Manuals Control Valve
Manuals Control Valve
Manuals Control Valve
Mounting and
Operating Instructions
EB 8059 EN
Edition May 2006
Contents
Contents Page
1. Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
2. Assembling valve and actuator . . . . . . . . . . . . . . . . . . . . . . . 6
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Signal pressure line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Shut-off valves and bypass . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Troubleshooting - replacing parts . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Replacing parts of standard valves . . . . . . . . . . . . . . . . . . . . . . 8
5.1.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1.2 Seat and/or plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Replacing parts in valve with bellows seal . . . . . . . . . . . . . . . . . . . 10
5.2.1 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2.2 Metal bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Replacing parts in valve with insulating section . . . . . . . . . . . . . . . . 10
6. Description of nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 EB 8059 EN
Safety instructions
EB 8059 EN 3
Design and principle of operation
4 EB 8059 EN
Design and principle of operation
8.6
8
8.3
8.4
8.2 8.5
8.1 8.5
7 5.5
6.1
6.2
5.2
6
4.2 5.3
5
5.1
1 Valve body 6 Plug stem
1.1 1.1 Lens ring gasket 6.1 Stem connector nut
2 Seat 6.2 Lock nut
3 Plug 7 Stem connector
4.2 Packing 8 Actuator
3 5 Valve bonnet 8.1 Actuator stem
5.1 Nuts and expansion 8.2 Ring nut
1 bolts 8.3 Springs
5.2 Threaded bushing 8.4 Diaphragm
2 5.3 Yoke 8.5 Signal air connection
5.5 Travel indicator 8.6 Vent
scale
Tightening torques
Nominal size Expansion bolts (5.1) Seat (2)
DN
Seat thread Reduced seat bore
16, 24, 30 150 Nm + 10 % M36 x 1.5 400 Nm
45, 58 300 Nm + 10 % M58 x 1.5 1000 Nm
70, 90 900 Nm + 10 % M100 x 2 2700 Nm
EB 8059 EN 5
Assembling valve and actuator
2. Assembling valve and actuator tween 0.4 to 2 bar) to the upper dia-
phragm chamber connection.
If the valve and the actuator were not assem- 5. Turn the stem connector nut (6.1) by
bled by the manufacturer or if the original hand until it contacts the actuator stem
actuator attached to the valve is to be ex- (8.1). Turn it another 1/4 turn and se-
changed for an actuator of another type or cure this position with the lock nut (6.2).
size, proceed as follows:
6. Attach the stem connector parts (7) and
1. Loosen the lock nut (6.2) and the stem screw tight.
connector nut (6.1) on the valve. Align the travel indicator scale (5.5)
Press the plug and plug stem firmly into with the tip of the stem connector.
the seat ring, then thread the stem con-
nector nut and the lock nut down
2. Unscrew the connector stem parts (7)
and the ring nut (8.2) from the actuator. Note on disassembly:
Slide the ring nut over the plug stem of When disassembling an actuator, first
the valve. apply a loading pressure slightly higher
3. Place the actuator on the yoke (5.3) than the lower bench range value (see
and secure with the ring nut (8.2). nameplate on actuator) to the signal press -
Read the bench range and fail-safe ac- ure connection before unscrewing the ring
tion of the actuator stated on the name- nut (8).
plate.
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, and with a symbol on
the Type 3277 Actuator.
The lower bench range value corresponds
to the initial value of the bench range to be
set and the upper bench range value corre-
sponds to the final value of the bench range.
4. For actuators with actuator stem ex-
tends, apply a signal pressure that
corresponds to the lower bench range
value (e.g. 0.8 when the range is be-
tween 0.8 to 2.4 bar) to the lower dia-
phragm chamber connection.
For actuators with actuator stem re-
tracts, apply a signal pressure that
corresponds to the upper bench range
value (e.g. 2 bar when the range is be-
6 EB 8059 EN
Installation
EB 8059 EN 7
Troubleshooting replacing parts
8 EB 8059 EN
Troubleshooting replacing parts
Assembly
1. Apply lubricant (order no. 8150-0111) 5.2
to all parts as well as to the plug stem
4.6
(6). Do not apply lubricant to graphite 4.5
packing! 4.2
2. Push the plug stem into the valve bonnet 4.4
(5).
3. Carefully slide the packing parts over
4.3
the plug stem into the packing cham-
ber. Make sure you keep the correct 4.6
order. Depending on the nominal size 4.5
of the valve, the number of bushings
(4.3) may vary. 4.2
4. Screw threaded bushing (5.2) over the 4.4
plug stem into the valve bonnet. Do not
4.1
tighten.
5. Insert a new lens ring gasket (1.1) into 4.3
the valve body and carefully push the
whole valve bonnet into the valve body.
6. Attach expansion bolts with nuts (5.1) Standard High-temperature
and fasten the valve bonnet in the valve
body. (See table on page 5 for tighte-
ning torques used for expansion bolts). 4.1 Spring 4.5 Carbon bushing(s)
4.2 V-ring packing 4.6 Graphite, compressed
7. Screw tight the threaded bushing (5.2). 4.3 Spacer(s) 5.2 Threaded bushing
With high-temperature packings, only 4.4 Washer(s)
slightly tighten the threaded bushing. In
case of leakage, also only tighten
slightly.
Fig. 3 ⋅ Packing
EB 8059 EN 9
Troubleshooting replacing parts
10 EB 8059 EN
Troubleshooting replacing parts
11
11.1
11.2
9.1
9 Intermediate piece
9.1 Gaskets
10 Metal bellows
11 Bonnet
9.1 11.1 Test connection
11.2 Nuts and expansion bolts
10
EB 8059 EN 11
Description of nameplates
6. Description of nameplates
SAMSON 3 -4 5 6 SAMSON 1 2 3 4
1 7 8
H 5 F 6 V 7
9 10
Germany
2
Made in
11 12 13 14 15
Fig. 5 ⋅ Nameplates
12 EB 8059 EN
Customer inquiries
7. Customer inquiries
Should you have any questions regarding
the control valve, please submit the follow-
ing details (see also nameplate):
Order number
Type, product number, 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.g. 0.2 to 1 bar) of the
mounted actuator
Has a strainer been installed?
Installation drawing
EB 8059 EN 13
S/Z 2006-05
Type 3271
Type 3271-52
Mounting and
Operating Instructions
EB 8310 EN
Edition October 2004
Contents Safety instructions
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 3
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Reversing the operating direction (fail-safe action) . . . . . . . . . . . . 6
2.1.1 Type 3271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.2 Actuator with handwheel . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Replacing the diaphragm and stem seal . . . . . . . . . . . . . . . . 10
2.3 Adjusting the travel stop . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Manual operation of Type 3271 with side-mounted handwheel . . . . . 12
2.4.1 Normal operation with the handwheel locked . . . . . . . . . . . . . 12
2.4.2 Actuator stem extends upon air supply failure . . . . . . . . . . . . . 12
2.4.3 Actuator stem retracts upon air supply failure. . . . . . . . . . . . . . 12
2.4.4 Actuator stem extends when supply air is applied . . . . . . . . . . . . 13
2.4.5 Actuator stem retracts when supply air is applied . . . . . . . . . . . . 13
3 Description of nameplate . . . . . . . . . . . . . . . . . . . . . . . 14
4 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 EB 8310 EN
Design and principle of operation
9 8.1
7
12 10
a
12.1 11
3 15 9 Nuts and bolts
1 Nut 10 Bottom diaphragm case
1.1 Nut 13
11 Loading pressure connection
2 Actuator stem 16 12 Stem seal
3 Vent plug 6 Springs
12.1 Dry bearing
4 Loading pressure 7 Diaphragm plate 13 Wiper
connection 8 Diaphgram
15 Ring nut
5 Top diaphragm 8.1 Hose clamp
16 Stem connector
case
Fig. 2 · Sectional diagram of Type 3271
EB 8310 EN 3
Design and principle of operation
A maximum of 30 springs can be installed, sure connection (4) to fill the top diaphragm
partly fitted inside one another. chamber with air which causes the actuator
stem to move downwards.
In an actuator with the fail-safe action
The stem connector (16) connects the actua-
"Actuator stem extends FA", the loading
tor stem (2) to the plug stem of the valve.
pressure is connected to the loading pres-
sure connection (11) to fill the bottom dia- Fail-safe action
phragm chamber with air which causes the
When the signal pressure fails, the fail-safe
actuator stem to move upwards.
action of the actuator depends on whether
In an actuator with the fail-safe action
the springs are installed in the top or bottom
"Actuator stem retracts FE", the loading
diaphragm chamber.
pressure is connected to the loading pres-
2 1 1.1 6 9
5
3
4
8
11
7
7.1
12
12.1 10 2.1
20 21 22
13
15
16
1 Nut
1.1 Nut 7 Diaphragm plate 21
2 Actuator stem 7.1 Metal plate 22 13 Wiper
2.1 Bushing 8 Diaphragm 15 Ring nut
3 Vent plug 9 Nuts and bolts 16 16 Stem connector
3.1 Vent plug 10 Bottom diaphragm case 20
2
Screw (60 cm )
4 Loading press. connection 11 Loading press. connection 21 Washer (60 cm )
2
Fig. 3 · Type 3271-5 Actuators with 120 cm2 (top) and 60 cm2 (bottom) effective diaphragm area
4 EB 8310 EN
Design and principle of operation
EB 8310 EN 5
Operation
6 EB 8310 EN
Operation
5. Lift off the diaphragm plate with dia- Reversing the fail-safe action "Actuator
phragm and replace them in reverse or- stem retracts" to "Actuator stem extends"
der. Tighten nut (1). (Fig. 2)
6. Apply lubricant/sealant (order no. 1. Unthread nuts and remove the bolts (9)
8152-0043) to the actuator stem. and lift off the top diaphragm case (5).
7. Place the diaphragm plate with dia- 2. Pull the diaphragm plate (7) and dia-
phragm in the top diaphragm case. In- phragm with the actuator stem (2) out of
sert the springs (6) and slide the lower the bottom diaphragm case (10). Re-
diaphragm case over the actuator stem. move the springs (6).
8. Screw tight the nuts and bolts of the dia- 3. Unscrew nut (1), while holding the nut
phragm cases. (1.1) stationary with a suitable tool.
9. Remove vent plug (3) from top dia- Caution! Proceed carefully to avoid
phragm case and screw it into the load- damaging the seals of the actuator stem.
ing pressure connection on the bottom 4. Remove the diaphragm plate with dia-
diaphragm case. phragm and replace them in reverse or-
The actuator springs now press against the der. Screw tight nut (1).
diaphragm plate from below and cause the 5. Coat the actuator stem with sealant/lu-
actuator stem to retract. The loading pres-
bricant (order no. 8152-0043) and in-
sure is connected over the connection (4) to
sert it into the bottom diaphragm cham-
the top diaphragm chamber. The actuator
stem starts to extend when the signal pres- ber along with the diaphragm plate and
sure overcomes the force of the springs. diaphragm.
6. Insert springs (6) and place the top dia-
10. Record the changed fail-safe action on phragm case back on.
the nameplate! 7. Screw tight the nuts and bolts of the dia-
phragm cases.
Proceed in the same manner for the Type
8. Remove the vent plug (3) from the bot-
3271-5 Actuator, but additionally install the
tom loading pressure connection and
metal plate (7.1).
For the version intended for attachment to place it in the top connection.
micro-flow valves, additionally install the
bushing (2.1) for the mechanical travel stop. The springs which are now pressed from the
In Type 3271-52 Actuator with 60 cm2 dia- top against the diaphragm plate cause the
phragm area, unthread the screw (20) and actuator stem to extend.
then remove the washer (21) and sleeve The signal pressure is connected via the con-
(22). nection (11) to the bottom diaphragm cham-
ber. The actuator stem starts to retract when
the signal pressure overcomes the force of
the springs.
EB 8310 EN 7
Operation
8 EB 8310 EN
Operation
After reversing the operating direction: 2. Attach the ring (24) with clamping
1. Place the flange part (21) and the cou- sleeve (23).
pling nut (25) and then secure flange 3. Screw coupling nut (25) as far as it will
part (21) with ring nut (28). go onto the coupling (22) and secure
with threaded pins (26).
2 Actuator stem
3 Vent plug
4 Loading press. connection
17
5 Top diaphragm case
20 6 Springs
6.1 Additional springs
21
7 Diaphragm plate
22 8 Diaphragm
Neutral position
9 Nuts and bolts
Pointer points to groove in
23 8.1 Hose clip
coupling (22)
24 10 Bottom diaphragm case
26 11 Loading press. connection
25
28 16 Stem connector
3
27 4 17 Handwheel
5 20 Lock nut
8.1 6 21 Flange part
7 22 Coupling
23 Clamping sleeve
24 Ring
9
25 Coupling nut
8 26 Threaded pin
6.1 27 Spindle with nut
10 28 Ring nut
2 11
16
EB 8310 EN 9
Operation
10 EB 8310 EN
Operation
2 Actuator stem
7 Diaphragm plate
31 Lock nut
32 Nut
33 Cap
34 Lock nut
EB 8310 EN 11
Operation
2.4 Manual operation of Type 4 Pull the locking knob on the side all the
3271 with side-mounted way out and turn it to unlock the
handwheel.
handwheel
4 Turn the handwheel counterclockwise
(direction Auf/Open/Ouvert), the pin
Note! To operate the handwheel on actua- sinks into the flange.
tors with 1400 and 2800 cm2 diaphragm Initially, the handwheel is easy to turn
areas, do not use any additional tools such and after a certain point of pressure is
as a lever or wrench. reached, the valve starts to open.
4 On reaching the final position at the
stop, do not turn the handwheel any fur-
2.4.1 Normal operation with the ther by force.
handwheel locked Caution! Risk of damage.
4 After finishing manual operation, turn
The handwheel is not used. The valve is po- the handwheel to bring the pin back into
sitioned by the pneumatic signal pressure the neutral position again.
applied to the valve. 4 Turn the locking knob until it engages to
To achieve this, the pin next to the actuator lock the handwheel again.
stem must be in the neutral position:
The pin must sink into the flange so far that 2.4.3 Actuator stem retracts upon
its groove is aligned with the top of the
flange.
air supply failure
If this is not case: The manual override must overcome the
force of the actuator springs to close the
4 Pull the locking knob on the side all the valve.
way out and turn it to unlock the
handwheel. 4 Pull the locking knob on the side all the
4 Turn the handwheel until the pin reaches way out and turn it to unlock the
the neutral position. handwheel.
4 Turn the locking knob until it engages to 4 Turn the handwheel clockwise (direction
lock the handwheel again. Zu/Close/Fermé), the pin emerges from
The easiest way to adjust the handwheel is the flange.
with the valve in the fail-safe position. Initially, the handwheel is easy to turn
and after a certain point of pressure is
2.4.2 Actuator stem extends upon reached, the valve starts to close.
air supply failure 4 On reaching the final position at the
stop, do not turn the handwheel any fur-
The manual override must overcome the ther by force.
force of the actuator springs to open the Caution! Risk of damage.
valve.
12 EB 8310 EN
Operation
4 After finishing manual operation, turn 2.4.5 Actuator stem retracts when
the handwheel to bring the pin back into supply air is applied
the neutral position again.
4 Turn the locking knob until it engages to The manual override must overcome the
lock the handwheel again. force of the actuator springs to close the
valve.
2.4.4 Actuator stem extends when Do not open the valve any further than be-
supply air is applied fore unlocking the handwheel.
EB 8310 EN 13
Description of nameplate
4 Pull the locking knob on the side all the 3 Description of nameplate
way out and turn it to unlock the
handwheel.
4 Turn the handwheel clockwise (direction
Zu/Close/Fermé), the pin emerges from
the flange.
After a certain point of pressure is SAMSON 1 2 3 4
reached, the valve starts to close. H 5 F 6 V 7
4 On reaching the final position at the
stop, do not turn the handwheel any fur-
ther by force.
Caution! Risk of damage. 1 Type designation
4 After finishing manual operation, turn 2 Modification index
the handwheel to bring the pin back into 3 Effective diaphragm area
the neutral position again. 4 Operating direction:
4 Turn the locking knob until it engages to Actuator stem extends FA
lock the handwheel again. Actuator stem retracts FE
5 Travel
6 Bench range (spring range)
7 Bench range with preloaded springs
Fig. 9 · Nameplate
14 EB 8310 EN
Customer inquiries
4 Customer inquiries
Please specify the following details on mak-
ing inquires:
4 Type and model number
4 Effective diaphragm area
4 Bench range (spring range) in bar
4 Actuator version and its operating direc-
tion
EB 8310 EN 15
S/Z 2004-11
Fig. 1 · Type 3277 Pneumatic Actuator Fig. 2 · Type 3277-5 Pneumatic Actuator
Mounting and
Operating Instructions
EB 8311 EN
Edition July 2006
Design and principle of operation
1 Design and principle of actuator stem over a spindle after the lock-
operation ing mechanism (lock nut) has been disen-
gaged. In addition, the actuator can be
The Type 3277 Pneumatic Actuators with an equipped in a special version with a me-
effective diaphragm area of 240, 350 or chanically adjustable travel stop.
700 cm² are primarily mounted to control The signal pressure creates a force at the di-
valves from the Series 240, 250 and 280. aphragm surface which is balanced by the
Type 3277-5 with a die-cast aluminum case springs (6) arranged in the actuator. The
and an effective diaphragm area of number of springs and their compression
120 cm², is mounted to Type 3510 and Se- determine the bench range (signal pressure
ries 240 Valves. range) while taking the rated travel into ac-
count which is directly proportional to the
The actuator is made up of two diaphragm signal pressure. A maximum of 30 springs
cases, a rolling diaphragm and springs. The can be installed, partly fitted inside one an-
lower diaphragm case is permanently fixed other.
to the yoke which allows the direct attach-
ment of either a pneumatic or electropneu- The stem connector (16) connects the actua-
matic positioner or a limit switch. tor stem (2) with the plug stem of the control
valve.
Actuators with manual override (Fig. 5) ad-
ditionally have a handwheel mounted on the
diaphragm case. The handwheel moves the
2 EB 8311 EN
Design and principle of operation
5 1.1 1 6 6.1 3
4
7
1 Nut
1.1 Nut
2 Actuator stem
3 Vent plug 8
4 Loading pressure9
connection 12
5 Top diaphragm 2
case 12.1
a
6 Springs
7 Diaphragm plate 11
8 Diaphragm
10
9 Nuts and bolts
10 Yoke with bottom 12.1
diaphragm case
Dimension a 15
11 Loading pressure 350 cm² = 209 mm
connection 700 cm² = 246 mm
12 Stem seal 13
12.1Dry bearing
13 Wiper
15 Ring nut
16
16 Stem connector
Fig. 3 · Sectional diagram of Type 3277 with 240, 350 and 700 cm² effective diaphragm area
EB 8311 EN 3
Design and principle of operation
4 EB 8311 EN
Design and principle of operation
9 6 1 2 1.1 2.1 2
7 7.1
a
a
12 14.1
8
12.1
10 14.2
14
14
1 Nut 15
1.1 Nut 12.1 Dry bearing
2.1 Bushing 13 Wiper
13
5 Diaphragm case 14 Switchover or connecting
6 Springs plate 16
7 Diaphragm plate 16 Air routing:
7.1 Metal plate 14.1 for actuator stem extends Actuator with threaded
8 Diaphragm 14.2 for actuator stem retracts connection for a
9 Nuts and bolts 15 Ring nut micro-flow valve
10 Yoke 16 Stem connector
Switchover plate Connecting plate
12 Stem seal
14.6
14.3 Symbol
14.4 Marking for signal
pressure input 14.8
14.7 14.5 For left attachment
14.6 For right attachment
14.3
14.5 14.7 Seal with filter
14.4
14.3 14.8 Loading pressure
connection
14.4 Actuator stem retracts
Actuator stem extends
Left attachment Right attachment Actuator stem
Left attachment Right attachment
extends retracts
Fig. 4 · Type 3277-5 Actuators with 120 cm2 effective diaphragm area
EB 8311 EN 5
Operation
6 EB 8311 EN
Reversing the operating direction (fail-safe action)
EB 8311 EN 7
Reversing the operating direction (fail-safe action)
tor stem only starts to retract when the signal Reversing the fail-safe action "Actuator
pressure overcomes the force of the springs. stem extends" to "Actuator stem retracts"
9. Record the changed fail-safe action on 4 Proceed as described in section 2.1.1.
the nameplate! However, use the word "spindle with nut
(27)" in place of "nut (1)".
2.1.2 Actuator with handwheel
After reversing the operating direction:
Type 3277 (Fig. 5) only
1. Replace the flange part (21) with ring
1. Undo lock nut (20) and relieve the nut (15) and coupling nut (25).
springs (6) by turning the handwheel 2. Tighten ring nut (15). Attach the ring
(17). (24) with clamping sleeve (23).
2. Loosen threaded pin (26) and unscrew 3. Screw coupling nut (25) as far as it will
coupling nut (25) from the coupling go onto the coupling (22) and secure
(22). with threaded pins (26).
3. Knock out the clamping sleeve (23) and
remove the ring (24). Reversing the fail-safe action "Actuator
4. Unthread the ring nut (15) and lift off the stem retracts" to "Actuator stem extends"
flange part (21) together with the cou-
pling nut (25).
4 Proceed as described in section 2.1.1.
However, use the word "spindle with nut
(27)" in place of "nut (1)".
8 EB 8311 EN
Reversing the operating direction (fail-safe action)
17
20
2 Actuator stem
Neutral position
Pointer points to groove 21 3 Vent plug
in coupling (22) 4 Loading press. connection
5 Top diaphragm case
22 6 Springs
23 24 6.1 Additional springs
26 13 7 Diaphragm plate
15 8 Diaphragm
25 3 9 Nuts and bolts
10 Bottom diaphragm case
12 4
11 Loading press. connection
6 15 Ring nut
5 12 Stem seal
27 12.1 Dry bearing
13 Wiper
17 Handwheel
20 Lock nut
21 Flange part
8 9 22 Coupling
6.1 23 Clamping sleeve
12 24 Ring
10 25 Coupling nut
7 26 Threaded pin
27 Spindle with nut
11
12.1
13
EB 8311 EN 9
Adjusting the travel stop
2 Actuator stem
5 Top diaphragm case
7 Diaphragm plate
31 Lock nut
32 Nut
33 Cap
10 EB 8311 EN
Replacing the diaphragm and stem seal
EB 8311 EN 11
S/Z 2006-08
Scope of these instructions: These instructions are valid for multi-turn actuators of the type range
SA(R)ExC 07.1 – SA(R)ExC 16.1 in version AUMA NORM.
These operation instructions are only valid for “clockwise closing”, i.e.
driven shaft turns clockwise to close the valve
2
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
Page
18. Maintenance 25
19. Lubrication 26
20. Disposal and recycling 26
21. Service 26
22. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with plug/ socket connector 28
23. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with terminal connection 30
24. PTB certificate 32
25. Declaration of Conformity and Declaration of Incorporation 34
Index 35
Addresses of AUMA offices and representatives 36
3
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
1. Safety instructions
1.1 Range of application AUMA actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves and ball valves.
For other applications, please consult us. The manufacturer is not liable for
any possible damage resulting from use in other than the designated appli-
cations. Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the
actuators’ designated use.
1.2 Commissioning For work carried out in hazardous areas, special regulations (Standard
(electrical connection) EN 60079-17) must be observed.
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.
Pay attention to additional national regulations.
During electrical operation certain parts inevitably carry lethal voltages.
Work on the electrical system or equipment must only be carried out by 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.
1.3 Maintenance The maintenance instructions (refer to page 25) must be observed, other-
wise a safe operation of the actuator is no longer guaranteed.
1.4 Warnings and notes Non-observance of the warnings and notes may lead to serious injuries or
damage. Qualified personnel must be thoroughly familiar with all warnings
and notes in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe
operation.
The following references draw special attention to safety-relevant proce-
dures in these operation instructions. Each is marked by the appropriate
pictograph.
This pictograph means: Note!
“Note” marks activities or procedures which have major influence on the
correct operation. Non-observance of these notes may lead to consequen-
tial damage.
This pictograph means: Electrostatically endangered parts!
If this pictograph is attached to a printed circuit board, it contains parts
which may be damaged or destroyed by electrostatic discharges. If the
boards need to be touched during setting, measurement or for exchange, it
must be assured that immediately before a discharge through contact with
an earthed metallic surface (e.g. the housing) has taken place.
This pictograph means: Warning!
“Warning” marks activities or procedures, which, if not carried out correctly,
can affect the safety of persons or material.
2. Short description AUMA multi-turn actuators type SA(R)ExC 07.1 – SA(R)ExC 16.1 have a
modular design. The limitation of travel is realised via limit switches in both
end positions. Torque seating is also possible in both end positions. The type
of seating is determined by the valve manufacturer.
4
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
3. Technical data
Table 1: Technical data multi-turn actuator SA(R)ExC 07.1 – SA(R)ExC 16.1
Application
Multi-turn actuators AUMA NORM require external controls. AUMA offers the controls AMExC 01.1 or ACExC 01.1. These can
also easily be mounted to the actuator at a later date.
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 - 15 min
SARExC Intermittent duty S4 - 25 %
Option: SAExC Short time duty S2 - 30 min
SARExC Intermittent duty S4 - 50 %
Motors 3-ph AC asynchronous motor, type IM B9 according to IEC 34
Insulation class F, 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 5,000 turns per stroke)
Standard: Single switch (1 NC and 1 NO) for each end position:
Options: Tandem switch (2 NC and 2 NO) for each end position,
switches galvanically isolated
Triple switch (3 NC and 3 NO) for each end position, switches galvanically isolated
Intermediate position switch (DUO limit switching), 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 01.1)
for 1 to 500 turns per stroke or for 10 to 5,000 turns per stroke
Position feedback signal, Potentiometer or 0/4 – 20 mA
analogue (options) For further details see separate data sheet
Torque feedback signal, analogue Only available in connection with magnetic limit and torque transmitter MWG and the
(option) actuator controls ACExC 01.1
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Running indication Blinker transmitter
Heater in switch compartment Standard: self-regulating PTC heater, 5 – 20 W
110 – 250 V DC/AC
Options: 24 – 48 V DC/AC
A resistance type heater (5 W, 24 V DC) is installed in the actuator in combination with the
actuator controls AMExC or ACExC .
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during
electric operation.
Option: Handwheel lockable
Electrical connection Standard: Ex-plug/socket connector with terminal board (screw type connection)
Options: Ex-plug-in terminal connection
Threads for cable glands Standard: Metric thread
Options: Pg thread, NPT thread, G thread
1) Based on 20 °C ambient temperature and at an average load with running torque according to Technical data SA(R)ExC.
The type of duty must not be exceeded
2) PTC thermistors require additionally a suitable tripping device in the controls
3) According to EN 60079-14 a thermal overload relay (e.g. motor protection switch) must be installed for explosion-proof actuators in addition to the
thermoswitches.
5
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
Other information
EC directives ATEX directive: (94/9/EC)
Electromagnetic Compatibility (EMC): (89/336/EEC)
Low Voltage Directive: (73/23/EEC)
Machinery Directive: (98/37/EC)
Reference documents Product description “Electric multi-turn actuators SA/SAR”
Information “Electric actuators and valve gearboxes according to ATEX”
Dimension sheets SA(R)ExC
Electrical data sheets SA(R)ExC
Technical data SAExC
4) If occasionally or permanently exposed to aggressive substances, we recommend a higher corrosion protection KS or KX.
5) Under certain conditions (special sizing) up to + 60 °C possible
6) For standard version with Ex-plug/socket connector with terminal board
6
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
.
Do not attach ropes or hooks to the handwheel for the purpose of lifting by
hoist.
..
If multi-turn actuator is mounted on valve, attach ropes or hooks for the
purpose of lifting by hoist to valve and not to multi-turn actuator.
Store in well-ventilated, dry room.
..
Protect against floor dampness by storage on a shelf or on a wooden
pallet.
Cover to protect against dust and dirt.
Apply suitable corrosion protection agent to bright surfaces.
If multi-turn actuators are to be stored for a long time (more than 6 months),
.
the following points must be observed additionally:
.
Prior to storage: Protect bright surfaces, in particular the output drive parts
and mounting surface, with long-term corrosion protection agent.
Check for corrosion approximately every 6 months. If first signs of corro-
sion show, apply new corrosion protection.
5. Packaging Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can
easily be separated and recycled.
For the disposal of the packaging material we recommend recycling and
collection centres.
We use the following packaging materials: wood, cardboard, paper and PE
foil.
7
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
6. Mounting to valve/ gearbox . Prior to mounting the multi-turn actuator must be checked
for damage. Damaged parts must be replaced by original
. spare parts.
After mounting to valve/ gearbox, touch up any possible
Mounting is most easily done with the valve shaft/gearbox shaft pointing
vertically upward. But mounting can be done in any other position as well.
The multi-turn actuator leaves the factory in position CLOSED (limit switch
.
CLOSED tripped).
The output drive types B1, B2, B3 or B4 (figure A) are delivered with bore
and keyway (usually according to ISO 5210).
Figure A
Output drive type B1/B2 Output drive type B3/B4
Plug sleeve Bore with keyway
For output drive type A (figure B-1), the internal thread of the stem nut must
match the thread of the valve stem. If not ordered explicitly with thread, the
..
stem nut is unbored or with pilot bore when delivered. For finish machining
of stem nut refer to next page.
Check whether bore and keyway match the input shaft of valve/gearbox.
..
Thoroughly degrease mounting faces at multi-turn actuator and valve/
gearbox.
Apply a small quantity of grease to input shaft of valve/gearbox.
Place actuator on valve/ gearbox and fasten. Fasten bolts (at least quality
8.8, refer to table 2) evenly crosswise.
8
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
80.3
80.01/ 80.02
80.2
..
The output drive flange does not have to be removed from the actuator.
..
Take off stem nut (80.3) together with thrust bearing (80.01) and thrust
bearing races (80.02).
Remove thrust bearing and thrust bearing races from stem nut.
..
Drill and bore stem nut and cut thread.
When fixing in the chuck, make sure stem nut runs true!
Clean the machined stem nut.
.
Apply ball bearing grease to thrust bearing and races, then place them on
stem nut.
..
Re-insert stem nut with thrust bearings into the mounting flange. Ensure
that dogs are placed correctly in the slots of the hollow shaft.
Screw in spigot ring until it is firm against the shoulder.
Press Lithium soap EP multi-purpose grease on mineral oil base, quanti-
ties see table, into the grease nipple with a grease gun:
.
Protection tube for rising valve stem
..
Protection tubes may be supplied loose. Seal thread with hemp, Teflon
tape or thread sealing material.
.
Screw protection tube (1) into thread (figure B-2) and tighten it firmly.
For corrosion protection KS/ KX, push down the seal (2) to the housing.
Check, whether cap (3) is available and without damage.
Figure B-2: Protection tube for rising valve stem
9
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
7. Manual operation The actuator may be operated manually for purposes of setting and
commissioning, and in case of motor failure or power failure.
Manual operation is engaged by an internal change-over mechanism.
Engaging manual operation: . Lift change-over lever in the centre of the handwheel up to approx. 85°,
while slightly turning the handwheel back and forth until manual drive
engages (figure C).
Figure C Figure D
.
force may damage the change-over mechanism.
Release change-over lever (should snap back into initial position by spring
action, figure D), if necessary push it back manually.
Figure E Figure F
Disengaging manual operation: Manual operation is automatically disengaged when motor is started again.
The handwheel does not rotate during motor operation.
10
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
For the Ex-plug/socket connector (figure G-1), the electrical mains connec-
Figure G-1: Connection tion is made after removing the plug cover (50.0) at the EEx e terminals of
the terminal board (51.0). The flameproof compartment (type of protection
50.0
.
EEx d) remains hereby closed.
50.01
.
Check whether type of current, supply voltage and frequency correspond
to motor data (refer to name plate at motor).
.
Loosen bolts (50.01) (figure G-1) and remove plug cover.
.
Seal cable entries which are not used with suitable plugs.
..
Strip wires: Controls max. 8 mm, motor max. 12 mm.
mains For stranded wires use end-sleeves according to DIN 46228.
50.0
2 wires for each connection permitted.
Connect cables according to order related terminal plan KMS TP . . .
The terminal plan applicable to the actuator KMS TP . . . is attached to
51.0 the handwheel in a weather-proof bag, together with the operation instruc-
tions. In case the terminal plan is not available, it can be obtained from
AUMA (state commission no., refer to name plate) or downloaded directly
51.02 from the Internet (www.auma.com).
If the actuator must be taken from the valve, e.g. for service purposes, it can
be separated from the mains without having to remove the wiring
(figure G-2). For that the screws (51.02) are removed and the plug/ socket
connector is pulled off. Plug cover (50.0) and terminal board (51.0) remain
together.
Parking frame
11
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
Table 4: Technical data Ex-plug/ socket connector with terminal board for explosion-proof actuators
Technical data Motor power connections1) Protective earth Control pins
No. of contacts max. 3 1 (leading contact) 38 pins / sockets
Marking U1, V1, W1 according to VDE 1 to 24, 31 to 40, 47 to 50
Voltage max. 550 V – 250 V
Current max. 25 A – 10 A
Type of customer connection Screws Screws Screws
Cross section max. 6 mm2 6 mm2 1.5 mm2
Material: Pin / socket carrier Araldite / Polyamide Araldite / Polyamide Araldite / Polyamide
Contacts Brass (Ms) Brass (Ms) Brass (Ms) tin-plated
1) Suitable for copper wires. For aluminium wires contact AUMA.
.
realised via a flameproof line bushing with integral plug/ socket connector.
.
51.01 Check whether type of current, supply voltage and frequency correspond
to motor data (refer to name plate at motor).
.
Loosen bolts (51.01) (figure G-4) and remove terminal cover (50.1).
..
Seal cable entries which are not used with suitable plugs.
12
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
A special parking frame (figure G-6) for protection against touching the bare
contacts and against environmental influences is available.
Parking frame
8.3 Delay time The delay time is the time from the tripping of the limit or torque switches to
the motor power being removed. To protect the valve, we recommend a
delay time < 50 ms. Longer delay times are possible provided the output
speed, output drive type, valve type and the type of installation are taken
into consideration.
We recommend to switch off the corresponding contactor directly by the limit
or torque switch.
8.4 Heater AUMA multi-turn actuators have a heater installed as standard. To prevent
condensation, the heater must be connected.
8.5 Motor protection In order to protect against overheating and impermissibly high temperatures
at the actuator, PTC thermistors or thermoswitches are embedded in the
motor winding. The thermoswitch is tripped as soon as the max. permissible
winding temperature has been reached.
8.6 Remote position transmitter For the connection of remote position transmitters (potentiometer, RWG)
screened cables must be used.
13
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
Only the same potential can be switched on the two circuits (NC/ NO
Figure G-7 contact) of a limit or torque switch. If different potentials are to be switched
simultaneously, tandem switches are required.
RD
BK
I Single switch
For correct signalisation, the leading contacts must be connected at the
tandem switch.
Use the lagging contacts for switching off.
BK
Mechanical
life time = 2 x 106 starts
NO NC NC NO
BK 2
RD
BK
1-phase AC
5A 5A 5A
(ind. load) cos phi = 0.8
DC
2A 0.5 A 0.4 A
(resistive load)
with gold plated
min. 5 V, max. 50 V
contacts
RD 2
BK 2
RD
BK
..
Clean sealing faces at the plug cover or terminal cover and the housing.
Check whether O-ring is in good condition.
Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.
Preserve joint surfaces with an acid-free corrosion protection agent.
.
way. Do not jam cover during fitting.
.
Replace cover (50.0 figure G-1 or 50.1 figure G-4) and fasten 4 bolts
evenly crosswise.
Fasten cable glands with the specified torque to ensure the required
enclosure protection.
14
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
9. Opening the switch To be able to make the following settings (clause 10. to 16.) the switch
compartment compartment must be opened and, if installed, the indicator disc must be
removed.
These settings are only valid for “clockwise closing”, i.e. driven shaft turns
clockwise to close the valve.
. Remove 4 bolts and take off the cover at the switch compartment
(figure H) .
Figure H-1: Cover with indicator glass Figure H-2: Cover without indicator glass
Bolts
.
9.2 Pulling off the indicator disc (option)
If installed, pull off indicator disc (figure J). Open end spanner (approx.
14 mm) may be used as lever.
RSD
RDW
Indicator disc
15
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
..
10.1 Setting for end position CLOSED (black section)
.
1/2 a turn (overrun). During test run (page 17) check overrun and, if
necessary, correct setting of the limit switching.
Press down and turn setting spindle A (figure K-1) with screw driver
(5 mm) in direction of arrow, thereby observe pointer B.
While a ratchet is felt and heard, the pointer B moves 90° every time.
When pointer B is 90° from mark C, continue turning slowly. When pointer
B has reached the mark C, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer
has snapped), continue turning the setting spindle in the same direction
and repeat setting process.
T P
B
E
C F
A D
.
10.2 Setting for end position OPEN (white section)
.
Turn handwheel counterclockwise until valve is open, then turn back
approximately 1/2 a turn.
Press down and turn setting spindle D (figure K-1) with screw driver
(5 mm) in direction of arrow, thereby observe pointer E.
While a ratchet is felt and heard, the pointer E moves 90° every time.
When pointer E is 90° from mark F, continue turning slowly. When pointer
E has reached the mark F, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer
has snapped), continue turning the setting spindle in the same direction
and repeat setting process.
10.3 Checking the switches The red test buttons T and P (figure K-1) serve for operating the limit
.
switches manually.
.
Turning T in direction of the arrow LSC (WSR) triggers limit switch
CLOSED.
Turning P in direction of the arrow LSO (WÖL) triggers limit switch OPEN.
16
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
..
11.1 Setting for direction CLOSE (black section)
T P
C F
H L
G K
..
11.2 Setting for direction OPEN (white section)
17
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
O P O P
.
3.5 da Nm = 35 Nm for direction CLOSE
4.5 da Nm = 45 Nm for direction OPEN
.
Tighten lock screws O again
. operation.
The torque switching acts as overload protection over full
travel, also when stopping in the end positions by limit
switching.
12.2 Checking the switches for torque and DUO limit switching
The red test buttons T and P (figure K-2) serve for operating the torque
.
switches manually:
.
Turning T in direction of the arrow TSC (DSR) triggers torque switch
CLOSED.
.
Turning P in direction of the arrow TSO (DÖL) triggers torque switch
OPEN.
If a DUO limit switching (optional) is installed in the actuator, the interme-
diate position switches will be operated at the same time.
18
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
13. Test run 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 direction of rotation of the indicator disc (figure M-1) indicates the
direction of rotation of the output drive.
If there is no indicator disc, the direction of rotation can also be observed
on the hollow shaft. To this end, remove screw plug (no. 27) (figure M-2).
Figure M-1: Indicator disc Figure M-2: Opening the hollow shaft
CLOSED OPEN 27
S1/S2
.
.
Move actuator manually to intermediate position or to sufficient distance
from end position.
Switch on actuator in direction CLOSE and observe the direction of rotation:
Table 7:
Direction of rotation of the indicator disc:
counterclockwise correct
Direction of rotation of the hollow shaft:
clockwise correct
13.2 Check limit switching: .. Move actuator manually into both end positions of the valve.
Check whether limit switching is set correctly. Hereby observe that the
appropriate switch is tripped in each end position and released again after
the direction of rotation is changed. If this is not the case, the limit
switching must first be set, as described from page 15.
.
If no other options (clauses 14. to 16.) require setting:
Close switch compartment (see page 24, clause 17.).
19
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
..
– For remote indication –
.
Move valve to end position CLOSED.
If installed, pull off indicator disc.
.
Turn potentiometer (E2) clockwise until stop is felt.
End position CLOSED corresponds to 0 %, end position OPEN to 100 %.
Turn potentiometer (E2) back a little.
.
for adjustment (setting potentiometer) must be provided.
E2
20
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
The position transmitter board (figure P-1) is located under the cover plate
(figure P-2).
21
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
..
15.1 Setting for 2-wire system 4 – 20 mA and 3- /4-wire system 0 – 20 mA
..
Connect voltage for electronic position transmitter.
Move valve to end position CLOSED.
If installed, pull off indicator disc.
Connect ammeter for 0 – 20 mA to measuring points (figure P-2).
..
measured.
Cover plate
E2
..
for 2-wire system: approx. 4.1 mA.
This ensures that the signal remains above the dead and live zero point.
.
Move valve to end position OPEN.
Set potentiometer “max.” to end value 20 mA.
Approach end position CLOSED anew and check minimum value (0.1 mA
or 4.1 mA). If necessary, correct the setting.
22
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
..
15.2 Setting for 3- / 4- wire system 4 – 20 mA
..
Connect voltage for electronic position transmitter.
Move valve to end position CLOSED.
If installed, pull off indicator disc.
Connect ammeter for 0 – 20 mA to measuring points (figure P-2).
..
measured.
Cover plate
E2
..
Turn back potentiometer “0” until a residual current of approx. 0.1 mA is
reached.
..
Move valve to end position OPEN.
Set potentiometer “max.” to end value 16 mA.
Move valve to end position CLOSED.
Set potentiometer “0” from 0.1 mA to initial value 4 mA.
.
This results in a simultaneous shift of the end value by 4 mA, so that the
range is now 4 – 20 mA.
Approach both end positions anew and check setting. If necessary, correct
the setting.
23
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
..
.
Place indicator disc on shaft.
Move valve to end position CLOSED.
..
Turn lower indicator disc (figure Q1) until symbol CLOSED is in align-
ment with the mark on the cover (figure Q-2).
Move actuator to end position OPEN.
Hold lower indicator disc CLOSED in position and turn upper disc with
symbol OPEN until it is in alignment with the mark on the cover.
Figure Q-1: Figure Q-2:
Indicator disc
Mark
Indicator disc rotates approximately 180° to 230° at full travel from OPEN to
CLOSED or vice versa. A suitable reduction gearing was installed in our
works.
If the turns per stroke are changed at a later date, the reduction gearing
may have to be exchanged, too.
.
way. Do not jam cover during fitting.
24
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
18. Maintenance For any maintenance work, the following should be observed:
. required.
When working in potentially explosive areas, observe the
standard EN 60079-17 “Inspection and Maintenance of
.
Pay attention to national regulations.
.
Do a thorough touch-up of possible damage to paint finish to prevent
corrosion. Original paint in small quantities can be supplied by AUMA.
Cable entries, cable glands, plugs etc. have to be checked for correct
tightness and sealing. Observe torques according to manufacturer’s
..
details. If required, replace the components. Only use components which
have a test certificate.
Check whether Ex-connections are fastened correctly.
.
Take care of possible discolouration of the terminals and wires. This would
indicate an increased temperature.
For Ex housings, take care especially of a possible collection of water.
This may originate from ‘breathing’ due to severe temperature variations
.
(e. g. change of night and day), from damaged seals etc. Remove any
water immediately.
Check the flame path gaps of flameproof enclosures for dirt and corro-
sion.
Since the dimensions of all flameproof joints are strictly defined and
inspected, no mechanical work (such as grinding) shall be performed on
.
them. The joint surfaces have to be cleaned chemically (e. g. with
Esso-Varsol).
.
Before fitting, the joint surfaces have to be preserved with an acid-free
corrosion protection agent (e. g. Esso Rust BAN 397).
..
Ensure that all housing covers are handled carefully and that the seals are
checked.
All cable and motor protection components have to be checked.
..
If defects which affect the safety are detected during maintenance, repair
measures have to be initiated without delay.
Any kind of surface coating for the joint surfaces is not permitted.
.
When exchanging parts, seals etc. only original spare parts shall be used.
25
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
.
We recommend additionally:
.
If operated seldom, perform a test run about every 6 months. This ensures
that the actuator is always ready to operate.
Approximately six months after commissioning and then every year check
.
bolts between actuator and valve/gearbox for tightness. If required, tighten
applying the torques given in table 2, page 8.
For multi-turn actuators with output drive type A: at intervals of approx.
6 months from commissioning press in Lithium soap EP multi-purpose
grease on mineral oil base at the grease nipple with grease gun (quantity
see table 3, page 9).
19. Lubrication .. The gear housing is filled with lubricant in the factory.
..
A grease change is recommended after the following operation time:
..
sembled, separated and sorted according to materials, i.e.:
..
electronic scrap
various metals
plastics
greases and oils
.
The following generally applies:
.
Collect greases and oils during disassembly. As a rule, these substances
are hazardous to water and must not be released into the environment.
.
See disassembled material to a sound disposal or to separate recycling
according to materials.
Observe the national regulations for waste disposal.
21. Service AUMA offers extensive services such as maintenance and inspection for
actuators. Addresses of AUMA offices and representatives can be found on
page 36 and on the Internet (www.auma.com).
26
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
Notes
27
28
SAExC 14.1 – SAExC 16.1
SARExC 14.1 – SARExC 16.1 S2
AUMA NORM
50.0
79.0-2
79.0-3 160.2
S1 / S2
S2
160.1
S2 51.0
51.1 153.2
51.3
SAExC 07.1 – SAExC 10.1 79.0-1 51.2
S1 / S2
SARExC 07.1 – SARExC 10.1 51.4
52.0 153.1
58.0 152.2
70.0 27
151.0 153.3
56.0 S1 / S2
52.3 57.0 152.1 155.0
S1 / S2 153.0
S1 / S2 20.0 39
S2
24
59.0
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
153.5
5.7 5.0
25.0 19.0 5.12 S2
019 17.0
020
70.1 24.0 / 23.0 5.8 9.0
49.0 22.0
5.37 30.0
S2 5.32
10.0
S2
053 S2
18
105.0 1.0 012
S1 / S2 6
3.0
14
80.001
156.0
107
60.0 80.0
100 90.001
106.0 80.3
S2
61.0 S2 80.001 85.001
90.0
Sample name plate 2.0
85.0
15.0
22. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with plug/ socket connector
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
Note:
When placing orders for spare parts, it is essential to mention type of actuator and our commission number
(refer to actuator name plate)
.
No. Type Designation No. Type Designation
012 E Notched pin 58.0 B Wire for protective earth
019 E Cheese head screw Pin for motor and thermoswitch
59.0 1) B in motor plug
020 E Clamping washer
053 E Countersunk screw Control unit assly. (but without torque head,
60.0 B without switches)
1.0 B Housing assly.
2.0 B Flange, bottom assly. 61.0 B Torque switching head
3.0 B Hollow shaft assly. (without worm wheel) 70.0 B Motor
5.0 B Worm shaft assly. Motor pin carrier
70.1 1) B (without pins)
5.12 E Grub screw
5.32 E Coupling pin 79.0-1 2) B Planetary gearing for motor drive assly.
5.37 B Pull rod assly. 79.0-2 2) B Planetary gearing for motor drive assly.
E 2)
5.7 Motor coupling 79.0-3 B Ex-motor mounting flange
5.8 B Manual drive coupling assly. Output drive Form A assly.
80.0 3) B (without thread in stem nut)
6 E Worm wheel
9.0 B Planetary gear for manual drive assly. 80.0013) E Thrust bearing set
10.0 B Retaining flange assly. 80.3 3) E Stem nut Form A (without thread)
3)
14 E Change-over lever 85.0 B Output drive B3
15.0 B Cover for switch compartment assly. 85.0013) E Snap ring
17.0 B Torque lever assly. 90.0 3) B Output drive D
18 E Gear segment 3)
90.001 E Snap ring
19.0 B Crown wheel assly. Switch for limit / torque switching
100 B (including pins at wires)
20.0 B Swing lever assly.
22.0 B Drive pinion II for torque switching assly. Blinker transmitter including pins at wires
105.0 B (without impulse disc and insulation plate)
23.0 B Drive wheel for limit switching assly.
24 E Drive wheel for limit switching 106.0 B Stud bolt for switches
24.0 B Intermediate wheel for limit switching assly. 107 E Spacer
25.0 E Locking plate 151.0 B Space heater
27 E Screw plug 3)
152.1 B Potentiometer (without slip clutch)
30.0 B Handwheel with ball handle assly. 152.2 3) B Slip clutch for potentiometer
39 E Screw plug 3)
153.0 B RWG assly.
49.0 1) B Motor plug, socket assly. Potentiometer for RWG
153.1 3) B (without slip clutch)
50.0 B Cover assly.
51.0 B Terminal board assly. 153.2 3) B Slip clutch for RWG
51.1 E Screw - Control terminal 153.3 3) B Electronic board RWG
51.2 E Washer - Control terminal 153.5 3) B Wires for RWG
51.3 E Screw - Power terminal 155.0 3) B Reduction gearing
3)
51.4 E Washer - Power terminal 156.0 B Mechanical position indicator
52.0 B Pin carrier (without pins) 160.1 3) E Protection tube (without cap)
3)
52.3 E Circlip 160.2 E Cap for stem protection tube
56.0 B Pin for control S1 S Seal-kit, small
57.0 B Pin for motor S2 S Seal-kit, large
Type B = sub-assembly Type E = component Type S = set assly. = assly.
1) SAExC 16.1 with output speeds of 32 to 180 rpm or SARExC 16.1 with output speeds of 32 and 45 rpm without
plug/ socket connector; motor directly wired to pin carrier (No. 52.0).
2) only required for some output speeds
3) not included in basic equipment
29
30
SAExC 14.1 – SAExC 16.1
SARExC 14.1 – SARExC 16.1 S2
AUMA NORM
79.0-2
79.0-3
50.1
51.16
160.2
S2 S1 / S2
S2 S1 / S2
54.2
79.0-1 S2 50.021 153.2
SAExC 07.1 – SAExC 10.1 160.1 50.024
50.020
SARExC 07.1 – SARExC 10.1 54.0 50.023 50.016
153.1
50.2
70.0 27
54.2 153.3
S1 / S2 152.2
52.0
56.0 S1 / S2 151.0 153.0 155.0
S1 / S2
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
57.0 39 152.1
20.0 S2
24
59.0
5.0 153.5
5.7
25.0 19.0 5.12 S2
019 17.0
020
70.1 24.0 / 23.0 5.8 9.0
49.0 22.0
5.37 30.0
S2 5.32
10.0
S2
053 S2
18
S1 / S2 105.0 1.0 6 012
3.0
14
80.001
156.0 107
60.0 100 80.0
90.001
106.0 80.3
S2 85.001
61.0
S2 80.001
Sample name plate 90.0
85.0
2.0
15.0
- Actuator type 85.001
- Commission number S2 90.001
- Works number B1 / C A D B3 / B4 / E
- Protection type
Torque range
23. Spare parts list multi-turn actuator SAExC 07.1 – SAExC 16.1 with terminal connection
in CLOSE/OPEN
Operation instructions
- Lubricant
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
Note:
When placing orders for spare parts, it is essential to mention type of actuator and our commission number
(refer to actuator name plate)
1) SAExC 16.1 with output speeds of 32 to 180 rpm or SARExC 16.1 with output speeds of 32 and 45 rpm without
plug/ socket connector; motor directly wired to pin carrier (No. 52.0).
2) only required for some output speeds
3) not included in basic equipment
31
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
32
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
33
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
AUMA NORM Operation instructions
34
Multi-turn actuators SA(R)ExC 07.1 – SA(R)ExC 16.1
Operation instructions AUMA NORM
Index
C M T
Corrosion protection 7 Maintenance 4 Tandem switch 14
Manual operation 10 Technical data 5
D
Mechanical position indicator 24 Test run 19
Declaration of Conformity 34
Motor protection 13 Thermoswitches 13
Declaration of Incorporation 34
Mounting to valve/ gearbox 8 Torque setting 18
DUO limit switching 17
Transport 7
N
E Tripping torque 18
Name plate 28
Electrical connection 11
Electronic position transmitter O
RWG 21 Output drive types 8
2-wire system 22
P
3-/ 4-wire system 23
Parking frame 11
F Position indicator 24
Finish machining of stem nut 9 Position transmitter RWG 21
Potentiometer 20
H
Protection tube 9
Handwheel 10
PTB certificate 32
Heater 13
PTC thermistors 13
I
R
Indicator disc 24
Remote indication 20,21
Internet 35
S
L
Safety instructions 4
Limit switches 14
Service 26
Limit switching 16,17
Spare parts list 28
Lubrication 26
Actuator 28
Spare parts list SA(R)ExC with
terminal connection 31
Storage 7
Information also available Terminal plan, inspection records and further actuator information
on the Internet: can be downloaded directly from the internet by entering the order no.
or comm no. (refer to name plate).
Our homepage: http://www.auma.com
35
AUMA (Schweiz) AG INDUSTRA
Europe CH-8965 Berikon PT-2710-297 Sintra
Suplibarca
VE- Maracaibo Estado, Zulia
AUMA Riester GmbH & Co. KG Tel +41 566 400945 Tel +351 2 1910 95 00 Tel +58 261 7 555 667
Factory Müllheim Fax +41 566 400948 Fax +351 2 1910 95 99 Fax +58 261 7 532 259
RettichP.ch@auma.com jpalhares@tyco-valves.com suplibarca@intercable.net.ve
DE-79373 Müllheim
Tel +49 7631 809 - 0 AUMA Servopohony spol. s.r.o. MEGA Endüstri Kontrol Sistemieri Tic. Ltd.
Fax +49 7631 809 - 250 CZ-10200 Praha 10 Sti. Asia
riester@auma.com Tel +420 272 700056 TR-06460 Övecler Ankara AUMA Actuators (Tianjin) Co., Ltd.
www.auma.com Fax +420 272 704125 Tel +90 312 472 62 70 CN-300457 Tianjin Teda District
Factory Ostfildern-Nellingen auma-s@auma.cz Fax +90 312 472 62 74 Tel +86 22 6625 1310
www.auma.cz megaendustri@megaendustri.com.tr
DE-73747 Ostfildern Fax +86 22 6625 1320
Tel +49 711 34803 - 3000 OY AUMATOR AB CTS Control Limited Liability Company mailbox@auma-china.com
Fax +49 711 34803 - 3034 FI-02270 Espoo UA-02099 Kiyiv www.auma-china.com
riester@wof.auma.com Tel +35 895 84022 Tel +38 044 566-9971, -8427 AUMA (INDIA) PRIVATE LIMITED
Service Centre Cologne Fax +35 895 8402300 Fax +38 044 566-9384 IN-560 058 Bangalore
auma@aumator.fi v_polyakov@cts.com.ua
DE-50858 Köln Tel +91 80 2839 4655
Tel +49 2234 20379 - 00 AUMA France Fax +91 80 2839 2809
Fax +49 2234 20379 - 99 FR-95157 Taverny Cédex Africa info@auma.co.in
Service@sck.auma.com Tel +33 1 39327272 AUMA South Africa (Pty) Ltd. www.auma.co.in
Service Centre Magdeburg Fax +33 1 39321755 ZA-1560 Springs AUMA JAPAN Co., Ltd.
stephanie.vatin@auma.fr Tel +27 11 3632880 JP-210-0848 Kawasaki-ku,
DE-39167 Niederndodeleben
www.auma.fr Fax +27 11 8185248
Tel +49 39204 759 - 0 Kawasaki-shi Kanagawa
Fax +49 39204 759 - 19 AUMA ACTUATORS Ltd. aumasa@mweb.co.za Tel +81 44 329 1061
Service@scm.auma.com GB- Clevedon North Somerset BS21 6QH A.T.E.C. Fax +81 44 366 2472
Service Centre Bavaria Tel +44 1275 871141 EG- Cairo mailbox@auma.co.jp
Fax +44 1275 875492 Tel +20 2 3599680 - 3590861
DE-85386 Eching AUMA ACTUATORS (Singapore) Pte Ltd.
mail@auma.co.uk Fax +20 2 3586621
Tel +49 81 65 9017-0 SG-569551 Singapore
www.auma.co.uk atec@intouch.com
Fax +49 81 65 9017-18 Tel +65 6 4818750
Riester@scb.auma.com AUMA ITALIANA S.R.L. Fax +65 6 4818269
North Office, Ship building sector IT-20023 Cerro Maggiore Milano America sales@auma.com.sg
Tel +39 0331-51351 AUMA ACTUATORS INC. www.auma.com.sg
DE-21079 Hamburg
Fax +39 0331-517606 US-PA 15317 Canonsburg AUMA Middle East Rep. Office
Tel +49 40 791 40285
info@auma.it Tel +1 724-743-AUMA (2862)
Fax +49 40 791 40286 AE- Dubai
www.auma.it Fax +1 724-743-4711
Stephan.Dierks@auma.com Tel +971 4 3682720
North Office, Industry AUMA BENELUX B.V. mailbox@auma-usa.com Fax +971 4 3682721
DE-29664 Walsrode NL-2314 XT Leiden www.auma-usa.com auma@emirates.net.ae
Tel +31 71 581 40 40 AUMA Chile Respresentative Office PERFECT CONTROLS Ltd.
Tel +49 5167 504
Fax +31 71 581 40 49 CL- Buin
Fax +49 5167 565 HK- Tsuen Wan, Kowloon
office@benelux.auma.com Tel +56 2 821 4108
Erwin.Handwerker@auma.com Tel +852 2493 7726
www.auma.nl Fax +56 2 281 9252
East Office Fax +852 2416 3763
AUMA Polska Sp. z o.o. aumachile@adsl.tie.cl joeip@perfectcontrols.com.hk
DE-39167 Niederndodeleben
Tel +49 39204 75980 PL-41-310 Dabrowa Górnicza LOOP S. A. DW Controls Co., Ltd.
Tel +48 32 26156 68 AR-C1140ABP Buenos Aires
Fax +49 39204 75989 KR-153-803 Seoul Korea
Fax +48 32 26148 23 Tel +54 11 4307 2141
Claus.Zander@auma.com Tel +82 2 2113 1100
R.Ludzien@auma.com.pl Fax +54 11 4307 8612
West Office Fax +82 2 2113 1088/1089
www.auma.com.pl contacto@loopsa.com.ar
DE-45549 Sprockhövel sichoi@actuatorbank.com
OOO Priwody AUMA Asvotec Termoindustrial Ltda. www.actuatorbank.com
Tel +49 2339 9212 - 0
Fax +49 2339 9212 - 15 RU-141400 Moscow region for mail: BR-13190-000 Monte Mor/ SP. AL-ARFAJ Eng. Company W. L. L.
Karlheinz.Spoede@auma.com 124365 Moscow a/ya 11 Tel +55 19 3879 8735 KW-22004 Salmiyah
Tel +7 495 221 64 28 Fax +55 19 3879 8738 Tel +965 4817448
Württemberg Office Fax +7 495 221 64 38 atuador.auma@asvotec.com.br Fax +965 4817442
DE-73747 Ostfildern aumarussia@auma.ru
Tel +49 711 34803 80 TROY-ONTOR Inc. arfaj@qualitynet.net
www.auma.ru
Fax +49 711 34803 81 CA-L4N 5E9 Barrie Ontario BEHZAD Trading Enterprises
Siegfried.Koegler@wof.auma.com ERICHS ARMATUR AB Tel +1 705 721-8246 QA- Doha
SE-20039 Malmö Fax +1 705 721-5851 Tel +974 4433 236
SoutheWest Office Tel +46 40 311550 troy-ontor@troy-ontor.ca Fax +974 4433 237
DE-74937 Spechbach Fax +46 40 945515
Tel +49 6226 786141 MAN Ferrostaal de Colombia Ltda. behzad@qatar.net.qa
info@erichsarmatur.se
Fax +49 6226 786919 www.erichsarmatur.se CO- Bogotá D.C. Sunny Valves and Intertrade Corp. Ltd.
Rudolf.Bachert@auma.com Tel +57 1 401 1300 TH-10120 Yannawa Bangkok
GRØNBECH & SØNNER A/S Fax +57 1 416 5489
Baden Office Tel +66 2 2400656
DK-2450 København SV dorian.hernandez@manferrostaal.com Fax +66 2 2401095
DE-76764 Rheinzabern Tel +45 33 26 63 00 www.manferrostaal.com sunnyvalves@inet.co.th
Tel +49 7272 76 07 - 23 Fax +45 33 26 63 21
Fax +49 7272 76 07 - 24 PROCONTIC Procesos y Control Automático www.sunnyvalves.co.th/
GS@g-s.dk
Wolfgang.Schulz@auma.com www.g-s.dk EC- Quito Top Advance Enterprises Ltd.
Power plant sector Tel +593 2 292 0431 TW- Jhonghe City Taipei Hsien (235)
IBEROPLAN S.A. Fax +593 2 292 2343
DE-79373 Müllheim Tel +886 2 2225 1718
ES-28027 Madrid info@procontic.com.ec Fax +886 2 8228 1975
Tel +49 7631 809 192 Tel +34 91 3717130
Fax +49 7631 809 294 IESS DE MEXICO S. A. de C. V. support@auma-taiwan.com.tw
Fax +34 91 7427126 www.auma-taiwan.com.tw
Klaus.Wilhelm@auma.com iberoplan@iberoplan.com MX-C.P. 02900 Mexico D.F.
Tel +52 55 55 561 701
Büro Bavaria
DE-93356 Teugn/Niederbayern
D. G. Bellos & Co. O.E. Fax +52 55 53 563 337 Australia
GR-13671 Acharnai Athens informes@iess.com.mx
Tel +49 9405 9410 24 BARRON GJM Pty. Ltd.
Tel +30 210 2409485
Fax +49 9405 9410 25 Corsusa S.A.C. AU-NSW 1570 Artarmon
Fax +30 210 2409486
Mathias.Jochum@auma.com info@dgbellos.gr PE- Miralflores - Lima Tel +61 294361088
AUMA Armaturenantriebe GmbH Tel 00511444-1200 / 0044 / 2321 Fax +61 294393413
SIGURD SØRUM A. S. Fax 00511444-3664 info@barron.com.au
AT-2512 Tribuswinkel NO-1301 Sandvika corsusa@corsusa.com www.barron.com.au
Tel +43 2252 82540 Tel +47 67572600 www.corsusa.com
Fax +43 2252 8254050 Fax +47 67572610
office@auma.at PASSCO Inc.
post@sigurd-sorum.no
www.auma.at PR-00936-4153 San Juan 2006-03-08
Tel +18 09 78 77 20 87 85
Fax +18 09 78 77 31 72 77
Passco@prtc.net
AUMA Riester GmbH & Co. KG AUMA Riester GmbH & Co. KG
P. O. Box 1362 P. O. Box 1151
D - 79373 Müllheim D - 73747 Ostfildern
Tel +49 (0)7631/809-0 Tel +49 (0)711 / 34803 0
Fax +49 (0)7631/809 250 Fax +49 (0)711 / 34803 34
riester@auma.com riester@wof.auma.com Certificate Registration No.
12 100/104 4269
www.auma.com www.auma.com
For detailed information about AUMA products refer to the Internet:
www.auma.com Y002.775/003/en/1.05
Series 3730
Electropneumatic Positioner
Type 3730-3
®
With HART communication
Mounting and
Operating Instructions
EB 8384-3 EN
Firmware version 1.4x
Edition March 2007
Contents
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 8
1.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Attachment to the control valve – Mounting parts and accessories . . . 13
2.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.1 Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 20
2.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 22
2.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 24
2.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26
2.5.1 Pressure gauge attachment . . . . . . . . . . . . . . . . . . . . . . 26
2.6 Attaching an external position sensor . . . . . . . . . . . . . . . . . 28
2.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 28
2.6.2 Mounting the position sensor with attachment according to IEC 60534-6 30
2.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 31
2.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 32
2.7 Attaching positioners with stainless steel housings. . . . . . . . . . . . 34
2.8 Air purging function for single-acting actuators . . . . . . . . . . . . . 34
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 40
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Operator controls and display . . . . . . . . . . . . . . . . . . . . . 42
4.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 44
4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 45
4.3.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 46
5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 47
5.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . 47
5.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 EB 8384-3 EN
Contents
EB 8384-3 EN 3
Safety instructions
4 EB 8384-3 EN
Versions
Explosion protection
Without 0
II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C 1
acc. to ATEX
CSA/FM intrinsically safe/non incendive 3
II 3 G EEx na II T6 / II 3 D IP 65 T 80 °C 8
acc. to ATEX
Additional equipment
Inductive Without 0
limit switch With Type SJ 2-SN 1 0
Analog Without 0
position transmitter With 1
External Without 0
Position sensor With 0 1
Diagnostics EXPERT 1
EXPERT+ (extended) 2
IECEx 1 0 1 2
EB 8384-3 EN 5
Firmware modification
Previous New
1.00 1.10
1.10 1.20
1.20 1.30
The position transmitter (Code 37) and solenoid valve (Code 45) options are
automatically recognized.
1.30 1.40
All EXPERT+ functions can be used over HART® communication in this firm-
ware version and higher.
6 EB 8384-3 EN
Firmware modification
The fault alarm contact is triggered by the condensed status of the positioner.
It is always active with “Maintenance alarm” condensed status.
If Code 32 is set to Yes: Also active with “Function check” condensed status
If Code 33 is set to Yes: Also active with “Maintenance required/Mainte-
nance demanded” condensed status
The “Function check” condensed status is additionally set for Test A1, A2,
fault alarm output and position transmitter.
1.40 1.41
Internal modifications
1.41 1.42
Internal modifications
EB 8384-3 EN 7
Design and principle of operation
8 EB 8384-3 EN
Design and principle of operation
1 Control valve
Serial 2 Travel sensor
20 16
Interface 3 PD controller
13
21 FSK 4 A/D converter
mm
% A3 5 Microcontroller
S 15 6 i/p converter
4 5 A2 7 Air capacity booster
w 19
14 8 Pressure regulator
A1 9 Flow regulator
14 10 Volume restriction
24V DC w 11* Inductive limit switch
PD 12* Solenoid valve
2 11
x 13* Analog position transmitter
17 18 3 14 Software limit switches
12 G G Alarm 1/2
15 Fault alarm output
6 Alarm 3
9
16 Display
17* Solenoid valve control
8 1 18* Galvanic isolation
y
19 D/A converter
Q 10 x
7 20 Communication interface
21 HART modulation
* Optional
Fig. 2 · Functional diagram
EB 8384-3 EN 9
Design and principle of operation
10 EB 8384-3 EN
Design and principle of operation
Transit time Separately adjustable up to 240 seconds for supply air and exhaust air
Direction of action Reversible
Air consumption, steady
Independent from supply pressure approx. 110 ln/h
state
Air output capacity
Actuator pressurized At Δp = 6 bar: 8.5 mn3/h, at Δp = 1.4 bar: 3.0 mn3/h KVmax (20 °C) = 0.09
Actuator vented at Δp = 6 bar: 14.0 mn3/h, at Δp = 1.4 bar: 4.5 mn3/h KVmax (20 °C) = 0.15
–20 to +80 °C, with metal cable gland –45 to +80 °C
Permissible ambient
The limits specified in the EC Type Examination Certificate additionally apply for
temperature
explosion-protected devices.
Temperature: ≤ 0.15 %/10 K Supply air: None
Influences
Vibration: ≤ 0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Electromagnetic
Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21
compatability
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, II, III, Division 1, Group A, B, C, D, E, F, G, T6
FM/CSA non incendive Class I, Division 2, Group A, B, C, D, T6
Degree of protection IP 66 / NEMA 4X
Communication (local) SAMSON SSP interface and serial interface adapter
Software requirements TROVIS-VIEW with database module 3730-3
HART® field communication protocol
Communication (HART) Impedance in the HART frequency range: receive 350 to 450 Ω,
send: approx. 155 Ω
For handheld communicator: device description for 3730-3,
Software requirements For PC: DTM file acc. to Specification 1.2, suitable for integrating the positioner in
(HART®) frame applications that supports the FDT/DTM concept (e.g. PACTware);
other integration options (e.g. AMS, PDM) available.
Binary contacts
2 software limit switches, reverse polarity protection, configurable switching characteristics,
default settings as per table
Signal status: Without explosion protection: Exp.-protected version:
No response: Non-conducting ≤ 1.2 mA
Response: Conductive (R = 348 Ω ) ≥ 2.1 mA
1 fault alarm contact
Signal status: Without explosion protection: Exp.-protected version:
No response/No alarm Conductive R = 348 Ω ≥ 2.1 mA
Response/Fault alarm Non-conducting ≤ 1.2 mA
Positioners with model no. ../9000 only for connection to
Only for connection to
signal converter acc. to EN 60947-5-6.
Operating voltage signal converter acc. to
All other versions also for connection to binary input of
EN 60957-5-6
the PLC acc. to EN 61131, Pmax = 400 mW
EB 8384-3 EN 11
Design and principle of operation
12 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 13
Attachment to the control valve – Mounting parts and accessories
14 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter)
Table 3
according to IEC 60534-6, see Fig. 6
Travel in mm Lever For actuators Order no.
7.5 S Type 3271-5 with 60/120 cm² on Type 3510 Valve (Fig. 7) 1400-7457
Without (lever M on Actuators from other manufacturers and Type 3271 with
5 to 50 1400-7454
basic model) 120 to 700 cm²
Actuators f. other manufacturers and Type 3271, 1400-60
14 to 100 L 1400-7455
version
Actuators from other manufacturers and Type 3271, versions
40 to 200 XL 1400-7456
1400-120 and 2800 cm² with 120 mm travel
Type 3271, versions 1400-120 and 2800 cm² with
30 or 60 L 1400-7466
30/60 mm travel
Mounting brackets for Emerson and Masoneilan linear actuators
1400-6771
In addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above.
Connecting plate G ¼: 1400-7461 ¼ NPT : 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Accessories
Pressure gauge mounting kit up to max. 6 bar
St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951
(output/supply)
Table 4 Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 8 and 9
With follower clamp VDI/VDE 3845 for all sizes of fixing level 2 1400-7448
and coupling wheel, for Type 3278 Actuator with 160/320 cm2 1400-7614
CrNiMo steel bracket for Camflex II 1400-9120
Mounting
parts VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty version 1400-9244
Mounting parts for rotary actuators VDI/VDE 3845 (level 1), heavy-duty version 1400-9526
SAMSON Type 3278 160 cm² / VETEC Type S160 and Type R 1400-9245
Connecting plate G ¼: 1400-7461 ¼ NPT: 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Accessories
Pressure gauge mounting kit up to max. 6 bar
St.st./Bs: 1400-6950 St.st./St.st: 1400-6951
(output/supply)
Table 5 General accessories
Pneumatic reversing amplifier for double-acting G¼ 1079-1118
actuators ¼ NPT 1079-1119
Cable gland M20 x 1.5 Nickel-plated brass 1890-4875
Adapter M 20 x 1.5 to ½ NPT, aluminum 0310-2149
EB 8384-3 EN 15
Attachment to the control valve – Mounting parts and accessories
16 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
1 Lever
Symbols 1.1 Nut
Switchover plate (9)
1.2 Disk spring
Actuator stem 2 Follower pin
extends
3 Follower clamp
4 Screw plug
Attachment left Attachment right
5 Stopper
6 Connecting plate
Actuator stem
6.1 Seal rings
retracts
7 Pressure gauge bracket
Signal pressure 8 Press. gauge mounting kit
input for left Signal pressure 9 Switchover plate
attachment Marking input for right for actuator
attachment 10 Cover plate
10.1Seal ring
15 11 Cover
14 Gasket
14
15 Formed seal
Lever M
1
1.1
1.2
Cut-out of cover
plate
10.1
9 11
6.1 10
6
6
5 Note!
Always use the connecting plate (6)
Supply 9 Output 38 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
Attachment to the control valve – Mounting parts and accessories
2.1.2 Type 3277 Actuator rests on the top of the follower clamp
(3). Adjust the lever (1) correspondingly
Refer to Table 2 on page 14 or the required and open the positioner cover to hold
mounting parts as well as the accessories the positioner shaft in position at the cap
with their order numbers.
or the switch (Fig. 19). The lever (1) must
Note the travel table on page 13!
rest on the follower clamp with spring
Actuators with 240 to 700 cm² force. Mount the positioner on the cover
plate (10) using the two fixing screws.
The positioner can be mounted either on the 6. Make sure that the tip of the gasket (16)
left or on the right side of the yoke. The sig- projecting from the side of the connec-
nal pressure is routed to the actuator over tion block (12) is positioned above the
the connection block (12), for actuators with
actuator symbol that corresponds with
fail-safe action "Actuator stem extends" in-
the actuator with fail-safe action "Actua-
ternally through a bore in the valve yoke
and for "Actuator stem retracts" through ex- tor stem extends" or "Actuator stem re-
ternal piping. tracts." If necessary, remove the three
fixing screws and the cover. Then repo-
1. Place follower clamp (3) on the actuator sition the gasket (16) turned by 180°.
stem, align and screw tight so that the The previous version of the connection
mounting screw is located in the groove block (Fig. 5, bottom) requires the switch
of the actuator stem. plate (13) to be turned such that the cor-
2. Mount cover plate (10) with narrow side responding actuator symbol points to the
of the cut-out opening (Fig. 5, on the marking.
left) pointing towards the signal pressure 7. Place the connection block (12) with the
connection. Make sure that the bonded associated seal rings against the
gasket (14) points towards the actuator positioner and the actuator yoke. Screw
yoke. it tight using the fixing screw (12.1). For
3. For actuators with 700 cm², remove the actuators with fail-safe action "Actuator
follower pin (2) at lever M (1) on the stem retracts", additionally remove the
back of the positioner from pin position stopper (12.2) and fit on the external
35, reposition it in the bore for pin posi- signal pressure piping.
tion 50 and screw tight. 8. Mount cover (11) on the other side.
For actuators 240 and 350 cm² with Make sure that the vent plug points
15 mm travel, the follower pin (2) re- downwards when the control valve is in-
mains in pin position 35. stalled to allow any condensed water
4. Insert formed seal (15) in the groove of that collects to drain off.
the positioner casing.
5. Place positioner on the cover plate in
such a manner that the follower pin (2)
18 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
2
Lever M
1.1
1.2
Cut-out of
cover plate (10)
A
16
12.1 12.2
Fig. 5 · Direct attachment – Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm²
EB 8384-3 EN 19
Attachment to the control valve – Mounting parts and accessories
20 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
15
11
10
Attachment to
9
NAMUR rib
9.1
3.1
16
Additional bracket for
2
actuators with 2800 cm
Lever XL and L and travel ≥ 60 mm 14
1 Lever
1.1 Nut 1 3
1.2 Disk spring
1 14.1
2 Follower pin
3 Follower plate
3.1 Follower plate
2
6 Connecting plate
1.1
6.1 Seal rings 6.1 6 7 8
1.2
7 Pressure gauge bracket
1
8 Pressure gauge
mounting kit
9 Stem connector
9.1 Bracket
10 NAMUR bracket
11 Screw
14 Bolt
14.1 Screw
Note!
15 U-bolt Always use the connecting plate (6) included in the accessories to connect
16 Bracket supply and output. Never screw threaded parts directly into the housing.
EB 8384-3 EN 21
Attachment to the control valve – Mounting parts and accessories
22 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
3 Clamp
6 Connecting plate
6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge
mounting kit 3
10 Bracket
11 Screw
10
11
Note!
Always use the connecting plate (6)
included in the accessories to connect
supply and output.
Never screw threaded parts directly 11
into the housing.
1.2 1.1 2 1
6 6.1
Lever S
8 7
Fig. 7 · Attachment to Type 3510 Micro-flow Valve
EB 8384-3 EN 23
Attachment to the control valve – Mounting parts and accessories
24 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
6.1
6
(7, 8)
10 1
1.2
1.1
2
10.1 4.3
4
5
Note!
Always use the connecting
plate (6) included in the
accessories to connect
supply and output.
Never screw threaded Control valve opens counterclockwise
parts directly into the
housing. Slot
Legends Figs. 8 + 9
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
3 Follower clamp (Fig. 8)
4 Coupling wheel
4.1 Screw Control valve opens clockwise
4.2 Disk spring
4.3 Scale plate
4.3 Scale plate
5 Actuator shaft
Adapter for Type 3278
6.1 Seal rings
7 Pressure gauge bracket
8 Pressure gauge
mounting kit
10 Top pair of brackets
10.1 Bottom pair of brackets Slot
EB 8384-3 EN 25
Attachment to the control valve – Mounting parts and accessories
26 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
A1 Z
A2
Z
Output 38
A1
EB 8384-3 EN 27
Attachment to the control valve – Mounting parts and accessories
28 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
Type 3277 Actuator with 240 to 700 cm²: 2. Screw the position sensor (20) onto the
The signal pressure is routed to the connec- mounting plate (21).
tion at the side of the actuator yoke for the 3. Depending on the actuator size and
version "Actuator stem extends". rated travel of the valve, determine the
For the fail-safe position "Actuator stem re- required lever and position of the fol-
tracts" the connection on the top diaphragm lower pin (2) from the travel table on
case is used. The connection at the side of page 14.
the yoke must be fitted with a venting plug The positioner is delivered with lever M
(accessories). in pin position 35 on the sensor. If nec-
Mounting the position sensor essary, remove the follower pin (2) from
its pin position and move it to the bore-
1. Place the lever (1) on the sensor in
hole for the recommended pin position
mid-position and hold it in place.
and screw tight.
Unthread the nut (1.1) and remove the
4. Place the lever (1) and disk spring (1.2)
lever together with the disk spring (1.2)
on the sensor shaft.
from the sensor shaft.
2
3
11
1.1
1.2
20
21
9 Signal pressure
Vent plug
1 Lever
Signal pressure 1.1 Nut
1.2 Disk spring
2 Follower pin
Actuator stem 3 Follower clamp
Symbol
extends retracts
9 Connecting plate
11 Cover
Marking 20 Position sensor
21 Mounting plate
Fig. 12 · Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)
EB 8384-3 EN 29
Attachment to the control valve – Mounting parts and accessories
Place the lever (1) in mid-position and 2.6.2 Mounting the position sensor
hold it in place. Screw on the nut (1.1). with attachment according to
5. Place the follower clamp (3) on the actu- IEC 60534-6
ator stem, align and fasten it, making
sure that the fastening screw rests in the For the required mounting parts as well as
groove of the actuator stem. the accessories, refer to the order numbers
6. Place the mounting plate (21) together listed in Tables 6 and 7 on page 33.
with the sensor onto the actuator yoke so 1. Place the lever (1) on the sensor in
that the follower pin (2) rests on the top mid-position and hold it in place.
of the follower clamp (3). It must rest on Unthread the nut (1.1) and remove the
it with spring force. lever together with the disk spring (1.2)
Screw tight the mounting plate (21) onto from the sensor shaft.
the actuator yoke using both fixing 2. Screw the position sensor (20) onto the
screws. bracket (21).
7. Mount cover (11) on the other side. The standard attached lever M with the fol-
Make sure that the vent plug points lower pin (2) at position 35 is designed for
downwards when the control valve is in- 120, 240 and 350 cm² actuators with
stalled to allow any condensed water 15 mm rated travel.
that collects to drain off.
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
3 Follower plate
9 Stem connector
9.1 Bracket
14 Bolt
14.1 Screws
20 Position sensor
21 Bracket
2
30 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
For other actuator sizes or travels, select the Place the lever (1) in mid-position and
lever and pin position from the travel table hold it in place. Screw on the nut (1.1).
on page 14. Lever L and XL are included in 4. Place the follower clamp (3) on the stem
the mounting kit. connector, align it at a right angle and
3. Place the lever (1) and disk spring (1.2) screw tight.
on the sensor shaft. 5. Position the bracket (21) with the posi-
Place the lever (1) in mid-position and tion sensor on the valve yoke and screw
hold it in place. Screw on the nut (1.1). tight, making sure the follower pin (2)
4. Screw both bolts (14) to the bracket slides into the groove of the follower
(9.1) of the stem connector (9). Attach clamp (3).
the follower plate (3) and fix with the
screws (14.1).
5. Place the bracket with the sensor at the
NAMUR rib in such a manner that the
follower pin (2) rests in the slot of the fol-
lower plate (3), then screw the bracket 1 Lever
1.1 Nut
using its fixing screws onto the valve.
1.2 Disk spring
2 Follower pin
2.6.3 Mounting the position sensor 3 Follower clamp
to Type 3510 Micro-flow 20 Position sensor
Valve 1.1 21 Bracket
20 21 1.2
For the required mounting parts as well as
the accessories, refer to the order numbers
listed in Tables 6 and 7 on page 33.
1. Place the lever (1) in mid-position and
1
hold it in place. Unscrew the nut (1.1)
2
and remove the standard attached lever
M (1) together with the disk spring (1.2)
from the sensor shaft. 3
2. Screw the position sensor (20) onto the
bracket (21).
3. Select the lever S (1) from the accesso-
ries and screw the follower pin (2) into
the hole for pin position 17.
Place the lever (1) and disk spring (1.2)
on the sensor shaft. Fig. 14 · Mounting a micro-flow valve
EB 8384-3 EN 31
Attachment to the control valve – Mounting parts and accessories
2.6.4 Mounting the position sensor 4. Place the lever (1) and disk spring (1.2)
to rotary actuators on the sensor shaft.
Place the lever (1) in mid-position and
For the required mounting parts as well as hold it in place. Screw on the nut (1.1).
the accessories, refer to the order numbers
listed in Tables 6 and 7 on page 33.
Follow the instructions describing attachment
1. Place the lever (1) in mid-position and to the standard positioner in section 2.4
hold it in place. Unscrew the nut (1.1) Instead of the positioner, attach the position
and remove the standard attached lever sensor (20) with its mounting plate (21).
M (1) together with the disk spring (1.2)
from the sensor shaft.
2. Screw the position sensor (20) onto the
mounting plate (21).
3. Replace the follower pin (2) normally at-
tached to the lever (1) with the metal fol-
lower pin (Ø 5) from the accessories
and screw it into the hole for pin posi-
tion 90°.
20
21
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
20 Position sensor
2 1 1.1, 1.2 21 Mounting plate
32 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 33
Attachment to the control valve – Mounting parts and accessories
34 EB 8384-3 EN
Attachment to the control valve – Mounting parts and accessories
EB 8384-3 EN 35
Connections
3.1 Pneumatic connections To monitor the supply air (Supply) and sig-
nal pressure (Output), we recommend that
pressure gauges be attached (see accesso-
Caution! ries in Tables 1 to 5).
The threads in the positioner housing are not
designed for direct air connection!
3.1.2 Supply pressure
The required supply air pressure depends
The screw glands must be screwed into the
on the bench range and the actuator's oper-
connecting plate, the pressure gauge mount-
ating direction (fail-safe action).
ing block or the connection block from the
The bench range is registered on the name-
accessories. The air connections are option-
plate either as spring range or signal pres-
ally designed as a bore with ¼ NPT or G ¼
sure range depending on the actuator. die
thread.
The direction of action is marked FA or FE,
The customary fittings for metal and copper
or by a symbol.
pipes or plastic hoses can be used.
Actuator stem extends FA (Air to open
Note! ATO)
The supply air must be dry and free from oil
and dust. The maintenance instructions for Fail-safe position "Valve Closed"
upstream pressure reducing stations must be (for globe and angle valves):
observed. Required supply pressure = Upper bench
Blow through all air tubes and hoses thor- range value + 0.2 bar, minimum 1.4 bar.
oughly prior to connecting them.
Actuator stem retracts FE (Air to close ATC)
If the positioner is attached directly to the Fail-safe position "Valve Open"
Type 3277 Actuator, the connection of the (for globe and angle valves):
positioner's output pressure to the actuator For tight-closing valves, the maximum signal
is fixed. For attachment according to pressure pstmax is roughly estimated as fol-
IEC 60534-6 (NAMUR), the signal pressure lows:
can be routed to either the top or bottom di-
aphragm chamber of the actuator, depend-
d2 ⋅ π ⋅ Δp
ing on the actuator's fail-safe action "Actua- pstmax = F + [bar]
tor stem extends" or "Actuator stem re- 4⋅A
tracts".
For rotary actuators, the manufacturer's
specifications for connection apply.
36 EB 8384-3 EN
Connections
Note!
The signal pressure at the output (Out-
put 38) of the positioner can be limited to
1.4, 2.4 or 3.7 bar over Code 16 or the
pressure limit can be deactivated (MAX).
EB 8384-3 EN 37
Connections
38 EB 8384-3 EN
Connections
The wires for the reference variable must be The position transmitter is operated on a
connected to the terminals 11 and 12 lo- two-wire circuit. The usual supply voltage is
cated in the housing. Only use a current 24 V DC. Considering the resistance of the
source! supply leads, the voltage at the position
If the reference variable exceeds 22 mA, transmitter terminals can be between 12 V
OVERLOAD appears on the LC display to and 30 V DC.
warn the user. Refer to Fig. 16 or the label on the terminal
strip for terminal assignment.
Caution! The erroneous connection of a volt- Note! The minimum permissible reference
age source of just around 7 V (or around variable should not fall below 3.8 mA for
2 V when connected to the wrong pole) can operating the positioner.
damage the positioner. Accessories:
Plastic cable gland M20 x 1.5:
Black Order no. 8808-1011
In general, it is not necessary to connect the Blue Order no. 8808-1012
positioner to a bonding conductor. Should Nickel-plated brass Order no. 1890-4875
this be required, however, this conductor Adapter M20 x 1.5 to ½ NPT
can be connected inside the device. Aluminum, powder-coated
Depending on the version, the positioner is Order no. 0310-2149
equipped with inductive limit switches
and/or a solenoid valve.
Optional Optional
A3 A2 A1 G
+81 -82 +11 -12 +83 -84 +51 -52 +41 -42 +31 -32
Switching amplifier
A
acc. to EN 60947-5-6
EB 8384-3 EN 39
Connections
Handheld communicator
Connection in non-hazardous area
or second FSK modem
4 to 20 mA 3730-30
Controller/control station
Hazardous area
Connection in hazardous area
Safe area
3730-31
Handheld communicator
or second FSK modem (explosion-protected)
40 EB 8384-3 EN
Connections
EB 8384-3 EN 41
Operation
42 EB 8384-3 EN
Operation
SSP interface
INTERFACE
SERIAL
Switch for
INIT
VALVE
fail-safe action
AIR TO
CAUTION
ACTUATES
of the actuator
CLOSE
OPEN
%
mm mm
%
S
Volume restriction
MAX SIDE
MIN BACK
MIN SIDE
MAX BACK
Rotary pushbutton
Q
EB 8384-3 EN 43
Operation
4 From the current display, turn the rotary The code list on page 71 onwards in section
pushbutton until Code 3 and OFF ap- 12 shows all parameters that can be ad-
pear on the display. justed, including their description and their
Confirm Code 3 by pressing the but- default settings.
ton, the code number blinks.
44 EB 8384-3 EN
Operation
EB 8384-3 EN 45
Start-up and settings
Note!
Once the positioner is initialized, the current
The positioner performs a test in the start-up
valve position is indicated on the digital dis-
phase while following its automation task at
play in %.
the same time. During the start-up phase,
operation on site is unrestricted, yet write
access is restricted.
If you want to return the valve from the
fail-safe position to the operating mode
AUtO or MAN, the button must be
pressed while Code 0 is active.
When the code number blinks, turn the
button to switch to the desired operating
mode.
Press the button to confirm.
46 EB 8384-3 EN
Start-up and settings
EB 8384-3 EN 47
Start-up and settings
5.4 Limiting the signal pressure 3. Turn the button until Code 1 appears,
confirm Code 1 by pressing button.
If the maximum actuator force may cause The hand symbol and Code 1 blink.
damage to the valve, the signal pressure 4. Position control valve by turning the
must be limited. Select Code 3 to enable
button several times until pressure builds
configuration and then access Code 16 to
up, and the control valve moves to its fi-
set the pressure limit to 1.4, 2.4 or 3.7 bar.
nal positions so that the travel/angle of
The required signal pressure limit is only au- rotation can be checked.
tomatically recognized on initialization The permissible range has been ex-
when the fail-safe position AIR TO OPEN is
ceeded when the displayed angle is
set.
higher than 30°, and the outer right or
left bar graph element blinks.
5.5 Checking the operating
If this is the case, it is absolutely neces-
range of the positioner sary to check lever and pin position as
To check the mechanical attachment and the described in section 2.
proper functioning, the valve should be
moved through the operating range of the Note!
positioner in the manual operating mode If the selected pin position is smaller than in-
with the manual reference variable. tended for the respective travel range, the
positioner switches to the SAFE mode, the
Code 0 valve moves to the fail-safe position (see
Select section 4.3.2 on page 44).
manual operation
Default MAN
5. Initialize positioner as described in sec-
Code 1 tion 5.6.
Position valve using the
rotary pushbutton, the
current angle of rotation is
indicated
48 EB 8384-3 EN
Start-up and settings
Simplified start-up!
For most applications, the positioner with its default settings is ready for operation,
provided it has been properly attached.
After the fail-safe position and the volume restriction have been set, the positioner only
needs to be initialized by pressing the INIT key.
Caution!
Prior to starting the initialization procedure, check the maximum permissible supply
pressure of the control valve to prevent the valve from being damaged. On initialization,
the positioner supplies the maximum available supply pressure. If necessary, restrict the
signal pressure by using a pressure reducing valve upstream of the control valve.
Initialization is run in default mode MAX (section 5.6.1). During this process, the
positioner adapts itself optimally to the maximum travel/angle of rotation range.
The only parameter that must be checked is the direction of action, i.e. whether the default
setting (Code 7 to ää = increasing/increasing) matches the application or whether it
must be changed.
The initialization modes described in following serve to individually adapt and optimize
the positioner to the way it is attached to the valve.
EB 8384-3 EN 49
Start-up and settings
the initialization process has been com- The control position in % predetermined by
pleted. See note at the end of this section. the reference variable appears on the dis-
play.
Warning! A malfunctioning leads to the process being
During the initialization, the control interrupted. The initialization error appears
valve moves through its entire on the display according to how it has been
travel/angle of rotation range. classified by the condensed status. See sec-
Therefore, do not start initialization tion 5.7 on page 57.
while a process is running, but only
If the slide switch is set to AIR TO CLOSE,
during start-up, when all shut-off
the positioner automatically switches to the
valves are closed.
direction of action increasing/decreasing
Note!
(äæ) on successful completion of initializa-
The initialization procedure can be
tion. This results in the following assignment
interrupted while running by press-
between reference variable and valve posi-
ing . StOP appears three seconds
tion:
long and the positioner then moves
to the fail-safe position. Fail-safe Direction of Valve
position action Closed at Open at
Actuator stem
extends FA ää 4 mA 20 mA
Alternating displays AIR TO OPEN
Initialization running Actuator stem
retracts FE äæ 20 mA 4 mA
AIR TO CLOSE
50 EB 8384-3 EN
Start-up and settings
Default OFF
In addition, the lower (Code 8) and the up-
per (Code 9) x-range value can only be dis-
played and modified in %.
Turn → Code 3, press , During MAX initialization, an increased sys-
tem deviation (undefined final position of the
turn → ON, press . actuator) in the upper control range may oc-
cur with some control valves due to the
pneumatic actuator design.
EB 8384-3 EN 51
Start-up and settings
(Code 7).
The calibrated sensor enables the effective
valve travel to be preset very accurately. Turn → Code 4, press ,
During the initialization procedure, the turn → Select pin position entered during
positioner checks whether the control valve installation, press .
can move through the indicated nominal
range (travel or angle) without collision.
In case of a positive result, the indicated
nominal range is adopted with the limits of
Default 15
lower x-range and upper x-range values as mm
52 EB 8384-3 EN
Start-up and settings
selected range
(with default upper x-range value by means
of manual adjustment). Turn → Code 0, press ,
Initialization mode just as NOM, however, turn → MAN, press .
for starting up valves with unknown nominal
range.
In this mode, the positioner expects the con-
trol valve to be moved manually to the de- Default MAN
sired OPEN position prior to enabling the
initialization procedure.
The upper range travel/angle of rotation Turn → Code 1, press ,
value is adjusted using the rotary Code 1 blinks.
pushbutton. The positioner uses this OPEN
position and the CLOSED position to calcu-
late the differential travel/angle and accepts
EB 8384-3 EN 53
Start-up and settings
54 EB 8384-3 EN
Start-up and settings
Enable configuration:
Default ää
Default OFF
Default 100.0
mm
Default OFF
Default OFF
mm
Default 15
Default 7
Default MAX
Turn → Code 17
Turn → Code 6, press , Retain default. Proceed as follows only if
known:
turn → SUb, press .
Press ,
EB 8384-3 EN 55
Start-up and settings
Default CCL
56 EB 8384-3 EN
Start-up and settings
EB 8384-3 EN 57
Start-up and settings
58 EB 8384-3 EN
Start-up and settings
EB 8384-3 EN 59
Status and diagnostic alarms
For start-up and settings, proceed as de- 6 Status and diagnostic alarms
scribed in section 5, 5.1 to 5.4. Refer to the
code list in section 12 as well as section The Type 3730-3 Positioner contains an in-
13.4 for the parameters necessary for the tegrated diagnostic approach to generate
operator interface. classified status and diagnostic alarms.
There are two different on-board diagnostics
Note! available: the standard integrated diagnos-
The write access for HART® communication tics (EXPERT) and the optional extended
can be disabled over Code 47. You can EXPERT+ diagnostics.
only disable or enable this function locally at
the positioner. 6.1 Standard EXPERT diagnostics
The write access is enabled by default. The
on-site operation including the INIT key can The standard EXPERT diagnostics provides
be locked over HART®communication. The information about positioner states such as
word "HART" then blinks on the display operating hours counter, process monitor-
when Code 3 is selected. This locking func- ing, number of zero calibrations and
tion can only be disabled over HART® com- initializations, total valve travel, tempera-
munication. On-site operation is enabled by ture, initialization diagnostics, zero/control
default. loop errors, logging of the last 30 alarms,
etc.
60 EB 8384-3 EN
Status and diagnostic alarms
EB 8384-3 EN 61
Status and diagnostic alarms
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 modi-
fied over the parameters in DD or easily en-
tered over the DTM.
Note!
All additional alarms generated by EXPERT+
have the status “No alarm” by default.
EB 8384-3 EN 63
Adjusting the limit switch
7 Adjusting the limit switch The desired switching function, i.e. whether
the output relay shall be picked up or re-
The positioner version with inductive limit leased when the tag has entered the field,
switch has one adjustable tag (1) mounted has to be determined, if necessary, at the
on the shaft which operates the proximity switching amplifier.
switch (3).
For operation of the inductive limit switch, Note!
the corresponding switching amplifier (see The inductive limit switch replaces the soft-
section 3.2.1) must be connected to the out- ware limit switch A1 with terminal assign-
put. ment +41/–42.
Each switching position can optionally be
If the tag (1) is inside the field of the switch,
set to indicate when the tag has entered the
the switch assumes a high resistance. If the
field, or when it has left the field.
tag is outside of the field, the switch assumes
The second software limit switch remains ef-
a low resistance.
fective, the function of the software limit
Normally, the limit switch is adjusted such switch A1 is disabled.
that it will provide a signal in both end posi-
tions of the valve. The switch, however, can
also be adjusted to indicate intermediate
valve positions.
64 EB 8384-3 EN
Adjusting the limit switch
To ensure safe switching under any ambient Tag leaving the field > Contact is made.
conditions, the switching point should be Tag entering the field > Contact is opened.
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 adjust-
ment screw (2) until the tag enters or
leaves the field and the switching ampli-
fier 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.
EB 8384-3 EN 65
Quick start-up guide
66 EB 8384-3 EN
Quick start-up guide
EB 8384-3 EN 67
Quick start-up guide
68 EB 8384-3 EN
Upgrading options
9 Upgrading options
1
9.1 Retrofitting an inductive limit 2
switch 4
EB 8384-3 EN 69
Maintenance
70 EB 8384-3 EN
Code list
12 Code list
Code Parameter – Display, values
Description
no. [default setting]
Note! Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
1 Manual w Adjust the manual set point with the rotary pushbutton, the
0 to 100 [0] % current travel/angle is displayed in % when the positioner is ini-
of the nominal range tialized, otherwise the sensor position in relation to the central
axis is indicated in degrees °.
EB 8384-3 EN 71
Code list
4* Pin position For initialization using NOM or SUb, the follower pin must be in-
[OFF] serted into the correct pin position according to the valve
17, 25, 35, 50 mm travel/angle of rotation.
70, 100, 200 mm, Pin position Standard Adjustment range
90° with rotary actuators Code 4 Code 5 Code 5
ESC 17 7.5 3.6 to 17.7
25 7.5 5.0 to 25.0
35 15.0 7.0 to 35.4
Note!
50 30.0 10.0 to 50.0
If you select a pin position in
70 40.0 14.0 to 70.7
Code 4 that is too small, the
100 60.0 20.0 to 100.0
positioner switches to SAFE
200 120.0 40.0 to 200.0
mode for reasons of safety
90° 90.0 24.0 to 110.0
5* Nominal range For initialization using NOM or SUb, the nominal travel/angle of
[15.0] mm or angle ° rotation of the valve must be entered.
The permissible adjustment range depends on the pin position
ESC
according to the table.
After initialization has been successfully completed, the maximum
nominal travel/angle reached on initialization is displayed.
72 EB 8384-3 EN
Code list
8* Lower x-range value Lower range value for the travel/angle of rotation in the nominal
0.0 to 80.0 [0.0] % of the or operating range.
nominal range, The operating range is the actual travel/angle of the control
Specified in mm or angle ° provided valve and is limited by the lower x-range value (Code 8) and the
Code 4 is set upper x-range value (Code 9).
ESC Usually, the operating range and the nominal range are iden-
tical. The nominal range can be limited to the operating range by
the lower and upper x-range values.
Value is displayed or must be entered.
The characteristic is adapted. See also the example in Code 9!
9* Upper x-range value Upper range value for the travel/angle of rotation in the nominal
20.0 to 100.0 [100.0] % or operating range. Value is displayed or must be entered.
nominal range, The characteristic is adapted.
Example: The operating range is modified, for example, to limit
Specified in mm or angle ° provided
the range of a control valve which has been sized too large. For
Code 4 is set
this function, the entire resolution range of the reference variable
ESC is converted to the new limits. 0 % on the display corresponds to
the set lower limit and 100 % to the set upper limit.
10* Lower x-limit Limitation of the travel/angle of rotation downwards to the en-
[OFF] tered value, the characteristic is not adapted.
0.0 to 49.9 % of the
operating range The characteristic is not adapted to the reduced range. See also
ESC example in Code 11.
11* Upper x-limit Limitation of the travel/angle of rotation upwards to the entered
[100 %] value, the characteristic is not adapted.
50.0 to 120.0 [100] % of Example: In some applications, it makes sense to limit the valve
the operating range travel, e.g. if a certain minimum medium flow is required or a
or OFF maximum flow must not be reached.
ESC The lower limit must be adjusted with Code 10, and the upper
limit with Code 11. If a tight-closing function has been set up, it
has priority over the travel limitation!
When set to OFF, the valve can be opened past the nominal
travel with a reference variable outside of the 4 to 20 mA range.
EB 8384-3 EN 73
Code list
12* w-start Lower range value of the applicable reference variable range
0.0 to 75.0 [0.0] % of the must be smaller than the final value w-end, 0 % = 4 mA
reference variable range The reference variable range is the difference between w-end
and w-start, and must be Δw ≥ 25 % = 4 mA.
ESC
For an adjusted reference variable range of 0 to 100 % = 4 to
20 mA, the control valve must move through its entire operating
range from 0 to 100 % travel/angle of rotation.
In split-range operation, the valves operate with smaller refer-
ence variables. The control signal of the control unit to control
two valves is divided such, for instance, 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).
13* w-end Upper range value of the applicable reference variable range,
25.0 to 100.0 [100.0] % of must be greater than w-start.
the reference variable range 100 % = 20 mA
ESC
14* Final position w < If w approaches the percentage adjusted towards the final value
0.0 to [1.0] % that causes the valve to close, the actuator is immediately com-
of the span adjusted via pletely vented (with AIR TO OPEN) or filled with air (with AIR TO
Code 12/13 CLOSE).
OFF This action always lead to maximum tight-closing of the valve.
ESC
Codes 14/15 have priority over Codes 8/9/10/11.
15* Final position w > If w approaches the percentage adjusted towards the final value
[OFF] that causes the valve to open, the actuator is immediately com-
50.0 to 100.0 % pletely filled with air (with AIR TO OPEN) or vented (with AIR TO
of the span adjusted via CLOSE).
Code 12/13 This action always lead to the valve being completely opened.
Codes 14/15 have priority over Codes 8/9/10/11.
ESC
Example: Set the final position w > to 99 % for three-way valves.
16* Pressure limit The signal pressure can adopt the value of the applied supply
[OFF] pressure at the maximum [OFF] or it can be limited in stages of
1.4, 2.4 or 3.7 bar. This pressure limitation is already effective
1.4 2.4 3.7 bar
during the initialization.
ESC Note: After changing a pressure limit already set, the actuator
must be vented once (e.g. by selecting the fail-safe position over
Code 0).
The pressure limit of double-acting actuators must always be set
to OFF after initialization is completed.
74 EB 8384-3 EN
Code list
21* w-ramp Open The time required to pass through the operating range when the
0 to 240 s [0] valve opens.
Limitation of the transit time (Code 21 and 22):
ESC
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.
EB 8384-3 EN 75
Code list
22* w-ramp Closed The time required to pass through the operating range when the
0 to 240 s [0] valve closes.
ESC
RES
ESC
24* LV total valve travel Limit value of total valve travel. If the limit value is exceeded, the
7 fault symbol and the wrench symbol appear.
1000 to 99 · 10
[1 000 000]
Exponential reading from 9999 travel
cycles onwards
ESC
25* Alarm mode Switching mode of software limit switches alarm A1 and A2 in
0 to 3 [2] responding state (when positioner has been initialized).
ESC
1) Explosion-protected version according to EN 60947-5-6
0: A1 ≥ 2.1 mA A2 ≤ 1.2 mA
1: A1 ≤ 1.2 mA A2 ≤ 1.2 mA
2: A1 ≥ 2.1 mA A2 ≥ 2.1 mA
3: A1 ≤ 1.2 mA A2 ≥ 2.1 mA
76 EB 8384-3 EN
Code list
26* Limit value A1 Alarm A1 goes into the state of response when the value exceeds
OFF the limit.
0.0 to 100.0 [2.0] % of the Displaying or changing the software limit value A1 in relation to
operating range the operating range.
Setting has no effect when an inductive limit switch has been in-
ESC
stalled.
27* Limit value A2 Alarm A2 goes into the state of response when the value falls
OFF below the limit.
0.0 to 100.0 [98.0] % of the Displaying or changing the software limit value A2 in relation to
operating range the operating range.
ESC
28* Alarm test Testing the software limit switches alarm A1 and A2 in addition
Reading direction: to the fault alarm contact A3.
If the test is activated, the respective limit switches five times.
Standard Turned
[OFF] [OFF] RUN1/1 RUN: Software limit switch A1 to ≥ 2.1 mA
RUN 1 1 RUN RUN2/2 RUN: Software limit switch A2 to ≥ 2.1 mA
RUN 2 2 RUN RUN3/3 RUN: Fault alarm contact A3 to ≤ 1.2 mA
RUN 3 3 RUN
ESC ESC
3)
29* Position transmitter x/ix Operating direction of the position transmitter; indicates how the
[ää] travel/angle position is assigned to the output signal i, based on
äæ the closed position.
ESC The operating range (see Code 8) of the valve is represented by
the 4 to 20 mA signal. Values exceeding or falling below the
limits 2.4 to 21.6 mA can be represented.
When a positioner has not been initialized (reference variable
less than 3.6 mA), the power consumption of the feedback signal
is effective (current approx. 1.8 mA).
When YES is set in Code 32 , the position transmitter issues the
value as per Code 30 during initialization or zero calibration.
When NO is set in Code 32, 4 mA is issued during a running
self-adaptation.
3)
30* Fault alarm ix Used to select whether faults causing the fault alarm contact to
[OFF] HI LO switch should also be signaled by the position transmitter output
and how they should be signaled
ESC
HI ix > 21.6 mA or LO ix < 2.4 mA
EB 8384-3 EN 77
Code list
3)
31* Position transmitter test Testing the position transmitter. Values can be entered in relation
–10.0 to 110.0 [default to the operating range.
value is last indicated value The current actual value is used in initialized positioners locally
of the position transmitter] as the start value (bumpless changeover to the test mode). On
% of the operating range testing over software, the entered simulation value is issued as
the position feedback signal for 30 seconds.
ESC
3)
Analog position transmitter: Code 29/30/31 can only be selected if the position transmitter (optional) is installed.
32* Fault alarm with “Function Determines whether a fault alarm is to be issued when “Function
check” condensed status check” condensed status occurs.
NO [YES]
ESC
33* Fault alarm with “Mainte- NO: Fault alarm only with “Maintenance alarm” condensed
nance alarm” or “Mainte- status
nance required” condensed YES: Fault alarm only with “Maintenance alarm” condensed
status status and with “Maintenance required” condensed status
NO [YES]
ESC
38* Inductive alarm Indicates whether the inductive limit switch option is installed or
[NO] YES not.
ESC
78 EB 8384-3 EN
Code list
EB 8384-3 EN 79
Code list
48 Diagnostics
d Diagnostic parameters
d0 Current temperature Operating temperature [°C] inside the positioner
–55 to 125
d1 Minimum temperature The lowest temperature below 20 °C that has ever occurred.
[20]
d2 Maximum temperature The highest temperature above 20 °C that has ever occurred.
[20]
d3 Number of zero The number of zero calibrations since the last initialization.
calibrations
d4 Number of initializations The number of initializations that have been performed.
d5 Zero point limit Limit for the zero point monitoring.
[5 %]
0.0 to 100.0 %
d6 Condensed status Condensed status, made up from the individual states.
OK: Okay, C: Maintenance required, CR: Maintenance de-
manded, B: Maintenance alarm, I: Function check.
d7 Start reference run Triggering of a reference run for the functions: Drive signal y
[OFF] steady-state and drive signal y hysteresis.
ON The reference run can only be activated in manual operation as
ESC 1 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.
+ +
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.
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 Control loop error, the control valve does not react within the tol-
erable times of the controlled variable (tolerance band alarm
Additional alarm at the fault Code 19).
alarm contact!
• Actuator mechanically blocked.
• Attachment of the positioner subsequently postponed.
• Supply pressure not sufficient.
Remedy Check attachment.
58 Zero point Zero point incorrect. Error may arise when the mounting posi-
tion/linkage of the positioner moves or when the valve seat 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
Code list
60 Fatal error An error was detected in the data relevant for safety,
autocorrection is not possible. This may be due to EMC distur-
Additional alarm at the fault bances.
alarm contact! The control valve moves to its fail-safe position.
Remedy Reset over Code 36.
Re-initialize the positioner.
Hardware error (indicated on the display by the condensed status with the corresponding classification)
62 x signal Determination of the measured value for the actuator has failed.
Conductive plastic element is defective.
Additional alarm at the fault The positioner continues to run in emergency mode, but should
alarm contact! be replaced as soon as possible.
The emergency mode on the display is indicated by a blinking
control symbol and 4 dashes instead of the position indication.
63 w too small The reference variable is much smaller than 4 mA (0 %); occurs if
the power source that drives the positioner does not comply with
the standard.
This state is indicated on the positioner display by a blinking
LOW.
Remedy Check reference variable.
If necessary, limit the current source downwards so that no values
below 4 mA can be issued.
64 i/p converter (y) The circuit of the i/p converter has been interrupted.
Remedy Cannot be remedied.
Return the positioner to SAMSON AG for repair.
EB 8384-3 EN 83
Code list
Error appendix
66 Data memory The writing of data to the data memory does not work anymore,
Additional alarm at the fault e.g. when the written data deviate from the read data.
alarm contact! Valve moves to the fail-safe position.
Remedy Return the positioner to SAMSON AG for repair.
71 General parameters Parameter errors that are not critical for the control.
Remedy Confirm error.
Check and, if necessary, reset required parameters.
84 EB 8384-3 EN
Code list
75 Info parameters Error in the info parameters that are not critical for the control
function.
Remedy Confirm error.
Check and, if necessary, reset required parameters.
76 No emergency mode The travel measuring system of the positioner has a self-moni-
toring function (see Code 62).
A controlled emergency mode is not available on certain actua-
tors, such as double-acting actuators. For this reason, the
positioner moves to the fail-safe position when a measuring error
occurs. During the initialization, the positioner checks whether
the actuator has such a function or not.
Remedy Merely information, confirm, if necessary.
No further action necessary.
77 Program loading error When the device starts operation for the first time after the input
Additional alarm at the fault signal has been applied, it carries out a self-test (tEStinG runs
alarm contact! across the display).
If the device loads a program that does not correspond to that of
the positioner, the valve moves to the fail-safe position. It is not
possible to make the valve leave this fail-safe position again by
operating the positioner.
Remedy Interrupt current and restart positioner. Otherwise, return the
positioner to SAMSON AG for repair.
EB 8384-3 EN 85
Code list
86 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 87
Setting with TROVIS-VIEW software – Parameter list
13.2 Starting TROVIS-VIEW and You can also activate the listed functions in
performing basic settings the Device menu.
88 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
1. Start TROVIS-VIEW
When the Trend Viewer is activated, all operating data are uploaded cyclically from the
positioner in online mode and shown in the form of graphs.
Right-click on the graph to edit the graph format or to copy the logged data to a file.
EB 8384-3 EN 89
Setting with TROVIS-VIEW software – Parameter list
7. Select Load Factory Defaults in Edit menu to upload default settings to the operator inter-
face.
90 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
The parameters in all the folders are listed in the following parameter list.
EB 8384-3 EN 91
Setting with TROVIS-VIEW software – Parameter list
92 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Identification – Positioner
Device type 3730-3 Indicates exact model designation
Identification – Positioner – Actuator
Type identification Manufacturer ID number of the actuator that the
actuator positioner is mounted upon
Actuator type Single-acting Single-acting Actuator with or without spring return mecha-
Double-acting nism
Attachment Integral/ Integral Defines the attachment of the positioner on the
NAMUR control valve
Booster Not present/ Not present Pneumatic volume booster
present
Actuator size 60...5600 240 cm² Effective diaphragm or piston area of the actu-
ator
Signal pressure 0.0...6 0.2 bar Initial value of the actuator bench range
lower value
Signal pressure 0.0...6 1.0 bar Final value of the actuator bench range
upper value
Supply pressure 0.0...6 6.0 bar Supply pressure of compressed air network
Identification – Positioner – Valve
Type identification Manufacturer ID number of the valve that the
valve positioner is mounted upon
Direction of flow Flow-to-open Flow-to-open Indicates in which direction the process medium
(FTO)/ (FTO) flows to the valve plug.
Flow-to-close
(FTC)
Packing Adjustable/ Self- Sealing of the plug stem to the atmosphere
Self-adjusting/ adjusting
Bellows seal
Seating surface Metal sealing/ Metal sealing Type of sealing between seat and plug
(leakage class) Lapped-in metal/
Soft sealing/
Nickel sealing
Pressure balancing Without/ Without Plug with pressure balancing to compensate for
With (PTFE)/ forces
With (graphite)
EB 8384-3 EN 93
Setting with TROVIS-VIEW software – Parameter list
Flow characteristic Linear 30:1/ Linear 50:1 Valve characteristic: Flow to valve travel
Eq. perc. 30:1/
Linear 50:1/
Eq. perc. 50:1/
Other
Valve dimensions DIN/ANSI DIN Valve dimensions according to DIN or ANSI
standard
Nominal size DN 8...2100 50 Nominal size in mm (DIN) or inch (ANSI)
Kvs coefficient 0.0001... 1.0000 Kv Valve flow coefficient
20000.0000
Kvs unit Kv/cv Kv Flow coefficient, metric unit (Kvs) or US Amer-
ican units (cv)
Seat diameter of the 2.0...500.0 6.0 mm Diameter of valve seat bore
valve
Identification – Positioner – Additional components
Solenoid valve Code 45
Position transmitter Not Code 37
installed
Inductive limit Installed/ Code 38
switch Not installed
Operation unit
HART write protec- Not write Code 47
tion protected
Start with default Code 36
settings
Positioner – Operating mode
Current operating Indicated the current operating mode used by
mode the device
Target operating Automatic/ Automatic Code 0
mode Manual/Fail-safe
position
Positioner – Process data
Reference variable w Code 42
Controlled variable x Current position
System deviation e Deviation from target position (e = w–x)
Displays current
Manipulated process variables Indicates the control signal y in % in relation to
variable y the travel range found on initialization after the
device has been initialized.
94 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Status
Condensed state Summarized state of the positioner.
The condensed status is made up from the var-
ious states.
The condensed status can take on the following
states:
No alarm
Maintenance required
Maintenance demanded
Maintenance alarm
Function check
EB 8384-3 EN 95
Setting with TROVIS-VIEW software – Parameter list
96 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
Positioner – Characteristic
Characteristic Linear Linear Code 20
selection Equal percentage
Eq. perc. reverse
SAMSON
butterfly valves
linear
eq. perc.
VETEC rotary
plug valves
linear
eq. perc.
Segmented ball
valves
linear
eq. perc. Graphs of the user-defined characteristics,
loading and saving characteristics.
User defined See example on the next page.
Characteristic type Free text for describing the user-defined char-
acteristic
EB 8384-3 EN 97
Setting with TROVIS-VIEW software – Parameter list
98 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 99
Setting with TROVIS-VIEW software – Parameter list
Maintenance demanded
Maintenance alarm
The fault alarm present in the device with the highest priority determines which condensed status is dis-
played.
The condensed states “Maintenance required” and “Maintenance demanded” are also indicated on the
positioner display by .
The condensed status “Maintenance alarm” causes the fault alarm symbol to appear on the dis-
play.
100 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 101
Setting with TROVIS-VIEW software – Parameter list
Positioner – Start-up
Reading direction Pneumatic Pneumatic Code 2
connection connection
right/left right
Pin position Off Off Code 4
17/25/35/50/
70/100/200 mm
90°
Initialization mode Nominal range Maximum Code 6
Maximum range range
Manual adjust-
ment
Substitution
Pressure limit Off /2.4/3.7/ Off Code 16
1.4 bar
Determined nom- Code 5
inal range
Minimum transit Code 40
time OPEN
Minimum transit Code 41
time CLOSED
Fail-safe action Fail-safe action of the actuator upon air/auxil-
iary power failure or device start-up.
Determined during initialization by the position
of the slide switch (see section 5.1).
In double-acting actuators, the fail-safe position
relates only to the failure of the auxiliary power
supply. There is no defined position when the
supply air fails.
Positioner – Start-up – Initialization
Initialization mode Nominal range Maximum Code 6
Maximum range range
Manual adjust-
ment
Substitution
Device initialized Status of device initialization
Initialization Starting of initialization procedure.
The initialization mode parameter must be first
set to the required initialization procedure.
EB 8384-3 EN 102
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 103
Setting with TROVIS-VIEW software – Parameter list
Positioner – Simulation
Alarm test A1 Code 28
Alarm test A2 Code 28
Alarm test A3 Code 28
(alarm fault output)
Diagnosis
Diagnosis level Expert
setting
Current operating Automatic Indicates current operating mode of positioner
mode
Diagnosis – Status alarms
Status
Condensed status Alarm symbol Summarized condensed status.
Made up from various states.
Operating hours Time elapsed since first initialization
counter
Device in closed Time elapsed in closed loop since first initializa-
loop tion
Device switched on Time elapsed since last initialization
since last
initialization
Device in closed Time elapsed in closed loop since last initializa-
loop since last tion
initialization
Error occurred Status of fault alarm output
(fault alarm output)
Solenoid valve Display or status Status of optional solenoid valve
status
Fail-safe position Fail-safe action of actuator upon air
supply/auxiliary power failure or device
start-up.
Determined during initialization.
Device initialized Status of device initialization
Start performed Indicates whether a start has been performed
with default settings with default settings.
Local operation Local operation is active
active
Configuration Status of device status bit configuration
changed changed.
104 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 105
Setting with TROVIS-VIEW software – Parameter list
Data memory
Control parameter Code 68
Poti parameter Code 69
Calibration Code 70
parameter
General parameters Code 71
Internal device Code 73
Alarm
error 1
HART parameter Code 74
Info parameter Code 75
Option parameter Code 78
Diagnostic Code 80
parameters
Temperature
Min. temperature Lowest temperature recorded in the positioner
Max. temperature Highest temperature recorded in the positioner
Min. temperature Operating hours counter logging when the
(time) lowest temperature was recorded in the
Display
positioner
Max. temperature Operating hours counter logging when the
(time) highest temperature was recorded in the
positioner
Diagnosis – Status messages – Data logger
Alarms Recorded alarms issued by the positioner
(1) to (30)
Operating hours Alarm Operating hours counter logging of each alarm
since first initializa-
tion
Diagnosis – Status alarms – Reset
Reset absolute total Reset counter for absolute total valve travel
travel back to 0
Reset Set back default values flag to 0
default values flag
Resetting corresponding
Reset device setting alarms Reset device status bit
changed device setting changed.
106 EB 8384-3 EN
Setting with TROVIS-VIEW software – Parameter list
EB 8384-3 EN 107
108 EB 8384-3 EN
Dimensions in mm
14 Dimensions in mm
Pressure gauge or connecting plate Attachment acc. to IEC 60534-6
bracket
Lever mm External position sensor
S = 17
M = 50 Schild
28
L = 100
XL = 200
15
70
46 58
70
70
34
Direct attachment
210
M20 x 1.5
80
34
14
40 28
58
164 Output (38) Supply (9)
VDI/VDE 3845
for all sizes of fixing level 2
Output A1
50 Supply (9)
A1 Z
76
Connecting
A2
plate
G ¼ or
49
59
¼ NPT 58
79
EB 8384-3 EN 109
110 EB 8384-3 EN
EB 8384-3 EN 111
112 EB 8384-3 EN
EB 8384-3 EN 113
114 EB 8384-3 EN
EB 8384-3 EN 115
116 EB 8384-3 EN
EB 8384-3 EN 117
118 EB 8384-3 EN
EB 8384-3 EN 119
120 EB 8384-3 EN
EB 8384-3 EN 121
122 EB 8384-3 EN
EB 8384-3 EN 123
124 EB 8384-3 EN
NEMA 4x
EB 8384-3 EN 125
126 EB 8384-3 EN
EB 8384-3 EN 127
S/Z 2007-05
Mounting and
Operating Instructions
EB 8356 EN
Edition April 2004
Contents
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Attachment to control valve . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.2 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.1 Mounting the follower roll lever . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.3 Adjusting the cam disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . . . . 14
3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Pneumatic connections for versions with solenoid valve . . . . . . . . . . . . 19
4 Operation – Adjusting the limit contacts . . . . . . . . . . . . . . . . . . . 20
5 Servicing explosion-protected versions . . . . . . . . . . . . . . . . . . . . 22
6 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 EB 8356 EN
Safety instructions
EB 8356 EN 3
Design and principle of operation
1 Design and principle of operation the rotary motion to two adjustable tags (4)
which, in return, operate the associated
The Type 3768 Limit Switch is designed for proximity switches (5).
attachment to pneumatic control valves. It is The operation of the inductive limit switches
equipped with inductive switching elements requires that switching amplifiers be con-
that issue a limit signal whenever the valve nected in the output circuit (see section 3).
travel exceeds or falls below a certain
preset limit, especially when the valve has Version with solenoid valve
reached one of its end positions. The limit The solenoid valve is used to move the con-
signal is transmitted to an alarm or indicat- trol valve to its fail-safe position regardless
ing unit. of the output signal issued by the control
The limit switch is also available with a sole- unit. When a control signal which corre-
noid valve which is used to move the control sponds to the binary signal 0 (OFF) is ap-
valve to fail-safe position. plied to the input, the signal pressure pst is
The limit switch is designed for either direct shut off and the actuator vented. As a result,
attachment to SAMSON Type 3277 Actua- the springs installed in the actuator force the
tors or for attachment to control valves com- valve to move to its fail-safe position.
plying with IEC 60534-6 (NAMUR) by Whereas a control signal corresponding to
means of an adapter housing. the binary signal 1 (ON) causes the signal
The valve travel and, hence, the valve posi- pressure pst to be transmitted to the actua-
tion is transmitted via the pin (1.1) to the tor, resulting in activation of the control
lever (1), thus converting the linear travel valve.
into a rotary motion. The shaft (2) transmits
u[V]
7
3 1.1 supply
2 1
pst
1 Lever 4 Tag
1.1 Pin 5 Proximity switch
2 Shaft 6 Adjustment screw
6 4 5
3 Spring 7 Pressure regulator
4 EB 8356 EN
Technical data
1.1 Versions
Model 3768- 2 0 0
Explosion protection Without 0
Ex II 2 G EEx ia IIC T6 acc. ATEX 1
Ex ia FM/CSA 3
Ex II 3 G EEx nA II T6 acc. ATEX 8
Solenoid valve Without 0
6 V DC 2
12 V DC 3
24 V DC 4
Pneumatic connections Without 0
1/4-NPT 1
ISO 288/1-G 1/4 2
Electrical connections M20 x 1.5 blue 1
M20 x 1.5 black 2
Plug connector HAN 7D (not with CSA/FM) 4
EB 8356 EN 5
Attachment to control valve
6 EB 8356 EN
Attachment to control valve
Type 3277
Adapter block
18 only for version with
1.2 solenoid valve
D2
D1
Symbol for
actuator stem Actuator stem
extends retracts
retracts extends
Marking
Cover plate
Tip of gasket Switch plate (13)
(16)
extends
Marking
Switchover plate
only for version with solenoid valve
15
EB 8356 EN 7
Attachment to control valve
8 EB 8356 EN
Attachment to control valve
Mounting position
27b
A B
Attachment to
26 27a 28 NAMUR rib
1,5 2
1
24 25 22 23 19 21 20 18
32
Fig. 4 ⋅ Attachment according to NAMUR (shown for attachment to the left side)
EB 8356 EN 9
Attachment to control valve
10 EB 8356 EN
Attachment to control valve
33
Attachment to
SAMSON Type 3278
37 35 38
Attachment acc. to
VDI/VDE 3845
39
40
39
40
Vent plug or
filter check valve
34
34
36
44
45
33 Limit switch
34 Intermediate piece 42
35 Lever with follower roll
36 Adapter 43
37 Transmission lever
38 Screws
39 Scale
40 Cam disk
41 Actuator shaft
42 Disk
43 Mounting bracket
44 Coupling
45 Seal
Fig. 5 ⋅ Attachment to rotary actuators
EB 8356 EN 11
Attachment to control valve
2.3.3 Adjusting the cam disk Securing the aligned cam disk
To additionally prevent the cam disk from
The adjustment of the cam disk depends on
being turned, drill a hole into the adapter
the valve’s direction of rotation, i.e. whether
(36) or the coupling (44) and install a 2 mm
it opens clockwise or counterclockwise.
dowel pin.
Four bore holes are available on the cam
Important!
disk, and they are located centrically
Starting position is the closed valve.
around the center bore hole. Select the suit-
The starting point (bore) of the cam must be
able bore to secure.
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.
When aligning the cam disk, the double-
sided scale disk must be clipped on the cam
disk in such a way that the value on the sca-
le matches the control valve’s direction of ro-
tation. Secure the cam disk using the faste-
ning screw.
12 EB 8356 EN
Attachment to control valve
Follower roll
Starting point Starting point
90˚
90˚
60˚
60
˚
30 ˚
˚ 0˚ 30
0˚
EB 8356 EN 13
Reversing amplifier for double-acting actuators
Assembly
Important!
Remove the sealing plug (1.5) before instal-
ling the reversing amplifier. The rubber
seal (1.4) must remain installed.
14 EB 8356 EN
Reversing amplifier for double-acting actuators
A1 Z
A2
Z
Output 38
A1
EB 8356 EN 15
Mounting parts table
16 EB 8356 EN
Mounting parts table
EB 8356 EN 17
Electrical connections
18 EB 8356 EN
Pneumatic connections for versions with solenoid valve
EB 8356 EN 19
Operation – Adjusting the limit contacts
4 Operation – Adjusting the limit of the limit switch and the limit position of
contacts the valve (either valve Open or Closed).
The switches A and B are optionally as-
On the rotary axis, there are two adjustable signed to the terminal pairs 41/42 and
tags (51) which operate the associated 51/52 by turning the associated name
proximity switches (50). plate on the terminal block (see also Fig. 8).
To operate the inductive limit switches,
corresponding switching amplifiers must be Important!
connected in the output circuit (see section Since the tags of the limit switches cannot
3). be turned by 360°, correct assignment of
When the tag (4) is in the inductive field of the switches A and B to the valve positions
the switch, the switch assumes a high resist- Open and Closed must be observed, especi-
ance. When it is no longer in the field, the ally when the limit switches are to be con-
switch assumes a low resistance. nected in fail-safe circuits.
The limit contacts are usually adjusted to
issue a signal for both limit positions. The
switches, however, can also be adjusted to The desired switching function, i.e. whether
signalize intermediate positions. the output relay must be picked up or re-
The assignment of the switches A and B leased when the tag has entered the field,
must be determined according to Tables 7 must be determined by means of jumpers
and 8. It depends on the mounting position for either working current or closed circuit
current at the switching amplifier.
20 EB 8356 EN
Operation – Adjusting the limit contacts
Table 8 NAMUR attachment (Fig. 4) Mounting position of adapter housing when looking onto the lever (18)
Attachment left Attachment right
Cable gland Switch Cable gland Switch
points Valve Tag points Valve Tag
towards position towards position
OUT IN OUT IN
Front Closed B A Front Closed A B
Open A B Open B A
Back Closed A B Back Closed B A
Open B A Open A B
EB 8356 EN 21
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, the limit switch must not
be operated again, unless an expert has in-
spected the device according to the explo-
sion protection requirements, issued a certifi-
cate stating this, or equipped the device
with his mark of conformity.
The inspection by an expert does not have
to be carried out, if the manufacturer per-
forms a routine check test on the device
prior to taking it into operation again, and
the success of the routine check test is do-
cumented by attaching a mark of conform-
ity to the device.
Parts used in explosion-protected versions
should only be exchanged for original de-
tail inspected parts from the manufacturer.
22 EB 8356 EN
Dimensions in mm
6 Dimensions in mm
185
M20 x 1.5
68
19.5
164 29 14 Output (38)
76
37
28
150 Supply (9)
Reversing amplifier
(optional)
68
35
39
36
44
50
19.5
N1=113
N2=200
Ø110
56 58
Pneumatic connection
50 82 Fulcrum of the reversing amplifier
actuator shaft Output 1 (A1)
28.5
46
56
28.5
76
50
66
EB 8356 EN 23
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
S/Z 2004-05
Port Thread Form Adjustment Drain Bowl Element Diaphragm Spring (Outlet Pressure Range) * Gauge
2 ....1/4" A....PTF K....Knob A....Automatic D....Metal with liquid level indicator 1 ....5 µm N....Non-relieving F ....0,3 to 4 bar (5 to 60 psig) G....With
3 ....3/8" B....ISO Rc taper T ....T-bar Q....Manual, 1/4 turn P....Transparent with guard 2 ....25 µm R....Relieving M...0,3 to 10 bar (5 to 150 psig) N....Without
4 ....1/2" G....ISO G parallel T ....Transparent 3 ....40 µm S....0,7 to 17 bar (10 to 250 psig)
* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.
© Norgren 1998
IM-180.300.02 (4/98)
a subsidiary of IMI plc Supersedes 12/97
No.:IL01-OM00006
OPERATION MANUAL
BOOSTER RELAY
IL100
SMC CORPORATION
フォーマット No:FSM027-1
CONTENTS
Page
1. Outline 3
2. Specification 3
5. Precautions in Using 6
6. Maintenance 7~8
Drawings 11~12
IL100-※※
0
Instructions for your safety
Please read thoroughly this operation manual before using the product.
Please keep this manual so that you will be able to refer to it anytime, and ensure to give it to end
users.
These instructions are intended to prevent a hazardous situation and / or equipment damage. These
instructions indicate the level of potential hazard by label of “Caution” “Warning”, or “Danger”. To
ensure safety, be sure to observe ISO 4414 (Note 1), JIS B 8370 (Note 2) and other safety practices.
(Note 1) ISO 4414 Pneumatic fluid power-Recommendations for the application of equipment to
transmission and control system.
1
! Warning
1. The compatibility of pneumatic equipment is the responsibility of the person who designs the
pneumatic system or decides its specifications.
Since the products specified here are used in various operating conditions, their
compatibility for the specific pneumatic system must be based on specifications or after
analyses and/or tests to meet your specific requirements.
2. Only trained personal should operate pneumatically operated machinery and equipment.
Compressed air can be dangerous if an operator is unfamiliar with it. Assembly, handling or
repair of pneumatic systems should be performed by trained and experienced operator.
3. An application which has the possibility of having negative effects on people, property,
or animals requiring special safety analysis.
2
1. Outline
Increase the operating speed of controlling part when the piping between the instruments and the
controlling part is very long, or the controlling part capacity is large.
2. Specification
Hysteresis Within 1%
Mass 560g
Input force from the instrument enters to the input chamber and act to diaphragm A. This works
against the force generated by diaphragm B. When the force generated by the input is strong, the
internal valve is pressed down and the supply air flows to the output side. When not strong, the
internal valve is closed and the exhaust port opens for exhaust. This is how the force generated by
diaphragm A and B is balanced. Opening of the needle valve connect the air path of the input and
the output. The adjustment of the throttle valve, the stability of the closed loop including the booster
relay is improved.
3
4
4. Transportation and Storage
! Warning
(1) Handle the product with care.
(3) The product is packed in a vinyl bag for shipment to prevent from dust. Avoid taking out
of the bag just before piping even after unpacking.
(4) If the product is kept unpacking for a certain period, select a place where there is no
moisture nor corrosive gas.
While the product shipped has been applied specified paint and surface treatment, take
care that inappropriate storing environment may cause generating rust.
5
5. Precautions in using
Warning Operation
!
(1) Do not operate the booster relay out of the specifications, because it causes
malfunction.
(2) If booster relay failure affecting the system is expected, provide a safety circuit for the
system to avoid danger.
! Warning Handling
(1) Excess vibration and impact on the booster relay cause failure, may cause failure, so
that take care in handling during transportation and operation.
(2) Mount the filter to the pressure supply line. Use the mist separator when the oil mist
and carbon are contained.
(3) Flush the air piping before connecting the booster relay.
(4) Mind the arrow direction of the air flow when piping.
(5) The needle valve is opened for 3/4 turn and locked. No adjustment is necessary except
when the control system is unstable.
(6) Opening the needle valve delays the response, closing quickens the response.
(2) Avoid using compressed air compressed air containing chemicals, synthetic fluid
including organic solvent, salinity, and corrosive gas as it may cause malfunction.
! Warning Environment
(1) Do not use in environment where the product is exposed to corrosive gas, chemicals,
salt water, water or steam.
(2) Do not operate the product in a location where it is subject to strong vibration and/or
shock. For vibration, it should be within IG 60Hz.
6
6. Maintenance
! Warning
(1) To handle compressed air, person that has experienced and has knowledge about
instrumentation machine is suitable. That kind of person should operate unit
replacement and maintenance with keeping product specification.
(2) To remove booster relay or to replace unit with product set, please exhaust residual
pressure within piping with supply air stopped.
(3) After mounting, maintenance and disassemble, please test leakage and function with
compressed air supplied. When louder breed sound than initial, or when machine do not
operate properly, please confirm correct mounting.
!
Caution
(1) Periodical check (recommended : once / year)
Please check once per year on this product. To check, disassemble product following
disassemble drawing, and check following item. When disassemble, pay attention in
order not to damage diaphragm, in the case of diaphragm stick to body.
To re-assemble, ensure no foreign matter inside product and pay attention for air path
position of each part.
7
! Warning
(Adjustment on Part replacement)
Diaphragm replacement and product disassemble & re-assemble may change in/output
characteristics. For that circumstances, adjust main valve length. Main valve, as shown
below, is adjusted the length by screw and fixed with lock nut. To adjust length, loose lock
nut. For the main valve length adjustment, make longer when output is low to input
signal. Make shorter when output is high to input signal. Main valve total length is
basically 25±1mm.
8
7. Countermeasures for failure
! Warning
9
10
11
12