actuator stem seal 10 EB 8310 EN . replace the dry bearing (12. Fit the hose clamp (8. 3.1) and pull it together with the diaphragm (8) off the diaphragm plate (7) (not necessary with Type 3271-5 as the diaphragm is held in place by the metal plate (7.1)). 8152-0043) and insert it.1.1. 2) 1. 2. Stretch the new diaphragm onto the diaphragm plate.1 Fig. Reassemble actuator as described in section 2. 2. Remove the hose clamp (8. If necessary. 3. 6) 1. 2 13 12 12.1.2 Replacing the diaphragm and stem seal Diaphragm (Fig. Stem seal (Fig.1. 4. Remove the diaphragm plate (7) together with the actuator stem (2) from the diaphragm case as described in section 2. 4.

3 Adjusting the travel stop 33 31 32 (Type 3271 in special version only) The travel stop can be adjusted upwards or downwards to 50 % of the travel. Undo the lock nut (34) and unscrew the cap (33). 2. 7 · Travel stop EB 8310 EN 11 . 2. 34 5 Upward travel stop (actuator stem retracts) 1. Undo the lock nut (34) and adjust the cap (33) to set the required travel stop. 3.Operation 2. Tighten the lock nut (31) again. Downward travel stop (actuator stem extends) 1. Tighten the lock nut (34) again. 7 2 Actuator stem retracts 2 7 31 32 33 34 Actuator stem extends Actuator stem Diaphragm plate Lock nut Nut Cap Lock nut Fig. Undo the lock nut (31) and adjust the nut (32) to set required travel stop.

If this is not case: way out and turn it to unlock the handwheel. do not turn the handwheel any further by force. On reaching the final position at the stop. Initially. 12 EB 8310 EN . Turn the locking knob until it engages to lock the handwheel again. the valve starts to close. Turn the handwheel clockwise (direction Zu/Close/Fermé).4. the handwheel is easy to turn and after a certain point of pressure is reached. Caution! Risk of damage. Caution! Risk of damage.2 Actuator stem extends upon air supply failure The manual override must overcome the force of the actuator springs to open the valve. After finishing manual operation. Turn the handwheel counterclockwise (direction Auf/Open/Ouvert).1 Normal operation with the handwheel locked The handwheel is not used. 4 way out and turn it to unlock the handwheel.4. The valve is positioned by the pneumatic signal pressure applied to the valve. 4 Pull the locking knob on the side all the 4 2. 4 4 4 2. Initially. the pin emerges from the flange. the handwheel is easy to turn and after a certain point of pressure is reached. To achieve this.4. the valve starts to open. the pin next to the actuator stem must be in the neutral position: The pin must sink into the flange so far that its groove is aligned with the top of the flange. On reaching the final position at the stop. do not turn the handwheel any further by force.Operation 2. Turn the handwheel until the pin reaches the neutral position.4 Manual operation of Type 3271 with side-mounted handwheel 4 Pull the locking knob on the side all the 4 Note! To operate the handwheel on actuators with 1400 and 2800 cm2 diaphragm areas. 4 Pull the locking knob on the side all the 4 4 way out and turn it to unlock the handwheel. Turn the locking knob until it engages to lock the handwheel again. turn the handwheel to bring the pin back into the neutral position again. The easiest way to adjust the handwheel is with the valve in the fail-safe position. do not use any additional tools such as a lever or wrench. 2. the pin sinks into the flange.3 Actuator stem retracts upon air supply failure The manual override must overcome the force of the actuator springs to close the valve.

After finishing manual operation. 4 Pull the locking knob on the side all the 4 way out and turn it to unlock the handwheel.4. 8 · Side-mounted handwheel EB 8310 EN 13 . Do not close the valve any further than before unlocking the handwheel. the pin sinks into the flange.4. Do not open the valve any further than before unlocking the handwheel. 2.Operation 4 After finishing manual operation. After a certain point of pressure is reached (how long depends on the valve travel). Locking knob (locked) Version in this drawing for 80 mm travel Fig. do not turn the handwheel any further by force. Turn the handwheel counterclockwise (direction Auf/ Open/Ouvert). Pin with groove 2. Turn the locking knob until it engages to lock the handwheel again. the handwheel is easy to turn and the pin’s position does not move anymore. turn 4 the handwheel to bring the pin back into the neutral position again. Caution! Risk of damage. the valve starts to open. Neutral position 4 On reaching the final position at the 4 4 stop.5 Actuator stem retracts when supply air is applied The manual override must overcome the force of the actuator springs to close the valve. Turn the locking knob until it engages to lock the handwheel again.4 Actuator stem extends when supply air is applied The manual override must overcome the force of the actuator springs to open the valve. Initially. turn the handwheel to bring the pin back into the neutral position again.

3 Description of nameplate SAMSON H 5 F 1 6 2 V 3 7 4 1 2 3 4 Type designation Modification index Effective diaphragm area Operating direction: Actuator stem extends FA Actuator stem retracts FE Travel Bench range (spring range) Bench range with preloaded springs 5 6 7 Fig. On reaching the final position at the stop. After finishing manual operation. Turn the handwheel clockwise (direction Zu/Close/Fermé). After a certain point of pressure is reached. the valve starts to close. the pin emerges from the flange. Turn the locking knob until it engages to lock the handwheel again.Description of nameplate 4 Pull the locking knob on the side all the 4 4 4 4 way out and turn it to unlock the handwheel. turn the handwheel to bring the pin back into the neutral position again. Caution! Risk of damage. do not turn the handwheel any further by force. 9 · Nameplate 14 EB 8310 EN .

EB 8310 EN 15 .Customer inquiries 4 Customer inquiries Please specify the following details on making inquires: 4 Type and model number 4 Effective diaphragm area 4 Bench range (spring range) in bar 4 Actuator version and its operating direction Dimensions and weights Refer to the Data Sheets T 8310-1 EN or T 8310-2 EN for the different actuator versions.

SAMSON AG ⋅ MESS.UND REGELTECHNIK Weismüllerstraße 3 ⋅ 60314 Frankfurt am Main ⋅ Germany Phone +49 69 4009-0 ⋅ Fax +49 69 4009-1507 Internet: http://www.de EB 8310 EN S/Z 2004-11 .samson.

Pneumatic Actuator Type 3277 Fig. 1 · Type 3277 Pneumatic Actuator Fig. 2 · Type 3277-5 Pneumatic Actuator Mounting and Operating Instructions EB 8311 EN Edition July 2006 .

According to these mounting and operating instructions. 250 and 280. The stem connector (16) connects the actuator stem (2) with the plug stem of the control valve. their knowledge and experience as well as their knowledge of the relevant standards. The lower diaphragm case is permanently fixed to the yoke which allows the direct attachment of either a pneumatic or electropneumatic positioner or a limit switch. is mounted to Type 3510 and Series 240 Valves. 350 or 700 cm² are primarily mounted to control valves from the Series 240. start-up and operation of the device may only be performed by 4 4 trained and experienced personnel familiar with this product.Design and principle of operation 1 Design and operation principle of The Type 3277 Pneumatic Actuators with an effective diaphragm area of 240. 5) additionally have a handwheel mounted on the diaphragm case. The signal pressure creates a force at the diaphragm surface which is balanced by the springs (6) arranged in the actuator. In addition. The number of springs and their compression determine the bench range (signal pressure range) while taking the rated travel into account which is directly proportional to the signal pressure. The handwheel moves the actuator stem over a spindle after the locking mechanism (lock nut) has been disengaged. the actuator can be equipped in a special version with a mechanically adjustable travel stop. a rolling diaphragm and springs. 2 EB 8311 EN . 4 Assembly. Proper shipping and appropriate storage are assumed. Any hazards which could be caused by the signal pressure and moving parts of the actuator are to be prevented by means of appropriate measures. A maximum of 30 springs can be installed. partly fitted inside one another. trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training. Type 3277-5 with a die-cast aluminum case and an effective diaphragm area of 120 cm². Actuators with manual override (Fig. The actuator is made up of two diaphragm cases.

the springs move the actuator stem upwards and open the valve.1Dry bearing 13 Wiper 15 Ring nut 16 Stem connector 8 12 a 12. 350 and 700 cm² effective diaphragm area EB 8311 EN 3 . the springs move the actuator stem downwards and close the valve. the fail-safe action of the actuator depends on whether the springs are installed in the top or bottom diaphragm chamber.Design and principle of operation Fail-safe action When the signal pressure fails. 4 7 1.1 6 6.1 2 3 4 Nut Nut Actuator stem Vent plug Loading pressure9 connection 5 Top diaphragm 2 case 6 Springs 7 Diaphragm plate 8 Diaphragm 9 Nuts and bolts 10 Yoke with bottom diaphragm case 11 Loading pressure connection 12 Stem seal 12. 3 · Sectional diagram of Type 3277 with 240. Actuator stem extends When the signal pressure is reduced or the air supply fails. The valve opens when the signal pressure is increased enough to overcome the force exerted by the springs. The valve closes when the signal pressure is increased enough to overcome the force exerted by the springs.1 Dimension a 350 cm² = 209 mm 700 cm² = 246 mm 15 13 16 Fig.1 3 1 1.1 11 10 12. 5 1 Actuator stem retracts When the signal pressure is reduced or the air supply fails.

Design and principle of operation Loading pressure connection Type 3277 Actuator (Fig. Index Switchover plate Connecting plate New Old New Old: G thread Old NPT thread 01 00 01 00 00 Order no. do not let the supply pressure exceed the upper spring range value by more than 3 bar when the actuator is used for flow-switching service (on-off valve) with the fail-safe position "Actuator stem retracts".g. 4 Turn the connecting plate to align the 4 4 symbol (14. the loading pressure is connected the loading pressure connection (4) to fill the top diaphragm chamber which causes the actuator stem to move downwards. Make sure that the flat gasket of the connecting plate is correctly inserted.4).4). Label actuators that have a reduced supply pressure with a sticker "max. Seal the bore not required with a rubber gasket and square plug. bottom right. 4) In the Type 3277-5 Actuator. To prevent the actuator from being damaged. A switchover plate (14. 4. See Fig. Old and new plates are not interchangeable. A connecting plate (accessories) is required instead of the switchover plate if the actuator is operated without a positioner. Accessories: The switchover plate or connecting plate must be ordered separately. The operating direction (>>) or (<>) of the positioner determines whether the left or right attachment is to be used. Note! The pneumatic actuators are designed for a maximum supply pressure of 6 bar. accessories) directs the air to one of the diaphragm chambers. 4.00) are equipped with new plates.3) for the appropriate fail-safe action "Actuator stem extends" or "Actuator stem retracts" with the mark (14. 3277-531xxx20. depending on the fail-safe action of the actuator ("Actuator stem extends" or "Actuator stem retracts"). Note! Refer to the operating instructions of the corresponding valve on how to mount and remove the actuator from the valve. 4 EB 8311 EN . the loading pressure is connected to a borehole either at the left or right of the yoke. the loading pressure is connected to the loading pressure connection (11) at the side of the yoke to fill the bottom diaphragm chamber which causes the actuator stem (2) to move upwards.4). bottom left.3) for the appropriate fail-safe action with the mark (14. The connecting plate has both NPT and G threaded bores. In an actuator with the fail-safe action "Actuator stem retracts".01 (old = . Please note that actuators with modification index 01 e. See Fig. 3) In the Type 3277 Actuator with fail-safe action "Actuator stem extends".8) of the connecting plate to fill the diaphragm chamber. supply pressure limited to … bar". 1400-6822 1400-6819 1400-6823 1400-6820 1400-6821 4 Turn the switchover plate to align the symbol (14. Type 3277-5 Actuator (Fig. The loading pressure is directly connected to the loading pressure connection (14. which is determined by how the plate is aligned with the mark (14.

2 14 15 13 16 Actuator with threaded connection for a micro-flow valve Connecting plate 1 1.6 For right attachment 14.8 14.5 14.2 for actuator stem retracts 15 Ring nut 16 Stem connector 14.5 with 20 mm travel Fig.6 14.1 8 9 10 12 Nut Nut Bushing Diaphragm case Springs Diaphragm plate 16 Metal plate Diaphragm Nuts and bolts Yoke Switchover plate Stem seal 12.Design and principle of operation 9 6 1 2 1.7 14.5 For left attachment 14.1 2.8 Loading pressure connection Actuator stem retracts Left attachment Right attachment Actuator stem extends retracts 14.1 a 7 8 14 10 7.1 Dry bearing 13 Wiper 14 Switchover or connecting plate Air routing: 14.7 Seal with filter 14.1 5 6 7 7.1 for actuator stem extends 14.3 14.4 14.1 14.1 2 a 12 12.5 with 15 mm travel and 185.1 14.3 Symbol 14.3 14.4 Actuator stem extends Left attachment Right attachment Dimension a = 188. 4 · Type 3277-5 Actuators with 120 cm2 effective diaphragm area EB 8311 EN 5 .1 2.4 Marking for signal pressure input 14.

6 EB 8311 EN . Pull the actuator stem (2) with diaphragm plate (7) and diaphragm (8) out of the yoke (10). 2. while holding the nut (1. Caution! Proceed carefully to avoid damaging the seals of the actuator stem.1) stationary or clamping the actuator stem with a suitable tool. fail-safe action. of pneumatic actuators can be changed. are preloaded by approx. Make sure in versions with a handwheel that the plug stem can move freely when the valve is being positioned by the pneumatic actuator by moving the handwheel into a neutral position.1 Reversing the operating direction (fail-safe action) The operating direction. Note! Actuators with 700 cm² (travel = 30 mm) that are mounted to valves with 15 mm travel.1 Standard actuator Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts" Note! It is important for a trouble-free operation of the Type 3277 Actuator that the vent plug (3) is not blocked.e. "Actuator stem extends" "Actuator stem retracts" Caution! To disassemble an actuator with preloaded actuator springs (recognizable by the long bolts on the diaphragm chambers). 75 % on mounting them to the valve. Prior to proceeding. Lift off the top diaphragm case (5) and remove the springs (6). The signal pressure range is recorded on the nameplate when the actuators have been preloaded on mounting them to the valve. i. Unthread nuts and remove the bolts (9) from the diaphragm cases. 2. always undo the short bolts first and then unthread the long bolts slowly and evenly until the actuator springs are fully decompressed. Unscrew nut (1). you must remove the actuator from the valve. 1.Operation 2 Operation 2. 4. The fail-safe action is represented by a symbol on the nameplate.1. 3.

Coat the sealing parts of the actuator stem with sealant/lubricant (order no. Turn over top diaphragm case (5). but additionally attach the bushing (2. if applicablethe diaphragm plate (7) out of the yoke and bottom diaphragm case (10). Screw tight the nuts and bolts of the diaphragm cases. Remove vent plug (3) in Type 3277 Actuator. it has been loosened. into the bottom diaphragm case with yoke. 7. If. Screw the vent plug (3) into the top loading pressure connection of the Type 3277 Actuator. 8. Unscrew nut (1). 9. Proceed in the same manner for the Type 3277-5 Actuator intended for the micro-valve. It is painted over to protect it. The actuator stem only starts to extend when the signal pressure overcomes the force of the springs. while holding the nut (1. 8. diaphragm and metal plate (7. The springs now press from below against the diaphragm plate and cause the actuator stem to retract (fail-safe action).Reversing the operating direction (fail-safe action) Caution! Do not loosen the nut (1. Pull the actuator stem with diaphragm plate. however. Place the actuator stem with diaphragm plate. 4.1).1) for mechanical travel stop. 2. 5. Apply lubricant/sealant (order no.1) stationary or clamping the actuator stem with a suitable tool. Unthread nuts and remove the bolts (9) and lift off the top diaphragm case (5).1). Insert the springs (6) and slide the yoke with bottom diaphragm case over the actuator stem. Remove the diaphragm plate with diaphragm and replace them in reverse order. 6. if applicable. if applicable in the case. Proceed in the same manner for the Type 3277-5 Actuator intended for the micro-valve. The actua- EB 8311 EN 7 . 3 and 4) measured from the top of the nut to the bottom of the actuator stem is kept. but additionally attach the bushing (2.1) on the actuator stem.1) for the mechanical travel stop. The springs now press from the top against the diaphragm plate and cause the actuator stem to extend (fail-safe action). Screw tight nut (1). 7. it is essential that the dimension a (Figs. Record the changed fail-safe action on the nameplate! Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" 1. 8152-0043) to the sealing places on the actuator stem.1). 6. 5. diaphragm and metal plate (7. Insert the actuator stem with diaphragm plate. 8152-0043). diaphragm and metal plate (7. Insert springs (6) and place the top diaphragm case back on. Screw tight the nuts and bolts of the diaphragm cases. Caution! Proceed carefully to avoid damaging the seals of the actuator stem. 3.

5) only 1. 2. Tighten ring nut (15).2 Actuator with handwheel Type 3277 (Fig. Loosen threaded pin (26) and unscrew coupling nut (25) from the coupling (22). After reversing the operating direction: However. Replace the flange part (21) with ring nut (15) and coupling nut (25).1. Attach the ring (24) with clamping sleeve (23). Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26).1. Attach the ring (24) with clamping sleeve (23). 2. 2. Undo lock nut (20) and relieve the springs (6) by turning the handwheel (17). 2.1. 1. use the word "spindle with nut (27)" in place of "nut (1)".1.1. 3. After reversing the operating direction: However. Unthread the ring nut (15) and lift off the flange part (21) together with the coupling nut (25). Attach the ring (24) with clamping sleeve (23). 9. 3. 8 EB 8311 EN . Record the changed fail-safe action on the nameplate! Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts" 4 Proceed as described in section 2. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26). Replace the flange part (21) with ring nut (15) and coupling nut (25). 4. use the word "spindle with nut (27)" in place of "nut (1)". 1. 3. Tighten ring nut (15).Reversing the operating direction (fail-safe action) tor stem only starts to retract when the signal pressure overcomes the force of the springs. Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" 4 Proceed as described in section 2. Knock out the clamping sleeve (23) and remove the ring (24).

connection Top diaphragm case Springs Additional springs Diaphragm plate Diaphragm Nuts and bolts Bottom diaphragm case Loading press.Reversing the operating direction (fail-safe action) 17 20 Neutral position Pointer points to groove in coupling (22) 21 22 24 13 15 3 4 6 23 26 25 12 5 27 8 12 10 9 6.1 7 8 9 10 11 15 12 12. 5 · Type 3277 Actuator with additional handwheel EB 8311 EN 9 . connection Ring nut Stem seal Dry bearing Wiper Handwheel Lock nut Flange part Coupling Clamping sleeve Ring Coupling nut Threaded pin Spindle with nut 12.1 13 17 20 21 22 23 24 25 26 27 Actuator stem Vent plug Loading press.1 7 11 2 3 4 5 6 6.1 13 Fig.

2. Tighten the lock nut (31) again. 6 · Travel stop 10 EB 8311 EN . Undo the lock nut (34) and unscrew the cap (33).2 Adjusting the travel stop 33 31 32 34 5 (with Type 3277 in special version only) The travel stop can be adjusted upwards or downwards to 50% of the travel. Tighten the lock nut (34) again. Downward travel stop (actuator stem extends) 1. 2. Upward travel stop (actuator stem retracts) 1.Adjusting the travel stop 2. 7 2 Actuator stem retracts 2 5 7 31 32 33 Actuator stem extends Actuator stem Top diaphragm case Diaphragm plate Lock nut Nut Cap Fig. 3. Undo the lock nut (34) and adjust the cap (33) to set the required travel stop. Undo the lock nut (31) and adjust the nut (32) to set required travel stop.

Reassemble actuator as described in section 2. Fit the hose clamp evenly into the groove intended for it and tighten. 13 Fig. Remove the diaphragm plate (7) together with the actuator stem (2) from the diaphragm case as described in section 2. 4. 4 Type and model number 4 Effective diaphragm area 4 Bench range (spring range) in bar 4 Actuator version and its operating direction Dimensions and weights Refer to the Data Sheet T 8310-1 EN dimensions and weights of the different actuator versions.2 Stem seal 2 12. 8152-0043) and insert it. replace the dry bearing (12. 2. If necessary.1 1.1)).1.1 (Fig. Reassemble the actuator as described in section 2. 12 3.1.1. 3) Replacing the diaphragm and stem seal Diaphragm 4 Customer inquiries Please specify the following details on making inquires: 1. 2. Remove the hose clamp and pull it together with the diaphragm (8) off the diaphragm plate (7) (not necessary with Type 3277-5 as the diaphragm is held in place by the metal plate (7.1. 3.1.1. 3. Remove the diaphragm plate (7) together with diaphragm (8) and actuator stem (2) from the diaphragm case as described in section 2. Stretch the new diaphragm onto the diaphragm plate.1) and wiper (13) with new ones as well.1. 7 · Actuator stem seal EB 8311 EN 11 . 4.Replacing the diaphragm and stem seal 3 3.1. Coat the new stem seal (12) with lubricant/sealant (order no.

SAMSON AG · MESS.samson.de EB 8311 EN S/Z 2006-08 .UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 Internet: http://www.

1 – SARExC 16.Electric multi-turn actuators SAExC 07.1 AUMA NORM Certificate Registration No. 12 100/104 4269 Operation instructions .1 SARExC 07.1 – SAExC 16.

Test run 13. Setting of the torque switching 12.1 Programming 12. Electrical connection 8.1 in version AUMA NORM. Setting of electronic position transmitter RWG (option) 15. 17. 4.2 Checking the switches for torque and DUO limit switching 13./ 4.1 Removal of the switch compartment cover 9.6 Remote position transmitter 8.3 Maintenance 1. Setting of the potentiometer (option) 15. Setting of the DUO limit switching (option) 11.1 Ex-plug/socket connector with terminal board 8. i.3 Delay time 8.e.1 AUMA NORM Scope of these instructions: Operation instructions These instructions are valid for multi-turn actuators of the type range SA(R)ExC 07. 3.2 Setting for direction OPEN (white section) 12.1 – SA(R)ExC 16.5 Motor protection 8.1 Range of application 1.2 Ex-plug-in terminal connection 8. Setting of the limit switching 10.2 Setting for 3.8 Fitting of the cover 9.3 Checking the switches 11. Short description Technical data Transport and storage Packaging Mounting to valve/ gearbox Manual operation Page 4 4 4 4 4 4 5 7 7 8 10 11 11 12 13 13 13 13 14 14 15 15 15 16 16 16 16 17 17 17 18 18 18 19 19 19 20 21 22 23 24 24 8.Multi-turn actuators SA(R)ExC 07. 6.1 Setting for direction CLOSE (black section) 11.4 Heater 8. 7.2 Setting for end position OPEN (white section) 10.7 Limit and torque switches 8. driven shaft turns clockwise to close the valve Table of contents 1./4-wire system 0 – 20 mA 15.1 Setting for 2-wire system 4 – 20 mA and 3.1 Check direction of rotation: 13.4 Warnings and notes 2.2 Pulling off the indicator disc (option) 10. 5. These operation instructions are only valid for “clockwise closing”. Safety instructions 1.2 Commissioning (electrical connection) 1.1 Setting for end position CLOSED (black section) 10.1 – SA(R)ExC 16.wire system 4 – 20 mA 16. Opening the switch compartment 9.2 Check limit switching: 14. Setting of the mechanical position indicator (option) Closing the switch compartment 2 .

Maintenance Lubrication Disposal and recycling Service Spare parts list multi-turn actuator SAExC 07.1 AUMA NORM Page 18.1 – SAExC 16. 19.1 with plug/ socket connector Spare parts list multi-turn actuator SAExC 07. 24.Operation instructions Multi-turn actuators SA(R)ExC 07. 21. 25. 23. 20. 22.1 – SAExC 16.1 – SA(R)ExC 16.1 with terminal connection PTB certificate Declaration of Conformity and Declaration of Incorporation Index Addresses of AUMA offices and representatives 25 26 26 26 28 30 32 34 35 36 3 .

1 – SA(R)ExC 16. The limitation of travel is realised via limit switches in both end positions. it must be assured that immediately before a discharge through contact with an earthed metallic surface (e. which. please consult us. Observance of these operation instructions is considered as part of the actuators’ designated use. can affect the safety of persons or material.3 1. Pay attention to additional national regulations. This pictograph means: Note! “Note” marks activities or procedures which have major influence on the correct operation.2 Commissioning (electrical connection) 1. Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules. Such risk lies entirely with the user. This pictograph means: Electrostatically endangered parts! If this pictograph is attached to a printed circuit board. The maintenance instructions (refer to page 25) must be observed. as well as careful commissioning are essential to ensure a trouble-free and safe operation. Work at the open actuator under voltage must only be performed if it is assured that for the duration of the work there is no danger of explosion. The following references draw special attention to safety-relevant procedures in these operation instructions. Non-observance of the warnings and notes may lead to serious injuries or damage.1 Safety instructions Range of application AUMA actuators are designed for the operation of industrial valves. special regulations (Standard EN 60079-17) must be observed. Qualified personnel must be thoroughly familiar with all warnings and notes in these operation instructions. Non-observance of these notes may lead to consequential damage. For other applications. if not carried out correctly.1 – SA(R)ExC 16.g. 1. Each is marked by the appropriate pictograph.4 Maintenance Warnings and notes 2. This pictograph means: Warning! “Warning” marks activities or procedures. butterfly valves and ball valves.Multi-turn actuators SA(R)ExC 07. proper storage. it contains parts which may be damaged or destroyed by electrostatic discharges. the housing) has taken place. If the boards need to be touched during setting. Short description 4 . otherwise a safe operation of the actuator is no longer guaranteed. The type of seating is determined by the valve manufacturer. 1. Correct transport. gate valves. AUMA multi-turn actuators type SA(R)ExC 07. During electrical operation certain parts inevitably carry lethal voltages. e.1 have a modular design. The manufacturer is not liable for any possible damage resulting from use in other than the designated applications. mounting and installation. measurement or for exchange. For work carried out in hazardous areas. globe valves.1 AUMA NORM Operation instructions 1.g. Torque seating is also possible in both end positions.

motor protection switch) must be installed for explosion-proof actuators in addition to the thermoswitches. analogue Only available in connection with magnetic limit and torque transmitter MWG and the (option) actuator controls ACExC 01. 5 . Technical data Table 1: Technical data multi-turn actuator SA(R)ExC 07.15 min SARExC Intermittent duty S4 .1 or ACExC 01. 24 V DC) is installed in the actuator in combination with the actuator controls AMExC or ACExC .1 – SA(R)ExC 16.000 turns per stroke Position feedback signal.1 – SA(R)ExC 16.50 % Motors 3-ph AC asynchronous motor. handwheel does not rotate during electric operation.30 min SARExC Intermittent duty S4 . tropicalized Motor 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. switches galvanically isolated Intermediate position switch (DUO limit switching).25 % Option: SAExC Short time duty S2 .g. switches galvanically isolated Triple switch (3 NC and 3 NO) for each end position. 5 – 20 W 110 – 250 V DC/AC Options: 24 – 48 V DC/AC A resistance type heater (5 W. available for any intermediate position Torque switching adjustable torque switching for direction OPEN and CLOSE Standard: Single switch (1 NC and 1 NO) for each direction Options: 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. type IM B9 according to IEC 34 Insulation class F. 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 thread Options: Pg thread. Features and functions Explosion protection Standard: II2G EEx de IIC T4 II2G c IIC T4 Options: II2G EEx d IIC T4 II2G IIC T4 Protection types Motor compartment: d flameproof enclosure EEx d Switch compartment: d flameproof enclosure EEx d Terminal compartment: e increased safety EEx e d (Option) flameproof enclosure EEx d Gear housing : c constructional safety EC type examination certificate PTB 01 ATEX 1087 Type of duty 1) Standard: SAExC Short-time duty S2 .Operation instructions Multi-turn actuators SA(R)ExC 07.1.1 Mechanical position indicator Continuous indication.1 AUMA NORM 3.1 Application Multi-turn actuators AUMA NORM require external controls. 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. These can also easily be mounted to the actuator at a later date. Potentiometer or 0/4 – 20 mA analogue (options) For further details see separate data sheet Torque feedback signal. The type of duty must not be exceeded 2) PTC thermistors require additionally a suitable tripping device in the controls 3) According to EN 60079-14 a thermal overload relay (e. AUMA offers the controls AMExC 01. adjustable indicator disc with symbols OPEN and CLOSED (option) Running indication Blinker transmitter Heater in switch compartment Standard: self-regulating PTC heater. Manual operation Manual drive for setting and emergency operation.1) for 1 to 500 turns per stroke or for 10 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.

chemical industry) KX Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration KX-G same as KX. B. 5) Under certain conditions (special sizing) up to + 60 °C possible 6) For standard version with Ex-plug/socket connector with terminal board 6 . we recommend a higher corrosion protection KS or KX. similar to RAL 9007) Option: Other colours are possible on request Ambient 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) 2 g. for an expected lifetime of a minimum of operation hours 5.1 Typ Starts in millions min.1 – SARExC 14.000 10. however aluminium-free version (outer parts) Finish coating Standard: two-component iron-mica combination Standard colour Standard: silver-grey (DB 701. B2.000 h 1.000 500 250 700 350 175 600 300 150 SARExC 07. B3.1 AUMA NORM Operation instructions Terminal plan Output drive types SAExC: KMS TP 210/001 (basic version) SARExC: KMS TP 200/001 (basic version) A. IB1.25 %.or power plants with a low pollutant concentration4) Options: KS Suitable for installation in occasionally or permanently aggressive atmosphere with a moderate pollutant concentration (e.0 3.000 5.000 Number of starts based on S4 .5 with 30 turns per stroke 20. B1.000 h 10. from 10 Hz to 200 Hz (without controls) according to EN 60068-2-6 Lifetime Type Operating cycles (OPEN-CLOSE-OPEN) SAExC 07.1 – SARExC 10. D.5 SARExC 16. in wastewater treatment plants.1 – SAExC 10.double sealed Corrosion protection Standard: KN Suitable for installation in industrial units.1 – SAExC 48. B4 according to EN ISO 5210 A. in water. AK.000 15.g.1 – SAExC 30.Multi-turn actuators SA(R)ExC 07.1 SAExC 35. 5.1 – SAExC 16.1 – SA(R)ExC 16.5 3. IB3 Service conditions Enclosure protection according to Standard: IP 67 EN 60 529 Option: IP 68 For both enclosure protections (IP 67 and IP 68) the terminal compartment ist additionally sealed against the interior .1 SARExC 14.1 SAExC 25. AG. E according to DIN 3210 C according to DIN 3338 Special output drives: AF.1 SAExC 14.000 h 20.1 Other information EC directives Reference documents ATEX directive: (94/9/EC) Electromagnetic Compatibility (EMC): (89/336/EEC) Low Voltage Directive: (73/23/EEC) Machinery Directive: (98/37/EC) Product description “Electric multi-turn actuators SA/SAR” Information “Electric actuators and valve gearboxes according to ATEX” Dimension sheets SA(R)ExC Electrical data sheets SA(R)ExC Technical data SAExC 4) If occasionally or permanently exposed to aggressive substances.

7 . Check for corrosion approximately every 6 months. . connect actuator immediately to electrical system. Apply suitable corrosion protection agent to bright surfaces. dry room. the following points must be observed additionally: Prior to storage: Protect bright surfaces. If multi-turn actuators are to be stored for a long time (more than 6 months). . . Transport and storage . . . Multi-turn actuators SA(R)ExC 07. Do not attach ropes or hooks to the handwheel for the purpose of lifting by hoist. Cover to protect against dust and dirt. 5. We use the following packaging materials: wood. . If first signs of corrosion show. Protect against floor dampness by storage on a shelf or on a wooden pallet. For the disposal of the packaging material we recommend recycling and collection centres.1 AUMA NORM Transport to place of installation in sturdy packing. paper and PE foil. in particular the output drive parts and mounting surface. cardboard. apply new corrosion protection. . If multi-turn actuator is mounted on valve. so that condensation is prevented by the heater.Operation instructions 4. Packaging Our products are protected by special packaging for the transport ex works. with long-term corrosion protection agent. After mounting. attach ropes or hooks for the purpose of lifting by hoist to valve and not to multi-turn actuator. The packaging consists of environmentally friendly materials which can easily be separated and recycled.1 – SA(R)ExC 16. Store in well-ventilated. .

For finish machining of stem nut refer to next page. Fasten bolts (at least quality 8. For output drive type A (figure B-1).Multi-turn actuators SA(R)ExC 07. Check if mounting flange fits the valve/ gearbox. the internal thread of the stem nut must match the thread of the valve stem. Damaged parts must be replaced by original spare parts. . Spigot at flanges should be loose fit! The output drive types B1.8. Place actuator on valve/ gearbox and fasten. Figure A Output drive type B1/B2 Plug sleeve Output drive type B3/B4 Bore with keyway . The multi-turn actuator leaves the factory in position CLOSED (limit switch CLOSED tripped). If not ordered explicitly with thread.1 AUMA NORM 6. . Increased temperatures at the valve flange or valve stem: If temperatures > 40 °C are to be expected at the valve mounting flange or the valve stem (e. After mounting to valve/ gearbox.g. Apply a small quantity of grease to input shaft of valve/gearbox. B3 or B4 (figure A) are delivered with bore and keyway (usually according to ISO 5210). Table 2: Fastening torque for bolts Strength class 8. But mounting can be done in any other position as well. . due to hot media). touch up any possible damage to paint finish.1 – SA(R)ExC 16. refer to table 2) evenly crosswise. Check whether bore and keyway match the input shaft of valve/gearbox. Operation instructions Prior to mounting the multi-turn actuator must be checked for damage. . the stem nut is unbored or with pilot bore when delivered. Mounting to valve/ gearbox . Temperatures > 40 °C are not considered with regards to the non-electrical explosion protection. B2. Thoroughly degrease mounting faces at multi-turn actuator and valve/ gearbox. Mounting is most easily done with the valve shaft/gearbox shaft pointing vertically upward.8 M 8 M 10 M 12 M 16 TA (Nm) 25 50 87 220 8 . please consult AUMA. . .

1 – SA(R)ExC 16.2 5g A 25.2 10 g A 30. quantities see table.2 20 g A 40. Remove spigot ring (80.2 3g A 16. Drill and bore stem nut and cut thread.2 14 g A 35. make sure stem nut runs true! Clean the machined stem nut.9 kg/dm³ Protection tube for rising valve stem Protection tubes may be supplied loose. . Ensure that dogs are placed correctly in the slots of the hollow shaft. . Figure B-2: Protection tube for rising valve stem . Screw protection tube (1) into thread (figure B-2) and tighten it firmly.1 AUMA NORM Finish machining of stem nut (output drive type A): Figure B-1 Output drive type A Stem nut 80. . Table 3: Grease quantities for output drive A Output drive Qty1) A 07. Take off stem nut (80. Remove thrust bearing and thrust bearing races from stem nut. push down the seal (2) to the housing.5 g 2g A 14. Check. . Screw in spigot ring until it is firm against the shoulder. then place them on stem nut. For corrosion protection KS/ KX. whether cap (3) is available and without damage.01/ 80. Apply ball bearing grease to thrust bearing and races.3 80.2 A 10. .01) and thrust bearing races (80.3) together with thrust bearing (80.02). into the grease nipple with a grease gun: .2 25 g A 48. . .2 The output drive flange does not have to be removed from the actuator.Operation instructions Multi-turn actuators SA(R)ExC 07. Re-insert stem nut with thrust bearings into the mounting flange. . 3 1 2 9 .02 80. . figure B-1) from mounting flange.2 30 g 1) For grease with a density ρ = 0.2. When fixing in the chuck. Press Lithium soap EP multi-purpose grease on mineral oil base.2 1. . . Teflon tape or thread sealing material. Seal thread with hemp.

Manual operation is engaged by an internal change-over mechanism. Engaging manual operation: .1 AUMA NORM Operation instructions 7. Disengaging manual operation: Manual operation is automatically disengaged when motor is started again. figure D). while slightly turning the handwheel back and forth until manual drive engages (figure C). Turn handwheel into desired direction (figure F). 85°. It is not necessary to use an extension. 10 . Release change-over lever (should snap back into initial position by spring action. The handwheel does not rotate during motor operation. Manual force is sufficient for operating the change-over lever. if necessary push it back manually. Excessive force may damage the change-over mechanism. Figure E Figure F .1 – SA(R)ExC 16.Multi-turn actuators SA(R)ExC 07. and in case of motor failure or power failure. Manual operation The actuator may be operated manually for purposes of setting and commissioning. Figure D Figure C . Lift change-over lever in the centre of the handwheel up to approx. Operating the change-over lever while the motor is running (figure E) can lead to increased wear at the change-over mechanism.

02) are removed and the plug/ socket connector is pulled off.02 Remove cable sheathing in a length of 120 –140 mm.1 – SA(R)ExC 16. 2 wires for each connection permitted.01 . The terminal plan applicable to the actuator KMS TP .0 51. Flameproof enclosure! Before opening.0) remain together. Enclosure protection IP 67 or IP 68 is only ensured if suitable cable glands are used. 12 mm.0 51.auma. For stranded wires use end-sleeves according to DIN 46228. . Figure G-2: Disconnection from the mains 50. Parking frame 11 . 8. 51. In case the terminal plan is not available. . . If the actuator must be taken from the valve. Figure G-3: Parking frame (accessory) A special parking frame (figure G-3) for protection against touching the bare contacts and against environmental influences is available. Check whether type of current. .g. .1 AUMA NORM When working in potentially explosive areas.1 Ex-plug/socket connector with terminal board For the Ex-plug/socket connector (figure G-1). supply voltage and frequency correspond to motor data (refer to name plate at motor).com).0).. . Loosen bolts (50. it can be separated from the mains without having to remove the wiring (figure G-2). together with the operation instructions.Operation instructions Multi-turn actuators SA(R)ExC 07. . Plug cover (50. Strip wires: Controls max. The flameproof compartment (type of protection EEx d) remains hereby closed.0 50. is attached to the handwheel in a weather-proof bag.01) (figure G-1) and remove plug cover.0 . observe the European Standards EN 60079-14 “Electrical Installations in Hazardous Areas” and EN 60079-17 “Inspection and Maintenance of Electrical Installations in Hazardous Areas”. Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules. . e. Insert cable glands with “EEx e” approval and of size suitable for connecting cables. the electrical mains connection is made after removing the plug cover (50. Connect cables according to order related terminal plan KMS TP . it can be obtained from AUMA (state commission no. Seal cable entries which are not used with suitable plugs.0) and terminal board (51. For that the screws (51. 8 mm.0) at the EEx e terminals of the terminal board (51. Electrical connection 8. refer to name plate) or downloaded directly from the Internet (www. . motor max. ensure that there is no explosive gas and no voltage. . Figure G-1: Connection 50. for service purposes.

. . it can be obtained from AUMA (state commission no. Flameproof enclosure! Before opening. supply voltage and frequency correspond to motor data (refer to name plate at motor). If the actuator must be taken from the valve. of contacts max. 31 to 40. . Check whether type of current. For that the screws (51. Current max. Enclosure protection IP 67 or IP 68 is only ensured if suitable cable glands are used. Figure G-4: Connection 50.16 Figure G-5: Disconnection from the mains 50. . Type of customer connection Cross section max.g. is attached to the handwheel in a weather-proof bag.01 . for service purposes. The terminal compartment is designed for explosion protection “EEx e” (increased safety).5 mm2 Araldite / Polyamide Brass (Ms) tin-plated 1) Suitable for copper wires. .1 51. Insert cable glands with “EEx e” approval and of size suitable for connecting cables. Material: Pin / socket carrier Contacts Motor power connections1) 3 U1.1 AUMA NORM Operation instructions Table 4: Technical data Ex-plug/ socket connector with terminal board for explosion-proof actuators Technical data No. . together with the operation instructions. (51. . Marking Voltage max. 51. Terminal cover (50. with the integral plug/ socket connector is pulled off.com).. 8.16 51. V1. .02) are removed and the frame assly. Seal cable entries which are not used with suitable plugs. In case the terminal plan is not available.1 Connect cables according to order related terminal plan KMS TP . 47 to 50 250 V 10 A Screws 1.2 Ex-plug-in terminal connection The electrical connection to the mains is on terminals (figure G-4). For aluminium wires contact AUMA. it can be separated from the mains without removing the wiring (figure G-5). W1 550 V 25 A Screws 6 mm2 Araldite / Polyamide Brass (Ms) Protective earth 1 (leading contact) according to VDE – – Screws 6 mm2 Araldite / Polyamide Brass (Ms) Control pins 38 pins / sockets 1 to 24.auma. The terminal plan applicable to the actuator KMS TP .1 – SA(R)ExC 16. e. . Loosen bolts (51. ensure that there is no explosive gas and no voltage.1). .16) remain together.Multi-turn actuators SA(R)ExC 07. . The separation between the terminal compartment (increased safety) and the switch compartment (flameproof enclosure) is realised via a flameproof line bushing with integral plug/ socket connector.1) and frame assly.02 12 . 51. refer to name plate) or downloaded directly from the Internet (www.01) (figure G-4) and remove terminal cover (50.

1 – SA(R)ExC 16. Motor power connections1) 3 U1.1 AUMA NORM Figure G-6: Parking frame (accessory) A special parking frame (figure G-6) for protection against touching the bare contacts and against environmental influences is available.4 Heater 8. In order to protect against overheating and impermissibly high temperatures at the actuator. Parking frame Table 5: Technical data Ex-plug-in terminal connection for explosion-proof actuators Technical data Terminals max. PTC thermistors or thermoswitches are embedded in the motor winding.3 Delay time The delay time is the time from the tripping of the limit or torque switches to the motor power being removed. 13 . otherwise the guarantee for the motor will lapse. To prevent condensation. Current max. W1 Protective earth 1 according to VDE – Control terminals 48 1 to 48 250 V 16 A Screws 10 mm2 Cage clamp2) 2. the heater must be connected. For aluminium wires contact AUMA. valve type and the type of installation are taken into consideration. V1. PTC thermistors and PTC tripping device or thermoswitches and thermal overload relay have to be connected. Marking Voltage max. 8.5 Motor protection 8. To protect the valve. We recommend to switch off the corresponding contactor directly by the limit or torque switch.1 1) Suitable for copper wires.5 mm2 flexible. 2) Optional with screw connections 8. Longer delay times are possible provided the output speed. output drive type.Operation instructions Multi-turn actuators SA(R)ExC 07. AUMA multi-turn actuators have a heater installed as standard. we recommend a delay time < 50 ms. permissible winding temperature has been reached. RWG) screened cables must be used.6 Remote position transmitter For the connection of remote position transmitters (potentiometer. Type of connection Cross section max. The thermoswitch is tripped as soon as the max. 4 mm2 solid 750 V 25 A Screws 10 mm2 up to SA 16.

For correct signalisation. 400 mA 250 V 5A 0. Table 6: Technical data limit and torque switches RD BK Mechanical life time = 2 x 106 starts NO NC NC NO II Tandem switch RD 2 BK 2 RD BK Type of current 30 V 1-phase AC (ind. Fasten cable glands with the specified torque to ensure the required enclosure protection. Apply a thin film of non-acidic grease (e.1 AUMA NORM 8. Vaseline) to the sealing faces.8 Fitting of the cover . . max. Use the lagging contacts for switching off.0 figure G-1 or 50. 4 mA. Joint surfaces must not be damaged or soiled in any way. After connection: Clean sealing faces at the plug cover or terminal cover and the housing. Check whether O-ring is in good condition.g.Multi-turn actuators SA(R)ExC 07. .8 DC (resistive load) with gold plated contacts Current 5A 2A Switch rating Imax 125 V 5A 0. Do not jam cover during fitting. Flameproof enclosure! Handle cover and housing parts with care. If different potentials are to be switched simultaneously. Replace cover (50. . Preserve joint surfaces with an acid-free corrosion protection agent. the leading contacts must be connected at the tandem switch.1 figure G-4) and fasten 4 bolts evenly crosswise. load) cos phi = 0. 50 V min. 14 .1 – SA(R)ExC 16. max. . 5 V. tandem switches are required.5 A min.7 Limit and torque switches Operation instructions Figure G-7 RD BK I Single switch Only the same potential can be switched on the two circuits (NC/ NO contact) of a limit or torque switch. .4 A RD 2 DSR 1 / DÖL 1 WSR 1 / WÖL 1 DSR / DÖL WSR / WÖL BK 2 RD BK 8.

i.1 – SA(R)ExC 16. These settings are only valid for “clockwise closing”.1 Removal of the switch compartment cover Flameproof enclosure! Before opening. observe the European Standards EN 60079-14 “Electrical Installations in Hazardous Areas” and EN 60079-17 “Inspection and Maintenance of Electrical Installations in Hazardous Areas”. . Opening the switch compartment 9.1 AUMA NORM To be able to make the following settings (clause 10. to 16. ensure that there is no explosive gas and no voltage.) the switch compartment must be opened and. driven shaft turns clockwise to close the valve. Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules. 14 mm) may be used as lever. Remove 4 bolts and take off the cover at the switch compartment (figure H) . Figure H-2: Cover without indicator glass Figure H-1: Cover with indicator glass Bolts 9. pull off indicator disc (figure J).Operation instructions Multi-turn actuators SA(R)ExC 07. Figure J: Pulling off the indicator disc RSD RDW Indicator disc 15 . Open end spanner (approx. if installed. 9. . When working in potentially explosive areas.2 Pulling off the indicator disc (option) If installed. the indicator disc must be removed.e.

While a ratchet is felt and heard. the pointer B moves 90° every time. if necessary. continue turning the setting spindle in the same direction and repeat setting process. 16 . . .Multi-turn actuators SA(R)ExC 07. Press down and turn setting spindle D (figure K-1) with screw driver (5 mm) in direction of arrow. continue turning slowly. .1 AUMA NORM Operation instructions 10. Press down and turn setting spindle A (figure K-1) with screw driver (5 mm) in direction of arrow.1 – SA(R)ExC 16. continue turning the setting spindle in the same direction and repeat setting process. . When pointer E has reached the mark F.2 Setting for end position OPEN (white section) Turn handwheel counterclockwise until valve is open. thereby observe pointer B. turn back handwheel approximately 1/2 a turn (overrun). If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped). . Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED. stop turning and release setting spindle. correct setting of the limit switching. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped). While a ratchet is felt and heard. During test run (page 17) check overrun and. continue turning slowly. Setting of the limit switching 10. . The red test buttons T and P (figure K-1) serve for operating the limit switches manually. stop turning and release setting spindle. When pointer E is 90° from mark F. then turn back approximately 1/2 a turn. After having reached the end position. Turning P in direction of the arrow LSO (WÖL) triggers limit switch OPEN.1 Setting for end position CLOSED (black section) Turn handwheel clockwise until valve is closed. When pointer B has reached the mark C.3 Checking the switches . 10. the pointer E moves 90° every time. thereby observe pointer E. When pointer B is 90° from mark C. Figure K-1: Control unit T P B E C A D F 10.

For setting.1 – SA(R)ExC 16. When pointer L is 90° from mark F. thereby observe pointer L. When pointer H has reached the mark C. Press down and turn setting spindle G (figure K-2) with screw driver (5 mm) in direction of arrow. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped). When pointer L has reached the mark F. continue turning the setting spindle in the same direction and repeat setting process. . . While a ratchet is felt and heard. When pointer H is 90° from mark C. Figure K-2: Control unit T P C H G K L F 11. .2 Setting for direction OPEN (white section) Move valve to desired intermediate position. stop turning and release setting spindle. the switching point (intermediate position) must be approached from the same direction as afterwards in electrical operation. stop turning and release setting spindle.1 AUMA NORM 11. continue turning slowly. Press down and turn setting spindle K (figure K-2) with screw driver (5 mm) in direction of arrow. the pointer H moves 90° every time. thereby observe pointer H.Operation instructions Multi-turn actuators SA(R)ExC 07. the pointer L moves 90° every time. While a ratchet is felt and heard. continue turning slowly. 17 . 11. . continue turning the setting spindle in the same direction and repeat setting process. Setting of the DUO limit switching (option) Any application can be switched on or off via the two intermediate position switches. If you override the tripping point inadvertently (ratchet is heard after the pointer has snapped).1 Setting for direction CLOSE (black section) Move valve to desired intermediate position.

2 Checking the switches for torque and DUO limit switching . The torque switches can also be operated in manual operation.1 AUMA NORM Operation instructions 12. Turning P in direction of the arrow TSO (DÖL) triggers torque switch OPEN.Multi-turn actuators SA(R)ExC 07. . The set torque must suit the valve! This setting should only be changed with the consent of the valve manufacturer! Figure L: Torque switching heads Setting CLOSED Setting OPEN .1 – SA(R)ExC 16. The red test buttons T and P (figure K-2) serve for operating the torque switches manually: Turning T in direction of the arrow TSC (DSR) triggers torque switch CLOSED. .1 Programming .5 da Nm = 45 Nm for direction OPEN Tighten lock screws O again . Setting of the torque switching 12. Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm). If a DUO limit switching (optional) is installed in the actuator. . Example: Figure J shows the following setting: 3. . 12. 18 . also when stopping in the end positions by limit switching.5 da Nm = 35 Nm for direction CLOSE 4. The torque switching acts as overload protection over full travel. the intermediate position switches will be operated at the same time. O P O P Loosen both lock screws O at the torque dial (figure L). . .

. Hereby observe that the appropriate switch is tripped in each end position and released again after the direction of rotation is changed. the limit switching must first be set. If no other options (clauses 14. If provided. Figure M-1: Indicator disc CLOSED . to 16. Test run 13. the direction of rotation can also be observed on the hollow shaft. To this end. . . place indicator disc on shaft. The direction of rotation of the indicator disc (figure M-1) indicates the direction of rotation of the output drive. .2 Check limit switching: . Check whether limit switching is set correctly. clause 17. 19 . Repeat test run.) require setting: Close switch compartment (see page 24. 27) (figure M-2). Switch on actuator in direction CLOSE and observe the direction of rotation: If the direction of rotation is wrong switch off immediately Correct phase sequence at motor connection.Operation instructions Multi-turn actuators SA(R)ExC 07.1 Check direction of rotation: .). Move actuator manually into both end positions of the valve.1 – SA(R)ExC 16. If there is no indicator disc.1 AUMA NORM Work at the open actuator under voltage must only be performed if it is assured that for the duration of the work there is no danger of explosion. If this is not the case. Figure M-2: Opening the hollow shaft OPEN 27 S1/S2 13. remove screw plug (no. Table 7: Direction of rotation of the indicator disc: counterclockwise Direction of rotation of the hollow shaft: clockwise correct correct 13. as described from page 15. Move actuator manually to intermediate position or to sufficient distance from end position.

. Due to the ratio of the reduction gearings for the position transmitter the complete resistance range is not always utilized for the whole travel. Turn potentiometer (E2) clockwise until stop is felt. Therefore an external possibility for adjustment (setting potentiometer) must be provided. Perform fine-tuning of the zero point at external setting potentiometer (for remote indication). Turn potentiometer (E2) back a little. – For remote indication – Move valve to end position CLOSED.1 – SA(R)ExC 16. pull off indicator disc.Multi-turn actuators SA(R)ExC 07. Setting of the potentiometer (option) . . . end position OPEN to 100 %. Figure N: Control unit E2 20 . If installed. End position CLOSED corresponds to 0 %. .1 AUMA NORM Operation instructions 14.

Setting of electronic position transmitter RWG (option) – For remote indication or external control – After mounting the multi-turn actuator to the valve. input current Max. if necessary.or 4. 4 – 20 mA 24 V DC. max. Table 8: Technical data RWG 4020 Terminal plans KMS TP_ _ 4 / _ _ _ for 3. ±15 % smoothed 24 mA at 20 mA output current 600 Ω KMS TP _ 4 _ / _ _ _ KMS TP _ 5 _ / _ _ _ for 2-wire system 4 – 20 mA 14 V DC + (I x RB). check setting by measuring the output current (see subclause 15.Operation instructions Multi-turn actuators SA(R)ExC 07. 30 V 20 mA (Uv .1 or 15.2) and re-adjust.14 V) / 20 mA Output current Voltage supply Max.1 AUMA NORM 15.1 – SA(R)ExC 16. load Ia Uv I RB The position transmitter board (figure P-1) is located under the cover plate (figure P-2).wire system 0 – 20 mA. Figure P-1: Position transmitter board 21 .

load RB). the selection of the reduction gearing must be checked. If installed. If necessary. Set potentiometer “max. Turn potentiometer “0” clockwise until output current starts to increase. otherwise no value can be measured. Move valve to end position OPEN. Move valve to end position CLOSED.” to end value 20 mA. 22 .Multi-turn actuators SA(R)ExC 07.or 4-wire system: approx. . 4. The circuit (external load) must be connected (max. This ensures that the signal remains above the dead and live zero point. or the appropriate poles at the terminals (refer to terminal plan) must be linked. Approach end position CLOSED anew and check minimum value (0. .1 – SA(R)ExC 16. correct the setting./4-wire system 0 – 20 mA Operation instructions . . . “0” (0/4 mA) “max. Turn potentiometer (E2) back a little.” (20 mA) Figure P-2 Cover plate E2 Measuring point (+) 0/4 – 20 mA Measuring point (–) 0/4 – 20 mA .1 AUMA NORM 15. . .1 mA). . Connect voltage for electronic position transmitter.1 mA for 2-wire system: approx.1 mA or 4. 0.1 Setting for 2-wire system 4 – 20 mA and 3. If the maximum value can not be reached.1 mA. . . pull off indicator disc. Turn potentiometer “0” back until the following value is reached: for 3. Turn potentiometer (E2) clockwise until stop is felt. Connect ammeter for 0 – 20 mA to measuring points (figure P-2).

Approach both end positions anew and check setting. . Move valve to end position CLOSED. ./ 4. 23 .1 AUMA NORM 15. so that the range is now 4 – 20 mA.1 mA to initial value 4 mA. correct the setting.1 – SA(R)ExC 16. Set potentiometer “max. If necessary. Figure P-2 Cover plate E2 Measuring point (+) 0/4 – 20 mA Measuring point (–) 0/4 mA – 20 mA . “0” (0/4 mA) “max. Turn potentiometer “0” clockwise until output current starts to increase. otherwise no value can be measured. Move valve to end position CLOSED. . .2 Setting for 3. Turn potentiometer (E2) back a little. Turn potentiometer (E2) clockwise until stop is felt. . 0. the selection of the reduction gearing must be checked. or the appropriate poles at the terminals (refer to terminal plan) must be linked. If the maximum value can not be reached. Move valve to end position OPEN. pull off indicator disc. This results in a simultaneous shift of the end value by 4 mA. Set potentiometer “0” from 0. Connect ammeter for 0 – 20 mA to measuring points (figure P-2). . If installed. . . The circuit (external load) must be connected (max.Operation instructions Multi-turn actuators SA(R)ExC 07.1 mA is reached.” to end value 16 mA. .wire system 4 – 20 mA Connect voltage for electronic position transmitter. Turn back potentiometer “0” until a residual current of approx.” (20 mA) . . load RB). .

. . Move actuator to end position OPEN. If the turns per stroke are changed at a later date. . Preserve joint surfaces with an acid-free corrosion protection agent. Touch up possible defects to paint finish after commissioning. Joint surfaces must not be damaged or soiled in any way. Figure Q-2: Figure Q-1: Indicator disc Mark Indicator disc rotates approximately 180° to 230° at full travel from OPEN to CLOSED or vice versa. Apply a thin film of non-acidic grease to the sealing faces. 17. .Multi-turn actuators SA(R)ExC 07. . A suitable reduction gearing was installed in our works. Hold lower indicator disc CLOSED in position and turn upper disc with symbol OPEN until it is in alignment with the mark on the cover. Turn lower indicator disc (figure Q1) until symbol CLOSED is in alignment with the mark on the cover (figure Q-2).1 – SA(R)ExC 16. 24 . Clean sealing faces of housing and cover Check whether O-ring is in good condition. Closing the switch compartment . Flameproof enclosure! Handle cover and housing parts with care. the reduction gearing may have to be exchanged. Move valve to end position CLOSED. too. Setting of the mechanical position indicator (option) .1 AUMA NORM Operation instructions 16. Do not jam cover during fitting. . Place indicator disc on shaft. . . Replace cover on switch compartment and fasten bolts evenly crosswise.

g. Esso Rust BAN 397). Observe torques according to manufacturer’s details. Check whether Ex-connections are fastened correctly. . This may originate from ‘breathing’ due to severe temperature variations (e. . Cable entries.Operation instructions Multi-turn actuators SA(R)ExC 07. Any kind of surface coating for the joint surfaces is not permitted. . Do a thorough touch-up of possible damage to paint finish to prevent corrosion. 25 . Ensure that all housing covers are handled carefully and that the seals are checked. Regular inspection and maintenance (in 3 year intervals) performed by qualified and trained personnel according to the European standard EN 60079-17 “Inspection and Maintenance of Electrical Installations in Hazardous Areas” is required. Joint surfaces must not be damaged or soiled in any way. . Check the flame path gaps of flameproof enclosures for dirt and corrosion. The electric connecting cables must be without damage and wired correctly. . The joint surfaces have to be cleaned chemically (e. cable glands. Remove any water immediately. the joint surfaces have to be preserved with an acid-free corrosion protection agent (e. Work at the open actuator under voltage must only be performed if it is assured that for the duration of the work there is no danger of explosion. Do not jam cover during fitting. . When working in potentially explosive areas. plugs etc. Housing parts and joint surfaces in particular must not be processed mechanically. Pay attention to national regulations. . observe the standard EN 60079-17 “Inspection and Maintenance of Electrical Installations in Hazardous Areas”. . . Flameproof enclosure! Handle cover and housing parts with care. . no mechanical work (such as grinding) shall be performed on them. This would indicate an increased temperature. take care especially of a possible collection of water. Before fitting.1 AUMA NORM For any maintenance work. from damaged seals etc. change of night and day). ensure that there is no explosive gas and no voltage. Flameproof enclosure! Before opening. . Since the dimensions of all flameproof joints are strictly defined and inspected. replace the components. . g. Maintenance . If defects which affect the safety are detected during maintenance. with Esso-Varsol). g. Ensure that no outside damage or changes are visible. . . have to be checked for correct tightness and sealing. . . seals etc. . For Ex housings. the following should be observed: 18. Check actuator visually. Original paint in small quantities can be supplied by AUMA. only original spare parts shall be used. If required.1 – SA(R)ExC 16. repair measures have to be initiated without delay. Take care of possible discolouration of the terminals and wires. When exchanging parts. All cable and motor protection components have to be checked. Only use components which have a test certificate.

.1 – SA(R)ExC 16. page 9). tighten applying the torques given in table 2. . .com). Lubrication We recommend additionally: If operated seldom. . However. For multi-turn actuators with output drive type A: at intervals of approx. 19.1 AUMA NORM Operation instructions . there will come a time when you have to replace them. . . . 21. .e. .Multi-turn actuators SA(R)ExC 07. Observe the national regulations for waste disposal. Disposal and recycling AUMA actuators have an extremely long lifetime. Approximately six months after commissioning and then every year check bolts between actuator and valve/gearbox for tightness. . i. 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. Addresses of AUMA offices and representatives can be found on page 36 and on the Internet (www. If required. 26 . AUMA offers extensive services such as maintenance and inspection for actuators. separated and sorted according to materials. . The actuators have a modular design and may therefore easily be disassembled. 6 months from commissioning press in Lithium soap EP multi-purpose grease on mineral oil base at the grease nipple with grease gun (quantity see table 3. 20.auma. page 8.: electronic scrap various metals plastics greases and oils . these substances are hazardous to water and must not be released into the environment. Service The following generally applies: Collect greases and oils during disassembly. . This ensures that the actuator is always ready to operate. As a rule. perform a test run about every 6 months. See disassembled material to a sound disposal or to separate recycling according to materials.

Operation instructions Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1 AUMA NORM Notes 27 .

0 9.0 019 020 24.0 79.1 SARExC 07.1 with plug/ socket connector .1 49.0 S2 18 105.1 51.0 24 151.1 19. Spare parts list multi-turn actuator SAExC 07.5 52.Commission number .3 20.Works number .Actuator type .0 S2 61.0-3 160.0 S2 012 5.0 60.0 17.3 80.1 27 56.0 70.0 S2 90.0 15.001 85.0 80.7 S2 5.Lubricant .001 80.1 SARExC 14.2 160.001 107 100 106.2 51.1 – SAExC 10.0 30.0-1 S1 / S2 51.0 / 23.0 153.001 85.8 S2 5.Temperature range B1 / C A D B3 / B4 / E .0 58.001 14 5.2 52.001 90.0 1.32 053 6 3.1 S2 S2 S2 SAExC 07.4 153.0 152.0 SAExC 14.1 – SA(R)ExC 16.0 153.37 10.Protection type Torque range in CLOSE/OPEN .0 79.0-2 79.0 85.3 153.1 70.1 AUMA NORM 59.0 80.0 S1 / S2 57.0 5.1 – SAExC 16.0 51.0 90.3 153.0 152.0 S2 2.0 S1 / S2 Multi-turn actuators SA(R)ExC 07.12 25.0 Sample name plate Operation instructions 22.1 – SARExC 16.0 155.1 – SARExC 10.1 S1 / S2 39 S2 5.0 22.1 – SAExC 16.0 S1 / S2 156.2 S1 / S2 51.28 50.

(without worm wheel) Worm shaft assly.0 70.0 24 24.0 106.3 3) 153.0 23.2 3) 153. (but without torque head. No.1 – SA(R)ExC 16. large assly. Drive pinion II for torque switching assly. Motor coupling Manual drive coupling assly.0-1 2) 79.1 51.0 17.1 1) 79.0 3) 90.001 100 105.8 6 9. 2) only required for some output speeds 3) not included in basic equipment 29 . Torque lever assly.1 153.0 1) 50.0013) 90.7 5. (without thread in stem nut) Thrust bearing set Stem nut Form A (without thread) Output drive B3 Snap ring Output drive D Snap ring Switch for limit / torque switching (including pins at wires) Blinker transmitter including pins at wires (without impulse disc and insulation plate) Stud bolt for switches Spacer Space heater Potentiometer (without slip clutch) Slip clutch for potentiometer RWG assly.Operation instructions Multi-turn actuators SA(R)ExC 07.2 51.2 S1 3) 160.0 5.0 160.0 107 151. Grub screw Coupling pin Pull rod assly.1 with output speeds of 32 to 180 rpm or SARExC 16. Worm wheel Planetary gear for manual drive assly. Screw plug Motor plug.Control terminal Screw .3 51.3 56.0 70.37 5. socket assly.0-2 2) 79. it is essential to mention type of actuator and our commission number (refer to actuator name plate) .3 3) 85.0 39 49.0 52.0 10.0 18 19. Ex-motor mounting flange Output drive Form A assly. Retaining flange assly. 012 019 020 053 1.1 3) 153.0 59.0 14 15.0).0 5.0 3) 2) Type B B B B B B B B B B E E B E B 3) Designation Wire for protective earth Pin for motor and thermoswitch in motor plug Control unit assly.5 3) 155.0 3) E B B B E B B B B B B B B B B E E S 152. 58.0 25. = assly.0 3) 80.0 Pin for motor Type B = sub-assembly S S2 Type S = set 1) SAExC 16. Drive wheel for limit switching assly. Terminal board assly. Screw .12 5.0 51. Drive wheel for limit switching Intermediate wheel for limit switching assly.0 22.4 52.0 3) 156.0 61. without switches) Torque switching head Motor Motor pin carrier (without pins) Planetary gearing for motor drive assly. Hollow shaft assly. Gear segment Crown wheel assly.0 Type E E E E B B B B E E B E B E B B E B B E B B B B E B E E B E B B B E E E E B E B Notched pin Cheese head screw Clamping washer Countersunk screw Housing assly.0 27 30.1 AUMA NORM Note: When placing orders for spare parts. Flange. bottom assly.0 51.1 with output speeds of 32 and 45 rpm without plug/ socket connector.0 3. Planetary gearing for motor drive assly. Locking plate Screw plug Handwheel with ball handle assly. 85.Power terminal Washer . small Seal-kit. Cover assly. Potentiometer for RWG (without slip clutch) Slip clutch for RWG Electronic board RWG Wires for RWG Reduction gearing Mechanical position indicator Protection tube (without cap) Cap for stem protection tube Seal-kit. 52.1 3) 3) B 57.0 152. motor directly wired to pin carrier (No.0 20.Power terminal Pin carrier (without pins) Circlip Pin for control Type E = component Designation No.0013) 80. Change-over lever Cover for switch compartment assly.Control terminal Washer .32 5.0-3 80.0 2. Swing lever assly.0 1) 60.2 3) 3) 153.

30 50.3 153.1 49.0 SAExC 14.1 – SARExC 16.0 70.0 019 020 24.0 1.0 70.0 80.0 5.0-3 51.0 61.1 50.001 85. Spare parts list multi-turn actuator SAExC 07.024 S1 / S2 54.0 S2 S2 2.16 S2 S2 79.Lubricant A D B3 / B4 / E .0 S2 012 5.Actuator type .1 153.001 80.0 S1 / S2 156.001 85.0 90.37 10.0 60.1 – SARExC 10.0-2 79.0 14 5.1 AUMA NORM S1 / S2 56.020 50.0 152.32 053 6 3.0 S2 85.001 90.Works number B1 / C .0 57.1 – SAExC 10.0 17.8 S2 5.2 S1 / S2 54.1 – SA(R)ExC 16.0 30.021 50.3 80.1 – SAExC 16.0 155.1 SARExC 07.0 9.Commission number .2 151.0 S2 18 105.0 153.2 50.1 153.023 27 S1 / S2 152.1 54.0 Multi-turn actuators SA(R)ExC 07.0 S2 39 50.0 59.0 23.001 107 100 106.2 52.0 22.1 – SAExC 16.001 90.5 S1 / S2 20.7 S2 5.0-1 SAExC 07.0 Sample name plate 15.0 / 23.1 160.2 153.1 S2 79.0 19.0 80.2 S2 160.1 SARExC 14.016 50.1 with terminal connection Operation instructions .0 24 5.Protection type Torque range in CLOSE/OPEN .12 25.

0 17.0 3) 85. (without terminals) No.0 14 15.1 50.2 3) 153. = assly.0).0-2 2) 79.0 10.16 B Pin carrier (without pins) 52.0 23.0 2. Drive pinion II for torque switching assly.8 6 9.1) Ex-motor mounting flange Output drive form A assly. large assly. End piece Terminal for controls Terminal for motor Terminal cover for controls Terminal cover for motor Cover assly.0 3) 106. Flange.3 3) 153.0 3) 160.0 3) 153. 51. Retaining flange assly. Locking plate Screw plug Handwheel with ball handle assly.0 3) 90.1 AUMA NORM Note: When placing orders for spare parts.0 24 24.021 50. (SA 16.1 3) 152. Grub screw Coupling pin Pull rod assly.0 22.5 3) 155. Screw plug Motor plug.1 3) 160. Motor coupling Manual drive coupling assly.020 50. bottom assly.0013) 90. 52.0 20.016 50.1 3) 153.0-1 54.0 57. Planetary gearing for motor drive assly.7 5. Drive wheel for limit switching Intermediate wheel for limit switching assly.0 1) 50.Operation instructions Multi-turn actuators SA(R)ExC 07.37 5.0 70.2 3) S1 S2 Type B B B B B B B B B B B E E B E B E B B B E B B B B B B B B B B E E S S Designation Pin for controls Pin for motor Pin for motor and thermoswitch in motor plug Control unit assly.12 5.1 1) 79.0 107 151.0 18 19.0 25. Terminal carrier-frame assly. (without thread in stem nut) Thrust bearing set Stem nut Form A (without thread) Output drive B3 Snap ring Output drive D Snap ring Switch for limit / torque switching (including pins at wires) Blinker transmitter including pins at wires (without impulse disc and insulation plate) Stud bolt for switches Spacer Space heater Potentiometer (without slip clutch) Slip clutch for potentiometer RWG assly. Hollow shaft assly.0 152.0-3 2) 80. 2) only required for some output speeds 3) not included in basic equipment 31 . 56. Change-over lever Cover for switch compartment assly.0 3. connection) 54.0 B Cable conduit assly.0 3) 156.1 with output speeds of 32 and 45 rpm without plug/ socket connector. (without worm wheel)) Worm shaft assly. Gear segment Crown wheel assly. Worm wheel Planetary gear for manual drive assly.0-1 2) 79.32 5. 012 019 020 053 1. (but without torque head. Swing lever assly. Torque lever assly.0 5. it is essential to mention type of actuator and our commission number (refer to actuator name plate) No.2 3) 153. socket assly.3 3) 85. Drive wheel for limit switching assly.1 with output speeds of 32 to 180 rpm or SARExC 16.0013) 100 105.2 Type E E E E B B B B E E B E B E B B E B B E B B B B E B E E B E B E E E E E B B Designation Notched pin Cheese head screw Clamping washer Countersunk screw Housing assly.024 50.023 50. B Frame extension assly.0 39 49. motor directly wired to pin carrier (No.0 1) 60. (cust.0 27 30. without switches) Torque switching head Motor Motor pin carrier (without pins) Planetary gearing for motor drive assly.0 70.0013) 80.0 3) 80.0 61. Potentiometer for RWG (without slip clutch) Slip clutch for RWG Electronic board RWG Wires for RWG Reduction gearing Mechanical position indicator Protection tube (without cap) Cap for stem protection tube Seal-kit.0 5.2 E Circlip Type B = sub-assembly Type E = component Type S = set 1) SAExC 16.0 59. small Seal-kit.1 – SA(R)ExC 16.

1 AUMA NORM Operation instructions 24.1 – SA(R)ExC 16. PTB certificate 32 .Multi-turn actuators SA(R)ExC 07.

1 – SA(R)ExC 16.1 AUMA NORM 33 .Operation instructions Multi-turn actuators SA(R)ExC 07.

Declaration of Conformity and Declaration of Incorporation 34 .1 AUMA NORM Operation instructions 25.1 – SA(R)ExC 16.Multi-turn actuators SA(R)ExC 07.

21 4 26 28 28 31 7 T Tandem switch Technical data Test run Thermoswitches Torque setting Transport Tripping torque 14 5 19 13 18 7 18 S Safety instructions Service Spare parts list Actuator Spare parts list SA(R)ExC with terminal connection Storage Information also available on the Internet: Terminal plan.Operation instructions Multi-turn actuators SA(R)ExC 07.auma. or comm no.com 35 . inspection records and further actuator information can be downloaded directly from the internet by entering the order no.17 26 M Maintenance Manual operation Mechanical position indicator Motor protection Mounting to valve/ gearbox N Name plate O Output drive types P Parking frame Position indicator Position transmitter RWG Potentiometer Protection tube PTB certificate PTC thermistors R Remote indication 4 10 24 13 8 28 8 11 24 21 20 9 32 13 20.1 – SA(R)ExC 16.1 AUMA NORM Index C Corrosion protection D Declaration of Conformity Declaration of Incorporation DUO limit switching E Electrical connection Electronic position transmitter RWG 2-wire system 3-/ 4-wire system F Finish machining of stem nut H Handwheel Heater I Indicator disc Internet L Limit switches Limit switching Lubrication 7 34 34 17 11 21 22 23 9 10 13 24 35 14 16. Our homepage: http://www. (refer to name plate).

auma.auma.com.Tsuen Wan.auma. Tel +52 55 55 561 701 Fax +52 55 53 563 337 informes@iess.fr www.gr SIGURD SØRUM A.Dubai Tel +971 4 3682720 Fax +971 4 3682721 auma@emirates. S. s..com.tw www. Kowloon Tel +852 2493 7726 Fax +852 2416 3763 joeip@perfectcontrols.com Power plant sector DK-2450 København SV Tel +45 33 26 63 00 Fax +45 33 26 63 21 GS@g-s. L.com AUMA (INDIA) PRIVATE LIMITED DE-73747 Ostfildern Tel +49 711 34803 ..C.com East Office NL-2314 XT Leiden Tel +31 71 581 40 40 Fax +31 71 581 40 49 office@benelux.Cairo Fax +44 1275 875492 Tel +20 2 3599680 .o.A. Box 1151 D .L.co.auma.com www.auma.Doha Tel +974 4433 236 Fax +974 4433 237 behzad@qatar. V.775/003/en/1.com.Koegler@wof.auma-taiwan. SE-20039 Malmö Tel +46 40 311550 Fax +46 40 945515 info@erichsarmatur. Tel +55 19 3879 8735 Fax +55 19 3879 8738 atuador.nl AUMA Polska Sp.com.com www.auma.Lima Tel 00511444-1200 / 0044 / 2321 Fax 00511444-3664 corsusa@corsusa..net 2006-03-08 For detailed information about AUMA products refer to the Internet: AUMA Riester GmbH & Co. KG Factory Müllheim AUMA (Schweiz) AG INDUSTRA CH-8965 Berikon Tel +41 566 400945 Fax +41 566 400948 RettichP.com West Office PL-41-310 Dabrowa Górnicza Tel +48 32 26156 68 Fax +48 32 26148 23 R.fi AUMA France UA-02099 Kiyiv Tel +38 044 566-9971.auma-usa.P.Jhonghe City Taipei Hsien (235) Tel +886 2 2225 1718 Fax +886 2 8228 1975 support@auma-taiwan.auma. Zulia Tel +58 261 7 555 667 Fax +58 261 7 532 259 suplibarca@intercable.Bogotá D. TW.com Baden Office CO.ua IN-560 058 Bangalore Tel +91 80 2839 4655 Fax +91 80 2839 2809 info@auma. 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1 · Type 3730-3 Mounting and Operating Instructions EB 8384-3 EN Firmware version 1.4x Edition March 2007 .Series 3730 Electropneumatic Positioner Type 3730-3 With HART communication ® Fig.

. .2 1. . . . .1 4. Type 3277 Actuator . . . Mounting the position sensor to rotary actuators . . .3 4. . . . .5 2. Determining the fail-safe position Setting the volume restriction Q . .1 5. . . . . . . . . .1 2. . . . . . . . . . . . . . . .2 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator controls and display . . . . .3 2. Attachment according to IEC 60534-6 . . . . . 9 Technical data . . . . . . . . . . . . . .2 3.1. . . . Establishing communication . . . . . . . . . . . . . . . . . . . . . . . . . . Type 3277-5 Actuator. . . . . . . . . . . . . . . . . Automatic and manual operating modes . . . Connections . . . . . . . . . . . . . . . . Adapting the display . . . . . . . .3 Page Design and principle of operation . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical connections . . . . . . . . . . . Switching amplifiers . . . . .1 3. . . . . . . . . . . . . . . . . . . . .2 4 4. . . . . . . . . . . . . . . . . . . Direct attachment . . . . .4 2. . . . . . . . . . . . . . . . . . . . . . .3 2. . . . . . . . . . .2 5 5. . . . 8 Communication .6. . . Enabling and selecting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . .6. . . . .2 3. . . . . . . . . . . . . . . . . . . . . . .2. . . . . . .1. . . . . . . . .1 4. . . . . .6. . . . . . . . . . . . . . . . .3. . . . . . . . . . .2 2.4 2. . . . . . . . . . . . . Attachment to rotary actuators . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating modes . . . . . . . . .Contents Contents 1 1. . . .1 2. . 9 Additional equipment . . . . . . . . . . .6 2. . . . . . . 10 Attachment to the control valve – Mounting parts and accessories . . . . . . . Attaching positioners with stainless steel housings. . . . . . . . . . . Supply pressure . . . .2 2. . Pneumatic connections . Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. SAFE – Fail-safe position . . . .2 4. . . . . . . . . . . . . . . . . . . . . Start-up and settings . . . . . . . . . . . . . . . . . . . . .3 2 2. 13 16 16 18 20 22 24 26 26 28 28 30 31 32 34 34 36 36 36 36 38 40 40 42 42 44 45 45 46 46 47 47 47 Operation . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . Reversing amplifier for double-acting actuators . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . .7 2. . . Air purging function for single-acting actuators . . Mounting the position sensor with direct attachment. . . . . . . . . . 2 EB 8384-3 EN . . . . . . . . . .1 1. . . . . . . . . . . . . Pressure gauge attachment .2 2. Attaching an external position sensor . . .6. . Mounting the position sensor with attachment according to IEC 60534-6 Mounting the position sensor to Type 3510 Micro-flow Valve . . .1 2. .8 3 3. . . . . Signal pressure gauges . . . . . . . . . . . . .1 2. . .5.

. . .3. . . .3. . . . . . . . . . . .1 13. . . . . . .11 6 6. . . . . . . . . . . 109 Certificates . . . . . . . . . . . . . . . . . . Zero calibration . . . . . Fault/failure . . . . . . .1 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard EXPERT diagnostics . . . . . . 70 Maintenance . . . . . . . . . . . . . . . . . . .2 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 5. . . . . . . . . . . . 64 Upgrading options . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . .3 9 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Activation of optional EXPERT+ diagnostics . . . . 69 Retrofitting an inductive limit switch . . . . . . . . . . . . . .2 8. . . . . . . . . . . . . . . . . . . . . . .1 8. . . . . . . . 70 Servicing explosion-protected devices . . . . . . . . . . . . . Start-up over HART® communication . .3 8. . . . . . . . . .3.1 6. . .2 8. . . . . . . . . . 87 87 88 91 92 Dimensions in mm . . .10 5. . 71 Setting with TROVIS-VIEW software – Parameter list . . . . . . . . . . . . . . . Reset to default values . . . . . . . . .2 6. . . . . . . . . . . . . . . . . . . . . . . . . General . . . . Setting the parameters. . 110 EB 8384-3 EN 3 . . . . . . . . . . . . . . . Starting TROVIS-VIEW and performing basic settings .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Classification of the status alarms and the condensed status . . . . . . . . Initialization . . . . . . . . . . . . . . .Contents 5.1 9. . . . . . . . . . . . . . . . . . . . . . . . . . Quick start-up guide . . . . . . . . . . . . . . . . .2 10 11 12 13 13. . . Start-up. . . . . . . . . Simplest method (MAX) Precise method (NOM) Manual method (MAN) . . . . . . . . Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 5. . . . . . . Extended EXPERT+ diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 5. . . . . . . . . . . . . . . . . . Checking the operating range of the positioner . . . . . . .9 5. . . . . . . . . . . . . . . . . . .4 14 Limiting the signal pressure . . . . . . . . . . .3 13. . . . . . .5 5. . Initialization modes . . . Parameter list . 48 48 49 51 57 58 59 59 59 60 60 61 61 66 66 67 68 68 68 68 Status and diagnostic alarms . . .3 7 8 8. Adjusting the limit switch . . Initialization . . . . . . . . . . . . . . . . . . . . .1 8. . . . . . . . . . . . . . . . . . . . . .

Refer to section 11 on Servicing explosion-protected versions. According to these mounting and operating instructions. 4 EB 8384-3 EN . trained personnel is referred to as individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training. The exhaust air opening must not be sealed when the positioner is installed on site. the operating pressure. If inadmissible motions or forces are produced in the actuator as a result of the supply pressure level. their knowledge and experience as well as their knowledge of the relevant standards. it must be restricted by means of a suitable supply pressure reducing station. 4 Proper shipping and appropriate storage are assumed. started up or operated by trained 4 4 4 and experienced personnel familiar with the product. Explosion-protected versions of this positioner may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas. Do not operate the positioner with the back of the positioner/exhaust air opening facing upwards. The declaration of conformity is available on request. Any hazards that could be caused by the process medium. the signal pressure or by moving parts of the control valve are to be prevented by means of the appropriate measures. 4 Note! The device with a CE marking fulfils the requirements of the Directives 94/9/EC (ATEX) and 89/336/EEC (EMC).Safety instructions General safety instructions 4 The positioner may only be assembled.

4581 Without Free of substances that impair painted surfaces Exhaust air with ¼ NPT connection Special versions Without IECEx 1 0 1 1 2 0 0 1 0 1 2 0 0 0 0 1 2 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 0 1 3 8 Explosion protection Without II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C acc. to ATEX Additional equipment Inductive limit switch Solenoid valve SIL 4 Without With Type SJ 2-SN Without 24 V DC 0 1 0 4 0 1 0 0 Analog Without position transmitter With External Position sensor Diagnostics Housing material Positioner for special applications Without With EXPERT EXPERT+ (extended) Aluminum Stainless steel 1. to ATEX CSA/FM intrinsically safe/non incendive II 3 G EEx na II T6 / II 3 D IP 65 T 80 °C acc.

HART tools as well as AMS or handheld communicators are currently not supported by the Revision 6 version.10 The HART protocol as per HART specification Revision 5 is supported by default setting.Firmware modification Modifications of positioner firmware in comparison to previous versions Previous 1. The position transmitter (Code 37) and solenoid valve (Code 45) options are automatically recognized.30 New EXPERT+ diagnostics functions (Code 48) added Positioner in EXPERT+ version with extended diagnostics features. 6 EB 8384-3 EN . the direction of action (Code 7) is automatically set to increasing/decreasing. The following additional status indications were implemented: Code 76 . A running initialization can be canceled by pressing the pushbutton. 1. Code 3.No emergency mode Code 77 .20 1. the activation period of the enabled configuration function was extended to 120 s. 1. no new functions added.10 1.30 1.20 Electronics changed. The setting can be changed to HART Revision 6 over TROVIS-VIEW.00 New 1.40 All EXPERT+ functions can be used over HART® communication in this firmware version and higher.Program loading error Displays number of zero calibrations performed since the last initialization. 1. For initialization of "AIR TO CLOSE" actuators.

Firmware modification The fault alarm contact is triggered by the condensed status of the positioner. values of the temperature monitoring can be reset./max. The min. If Code 32 is set to Yes: Also active with “Function check” condensed status If Code 33 is set to Yes: Also active with “Maintenance required/Maintenance demanded” condensed status The “Function check” condensed status is additionally set for Test A1. 1.41 1.41 Internal modifications 1. A2. It is always active with “Maintenance alarm” condensed status. fault alarm output and position transmitter.40 1.42 Internal modifications EB 8384-3 EN 7 .

the operation of the i/p converter (6) is changed so that the actuator (1) is filled or vented via the downstream air capacity booster (7). a coupling wheel included in the accessories is required to transfer the rotary motion for rotary actuators according to VDI/VDE 3845. Simultaneously. Instructions on how to operate the software can be found in Operating Instructions EB 8388 EN. The pneumatic air capacity booster (7) and the pressure regulator (8) are provided with supply air. The positioner basically consists of a travel sensor system that functions proportional to the resistance. The PD controller compares this actual position to the 4 to 20 mA DC control signal (reference variable) after it has been converted by the A/D converter (4). This causes the closure member of the control valve to move to the position determined by the reference variable. Refer to Data Sheet T 8388 EN for more details on EXPERT+ valve diagnostics. The volume restriction Q (10) is used to optimize the positioner by adapting it to the actuator size. Springless rotary actuators require an accessory reversing amplifier to permit the powered operation in either direction. To detect any valve faults at an early stage. Serial interface The positioner is equipped with an interface to allow the SAMSON TROVIS-VIEW Configuration and Operator Interface software to transmit data and parameters over an adapter cable from the RS-232 interface of a computer to the positioner. An intermediate flow regulator (9) with fixed settings is used to purge the positioner and also guarantees trouble-free operation of the pneumatic booster. The position of the valve is transmitted as linear travel motion or angle of rotation via pick-up lever and travel sensor (2) to an analog PD controller (3). Additionally. The positioner is designed depending on the corresponding accessories for direct attachment to Type 3277 Actuators or for attachment to actuators according to IEC 60534-6 (NAMUR). the positioner can optionally be equipped with EXPERT+ valve diagnostics. The DC control signal received from a control unit is compared to the travel or rotational angle of the control valve and issues a signal pressure (output variable y). an A/D converter (4) transmits the position of the valve to the microcontroller (5). The positioner is fitted with three binary contacts as standard: A fault alarm output is used to indicate a fault to the control station and two configurable software limit switches to indicate the valve’s end positions.Design and principle of operation 1 Design and operation principle of The electropneumatic positioner is mounted to pneumatic control valves and is used to assign the valve position (controlled variable x) to the control signal (reference variable w). You can access the functions provided by EXPERT+ valve diagnostics over TROVIS-VIEW software and over the DTM file of the device. Refer to section 13. 8 EB 8384-3 EN . an analog i/p module with downstream booster as well as the electronic unit with a microcontroller. The output signal pressure supplied by the booster can be limited over the software. In case of a system deviation.

Data are transmitted in a superimposed frequency (FSK = Frequency Shift Keying) on the existing signal loop for the 4 to 20 mA reference variable. Version with solenoid valve If the operating voltage for the solenoid valve (12) fails. 2 · Functional diagram 16 17* 18* 19 20 21 * EB 8384-3 EN 9 . an inductive limit switch or an external position sensor. the device can be additionally equipped with a solenoid valve for forced venting. 1 2 3 4 5 6 7 8 9 10 11* 12* 13* 14 15 Control valve Travel sensor PD controller A/D converter Microcontroller i/p converter Air capacity booster Pressure regulator Flow regulator Volume restriction Inductive limit switch Solenoid valve Analog position transmitter Software limit switches Alarm 1/2 Fault alarm output Alarm 3 Display Solenoid valve control Galvanic isolation D/A converter Communication interface HART modulation Optional Serial 20 Interface 21 FSK 16 mm 13 S % A3 15 19 A2 14 A1 14 w 4 5 24V DC w PD x 17 12 6 9 18 3 2 11 G G 8 7 Q 10 y 1 x Fig. an analog position transmitter.Design and principle of operation 1. the supply pressure for the i/p module is vented to the atmosphere. independent of the reference variable.2 Additional equipment The positioner is equipped with an interface for HART® protocol (Highway Addressable Remote Transducer) for communication purposes. As an option. Either a HART capable handheld communicator or a PC with FSK modem can be used to establish communication and operate the positioner.1 Communication 1. The positioner can no longer operate and the control valve moves to the fail-safe position determined by the actuator.

6 mA. Since this signal is issued independent of the positioner’s input signal (min. percentage/segmented ball valve linear/segmented ball valve eq.percentage Deviation from terminal-based conformity ≤ 1 % ≤ 0. Air quality acc.2 bar via software Linear/equal percentage/reverse equal percentage/butterfly valve linear/ butterfly valve eq.4 to 7 bar (20 to 105 psi). reverse polarity protection. The connection of x and y signals to the valve is established via cable and piping for air (only without inductive limit switch). min. user-defined adjustable over operating software Hysteresis Sensitivity 10 EB 8384-3 EN . to ISO 8573-1 (2001): Max. span 4 mA.2 V (corresponding to 410 Ω at 20 mA) Supply pressure from 1. 2-wire unit.4/3. current 3. particle size and density: Class 4 Oil content: Class 3.4 mA or >21.3 % ≤ 0.7 ±0. only the sensor is mounted to the control valve. the actual travel/angle of rotation is controlled in real-time. 1. to IEC 60534-6: 3. adjustable Travel range Reference variable w Minimum current Load impedance Supply air Signal pressure (output) Characteristic. Version with external position sensor In this version.8 mA for operation ≤ 8. The positioner is located separately from the valve. Additionally.Design and principle of operation Positioner with position transmitter The position transmitter (13) is a two-wire transmitter and issues the travel sensor signal as a 4 to 20 mA signal processed by the microcontroller. The optional inductive limit switch (11) leads to A1 and the software limit switch. leads to A2. the position transmitter provides the possibility of signaling a positioner fault over a signal current of <2. limitable to 1. Version with inductive limit switch The rotary shaft of the positioner carries an adjustable tag which actuates the installed proximity switch.8 mA).4/2.6 to 200 mm or 24° to 100° with rotary actuators Adjustable within the initialized travel/angle of rotation. 1 travel can be restricted to 5 at the maximum Signal range 4 to 20 mA. which keeps its function. static destruction limit 100 mA 3. 3.6 mA for display.6 to 30 mm Attachment acc. percentage/rotary plug valve linear/rotary plug valve eq.1 % Positioner Travel. pressure dew point: Class 3 or at least 10 K beneath the lowest ambient temperature to be expected 0 bar up to the capacity of supply pressure.3 Technical data Direct attachment to Type 3277: 3.

D.5 mn3/h. to EN 60957-5-6 Without explosion protection: Non-conducting Conductive (R = 348 Ω ) Exp. Division 1. B. B.-protected version: ≤ 1. Group A. Temperature: ≤ 0. G. reverse polarity protection. PACTware).. T6 FM/CSA non incendive Class I. E. Division 2.g. 155 Ω For handheld communicator: device description for 3730-3. at Δp = 1. C. with metal cable gland –45 to +80 °C The limits specified in the EC Type Examination Certificate additionally apply for explosion-protected devices. D.0 mn3/h. send: approx.1 mA EB 8384-3 EN 11 . Group A.g. PDM) available. to IEC 770 Complying with EN 61000-6-2. C. other integration options (e.4 bar: 3. to Specification 1. Pmax = 400 mW Exp. steady state Air output capacity Actuator pressurized Actuator vented Permissible ambient temperature Influences Electromagnetic compatability Separately adjustable up to 240 seconds for supply air and exhaust air Reversible Independent from supply pressure approx. F.2 mA ≥ 2./9000 only for connection to signal converter acc. All other versions also for connection to binary input of the PLC acc.09 at Δp = 6 bar: 14. . T6 Degree of protection Communication (local) Software requirements Communication (HART) IP 66 / NEMA 4X SAMSON SSP interface and serial interface adapter TROVIS-VIEW with database module 3730-3 HART® field communication protocol Impedance in the HART frequency range: receive 350 to 450 Ω.25 % up to 2000 Hz and 4 g acc. to EN 61131.2.2 mA Only for connection to signal converter acc. EN 61000-6-3 and NAMUR Recommendation NE 21 II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 °C or II 3 G EEx nA II T6 / II 3 D IP 65 T 80 °C Explosion protection IECEx ia IIC T6 / IP 54 and IP 65 T 80 °C FM/CSA intrinsically safe Class I. Software requirements (HART®) Binary contacts 2 software limit switches.5 mn3/h KVmax (20 °C) = 0.Design and principle of operation Transit time Direction of action Air consumption.0 mn3/h KVmax (20 °C) = 0. default settings as per table Signal status: No response: Response: 1 fault alarm contact Signal status: No response/No alarm Response/Fault alarm Operating voltage Without explosion protection: Conductive R = 348 Ω Non-conducting Positioners with model no. AMS.15 %/10 K Supply air: None Vibration: ≤ 0.1 mA ≤ 1. II. suitable for integrating the positioner in frame applications that supports the FDT/DTM concept (e. III. For PC: DTM file acc.15 –20 to +80 °C. 110 ln/h At Δp = 6 bar: 8.-protected version: ≥ 2. at Δp = 1. configurable switching characteristics.4 bar: 4. to EN 60947-5-6.

8 x 10–7 for a confidence level of 95 %. optional also for fault indication over 2. black polyamide Approx. reverse polarity protection. External position sensor Nominal travel Cable Adjustable same as positioner 10 m with M12x1 connector. to VDE 0472. Can be used in combination with a software limit switch. the limits specified in the EC Type Examination Certificate additionally apply for explosion-protected devices. to IEC 61508 24 V DC reverse polarity protection. The valves are therefore suitable for implementation in safety-related systems with a hardware fault tolerance of 1 or 2 up to and including SIL 4. reistant to oils. The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater or equal to 0. 1. static destruction limit 40 V 4 to 20 mA Reversible 0 to 100 % of the travel range.6 mA Type SJ 2SN Proximity Switch For connection to switching amplifier acc. Vibration immunity: up to 10 g in the range between 10 and 2000 Hz IP 67 Housing: Die-cast aluminum EN AC-AlSi12(Fe) (EN AC 44300) acc.99.4 mA or > 21.Design and principle of operation Solenoid valve SIL 4 approval acc. lubricants. to DIN EN 1706. U − 5.0 kg Ambient conditions Degree of protection Materials Weight 12 EB 8384-3 EN .5.4571 and 1.6 mA Linear Same as positioner Same as positioner Can be issued with current signal < 2.4581 External parts: Stainless steel 1.4 or 21.4301 Cable gland M20x1. to EN 60947-5-6. flame retardant acc.5 mA at 24 V) 4020 Ω Input Current consumption I = Signal Service life Implementation in safety-relevant systems in compliance with IEC 61508 Analog position transmitter Supply voltage Output signal Direction of action Operating range Characteristic Hysteresis and HF influence Other influences Fault indication Inductive limit switch Signal "0" no pick-up ≤ 15 V Signal "1" safe pick-up > 19 V > 5 x 106 switching cycles Probability of failure on demand of safety functions PFD < 2. static destruction limit 40 V. coolants as well as other corrosive media Permissible temperature: –60 to +105 °C. designed for continuous flexing. Two-wire transmitter 12 to 30 V DC. chromated and powder paint coated Special version: Stainless steel 1.6 V (corresponding to 4.

Attachment to the control valve – Mounting parts and accessories

2

Attachment to the control valve – Mounting parts and accessories

The positioner can be attached either directly to a SAMSON Type 3277 Actuator or according to IEC 60534-6 (NAMUR) to control valves with cast yokes or rod-type yokes as well as to rotary actuators according to VDI/VDE 3845. For attachment to the various actuators, corresponding mounting parts and accessories are required. These are listed with their order numbers in Tables 1 to 5. On attaching the positioner, it is important to observe the assignment between lever and pin position according to the travels listed in the travel tables. The tables show the maximum adjustment range at the positioner. The travel that can be implemented at the valve is restricted by the pin position used and additionally by the actuator spring compression required. The positioner is standard equipped with the lever M (pin position 35).

Note! If the standard mounted lever M (pin position 35) is replaced, the newly mounted lever must be moved once all the way as far as it will go in both directions to adapt it to the internal measuring lever.

Fig. 3 · Lever M with pin position 35

Travel table for direct attachment to Type 3277 Actuator Type 3277-5 and 3277 Actuators Actuator size cm² 120 120/240/350 700 Rated travel mm 7.5 15 30 Adjustment range at positioner Min. Travel Max. 5.0 7.0 10.0 25.0 35.4 50.0 Required lever M M M Assigned pin position 25 35 50

EB 8384-3 EN

13

Attachment to the control valve – Mounting parts and accessories

Travel table for attachment according to IEC 60534-6 (NAMUR) SAMSON valves cm² 60 and 120 with Type 3510 Valve 120 Type 3271 Actuator 120/240/350 700/1400/2800 1400/2800 1400/2800 1400/2800 Rotary actuators Rated travel mm 7.5 7.5 15 15 and 30/30 60 60 120 Other valves/actuators Min. 3.6 5.0 7.0 10.0 14.0 20.0 40.0 Travel Max. 17.7 25.0 35.4 50.0 70.7 100.0 200.0 Required lever S M M M L L XL M Assigned pin position 17 25 35 50 70 100 200 90°

Opening angle 24° to 100°

Table 1

Direct attachment to Type 3277-5 Actuator, see Fig. 4 1400-7452 1400-6819 1400-6822 1400-6820 1400-6821 1400-6823

Mounting parts For actuators with 120 cm² effective diaphragm area Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) Accessories for the actuator Connecting plate for additional attachment of a solenoid valve G 1/8 Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1/8 NPT Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new)

Note: Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates are not interchangeable.
Connecting plate (6) Accessories for the positioner Table 2 or pressure gauge bracket (7) Pressure gauge mounting kit (8) up to max. 6 bar (output/supply) G ¼: 1400-7461 G ¼: 1400-7458 St. st./Bs: 1400-6950 ¼ NPT: 1400-7462 ¼ NPT: 1400-7459 St. st./St. st.: 1400-6951

Direct attachment to Type 3277 Actuator, see Fig. 5 Mounting parts for actuators with 240, 350 and 700 cm² Required piping with screw fittings for "Actuator stem retracts" or when the top diaphragm chamber is filled with air Connection block with seals and screw Pressure gauge mounting kit up to max. 6 bar (output and supply) cm2 240 350 700 Steel 1400-6444 1400-6446 1400-6448 1400-7453 Stainless steel 1400-6445 1400-6447 1400-6449 ¼ NPT: 1400-8812 St.st/St.st.: 1400-6951

Accessories

G ¼: 1400-8811 St.st./Bs: 1400-6950

14

EB 8384-3 EN

Attachment to the control valve – Mounting parts and accessories

Table 3 Travel in mm 7.5 5 to 50 14 to 100 40 to 200 30 or 60

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 Lever S Without (lever M on basic model) L XL L For actuators Type 3271-5 with 60/120 cm² on Type 3510 Valve (Fig. 7) Actuators from other manufacturers and Type 3271 with 120 to 700 cm² Actuators f. other manufacturers and Type 3271, 1400-60 version Actuators from other manufacturers and Type 3271, versions 1400-120 and 2800 cm² with 120 mm travel Type 3271, versions 1400-120 and 2800 cm² with 30/60 mm travel Order no. 1400-7457 1400-7454 1400-7455 1400-7456 1400-7466 1400-6771

Mounting brackets for Emerson and Masoneilan linear actuators In addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above. Connecting plate Accessories or pressure gauge bracket (7) Pressure gauge mounting kit up to max. 6 bar (output/supply) Table 4 G ¼: 1400-7461 G ¼: 1400-7458

¼ NPT : 1400-7462 ¼ NPT: 1400-7459

St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951

Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 8 and 9 With follower clamp and coupling wheel, CrNiMo steel bracket VDI/VDE 3845 for all sizes of fixing level 2 for Type 3278 Actuator with 160/320 cm2 for Camflex II 1400-7448 1400-7614 1400-9120 1400-9244 1400-9526 1400-9245 ¼ NPT: 1400-7462 ¼ NPT: 1400-7459

Mounting parts

VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty version Mounting parts for rotary actuators VDI/VDE 3845 (level 1), heavy-duty version SAMSON Type 3278 160 cm² / VETEC Type S160 and Type R Connecting plate G ¼: 1400-7461 G ¼: 1400-7458 or pressure gauge bracket (7) Pressure gauge mounting kit up to max. 6 bar (output/supply)

Accessories

St.st./Bs: 1400-6950 St.st./St.st: 1400-6951

Table 5

General accessories Pneumatic reversing amplifier for double-acting actuators Cable gland M20 x 1.5 Nickel-plated brass Adapter M 20 x 1.5 to ½ NPT, aluminum G¼ ¼ NPT 1079-1118 1079-1119 1890-4875 0310-2149 1400-7460 German/English (standard) English/Spanish English/French 1990-0761 1990-3100 1990-3142 1400-9318

Accessories

Retrofit kit for inductive limit switch 1x SJ 2-SN Cover plate with list of parameters and operating instructions

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

EB 8384-3 EN

15

Attachment to the control valve – Mounting parts and accessories

2.1

Direct attachment

2.1.1 Type 3277-5 Actuator
Refer to Table 1 on page 14 for the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 13!
Actuator with 120 cm² Depending on the type of positioner attachment, the signal pressure is routed either left or right of the yoke through a bore to the actuator diaphragm. Depending on the fail-safe action of the actuator "Actuator stem extends" or "Actuator stem retracts" (valve closes or opens if the supply air fails), the switchover plate (9) must first be attached to the actuator yoke. Align the switchover plate with the corresponding symbol for left or right attachment according to the marking (view looking onto the switchover plate). 1. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges onto the positioner, making sure both seal rings (6.1) are seated properly. 2. Remove screw plug (4) on the back of the positioner and close the signal pressure output "Output 38" on the connecting plate (6) or on the pressure gauge bracket (7) with the stopper (5) included in the accessories. 3. Place follower clamp (3) on the actuator stem, align and screw tight so that the mounting screw is located in the groove of the actuator stem. 4. Mount cover plate (10) with narrow side of the cut-out opening (Fig. 4, on the 5.

6. 7.

8.

left) pointing towards the signal pressure connection. Make sure that the bonded gasket (14) points towards the actuator yoke. 15 mm travel: Keep the follower pin (2) at lever M (1) on the back of the positioner in the pin position 35 (delivered state). 7.5 mm travel: Remove the follower pin (2) from the pin position 35, reposition it in the bore for pin position 25 and screw tight. Insert formed seal (15) in the groove of the positioner casing. 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) correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch (Fig. 19). The lever (1) must rest on the follower clamp with spring force. Mount the positioner on the cover plate (10) using the two fixing screws. During the installation make sure that the seal ring (10.1) is inserted in the bore of the intermediate plate. Mount cover (11) on the other side. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off.

16

EB 8384-3 EN

Attachment to the control valve – Mounting parts and accessories

1 Symbols Actuator stem extends Attachment left Attachment right Actuator stem retracts Signal pressure input for left attachment Switchover plate (9)

Lever

1.1 Nut 1.2 Disk spring 2 3 4 5 6 Follower pin Follower clamp Screw plug Stopper Connecting plate

6.1 Seal rings 7 Pressure gauge bracket 8 Marking Signal pressure input for right attachment 9 Press. gauge mounting kit Switchover plate for actuator

10 Cover plate 10.1Seal ring 11 Cover

15 14
Lever M

14 Gasket 15 Formed seal

1 2

3 1.1 1.2
Cut-out of cover plate

4 10.1 10 6 9 11

6.1 6 5 Supply 9 Output 38

Note! Always use the connecting plate (6) included in the accessories to connect 7 supply and output. Never screw threaded parts directly 8 into the housing.

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

EB 8384-3 EN

17

2) and fit on the external signal pressure piping. 8. Mount the positioner on the cover plate (10) using the two fixing screws. 2. 5. 19).1). 7. For actuators with fail-safe action "Actuator stem retracts". for actuators with fail-safe action "Actuator stem extends" internally through a bore in the valve yoke and for "Actuator stem retracts" through external piping. Make sure that the tip of the gasket (16) projecting from the side of the connection block (12) is positioned above the actuator symbol that corresponds with the actuator with fail-safe action "Actuator stem extends" or "Actuator stem retracts. Screw it tight using the fixing screw (12. remove the three fixing screws and the cover. For actuators with 700 cm². Make sure that the bonded gasket (14) points towards the actuator yoke. 5. 1. The lever (1) must rest on the follower clamp with spring force. Mount cover plate (10) with narrow side of the cut-out opening (Fig. Note the travel table on page 13! Actuators with 240 to 700 cm² The positioner can be mounted either on the left or on the right side of the yoke.Attachment to the control valve – Mounting parts and accessories 2." If necessary. Place positioner on the cover plate in such a manner that the follower pin (2) rests on the top of the follower clamp (3). 4. Place the connection block (12) with the associated seal rings against the positioner and the actuator yoke. Mount cover (11) on the other side.1. Place follower clamp (3) on the actuator stem. on the left) pointing towards the signal pressure connection. reposition it in the bore for pin position 50 and screw tight. the follower pin (2) remains in pin position 35. For actuators 240 and 350 cm² with 15 mm travel. Insert formed seal (15) in the groove of the positioner casing. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off. 3. remove the follower pin (2) at lever M (1) on the back of the positioner from pin position 35. align and screw tight so that the mounting screw is located in the groove of the actuator stem. The previous version of the connection block (Fig. bottom) requires the switch plate (13) to be turned such that the corresponding actuator symbol points to the marking. Adjust the lever (1) correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch (Fig. Then reposition the gasket (16) turned by 180°. additionally remove the stopper (12. 5. 6.2 Type 3277 Actuator Refer to Table 2 on page 14 or the required mounting parts as well as the accessories with their order numbers. The signal pressure is routed to the actuator over the connection block (12). 18 EB 8384-3 EN .

350 and 700 cm² EB 8384-3 EN 19 .2 SUPPLY SUPPLY 13 12 Stem retracts Stem extends Marking Connection block (old) with switch plate (13) B 12 12. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240.2 Disk spring 2 Follower pin 3 Follower clamp 10 Cover plate 11 Cover 12 Connection block 15 10 14 1 2 3 11 2 Lever M Cut-out of cover plate (10) 1.2 16 A Actuator stem retracts extends 16 12 12.1 Nut 1.2 Stopper or connection for external piping 13 Switch plate 14 15 16 Gasket Formed seal Gasket 1.1 1.1 12.2 Fig.Attachment to the control valve – Mounting parts and accessories 1 Lever 12.1 12.1 Screw 12.

you must move it once all the way as far as it will go in both directions. 2. Select required lever size (1) M.Attachment to the control valve – Mounting parts and accessories 2.1). Screw the positioner to the NAMUR bracket using both its fixing screws. Align the NAMUR bracket (10) in such a way that the slot of the follower plate (3) is centrally aligned with the NAMUR bracket at mid valve travel. Note! If you have mounted a new lever (1).1) are seated properly. use two U-bolts (15) around the yoke. Place lever (1) on the positioner shaft and screw tight using the disk spring (1. 3. For attachment to valves with rod-type yokes. Screw the follower pin (2) in the assigned lever bore (pin position) as listed in the table.2) and nut (1. 3.1). place the follower plate (3) on top and use the screws (14. 7. Actuator size 2800 cm² and 1400 cm² (120 mm travel) only: For a travel of 60 mm or smaller. 6. mount the bracket (16) first and then the follower plate (3) to the bracket together with the bolts (14) and screws (14. Refer to Table 3 on page 15 for the required mounting parts as well as the accessories with their order numbers. or require a lever size L or XL. Adjust the lever (1) correspondingly. Should you require a pin position other than position 35 with the standard installed lever M. use an M8 screw (11) and toothed lock washer directly in the yoke bore. Note the travel table on page 14! 1. For a travel exceeding 60 mm. screw the longer follower plate (3.1) directly to the stem connector (9). 4. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges (8) on the positioner.1).1) of the stem connector (9).1) to tighten. L or XL and pin position according to the actuator size and valve travels listed in the table on page 14. Only use the longer follower pin (2) included in the mounting kit. Screw the two bolts (14) to the bracket (9.2 Attachment according to IEC 60534-6 The positioner is attached to the control valve with a NAMUR bracket (10). Mount NAMUR bracket (10) to the control valve as follows: For attachment to the NAMUR rib. 20 EB 8384-3 EN . making sure both seal rings (6. Place positioner on the NAMUR bracket in such a manner that the follower pin (2) rests in the slot of the follower plate (3. proceed as follows: 5.

Never screw threaded parts directly into the housing.1 6 7 8 14.1 Screw 15 U-bolt 16 Bracket Note! Always use the connecting plate (6) included in the accessories to connect supply and output.2 1 6.Attachment to the control valve – Mounting parts and accessories Attachment to rod-type yoke Rods with 20 to 35 mm Ø 11 10 9 9.1 1.1 6 6.1 7 8 9 9.1 16 Additional bracket for 2 actuators with 2800 cm and travel ≥ 60 mm 1 1 Lever XL and L 1 1.1 10 11 14 Lever Nut Disk spring Follower pin Follower plate Follower plate Connecting plate Seal rings Pressure gauge bracket Pressure gauge mounting kit Stem connector Bracket NAMUR bracket Screw Bolt 14 3 14. 6 · Attachment according to IEC 60534-6 (NAMUR) EB 8384-3 EN 21 .1 Attachment to NAMUR rib 15 3.1 2 1.2 2 3 3.1 1. Fig.

6. 4. Screw bracket (10) to the valve yoke using two screws (11). 5. Note the travel table on page 14! 1. Place lever S on the positioner shaft and screw tight using the disk spring (1. align at a right angle and screw tight. 22 EB 8384-3 EN . making sure both seal rings (6. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges to the positioner. Move lever once all the way as far as it will go in both directions. 2. 3. Unscrew the standard installed lever M (1) including follower pin (2) from the positioner shaft. Place positioner on the bracket (10) in such a manner that the follower pin slides into the groove of the clamp (3).1) are seated properly. Refer to Table 3 on page 15 for the required mounting parts as well as the accessories with their order numbers.1). Screw the positioner to the bracket (10) using both its screws.3 Attachment to Type 3510 Micro-flow Valve The positioner is attached to the valve yoke using a bracket. Place clamp (3) on the valve stem connector.Attachment to the control valve – Mounting parts and accessories 2. Adjust the lever (1) correspondingly. Take lever S (1) and screw follower pin (2) in the bore for pin position 17.2) and nut (1. 7.

1. Never screw threaded parts directly into the housing.1 2 1 8 7 Fig.1 7 8 10 11 Lever Nut Disk spring Follower pin Clamp Connecting plate Seal rings Pressure gauge bracket Pressure gauge mounting kit Bracket Screw 3 10 11 Note! Always use the connecting plate (6) included in the accessories to connect supply and output. 7 · Attachment to Type 3510 Micro-flow Valve EB 8384-3 EN 23 .2 2 3 6 6.1 Lever S 11 1.2 6 6.1 1.Attachment to the control valve – Mounting parts and accessories 1 1.

7. 2. 8 · Mounting the coupling wheel with Type 3278 24 EB 8384-3 EN .2). springless rotary actuators.1) and disk spring (4. It must be guaranteed that the lever (1) is parallel to the long side of the positioner when the actuator is at half its angle of rotation. Note! During the installation of the positioner as described below. Place positioner on the top pair of brackets (10) and screw tight. Refer to Table 4 on page 15 for the required mounting parts as well as the accessories with their order numbers.3) on the coupling wheel so that the arrow tip indicates the closed position. 9). Stick scale plate (4. Prior to the attachment of the positioner to the SAMSON Type 3278 Rotary Actuator. Screw the bottom pair of brackets (10. adjust lever (1) so that it engages in the slot of the coupling wheel (4) with its follower pin (see Fig.1 4. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges to the positioner. making sure both O-rings are seated properly. 6. and it can be easily read when the valve is installed. it is imperative that the actuator's direction of rotation be observed. Place coupling wheel (4) with flat side facing the actuator on the follower clamp (3). you have to mount the associated adapter (5) to the free end of the rotary actuator shaft. a reversing amplifier is required to attach the positioner to the actuator. Use the metal follower pin (Ø5) included in the mounting kit and screw tight into the bore for pin position 90°.Attachment to the control valve – Mounting parts and accessories 2. Refer to Fig. Unscrew the standard follower pin (2) from the positioner's lever M (1).1) with the bends pointing either to the inside or to the outside (depending on the actuator size) to the actuator case.2 5 2 3 Actuator flange Fig.2 1.4 Attachment to rotary actuators The positioner is mounted to the rotary actuator using two pairs of double brackets. Screw coupling wheel and follower clamp tightly onto the actuator shaft using screw (4. 3. 1 1. 8. see section 2. Considering the actuator's direction of rotation. Place follower clamp (3) on the slotted actuator shaft or the adapter (5). Position top pair of brackets (10) and screw tight.1 4. 9 to align slot so that it matches the direction of rotation when the valve is in its closed position.5. For double-acting. 4. 1. 5.

3 Scale plate 5 Actuator shaft Adapter for Type 3278 6. Never screw threaded parts directly into the housing.2 Disk spring 4.1 Screw 4. 8) 4 Coupling wheel 4.2 Disk spring 2 Follower pin 3 Follower clamp (Fig.2 1.1 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 10 Top pair of brackets 10.1 Nut 1. Control valve opens counterclockwise Slot Legends Figs.1 2 4.Attachment to the control valve – Mounting parts and accessories 6. 8 + 9 1 Lever 1.1 6 (7.3 Scale plate 4. 8) 10 10.1 1 1.1 Bottom pair of brackets Control valve opens clockwise Slot Fig.3 4 5 Note! Always use the connecting plate (6) included in the accessories to connect supply and output. 9 · Attachment to rotary actuators EB 8384-3 EN 25 .

Note! The sealing plug (1. 2.5. Mount the connecting plate (6) from the accessories in Table 5 to the positioner. Screw a pressure gauge bracket onto the connections A1 and Z. 10 remains unchanged.5) in the Type 3730 Positioner should not be unscrewed out of the reversing amplifier.3) from the accessories of the reversing amplifier into the boreholes of the connecting plate. 4.2) into the recess of the reversing amplifier and push both the hollowed special screws (1. which equals the required supply pressure when added to the pressure at A1. An opposing pressure. Thread the special nuts (1. Use a screwdriver (8 mm wide) to screw the enclosed filters (1.1).6) into the connecting boreholes A1 and Z. set Code 16 (Pressure limit) to OFF. Mounting 1. is applied at output A2. 26 EB 8384-3 EN . 3. Make sure that both O-rings (6. The rubber seal (1.1) are seated correctly. 6.4) is not required and can be removed when the sealing plug is used. Insert the gasket (1. Place the reversing amplifier onto the connecting plate (6) and screw tight using both the special screws (1. Pressure gauge bracket: G¼ ¼ NPT 1400-7106 1400-7107 Pressure gauges for supply air Z and output A1 as listed in Tables 1 to 4. After the initialization is completed. the positioner must be fitted with a reversing amplifier. The rule A1 + A2 = Z applies. 2.1 Pressure gauge attachment The mounting sequence shown in Fig. Signal pressure connections A1: Output A1 leading to the signal pressure connection at the actuator which opens the valve when the pressure increases A2: Output A2 leading to the signal pressure connection at the actuator which closes the valve when the pressure increases 4 Set slide switch on positioner to AIR TO OPEN. 5.5 Reversing amplifier for double-acting actuators For the use with double-acting actuators.1) into the connecting boreholes A1 and Z. The output signal pressure of the positioner is supplied at the output A1 of the reversing amplifier. The reversing amplifier is listed as an accessory in the Table 5 on page 15.Attachment to the control valve – Mounting parts and accessories 2.

2 Reversing amplifer Special screws Gasket Special nuts Rubber seal Sealing plug Filter Supply 9 Z Output 38 A1 1.3 A2 1.1 O-rings 6.4 1.3 1.5 1. 10 · Mounting a reversing amplifier EB 8384-3 EN 27 .4 1 1.1 6 6.2 1.2 Screws 6.6 Fig.1 1 1.2 1.6 1.5 1.1 1.3 1.6 6 Connecting plate 6.2 1.Attachment to the control valve – Mounting parts and accessories From the positioner Output 38 Supply 9 A1 Z A2 A1 Control signals to the actuator 1.1 1.

12 left) to the actuator diaphragm chamber. To proceed. 28 EB 8384-3 EN . 12.1 Mounting the position sensor with direct attachment Type 3277-5 Actuator with 120 cm² The signal pressure from the positioner is routed over the signal pressure connection of the connecting plate (9. In the positioner version with an external position sensor. Accessories for the pneumatic connection to the positioner housing can be found in Table 7. the sensor placed in a separate housing is attached over a plate or bracket to the control valve. 11 · Positioner unit with sensor mounted on a micro-flow valve 2.6. Make sure the seal rings (6. The positioner unit can be mounted as required to a wall or a pipe. depending on the accessory chosen.6 Attaching an external position sensor Refer to Table 6 on page 33 for a list of the mounting parts as well as the accessories required for mounting the position sensor.2 apply for the pneumatic and electrical connection. below). the instructions in section 3. For the pneumatic connection either a connecting plate (6) or a pressure gauge bracket (7) must be fixed to the housing. 4 Turn the connecting plate (9) so that the 4 4 correct symbol for the fail-safe position "Actuator stem extends" or "Actuator stem retracts" is aligned with the marking (Fig. Fig.1 and 3. Operation and setting are described in sections 4 and 5. For the electrical connection a 10 m connecting lead with M12x1 connectors plug is included.Attachment to the control valve – Mounting parts and accessories 2. first screw the connecting plate (9) included in the accessories onto the actuator yoke.1) are correctly inserted (see Fig. Seal the threaded connection that is not used with the rubber seal and square plug. 6. The connecting plate has boreholes with NPT and G threads. The travel pick-off corresponds to that of a standard device. bottom right). Fig. Make sure that the gasket for the connecting plate (9) is correctly inserted. Note! In addition.

determine the required lever and position of the follower pin (2) from the travel table on page 14. 4. Depending on the actuator size and rated travel of the valve. Screw the position sensor (20) onto the mounting plate (21). The positioner is delivered with lever M in pin position 35 on the sensor.1 1. remove the follower pin (2) from its pin position and move it to the borehole for the recommended pin position and screw tight. For the fail-safe position "Actuator stem retracts" the connection on the top diaphragm case is used. Place the lever (1) on the sensor in mid-position and hold it in place. Mounting the position sensor 1.1) and remove the lever together with the disk spring (1. 2 3 11 1.2 2 3 9 11 20 21 Lever Nut Disk spring Follower pin Follower clamp Connecting plate Cover Position sensor Mounting plate Signal pressure Symbol Actuator stem extends retracts Marking Fig.2) from the sensor shaft.2) on the sensor shaft.1 1.2 20 21 9 Signal pressure Vent plug 1 1. If necessary. 1 2. The connection at the side of the yoke must be fitted with a venting plug (accessories). Place the lever (1) and disk spring (1.Attachment to the control valve – Mounting parts and accessories Type 3277 Actuator with 240 to 700 cm²: The signal pressure is routed to the connection at the side of the actuator yoke for the version "Actuator stem extends". 12 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right) EB 8384-3 EN 29 . Unthread the nut (1. 3.

5. Mount cover (11) on the other side. 240 and 350 cm² actuators with 15 mm rated travel.6. 9 1 1.1 2. Place the lever (1) on the sensor in mid-position and hold it in place.1 20 21 2 Lever Nut Disk spring Follower pin Follower plate Stem connector Bracket Bolt Screws Position sensor Bracket Fig.1 14 14. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off. 13 · Mounting according to IEC 60534-6 (NAMUR) 30 EB 8384-3 EN .1 1.Attachment to the control valve – Mounting parts and accessories Place the lever (1) in mid-position and hold it in place. 6. 20 21 1. 2. Place the mounting plate (21) together with the sensor onto the actuator yoke so that the follower pin (2) rests on the top of the follower clamp (3). Unthread the nut (1.2) from the sensor shaft.1) and remove the lever together with the disk spring (1. refer to the order numbers listed in Tables 6 and 7 on page 33. Screw the position sensor (20) onto the bracket (21). 1. It must rest on it with spring force. Place the follower clamp (3) on the actuator stem. making sure that the fastening screw rests in the groove of the actuator stem.1 3 14 9.2 14. align and fasten it.1. The standard attached lever M with the follower pin (2) at position 35 is designed for 120.2 Mounting the position sensor with attachment according to IEC 60534-6 For the required mounting parts as well as the accessories.2 2 3 9 9. Screw on the nut (1. 1.1). 7. Screw tight the mounting plate (21) onto the actuator yoke using both fixing screws.

5.1 1. Position the bracket (21) with the position sensor on the valve yoke and screw tight. Place the lever (1) in mid-position and hold it in place. Place the lever (1) in mid-position and hold it in place. 2. 1. 4. Screw the position sensor (20) onto the bracket (21).1).1 1. Place the bracket with the sensor at the NAMUR rib in such a manner that the follower pin (2) rests in the slot of the follower plate (3).1) of the stem connector (9). Screw on the nut (1. Place the lever (1) in mid-position and hold it in place.1) and remove the standard attached lever M (1) together with the disk spring (1. Place the lever (1) and disk spring (1. 3.6. 14 · Mounting a micro-flow valve EB 8384-3 EN 31 . Place the follower clamp (3) on the stem connector.2 1 1.2) from the sensor shaft. Place the lever (1) and disk spring (1. 4. Attach the follower plate (3) and fix with the screws (14. Screw both bolts (14) to the bracket (9.3 Mounting the position sensor to Type 3510 Micro-flow Valve 20 21 1. 3. Screw on the nut (1. refer to the order numbers listed in Tables 6 and 7 on page 33. Select the lever S (1) from the accessories and screw the follower pin (2) into the hole for pin position 17.Attachment to the control valve – Mounting parts and accessories For other actuator sizes or travels. 5. 2.2) on the sensor shaft. 1 2 3 Fig. Unscrew the nut (1. align it at a right angle and screw tight.2 2 3 20 21 Lever Nut Disk spring Follower pin Follower clamp Position sensor Bracket For the required mounting parts as well as the accessories.1). making sure the follower pin (2) slides into the groove of the follower clamp (3).2) on the sensor shaft. then screw the bracket using its fixing screws onto the valve.1). Lever L and XL are included in the mounting kit. select the lever and pin position from the travel table on page 14.

1 1. refer to the order numbers listed in Tables 6 and 7 on page 33. 2.2) on the sensor shaft. Screw the position sensor (20) onto the mounting plate (21). Follow the instructions describing attachment to the standard positioner in section 2. Place the lever (1) in mid-position and hold it in place.2) from the sensor shaft.2 2 20 21 Lever Nut Disk spring Follower pin Position sensor Mounting plate Fig.4 Mounting the position sensor to rotary actuators For the required mounting parts as well as the accessories. 1.1. Unscrew the nut (1.2 1 1.1).1) and remove the standard attached lever M (1) together with the disk spring (1.4 Instead of the positioner. 1. 3. 4. 20 21 2 1 1. 15 · Positioner unit with sensor mounted on rotary actuators 32 EB 8384-3 EN .Attachment to the control valve – Mounting parts and accessories 2. Screw on the nut (1. Place the lever (1) and disk spring (1. Place the lever (1) in mid-position and hold it in place.6. attach the position sensor (20) with its mounting plate (21). Replace the follower pin (2) normally attached to the lever (1) with the metal follower pin (Ø 5) from the accessories and screw it into the hole for pin position 90°.

350 and 700 cm². see Fig. old) for Actuator Type 3277-5xxxxxx. see Fig. steel/Brass St. EB 8384-3 EN 33 .00 G 1/8 1/8 NPT Order no. see Fig. 12 left Connecting plate (9. 6 bar (output and supply) G¼ ¼ NPT G¼ ¼ NPT St. steel 1400-7471 1400-7468 1400-7469 1400-7473 1400-9384 1400-9385 Order no. see Fig. Old and new plates are not interchangeable. 13 Mounting parts for Type 3510 Micro-flow Valve. 15 VDI/VDE 3845 for all sizes of fixing level 2.st. 14 VDI/VDE 3845 for all sizes of fixing level 2 Mounting parts with follower clamp and coupling wheel CrNiMo steel bracket. heavy-duty version SAMSON Type 3278 160 cm2 / VETEC Type S160 and Type R./St. Direct attachment NAMUR attachment Attachment to micro-flow valves Mounting parts for actuators with 240. 1400-7472 1400-6820 1400-6821 1400-6823 Accessories for actuator 120 cm² Connecting plate (new) for Actuator Type 3277-5xxxxxx. lever L and XL.01 (new) Note: Only new switchover and connecting plates can be used with new actuators (Index 01).Attachment to the control valve – Mounting parts and accessories Table 6 Direct attachment Mounting parts for position sensor Mounting parts for actuators with 120 cm² see Fig. 12 right Mounting parts for attachment to NAMUR rib w. 1400-7461 1400-7462 1400-7458 1400-7459 1400-6950 1400-6951 0309-0111 Attachment to rotary actuators Bracket to mount the positioner on a wall Note! The other fastening parts are to be provided at the site of installation as wall foundations vary from site to site. heavy-duty version Table 7 Postioner accessories Connecting plate (6) or pressure gauge bracket (7) Accessories Pressure gauge mounting kit (8) up to max.

8 Air purging function for single-acting actuators Positioners with stainless steel housings require mounting parts that are completely made of stainless steel or free of aluminum. FE: The air purging function is automatically provided. An adapter available as an accessory is used for this purpose: Threaded bushing G ¼ (M20 x 1.5 connections in the housing which means just one cable gland can be installed. steel): ¼ NPT The Tables 1 to 5 (pages 14 and 15) apply for attaching positioners with stainless steel housings with the following restrictions: Direct attachment All mounting kits from Tables 1 and 2 can be used. 34 EB 8384-3 EN .Attachment to the control valve – Mounting parts and accessories 2.5): ¼ NPT 0310-2619 0310-2550 Note! The pneumatic connecting plate and pressure gauge bracket are available made of stainless steel (order numbers listed below). The connection block is not required. 5 on page 19) at the connection block and make a pneumatic connection to the spring chamber on the vented side. 240 to 700 cm² FA: Remove the stopper 12. A stainless steel version of the pneumatic reversing amplifier is not available.2 (Fig. The following must be observed: Direct attachment to Type 3277-5 (stem extends FA/stem retracts FE) The air purging function is automatically provided. Direct attachment to Type 3277. Connecting plate in stainless steel. Attachment acc. Note! The adapter uses one of the M20 x 1. The exhaust air from the positioner is diverted to the actuator spring chamber to provide corrosion protection inside the actuator. The stainless steel version of the pneumatic connecting plate routes the air internally to the actuator. Attachment to rotary actuators All mounting kits from Table 4 can be used except for the heavy-duty version.7 Attaching positioners with stainless steel housings 2. to IEC 60534-6 (NAMUR rib or attachment to rod-type yokes) and to rotary actuators The positioner requires an additional port for the exhaust air that can be connected over piping. 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 (stainless steel): G¼ ¼ NPT 1400-7476 1400-7477 1400-7108 Pressure gauge Only in bracket (st. Connecting plate in stainless steel.

quick exhaust valve). volume booster. EB 8384-3 EN 35 . solenoid valve.Attachment to the control valve – Mounting parts and accessories Should other valve accessories be used which vent the actuator (e. Otherwise the pressure in the positioner housing would rise above the ambient pressure and damage the positioner when the exhausting components respond suddenly. this exhaust air must also be included in the purging function. The connection over the adapter at the positioner must be protected with a check valve mounted in the piping.g.

depending on the actuator's fail-safe action "Actuator stem extends" or "Actuator stem retracts". the manufacturer's specifications for connection apply. die The direction of action is marked FA or FE. we recommend that pressure gauges be attached (see accessories in Tables 1 to 5). the connection of the positioner's output pressure to the actuator is fixed. the maximum signal pressure pstmax is roughly estimated as follows: d2 ⋅ π ⋅ Δp [bar] 4⋅A pstmax = F + 36 EB 8384-3 EN .1. Actuator stem extends FA (Air to open ATO) Fail-safe position "Valve Closed" (for globe and angle valves): Required supply pressure = Upper bench range value + 0.1.2 bar. Blow through all air tubes and hoses thoroughly prior to connecting them. The maintenance instructions for upstream pressure reducing stations must be observed. The customary fittings for metal and copper pipes or plastic hoses can be used. For attachment according to IEC 60534-6 (NAMUR).1 Connections Pneumatic connections 3. The air connections are optionally designed as a bore with ¼ NPT or G ¼ thread. Caution! The threads in the positioner housing are not designed for direct air connection! The screw glands must be screwed into the connecting plate. the signal pressure can be routed to either the top or bottom diaphragm chamber of the actuator. minimum 1. or by a symbol. 3. For rotary actuators. Fail-safe position "Valve Open" (for globe and angle valves): For tight-closing valves.Connections 3 3.4 bar. The bench range is registered on the nameplate either as spring range or signal pressure range depending on the actuator. Actuator stem retracts FE (Air to close ATC) Note! The supply air must be dry and free from oil and dust.2 Supply pressure The required supply air pressure depends on the bench range and the actuator's operating direction (fail-safe action). the pressure gauge mounting block or the connection block from the accessories. If the positioner is attached directly to the Type 3277 Actuator.1 Signal pressure gauges To monitor the supply air (Supply) and signal pressure (Output).

2.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.7 bar over Code 16 or the pressure limit can be deactivated (MAX). EB 8384-3 EN 37 .4 or 3.4. calculate as follows: Required supply pressure = Upper bench range value + 1 bar Note! The signal pressure at the output (Output 38) of the positioner can be limited to 1.

An additional cable gland can be installed when connecting the device over two separate cables. In Germany. the permissible maximum values specified in the EC type examination certificate apply (Ui or Uo.5 threaded bore in the housing that can be used for additional connection. The following standards apply for assembly and installation in hazardous areas: EN 60079-14: 2003 (VDE 0165 Part 1/ 8.Connections 3. 38 EB 8384-3 EN . For the interconnection of intrinsically safe electrical equipment. To run multi-core cables or lines with more than one intrinsically safe circuit.5 cable gland. Reversing the assignment of the electrical terminals may cause the explosion protection to become ineffective! Do not tamper with enameled screws inside or on the housing.99) "Electrical apparatus for use in the presence of combustible dust". Caution! The terminal assignment specified in the certificate must be adhered to. these are the VDE regulations and the accident prevention regulations of the employers' liability insurance association. The following applies for equipment connected to energy-limited circuits with type of protection EEx nL (energy-limited apparatus) according to the standard EN 50021 (1999): This type of equipment may be switched under normal operating conditions. For the interconnection of equipment to energy-limited circuits with type of protection EEx nL IIC. section 12. The following applies for equipment with type of protection EEx nA (non-sparking apparatus) according to the standard EN 50021 (1999): Connecting. Cable entries left unused must be sealed with blanking plugs. you are required to observe the relevant electrotechnical regulations and the accident prevention regulations that apply in the country of use.5 Nm.7 of this standard applies. and Li or Lo). when required. Cable entries The cable entry with M20 x 1.2.98) "Electrical apparatus for explosive gas atmospheres" and EN 50281-1-2: 1999 (VDE 0165 Part 2/11. There is a second M20 x 1.5 mm². Note on the selection of cables and wires: To install intrinsically safe circuits. observe section 12 of the standard EN 60079-14: 2003 (VDE 0165 Part 1). maintenance or repair work. Tighten by at least 0. Pi or Po. Devices used at ambient temperatures down to –20 °C must have metal cable entries. Ii or Io.2 to 2. Ci or Co.2. the permissible maximum values specified in the statement of conformity or the addenda to the statement of conformity apply. The screw terminals are designed for wire cross-sections of 0.2 Electrical connections For electrical installation. 6 to 12 mm clamping range. interrupting. or switching circuits while energized is only allowed during installation.

The position transmitter is operated on a two-wire circuit. Refer to Fig. to EN 60947-5-6 24 V DC solenoid valve mA Control signal A3 Fault indication Limit switches A2 A1 Software Software or inductive 2-wire transmitter supply unit for optional position transmitter only Fig. 1890-4875 Adapter M20 x 1. Caution! The erroneous connection of a voltage source of just around 7 V (or around 2 V when connected to the wrong pole) can damage the positioner.Connections The wires for the reference variable must be connected to the terminals 11 and 12 located in the housing. 8808-1011 Blue Order no. 16 or the label on the terminal strip for terminal assignment. 8808-1012 Nickel-plated brass Order no. this conductor can be connected inside the device. Only use a current source! If the reference variable exceeds 22 mA. Should this be required. powder-coated Order no. 16 · Electric connections EB 8384-3 EN 39 . Depending on the version. the positioner is equipped with inductive limit switches and/or a solenoid valve. In general. however. Accessories: Plastic cable gland M20 x 1. it is not necessary to connect the positioner to a bonding conductor.5: Black Order no.8 mA for operating the positioner. the voltage at the position transmitter terminals can be between 12 V and 30 V DC.5 to ½ NPT Aluminum. OVERLOAD appears on the LC display to warn the user. 0310-2149 Optional Optional A3 A2 A1 G +81 -82 +11 -12 +83 -84 +51 -52 +41 -42 +31 -32 A Switching amplifier acc. The usual supply voltage is 24 V DC. Note! The minimum permissible reference variable should not fall below 3. Considering the resistance of the supply leads.

2 Establishing communication Communication between PC and positioner (via FSK modem or handheld communicator. the relevant regulations must be observed. If the positioner is to be installed in hazardous areas. 8812-0132 If the supply voltage of the controller or control station becomes too low because it has been reduced by the load in the circuit. the amplifiers should comply with the limit values of the output circuits conforming to EN 60947-5-6. if necessary. Type Viator FSK modem RS 232 EExia Order no. 8812-0130 PCMCIA not ex Order no.2. 8812-0131 USB not ex Order no. 8812-0129 RS 232 not ex Order no.2. an isolation amplifier is to be connected between controller and positioner (interfacing Connection in non-hazardous area Handheld communicator or second FSK modem 4 to 20 mA 3730-30 Controller/control station Hazardous area Connection in hazardous area Safe area 3730-31 Controller/control station Ex isolating amplifier Handheld communicator or second FSK modem (explosion-protected) Fig.Connections 3. To ensure the operating reliability of the positioner. 3. switching amplifiers must be connected in the output circuit. using an isolation amplifier) is based on the HART protocol. 17 · Connection with a FSK modem 40 EB 8384-3 EN .1 Switching amplifiers For operation of the limit switches.

By means of the HART protocol. all control room and field devices connected in the loop are individually accessible through their address via point-to-point or standard bus (Multidrop). the positioner follows the analog current signal (reference variable) as for point-to-point communication. suitable for split-range operation of positioners (series connection). 18 · Adapting the output signal EB 8384-3 EN 41 . Point-to-point: The bus address/polling address must always be set to zero (0). for example. Note that in this case. At the Z box a voltage of 330 mV is released (16. the controller output load will increase. Standard bus (Multidrop): In the standard bus (Multidrop) mode. 22 μF 250 Ω Controller/control station Fig. the Z box (order no.Connections as for positioner connected in hazardous areas. 1170-2374) can be installed between output and communication interface. Alternatively. For adaptation. Note: Communication errors may occur when the process controller/control station output is not HART-compatible. 17). The bus address/polling address has to be within a range of 1 to 15.5 Ω at 20 mA). a 250-Ω resistor can be connected in series and a 22-μF capacitor can be connected in parallel to the analog output. see Fig. an explosion-protected isolation amplifier is to be used. If the positioner is used in hazardous areas. This operating mode is.

After an initialization has been completed. and functions. Symbols appear on the LC display that are assigned to parameters.1). the positioner display should read 0 % when the valve is closed and 100 % when the valve is open.3. codes. A leaflet including the same summary is also enclosed with the positioner. change the slide switch position and re-initialize the positioner. The bar graph in the operating modes Manual and Automatic indicates the system deviation that depends on the sign (+/–) and the value. One bar graph element appears per 1 % system deviation. Two fixed settings are possible depending on how the air is routed at the actuator (section 5. One bar graph element corresponds to approximately a 5° angle of rotation. the permissible angle of rotation has been exceeded. Slide switch AIR TO OPEN or AIR TO CLOSE 4 AIR TO OPEN applies when the increasing signal pressure opens the valve 4 AIR TO CLOSE applies when the increasing signal pressure closes the valve The signal pressure is the air pressure at the output of the positioner which is transferred to the actuator. Volume restriction Q The volume restriction is used to adapt the air delivery to the actuator size.1 Operator controls and display Rotary pushbutton The positioner is mainly operated with the rotary pushbutton. For checking purposes: After successfully completing initialization.2 in page 47). 42 EB 8384-3 EN . 4. If the fifth element blinks (value displayed > 30°). changing the switch position does not have any effect on the operation of the positioner. the lever position in degrees in relation to the longitudinal axis is indicated instead of the system deviation. parameter and values. Lever and pin position must be checked. Displays A self test is performed automatically (tEStinG runs across the display) when the positioner starts up for the first time after the electrical auxiliary power has been connected. The switch position is prompted prior to an initialization. If the device has not yet been initialized (see section 4. If this is not the case. Press it to confirm them.Operation 4 Operation Note! A summary about operating and start up can be found in section 8 on page 66. Turn the button to select and set codes. For positioners with an attached reversing amplifier for double-acting rotary actuators (section 2.5): switch position AIR TO OPEN.

Operation Displays and their meaning AUO CL CCL Err ESC HI LO LOW MAN Automatic mode Clockwise Counterclockwise Error Escape ix greater than 21.6 mA ix smaller than 2.4 mA w too low Manual mode MAX NO NOM ON OVERLOAD OFF RES RUN SAFE Maximum range Not available Nominal travel ON w > 22 mA OFF Reset Start Fail-safe position SUb tEStinG TunE YES ZP ää äæ Substitute calibration Test function active Initialization in progress Available Zero calibration Increasing/increasing Increasing/decreasing Blinking Controlled operation Blinking Not initialized Failure/fault Manual operation Control operation Code Bar graph for system deviation or lever position Designation Position Parameter Limit switch Alarm 1 Configuration enabled Initialization key Fig. 19 · Display and controls % mm Units Limit switch Alarm 2 mm S Maintenance required/ Maintenance demanded % Fail-safe position active Metal tag of proximity switch SSP interface SERIAL INTERFACE Cap or rotary switch Switch for fail-safe action of the actuator INIT CAUTION VALVE ACTUATES AIR TO OPEN CLOSE % mm mm S % Volume restriction MIN BACK MAX SIDE MAX BACK MIN SIDE Rotary pushbutton Q EB 8384-3 EN 43 .

If necessary. Now you can adjust the codes. turn the button until ESC appears on the display and press to confirm. including their description and their default settings. Configuration is enabled and is indicated by symbol appearing on the display. The code list on page 71 onwards in section 12 shows all parameters that can be adjusted. Confirm setting by pressing the button. the enabled configuration function becomes invalid and the display resets to Code 0. 4 Turn button until ON appears. For this purpose. turn the rotary pushbutton until Code 3 and OFF appear on the display. Confirm Code 3 by pressing the button. Note! After attaching the positioner to the valve as well as setting the fail-safe position and the volume restriction. 4 From the current display.Operation 4. 44 EB 8384-3 EN . it is sufficient for standard operation to press the initialization key in order to ensure optimum positioner operation (section 5. the positioner must be operated with its default values. Code 3 Configuration not enabled Note! To cancel a value that you have just entered under a code.9 on page 59).2 Enabling and selecting parameters The codes which are marked with an asterisk (*) in section 12 on page 71 onwards must be enabled with Code 3 before the associated parameters can be configured as described below. a reset must be carried out (section 5. Canceling the setting Configuration enabled Note! If no settings are entered within 120 seconds. Confirm settings by pressing the button.6 on page 49). parameters and values for the control valve in any desired order by turning the button. the code number blinks.

turn button clockwise until Code 1 appears.3. then confirm Code 1 by pressing the button. turn the button until enough the positioner has built up enough pressure and the control valve starts to react. Press button to switchover to the manual operating mode . EB 8384-3 EN 45 . the valve can be manually positioned by turning the button. The current position is displayed in %. NOM or MAN mode (section 5. Code 0 blinks.6.1). After initialization: After successful initialization in the MAX. First.Operation 4. The valve can only be positioned manually with the positioner. you can move the valve to the position required by turning the button. To proceed.1 Automatic and manual operating modes Prior to initialization: If the positioner has not been initialized yet. the automatic operating AUtO cannot be selected. you must reset the positioner to Code 0 and set it to automatic mode AUtO and confirm. Adjusting the manual set point If both the code number and the hand symbol are blinking. 4. Default % Press button to confirm. The positioner automatically returns to manual mode with Code 0 if the button is not activated within two minutes. To proceed.3 Operating modes Switching to manual operating mode Over Code 0. While Code 1 is blinking. Turn % % button until Code 1 appears. Code 1 blinks. the positioner is in the automatic control operation mode . The switchover is smooth since the manual operating mode starts up with the set point last used during automatic operating mode. press the button. AUtO appears in the display. Turn button until MAN appears. Switching from manual to automatic operating mode works in the same manner.

Apply an electrical reference variable of 4 to 20 mA (terminals 11 and 12).Start-up and settings 4. Risk of injury! Note! The positioner performs a test in the start-up phase while following its automation task at the same time. A leaflet including the same summary is also enclosed with the positioner. 46 EB 8384-3 EN . the button must be pressed while Code 0 is active. 4 Connect pneumatic supply air 4 4 S Press the button to confirm this setting.2 SAFE – Fail-safe position If you want to move the valve to fail-safe position. yet write access is restricted. Code 0 blinks. When the code number blinks. AUtO or MAN appears on the display. Turn the button until SAFE appears. the current valve position is indicated on the digital display in %. Once the positioner is initialized. (Supply 9). Operating mode SAFE has been selected.3.1. The voltage supply >19 V DC for version with a solenoid valve must be connected at terminals 81 (+) und 82 (–). If you want to return the valve from the fail-safe position to the operating mode AUtO or MAN. Caution! The valve moves to the fail-safe position. Warning! The signal pressure supplied may cause the actuator stem to move. During the start-up phase. 5 Start-up and settings Note! A summary about start-up and operation can be found in section 8 on page 66. proceed as follows: Select Code 0. turn the button to switch to the desired operating mode. symbol S for the fail-safe position appears. making sure the pressure is correct as described in section 3. operation on site is unrestricted. Press the button to confirm. press the button.

Turn button until the display is adjusted to the desired direction.g. for fail-safe position: actuator stem extends/valve closed AIR TO CLOSE = Signal pressure closes the valve.g. Note! The positioner needs to be initialized again after the position of the restriction has been changed. require a restricted air flow rate (MIN). EB 8384-3 EN 47 . then confirm reading direction by pressing the button. e. The “BACK“ position applies for actuators with a loading pressure connection at the back. After an initialization has been completed. in Type 3277-5. If the displayed data appear upside down. 5.1 Determining the fail-safe position The “SIDE”restriction position always applies for actuators from other manufacturers. for fail-safe position: actuator stem retracts/valve open.g. AIR TO OPEN = Signal pressure opens the valve. Type 3271-5.3 Adapting the display 5. Code 2 blinks. e. Reading direction for left attachment of pneumatic connections 4 The “SIDE“ position applies for actuators 4 4 with a loading pressure connection at the side. The position of volume restriction Q also depends on how the signal pressure is routed at the actuator in SAMSON actuators: 4 Turn the button until Code 2 appears.2 Setting the volume restriction Q The data representation on the positioner display can be turned by 180°. Actuators with a transit time ≥ 1 s do not require the air flow rate to be restricted (MAX). proceed as follows: Reading direction for right attachment of pneumatic connections The volume restriction Q is used to adapt the air delivery to the size of the actuator: 4 Actuators with a transit time < 1 s.Start-up and settings 5. Connection at the side Connection at the back * Intermediate positions are not permitted. e. 4 linear actuators with an effective area smaller than 240 cm². set slide switch to AIR TO OPEN or AIR TO CLOSE. Overview · Position of the volume restriction Q* Signal pressure Transit time <1s MIN SIDE MIN BACK ≥1 s MAX SIDE MAX BACK To adapt the positioner to the operating direction of the actuator. and press the button to confirm Code 2. changing the switch position does not have any effect on the operation of the positioner. The switch position is prompted prior to an initialization.

i. Code 0 Select manual operation Default MAN 3. Turn the button until Code 1 appears.4 Limiting the signal pressure If the maximum actuator force may cause damage to the valve. If this is the case.e.2 on page 44).5 Checking the operating range of the positioner To check the mechanical attachment and the proper functioning. the valve moves to the fail-safe position (see section 4. and the control valve moves to its final positions so that the travel/angle of rotation can be checked.6. Note! If the selected pin position is smaller than intended for the respective travel range.4 or 3. and the outer right or left bar graph element blinks. the valve should be moved through the operating range of the positioner in the manual operating mode with the manual reference variable.3. 48 EB 8384-3 EN . Position control valve by turning the button several times until pressure builds up.7 bar. The permissible range has been exceeded when the displayed angle is higher than 30°. manual operating mode. 5. The required signal pressure limit is only automatically recognized on initialization when the fail-safe position AIR TO OPEN is set.Start-up and settings 5. it is absolutely necessary to check lever and pin position as described in section 2. 2. then confirm Code 0 by pressing the button. Turn the button until Code 0 appears. confirm selected operating mode by pressing the button. Code 1 Position valve using the rotary pushbutton.4. Initialize positioner as described in section 5. the current angle of rotation is indicated 1. confirm Code 1 by pressing button. the positioner switches to the SAFE mode. Select Code 3 to enable configuration and then access Code 16 to set the pressure limit to 1. 4. 2. Turn the button until MAN appears in the display. The hand symbol and Code 1 blink. 5. the signal pressure must be limited.

The initialization modes described in following serve to individually adapt and optimize the positioner to the way it is attached to the valve.e. The time required for an initialization process depends on the transit time of the actuator and take several minutes. Caution! Prior to starting the initialization procedure. the positioner with its default settings is ready for operation.6. The type and extent of self-adaptation depends on the set initialization mode (see section 5. On initialization. it will automatically go to the operating mode used last after the electrical reference variable is applied.6.1). Initialization is run in default mode MAX (section 5. Note! Every time you re-initialize the positioner. check the maximum permissible supply pressure of the control valve to prevent the valve from being damaged. Refer to section 5. During this process. Code 0 appears on the display. the positioner only needs to be initialized by pressing the INIT key. MAX is the default setting for initialization based on the maximum nominal range. If the positioner has been initialized once already. 5. restrict the signal pressure by using a pressure reducing valve upstream of the control valve. the hand symbol appears on the display. Positioners with EXPERT+ diagnostic functions start plotting the reference graphs after EB 8384-3 EN 49 . After the fail-safe position and the volume restriction have been set.Start-up and settings Simplified start-up! For most applications.1). The only parameter that must be checked is the direction of action.9 on page 59. i. On initializing the positioner for the first time. Code 6 can be used to change to other initialization modes. it should be reset to its basic setting including the default values. the positioner supplies the maximum available supply pressure. If necessary. the positioner adapts itself optimally to the maximum travel/angle of rotation range. provided it has been properly attached.6 Initialization During initialization the positioner adapts itself optimally to the friction conditions and the signal pressure demand of the control valve. If configuration is enabled via Code 3. 4 Start the initialization process by pressing the INIT key with a suitable tool. whether the default setting (Code 7 to ää = increasing/increasing) matches the application or whether it must be changed.

The initialization error appears on the display according to how it has been classified by the condensed status. Further settings relevant for the valve can be entered subsequently. when all shut-off valves are closed. If the slide switch is set to AIR TO CLOSE. Note! Positioner with integrated EXPERT+ diagnostics automatically start to plot the reference graphs (drive signal y d1 and hysteresis d2) after initialization has been completed. An unsuccessful plotting of the reference graphs is indicated on the display by Code 81 (see error code list). This results in the following assignment between reference variable and valve position: Fail-safe position Actuator stem extends FA AIR TO OPEN Actuator stem retracts FE AIR TO CLOSE Direction of action ää Valve Closed at Open at 4 mA 20 mA Warning! During the initialization. % Initialization successful. Note! The initialization procedure can be interrupted while running by pressing . the control valve moves through its entire travel/angle of rotation range. StOP appears three seconds long and the positioner then moves to the fail-safe position.Start-up and settings the initialization process has been completed. Therefore. Set Code 15 (final position w>) to 99 % for three-way valves. positioner in automatic operating mode After a successful initialization. See note at the end of this section. See section 5. 50 EB 8384-3 EN . do not start initialization while a process is running.7 on page 57. the positioner automatically switches to the direction of action increasing/decreasing (äæ) on successful completion of initialization. the positioner runs in control operation indicated by the control symbol. TEST d1 and d2 appear on the display in an alternating sequence. The control position in % predetermined by the reference variable appears on the display. but only during start-up. Alternating displays Initialization running äæ 20 mA 4 mA Bar graph display indicating the progress of the initialization The tight-closing function is activated. A malfunctioning leads to the process being interrupted.

See the note on page 50. Code 5 remains disabled. . 4 Press INIT key to start initialization! The initialization procedure may take several minutes. the lower (Code 8) and the upper (Code 9) x-range value can only be displayed and modified in %.1 Initialization modes After enabling configuration with Code 3 and accessing Code 6. Note! For MAX initialization. you can choose one of the initialization modes MAX. an increased system deviation (undefined final position of the actuator) in the upper control range may occur with some control valves due to the pneumatic actuator design. press → MAX. Default OFF Turn turn → Code 3. Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. . EB 8384-3 EN 51 . press .8 on page 58.Start-up and settings After the initialization has been successfully completed. NOM. In addition. MAX – Initialization based on maximum range Initialization mode for simplified start-up for valves with two clearly defined mechanical travel stops.g. The positioner determines travel/angle of rotation of the closing member from the CLOSED position to the opposite side and adopts this travel/angle of rotation as the operating range from 0 to 100 %. the zero calibration is described in section 5. the positioner cannot indicate nominal travel/angle of rotation in mm/°. the positioner still works properly.6. even though the reference graph plotting has not been completed successfully. press . depending on the actuator size. During MAX initialization. e. The reference graphs are required for the extended diagnostic functions of EXPERT+. ZP. as the valve moves through its entire travel/angle of rotation range. three-way valves. press → ON. Enable configuration: Turn turn → Code 6. After enabling: Default MAX 5. MAN or SUb to start initialization.

Enable configuration: Default OFF Turn turn → Code 3. → Enter nominal valve travel. The lower and upper x-range values for Code 8 and 9 are displayed in mm/° and can be adapted accordingly. For this initialization mode. The calibrated sensor enables the effective valve travel to be preset very accurately. . 52 EB 8384-3 EN . press . especially for valves with maximum ranges that are clearly greater than the required nominal range. the direction of action (Code 7). if required. press . nominal travel/angle (Code 5) and.Start-up and settings If you want the display to indicate mm/°. NOM – Initialization based on nominal range Initialization mode for globe valves. the initialization is interrupted (error indication Code 52) because the nominal travel is not achieved. press . the indicated nominal range is adopted with the limits of lower x-range and upper x-range values as the operating range. the following parameters must be entered: pin position (Code 4). If you now switch to Code 5. After enabling: mm Default OFF Turn → Code 4. proceed as follows after configuration has been enabled: Turn → Code 4. mm Default 15 Turn turn press → Code 5. the positioner checks whether the control valve can move through the indicated nominal range (travel or angle) without collision. During the initialization procedure. turn → Select pin position entered during installation. press . press → ON. press . Note! The maximum possible travel must always be greater than the nominal travel entered. In case of a positive result. . the nominal range appears in mm/°. turn → Select pin position entered during installation. If this is not the case. press .

depending on the actuator size. . press . In this mode. Default MAX Turn turn → Code 0. The upper range travel/angle of rotation value is adjusted using the rotary pushbutton. press Code 1 blinks. Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. . press . press → MAN. . press → ON. EB 8384-3 EN 53 . The positioner uses this OPEN position and the CLOSED position to calculate the differential travel/angle and accepts Turn turn Turn → Code 3. press . . as the valve moves through its entire travel/angle of rotation range. See note on page 50. for starting up valves with unknown nominal range. however. MAN – Initialization based on a manually selected range (with default upper x-range value by means of manual adjustment). Default OFF 4 Press INIT key to start initialization! The initialization procedure may take several minutes. press → NOM. Default MAN Turn → Code 1. Enable configuration: Turn turn → Code 6. Initialization mode just as NOM. the positioner expects the control valve to be moved manually to the desired OPEN position prior to enabling the initialization procedure. . press . press . After enabling: → Code 4. press . press → MAN. Turn turn → Code 6 . turn → Select pin position entered during installation.Start-up and settings Default MAX it as the operating range with the lower x-range value and upper x-range value being the limits.

Turn until the valve reaches its OPEN position. subsequently the blocking position should be canceled as described on page 56. press . 4 Press INIT key to start initialization! The initialization procedure may take several minutes. After the old positioner has been replaced with a new one. The positioner switches to manual operation. direction of action (Code 7) and closing direction (Code 34). or pneumatically by means of a pres- 54 EB 8384-3 EN . nominal range (Code 5). After setting the AIR TO OPEN/CLOSE switch for the fail-safe position. In addition. setting the volume restriction and pressing the INIT key. the positioner calculates its configuration data on the basis of the blocking position and the closing direction as well as the other entered data. without initialization) This initialization mode is an emergency mode. You should always select a different initialization mode if the plant allows it. SUb (substitute configuration. The initialization mode SUb is used to replace a positioner while the process is in operation. TV (Code 18) and the pressure limit (Code 16) should remain set to their default values.Start-up and settings sure signal which is routed to the actuator externally. it is recommended to accept its KP and TV values. reset the spare positioner using Code 36. as the valve moves through its entire travel/angle of rotation range. the following parameters must be entered: pin position (Code 4). See note on page 50. the blocking position (Code 35) must be adjusted with the button so that it matches the position of the previously blocked valve. The blocking position ensures that the plant continues to operate with this valve position. If the configuration data of the new positioner are known. The positioner parameters are estimated and not determined by an initialization procedure. For this purpose. so that a high stationary accuracy cannot be expected. The parameters KP (Code 17). The default travel limit of 100 % (Code 11) must be disabled with OFF. depending on the actuator size. the control valve is usually fixed mechanically in a certain position. Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. If necessary. The spare positioner should not be initialized.

After enabling: mm Default OFF Default 100. press . press . . Default 7 Default MAX Turn Turn turn → Code 6. press . press → ON. . Retain default value for pressure limit. press . press → Select pin position entered during installation. press → SUb. change value only if necessary. → Enter nominal travel/angle. Default OFF mm Default 15 Turn Turn turn press → Code 5. press . → Code 17 Retain default. turn → Retain direction of action ää or select äæ. .Start-up and settings Enable configuration: Default ää Default OFF Turn Turn turn → Code 3. Turn turn press → Code 11.0 Turn → Code 4. → Deactivate travel limit. EB 8384-3 EN 55 . Proceed as follows only if known: Press . . → Code 7. Press . press . → Code 16. press .

e. 56 EB 8384-3 EN . Default CCL The adjusted blocking position is indicated mm Turn turn → Code 34. press turn → Enter blocking position. press .1 on page 44. . press . change only if known. Press .Start-up and settings turn press → Select KP. the error code 76 (no emergency mode) and possibly also error code 57 may appear on the display.g. OPEN or AIR TO CLOSE as described in section 5. Canceling the blocking position For the positioner to follow its reference variable again. turn in order to move the valve slightly past the blocking position. 4 Set switch for fail-safe position AIR TO 4 Set volume restriction as described in section 5.0 Turn → Code 35.2 on page 45. . Press . CCL = counterclockwise and CL = clockwise. As initialization has not been carried out completely. Direction of rotation which causes the valve to move to the CLOSED position (view onto the rotary switch movement while positioner cover is open). Default 2 Turn → Code 18. 5 mm (read off at travel indicator scale of the blocked valve or measure with a ruler). then cancel mechanical blocking. press Code 0 blinks. These alarms do not influence the positioner’s readiness for operation. the blocking position must be canceled and the positioner must be set to automatic operation AUtO as follows: Press → Code 1. . → Select closing direction. mm Default 0. Press . 4 Press INIT key! The positioner switches to manual operating mode! Retain default TV. Turn → Code 0.

EB 8384-3 EN 57 . To provide a better overview. turn the button past the Code 50.8 on page 58. If the positioner has not been initialized. if process operations allow it. the zero point must be adjusted according to section 5.Start-up and settings Turn Press until AUtO appears on the display. Zero point correction Finally. refer to the codes listed in section 12 on page 71 onwards. a signal is issued over the fault alarm contact when certain faults occur (see error code list). the gain KP (Code 17) must be decreased until the positioner shows a stable behavior. Caution! The positioner automatically moves to zero point.7 Fault/failure The positioner switches to automatic operating mode! The current valve position is indicated in %. the fault symbol appears on the display as the positioner cannot follows its reference variable. All status and fault alarms are assigned a classified status in the positioner. If the positioner still oscillates. Proceed as follows: Set TV to 4 (Code 18). The condensed status appears on the display with the following symbols: Condensed status Maintenance alarm Maintenance requested/Maintenance demanded Function check No alarm Text Display Note! If the positioner shows a tendency to oscillate in automatic operating mode. For the cause of the fault and its remedy. To access the error codes. the classified alarms are summarized in a condensed status for the positioner (see section 6). to confirm the operating mode. Additionally. Err appears on the display with the respective error code. 5. the parameters KP and TV must be slightly corrected.

.8 Display indicating an error code Zero calibration S After an error code has occurred. the positioner moves the control valve to the CLOSED position and readjusts the internal electrical zero point. 58 EB 8384-3 EN . Occurrences such as when the total valve travel is exceeded or when the temperature leaves the permissible temperature range affect the condensed state and cause a fault alarm to be displayed depending on its classification.g. . read the remedy instructions in the error code list. with soft-sealed plugs. After enabling: Default MAX Turn turn → Code 6. press . press → ON. press → ZP. The valve briefly moves from the current travel/angle of rotation position to the closed position.Start-up and settings 5. e. press . 4 Press INIT key! Zero calibration is started. . Turn turn → Code 3. this is displayed by Code 79 (see error code list). Should the error occur again. press . you should first try to confirm it as follows: Enable configuration: Turn turn → Code 3 . In case of discrepancies with the closing position of the valve. When a diagnostic alarm is issued by EXPERT+. The optional EXPERT+ diagnostics generates additional diagnostic alarms which are included in the condensed status with their corresponding status classification. then press to confirm it. it may become necessary to recalibrate the zero point. press → ON. Enable configuration: Default OFF Turn until the error code number appears.

9 Reset to default values This function resets all parameters to the factory default values (see code list in section 12). . for example. Use the TROVIS-VIEW software with 3730-3 device module installed.samson. If you have already installed the software. For start-up and settings. proceed as described in section 5. Default OFF Turn turn → Code 3.2 is available for communication. Enable configuration: 5.de (Support & Downloads TROVIS VIEW Updates).10 Start-up via local interface (SSP) The positioner must be supplied with at least 4 mA. All the positioner's parameters are then accessible over the DTM and the operator interface. . After enabling: Default OFF Turn turn → Code 36. a certain minimum version of the TROVIS-VIEW device module is required for communication. All parameters are reset and can be reconfigured. 5.11 Start-up over HART communication ® The positioner must be supplied with at least 4 mA current. Note! Depending on the firmware installed in the positioner. Refer to section 13 for more details. press . to be run with the PACTware operator interface.Start-up and settings 5. A DTM file (Device Type Manager) conforming to the Specification 1.1 to 5. press .4 and then proceed as described in section 13. The positioner can be connected directly to the PC via the local serial interface and the serial interface adapter. 5. you can download updates at www. The FSK modem must be connected in parallel to the current loop. EB 8384-3 EN 59 . This allows the device. press → RUN. press → ON.

total valve travel. etc. 6 Status and diagnostic alarms The Type 3730-3 Positioner contains an integrated diagnostic approach to generate classified status and diagnostic alarms. 6.1 Standard EXPERT diagnostics The standard EXPERT diagnostics provides information about positioner states such as operating hours counter. Alarms are classified in the following main groups: 4 Status 4 Operation 4 Hardware 4 Initialization 4 Data memory 4 Temperature 60 EB 8384-3 EN . logging of the last 30 alarms. The word "HART" then blinks on the display when Code 3 is selected. complex functions are started in the positioner. There are two different on-board diagnostics available: the standard integrated diagnostics (EXPERT) and the optional extended EXPERT+ diagnostics. The write access is enabled by default. You can only disable or enable this function locally at the positioner. In addition. which require a long calculation time or lead to a large quantity of data being stored in the volatile memory of the positioner. zero/control loop errors. proceed as described in section 5. This locking function can only be disabled over HART® communication.Status and diagnostic alarms For start-up and settings.1 to 5. Note! The write access for HART® communication can be disabled over Code 47. the alert “busy” is issued by the DTM file. the standard EXPERT diagnostics generates diagnostic and status alarms which allow faults to be pinpointed quickly when a fault occurs. initialization diagnostics. number of zero calibrations and initializations. 5. temperature. This alert is not a fault alarm and can simply be confirmed. On-site operation is enabled by default.4. The on-site operation including the INIT key can be locked over HART®communication. Note! In the case. Refer to the code list in section 12 as well as section 13. process monitoring.4 for the parameters necessary for the operator interface.

The following states are differentiated between: Maintenance alarm The positioner cannot perform its control task due to a functional fault in the device or in one of its peripherals or an initialization has not yet been successfully completed. Maintenance required The positioner still performs its control task (with restrictions).Status and diagnostic alarms 6. Additionally. Maintenance demanded The positioner still performs its control task (with restrictions). The optional diagnostic functions provided by EXPERT+ can be selected when ordering range travel range EB 8384-3 EN 61 . specifying the serial number of the positioner. the optional EXPERT+ extended diagnostics provides the following online and offline test functions which enable significant statements on the condition of the entire control valve.3 Classification of the status alarms and the condensed status 4 Data logger 4 Histogram 4 Cycle counter 4 Valve end position trend 4 Y = f (X) diagram (drive signal) 4 Hysteresis test Offline test functions (manual functions) The alarms are assigned a classification status in the positioner. Maintenance is necessary in the short term. an activation code can be ordered.2 Extended EXPERT diagnostics + In addition to the standard EXPERT diagnostic features. it is possible to activate EXPERT+ at a later point in time in an existing positioner. A maintenance demand or above average wear has been determined. Maintenance is necessary in the medium term. 4 Y = f (X) diagram over the entire valve 4 Hysteresis test over the entire valve travel 4 Static characteristic 4 Step response test The diagnostic tests are completely integrated in the positioner. The wear tolerance will soon be exhausted or is reducing at a faster rate than expected. 6. Online test functions (monitoring functions) the positioner. The wear tolerance will soon be exhausted or is reducing at a faster rate than expected. For this purpose. The required reference curves are automatically plotted after initialization and saved in the positioner if EXPERT+ is activated. Further status alarms are generated from the extensive information gained in the diagnostic tests of EXPERT+ which provide the user with information covering the whole control valve. A maintenance demand or above average wear has been determined.

Status and diagnostic alarms

Function check Test or calibration procedures are being performed. The positioner is temporarily unable to perform its control task until this procedure is completed. Classification process in the positioner An alarm is assigned to one of following classified states in the table:
Status alarm Alarm inactive Alarm active Classified as “No alarm” Alarm active Classified as “Maintenance required”/ ”Maintenance demanded” Alarm active Classified as “Function check” Alarm active Classified as “Maintenance alarm” Engineering tool

Condensed status To provide a better overview, the state of the positioner is summarized in a condensed status which is made up from a summary of all classified positioner alarms. If an event is classified as “No alarm”, this event does not have any affect on the condensed status of the positioner. The condensed status is displayed in the engineering tool as well as on the positioner display as in the following table:
Status alarm “Maintenance alarm” “Maintenance required” "Maintenance demanded” “Function check” “No alarm” Text Engineering tool Positioner display

62

EB 8384-3 EN

Status and diagnostic alarms

Status modification The classification of the status alarms can be changed as required. They can be modified using TROVIS-VIEW software over the local SSP interface. In addition, the classification can be modified over the parameters in DD or easily entered over the DTM.

Note! All additional alarms generated by EXPERT+ have the status “No alarm” by default.
Logging and displaying diagnostic functions/alarms The last 30 alarms are logged in the positioner. However, it is important to note that the same alarm is only logged once when it first occurs. The alarms and the condensed states appear on the display as described in the code list (section 12). In addition, the diagnostic parameters are issued over the communication interface of the positioner. The diagnostic functions can easily be displayed and configured using the TROVIS-VIEW software connected over the local interface (SSP) or over the DTM.

EB 8384-3 EN

63

Adjusting the limit switch

7

Adjusting the limit switch

The positioner version with inductive limit switch has one adjustable tag (1) mounted on the shaft which operates the proximity switch (3). For operation of the inductive limit switch, the corresponding switching amplifier (see section 3.2.1) must be connected to the output. If the tag (1) is inside the field of the switch, the switch assumes a high resistance. If the tag is outside of the field, the switch assumes a low resistance. Normally, the limit switch is adjusted such that it will provide a signal in both end positions of the valve. The switch, however, can also be adjusted to indicate intermediate valve positions.

The desired switching function, i.e. whether the output relay shall be picked up or released when the tag has entered the field, has to be determined, if necessary, at the switching amplifier.

Note! The inductive limit switch replaces the software limit switch A1 with terminal assignment +41/–42. Each switching position can optionally be set to indicate when the tag has entered the field, or when it has left the field. The second software limit switch remains effective, the function of the software limit switch A1 is disabled.

Adjustment screw (2)

Tag (1) Proximity switch (3)

Fig. 20 · Adjustment of the limit switch

64

EB 8384-3 EN

Adjusting the limit switch

Software adaptation Code 38 (inductive alarm is set to YES). The inductive limit switch is connected to the terminals +41/–42. The device is set up accordingly when delivered ex works SAMSON. Setting the switching point:

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 adjustment screw (2) until the tag enters or leaves the field of the proximity switch (3). You can measure the switching voltage as an indicator.

Note! During adjustment or testing, the switching point must always be approached from mid-position (50 %).
To ensure safe switching under any ambient conditions, the switching point should be adjusted to a value of approx. 5 % before the mechanical stop (OPEN – CLOSED). For CLOSED position: 1. Initialize positioner. 2. Use the MAN function to move the positioner to 5 % (see LC display). 3. Adjust the tag using the yellow adjustment screw (2) until the tag enters or leaves the field and the switching amplifier responds. You can measure the switching voltage as an indicator. Contact function: Tag leaving the field > contact is made. Tag entering the field > contact is opened.

Contact function: Tag leaving the field > Contact is made. Tag entering the field > Contact is opened.

EB 8384-3 EN

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Quick start-up guide

8 8.1

Quick start-up guide Mounting

4 Secure the positioner to the NAMUR

bracket, making sure that the follower pin is in the slot of the follower plate. Make sure the lever can still move.

Direct attachment to SAMSON Type 3277 Actuator
Travel mm 7.5 15 15/30 Actuator cm² 120 120/240/350 700 Pin position 25 35 50

Attachment to rotary actuators

4 Lever M pin position 90° 4 Put the valve into the closed position, determine the opening direction. 4 Place the follower plate on the slotted ac4

Note! Standard delivery includes lever M ready assembled with the follower pin on 35 mm pin position for 15 mm travel!
To mount the positioner, lift the lever so that the follower pin rests on the follower clamp of the actuator stem. NAMUR attachment

tuator shaft and fasten it to the coupling wheel. Attach the top pair of brackets and the bottom pair of brackets to the actuator. Place the positioner on the brackets and screw tight, making sure that the lever with its follower pin engages the slot of the coupling wheel, while taking into account the opening direction. It is important to make sure that the lever's mid position corresponds to the mid travel of the valve (lever's mid position = the lever is parallel to the long side of the positioner casing).

4 Determine the maximum travel range of 4 4 4

the control valve from the closed position to as far it will go in the other direction. Select the lever to match the maximum travel range as well the next largest pin position and screw onto the shaft of the positioner. Lever option/pin distance: see pin position table (Code 4) or cover plate on the positioner. Screw the NAMUR bracket onto the valve yoke so that it is aligned centrally to the slot of the follower plate when the travel position is at 50 %.

Pneumatic connections

4 Screw the threaded connections only into
the attached connection block, connecting plate or pressure gauge block from the accessories.

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Set the fail-safe position Position the slide switch according to fail-safe position of the control valve: AIR TO OPEN or AIR TO CLOSE. press → Display ok.Quick start-up guide 8. Connect pneumatic supply air (1. Changing the reading direction of the display (if necessary) Turn turn → Code 2. The configuration mode is shown in the display with the symbol. press . Apply an electrical reference variable (4 to 20 mA). .2 Start-up Operation Selecting the parameters or values Each parameter has a code number which is shown in the display. Enabling parameters Parameters that have a code marked with an asterisk (*) can only be changed when they are enabled beforehand using Code 3. Use the button to select. Adapt the volume restriction Q to the actuator size Only set the restriction for actuators < 240 cm² to: MIN SIDE for connection at the side or MIN BACK for connection at the back. the positioner must be re-initialized. Note! After each change of the volume restriction setting. Turn the button to select parameters or values and then push to confirm. Select and confirm ESC to prevent an entered value from being accepted.4 to 6 bar). See the code list on page 71 onwards or cover plate of the positioner for a description of the menu codes. EB 8384-3 EN 67 .

↵ → ON. ↵ → Code 36. the fault symbol appears on the display and the symbol blinks. ↵ Select pin position. → ON.1 Simplest method (MAX) Mount and start up the positioner and press the INIT key! READY! The positioner adapts itself automatically to the maximum travel/angle of rotation range of the control valve. Mount and start up the positioner.3 Initialization turn → Code 4. → select MAN. → valve open position. ↵ . then proceed as follows: Turn turn turn turn turn turn turn → Code 0. 8. ↵ . The final position of travel/angle of rotation (valve open) is entered manually. but for start-up of control valves with unknown nominal ranges. ↵ → Code 3.2 Precise method (NOM) Positioner adapts itself precisely to the nominal travel/rotational angle of the control valve! Mount and start up the positioner. ↵ turn → ON. ↵ turn turn → Code 5. ↵ Press INIT key! Note! After imposing the electrical reference variable. ↵ select NOM.3. the valve runs through its whole range of travel/angle of rotation. ↵ . ↵ Caution! During initialization.3. Code 0 appears in the display. ↵ Enter nominal travel/range.3. ↵ → Code 6. 8. 68 EB 8384-3 EN . select MAN. then proceed as follows: Turn → Code 3.3 Manual method (MAN) Initialization mode same as NOM. ↵ Press INIT key! Note! Perform a reset (Code 36) prior to each initialization Turn turn turn → Code 3. If the positioner has not yet been initialized. ↵ → Code 6. ↵ → Code 1.Quick start-up guide 8. ↵ . ↵ 8. the positioner is in the last used operating mode. ↵ select RUN.

Upgrading options 9 9. Remove the jumper at the socket ST1 of the top board and insert the cable connector (11). Make sure the flattened side of the positioner shaft is turned so that the rotary switch (5) can be attached with the metal tag next to the proximity switch. set the option "inductive alarm" under Code 38 from NO to YES. 7. the requirements in section 11 need to be kept. Push the connector (11) with cable through the opening and secure the proximity switch (7) on the cover with a dot of glue. Attach the clamping plate (8) onto the proximity switch. 21 · Retrofitting an inductive limit switch EB 8384-3 EN 69 . 1400-7460 Note! For explosion-protected devices. 6.1 Upgrading options Retrofitting an inductive limit switch 1 2 4 3 Required retrofit kit: Limit switch Order no. Insert the fixing screws (2) and screw tight. Attach the rotary switch (5). Use a knife to cut an opening at the marked location (4). 2. unthread the five fixing screws (2) and lift off the plastic cover (9). 8 7 6 9 7 Socket ST1(11) 1 2 3 4 5 Cap Screws Rotary pushbutton Marking Rotary switch 6 7 8 9 11 Metal tag Proximity switch Clamping plate Plastic cover Connector Fig. 5. 4. 5 1. Note! On start-up of the positioner. Take off the rotary pushbutton (3) and cap (1). Guide the cable in such a manner that the plastic cover can be placed back onto the positioner. 3.

Inspection by an expert is not required if the manufacturer performs a routine test on the device prior to putting it back into operation. Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future must comply with the safety demands placed on repaired devices. Plot reference curve with Code 48 → d7 Start reference run (see also Code 48 in code list). if required. There are filters with a 100 μm mesh size in the pneumatic connections for supply and output which can be removed and cleaned. The maintenance instructions of any upstream supply air pressure reducing stations must be observed. Enter the activation code in Code 48 → d8 EXPERT+ activation. Prior to operation.Maintenance 9. The passing of the routine test must be documented by attaching a mark of conformity to the device. has issued a certificate stating this or given the device a mark of conformity. Explosion-protected components may only be replaced by original. they must be tested according to the specifications stipulated for "Repairing explosion-protected devices". The required activation code is order number 1400-9318. 70 EB 8384-3 EN . If a part of the positioner on which the explosion protection is based needs to be serviced.2 Activation of optional + EXPERT diagnostics 11 Servicing explosion-protected devices The optional extended EXPERT+ diagnostics can be activated subsequently. checked components from the manufacturer. the positioner must not be put back into operation until an expert has inspected the device according to explosion protection requirements. On ordering this option. specify the serial number of the positioner (see nameplate or in the software). 10 Maintenance The positioner does not require any maintenance.

otherwise the sensor position in relation to the central axis is indicated in degrees °. codes can only read over the SSP interface. Adjust the manual set point with the rotary pushbutton. EB 8384-3 EN 71 . 0 Operating mode [MAN] AUtO SAFE ESC AUtO SAFE = Automatic mode = Fail-safe position MAN = Manual mode ESC = Escape Switchover from automatic to manual mode is smooth. Likewise. otherwise the position of the sensor in relation to the central axis is displayed in degrees °. The reading direction of the display is turned by 180°. Codes marked with an asterisk (*) can only be read and not overwritten. 1 Manual w 0 to 100 [0] % of the nominal range 2 Reading direction Normal or upside down ESC 3 Enable configuration [OFF] ON ESC Enables the option to modify data (automatically deactivated when the rotary pushbutton has not been operated for 120 s. When the positioner is initialized. values no. the current travel/angle is displayed in % when the positioner is initialized. the numerical display indicates the valve position or the angle of rotation in %. the symbol S appears on the display. In fail-safe mode. [default setting] Note! Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. In MAN and AUtO mode.Code list 12 Code list Description Code Parameter – Display. the system deviation is represented by the bar graph elements.) HART blinks on the display when the on-site operation is locked.

50 mm 70.0 7.7 20. After initialization has been successfully completed. 35.0 17 25 35 Note! 50 If you select a pin position in 70 Code 4 that is too small. the travel/angle of the closure member from the CLOSED position to the opposite stop in the actuator. the 100 positioner switches to SAFE 200 mode for reasons of safety 90° 5* Nominal range [15. a globe valve opens as the mA signal increases.0] mm or angle ° ESC For initialization using NOM or SUb. 200 mm.0 to 70.0 24.0 to 50.Code list 4* Pin position [OFF] 17. Pin position Code 4 Standard Code 5 7. NOM: Nominal range of the control valve.0 to 25.0 to 110.5 7.0 to 35. 25.0 90. the direction of action remains increasing/increasing (ää). the maximum nominal travel/angle reached on initialization is displayed.0 60.0 30. the follower pin must be inserted into the correct pin position according to the valve travel/angle of rotation.5 15.7 5. 6* Init mode [MAX] NOM MAN Sub ZP ESC 7* w/x [ää] äæ ESC 72 EB 8384-3 EN . AIR TO CLOSE: On completing initialization.0 40.0 Adjustment range Code 5 3.0 to 100.4 10. 90° with rotary actuators ESC For initialization using NOM or SUb. the nominal travel/angle of rotation of the valve must be entered.0 120.0 14. Select the initialization mode MAX: Maximum range of the control valve. the direction of action changes to increasing/decreasing (äæ ).0 to 200. The permissible adjustment range depends on the pin position according to the table. 100. a globe valve closes as the mA signal increases.0 40. MAN: Manual adjustment: upper x-range value SUb: No self-adjustment (emergency mode) ZP: Zero calibration Direction of action of the reference variable w in relation to the travel/angle of rotation x (increasing/increasing or increasing/decreasing) Automatic adaptation: AIR TO OPEN: On completing initialization. the travel/angle of the closure member measured from the CLOSED position to the indicated OPEN position.6 to 17.

Value is displayed or must be entered. If a tight-closing function has been set up. Limitation of the travel/angle of rotation downwards to the entered value. Value is displayed or must be entered. it makes sense to limit the valve travel. the valve can be opened past the nominal travel with a reference variable outside of the 4 to 20 mA range. The characteristic is adapted. The characteristic is adapted.g. for example. 0 % on the display corresponds to the set lower limit and 100 % to the set upper limit.0 [100.0 to 49. the operating range and the nominal range are identical. and the upper limit with Code 11. the characteristic is not adapted. Limitation of the travel/angle of rotation upwards to the entered value. The lower limit must be adjusted with Code 10.9 % of the operating range ESC 11* Upper x-limit [100 %] 50. See also example in Code 11. it has priority over the travel limitation! When set to OFF. The nominal range can be limited to the operating range by the lower and upper x-range values. to limit the range of a control valve which has been sized too large. if a certain minimum medium flow is required or a maximum flow must not be reached. Specified in mm or angle ° provided Code 4 is set ESC 10* Lower x-limit [OFF] 0. For this function.0 to 100. The operating range is the actual travel/angle of the control valve and is limited by the lower x-range value (Code 8) and the upper x-range value (Code 9). Usually.0 [0.0] % of the nominal range. 9* Upper x-range value 20. Example: In some applications. the characteristic is not adapted.0 to 80.0 to 120. e. the entire resolution range of the reference variable is converted to the new limits. The characteristic is not adapted to the reduced range.Code list 8* Lower x-range value 0. Specified in mm or angle ° provided Code 4 is set ESC Lower range value for the travel/angle of rotation in the nominal or operating range. Example: The operating range is modified. See also the example in Code 9! Upper range value for the travel/angle of rotation in the nominal or operating range.0 [100] % of the operating range or OFF ESC EB 8384-3 EN 73 .0] % nominal range.

25. the reference variable range 100 % = 20 mA w-end ESC Final position w < 0. the valves operate with smaller reference variables. 2. Codes 14/15 have priority over Codes 8/9/10/11.0 [100. the actuator must be vented once (e.g.0 % of the span adjusted via Code 12/13 ESC If w approaches the percentage adjusted towards the final value that causes the valve to open.0] % of the span adjusted via Code 12/13 OFF ESC If w approaches the percentage adjusted towards the final value that causes the valve to close.4 3.0 to 100. the actuator is immediately completely vented (with AIR TO OPEN) or filled with air (with AIR TO CLOSE).Code list 12* w-start 0. 13* Upper range value of the applicable reference variable range.4 ESC 2.0 [0.4. In split-range operation. and must be Δw ≥ 25 % = 4 mA. This action always lead to the valve being completely opened. The pressure limit of double-acting actuators must always be set to OFF after initialization is completed. Note: After changing a pressure limit already set. 14* 15* Final position w > [OFF] 50. that the valves move through their full travel/angle of rotation at only half the input signal (first valve set to 0 to 50 % = 4 to 12 mA and second valve set to 50 to 100 % =12 to 20 mA reference variable). The signal pressure can adopt the value of the applied supply pressure at the maximum [OFF] or it can be limited in stages of 1.0 to [1. by selecting the fail-safe position over Code 0).0] % of the reference variable range ESC Lower range value of the applicable reference variable range must be smaller than the final value w-end.7 bar 74 EB 8384-3 EN . Codes 14/15 have priority over Codes 8/9/10/11.0 to 100.0 to 75. Example: Set the final position w > to 99 % for three-way valves. for instance.7 bar. the control valve must move through its entire operating range from 0 to 100 % travel/angle of rotation. 0 % = 4 mA The reference variable range is the difference between w-end and w-start. This pressure limitation is already effective during the initialization. the actuator is immediately completely filled with air (with AIR TO OPEN) or vented (with AIR TO CLOSE).0] % of must be greater than w-start. 16* Pressure limit [OFF] 1. The control signal of the control unit to control two valves is divided such. For an adjusted reference variable range of 0 to 100 % = 4 to 20 mA. This action always lead to maximum tight-closing of the valve.4 or 3.

perc. Associated lag time [30] s is a reset criterion. during initialization. 18* TV step [2] 1 2 3 4 ESC OFF Displaying or changing TV. p. This effect decreases as the KP step increases. 9: User-defined * 19* Tolerance band 0. CAUTION! Changing the KP step influences the system deviation. a transit time is determined which is 6 times > 30 s. Should the positioner show a tendency for impermissibly high post-pulse oscillation due to additional interference. the KP and TV steps can be adapted after the initialization. the KP and TV values are optimized.0 [5] % of the operating range ESC 20* Characteristic 0 to 9 [0] ESC * Definition over SAMSON TROVIS-VIEW software or HART® communication 21* w-ramp Open 0 to 240 s [0] ESC The time required to pass through the operating range when the valve opens. the KP step can be decreased in increments.1 to 10. when the maximum value of 4 is reached. Select the characteristic: 0: Linear 1: Equal percentage 2: Reverse equal percentage 3: Butterfly valve linear 4: Butterfly valve eq. percentage 5: Rotary plug valve linear 6: Rotary plug valve eq. If. the 6fold transit time is accepted as lag time. either the TV step can be increased in increments until the desired response behavior is reached or. Used for error monitoring Determination of the tolerance band in relation to the operating range.Code list 17* KP step 0 to 17 [7] ESC Displaying or changing KP Note on changing the KP and TV steps: During the initialization of the positioner. See note under KP step A change of the TV step has no effect on the system deviation. Limitation of the transit time (Code 21 and 22): For some applications it is recommendable to limit the transit time of the actuator to prevent it from engaging too fast in the running process. 7: Segmented ball valve linear 8: Segmented ball valve eq. EB 8384-3 EN 75 . For this.

Note! The fault alarm output always switches to ≤ 1. the software limit switches both switch to ≤ 1.Code list 22* w-ramp Closed 0 to 240 s [0] ESC The time required to pass through the operating range when the valve closes.2 mA/R = 348 Ω when there is no fault.2 mA A2 ≤ 1.1 mA 1: A1 ≤ 1.1 mA A2 ≥ 2. RES ESC 24* LV total valve travel 1000 to 99 · 10 [1 000 000] 7 Limit value of total valve travel. it has ≥ 1. 76 EB 8384-3 EN . the fault symbol and the wrench symbol appear.2 mA A2 ≤ 1.2 mA A2 ≥ 2. 1) Explosion-protected version according to EN 60947-5-6 0: A1 ≥ 2. If the limit value is exceeded. 23* Total valve travel 0 to 99 · 10 [0] Exponential reading from 9999 travel cycles onwards 7 Totaled double valve travel.2 mA signal (Ex) or non-conducting (without explosion protection). Exponential reading from 9999 travel cycles onwards ESC 25* Alarm mode 0 to 3 [2] ESC Switching mode of software limit switches alarm A1 and A2 in responding state (when positioner has been initialized).2 mA 2: A1 ≥ 2.2 mA/ non-conducting in case of fault arises.1 mA 2) Version without explosion protection 0: A1 R = 348 Ω A2 Non-conducting 1: A1 Non-conducting A2 Non-conducting 2: A1 R = 348 Ω A2 R = 348 Ω 3: A1 Non-conducting A2 R = 348 Ω When a positioner has not been initialized. the software limit switches always register the signal as in the state of no response. Can be reset to 0 by Code 36 RUN.1 mA 3: A1 ≤ 1. If there is no mA signal at the terminals 11/12.

0 [98. Setting has no effect when an inductive limit switch has been installed.0 [2. If the test is activated. 27* Alarm A2 goes into the state of response when the value falls below the limit. based on the closed position. Values exceeding or falling below the limits 2.Code list 26* Limit value A1 OFF 0.0] % of the Displaying or changing the software limit value A2 in relation to the operating range. 4 mA is issued during a running self-adaptation. the position transmitter issues the value as per Code 30 during initialization or zero calibration.6 mA can be represented.6 mA or LO ix < 2.1 mA RUN3/3 RUN: Fault alarm contact A3 to ≤ 1. RUN1/1 RUN: Software limit switch A1 to ≥ 2.4 to 21. operating range Limit value A2 ESC Alarm test Reading direction: Standard [OFF] RUN 1 RUN 2 RUN 3 ESC Turned [OFF] 1 RUN 2 RUN 3 RUN ESC Testing the software limit switches alarm A1 and A2 in addition to the fault alarm contact A3. The operating range (see Code 8) of the valve is represented by the 4 to 20 mA signal. the respective limit switches five times. indicates how the travel/angle position is assigned to the output signal i.0 to 100. When NO is set in Code 32.4 mA EB 8384-3 EN 77 .6 mA). Displaying or changing the software limit value A1 in relation to the operating range.1 mA RUN2/2 RUN: Software limit switch A2 to ≥ 2.0] % of the operating range ESC Alarm A1 goes into the state of response when the value exceeds the limit.8 mA). 30* Fault alarm ix [OFF] HI ESC 3) LO Used to select whether faults causing the fault alarm contact to switch should also be signaled by the position transmitter output and how they should be signaled HI ix > 21.2 mA 28* 29* Position transmitter x/ix [ää] äæ ESC 3) Operating direction of the position transmitter. OFF 0. the power consumption of the feedback signal is effective (current approx. 1. When YES is set in Code 32 . When a positioner has not been initialized (reference variable less than 3.0 to 100.

Code list

31*

Position transmitter test

3)

–10.0 to 110.0 [default value is last indicated value of the position transmitter] % of the operating range ESC
3)

Testing the position transmitter. Values can be entered in relation to the operating range. The current actual value is used in initialized positioners locally as the start value (bumpless changeover to the test mode). On testing over software, the entered simulation value is issued as the position feedback signal for 30 seconds.

Analog position transmitter: Code 29/30/31 can only be selected if the position transmitter (optional) is installed.

32*

Fault alarm with “Function check” condensed status NO ESC [YES]

Determines whether a fault alarm is to be issued when “Function check” condensed status occurs.

33*

Fault alarm with “Maintenance alarm” or “Maintenance required” condensed status NO [YES] ESC

NO: Fault alarm only with “Maintenance alarm” condensed status YES: Fault alarm only with “Maintenance alarm” condensed status and with “Maintenance required” condensed status

34*

Closing direction CL ESC [CCL]

CL: Clockwise, CCL: Counterclockwise Turning direction in which the valve is moved to the CLOSED position (view onto the rotary switch motion when the positioner cover is open). Needs only be entered in initialization mode SUb (Code 6). Entering the blocking position. Distance up to the CLOSED position. Only necessary in initialization mode SUb. Resets all start-up parameters to default (factory setting). Note: After setting RUN, the positioner must be re-initialized. Display only, indicates whether the position transmitter option is installed. Indicates whether the inductive limit switch option is installed or not. Display only, indicates the deviation from the set point position (e = w–x).

35*

Blocking position [0] mm/° /% ESC

36*

Reset [OFF] ESC RUN

37 38*

Position transmitter Yes No Inductive alarm [NO] ESC YES

39

System deviation e info –99.9 to 999.9 % ,

78

EB 8384-3 EN

Code list

40 41 42

Transit time Open info 0 to 240 s [0] Transit time Closed info 0 to 240 s [0] Auto-w info 0.0 to 100.0 % of the span 4 to 20 mA

Display only, minimum opening time is determined during initialization Display only, minimum closing time is determined during initialization Display only, indicates the supplied automatic reference variable corresponding 4 to 20 mA. Display only, indicates the device type and the current firmware version of the positioner in alternating sequence. Display only. The control signal y is displayed in % in relation to the travel range 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. Display only, indicates whether a solenoid valve is installed. If a voltage supply is connected at the terminals of the installed solenoid valve, YES and HIGH appear on the display in alternating sequence. If a voltage supply is not connected (actuator vented, fail-safe position indicated on the display by the S symbol), YES and LOW appear on the display in alternating sequence. Select bus address

43

Firmware info Xxxx

44

y info [0] OP 0 to 100 % MAX

45

Solenoid valve info Yes No

46*

Polling address 0 to 63 [0] ESC Write protection HART YES [NO] ESC
®

47*

When the write protection function is activated, device data can only be read, but not overwritten over HART® communication.

EB 8384-3 EN

79

Code list

48

Diagnostics d d0 Current temperature –55 to 125 d1 Minimum temperature [20] d2 Maximum temperature [20] d3 Number of zero calibrations The number of zero calibrations since the last initialization. The highest temperature above 20 °C that has ever occurred. The lowest temperature below 20 °C that has ever occurred. Diagnostic parameters Operating temperature [°C] inside the positioner

d4 Number of initializations The number of initializations that have been performed. d5 Zero point limit [5 %] 0.0 to 100.0 % d6 Condensed status Limit for the zero point monitoring.

Condensed status, made up from the individual states. OK: Okay, C: Maintenance required, CR: Maintenance demanded, B: Maintenance alarm, I: Function check. Triggering of a reference run for the functions: Drive signal y steady-state and drive signal y hysteresis. The reference run can only be activated in manual operation as the valve moves through its entire travel range. If EXPERT+ is activated at later point in time, the reference graphs must be plotted in order to activate the diagnostic functions.

d7 Start reference run [OFF] ON ESC 1

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 or too low, the measuring sensor is close to its mechanical limit. • Pin positioned incorrectly. • Bracket slipped in case of NAMUR attachment or positioner is not central. • Follower plate incorrectly attached. Remedy Check attachment and pin position, set operating mode from SAFE 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 creates just an alarm. An angle below 6° leads to the initialization being canceled. 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 downwards permissible) • Mechanical or pneumatic error, e.g. wrong lever selected or supply pressure too low to move to the required position or pneumatic fault Remedy Check attachment and supply pressure. Re-initialize the positioner. Under certain circumstances, it may be possible to check the maximum travel/angle by entering the actual pin position and then performing an initialization under MAX. After initialization has been completed, the Code 5 indicates the maximum achieved travel or angle. 53 Init time > The initialization routine lasts too long. The positioner returns to its 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 was not or not properly connected so that an actuator pressure could not be built up. The message appears when you attempt to initialize the positioner. 2) If you attempt to initialize the device from the fail-safe position (SAFE). Remedy Re. 1) Check connection and supply voltage of the solenoid valve. Code 45 High/Low Re. 2) Set the MAN operating mode over Code 0. Then initialize the positioner.

55

Transit time <

The actuator transit times determined during the initialization are so 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 the pin position for the selected initialization modes NOM and SUb. Remedy Enter pin position over Code 4 and nominal travel/angle over Code 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 fault alarm contact!

Control loop error, the control valve does not react within the tolerable times of the controlled variable (tolerance band alarm Code 19). • Actuator mechanically blocked. • Attachment of the positioner subsequently postponed. • Supply pressure not sufficient.

Remedy Check attachment. 58 Zero point Zero point incorrect. Error may arise when the mounting position/linkage of the positioner moves or when the valve seat trim is worn, especially with soft-sealed plugs. Remedy Check valve and mounting of the positioner. If OK, perform a zero calibration over Code 6 (see section 5.8 on page 58). 59 Autocorrection Should an error occur in the data range of the positioner, the self-monitoring function recognizes it and automatically corrects it. Remedy Automatic

82

EB 8384-3 EN

The positioner continues to run in emergency mode. The emergency mode on the display is indicated by a blinking control symbol and 4 dashes instead of the position indication. The control valve moves to its fail-safe position. If necessary. occurs if the power source that drives the positioner does not comply with the standard. However. Remedy Cannot be remedied.Code list 60 Fatal error Additional alarm at the fault alarm contact! An error was detected in the data relevant for safety. This state is indicated on the positioner display by a blinking LOW. Hardware error (indicated on the display by the condensed status with the corresponding classification) 62 x signal Additional alarm at the fault alarm contact! Determination of the measured value for the actuator has failed. autocorrection is not possible. EB 8384-3 EN 83 . limit the current source downwards so that no values below 4 mA can be issued. Re-initialize the positioner. The positioner switches to emergency mode where the position cannot be accurately controlled anymore. Conductive plastic element is defective. Return the positioner to SAMSON AG for repair. 64 i/p converter (y) The circuit of the i/p converter has been interrupted. the positioner continues operation according to its reference variable signal so that the process remains in a safe state. This may be due to EMC disturbances. the positioner is still in a reliable state. but should be replaced as soon as possible. Note on the control: If the measuring system has failed. Remedy Return the positioner to SAMSON AG for repair. Remedy Check reference variable. 63 w too small The reference variable is much smaller than 4 mA (0 %). Remedy Reset over Code 36.

Subsequently. 71 General parameters Parameter errors that are not critical for the control. Data error 68 Control parameter Additional alarm at the fault alarm contact! Control parameter error. reset required parameters. Valve moves to the fail-safe position. Remedy Confirm error. Remedy Confirm error. 67 Test calculation Additional alarm at the fault alarm contact! The hardware positioner is monitored by means of a test calculation. If this is not successful. the device runs on default values Remedy Return the positioner to SAMSON AG for repair. Remedy Confirm error. Remedy Confirm error. If this is not possible.Code list Error appendix 65 Hardware Additional alarm at the fault alarm contact! A hardware error has occurred. when the written data deviate from the read data. 84 EB 8384-3 EN . Remedy Confirm error and return to the automatic operating mode.g. Remedy Return the positioner to SAMSON AG for repair. the positioner moves to the fail-safe position SAFE. if necessary. return the positioner to SAMSON AG for repair. 66 Data memory Additional alarm at the fault alarm contact! The writing of data to the data memory does not work anymore. Check and. 69 Poti parameter Additional alarm at the fault alarm contact! Parameter error of the digital potentiometer. return device to SAMSON AG for repair. perform reset and re-initialize the positioner. or perform a reset and re-initialize the device. 70 Calibration Additional alarm at the fault alarm contact! Error in the production calibration data. perform reset and re-initialize the positioner. e.

Remedy Confirm error. return the positioner to SAMSON AG for repair. It is not possible to make the valve leave this fail-safe position again by operating the positioner. the valve moves to the fail-safe position. 77 Program loading error Additional alarm at the fault alarm contact! When the device starts operation for the first time after the input signal has been applied. Otherwise.Code list 72 Start-up parameters Start-up parameter errors Remedy Confirm error. perform reset and re-initialize the positioner. reset required parameters. A controlled emergency mode is not available on certain actuators. Remedy Interrupt current and restart positioner. confirm. + EB 8384-3 EN 85 . For this reason. it carries out a self-test (tEStinG runs across the display). such as double-acting actuators. 76 No emergency mode The travel measuring system of the positioner has a self-monitoring function (see Code 62). the positioner checks whether the actuator has such a function or not. the positioner moves to the fail-safe position when a measuring error occurs. 75 Info parameters Error in the info parameters that are not critical for the control function. Alarms are generated in the EXPERT extended diagnostics if EXPERT+ has been successfully activated in Code 48. Check and. 74 HART parameters Error in the HART parameters that are not critical for the control function. if necessary. reset required parameters. No further action necessary. If the device loads a program that does not correspond to that of the positioner. ® Remedy Merely information. During the initialization. 73 Internal device error 1 Internal device error Remedy Return the positioner to SAMSON AG for repair. Check and. Remedy Confirm error. if necessary. if necessary. 78 79 Options parameter Diagnostic alarms Errors in options parameters.

• Reference run was interrupted • Reference line y steady-state or y hysteresis was not adopted. if necessary. Check and. Remedy Confirm error. 86 EB 8384-3 EN .Code list 80 Diagnostic parameters Error which is not critical for control. 81 Reference graphs Error on plotting the reference graphs of drive signal y steady-state or drive signal y hysteresis. start new reference run.

Enter this activation code into TROVIS-VIEW’s Activation dialog box. If the program does not start automatically. a dialog box will appear. prompting you to enter the CD key. a request code will be automatically generated. the CD-ROM usually starts the installation program automatically depending on the configuration of the operating system. Insert the installation CD-ROM to start the installation program. The TROVIS-VIEW Operator Interface can be used for different SAMSON devices. Once inserted. connect the serial interface to the serial interface (5-pole female socket) of the positioner using a SAMSON connecting cable with serial interface adapter (order no. EB 8384-3 EN 87 . Note that the installation program also offers you the option of installing a demo module. the software needs to be activated as described below: After installation. The software is now ready for use without any restrictions in the purchased scope. 1400-7700).Setting with TROVIS-VIEW software – Parameter list 13 Setting with TROVIS-VIEW software – Parameter list 13.txt file in the root directory of the CD-ROM.1 General A CD-ROM containing the program for installing the TROVIS-VIEW Configuration and Operator Interface is provided by SAMSON. To use the software without restrictions. Follow the on-screen prompts and instructions of the installation program.exe in the root directory of the CD-ROM in order to install TROVIS-VIEW. To enable communication with the PC. which you will find on the cover of the original CD-ROM. double-click setup. The system requirements are specified in the readme. The positioner settings configured in TROVIS-VIEW can be directly transferred over the SAMSON connecting cable to the positioner on site. The Activation dialog box will come up displaying the generated request code and an Internet link to SAMSON’s ac- tivation server where a unique activation code will then be generated and displayed. This online connection enables you to read any entered settings as well as providing a diagnostic function. Once you have entered the correct CD key and initiated the activation process.

open the corresponding drop-down menu.Setting with TROVIS-VIEW software – Parameter list 13.2 Starting TROVIS-VIEW and performing basic settings Settings may be entered into the TROVIS-VIEW operator interface when either the positioner is connected or not connected. To download individual parameters onto the positioner. alternatively. 88 EB 8384-3 EN . When the positioner is connected. Connection to the positioner is established by clicking the symbols on top right on the button bar: Upload data from the positioner and displayed in the operator interface Download the complete set of data from the operator interface onto the positioner. a stored TROVIS-VIEW file (*. You can also activate the listed functions in the Device menu. the default settings appear on the operator interface display or. Select Write to just download the selected parameter (see section 13. indicated by the TROVIS-VIEW 3 logo on the top right in the blue bar The positioner is in offline mode.tro) can be loaded and written over in the File menu by selecting Open. the data uploaded from the positioner can be overwritten. When the positioner is not connected.3) The positioner is in online mode.

EB 8384-3 EN 89 . 2.Setting with TROVIS-VIEW software – Parameter list 1. Right-click on the graph to edit the graph format or to copy the logged data to a file. all operating data are uploaded cyclically from the positioner in online mode and shown in the form of graphs. Start TROVIS-VIEW Make required settings in View menu by activating or deactivating functions. When the Trend Viewer is activated. The selected language can be changed at any time except in online mode. Select required language in Options menu.

4. if necessary. communication settings. 90 EB 8384-3 EN . It must match the version specified in the bar at the top. 6. Select Communication from the Options menu and choose. Select Load Factory Defaults in Edit menu to upload default settings to the operator interface. Select Convert in the File menu to select the firmware version of the positioner. Click on Port settings and select port as well as server setting. 5. 7. in Customer Data in the Edit menu. Enter more details about the plant.Setting with TROVIS-VIEW software – Parameter list 3.

Setting with TROVIS-VIEW software – Parameter list 13. EB 8384-3 EN 91 .3 Setting the parameters Click on one of the folders listed in the left column to open a window listing the settings of the corresponding parameters. Right-click on the parameter to open a drop-down menu providing further editing options. Double-click on a parameter to open a window to enable the parameter to be modified. Place the mouse arrow on the parameter name to open a tool tip providing information about that particular parameter. The parameters in all the folders are listed in the following parameter list.

xx EXPERT 0 1 January 2003 Date that can be entered.. 32 characters 92 EB 8384-3 EN .4 Parameter list Parameter Values Default setting Description Refer to section 12 for the description of the codes Tag identification of operation unit Identification – Operation unit TAG Long TAG Bus address Description Message Text field 1 to 5 Positioner serial number Positioner product number Firmware version Diagnosis level Final assembly number Date (day) Date (month) Date (year) Certification Number of preambles Required number of 5.16777215 1.31 3730-3 xxx x.Setting with TROVIS-VIEW software – Parameter list 13.. Code 43 0 Code 46 Freely available text fields Max.. Stored in the positioner Indicates whether the positioner can be used in hazardous area Number of required synchronization bytes Any number assignable to clearly identify the entire field device Serial number of the positioner Manufacturer model number of the positioner Current firmware version of device..20 preambles HART revision 5 5 5 Designates the version of the HART specification which is supported by the positioner 1900..2155 0....

0 bar 6... 3730-3 Indicates exact model designation Identification – Positioner – Valve Packing Selfadjusting Sealing of the plug stem to the atmosphere Seating surface (leakage class) Metal sealing Type of sealing between seat and plug Metal sealing/ Lapped-in metal/ Soft sealing/ Nickel sealing Without/ With (PTFE)/ With (graphite) Without Plug with pressure balancing to compensate for forces Pressure balancing EB 8384-3 EN 93 .0.0.Setting with TROVIS-VIEW software – Parameter list Identification – Positioner Device type Identification – Positioner – Actuator Type identification actuator Actuator type Attachment Booster Actuator size Signal pressure lower value Signal pressure upper value Supply pressure Type identification valve Direction of flow Flow-to-open (FTO)/ Flow-to-close (FTC) Adjustable/ Self-adjusting/ Bellows seal Single-acting Double-acting Integral/ NAMUR Not present/ present 60.5600 0..0 bar Defines the attachment of the positioner on the control valve Pneumatic volume booster Effective diaphragm or piston area of the actuator Initial value of the actuator bench range Final value of the actuator bench range Supply pressure of compressed air network Manufacturer ID number of the valve that the positioner is mounted upon Flow-to-open Indicates in which direction the process medium (FTO) flows to the valve plug.6 0..6 0...6 Manufacturer ID number of the actuator that the positioner is mounted upon Single-acting Actuator with or without spring return mechanism Integral Not present 240 cm² 0.2 bar 1..0..

perc. 30:1/ Linear 50:1/ Eq.0000 Kv/cv Linear 50:1 Valve characteristic: Flow to valve travel Valve dimensions standard Nominal size DN Kvs coefficient Kvs unit DIN 50 1.0. 20000.0001..Setting with TROVIS-VIEW software – Parameter list Flow characteristic Linear 30:1/ Eq.. metric unit (Kvs) or US American units (cv) Diameter of valve seat bore Seat diameter of the 2.500. perc.2100 0.0 mm Valve dimensions according to DIN or ANSI Nominal size in mm (DIN) or inch (ANSI) Valve flow coefficient Flow coefficient. 50:1/ Other DIN/ANSI 8.0000 Kv Kv 6....0 valve Solenoid valve Position transmitter Inductive limit switch Operation unit HART write protection Start with default settings Positioner – Operating mode Current operating mode Target operating mode Installed/ Not installed Identification – Positioner – Additional components Code 45 Not installed Code 37 Code 38 Not write protected Code 47 Code 36 Indicated the current operating mode used by the device Automatic Automatic/ Manual/Fail-safe position Code 0 Positioner – Process data Reference variable w Controlled variable x System deviation e Manipulated variable y Displays current process variables Code 42 Current position Deviation from target position (e = w–x) Indicates the control signal y in % in relation to the travel range found on initialization after the device has been initialized.. 94 EB 8384-3 EN .

The condensed status can take on the following states: No alarm Maintenance required Maintenance demanded Maintenance alarm Function check The condensed states “Maintenance required” and “Maintenance demanded” are also indicated on the positioner display by .Setting with TROVIS-VIEW software – Parameter list Status Condensed state Summarized state of the positioner. The condensed status is made up from the various states. The condensed status “Maintenance alarm” causes the fault alarm symbol to appear on the display. Fault exists (fault alarm contact) Status of limit switch A1 x falls below A1 Status of limit switch A2 x exceeds A2 Operational status Temperature Display and alarm Status of the fault alarm contact Status of the switching output for limit switch A1 Indicates whether the controlled variable x has fallen below the limit for A1 Status of the switching output for limit switch A2 Indicates whether the controlled variable x has exceeded the limit for A2 Indicates the current operational status of the internal control Current temperature in the positioner EB 8384-3 EN 95 .

..0..0 % On Code 10 Code 11 Enable travel/angle On/Off of rotation upper limit Travel/angle of 50.0.0 % w is greater Required transit time OPEN Required transit time CLOSED 0.0 % Off 100....0.12.120..0 mm range/angle of rotation range Enable travel/angle On/Off of rotation lower limit Travel/angle of rotation lower limit 0. <> Lower reference range value Upper reference range value 0..0 % 25.0 % Code 8 100.0..0 % Code 9 Off Code 10 0./decr.0 % 0.9 % 0..49.240 s Positioner – Working range 0.0..0..0 % Code 11 96 EB 8384-3 EN ..75.240 s 0.0 % 0s 0s Code 12 Code 13 Code 14 Code 14 Code 15 Code 15 Code 21 Code 22 Increasing/ Code 7 increasing >> Enable final posiOn/Off tion smaller than w Final position when 0.0 % On 1.0.0 mm Initial value of travel range/angle of rotation range Final value of travel 3.Setting with TROVIS-VIEW software – Parameter list Positioner – Reference variable Direction of action Increasing/ increasing >> Incr.9 % w is smaller Enable final posiOn/Off tion greater than w Final position when 50.0.0 % rotation upper limit 100..100...0 % 100....100.49.15..

loading and saving characteristics. reverse SAMSON butterfly valves linear eq. Segmented ball valves linear eq. User defined Characteristic type Linear Code 20 Graphs of the user-defined characteristics. perc.Setting with TROVIS-VIEW software – Parameter list Positioner – Characteristic Characteristic selection Linear Equal percentage Eq. perc. VETEC rotary plug valves linear eq. See example on the next page. perc. perc. Free text for describing the user-defined characteristic EB 8384-3 EN 97 .

• Double-click on Edit. Click on Characteristic button on the bottom right to open and save a characteristic. open or save characteristic to open a window where the characteristic can be edited.Setting with TROVIS-VIEW software – Parameter list Example for user-defined characteristic • Select User defined characteristic in Characteristic selection parameter. 98 EB 8384-3 EN .

Positioner – Error control Tolerance band Delay time 0.. A control loop error is issued when the delay time is exceeded and the system deviation is not within the tolerance band.1./high A1 Non-conduc..1).10./low A2 A1 Conducting/high Conducting/ high A2 Conduc.. In double-acting actuators./low A2 Conducting/high EB 8384-3 EN 99 .0 % 30 s Code 19 Reset criterion for running control loop monitoring. Determined during initialization by the position of the slide switch (see section 5. There is no defined position when the supply air fails..17 tional-action coefficient KP (step) Proportional-action coefficient KP (step) Required derivative-action time TV (step) Derivative-action time TV (step) Positioner – Fail-safe action Fail-safe position Closing Fail-safe action of the actuator upon air/auxiliary power failure or device start-up. the fail-safe position relates only to the failure of the auxiliary power supply./low Conducting/ A1 Non-conduc.9999 s 5.. Code 23 Code 24 Off/1/2/3/4 2 Code 17 Code 18 Code 18 Total valve travel Limit of the total valve travel Alarm mode 1000..Setting with TROVIS-VIEW software – Parameter list Parameter Values Default 7 Description Code 17 Positioner – Performance characteristics Required propor0./low high A2 Non-conduc. 990 000 000 1 1 000 000 Code 25 A1 Conducting/high A1 A2 Non-conduc..0 % 0..

The condensed states “Maintenance required” and “Maintenance demanded” are also indicated on the positioner display by .100.0 % 5.100.. fault alarm symbol to appear on the dis- 100 EB 8384-3 EN .Setting with TROVIS-VIEW software – Parameter list Enable limit value A1 Limit value A1 Enable limit value A2 Limit value A2 Fault alarm with “Function check” condensed status Fault alarm with “Maintenance alarm” or “Maintenance required” condensed status Zero point limit On/Off 0.. The condensed status “Maintenance alarm” causes the play.0 % On/Off 0.0 % No Code 26 Code 26 Code 27 Code 27 Code 32 Maintenance alarm only and Maintenance required only Maintenance Code 33 alarm 0...0 % On 98.0.0 % Limit for zero point monitoring Positioner – Error control – Classification report Condensed status error alarms Note! Each fault alarm has a status assigned to it.0.0 % Yes/No On 2.. The possible states are placed in order starting with the lowest priority: Maintenance required Maintenance demanded Maintenance alarm Function check Highest priority Lowest 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 displayed.0.100..

Setting with TROVIS-VIEW software – Parameter list x > range Delta x < range Attachment Initialization time exceeded Initialization/ solenoid valve Transit time not achieved Pin position Control loop Zero point Autocorrection x signal w too small Control parameter Poti parameter Calibration parameter General parameters Internal device error 1 HART parameter Parameter info No emergency mode Options parameter Total valve travel exceeded Temperature < –40 °C Temperature > 80 °C or symbol for function check Symbol for maintenance required and maintenance demanded Symbol Determines the individual status for each alarm with symbol an alarm is not added to the condensed status Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 57 Code 58 Code 59 Code 62 Code 63 Code 68 Code 69 Code 70 Code 71 Code 73 Code 74 Code 75 Code 76 Code 78 Determines the condensed status when a fault occurs Temperature fell below –40 °C during operation Temperature exceeded +80 °C during operation for maintenance alarm EB 8384-3 EN 101 .

the fail-safe position relates only to the failure of the auxiliary power supply. Determined during initialization by the position of the slide switch (see section 5. The initialization mode parameter must be first set to the required initialization procedure.Setting with TROVIS-VIEW software – Parameter list Positioner – Start-up Reading direction Pneumatic connection right/left Pneumatic connection right Code 2 Pin position Off Off 17/25/35/50/ 70/100/200 mm 90° Nominal range Maximum range Manual adjustment Substitution Maximum range Code 4 Initialization mode Code 6 Pressure limit Determined nominal range Minimum transit time OPEN Minimum transit time CLOSED Fail-safe action Off /2. Positioner – Start-up – Initialization Initialization mode Nominal range Maximum range Manual adjustment Substitution Device initialized Initialization Status of device initialization Starting of initialization procedure.4 bar Off Code 16 Code 5 Code 40 Code 41 Fail-safe action of the actuator upon air/auxiliary power failure or device start-up.1).4/3. There is no defined position when the supply air fails. In double-acting actuators. Maximum range Code 6 EB 8384-3 EN 102 .7/ 1.

The valve moves to fail-safe position. The control valve moves to its fail-safe position.Setting with TROVIS-VIEW software – Parameter list Initialization status Initialization canceled Target operating mode Current operating mode Initialization error x > range Delta x < range Attachment Initialization time exceeded Initialization/solenoid valve Transit time too short Pin position No emergency mode Positioner – Start-up – Substitution Initialized in Sub mode Closing direction Blocking position Positioner – Maintenance Start zero calibration Zero calibration Initialization status Initialization canceled Target operating mode Current operating mode Automatic Manual SAFE Automatic Counterclockwise 0.0 % Alarm Automatic Manual SAFE Automatic Status of the running initialization procedure Running initialization procedure has been canceled. Code 0 Indicates current operating mode of positioner EB 8384-3 EN 103 . Code 0 Indicates current operating mode of positioner Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 76 Indicates whether the substitute configuration (sub mode) has been performed Code 34 Code 35 Starts zero calibration Status of running initialization procedure Running initialization procedure has been canceled.

Device initialized Start performed with default settings Local operation active Configuration changed 104 EB 8384-3 EN . Local operation is active Status of device status bit configuration changed. Made up from various states.Setting with TROVIS-VIEW software – Parameter list Positioner – Simulation Alarm test A1 Alarm test A2 Alarm test A3 (alarm fault output) Diagnosis Diagnosis level setting Current operating mode Diagnosis – Status alarms Status Condensed status Operating hours counter Device in closed loop Device switched on since last initialization Device in closed loop since last initialization Error occurred (fault alarm output) Solenoid valve status Fail-safe position Display or status Alarm symbol Summarized condensed status. Determined during initialization. Time elapsed since first initialization Time elapsed in closed loop since first initialization Time elapsed since last initialization Expert Automatic Indicates current operating mode of positioner Code 28 Code 28 Code 28 Time elapsed in closed loop since last initialization Status of fault alarm output Status of optional solenoid valve Fail-safe action of actuator upon air supply/auxiliary power failure or device start-up. Status of device initialization Indicates whether a start has been performed with default settings.

Setting with TROVIS-VIEW software – Parameter list Number of zero calibrations Number of initializations Zero point limit Operation Control loop Zero point Autocorrection Fatal error w too small Total valve travel exceeded Temperature exceeded Hardware x-signal i/p converter Hardware Data memory Control calculation Program load error Initialization x range Delta x < range Attachment Initialization time exceeded Initialization/ solenoid valve Transit time too short Pin position No emergency mode Alarm Alarm Alarm Number of zero calibrations performed since last initialization Number of initializations performed Limit for zero point monitoring Code 57 Code 58 Code 59 Code 60 Code 63 Status of total valve travel limit Status alarm resulting from diagnosis analysis Code 62 Code 64 Code 65 Code 66 Code 67 Code 77 Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 76 EB 8384-3 EN 105 .

temperature Max. Alarm Recorded alarms issued by the positioner Operating hours counter logging of each alarm Display Lowest temperature recorded in the positioner Highest temperature recorded in the positioner Operating hours counter logging when the lowest temperature was recorded in the positioner Operating hours counter logging when the highest temperature was recorded in the positioner Alarm Code 68 Code 69 Code 70 Code 71 Code 73 Code 74 Code 75 Code 78 Code 80 106 EB 8384-3 EN . temperature Min. temperature (time) Max. temperature (time) Diagnosis – Status messages – Data logger Alarms (1) to (30) Operating hours since first initialization Diagnosis – Status alarms – Reset Reset absolute total travel Reset default values flag Reset device setting changed Resetting corresponding alarms Reset counter for absolute total valve travel back to 0 Set back default values flag to 0 Reset device status bit device setting changed.Setting with TROVIS-VIEW software – Parameter list Data memory Control parameter Poti parameter Calibration parameter General parameters Internal device error 1 HART parameter Info parameter Option parameter Diagnostic parameters Temperature Min.

Setting with TROVIS-VIEW software – Parameter list Reset initialization error Reset x > range Reset Delta x < range Reset attachment Reset initialization exceeded Reset initialization/ solenoid valve Reset transit time too short Reset pin position Reset operational error Reset zero point Reset autocorrection Reset hardware error Reset hardware Reset control calculation Reset data error Reset control parameter Reset poti parameter Reset general parameters HART parameter Reset options parameter Reset diagnostic parameters Reset statistical information Reset data logger Measured data in the data logger buffer memory are deleted Code 68 Code 69 Resetting corresponding alarms Code 71 Code 74 Code 78 Code 80 Resetting corresponding alarms Code 65 Code 67 Resetting corresponding alarms Code 58 Code 59 Resetting corresponding alarms Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 EB 8384-3 EN 107 .

108 EB 8384-3 EN .

5 34 40 58 Attachment to rotary actuators VDI/VDE 3845 for all sizes of fixing level 2 86 50 Output A1 Supply (9) 79 59 49 Connecting plate G ¼ or ¼ NPT 50 58 80 130 Reversing amplifier (option) 76 Output A2 14 80 EB 8384-3 EN 109 .Dimensions in mm 14 Dimensions in mm or connecting plate Pressure gauge bracket Attachment acc. to IEC 60534-6 External position sensor Lever mm S = 17 M = 50 L = 100 XL = 200 28 70 70 28 164 Output (38) Supply (9) A1 Z A2 Schild 15 70 46 58 34 Direct attachment 210 M20 x 1.

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SAMSON AG · MESS.samson.UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 Internet: http://www.de EB 8384-3 EN S/Z 2007-05 .

Inductive Limit Switch Type 3768 Fig. 1 ⋅ Type 3768 Mounting and Operating Instructions EB 8356 EN Edition April 2004 .

. . . . . . . 5 Technical data . . 10 . . . . .1 2. . . . . . .2 2 2. . . . . .1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting sequence . . . .2 2. . 20 Servicing explosion-protected versions . . . . . . .Contents Contents 1 1. . . . . .2 2. . . . . . . Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . 5 Attachment to control valve . . Mounting the intermediate piece . 6 . . . . . . . . . . . . . 8 . . . . . . . 4 Versions . 22 Dimensions in mm . . . . . . . . . . . . . . . .2. .1 4 5 6 Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct attachment . . . .2. .1 1. . . . 23 Test certificates . . . . . . . . . . . . . .4 3 3. . . . . . . . 18 Pneumatic connections for versions with solenoid valve . . . 6 . . . . . . . . . . . . . . . 24 2 EB 8356 EN . . . . . . . . . . . . . . . . . . .1 2. . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . 8 . . . . . . . . Attachment according to IEC 60534-6 . . . . . . . . . . . . . . 19 Operation – Adjusting the limit contacts . . .3 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical connections . . . . . . . . . . . . . .3. . . Mounting the follower roll lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . Attachment to rotary actuators . . 10 . . .3. Reversing amplifier for double-acting actuators . . . Adjusting the cam disk . . . . . . . .3 2. . 10 . . . . . .3. . . . . . . . . . . . .

EB 8356 EN 3 . their knowledge and experience as well as their knowledge of the applicable standards. this must be restricted by means of a suitable pressure reducing station. Any hazards which could be caused by the process medium. Proper shipping and appropriate storage are assumed. the signal pressure and moving parts of the control valve are to be prevented by means of appropriate measures. The declaration of conformity can be viewed and downloaded on the Internet at http://www. start-up and operation of the device may only be performed by trained and experienced personnel familiar with this product. Explosion-protected versions of this device may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas (for more details.samson.de. According to these mounting and operating instructions. refer to section 5). trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training. Note! The device with a CE marking fulfils the requirements of the Directives 94/9/EC (ATEX) and 89/336/EEC. If inadmissible motions or forces are produced in the pneumatic actuator as a result of the level of the supply air pressure.Safety instructions Assembly.

The limit switch is designed for either direct attachment to SAMSON Type 3277 Actuators or for attachment to control valves complying with IEC 60534-6 (NAMUR) by means of an adapter housing. As a result. The shaft (2) transmits the rotary motion to two adjustable tags (4) which. hence. It is equipped with inductive switching elements that issue a limit signal whenever the valve travel exceeds or falls below a certain preset limit. thus converting the linear travel into a rotary motion. The limit switch is also available with a solenoid valve which is used to move the control valve to fail-safe position. operate the associated proximity switches (5). When a control signal which corresponds to the binary signal 0 (OFF) is applied to the input.1 2 3 Lever Pin Shaft Spring 4 5 6 7 Tag Proximity switch Adjustment screw Pressure regulator Fig. Version with solenoid valve The solenoid valve is used to move the control valve to its fail-safe position regardless of the output signal issued by the control unit.Design and principle of operation 1 Design and principle of operation The Type 3768 Limit Switch is designed for attachment to pneumatic control valves. the springs installed in the actuator force the valve to move to its fail-safe position. resulting in activation of the control valve. 7 3 2 1 1. the signal pressure pst is shut off and the actuator vented. The limit signal is transmitted to an alarm or indicating unit. 2 ⋅ Functional diagram 4 EB 8356 EN .1) to the lever (1). The operation of the inductive limit switches requires that switching amplifiers be connected in the output circuit (see section 3). especially when the valve has reached one of its end positions. the valve position is transmitted via the pin (1. Whereas a control signal corresponding to the binary signal 1 (ON) causes the signal pressure pst to be transmitted to the actuator. The valve travel and. in return.1 supply u[V] pst 6 4 5 1 1.

4 to 6 bar (20 to 90 psi) 6 V DC ≤1.14 m3/h Closing time for For rated travel and signal pressure range Type 3277 Actuator cm2 0. DC signal at +80 °C Maximum permissible signal Coil resistance Ri at 20 °C Air consumption in steady state.2 V ≥5. to IEC 60534-6: 5.2 Technical data Travel range 2 proximity switches Differential gap Degree of protection Perm.5 s ≤2.5 s 120 Direct attachment: 7.4 to 2 bar 0. ambient temp.Technical data 1.1 Versions Model Without Ex II 2 G EEx ia IIC T6 acc.5 to 30 mm. DC signal at –25 °C Signal 1 (safe pick-up).5 s 700 ≤4 s ≤8 s ≤5 s "Off" ≤60 ln/h. EMC Solenoid valve Nominal signal Signal 0 (no pick-up) . Kvs= 0.4 V ≥9.6 V 25 V 5832 Ω 240 ≤1 s ≤2 s ≤1 s 24 V DC ≤4.5 black Plug connector HAN 7D (not with CSA/FM) Explosion protection 37680 1 3 8 0 2 3 4 0 1 2 1 2 4 2 0 0 1. filter check valve) –20 to +80 °C Requirements as per EN 50081/50082 are met Input Air supply Binary DC signal Supply air 1. ATEX Ex ia FM/CSA Ex II 3 G EEx nA II T6 acc.5 blue M20 x 1.7 V ≥18 V 32 V 11714 Ω 350 ≤1. Control circuit: values must match the downstream switching amplifiers ≤1% at rated travel IP 65 w/o solenoid valve. angle of rotation: 0-90° Type SJ 2-SN. Attachment acc.4 V 28 V 2909 Ω 12 V DC ≤2.2 to 1 bar 0. IP 54 with solenoid valve (special version IP 65 w.5 s ≤1.5 to 120 mm. ATEX Solenoid valve Without 6 V DC 12 V DC 24 V DC Pneumatic connections Without 1/4-NPT ISO 288/1-G 1/4 Electrical connections M20 x 1. "On" ≤10 ln/h EB 8356 EN 5 .6 to 3 bar ≤0.

1. Combined with an intermediate piece. 5. Reposition the gasket (16) turned by 180°. The additionally required mounting parts are listed together with their order numbers in the tables on pages 16 and 17. Screw the associated lever D1 or D2 to the lever of the limit switch. 240 to 700 cm2 actuators 1. the ready-to-use signal pressure line must be additionally mounted. 4. The old connection block version requires the switch plate (13) to be turned such that the corresponding actuator symbol points to the marking. Remove the M3 screw plug at the back of the limit switch and insert the plug included in the accessories in the lateral signal pressure output ("output 38"). Screw the clamp (1. 3. Make sure that the tip of the gasket (16) projecting from the side of the adapter block (Fig. 6 EB 8356 EN . the limit switch can also be mounted on rotary actuators. Any subsequent changes of the mounting position change the switching function of the limit switch. Mount the limit switch so that the bore in the distance plate (15) covers the seal in the bore of the actuator yoke.1) of the clamp (1.Attachment to control valve 2 Attachment to control valve The limit switch can be attached either directly to a SAMSON Type 3277 Actuator or to control valves with cast yokes or rod-type yokes according to IEC 60534-6 (NAMUR). Align the switchover plate with the corresponding actuator symbol and screw tight. Please also note the instructions in section 4. 2. Make sure the fastening screw rests in the groove of the actuator stem. Both are listed in Table 2 and 3 (page 16). The limit switch may be mounted on the lefthand or right-hand side of the control valve. use an adapter block or a switchover plate. 2. The standard limit switch is delivered without accessories. 2.2). remove the three fixing screws and the cover.2) to the actuator stem. 3. Attachment of versions with solenoid valve To establish the signal pressure connection to the actuator. middle) is positioned to match the actuator symbol for the actuator’s fail-safe action "Actuator stem extends" or "Actuator stem retracts". 120 cm2 actuators The signal pressure is transmitted to the diaphragm chamber via the switchover plate. Position the limit switch such that the lever D1 or D2 slides in line over the pin (1. For versions "Actuator stem retracts". 3. Mount cover (18). 2. Place the adapter block with its O-rings between the limit switch and the actuator yoke and secure using the fastening screw.1 Direct attachment 1. If this is not the case. Secure the distance plate (15) together with the gasket facing towards the actuator yoke.

3 ⋅ Direct attachment – Mounting of bracket.Attachment to control valve Type 3277 18 1.2 D2 D1 Adapter block only for version with solenoid valve 15 View onto the signal pressure connection < Attachment left Attachment right> Actuator stem < extends retracts > Signal pressure connection < internal over pipe connection > With switch plate (old) SUPPLY Side view of adapter block with gasket (new) Symbol for actuator stem extends retracts Tip of gasket (16) Cover plate Marking Actuator stem retracts extends Switch plate (13) Type 3277-5 with 120 cm2 Signal pressure input for right attachment Clamp Signal pressure input for left attachment Symbol for actuator stem retracts extends Marking Switchover plate only for version with solenoid valve 15 Fig. signal pressure connection EB 8356 EN 7 .

4. Screw the plate (20) to the carrier of the plug stem. Screw the studs (29) into the adapter housing. The clip must clasp the pin (19). Make sure that the lever (18) to be mounted subsequently is in horizontal position when the valve is at midtravel. Control valve with cast yoke: 1.Attachment to control valve 2. you require an adapter housing. For 2100 and 2800 cm2 actuator versions. The rated travel of the control valve determines which lever must be used. Move the valve to 50 % travel. Screw the plate (20) to the stem connector of the actuator and plug stem using the countersunk screws. Screw the pin (19) into the center row of holes on the plate (20) and lock it in a position above the correct lever marking (1 to 2). 2. 2. must the clip be clamped onto the lever with the open side pointing downwards. 6. Control valve with rod-type yoke: 1. Clamp the clip (21) onto the lever (18).2. The valve travel is transmitted via the lever (18) and shaft (25) to the bracket (28) of the adapter housing and then passed on to the pin (27a) located on the limit switch lever. use an additional mounting bracket (32). 5. 2. Adjust the shaft (25) in the adapter housing so that the black pointer (24) meets the cast mark on the adapter housing. Attach the lever (18) including clamping plate (22) to the shaft (25).2 Attachment according to IEC 60534-6 For limit switch attachment according to NAMUR. You can attach the limit switch either to the left or to the right of the control valve. 2.2 Presetting the travel 1. as indicated in Table 5. 4.2. 3. 2. Screw in the pin (27a) at the limit switch lever on the side of the press nut and lock with a hex nut (27b) on the other side. Screw the clamping plate (22) tight in this position using the screw (23). 3.1 Mounting sequence Choose the required mounting parts from Tables 4 and 5 on pages 16 and 17. Remove the rubber plug from inside the adapter housing and fasten the housing to the left or right side of the Namur rib using a hexagon screw. Place the housing with the mounting plate (30) on either the right or left side of the valve stem and screw tight using nuts (31). Only when connecting versions with solenoid valve and air connection pointing to the front. For the limit switch attachment you require the mounting parts listed in Table 4. Observe the mounting posi- 8 EB 8356 EN .

5 2 24 25 22 23 19 21 20 18 32 18 19 20 21 22 23 24 25 26 27a 27b 28 29 30 31 32 Lever N1. 4 ⋅ Attachment according to NAMUR (shown for attachment to the left side) EB 8356 EN 9 .Attachment to control valve 27b Mounting position A B 26 27a 28 Attachment to NAMUR rib 1 1. N2 Pin Plate Clip Clamping plate Screw Pointer Shaft Lever positioner Pin Lock nut Bracket Studs Plate Nuts Mounting bracket Attachment to rods 31 29 30 20 19 Fig.

Caution! The pin must not slip out of the bracket once installed.3. Align the cam disk and scale as described in section 2. make sure that you place the intermediate piece in such a manner that the air connections of the limit switch point towards the side of the diaphragm case. Actuators according to VDI/VDE 3845 1. to VDI/VDE 3845) and screw tight. 44 and 45) onto the mounting bracket included in the scope of actuator delivery (fixing level 1 acc. For this purpose. Place the entire intermediate piece (34. Screw the adapter (36) to the free end of the rotary actuator’s shaft.Attachment to control valve tion A or B according to Table 5 and Fig.3. you require the accessories and mounting parts listed in Table 6 on page 17. 2. 42.3. Place the limit switch on the adapter housing. 10 EB 8356 EN . 2. Secure with the supplied screws (38) and washers. The rotary motion of these actuators is transferred to the metal tags via the cam disk installed on the actuator shaft and a follower roll on the limit switch lever. 2. 2. Place the follower roll lever (35) on the side where the transmission lever (37) is located (opposite of the press nuts).3 Attachment to rotary actuators You have the possibility of attaching the limit switch to rotary actuators according to VDI/VDE 3845.1 Mounting the follower roll lever 1. Make sure that the pin (27a) rests against the bracket (28). For versions with solenoid valve. 2.2 Mounting the intermediate piece SAMSON Type 3278 Actuator 1. and fasten with screws. observing the operating direction. 5.3. 3.3. 4. Align the cam disk (40) and scale as described in section 2.3 and fasten with screws. Screw intermediate piece (34) with two screws to the actuator case.

Attachment to control valve 33 Attachment to SAMSON Type 3278 37 35 38 Attachment acc. 5 ⋅ Attachment to rotary actuators EB 8356 EN 11 . to VDI/VDE 3845 39 40 Vent plug or filter check valve 39 40 34 34 36 44 45 33 34 35 36 37 38 39 40 41 42 43 44 45 Limit switch Intermediate piece Lever with follower roll Adapter Transmission lever Screws Scale Cam disk Actuator shaft Disk Mounting bracket Coupling Seal 42 43 Fig.

Securing the aligned cam disk To additionally prevent the cam disk from being turned. whether it opens clockwise or counterclockwise. When aligning the cam disk. Select the suitable bore to secure. Four bore holes are available on the cam disk.3. The starting point (bore) of the cam must be positioned so that the fulcrum of the cam disk and the 0°-position on the scale as well as the arrow on the inspection glass form a horizontal line. and they are located centrically around the center bore hole.e.Attachment to control valve 2. drill a hole into the adapter (36) or the coupling (44) and install a 2 mm dowel pin.3 Adjusting the cam disk The adjustment of the cam disk depends on the valve’s direction of rotation. the doublesided scale disk must be clipped on the cam disk in such a way that the value on the scale matches the control valve’s direction of rotation. Secure the cam disk using the fastening screw. 12 EB 8356 EN . i. Important! Starting position is the closed valve.

6 ⋅ Adjusting the cam disk Control valve opens clockwise 60˚ 90˚ 90˚ ˚ 60 EB 8356 EN 13 .Attachment to control valve Follower roll Starting point Starting point 30 ˚ 0˚ 0˚ ˚ 30 Insert clip and press the tongues outwards Control valve opens counterclockwise Fig.

Place the reversing amplifier onto the limit switch and screw tight using the two special screws (1. is supplied at output A2.3) included in the accessories of the reversing amplifier into the threaded connections of the limit switch. 3. Screw the special nuts (1.1). Assembly Important! Remove the sealing plug (1.4 Reversing amplifier for double-acting actuators Limit switches fitted with solenoid valves which are intended for use with double-acting actuators must be equipped with a reversing amplifier.3. 1.1) into the connecting bore holes A1 and Z.4) must remain installed. 2.2) into the recess of the reversing amplifier and push the two hollowed special screws (1. The reversing amplifier is listed as an accessory in Table 7 on page 21. The rubber seal (1. Signal pressure connections A1: Connect output A1 to the signal pressure connection on the actuator that opens the valve when the pressure increases. The output signal pressure of the solenoid valve is supplied at output A1 of the reversing amplifier. A2 : Connect output A2 to the signal pressure connection on the actuator that closes the valve when the pressure increases. An opposing pressure. A1 + A2 = Z applies. 14 EB 8356 EN .5) before installing the reversing amplifier.Reversing amplifier for double-acting actuators 2. which equals the required supply pressure when added to the pressure at A1. Insert the gasket (1.

Reversing amplifier for double-acting actuators

From the limit switch

Output 38

Supply 9

A1

Z

A2

To the actuator

1.3 1.1 1.2 1.4 1.5 A2
1 1.1 1.2 1.3 1.4 1.5 Reversing amplifier Special screws Gasket Special nuts Rubber seal Sealing plug

A1

Vent plug or filter check valve

Supply 9

Z

Output 38

A1

1.3 1.2
Fig. 7 ⋅ Mounting a reversing amplifier

1.1

1

EB 8356 EN

15

Mounting parts table

Table 1

Direct attachment (Fig. 3)

Actuator size cm2 120 240 and 350 700 Actuator Type 3277-5xxxxxx. 00 (old) Actuator with index 3277-5xxxxxxxx. 00 (old) Actuator with index . 01or higher (new) G 1/8 1/8 NPT .01or higher (new)

Attachment kit Order no. 1400-6790 1400-6791 1400-6370 1400-6371 Order no. 1400-6819 1400-6822 1400-6820 1400-6821 1400-6823

Required lever with associated clamp and distance plate D1 with sealing plug for output (38) for version with solenoid valve G 1/4 1/4 NPT

D1 (33 mm long with 17-mm high bracket) D2 (44 mm long with 13-mm high bracket) Table 2 (only for versions with solenoid valve) Switchover plate for 120 cm2 actuators Switchover plate new Connection plate for additional attachment of, e.g. a solenoid valve Connection plate new

Note! Only new switchover and connecting plates can be used for new actuators (index 01). Old and new plates are not interchangeable. Required connection block for 240, 350 and 700 cm2 actuator (including seals and mounting screws) Table 3 (only for version with solenoid valve) Required tube connection including screw joint For actuator: Actuator stem retracts or when filling the top diaphragm chamber with air Accessories Pressure gauge mounting kit for supply air and signal pressure Actuator size in cm2 240 240 350 350 700 700 G 1/4 1/4 NPT Material Steel Stainless steel Steel Stainless steel Steel Stainless steel Stainless steel/Br SS/SS 1400-8811 1400-8812 Order no. 1400-6444 1400-6445 1400-6446 1400-6447 1400-6448 1400-6449 1400-6950 1400-6951 1790-7408

Filter check valve, replaces the vent plug and raises the degree of protection to IP 65

16

EB 8356 EN

Mounting parts table

Table 4 Attachment IEC 60534-6 (Fig. 4) NAMUR attachment kit Parts, see Fig. 4

Control valve Valve with cast yoke 20 to 25 20 to 25 25 to 30 25 to 30 30 to 35 30 to 35

Travel in mm 7.5 to 60 22.5 to 120

With lever N1 (125mm) N2 (212 mm) N1 N2 N1 N2 N1 N2

Order no. 1400-6787 1400-6789 1400-6436 1400-6437 1400-6438 1400-6439 1400-6440 1400-6441

Valve with rodtype yoke with rod diameter mm

Attachment to Fisher and Masoneilan linear actuators (one each of both attachment kits are required per actuator) Accessories (w. sol. valve) Press. gauge mount. block Press. gauge mount. kit for supply and signal pressure G 1/4: St. steel/brass: 1400-7098 1400-6950

1400-6771and 1400-6787 1/4 NPT: St. st./st. st.: 1400-7099 1400-6951 1790-7408

Filter check valve, replaces the vent plug and raises the degree of protection to IP 65 Table 5 Attachment acc. to IEC 60534-6 Travel in mm *) Pin on lever marking *) Distance between pin/lever fulcrum With lever Transmission pin (27a) in position
*)

7.5 1 42

15 2 84

15 1 42

30 2 84

30 1 42

60 2 84

30 1 84

60 2 168

60 1 84

120 2 168

N1 (125 mm long) A A B

N2 (212 mm long) A B

Interpolate intermediate values Rotary actuator for mounting parts (Fig. 5) 160 cm2 1400-7103 Camflex I DN 25...100 1400-7118 320 cm2 1400-7104 Camflex I DN 125...250 1400-7119 VDI/VDE 3845 1400-7105 Camflex II 1400-7120 1400-6664 1079-1118 1079-1119 1400-6950 1400-6951 1790-7408

Table 6 Order no.

SAMSON Type 3278 Actuator

Attachment Masoneilan Order no.

Cam disk with accessories cam disk, linear characteristics (0050-0072) angle of rotation 0 to 90° Reversing amplifier (Fig. 7) for double-acting springless actuators G threaded connection NPT threaded connection Accessories (only for versions with solenoid valves) Press. gauge mount. kit for supply air and signal pressure Stainless steel/brass Stainless steel/st. steel

Filter check valve, replaces the vent plug and raises the degree of protection to IP 65

EB 8356 EN

17

Electrical connections

3 Electrical connections
As far as the electrical installation of the device is concerned, the relevant national regulations governing the installation of electrical equipment and the national accident prevention regulations of the country of destination must be adhered to. In Germany, these are the VDE regulations and accident prevention regulations of the employer’s liability insurance. For installation in hazardous areas, the following standards apply: EN 60079-14: 1997; VDE 0165 Part 1/8.98 "Electrical apparatus for explosive gas areas" and EN 50281-12: VDE 0165 Part 2/11.99 "Electrical apparatus for use in the presence of combustible dust". For intrinsically safe electrical apparatus that are certified according to the Directive 79/196/EEC, the data specified in the certificate of conformity apply for connection of intrinsically safe circuits. For intrinsically safe electrical apparatus that are certified according to the Directive 94/9/EC, the data specified in the EC type examination certificate apply for connection of intrinsically safe circuits. Note: It is absolutely necessary to keep to the terminal plan specified in the certificate. Reversal of the electrical connections may cause the explosion protection to be ineffective! Do not tamper with any painted screws inside or on the case.

Switching amplifier To operate the inductive limit switches, switching amplifiers complying with EN 60947-5-6 must be connected in the output circuit. When the limit switch is installed in hazardous areas, you are required to observe the relevant regulations. Note on the selection of cables and wires! To run several intrinsically-safe circuits in a multi-core cable, observe paragraph 12 of EN 60079-14; VDE 0165/8.98 standards. Note especially that for commonly used insulating materials, such as polyethylene, the radial thickness of the conductor insulation must be minimum 0.2 mm. The diameter of a single wire of a flexible conductor must not be smaller than 0.1 mm. The conductor ends must be protected against unlaying, e.g. by using wire end ferrules. Any unused openings on the limit switch must be closed with plugs. Devices used in ambient temperatures down to −40 °C must be fitted with metal cable glands.

For the terminal assignment, refer to Fig. 8 or to the label on the terminal strip.

18

EB 8356 EN

Pneumatic connections for versions with solenoid valve

Accessories: Model code 3768-x...x. 03 and lower Cable gland PG 13.5: Black Order no. 1400-6781 Blue Order no. 1400-6782 Adapter PG 13.5 on 1/2" NPT: Metallic Order no. 1400-7109 Blue finish Order no. 1400-7110 Model code 3768-x...x. 04 and higher Cable gland M20 x 1.5: Black Order no. 1400-6985 Blue Order no. 1400-6986 Nickel-plated brass Order no. 1400-4875 Adapter M20 x 1.5 on 1/2" NPT: Aluminum powder-coated Order no. 0310-2149

3.1 Pneumatic connections for versions with solenoid valve
The air connections are either 1/4 NPT or G 1/4 tapped holes. The customary screw joints for metal and copper tubes or plastic hoses can be used. Important! Make sure that the supply air is dehumidified and free of oil and dust. You are required to observe the maintenance instructions for upstream pressure reducing stations. Thoroughly flush the pneumatic lines prior to installation. When attaching the Type 3277 Actuator directly, the signal pressure connection is fixed. When using NAMUR attachment, the signal pressure line is connected to either the upper or lower diaphragm chamber of the actuator, depending on the actuator’s fail-safe action, i.e. "Actuator stem retracts" or "Actuator stem extends". Exhaust air: Models with the index 3768-x...x. 03 and higher are equipped with a hinged cover without a venting hole. The exhaust air connections for these models are included in the mounting accessories. For direct attachment, the vent plug is located on the plastic cover of the actuator, whereas for NAMUR attachment, it is located on the adapter housing and for attachment to rotary actuators on the intermediate piece. Note! If you intend to replace older models with model indices 3768-x...x. 02 or lower, the mounting parts need replacing, too.

Rear connections

(B) A +41 –42 +51 –52

(A) B +81 –82 + – 6 to 24 V DC solenoid valve (optional)

Switching amplifier acc. to EN 60947-5-6

Fig. 8 ⋅ Electrical connections

EB 8356 EN

19

When the tag (4) is in the inductive field of the switch. there are two adjustable tags (51) which operate the associated proximity switches (50). The switches A and B are optionally assigned to the terminal pairs 41/42 and 51/52 by turning the associated name plate on the terminal block (see also Fig. especially when the limit switches are to be connected in fail-safe circuits. 9 ⋅ Limit contacts 20 EB 8356 EN . however. The desired switching function. the switch assumes a high resistance. The assignment of the switches A and B must be determined according to Tables 7 and 8. the switch assumes a low resistance. can also be adjusted to signalize intermediate positions. Fig. To operate the inductive limit switches. The switches. i. Important! Since the tags of the limit switches cannot be turned by 360°.Operation – Adjusting the limit contacts 4 Operation – Adjusting the limit contacts On the rotary axis. 8). corresponding switching amplifiers must be connected in the output circuit (see section 3). When it is no longer in the field.e. must be determined by means of jumpers for either working current or closed circuit current at the switching amplifier. whether the output relay must be picked up or released when the tag has entered the field. correct assignment of the switches A and B to the valve positions Open and Closed must be observed. The limit contacts are usually adjusted to issue a signal for both limit positions. It depends on the mounting position of the limit switch and the limit position of the valve (either valve Open or Closed).

3) Attachment left Switch Attachment right Valve position Closed Open Table 8 Tag OUT B A Tag IN A B Tag OUT A B Tag IN B A NAMUR attachment (Fig. the switching point should be adjusted to stop approx. 4) Attachment left Mounting position of adapter housing when looking onto the lever (18) Attachment right Cable gland points towards Valve position OUT Switch Tag IN A B B A Cable gland points towards Valve position OUT Switch Tag IN B A A B Front Back Closed Open Closed Open B A A B Front Back Closed Open Closed Open A B B A EB 8356 EN 21 . Table 7 Direct attachment to Type 3277 Actuator (Fig. To ensure safe switching under any condition.Operation – Adjusting the limit contacts Setting the switching point Move the valve to the switching position and adjust the tag by turning the adjustment screw (53) so that the switching point is reached and indicated by the LED on the switching amplifier. 2 % before the mechanical stop (Open – Closed) is reached.

The inspection by an expert does not have to be carried out. 22 EB 8356 EN .Servicing explosion-protected versions 5 Servicing explosion-protected versions In the event that a part of the limit switch on which the explosion protection is based must be serviced. if the manufacturer performs a routine check test on the device prior to taking it into operation again. Parts used in explosion-protected versions should only be exchanged for original detail inspected parts from the manufacturer. or equipped the device with his mark of conformity. issued a certificate stating this. the limit switch must not be operated again. and the success of the routine check test is documented by attaching a mark of conformity to the device. unless an expert has inspected the device according to the explosion protection requirements.

Dimensions in mm 6 Dimensions in mm 185 19.5 76 50 Supply (Z) N1=113 N2=200 36 EB 8356 EN 23 .5 66 164 Output 2 (A2) 28.5 164 29 14 Output (38) 37 76 150 Reversing amplifier (optional) 28 Supply (9) 39 35 68 44 19.5 68 M20 x 1.5 50 Ø110 56 58 50 82 46 Fulcrum of the actuator shaft 56 Pneumatic connection reversing amplifier Output 1 (A1) 28.

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 .

de EB 8356 EN S/Z 2004-05 .UND REGELTECHNIK Weismüllerstraße 3 ⋅ 60314 Frankfurt ⋅ Germany Phone: +49 69 4009-0 ⋅ Fax: +49 69 4009-1507 Internet: http://www.samson.SAMSON AG ⋅ MESS.

..0... Connect piping to proper ports using pipe thread sealant on male threads only. 19..... 47) ... q upstream of lubricators and cycling valves.PTF B. 46.... Do not remove the drains unless replacement is necessary....... 23) ....4380-020 Filter element.... 5µm (50) ...4000-51R Tamper resistant cover (knob adjustment only)..........1 to 2... or bowl with guard. 2.. Filter/regulator can be disassembled without removal from air line.. Inspect parts.. Disassemble in general accordance with the item numbers on exploded view.. KNOB ADJUSTMENT.. Tighten lock nut (8) to lock pressure setting.... When reducing from a higher to a lower setting.Relieving 3 ...................555 .. Always approach the desired pressure from a lower pressure....B73G Filter/Regulator B73G . Before applying inlet pressure to filter/regulator........... 25 µm. Rinse and dry parts.. Blow out internal passages in body (16) with clean.... Push knob down to lock pressure setting. 3... 38). 6... 51 (Louver) 1........... If made under no flow (dead-end) conditions.. Clean or replace filter element when dirty.. 5.....the portion of the body that contacts the bowl............ SERVICING 1.555 Port 2 .1/4" 3 .. Turn adjustment (1 or 7) fully counterclockwise.. 4.......Metal with liquid level indicator Q....... Install a pressure gauge or plug the gauge ports...... Replace those found to be damaged. or bowl with guard..06" to 0.4438-01 Filter element. 3.......Knob A..Without * Outlet pressure can be adjusted to pressures in excess of.. 54 (O-rings) 2... Do not use these units to control pressures outside of the specified ranges... 45... dry compressed air..40 µm Installation & Maintenance Instructions Spring (Outlet Pressure Range) * F .... Clean other parts with warm water and soap....4 (20 to 30) 22.. 22.... 47.. Class 3 and Class 5 (particulates) Typical flow with 10 bar (150 psig) inlet pressure. Replace plastic bowl with a metal bowl if plastic bowl shows signs of cracking or cloudiness. 2... q with air flow in direction of arrow on body...3/8" 4 . TECHNICAL DATA Fluid: Compressed air Maximum 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 at temperatures below +2°C (+35°F). Reduce pressure in inlet and outlet lines to zero....T-bar G.... 25µm (50) ..2 scfm) Manual operation: Depress pin inside drain outlet to drain bowl Gauge ports: 1⁄4 PTF with PTF main ports Rc1/4 with ISO Rc main ports Rc1/8 with ISO G main ports Materials: Body: Aluminum Bonnet: Aluminum Valve: Brass Bowl: Transparent: Polycarbonate Transparent with guard: Polycarbonate...25 µm R. 32......1/2" Adjustment Thread Form K.....4438-03 Manual drain (18... 3.. Remove and replace drains only if they malfunction. steel guard Metal: Aluminum Metal bowl liquid level indicator lens: Transparent nylon Element: Sintered polypropylene Elastomers: Neoprene and nitrile REPLACEMENT ITEMS Service Kit (includes items circled on exploded view): Relieving.... Gauge ports can also be used as additional outlets for regulated air..... Shut off air pressure....... 37 (Manual drain body) . 5.01 (4/98) a subsidiary of IMI plc Supersedes 12/97 . 4..ISO G parallel Drain Bowl A....... into body and turn fully clockwise. then bring up to the desired pressure.... NOTE With non-relieving filter/regulators..... Particle removal: 5 µm..push into body and turn counterclockwise.7 to 17 bar (10 to 250 psig) Gauge G.. Remove bowl .4383-600 Nonrelieving .. 5.threads and tip. 9 (Screw) 2..With N.. or 40 µm filter element Air quality: Within ISO 8573-1..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... 2. make pressure reductions with some air flow in the system.... then turn adjustment (1 or 7) clockwise to increase and counterclockwise to decrease pressure setting....4438-02 Filter element.... Lubricate the following items with o-ring grease...619-50 Automatic drain (21.4455-51 PANEL MOUNTING DIMENSIONS Panel mounting hole diameter: 48 mm (1.......Automatic D.4383-601 Liquid level lens kit (43......3 bar (90 psig) set pressure and 1 bar (15 psig) droop from set: 50 dm3/s (106 scfm) Nominal bowl size: 0....5 µm N..... 3.... Shut off inlet pressure..... Install tamper resistant cover (see Replacement Items) to make setting tamper resistant..... 35) with warm water only.ISO Rc taper T . 41 (Nut) 2.... 40µm (50) ..3 to 10 bar (5 to 150 psig) S.... turn adjustment (1 or 7) counterclockwise to remove all force on regulating spring (12). Push bowl. 20) ... Torque Table Item Torque in Nm (Inch-Pounds) 2...... CLEANING 1.3 to 3...7 to 3.......... 29...0..4 (15 to 30) 49 (Baffle).... T-BAR ADJUSTMENT...3 bar (5 psig) Bowl pressure required to open drain: Less than 0..... DISASSEMBLY 1. 3... © Norgren 1998 ADJUSTMENT 1.Transparent Diaphragm Element 1 ..... Open manual drain to expel accumulated liquids....... and the hole that accommodates the stem of drain valve (19..Non-relieving 2 . 28. 2....0. Blow air through filter element (50) from inside to outside to remove surface contaminants...Transparent with guard T .Manual. and less than.. 4... 34......300.. Clean plastic bowl (25. 26.. 7 (Adjusting screw) ... 4 (Thrust washer) .1 litre (3.. those specified..24") INSTALLATION 1. 1/4 turn P... Keep liquids below baffle (49).outer circumference and both sides...stem. first reduce to some pressure less than that desired. Do not allow sealant to enter interior of unit....... 18.3 to 2....89") Panel thickness: 2 to 6 mm (0....... into body and turn fully clockwise before pressurizing.. Pull knob up to release....... q as close as possible to the device being serviced....1 dm3/s (0.....2 (10 to 20) 1 12 3 2 13 16 4 15 5 14 53 6 7 8 10 9 54 52 51 50 11 49 26 18 21 25 17 20 19 23 24 22 28 34 31 35 33 30 27 29 32 47 37 36 42 39 38 41 44 40 48 46 45 43 IM-180.. Install filter/regulator in air line q vertically (bowl down)..........555 .. the filter/regulator will trap the over-pressure in the downstream line..2 bar (3 psig) Minimum air flow required to close drain: 0.. Push bowl....... ASSEMBLY 1..... Assemble the unit as shown on the exploded view.. 53 (Valve) .3 to 4 bar (5 to 60 psig) M........... Apply inlet pressure......8 (20 to 25) 43 (Screw) 1.. 2.

Polycarbonate plastic bowls can be damaged and possibly burst if exposed to such substances as certain solvents. © Norgren 1998 IM-180. externally or internally. compressor oils containing esterbased additives or synthetic oils. The relief pressure and flow capacity of the relief device must satisfy system requirements.02 (4/98) a subsidiary of IMI plc Supersedes 12/97 . Fumes of these substances in contact with the polycarbonate bowl. Clean with warm water only. Before using these products with fluids other than air. can also result in damage. Do not use these products where pressures and temperatures can exceed those listed under Technical Data. If outlet pressure in excess of the filter/regulator pressure setting could cause downstream equipment to rupture or malfunction. strong alkalies. the gauge should be calibrated before initial installation and at regular intervals during use. both during shipment (despite care in packaging) and during the service life. WARNING These products are intended for use in industrial compressed air systems only.B73G Installation & Maintenance Instructions CAUTION Water vapor will pass through these units and could condense into liquid form downstream as air temperature drops. If a pressure gauge is to be used with these products and if inaccurate indications may be hazardous to personnel or property. for non industrial applications. Use metal bowl in applications where a plastic bowl might be exposed to substances that are incompatible with polycarbonate. Install an air dryer if water condensation could have a detrimental effect on the application. or for life-support systems consult Norgren.300. install a pressure relief device downstream of the filter/regulator. The accuracy of the indication of pressure gauges can change.

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:IL01-OM00006 OPERATION MANUAL BOOSTER RELAY IL100 SMC CORPORATION フォーマット No:FSM027-1 .No.

Outline 2. Transportation and Storage 5. Precautions in Using 6.CONTENTS Page Instructions for your safety 1~2 1. Spare Parts List Drawings IL100-※※ 3 3 3~4 5 6 7~8 9 10 11~12 0 . Maintenance 7. Structure and the Operation Principle 4. Specification 3. Countermeasures for Failure 8.

JIS B 8370 (Note 2) and other safety practices. and ensure to give it to end users. there is a possibility of serious injury or loss of life ISO 4414 JIS B 8370 Pneumatic fluid power-Recommendations for the application of equipment to transmission and control system. ! ! ! (Note 1) (Note 2) Caution Warning Danger : : : Operator error could result in injury or equipment damage. Operator error could result in serious injury or loss of life. Please keep this manual so that you will be able to refer to it anytime. In extreme conditions. be sure to observe ISO 4414 (Note 1). Pneumatic system axiom 1 . To ensure safety. or “Danger”. These instructions indicate the level of potential hazard by label of “Caution” “Warning”.Instructions for your safety Please read thoroughly this operation manual before using the product. These instructions are intended to prevent a hazardous situation and / or equipment damage.

press applications. 3. 3. Warning The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system or decides its specifications. 4. 1. food and beverage. Since the products specified here are used in various operating conditions. railway. 2. 1. or safety equipment. handling or repair of pneumatic systems should be performed by trained and experienced operator. recreation equipment. Contact SMC if the product is to be used in any of the following conditions . their compatibility for the specific pneumatic system must be based on specifications or after analyses and/or tests to meet your specific requirements. Inspection and maintenance of machinery / equipment should only be performed after confirmation of safe locked-out control positions. 2. 2 . Compressed air can be dangerous if an operator is unfamiliar with it. 3. air navigation. An application which has the possibility of having negative effects on people. vehicles. Do not service machinery / equipment or attempt to remove component until safety is confirmed. 2. or if product is used outdoors. emergency stop circuits. Before machinery / equipment is restarted. confirm the safety process as mentioned above. or animals requiring special safety analysis. medical equipment. When equipment is removed. Assembly. property.! 1. take measures to prevent shooting out of cylinder piston rod etc. Only trained personal should operate pneumatically operated machinery and equipment. Conditions and environments beyond the given specifications. Installation on equipment in conjunction with atomic energy. Cut the supply pressure for this equipment and exhaust all residual compressed air in the system.

the internal valve is closed and the exhaust port opens for exhaust. Specification Supply pressure Input・Output pressure Output flow Air consumption Linearity Hysteresis Effective orifice (Cv factor) Ambient temperature and operating fluid temperature Port size Mass MAX. or the controlling part capacity is large. the internal valve is pressed down and the supply air flows to the output side.0.1 -5~60℃ PT 1/4・3/8 560g 3.7MPa Max.7MPa (Note 1) Within ±1% Within 1% 1. 1MPa (Note 1) 0.1. This works against the force generated by diaphragm B.14~0. Opening of the needle valve connect the air path of the input and the output. Outline Increase the operating speed of controlling part when the piping between the instruments and the controlling part is very long. Structure and the operation principle Input force from the instrument enters to the input chamber and act to diaphragm A. 2. This is how the force generated by diaphragm A and B is balanced. the stability of the closed loop including the booster relay is improved.0MPa MAX. The adjustment of the throttle valve. 3 . When not strong. When the force generated by the input is strong.1.

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select a place where there is no moisture nor corrosive gas. While the product shipped has been applied specified paint and surface treatment. Transportation and Storage ! Warning (1) Handle the product with care. take care that inappropriate storing environment may cause generating rust. (2) Do not expose to rain. (3) The product is packed in a vinyl bag for shipment to prevent from dust. 5 .4. Avoid taking out of the bag just before piping even after unpacking. (4) If the product is kept unpacking for a certain period.

6 . please use the mist separator. salinity. ! Warning Air supply (1) Please use the filter to the supply line. Use the mist separator when the oil mist and carbon are contained. For vibration. provide a safety circuit for the system to avoid danger. Where contained oil mist and carbon. (5) The needle valve is opened for 3/4 turn and locked. may cause failure. (2) Do not operate the product in a location where it is subject to strong vibration and/or shock. (2) Avoid using compressed air compressed air containing chemicals. (2) Mount the filter to the pressure supply line. ! Warning Environment (1) Do not use in environment where the product is exposed to corrosive gas. chemicals. (2) If booster relay failure affecting the system is expected. synthetic fluid including organic solvent. (4) Mind the arrow direction of the air flow when piping. salt water. because it causes malfunction. (3) Flush the air piping before connecting the booster relay. so that take care in handling during transportation and operation. Precautions in using ! Warning Operation (1) Do not operate the booster relay out of the specifications. closing quickens the response. ! Warning Handling (1) Excess vibration and impact on the booster relay cause failure. it should be within IG 60Hz. (6) Opening the needle valve delays the response.5. and corrosive gas as it may cause malfunction. water or steam. No adjustment is necessary except when the control system is unstable.

! Caution (1) Periodical check (recommended : once / year) Please check once per year on this product. maintenance and disassemble.10) “O”ring (11. pay attention in order not to damage diaphragm. main valve length adjustment etc. When disassemble. 7 . please exhaust residual pressure within piping with supply air stopped. That kind of person should operate unit replacement and maintenance with keeping product specification. Maintenance ! Warning (1) To handle compressed air. person that has experienced and has knowledge about instrumentation machine is suitable.12) Check items Confirmation Countermeasure No crack or flaw on Visual inspection the surface No crack or flaw on Visual inspection the surface Part replacement if abnormality is found. (2) To remove booster relay or to replace unit with product set.) make effects on property. Product replacement is recommended by whole product per 3 years if it is used on extremely important point. To re-assemble. retighten.6. disassemble product following disassemble drawing. please confirm correct mounting. or when machine do not operate properly. please test leakage and function with compressed air supplied. To check. and check following item. Part replacement adjustment (valve seat centering. Valve stem spring No crack due to hold Visual inspection (6) Without lock nut Main valve (3) Hand or tool If loosen. When louder breed sound than initial. in the case of diaphragm stick to body. loosen *( ) shows booster relay disassemble drawing part no. Part description Diaphragm (2. 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. (3) After mounting.

8 . Make shorter when output is high to input signal. For the main valve length adjustment. make longer when output is low to input signal. loose lock nut. To adjust length. For that circumstances. is adjusted the length by screw and fixed with lock nut. adjust main valve length.! Warning (Adjustment on Part replacement) Diaphragm replacement and product disassemble & re-assemble may change in/output characteristics. Main valve. as shown below. Main valve total length is basically 25±1mm.

replace the from exaust port part. and lock. Replace diaphragm optimum No signal even if input Restrictor open too much signal is applied Broken diaphragm Bad characteristic Valve stem length is Readjust into changed due to loosen lock valve. Dust attach supply port or (If flawed.) Broken diaphragm Pressure leak loosen screw due to Replace diaphragm Tighten screw Decrease open degrees of restrictor. and lock. Countermeasures for failure ! Warning Avoid use when failure is not solved. Phenomenon Too much exaust port flow Cause Countermeasures Disassemble and clean. nut Plugged restrictor Deformed diaphragm Disassemble and clean Replace diaphragm 9 .7.

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