Manuals

Pneumatic Control Valve Type 3241-1 and Type 3241-7
Type 3241-1 Type 3241-7

Fig. 1 Type 3241 Valve with Type 3271 Actuator and with Type 3277 Actuator
Mounting and Operating Instructions EB 8015 EN

Edition April 2004
Contents
Contents 1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 6 7 8 Assembling valve and actuator . . . . . . . . . . . . . . . . . Assembly and adjustment . . . . . . . . . . . . . . . . . . . . Pretensioning springs in actuator version Actuator stem extends. Valve and actuator with different rated travels . . . . . . . . . . Installation . . . . . Mounting position . Signal pressure line. Strainer, bypass . . Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 7 8 9 9 9 9 9 10 11 11 12 13 13 13 15 15 16 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance Replacing parts . . . . . . . . . Standard valve version . . . . . . . . . . . . . Stuffing box packing . . . . . . . . . . . . . . Seat and/or plug . . . . . . . . . . . . . . . . Valve with insulating section or metal bellows seal Stuffing box packing . . . . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . Metal bellows . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . Replacing the collar or seal . . . . . . . . . . .
Material identifying marks . . . . . . . . . . . . . . . . . . . . . . 18 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . 19 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Note! Non-electrical control valves which do not have a valve body lined with an insulating material coating do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC. Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to equipotential bonding system.
EB 8015 EN
Safety instructions
General safety instructions
4 The control valve may only be mounted, started up or serviced by fully
4 4
trained and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger. All safety instructions and warnings in these mounting and operating instructions, particularly those concerning assembly, start-up and maintenance, must be observed. The control valves fulfill the requirements of the European Pressure Equipment Directive 97/23/EC. Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assessment procedure. The declaration of conformity is available on request. For appropriate operation, make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the control valve by the process medium, operating pressure, signal pressure or by moving parts are to be prevented by means of the appropriate measures. Proper shipping and appropriate storage are assumed.
Caution!
4 For installation and maintenance work on the valve, make sure the relevant 4 4
section of the pipeline is depressurized and, depending on the process medium, drained as well. If necessary, allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve. Prior to performing any work on the valve, make sure the supply air and control signal are disconnected or blocked to prevent any hazards that could be caused by moving parts. Special care is needed when the actuator springs are pretensioned. These actuators are labeled correspondingly and can also be identified by three long bolts at the bottom of the actuator. Prior to starting any work on the valve, you must relieve the compression from the pretensioned springs.
EB 8015 EN
Design and principle of operation
Design and operation
principle
of
The Type 3241-1 and Type 3241-7 Pneumatic Control Valves consist of a Type 3241 single-seated Globe Valve and either a Type 3271 or Type 3277 Pneumatic Actuator. Thanks to the modular design, the actuators can be exchanged, and the standard version of the valve can be supplemented to form a version with insulating section or metal bellows seal. In the micro-flow valve version, a micro-trim element is installed in the valve body instead of the usual seat-plug assembly. The process medium flows through the valve in the direction indicated by the arrow. The position of the plug (3) determines the flow through the valve seat (2). The position of the plug (3) is changed by the signal pressure acting on the diaphragm of the actuator (bench range). Plug (3) and actuator stem (8.1) are connected via the stem connector (7) and sealed by the spring-loaded ring packing (4.2). Fail-safe position The control valve provides two different fail-safe positions depending on the arrangement of the springs in the actuator: Actuator stem extends When the signal pressure is reduced or the power supply fails, the springs move the actuator stem downwards and close the valve. When the signal pressure increases again, the valve opens acting against the force of the springs.
Actuator stem retracts When the signal pressure is reduced or the power supply fails, the springs move the actuator stem upwards and open the valve. When the signal pressure increases again, the valve closes acting against the force of the springs.
Assembling valve and actuator
The basic pneumatic actuator can be replaced by an electric actuator or a pneumatic actuator with additional handwheel. A pneumatic actuator (with or without handwheel) can be exchanged for another pneumatic actuator in a different size. If, in the valve-actuator assembly, the travel range of the actuator is larger than the travel range of the control valve, the actuator springs are preloaded by the manufacturer so that the travels match.
2.1
Assembly and adjustment
If the valve and actuator have not been pre-assembled by the manufacturer, or if the actuator of a control valve is to be replaced by an actuator of another type or another size, proceed as described below. 1. Unscrew the lock nut (6.2) and stem connector nut (6.1). Firmly press the plug together with the plug stem into the seat ring. Thread the stem connector nut and lock nut downwards. 2. Remove the stem connector clamps (7) and the ring nut (8.2) from the actuator (8). Slide the ring nut over the plug stem.
EB 8015 EN
Type 3271Actuator
1. Valve body 1.1 Nuts 1.2 Gasket 2 3 Seat Plug
4.1 Spring 4.2 Packing 5 Valve bonnet
8.2 8.1
5 5.3 7 6.1
5.2 Threaded bushing 5.3 Travel indicator scale 6 Plug stem 6.1 Stem connector nut 6.2 Lock nut 6.3 Yoke (DN 200 and 250) 7 Stem connector 8 Actuator 8.1 Actuator stem 8.2 Nut
1.1 1.2 1
6.2 6 5.2 4.2
2 3
4.1
Type 3241 Valve

Micro-trim element 15 Plug stem 16 Valve plug 17 Seat body 18 Spring 19 Seat nut
15 16 17 18 19
Fig, 2 Sectional drawings
EB 8015 EN
Type 3277 Actuator
8 8.1 8.2
7
1 1.1 1.2 2 3 4.1 4.2 5 5.2 5.3 6 6.1 6.2 6.3 7 Valve body Nuts Gasket Seat Plug Spring Packing Valve bonnet Threaded bushing Travel indicator scale Plug stem Stem connector nut Lock nut Yoke (DN 200 and 250) Stem connector
8 Actuator 8.1 Actuator stem 8.2 Nut
Fig. 3 Sectional drawings of Type 3241-7 and valve body DN 200 and 250
EB 8015 EN
3. Place actuator onto the valve bonnet (5) and secure with the ring nut (8.2). 4. Read bench range (or bench range with pre-loaded springs) and fail-safe action from the actuator's nameplate (e.g. 0.2 to 1 bar and "Actuator stem extends"). The lower value of the bench range corresponds to the lower bench range value to be adjusted; the upper bench range value corresponds to the lower bench range value. The fail-safe action "Actuator stem extends" (FA) or "Actuator stem retracts" (FE) is indicated on the Type 3271 Actuator. The Type 3277 Actuator bears the corresponding symbol. 5. For actuators with "Actuator stem extends", apply a signal pressure to the lower diaphragm chamber which corresponds to the lower bench range value (e.g. 0.2 bar). For actuators with "Actuator stem retracts", apply a signal pressure to the upper diaphragm chamber which corresponds to the upper bench range value (e.g. 1 bar). 6. Thread down the stem connector nut (6.1) by hand until it makes contact with the actuator stem (8.1). Then, turn it another 1/4 turn and secure this position with the lock nut (6.2). 7. Position the stem connector clamps (7) and screw tight. Align the travel indicator scale (5.3) with the tip of the stem connector.
Note on disassembling an actuator! Before disassembling an actuator with fail-safe action "Actuator stem extends" and particularly an actuator with pretensioned springs, apply a pressure to the lower signal pressure connection that slightly exceeds the lower bench range value (see nameplate of the actuator), so that you can loosen the ring nut (8.2).
2.2
Pretensioning springs in actuator version Actuator stem extends
To achieve a greater positioning force, the springs in actuators with "Actuator stem extends" can be preloaded with up to 12.5 % (actuator sizes 120 and 240 cm) or up to 25 % (350 cm and higher) of their travel or bench range. Example: If the springs are preloaded with, for example, 0.1 bar for a bench range of 0.2 to 1 bar, the bench range is shifted by 0.1 bar to result in a bench range of 0.3 to 1.1 bar (0.1 bar corresponds to a preload of 12.5 %). When adjusting the valve, the lower bench range is to be set to 0.3 bar. Make sure the new bench range of 0.3 to 1.1 bar is indicated on the nameplate as the bench range with pretensioned springs!
EB 8015 EN
2.3
Valve and actuator with different rated travels
Actuator version "Actuator stem retracts"
Actuator version "Actuator stem extends"
Caution! The springs in the actuator version Actuator stem retracts cannot be pretensioned!
If a valve is to be attached to a larger actuator (rated travel of actuator larger than the rated travel of the valve), just the first half of the bench range of the actuator can be used. Example: Valve DN 100 with 30 mm rated travel and 1400 cm actuator with 60 mm rated travel, 0.4 to 1 bar bench range: A useable bench range of 0.2 to 0.6 bar is available for the half valve range.
Note! Valves that have a travel smaller than the rated travel of the actuator always need to use pretensioned springs.
Example: Valve DN 100 with 30 mm rated travel and 1400 cm actuator with 60 mm rated travel, 0.4 to 2 bar bench range. 1. Set the signal pressure required for tensioning the springs above the signal pressure of 1.2 bar (1.2 to 2 bar range) which corresponds to the mid actuator travel (30 mm) to 1.6 bar. 2. Thread stem connector nut (6.1) until it touches the actuator stem. 3. Secure the position with lock nut and attach stem connector as described in section 2.1. 4. Enter the 1.6 to 2.4 bar bench range valid for the mounted valve on the nameplate of the actuator.
Note! Actuators which have been preloaded by the manufacturer without an attached valve are marked with a label. In addition, you will notice three extended bolts on the bottom diaphragm case. They enable you to evenly relieve the preload of the springs when disassembling the actuator.
EB 8015 EN
Installation
3 3.1
Installation Mounting position
3.3
Strainer, bypass
The valve can be mounted in any desired position. However, vertical installation with the actuator pointing upwards is preferable for valves in nominal size DN 100 or larger to facilitate maintenance. For valves with insulating section or metal bellows seal, or for actuators weighing more than 50 kg, mount a suitable support or suspension for the actuator.
We recommend you to install a SAMSON Type 2 Strainer upstream of the valve body. We also recommend to install a shut-off valve both upstream of the strainer and downstream of the valve, as well as a bypass, so that you do not need to shut down the plant for maintenance.
3.4
Test connection
Note! The valve must be installed with as little vibration as possible and free of stress. Flush the pipeline thoroughly before installation. Note! Do not insulate control valves which must conform to NACE MR 0175.
If there is a test connection (G 1/8) at the upper flange of a valve version with metal bellows seal (Fig. 6), you can check the tightness of the bellows there. Particularly for liquids and vapors, we recommend you to install a suitable leak indicator at the test connection, such as a contact pressure gauge, an outlet into an open vessel or an inspection window.
3.2
Signal pressure line
Operation
Connect the signal pressure line to the lower diaphragm case for valves with actuator version "Actuator stem extends" and to the upper diaphragm case for valves with actuator version "Actuator stem retracts". The lower signal pressure connection of the Type 3277 Actuator is located at the side of the yoke of the lower diaphragm case.
(e.g. reversing the fail-safe action of the actuator etc.) For details concerning operation, see Mounting and Operating Instructions EB 8310 EN for the Type 3271 Pneumatic Actuator and EB 8311 EN for the Type 3277 Pneumatic Actuator.
EB 8015 EN
Maintenance Replacing parts
The control valve is subject to natural wear, especially at the seat, plug and packing. Depending on the application, the valve needs to be checked regularly to prevent against possible failures. If leakage occurs, this could be caused by a damaged packing or a defective metal bellows. If the valve does not seal properly, the tight shut-off may be impeded by dirt or other impurities caught between the seat and plug, or by damaged seat joints. Remove the parts, clean them thoroughly and replace them, if necessary.
Caution! On performing any work on the valve, first shut off the signal pressure, disconnect the signal pressure line and remove the actuator. Note! Suitable seat and special tools as well as the appropriate tightening torques required for installation are listed in EB 029 EN (formerly WA 029 EN) which can be viewed on the Internet at http://www.samson.de/pdf_en/e00290en.pdf.
Removing the actuator: 1. Before disassembling an actuator with fail-safe action "Actuator stem extends" and particularly an actuator with preloaded springs, apply a pressure to the lower signal pressure connection that slightly exceeds the lower bench range value (see nameplate), so that you can remove the ring nut (8.2). Remove the stem connector clamps (7) and the ring nut (8.2). 2. Remove the actuator from the valve bonnet.
Note! Before servicing or disassembling the control valve, depressurize the concerned section of the plant and drain it, if necessary, depending on the medium used. Switch off the signal pressure for the actuator and remove the signal pressure line. As valves are not free of cavities, there might still be residual medium in the valve. This applies, in particular, for valve versions with insulating section and metal bellows seal.
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EB 8015 EN
5.1
Standard valve version
5.1.1 Stuffing box packing

1. Remove the body nuts (1.1) as well as the valve bonnet (5) together with the plug stem and plug from the body. 2. Unscrew the stem connector nut and lock nut (6.1 and 6.2) from the plug stem. 3. Screw the threaded bushing (5.2) out of the stuffing box. Pull the plug stem together with the plug out of the valve bonnet.
4. Pull all packing parts out of the packing chamber using a suitable tool. Replace damaged parts. Clean packing chamber thoroughly. 5. Remove the gasket (1.2) and carefully clean sealing faces in the valve body and on the bonnet. 6. Apply lubricant (order no. 8150-0111) to all the packing parts and the plug stem (6). 7. Slide the plug stem with plug into the valve bonnet.
5.2 5.2
4.2 4.3 4.1 4.2
4.3 4.1 6 6.3 5
4 Packing 4.1 Spring 4.2 PTFE ring packing or packing rings 4.3 Washer 5 Bonnet 5.2 Threaded bushing 6 Plug stem 6.3 Yoke
5 6
Fig. 4 Stuffing box packing
EB 8015 EN
11
8. Insert new flat gasket (1.2) into the body. Carefully place the valve bonnet onto the valve body and secure with nuts (1.1). 9. Carefully slide the stuffing box parts over the plug stem into the packing chamber. Make sure to keep the proper order. Screw in the threaded bushing (5.2) and tighten. 10. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 11. Mount the actuator and adjust the upper and lower bench range values as described in section 2.1.
12 mm. For seat bores of 63 mm and larger, the entire sealing ring can be exchanged, if necessary (the plug parts are screwed together). Seat:
4 Unscrew the seat (2) using the appropri-
ate seat wrench (see EB 029 EN). Apply lubricant (order no. 8150-0119) to the thread and sealing cone of the new seat (or possibly the old seat when it has been reworked or thoroughly cleaned) and screw it in.
Micro-trim insert In this version, the complete micro-trim element (Fig. 2) can be unscrewed from the valve body using a socket wrench (width across flats 27) and disassembled for cleaning. If individual parts are damaged, exchange the entire micro-trim element.
5.1.2 Seat and/or plug

We recommend you to also replace the packing (4.2) when exchanging the seat and plug. To exchange the packing, proceed as described in section 5.1.1. Plug:
4 Remove the old plug and replace it with
a new plug with plug stem. It is possible to use the old plug again, provided it has been reworked properly. Apply lubricant (order no. 8150-0111) to the plug stem before installation.
x
w
Seat bore 12 24...48 6...80

R0 .3
x [mm] 0.5 1.0 2.0 2.5
Reworking the plug
4 Slight damage at the sealing edges of
100...200
the plug can be eliminated by re-turning it on a lathe. Soft-sealing plugs can only be reworked until dimension x is reached, and if the seat bore exceeds
30
Fig. 5 Plug with soft sealing
12
EB 8015 EN
5.2
Valve with insulating section or metal bellows seal
5.2.2 Plug
When exchanging the plug, check the packing (4.2) or, preferably, replace it as described in section 5.2.1. Nominal sizes DN 15 to 150: To unscrew the plug (6) from the plug stem extension (6.3), screw two nuts onto the protruding thread of the extension to hold the plug stem extension in place.

1. Remove the stem connector nut and lock nut (6.1 and 6.2) from the plug stem extension (6.3). Unscrew the threaded bushing (5.2) out of the stuffing box. 2. Remove nuts (5.4) and carefully lift the bonnet (5) over the plug stem extension. 3. Pull all stuffing box parts out of the packing chamber using a suitable tool. Replace damaged parts. Clean packing chamber thoroughly. 4. Remove the gasket (5.5) in the intermediate piece (12) and carefully clean the sealing faces. 5. Apply lubricant (order no. 8150-0111) to all the packing parts and the plug stem (6). 6. Insert new gasket (5.5) in the intermediate piece. Carefully place the bonnet over the plug stem extension onto the bonnet and secure with nuts (5.4). 7. Carefully slide the stuffing box parts over the plug stem extension into the packing chamber. Make sure to keep the proper order. Screw in the threaded bushing (5.2) and tighten. 8. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 9. Mount the actuator and adjust the upper and lower bench range values as described in section 2.1.
Caution! To prevent damage to the version with the bellows seal (no bellows in the version with insulating section), make sure no torque is transmitted to the bellows, which is connected to the intermediate piece. We recommend you to use a clamping tool (see EB 029 EN).
1. Remove the nuts (1.1). 2. Remove the intermediate piece (12) together with the plug stem extension, plug stem and plug from the valve body. 3. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the intermediate piece. 4. Use an appropriate wrench to hold the nuts stationary, which are screwed onto the plug stem extension. Clamp the plug stem using a suitable tool and screw it out of the plug stem extension. Caution! Do not twist the plug stem extension with the welded-on bellows! 5. Apply lubricant (order no. 8150-0111) to the end of the plug stem (6) of the new or old, reworked plug (3). Check whether the two washers (6.4)
EB 8015 EN
13
1.1 Nuts 1.2 Gasket 3 Plug 3.5 Tension ring 3.6 Flange 3.7 Screws 4.2 Packing 5 Bonnet 5.2 Threaded bushing 5.4 Bolts 5.5 Gasket
6 Plug stem 6.1 Stem connector nut 6.2 Lock nut 6.3 Plug stem extension 6.4 Washers 6.5 Nut (DN 15 to 150) 6.6 Metal bellows 6.7 Seal 6.8 Seal (DN 200/250) 11 Test connection 12 Intermediate piece
DN 15 to 150 (forged valve body) DN 200 and 250 (with flow divider)
Fig. 6 Versions with metal bellows seal and insulating section
14
EB 8015 EN
are still in the plug stem extension (6.3). Screw the plug stem firmly into the plug stem extension (6.3); tightening torque is 50 Nm for 10 mm and 80 Nm for 16 mm. To complete assembly, refer to section 5.2.5.
5.2.4 Metal bellows

Nominal sizes DN 15 to 150: 1. Unscrew the plug (3) together with the plug stem (6) from the plug stem extension (6.3) as described for replacing the seat in section 5.2.2. 2. Unscrew the nut (6.5) using a SAMSON socket wrench (see EB 029 EN). 3. Pull the plug stem extension with the welded-on metal bellows (6.6) out of the intermediate section (12). 4. Clean the sealing faces on the intermediate piece. 5. Insert a new plug into the intermediate piece and screw down the nut (6.5).
Nominal sizes DN 200 and 250: 1. Remove the nuts (1.1). 2. Remove the intermediate piece (12) together with the plug stem and plug from the valve body. 3. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the intermediate piece. 4. Remove the hexagon head screws (3.7), tension ring (3.5) and flange (3.6). 5. Unscrew the plug from the plug stem. To do so, use a suitable tool to hold the plug stem in place, so that the metal bellows, which is welded onto the plug stem, cannot be twisted. 6. Screw a new plug with tension ring and flange to the plug stem. To complete assembly, refer to section 5.2.5. In the version with insulating section, there are no parts 3.5, 3.6 and 3.7. Plug (3) and plug stem(6) form one piece.
Caution! Do not twist the metal bellows!

6. Check whether both washers (6.4) are still in the plug stem extension (6.3). Apply lubricant (order no. 8150-0111) to the thread of the plug stem and firmly screw the plug stem into the plug stem extension (6.3) with a tightening torque of 50 Nm for a plug stem diameter of 10 mm and 80 Nm for a diameter of 16 mm.
5.2.3 Seat
Replace the seat (2) as described in section 5.1.2.
EB 8015 EN
15
Nominal sizes DN 200 and 250: 1. Unscrew the plug (3) from the plug stem as described in section 5.2.2. Pull the plug stem (6) together with the metal bellows (6.6) upwards, out of the intermediate piece (12). 2. Replace the seal (6.7) and insert a new plug stem with metal bellows (6.6). 3. Screw on the plug and secure with the tension ring (3.5), flange (3.6) and screws (3.7).
5.3
Replacing the collar or seal
For version with pressure-balanced plug: 1. Unscrew the stem connector nut and lock nut (6.1 and 6.2) from the plug stem. 2. Remove the body nuts (1.1) and carefully lift off the valve bonnet (5) with plug stem (6). 3. Screw the threaded bushing (5.2) out of the stuffing box. Pull plug stem and plug (3) out of the bonnet. 4. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the bonnet. Nominal size DN 40: 5. Pull the packing (4.2), washer (4.3) and spring (4.1) out of the packing chamber using an appropriate tool. Replace damaged parts. 6. Push out the bushing (3.2) and replace the collar (3.1). Clean the packing chamber thoroughly. 7. Apply lubricant (order no. 8150-0111) to the bushing (3.2) and push it in again. 8. Also apply lubricant to the packing parts, plug stem (6) and the contact faces of the collar (3.1). 9. Insert the plug stem and plug into the valve bonnet.
5.2.5 Reassembly
1. Insert new gasket (1.2) into the valve body. Place the intermediate piece (12) onto the valve body (1) and secure with nuts (1.1). 2. Insert new gasket (5.5) into the intermediate piece. Place the valve bonnet (5) onto the intermediate piece and secure with bolts (5.4) and nuts. Observe the tightening torques specified in EB 029 EN. 3. Tighten the threaded bushing (5.2). 4. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem extension (6.3) or plug stem. 5. Mount the actuator and adjust the upper and lower bench range values as described in section 2.1.
16
EB 8015 EN
Completion of reassembly: 10. Insert new gasket (1.2) into the valve body. Carefully place the valve bonnet on the valve body and secure with nuts (1.1). Observe the tightening torques specified in EB 029 EN. 11. Slide the stuffing box parts over the plug stem into the packing chamber. Make sure to keep the proper order.
12. Screw in the threaded bushing (5.2) and tighten. 13. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 14. Mount the actuator and adjust the upper and lower range values as described in section 2.1.
DN 40 DN 50
DN 65 and 80
3 3.1 3.2 3.3 3.4 6 DN 100 to 150
Plug Collar, seal Bushing Washer, ring Screw Plug stem DN 200 to 250
Fig. 7 Pressure-balanced plug
EB 8015 EN
17
Material identifying marks
Nominal sizes DN 50 to 150 5. Remove screw (3.4) with its locking device and washer (3.3). Replace collar (3.1). 6. Insert washer (3.3). Thread down the screw (3.4) with its locking device. 7. Apply lubricant (order no. 8150-0111) to the packing parts, plug stem (6) and contact faces of the collar (3.1). 8. Insert the plug stem and plug into the valve bonnet. Complete reassembly as described for DN 40, steps 10 to 14. Nominal sizes DN 200 and 250: 5. Remove the screw (3.4) with its locking device. 6. Lift off the ring (3.3) and replace collar or seal (3.1). 7. Insert ring (3.3). Thread down screw (3.4) and its locking device. 8. Apply lubricant (order no. 8150-0111) to the packing parts, plug stem (6) and contact faces of the collar (3.1). 9. Insert the plug stem and plug into the valve bonnet. Complete reassembly as described for DN 40, steps 10 to 14.
Guide bushing, seat and plug have the following identifying marks: Guide bushing (groove on plane face)
4 No groove: 1.4305 4 Sharp recessed groove: 1.4571 4 Flat recessed groove: Hastelloy
Seat The material number according to DIN is either stamped or engraved on the seat.
4 Stellited seats are marked by a

stamped-on "st". Plug Groove below the plug stem thread:
4 No groove: 1.4006 4 Sharp recessed groove: 1.4571 4 Two sharp recessed grooves: 1.4301 4 Flat recessed groove: Hastelloy 4 When other materials are used, either
The Kvs value and characteristic are engraved on the plug.
the material number or its designation is engraved on the plug.
4 Stellited plugs are marked by an

engraved "st".
Dimensions and weights of the valve versions can be found in Data Sheet T 8015 EN.
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EB 8015 EN
Description of nameplates
1 1 2 3 4 5 6 7 8 9 10 11 12 CE marking or "Art. 3, Abs.3" (see article 3, 3 of PED), where applicable Identification no. of notified body, fluid group and category, where applicable Type designation Modification index of valve Material Year of manufacture Nominal size: DIN: DN, ANSI: Size Permissible excess pressure at room temperature DIN: PN, ANSI: CL Order number with modification index Position of item in order Flow coefficient: DIN: KVS, ANSI: Cv Characteristic: % equal percentage, Lin linear, DIN: A/Z quick opening, ANSI: O/C Sealing: ME metal, ST stellited, Ni nickel-plated PT soft sealing with PTFE, PK soft sealing with PEEK Pressure-balanced: DIN: D, ANSI: B I or III flow divider 2 3 4
Type designation Modification index Effective diaphragm area Fail-safe action: FA Actuator stem extends FE Actuator stem retracts Travel Bench range (spring range) Bench range with pretensioned springs
5 6 7
13
14 15
Fig. 8 Valve nameplate (left) and actuator nameplates (right)
Customer inquiries
If you encounter any problems, please submit the following details:
4 Order number 4 Type, product number, nominal size and

version of the valve
4 Pressure and temperature of the process medium 4 Flow rate in m/h 4 Bench range of the actuator (e.g. 0.2 to 1 bar) 4 Has a strainer been installed? 4 Installation drawing
EB 8015 EN
19
SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt am Main Germany Phone: +49 69 4009-0 Fax: +49 69 4009-1507 Internet: http://www.samson.de
EB 8015 EN
S/Z 2005-11
Globe Valve Type 3241
Fig. 1 Type 3241 Globe Valve
Mounting and Operating Instructions EB 8015-1 EN

Edition June 2004
Contents
Contents 1 2 2.1 3 3.1 3.2 3.3 4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 6 7 8
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 4 Assembling valve and actuator . . . . . . . . . . . . . . . . . . . . . 6 Travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . Mounting position Strainer, bypass . Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 6 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Maintenance Replacing parts. . . . . . . . . . . . . . . . . . . . . . 7 Standard valve version . . . . . . . . . . . . . . . . . . . . . . . . . 8 Stuffing box packing . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Seat and/or plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Valve with insulating section or metal bellows seal . . . . . . . . . . . 10 Stuffing box packing . . . . . . . . . . . . . . . . . . . . . . . . . 10 Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Metal bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Replacing the collar or seal . . . . . . . . . . . . . . . . . . . . . . 14 Material identifying marks . . . . . . . . . . . . . . . . . . . . . . 16 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . 17 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Note! Non-electrical control valves which do not have a valve body lined with an insulating material coating do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC. Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to equipotential bonding system.
EB 8015-1 EN
Safety instructions
4 4
trained and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger. All safety instructions and warnings in these mounting and operating instructions, particularly those concerning assembly, start-up and maintenance, must be observed. The control valves fulfill the requirements of the European Pressure Equipment Directive 97/23/EC. Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assessment procedure. The declaration of conformity is available on request. For appropriate operation, make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the control valve by the process medium, operating pressure, signal pressure or by moving parts are to be prevented by means of the appropriate measures. Proper shipping and appropriate storage of the control valve are assumed.
Caution!
4 For installation and maintenance work on the valve, make sure the relevant 4
section of the pipeline is depressurized and, depending on the process medium, drained as well. If necessary, allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve. Prior to performing any work on the valve, make sure the lines for the electrical or supply air as well as the control signal are disconnected or blocked to prevent any hazards that could be caused by moving parts.
EB 8015-1 EN
Design and principle of opera- electric control valve. Additionally, the valve can be fitted with a hand-operated actuator. tion
Thanks to the modular design, the actuators can be exchanged, and the standard version of the valve can be supplemented to form a version with insulating section or metal bellows seal.
The single-seated Type 3241 Globe Valve can be combined with different actuators to form either a pneumatic control valve or an
Micro-trim element 15 Plug stem 16 Seat body 17 Valve plug 18 Spring 19 Seat nut
Fig. 2 Sectional drawing of Type 3241 in nominal sizes DN 15 to 150
EB 8015-1 EN
In the micro-flow valve version, a micro-trim element is installed in the valve body instead of the usual seat-plug assembly. The process medium flows through the valve in the direction indicated by the arrow. The position of the plug (3) determines the flow through the valve seat (2). The position of
the plug (3) is changed by the signal pressure acting on the diaphragm of the actuator (bench range). Plug (3) and actuator stem (8.1) are connected via the stem connector (7) and sealed by the spring-loaded ring packing (4.2).
Travel adjustment (with a valve closed) DN 15 to 80 100 to 150 200 and 250 Dimension A 75 0.1 90 0.1 165 (225)
1. 1.1 1.2 2 3 4.1 4.2 5 5.2 5.3 6 6.1 6.2 6.3
Valve body Nuts Gasket Seat Plug Spring Packing Valve bonnet Threaded bushing Travel indicator scale Plug stem Stem connector nut Lock nut Yoke (DN 200 and 250) 7 Stem connector 8 Actuator 8.1 Actuator stem 8.2 Nut
Fig. 3 Sectional drawing of Type 3241 in nominal sizes DN 200 and 250
EB 8015-1 EN
Note! Refer to the Mounting and Operating Instructions of the corresponding actuator for assembly.
Note! The valve must be installed with as little vibration as possible and free of stress. Flush the pipeline thoroughly before installation. Note! Do not insulate control valves which must conform to NACE MR 0175.
2.1
Travel adjustment
When valve and actuator are shipped separately, dimension A, which extends from the top of the stem connector nut (6.1) to the top of the valve bonnet (yoke), is adjusted according to the table in Fig. 3. Check this dimension on assembly and, if necessary, readjust it by turning the stem connector nut.
3.2
Strainer, bypass
3 3.1
We recommend you to install a SAMSON Type 2 Strainer upstream of the valve body. We also recommend to install a shut-off valve both upstream of the strainer and downstream of the valve, as well as a bypass, so that you do not need to shut down the plant for maintenance.
3.3
Test connection
The valve can be mounted in any desired position. However, vertical installation with the actuator pointing upwards is preferable for valves in nominal size DN 100 or larger. Otherwise, difficulties during maintenance work can occur. For valves with insulating section or metal bellows seal, or for actuators weighing more than 50 kg, mount a suitable support or suspension for the actuator.
EB 8015-1 EN
Operation
Operation
As the operating instructions only apply when the valve is used in conjunction with an actuator, refer to the associated Mounting and Operating Instructions of the actuator mounted on the valve.
The control valve is subject to natural wear, especially at the seat, plug and packing. Depending on the application, the valve needs to be checked regularly to prevent against possible failures. If leakage occurs, this could be caused by a damaged packing or a defective metal bellows. If the valve does not seal properly, the tight shut-off may be impeded by dirt or other impurities caught between the seat and plug, or by damaged seat joints. Remove the parts, clean them thoroughly and replace them, if necessary.
Note! Before servicing or disassembling the control valve, depressurize the concerned section of the plant and drain it, if necessary, depending on the medium used. Wait until the medium has cooled down, if necessary. As valves are not free of cavities, there might still be residual medium in the valve. This applies, in particular, for valve versions with insulating section and metal bellows seal. We recommend removing the valve from the pipeline. Caution! On performing any work on the valve body, first shut off the electric or pneumatic auxiliary energy supply and block it as well as interrupt the control signals to prevent any hazards caused by moving parts. Remove the actuator from the valve before carrying out any work on the valve body.
Note! Suitable seat and special tools as well as the appropriate tightening torques required for installation are listed in EB 029 EN (formerly WA 029 EN) which can be viewed on the Internet at http://www.samson.de/pdf_en/e00290en.pdf.
EB 8015-1 EN
5.1

1. Remove the body nuts (1.1) as well as the valve bonnet (5) together with the plug stem and plug from the body. 2. Unscrew the stem connector nut and lock nut (6.1 and 6.2) from the plug stem. 3. Unscrew the threaded bushing (5.2) out of the stuffing box. Pull the plug stem together with the plug out of the valve bonnet.
4. Pull all stuffing box parts out of the packing chamber using a suitable tool. Replace damaged parts. Clean packing chamber thoroughly. 5. Remove the gasket (1.2) and carefully clean sealing surfaces in the valve body and on the bonnet. 6. Apply lubricant (order no. 8150-0111) to all the packing parts and the plug stem (6). 7. Slide the plug stem with plug into the valve bonnet.
5.2 5.2
4.2 4.3 4.1 4.2
4.3 4.1
4 Packing 4.1 Spring 4.2 PTFE ring packing or packing rings 4.3 Washer 5 Bonnet 5.2 Threaded bushing 6 Plug stem 6.3 Yoke
5 6
6 6.3 5
Fig. 4 Stuffing box packing
EB 8015-1 EN
8. Insert a new gasket (1.2) into the body. Carefully place the valve bonnet onto the valve body and secure with nuts (1.1). 9. Carefully slide the stuffing box parts over the plug stem into the packing chamber. Make sure to keep the proper order. Screw in the threaded bushing (5.2) and tighten. 10. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 11. Adjust the travel as described in section 2.1 and mount the actuator.
larger, the entire sealing ring can be exchanged, if necessary (the plug parts are screwed together). Seat:
4 Unscrew the seat (2) using the appropri-
ate seat wrench (see EB 029 EN). Apply lubricant (order no. 8150-0119) to the thread and sealing cone of the new seat (or possibly the old seat when it has been reworked or thoroughly cleaned) and screw it in.
Micro-flow valve version In this version, the complete micro-trim element (Fig. 2) can be unscrewed from the valve body using a socket wrench (width across flats 27) and disassembled for cleaning. If any parts are damaged, exchange the entire micro-trim element.

We recommend you to also replace the packing (4.2) when exchanging the seat and plug. To exchange the packing, proceed as described in section 5.1.1. Plug:
4 Remove the old plug and replace it with
a new plug with plug stem. It is possible to use the old plug again, provided it has been reworked properly. Apply lubricant (order no. 8150-0111) to the plug stem before installation.
x
w
Seat bore 12 24...48 63...80 100...200
x [mm] 0.5 1.0 2.0 2.5
Reworking the plug
4 Slight damage at the sealing edges of
the plug can be eliminated by re-turning it on a lathe. Soft-sealing plugs can only be reworked until dimension x (Fig. 5) is reached, and if the seat bore exceeds 12 mm. For seat bores of 63 mm and
R0
.3
30
Fig. 5 Plug with soft sealing
EB 8015-1 EN
5.2
5.2.2 Plug
When exchanging the plug, check the packing (4.2) or, preferably, replace it as described in section 5.1. DN 15 to DN 150: To unscrew the plug (6) from the plug stem extension (6.3), screw two nuts onto the protruding thread of the extension to hold the plug stem extension in place.

1. Remove the stem connector nut and lock nut (6.1 and 6.2) from the plug stem extension (6.3). Unscrew the threaded bushing (5.2) out of the stuffing box. 2. Remove nuts (5.4) and carefully lift the bonnet (5) over the plug stem extension. 3. Pull all packing parts out of the packing chamber using a suitable tool. Replace damaged parts. Clean packing chamber thoroughly. 4. Remove the gasket (5.5) in the intermediate piece (12) and carefully clean the sealing faces. 5. Apply lubricant (order no. 8150-0111) to all the packing parts and the plug stem (6). 6. Insert a new gasket (5.5) in the intermediate piece. Carefully place the bonnet over the plug stem extension onto the bonnet and secure with nuts (5.4). 7. Carefully slide the stuffing box parts over the plug stem extension into the packing chamber. Make sure to keep the proper order. Screw in the threaded bushing (5.2) and tighten. 8. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 9. Adjust the travel as described in section 2.1 and mount the actuator.
Caution! To prevent damage to the version with the bellows seal (no bellows in the version with insulating section), make sure no torque is transmitted to the bellows, which is connected to the intermediate piece. We recommend you to use a clamping tool (see EB 029 EN).
1. Remove the nuts (1.1). 2. Remove the intermediate piece (12) together with the plug stem extension, plug stem and plug from the valve body. 3. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the intermediate piece. 4. Use an appropriate wrench to hold the nuts stationary, which are screwed onto the plug stem extension. Clamp the plug stem using a suitable tool and screw it out of the plug stem extension. Caution! Do not twist the plug stem extension with the welded-on bellows! 5. Apply lubricant (order no. 8150-0111) to the end of the plug stem (6) of the new or old, reworked plug (3).
10
EB 8015-1 EN
1.1 Nuts 1.2 Gasket 3 Plug 3.5 Tension ring 3.6 Flange 3.7 Screws 4.2 Packing 5 Bonnet 5.2 Threaded bushing 5.4 Bolts 5.5 Gasket
6 Plug stem 6.1 Stem connector nut 6.2 Lock nut 6.3 Plug stem extension 6.4 Washers 6.5 Nut (DN 15 to DN 150) 6.6 Metal bellows 6.7 O-ring 6.8 O-ring (DN 200/250) 11 Test connection 12 Intermediate piece
DN 15 to 150 (forged steel body) DN 200 and 250 (with flow divider)
Fig. 6 Version with metal bellows and insulating section
EB 8015-1 EN
11
Check whether the two washers (6.4) are still in the plug stem extension (6.3). Screw the plug stem firmly into the plug stem extension (6.3); tightening torque is 50 Nm for 10 mm and 80 Nm for 16 mm. To complete assembly, refer to section 5.2.5.
5.2.4 Metal bellows

DN 15 to DN 150: 1. Unscrew the plug (3) together with the plug stem (6) from the plug stem extension (6.3) as described for replacing the seat in section 5.2.2. 2. Unscrew the nut (6.5) using a SAMSON socket wrench (see EB 029 EN). 3. Pull the plug stem extension with the welded-on metal bellows (6.6) out of the intermediate section (12). 4. Clean the sealing faces on the intermediate piece. 5. Insert a new plug into the intermediate piece and screw down the nut (6.5).
DN 200 and DN 250: 1. Remove the nuts (1.1). 2. Remove the intermediate piece (12) together with the plug stem extension, plug stem and plug from the valve body. 3. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the intermediate piece. 4. Remove the hexagon head screws (3.7), tension ring (3.5) and flange (3.6). 5. Unscrew the plug from the plug stem. To do so, use a suitable tool to hold the plug stem in place, so that the metal bellows, which is welded onto the plug stem, cannot be twisted. 6. Screw a new plug with tension ring and flange to the plug stem. To complete assembly, refer to section 5.2.5. In the version with insulating section, there are no parts 3.5, 3.6 and 3.7. Plug (3) and plug stem(6) form one piece.
Caution! Do not twist the metal bellows!

6. Check whether both washers (6.4) are still in the plug stem extension (6.3). Apply lubricant (order no. 8150-0111) to the thread of the plug stem and firmly screw the plug stem into the plug stem extension (6.3) with a tightening torque of 50 Nm for a plug stem diameter of 10 mm and 80 Nm for a diameter of 16 mm. DN 200 and DN 250: 1. Unscrew the plug (3) from the plug stem as described in section 5.2.2. Pull the plug stem (6) together with the metal bellows (6.6) upwards, out of the intermediate piece (12).
5.2.3 Seat
Replace the seat (2) as described in section 5.1.2.
12
EB 8015-1 EN
2. Replace the O-ring (6.7) and insert a new plug stem with metal bellows (6.6). 3. Screw on the plug and secure with the tension ring (3.5), flange (3.6) and screws (3.7).
5.2.5 Reassembly
1. Insert a new gasket (1.2) into the valve body. Place the intermediate piece (12) onto the valve body (1) and secure with nuts (1.1). 2. Insert a new gasket (5.5) into the intermediate piece. Place the valve bonnet (5) onto the intermediate piece and secure with nuts and bolts (5.4). Observe the tightening torques specified in EB 029 EN. 3. Tighten the threaded bushing (5.2). 4. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem extension (6.3) or plug stem. 5. Adjust the travel as described in section 2.1 and mount the actuator.
EB 8015-1 EN
13
5.3
Replacing the collar or seal
Completion of reassembly: 10. Insert a new gasket (1.2) into the valve body. Carefully place the valve bonnet on the valve body and secure with nuts (1.1). Observe the tightening torques specified in EB 029 EN. 11. Slide the stuffing box parts over the plug stem into the packing chamber. Make sure to keep the proper order. 12. Screw in the threaded bushing (5.2) and tighten. 13. Loosely screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 14. Adjust the travel as described in section 2.1 and mount the actuator. DN 50 to DN 150: 5. Remove screw (3.4) with its locking device and washer (3.3). Replace collar (3.1) with a new one. 6. Insert washer (3.3). Thread down the screw (3.4) with its locking device. 7. Apply lubricant (order no. 8150-0111) to the packing parts, plug stem (6) and contact faces of collar (3.1). 8. Insert the plug stem and plug into the valve bonnet. Complete reassembly as described for DN 40, steps 10 to 14.
For version with pressure-balanced plug: 1. Unscrew the stem connector nut and lock nut (6.1 and 6.2) from the plug stem. 2. Remove the body nuts (1.1) and carefully lift off the valve bonnet (5) with plug stem (6). 3. Screw the threaded bushing (5.2) out of the stuffing box. Pull plug stem and plug (3) out of the bonnet. 4. Remove gasket (1.2) and carefully clean the sealing faces in the valve body and on the bonnet. DN 40: 5. Pull the packing (4.2), washer (4.3) and spring (4.1) out of the packing chamber using an appropriate tool. Replace damaged parts. 6. Push out the bushing (3.2) and replace the collar (3.1). Clean the packing chamber thoroughly. 7. Apply lubricant (order no. 8150-0111) to the bushing (3.2) and push it in again. 8. Also apply lubricant to the packing parts, plug stem (6) and the contact faces of the collar (3.1). 9. Insert the plug stem and plug into the valve bonnet.
14
EB 8015-1 EN
DN 200 and DN 250: 5. Remove the screw (3.4) with its locking device. 6. Lift off the ring (3.3) and replace collar or seal (3.1). 7. Insert ring (3.3). Thread down screw (3.4) and its locking device.
8. Apply lubricant (order no. 8150-0111) to the packing parts, plug stem (6) and contact faces of the collar (3.1). 9. Insert the plug stem and plug into the valve bonnet.
4 Complete reassembly as described for

DN 40, steps 10 to 14.
DN 40 DN 50 DN 65 and 80
3 3.1 3.2 3.3
Plug Collar, O-ring Bushing Washer, ring
3.4 Screw 6 Plug stem DN 100 to DN 150 DN 200 to DN 250
Fig. 7 Pressure-balanced plugs
EB 8015-1 EN
15
Seat The material number according to DIN is either stamped or engraved on the seat.

The Kvs coefficient and characteristic are engraved on the plug.

engraved "st".
16
EB 8015-1 EN
1 2 3 4 5 6 7 8 9 10 11 12
CE marking or "Art. 3, Abs.3" (see article 3, 3 of PED), where applicable Identification no. of notified body, fluid group and category, where applicable Type designation Modification index of valve Material Year of manufacture Nominal size: DIN: DN, ANSI: Size Permissible excess pressure at room temperature DIN: PN, ANSI: CL Order number with modification index Position of item in order Flow coefficient: DIN: KVS, ANSI: Cv Characteristic: % equal percentage, Lin linear, DIN: A/Z quick opening, ANSI: O/C Sealing: ME metal, ST stellited, Ni nickel-plated PT soft sealing with PTFE, PK soft sealing with PEEK Pressure-balanced: DIN: D, ANSI: B I or III flow divider
1 2 3 4
5 6 7
13
14 15
EB 8015-1 EN
17
Customer inquiries
Customer inquiries
If you encounter any problems, please submit the following details:
4 Order number 4 Type, product number, nominal size and version of the valve 4 Pressure and temperature of the process medium 4 Flow rate in m/h 4 Has a strainer been installed? 4 Installation drawing
18
EB 8015-1 EN
EB 8015-1 EN
19
EB 8015-1 EN
S/Z 2006-02
Pneumatic Control Valves Type 3251-1 and Type 3251-7
Fig. 1 Type 3251-1 Control Valve

Edition October 2003
Contents
Contents 1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.3 5.4 6 7 Assembling valve and actuator . . . . . . . . . . Assembly and adjustment . . . . . . . . . . . . . Option of pretensioning for "Actuator stem extends" . Different rated travels of valve and actuator . . . . . Installation . . . . Mounting position . Signal pressure line Strainer, bypass . . Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . 4 4 6 6 8 8 8 8 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance Replacing parts . . . . . . . . Replacing parts of standard valves . . . . . . . Packing . . . . . . . . . . . . . . . . . . . . Seats and/or plug . . . . . . . . . . . . . . . Replacing parts of valves with metal bellows seal Packing . . . . . . . . . . . . . . . . . . . . Metal bellows . . . . . . . . . . . . . . . . . Seats and/or plug . . . . . . . . . . . . . . . Replacing parts of valves with insulating section . Disassembling the flow divider . . . . . . . . . . 9 . 10 . 10 . 11 . 12 . 12 . 12 . 12 . 13 . 13
Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Note! Non-electrical control valves which do not have a valve body lined with an insulating material coating do not have their own potential ignition source according to the risk assess ment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 para graph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC.
EB 8051 EN
Safety instructions
The control valve may only be mounted, started up or serviced by fully trained
For appropriate operation, make sure that the control valve is only used in
and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger. All safety instructions and warnings in these instructions, particularly those concerning installation, start-up and maintenance, must be observed. The control valve fulfills the requirements of the European Pressure Equipment Directive 97/23/EC. Valves with a CE marking have a declaration of con formity that includes information on the applied conformity assessment proce dure. The declaration can be viewed and downloaded on the Internet at http://www.samson.de. areas where the operating pressure and temperatures do not exceed the oper ating values based on the valve sizing data submitted in the order. The manu facturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the control valve by the process me dium, operating pressure, signal pressure or by moving parts are to be prevented by means of the appropriate measures.
Proper shipping and appropriate storage are assumed.

Caution!
For installation and maintenance work on the valve, make sure the relevant
When working on the valve, make sure that the supply lines for the air supply
as well as the control signal are disconnected to prevent any hazards that could be caused by moving parts.
section of the pipeline is depressurized and, depending on the process me dium used, drained as well. If necessary, allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve.
Special care is needed when the actuator springs are pretensioned. These ac -
tuators are labeled correspondingly and can also be identified by three long bolts at the bottom of the actuator. Prior to starting any work on the valve, you must relieve the compression from these pretensioned springs.
EB 8051 EN
1 Design and principle of operation

The Type 3251-1 and Type 3251-7 Pneumatic Control Valves consist of a singleseated Type 3251 Globe Valve and either the Type 3271 or Type 3277 Pneumatic Actuator. The process medium flows through the valve in the direction indicated by the arrow. The position of the plug (3) determines the flow rate through the valve seat (2). The plug (3) is moved by changing the signal pressure acting on the diaphragm of the actuator (8). The plug stem (6) with the plug is connected to the actuator stem (8.1) over a stem connector (7) and sealed with spring-loaded PTFE V-ring packing (4.2) or adjustable HT packing. Fail-safe position: Depending on how the compressed springs (8.4) are arranged in the actuator, there are two different fail-safe positions: Actuator stem extends: When the signal pressure is reduced or the supply air fails, the springs move the actuator stem downwards, closing the valve. The valve opens as the signal pressure increases and overcomes the force exerted by the actuator springs. Actuator stem retracts: When the signal pressure is reduced or the supply air fails, the springs move the actuator stem upwards, opening the valve. The valve closes as the signal pressure increases and overcomes the force exerted by the actuator springs.
2 Assembling valve and actuator

A pneumatic actuator with an additional handwheel or an electric actuator can be mounted to the valve in place of the simple pneumatic actuator. The standard pneumatic actuator can be replaced by a larger or smaller actuator, regardless of the nominal valve size. If the travel range of the actuator is larger than that of the valve in a valve/actuator combination, the spring assembly in the actuator is preloaded by the manufacturer to make the travels match. Each valve is equipped with the parts required for mounting its standard actuator. If you intend using a different actuator, the matching mounting parts need to be ordered together with the actuator. The necessary parts with their order numbers can be found in the overview sheet 16000501...0550 available on request. These additionally delivered parts are then used instead of the original parts.
2.1 Assembly and adjustment

If the actuator has not already been mounted by the manufacturer on the valve or you intend replacing the original actuator with an actuator of a different sort or size, proceed as follows: 1. Loosen the lock nut (6.2) and stem connector nut (6.1) at the valve. Firmly press the plug and plug stem into the seat ring, then thread the stem connector nut and lock nut downwards. 2. Unscrew the coupling parts (7) of the stem connector and the ring nut (8.2) from the actuator.
EB 8051 EN
Slide the ring nut over the plug stem of the valve. 3. Place the actuator on the yoke (5.3) and screw tight using the ring nut (8.2). 4. Read the bench range (or bench range with pretensioned springs) and the actuators fail-safe action indicated on the
nameplate of the actuator (e.g. 0.2 to 1 bar and "Actuator stem extends". The lower bench range value (0.2 bar) corresponds to the lower range value of the signal pressure to be adjusted, the upper bench range value (1 bar) to the upper range value of signal pressure.
8.6 8.4 8.3
8.2
4.2
5.1 1.1 1
8.5 8.1 5.5 7 6.1 6.2 6 5.2 5.4 5.3 5 3 2

1 1.1 2 3 4.2 5 5.1 5.2 5.3 5.4 5.5 Valve body Gasket Seat Plug PTFE V-ring packing Valve bonnet Nuts Guided bushing Yoke Nut for yoke Travel indicator scale 6 6.1 6.2 7 8 8.1 8.2 8.3 8.4 8.5
8.5
Plug stem Stem connector nut Lock nut Stem connector Actuator Actuator stem Nut for actuator Diaphragm Spring Loading pressure connection 8.6 Venting
Fig. 2 Sectional drawings of Type 3251-1 and Type 3251-7 (right)
EB 8051 EN
The fail-safe action "Actuator stem extends" or "Actuator stem retracts" is indicated by the abbreviation FA or FE on the nameplate of the Type 3271 Actuator and by a symbol on the Type 3277 Actuator. 5. For actuators with "Actuator stem extends", apply a loading pressure corresponding to the lower signal pressure range (e.g. 0.2 bar) to the connection on the bottom diaphragm chamber. For actuators with "Actuator stem retracts", apply a loading pressure corresponding to the upper signal pressure range (e.g. 1 bar) to the connection on the top diaphragm chamber. 6. Turn the stem connector nut (6.1) by hand until it touches the actuator stem (8.1), then turn it another 1/4 turn and secure this position using the lock nut (6.2). 7. Attach the coupling parts (7) of the stem connector and screw them tight. Align the travel indicator scale (5.5) with the tip on the side of the stem connector. Note about disassembling actuators On removing an actuator mounted on a valve, and in particular, in a version with pretensioned springs, a loading pressure slightly higher than the lower bench range (see nameplate on the actuator) must be ap plied to the loading pressure connection be fore the ring nut (8.2) can be unscrewed.
2.2 Option of pretensioning for "Actuator stem extends"

To achieve a more powerful positioning force, the springs in the actuators can be pretensioned by up to 25 % of its travel or bench range during the valve adjustment procedure. For example, the springs should be pretensioned by 0.1 bar for a bench range of 0.2 to 1 bar. This means the bench range is shifted by 0.1 bar to achieve a range from 0.3 to 1.1 bar (0.1 bar corresponds to pretensioning the springs by 12.5 %). On adjusting the valve, a signal pressure of 0.3 bar must now be set as the lower signal pressure range. It is essential that the new bench range (e.g. 0.3 to 1.1 bar) is recorded on the nameplate as bench range with pretensioned springs.
2.3 Different rated travels of valve and actuator

Actuator version "Actuator stem extends" Note! Valves that have a smaller rated travel than that of the actuators must always use pretensioned spring ranges. Example: Valve DN 100 with a rated travel of 30 mm is to be mounted to an actuator 1400 cm2 with a rated travel of 60 mm and a bench range from 0.4 to 2 bar. 1. Set the signal pressure required to preload the springs to 1.6 bar. This signal pressure value is above the signal press-
EB 8051 EN
ure of 1.2 bar (range 1.2 to 2 bar) that corresponds to the mid-travel of the actuator (30 mm). 2. Thread the stem connector nut (6.1) until it touches the actuator stem. 3. Secure this position using the lock nut. Attach the stem connector as described in section 2.1. 4. Record the bench range (e.g. 1.6 to 2.4 bar) valid for the mounted valve on the nameplate of the actuator. Actuator version "Actuator stem retracts" Note! The actuator springs in the version "Actuator stem retracts" cannot be pretensioned. When a valve is mounted to a larger actuator (rated travel of the actuator is larger than that of the valve), only the first half of the actuators bench range can be used. Example: Valve DN 100 with a rated travel of 30 mm and an actuator 1400 cm2 with a rated travel of 60 mm and a bench range from 0.2 to 1 bar: For mid-travel of the valve, a bench range from 0.2 to 0.6 bar can be used.
Note! Actuators which have already been pretensioned by the manufacturer are labeled correspondingly. Additionally, they can also be identified by three long bolts on the bottom diaphragm case.
EB 8051 EN
Installation
3 Installation 3.1 Mounting position

The control valve can be mounted in any position. However, valves in nominal sizes DN 100 and larger should preferably be mounted upright with the actuator pointing upwards. This makes maintenance work easier. Valves with an insulating section or bellows seal or actuators that weigh more than 50 kg should be fitted with suitable supports or, in the case of the actuator, suspended. Important! The valve must be installed with the least amount of vibrations possible and without any tension. Clean out the pipeline thoroughly prior to in stalling the valve. Note! Control valves with insulating section or bel lows seal may only be insulated up to the cover flange of the valve body for medium temperatures below 0 C as well as temperatures above 220 C. Valves that should meet the requirements of NACE MR 0175 standard should not be insulated.
The lower loading pressure connection is located at the side of the yoke underneath the bottom diaphragm case in the Type 3277 Actuator.
3.3 Strainer, bypass

We recommend installing a strainer upstream of the valve. If the plant should continue to operate during valve maintenance, install a shut-off valve both upstream of the strainer and downstream of the control valve as well a bypass.
3.4 Test connection

Versions with a metal bellows seal (Fig. 5) include a test connection (11.1) located on the top flange to check the bellows for any leakage. We recommend connecting a suitable leakage indicator (e.g. contact pressure gauge, drainage into an open vessel or sight glass).
4 Operation
(e.g. reversing the operating direction etc.) Refer to the mounting and operating instructions of the pneumatic actuators EB 8310 EN for Type 3271 and EB 8311 EN for Type 3277.
3.2 Signal pressure line

For valves mounted to actuator versions "Actuator stem extends", connect the signal pressure to the loading pressure connection on the bottom diaphragm case and for valves mounted to actuator versions "Actuator stem retracts", connect the signal pressure to the connection on the top diaphragm case.
EB 8051 EN
5. Maintenance Replacing parts

The control valve is subject to natural wear especially at the seat, plug and packing. Depending on the application conditions that prevail, the valve must be inspected at appropriately scheduled intervals to prevent any problems before they occur. If any leaks occur to the atmosphere, the packing may be leaking. If the valve does not seal properly, this may be because tight shut-off is prevented by dirt between the seat and plug or because the seating surface is damaged. We recommend removing the parts, thoroughly cleaning them and replacing them, if necessary. Important! If you intend carrying out maintenance work on the valve, first relieve the corresponding plant section of pressure and, depending on the process medium, drain it as well. Let the plant section cool down to reach ambient temperature, if necessary. As the process medium cannot drain completely out of the valve, be aware that some of the process medium could still be in the valve. This is particularly the case for valve versions with bellows seals and insulating sections. We recommend that you remove the valve from the pipeline. On carrying out any work on the valve, first disconnect the signal pressure, remove the signal pressure
line and remove the actuator from the valve. Important! Control valves fitted with a ceramic seat and plug must be handled with extreme care as they can easily break. The valve in this version cannot be remachined as described in section 5.1.2. Note on SAMSON special tools Suitable seat wrenches and special tools as well as the appropriate tightening torques can be found in EB 029 EN (formerly WA 29 EN). The instructions can be viewed on the Internet at http://www.samsson.de/pdf_en/e00290en.pdf. Removing the actuator: 1. Unscrew the ring nut (8.2) and take off the stem connector (7). For the version "Actuator stem extends", and in particular, in a version with pretensioned springs, apply a loading pressure slightly higher than the lower bench range (see nameplate on the actuator) to the loading pressure connection to allow the ring nut (8.2) to be unscrewed. After you have loosened the nut, disconnect the supply pressure again. 2. Remove the actuator from the valve yoke.
EB 8051 EN
5.1 Replacing parts of standard valves 5.1.1 Packing

If the valve leaks at the packing, the packing (4.2) and seal elements (4.5 and 4.6) must be replaced as follows: Disassembly 1. Unscrew the nuts (5.1) and lift the valve bonnet (5) together with the plug stem and plug off from the valve body. 2. Unscrew the stem connector nut (6.1) and lock nut (6.2) off the plug stem. Unthread the guided bushing (5.2) out of the packing. 3. Pull the plug together with the plug stem out of the valve bonnet. 4. Pull all the packing parts using a suitable tool out of the packing space. Replace any damaged parts with new ones. Carefully clean the packing space. Assembly 1. Apply lubricant (order no. 8150-0111) to all parts as well as the plug stem (6). Do not use any lubricant for graphite packing! 2. Place the plug into the valve body and insert a new flat gasket (1.1). 3. Place the valve bonnet carefully over the plug stem onto the valve body and screw the nuts (5.1) tight. 4. Carefully slide the packing parts over the plug stem into the packing space. Make sure the packing parts are replaced in the right order. Note that the
number of spacers (4.3) varies depending on the nominal size. 5. Thread in the guided bushing (5.2) and tighten. For high-temperature packing, tighten the guided bushing only slightly, even if it starts to leak, it should only be tightened slightly.
5.2 4.6 4.5 4.2 4.4 4.3 4.6 4.5 4.2 4.4 4.1 4.3
4.1 4.2 4.3 4.4
Spring V-ring packing Spacer(s) Washer(s)
4.5 Carbon bushing(s) 4.6 Graphite, compressed 5.2 Guided bushing
Fig. 3 Packing, standard (left) high-temperature (right)
10
EB 8051 EN
6. Screw the lock nut (6.2) and stem connector nut (6.1) onto the plug stem without tightening them. 7. Attach the actuator as described in section 2.1 and set the lower and upper bench range.
to the plug stem (6) before fitting it back into the valve. Remachining the plug The plug can be machined when the plugs seating surface is slightly damaged. Plugs with a soft sealing can only be machined up to the dimension x (Fig. 4).
5.1.2 Seats and/or plug

When replacing the seat or plug, we recommend replacing the packing (4.2 or 4.5 and 4.6) as well. Seat: 1. Unscrew the nuts (5.1) and lift the valve bonnet (5) together with the plug stem and plug off the valve body. 2. Unscrew the seat (2) using the appropriate seat wrench (see EB 029 EN). 3. Apply lubricant (order no. 8150-0119) to the thread and sealing cone of the new seat (or the old seat after it has been remachined or thoroughly cleaned) and screw it back in. The tightening torques for the seat are likewise listed in EB 029 EN. Plug: 1. Unscrew the nuts (5.1) and lift the valve bonnet (5) together with the plug stem (6) and plug off the valve body (1). 2. Unscrew nuts (6.1, 6.2) and guided bushing (5.2). 3. Pull the plug out of the valve bonnet. 4. Change the plug and insert the new plug and plug stem (6). It may be possible to use the old plug again after it has been remachined. Apply lubricant (order no. 8150-0119)
x
R 0.3
Seating surface
30
Seat bore 31 to 50 63 to 150
x (mm) 1 2
Fig. 4 Remachining a plug with soft sealing
EB 8051 EN
11
5.2 Replacing parts of valves with metal bellows seal

Caution! To prevent damage in the valve with bellows seal (a valve with insulating section does not contain a bellows), make sure that no torque is transferred to the bellows.
5.2 11 11.1
5.2.1 Packing
Replace parts as described in section 5.1.1 for the standard valve. However, unthread the guided bushing (5.2), unscrew nuts (11.2) and separate the bonnet (11) from the intermediate piece (9). Replace gasket (9.1) with a new one.
5.2 Guided bushing 6 Plug stem 9 Intermediate piece 9.1 Gasket 10 Metal bellows 11 Bonnet 11.1 Test connection 11.2 Nuts 20 Plug 21 Nut 22 Disk 23 Ring 24 Screw
9.1
11.2
5.2.2 Metal bellows

The metal bellows (10) can only be replaced as an entire unit together with the plug stem. To do this, proceed as described in section 5.1.2 (Fig. 5).
10 6
5.2.3 Seats and/or plug

Replace parts as described in section 5.1.2 for the standard valve. The plug stem can only be exchanged together with the metal bellows seal. The plug can be removed from the plug stem: in valve size DN 15 to 40, the plug is attached by a nut and from valve size DN 50 and above, it is attached with a clamping disk. Prior to attaching the plug, apply lubricant (order no. 8150-0111) to the thread of the plug stem.
23 21
24 22 20
20
DN 15...40
DN 50 upwards
Fig. 5 Bellows seal, shown for sizes DN 50 to 150
12
EB 8051 EN
In the version with the plug attached by
a nut, screw on the nut (21) by hand on to the plug stem as far as it will go. Place the plug on the hexagonal neck of the plug stem. Place an open-end wrench on the flattened area of the plug stem and screw the nut onto the plug with a tightening torque of 40 Nm.
5.4 Disassembling the flow divider

For valves with flow dividers, the gasket (1.1) and shims (1.2) must be replaced with new ones every time the flow divider is removed. The number of shims required and the dimension x must be determined when a new gasket (1.1) is used: First measure dimension A, then dimension B. Dimension x is calculated from A B and must be filled out with shims (0.5 or 2 mm thick). The maximum compression should be approximately 0.5 mm.
5.3 Replacing parts of valves with insulating section

Replace the packing as described in section 5.1.1 for the standard valve. Replace the seat and plug as described in section 5.1.2 for the standard valve.
Bonnet
(1.1)
B A
(1.2)
Body
Cage element
Flow divider
ST1
ST3
Fig. 6 Installing a flow divider
x
EB 8051 EN
B A
13
6 Description of nameplates
Valve nameplate Type 3271 Actuator nameplate
5 8 13 14 15
Made in Germany
SAMSON
1 2
3 -4 7 9 11 12 10
SAMSON
H 5 F
1 6
2 V
3 7
3 4 5 6 7 8 9 10 11 12
13
14 15
CE marking or "Art. 3, Abs. 3" (see article 3, 3 of PED), where applicable Ident. number of notified body, fluid group and category, where, applicable Type designation Modification index of valve Material Year of manufacture Nominal size: DIN: DN, ANSI: Size Perm. operating pressure at room temperature DIN: PN, ANSI: CL Order number with modification index Item position on order Flow coefficient: DIN: K85 value , ANSI: Cv value Characteristic: % equal percentage, Lin linear, DIN: A/Z, ANSI: O/C for quick opening Sealing: ME metal, ST stellited, Ni nickel plated PT soft sealing with PTFE, PK soft sealing with PEEK Pressure balancing: DIN: D, ANSI: B I or III flow divider
Type designation Modification index Effective diaphragm area Fail-safe action: FA Actuator stem extends FE Actuator stem retracts 5 Travel 6 Bench range (spring range) 7 Bench range with pretensioned springs
1 2 3 4
Type 3277 Actuator nameplate
SAMSON
Model - No. Serial - No. Pneum. Stellantrieb 3 Pneum. actuator Servo - monteur pneum. Federbereich Spring range Plage des ressorts Stelldruckbereich Signal pressure range Plage avec prcontrainte Hub cm Stroke Course mm bar bar
Zuluft max. 6 bar Begrenzt auf Air supply 90 psi Up to Air d' alimentation Limit
Made in France
bar
Fig. 7 Nameplates
14
EB 8051 EN
Customer inquiries
7 Customer inquiries

Please submit the following details: Order number Type, model number, nominal size and version of the valve Pressure and temperature of the process medium Flow rate in m3/h Bench range (e.g. 0.2 to 1 bar) of the mounted actuator Has a strainer been installed? Installation drawing
Dimensions and weights Refer to the Data Sheet T 8051 EN for dimensions and weights of the valve versions.
EB 8051 EN
15
EB 8051 EN
VETEC
Ventiltechnik GmbH
Wartung
Einbauvorschrift und Wartung der Armaturen
Die Ventile einschl. Antrieb mit Stellungsregler und Kennlinienumformer sind vom Werk aus nach der Bestellspezifikation montiert und eingestellt. Vor dem Einbau der Ventile sind smtliche Anschluleitungen von Schmutz, Fett, l und anderen Fremdkrperen zu subern. Bei der Montage ist darauf zu achten, da der auf dem Armaturengehuse angegebene Pfeil immer in Strmungsrichtung zeigt.
Maintenance
Installation and maintenance of the valve
The Maxifluss-control valves are tested and designed according to the customers specification.
Before installation, all connection pipes of the valve have to be cleaned of dirt, grease, oil and other impurties. Apart from the flanged types, the sandwich models are clamped between the pipe flanges by means of tie rods. Take care that the arrow on the body always points in the direction of flow.
MAXI_WARTUNG_N1.doc
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VETEC
Ventiltechnik GmbH
Wartung
Austausch von Sitz und Kegel bei MaxiflussVentilen
Maintenance
Replacing seat ring and plug of MaxiflussControl-Valves
Auflageflche bearing surface Sitzschrge Stirnflche front surface seat shape
DN
25 40 50 80 100 150 200 250 300 400
Sitzschrg e 23 25 28 30 33 36 33 34,5 37 36,5
Kvs 100 % 16 40 80 245 370 685 950 1925 2680 4200
SitzSitzschrg e 18 19 26 19 36 21 60 26 76 26 105 27 135 26 170 29,5 210 28 290 27,5
Kvs 60 % 10 24 48 147 220 410 570 1230 1640 2520
Sitz 16 21,5 29,5 50 60 86 106 146 163 225
Sitzschrg e 17 17 17 22,5 23 22 21 25 22,5 22,5
Kvs 40 % 6 16 33 105 150 275 380 770 1070 1680
Sitz 14 18,5 25,5 44 53 73 88 126 133 184
Sitzschrg e 12,5 14,5 14,5 19 19 18,5 17,5 20 21,5 21,5
Kvs 25 % 4 12 20 63 93 179 240 480 670 1070
Sitz 10 16 21 37 45 62 73 102 116 160
MAXI_WARTUNG_N1.doc
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VETEC
Ventiltechnik GmbH
Wartung
Austausch von Sitz und Kegel bei Maxifluss-Ventilen
17 22 21 10
Maintenance
Replacing seat ring and plug of Maxifluss-Control-Valves
8 9 2 25 24 7
27
26 4 6
16
15
14
13
12 3
Vor der Demontage des Ventils sollte die genaue Stellung der Welle zum Kegel notiert werden, d.h. Nutstellung der Welle Pos.3 zu Verzahnung von Kegel Pos.2.
Before disassembly of the valve consider exactly the position of shaft and plug, that means, key position of the shaft ( Pos. 3) to grooves of the plug ( Pos. 2 ).
Only types 72.1 72.4 Remove seat holder ( 9 ) with mounting tool. Only types 72.1 72.4 Remove seat ring ( 8 ) and seal ( 25 ). Only types 72.1 / 72.2 / 72.5 and 72.6 Loosen bolts ( 27 ) and pull out a) seat flange ( Pos.7 ) types 72.1 and 72.2 b) seat ( Pos. 7 ) types 72.5 and 72.6 and seal ( 24 ). Loosen both bolts ( 26 ) and pull out bearing (4) and seal (6).
1.
Nur bei Typen 72.1 72.4 Herausnehmen des Gewinderinges ( Pos.9 ), mit Montageschlssel. Nur bei Typen 72.1 72.4 Herausnehmen des Sitzringes ( Pos.8 ) und der Dichtung ( Pos.25 ). Nur bei Typen 72.1 / 72.2 / 72.5 und 72.6 Lsen der Schrauben ( Pos.27 ) und Abnehmen a) des Halteringes ( Pos.7 ) Typen 72.1 und 72.2 b) des Einlaufringes ( Pos.7 ) Typen 72.5 und 72.6 sowie der Dichtung ( Pos.24). Lsen der Sechskantschrauben ( Pos.26 ) und Herausziehen des Lagerzapfens ( Pos.4 ) mit Dichtung ( Pos.6 ).
2.
3.
4.
MAXI_WARTUNG_N1.doc
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VETEC
Ventiltechnik GmbH
5.
Herausschrauben der Halteschraube ( Pos.21 ) und Dichtring ( Pos.23 ).
Unscrew plug ( 21 ) and the gasket ( 23 ).
23
6.
Aus dem Gehuse (Pos.1) Welle (Pos.3) mit Packungsringen ( Pos.14), Schmierbuchse (Pos.15), Grundring (Pos.13), Geteilter Ring (Pos.12) und Distanzbuchse (Pos.11) herausziehen ( Distanzbuchse nur bei DN 80 - 200). Die Welle ist zu markieren, damit beim Einbauen die gleiche Lage der Federn zu den Nuten des Kegels gewhrleistet ist.
13 21
Pull the shaft ( 3 ), with packing rings ( 14 ), lubricator (15) , container ring ( 13 ), split ring ( 12 ) and distance washer ( 11 ) out of the body. Distance washer only with DN 80 to 200. For replacing please mark the shaft to be sure that the keys of the shaft and the grooves in the plug have the same position. Remove plug (2) from body Install the plug into the body. Attention: Before mounting plug and shaft into the valve, these parts first have to be mounted outside the valve for exact tolerances. Push shaft in axial direction into the body and into the grooves of the plug ( fig.1 ). Be sure that the keys of the shaft and the grooves in the plug have the same position as with the old plug, just to maintain the right position of the plug in the body.
7. 8.
Herausnehmen des Kegels aus dem Gehuse. Austauschkegel in das Gehuse einbringen. : Kegel und Welle vorher , auerhalb einpassen.
9.
Welle in axialer Richtung in das Gehuse und in die Nuten des Kegels einschieben (Abb.1). Hierbei ist darauf zu achten, da die Federn der Welle und die der Nuten des Kegels so stehen, wie vorher die des alten Kegels, um die gleiche Stellung des Kegels im Gehuse zu erhalten.
10.
Einlegen der Dichtung ( Pos.6 ), Lagerzapfen ( Pos.4 ) einfhren und mit den Sechskantschrauben fest anziehen. Halteschraube ( Pos.21 ) und Dichtring ( Pos.23 ) einschrauben. Es ist darauf zu achten , da der Zapfen der Halteschraube in die Nut des Grundrings ( Pos.13 ) hineinragt, damit die Welle gegen axiales Verschieben gesichert ist.
Put in seal ( 6 ), install bearing ( 4 ) and tighten flange bolts. Install plug ( 21 ) and gasket ( 23 ). Be sure that the end of the plug slips into the opening of the retaining ring ( 13 ), to prevent axial sliding of the shaft.
11.
23
13 21
12.
Nur bei Typen 72.1 / 72.2 / 72.5 und 72.6 Einlegen der Dichtung ( Pos.24 ) und a) des Halteringes ( Pos.7 ) Typen 72.1 und 72.2 b) des Einlaufringes ( Pos.7 ) Typen 72.5 und 72.6 sowie Festziehen der Innensechskantschrauben. Kegel ( Pos.2 ) nun in Zustellung bringen und Nur bei Typen 72.1 72.4 Dichtung (Pos.25) sowie Sitzring (Pos.8) einlegen ( der Sitzring zentriert sich selbst).
Only types 72.1 / 72.2 / 72.5 and 72.6 Put in gasket ( 24 ) and a) seat flange ( Pos.7 ) types 72.1 and 72.2 b) seat ( Pos. 7 ) types 72.5 and 72.6 and tighten inner hexagonal bolts. Now turn plug ( Pos.2 ) in closed position and Only types 72.1 72.4 insert gasket ( Pos. 25 ) and seat ring ( Pos. 8 ).
13.
MAXI_WARTUNG_N1.doc
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VETEC
Ventiltechnik GmbH
14.
Nur bei Typen 72.1 72.4 Gewindering (Pos.9) Einschrauben und von Hand leicht anziehen. Kegel in Richtung Auf schwenken. Kegel nun wieder in Zu-Stellung bringen, damit die Zentrierung gewhrleistet ist. Gewindering fest anziehen. Hierbei ist darauf zu achten, da der Kegel sich an den Sitzring anlehnen mu und nicht in den Sitzring eingepret werden darf ( Kegel mu ohne Losbrechmoment von Zu-in Auf-Stellung gebracht werden knnen).
Only types 72.1 72.4 Screw in seat holder 9 slightly by hand Turn plug in open position and tighten seat holder 9. Again turn plug 2 in the closed position. Be sure that there is no breake torque in moving the plug from closed to open posotion.
15. 16.
Kommt es dennoch vor, da der Kegel sich nicht ganz in Zu-Stellung bringen lt ( was sich aufgrund der Vielzahl der Toleranzen nicht vermeiden lt) ist wie folgt zu verfahren:
If the plug cannot be fully brought into the closed position ( because of inevitable production tolerances ) : Remove a) seat ring , see point 1 + 2 types 72.1 - 72.4 b) seat , see point 3 types 72.5 + 72.6 Turn off a little at front surface and machine seat shape. If the moves beyond the close position. Remove b) seat ring , see point 1 + 2 types 72.1 - 72.4 b) seat , see point 3 types 72.5 + 72.6 Turn off seat ring a little at the bearing surface.
17.
Herausnehmen des a) Sitzringes nach Punkt 1 + 2, Typen 72.1 72.4 b) Einlaufringes nach Punkt 3, Typen 72.5 + 72.6 geringfgig Abdrehen an der Stirnflche und anbringen der Sitzschrge.
Tritt der Fall ein, da sich der Kegel ber die Zustellung hinaus schwenken lt, dann ist folgendes zu beachten:
18.
Herausnehmen des a) Sitzringes nach Punkt 1 + 2, Typen 72.1 72.4 b) Einlaufringes nach Punkt 3, Typen 72.5 + 72.6 geringes Abdrehen an der Auflageflche.
MAXI_WARTUNG_N1.doc
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Pneumatic Control Valve Type 3510-1 and Type 3510-7
Type 3510-1 with 120 cm2 actuator Type 3510-7 with 120 cm2 actuator and integrated positioner Type 3510-1 with 60 cm2 actuator Fig. 1 Pneumatic control valves

Edition July 2002
Contents
Contents 1 2 2.1 2.2 3 3.1 4 5 5.1 5.2 6
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 Assembling and adjusting valve and actuator . . . . . . . . . . . . . . . . 6 Signal pressure connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation Reversing the operating direction . . . . . . . . . . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Replacing the stuffing box packing . . . . . . . . . . . . . . . . . . . . . . 10 Replacing seat and plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Note! Non-electrical control valves which do not have a valve body lined with an insulating material coating do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC.
EB 8091 EN
Safety instructions
The device may only be assembled, started up or operated by trained and experienced personnel familiar with the product. According to these mounting and operating instructions, trained personnel is referred to as individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training, their knowledge and experience, as well as their knowledge of the applicable standards. Any hazards which could be caused in the control valve by the process medium, the operating pressure, the signal pressure or the moving parts are to be prevented by means of the appropriate measures. In addition, it is necessary to make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. Proper shipping and appropriate storage are assumed.
EB 8091 EN

The pneumatic control valve consists of a Type 3510 Micro-flow Valve (globe or angle body style) and either a Type 3271-5 Pneumatic Actuator (Type 3510-1 Control Valve) or a Type 3277-5 Pneumatic Actuator (Type 3510-7 Control Valve). The modular design enables the actuators to be exchanged, and the standard valve version to be enhanced to a version incorporating either a bellows seal or an insulating section. The process medium flows through the valve in the direction indicated by the arrow. The position of the valve plug (3) determines the cross-sectional area of flow between the
valve seat (2) and the plug. A change in the signal pressure acting on the diaphragm of the actuator causes the valve plug to move correspondingly. The plug stem (6) is connected to the actuator stem (8.1) via the stem connector (7) and sealed with an adjustable stuffing box with packing that contains PTFE sealing rings. Fail-safe action: Depending on the arrangement of the springs (8.3) in the actuator, the control valve has two different fail-safe actions:
Actuator stem retracts
Actuator stem extends
Type 3271-55 with 60 cm2
Type 3271-5 Actuator with 120 cm2
Actuator stem retracts Fig. 2 Type 3271-5 Actuators
EB 8091 EN
Actuator stem extends: When the signal pressure is reduced or in case of a supply air failure, the springs move the actuator stem downwards and close the valve. The valve is opened against the spring force, when the signal pressure increases.
Actuator stem retracts: When the signal pressure is reduced or in case of a supply air failure, the springs move the actuator stem upwards and open the valve. The valve is closed against the spring force, when the signal pressure increases.
1 1.1 2 2.1 2.2 2.3 2.4
Body Screw Seat trim Seat Plug Sealing ring Anti-rotation device with trim identification number 3 Nuts 4 Packing rings 4.1 Packing washer 5 Valve bonnet 5.1 Threaded bushing 5.2 Slotted round nut 6 Yoke 6.1 Travel indicator scale 7 Stem connector 7.1 Stem connector nut 7.2 Stem connector sleeve 7.3 Lock nut 8 Actuator 8.1 Actuator stem 8.2 Slotted round nut 8.3 Spring 8.4 Diaphragm 14 Connecting or switchover plate 14.1 Signal pressure route "Actuator stem extends" 14.2 Signal pressure route "Actuator stem retracts"
8.4 8.3 8 8.1 8.2 7.3 7 7.1 7.2 5.1 5.2 5
14 14.1
14.2
6 6.1 3 4.1 4 1.1 2.4 2.3 2 2.2 2.1 1
Fig. 3 Sectional drawing of micro-flow control valve with Type 3277-7 Actuator
EB 8091 EN
Assembling and adjusting valve and actuator
2 Assembling and adjusting valve and actuator

If control valve and actuator have not been pre-assembled by the manufacturer, observe the different signal pressure connections of the actuators on assembly.
2.1 Signal pressure connection

Type 3510-1 Control Valve with Type 3271-5 Actuator The signal pressure connection for failsafe action "Actuator stem extends" is located at the bottom of the diaphragm case. For "Actuator stem retracts", the connection is to be found at the top of the diaphragm case. Type 3510-7 Control Valve with Type 3277-5 Actuator Actuator with positioner: The signal pressure is transferred to the diaphragm case via bores at the left and right side of the yoke and via a switchover plate (accessories). The fail-safe action "Actuator stem extends" or "Actuator stem retracts" determines how the switchover plate needs to be aligned to the mark. Turn the switchover plate, so that the appropriate symbol for the fail-safe action is aligned to the mark. Whether the actuator is attached to the left or right depends on the operating direction (>>) or (<>) of the positioner.
Actuator without positioner: Instead of a switchover plate, a connecting plate (accessories) is required if the actuator is used without positioner Here, the signal pressure is transferred to the diaphragm case directly via the signal pressure connection of the connecting plate. Turn the connecting plate, so that the appropriate symbol for the fail-safe action "Actuator stem extends" or "Actuator stem retracts" is aligned to the mark. Make absolutely sure that the gasket of the connecting plate is inserted correctly. The connecting plate provides bores for NPT and G threads. Seal the unused connection with a rubber gasket and a square plug. Accessories: Switchover plate and connecting plate need to be ordered as accessories. Note that actuators with device modification index 01, e.g. 3277-531xxx20.01 (old = .00) must be equipped with new plates. Old and new plates are not interchangeable. Switchover plate new Order no. 1400-6822 old Order no. 1400-6819 Connecting plate new Order no. 1400-6823 old G thread Order no. 1400-6820 old NPT thread Order no. 1400-6821
EB 8091 EN
Assembling and adjusting valve and actuator
Note! When used in connection with the microflow valve, the pneumatic actuators with failsafe action "Actuator stem retracts" are limited to the max. permissible supply pressures [bar] listed in the table. For actuators with fail-safe action "Actuator stem extends", the max. supply pressure is limited to 4 bar. Valves with positioners are to be adjusted to these max. perm. supply pressures.
Signal pressure range 0.2 to 1 0.4 to 2.0 1.4 to 2.3 2.1 to 3.3 Adjusted to 0.4 to 0.8 0.8 to 1.6 1.7 to 2.1 2.4 to 3.0 Max. perm. pressure 2.5 3.3 3.8 4.7
2.2 Assembly and adjustment

For actuators with a switchover plate for attachment of a positioner, a suitable adapter needs to be connected to the bores at the side. Alternatively, the connecting plate (Fig. 4, right) can be used. 1. On the actuator stem, loosely screw both stem connector nut (7.1) and lock nut (7.3) all the way up (Fig. 3). 2. Slide slotted round nut (8.2 ) over both coupling nut and lock nut. 3. Place the actuator on the yoke (7) and fasten with slotted round nut (8.2). For fail-safe action "Actuator stem extends", apply approx. 50 % of the signal pressure range (see nameplate) to the signal pressure connection of the actuator using a pressure regulator, caus-
Switchover plate Signal pressure
Connecting plate
Signal pressure
Signal pressure Symbol Mark Actuator stem extends Left Attachment Right Actuator stem retracts Left Attachment Right Actuator stem extends retracts
Fig. 4 Signal pressure connections
EB 8091 EN
Installation
ing the actuator stem to retract far enough to screw together stem connector nut (7.1) and stem connector sleeve (7.2). 4. Screw together stem connector sleeve (7.2) and stem connector nut (7.1) as tightly as possible. 5. Apply lower range value of the signal pressure range to the signal pressure connection. For a signal pressure range (bench range) of, for example, 0.4 to 0.8 bar and an actuator with fail-safe action "Actuator stem extends", the lower signal pressure range value is 0.4 bar; for "Actuator stem retracts" it is 0.8 bar. 6. Rotate stem connector (7) on actuator stem until plug stem moves from the closed position at the corresponding initial value. To do so, change signal pressure each time using the pressure regulator, and return to the initial lower range value. 7. Fasten lock nut (7.3) to secure the stem connector. 8. Align travel indicator scale (6.1) to the black ring on the stem connector.
3 Installation 3.1 Mounting position

Any desired mounting position is possible. Note! Make sure the valve is installed free of stress. If necessary, support the pipes near the connections. Flush pipes thoroughly before installing the valve. For valve versions with bellows seal or insulating section, which are installed in pipes to be insulated, do not insulate the bellows intermediate piece or insulating section (9). Test connection The version with metal bellows seal can be equipped with a test connection (16) with G 1/8 thread at the bellows seal. This connection is used to check the tightness of the bellows. It is recommended to install a suitable leakage indicator, in particular when explosive and hazardous media are used.
4 Operation - Reversing the operating direction

If it becomes necessary to reverse the failsafe action of the actuator from "Actuator stem extends" to "Actuator stem retracts" or vice versa, refer to the mounting and operating instructions of the actuator for details. EB 8310 EN for Type 3271-5, EB 8311 EN for Type 3277-5.
EB 8091 EN
Troubleshooting
5 Troubleshooting
If the valve leaks, the packing may be defective or, in the bellows version, the metal bellows may be defective. Tight shut-off of the valve can also be impaired by impurities or other foreign particles between seat and plug, or by damaged seat joints. Remove the affected components, clean them thoroughly and, if necessary, replace them.
Caution! Make sure to relieve the pressure from the pressurized part of the plant and, depending on the medium, drain it completely before performing maintenance. For high temperatures, allow the plant to cool down to ambient temperature. Disconnect and lshut off the supply air as well as the control signals to prevent against danger posed by moving parts at the valve. As valves are not free of dead cavities, remember that there might still be residual media in the valve. This particularly applies for valve version with bellows seal or insulating section. It is recommended to remove the valve from the pipeline for maintenance.
Note! The seat and special tools required for installation as well as the appropriate tightening torques are to be found in the SAMSON Special tools brochure WA 029. A complete tool kit for the Type 3510 Micro-flow Valve can be ordered separately (order no. 1280-3050).
EB 8091 EN
Troubleshooting
5.1 Replacing the stuffing box packing

If leakage occurs at the stuffing box, the stuffing box packing must be replaced as described below. 1. For actuators with "Actuator stem extends", apply approx. 50 % of the signal pressure range (see nameplate) to the actuator, causing the actuator stem to retract. Place socket wrench (width across flats (SW) 17) on stem connector nut (7.1) and unscrew stem connector sleeve (7.2) with a second SW 17 wrench. 2. Unscrew the bottom slotted round nut (5.2). Remove actuator (8) including yoke (6) from the valve, turning the slotted round nut (5.2), so that a groove points towards the travel indicator scale (6.1). 3. Take out the nuts (3). Remove stem connector sleeve (7.2) from the plug stem. 4. Remove the screw (1.1) and the anti-rotation device (2.4). Unscrew the valve bonnet (5) from the valve body. 5. Unscrew threaded bushing (5.1). Pull the plug stem, together with the plug (2.2), out of the valve bonnet (5). For versions with bellows intermediate piece or insulating section, separate valve bonnet and bellows intermediate piece/insulating section (9). The plug stem extension (10.1, Fig. 6) remains fixed in the extension bonnet. 6. Remove packing washers (4.1) and packing rings (4) from the packing chamber using a suitable tool. Make
sure not to damage the sealing edges. Clean packing chamber thoroughly. Assembly: 7. Insert new sealing rings. Start with a white ring, followed by two black rings and another white one. Make sure that the butt joints of successive rings are not positioned on top of each other. 8. Insert packing washer(s) (4.1). Tighten threaded bushing (5.1) manually. 9. Slide plug stem with plug (2.2) into the valve bonnet as far as it will go. Tighten threaded bushing (5.1), observing a minimum gap of 1.3 mm between valve bonnet and threaded bushing. If this is not the case, add required number of packing washers (4.1) (min. 1, max. 3 washers). 10. Insert new sealing ring (2.3) into the body. Screw together valve bonnet and body. 11. Place anti-rotation device (2.4) on the valve bonnet and tighten it, so that the fastening screw (1.1) is seated in the oblong hole. 12. Push stem connector sleeve (7.2) onto the plug stem with the thread facing upwards. Screw on nuts (3). Lock nuts against each other, so that approx. 1 mm of the thread is still visible. 13. Place actuator including yoke onto valve bonnet. Tighten with slotted round nut (5.2). For actuators with "Actuator stem extends", apply approx. 50 % of the signal pressure range (see nameplate) to the actuator using a pressure regulator, causing the actuator stem to retract far
10
EB 8091 EN
Troubleshooting
enough to screw together stem connector nut (7.1) and stem connector sleeve (7.2). 14. Screw together stem connector sleeve (7.2) and stem connector nut (7.1) as tightly as possible. Tighten lock nut (7.3).
15. Check adjustment according to instructions given in section 2.2, items 5 to 8.
8.1 7.3
6 6.1 3
7.1 7 7.2 5.1

1 1.1 2 2.1 2.2 2.3 2.4 3 4 4.1 5 5.1 5.2 6 6.1 7 7.1 7.2 7.3 8.1 Body 5.2 Screw Seat trim 5 Seat Plug Sealing ring Anti-rotation device Nuts Packing rings Packing washer Valve bonnet Threaded bushing Slotted round nut Yoke Travel indicator scale Stem connector Stem connector nut Stem connector sleeve Lock nut Actuator stem
4.1 4 1.1 2.4 2.3 2 2.2 2.1
Fig. 5 Replacing the stuffing box packing
EB 8091 EN
11
Troubleshooting
5.2 Replacing seat and plug

Standard version: For assembly/disassembly, proceed as described in section 5.1. Additionally, unscrew the seat (2.1) using a socket wrench.
Versions with bellows seal or insulating section: Unscrew valve bonnet (5). In the insulating section version, remove insulating section (9) from the valve body, so that the plug stem including plug (2.2) can be unscrewed from the plug stem extension (10.1). In the metal bellows version, unscrew bellows seal (10) together with plug stem extension (10.1) and plug (2.2) from the bellows intermediate piece (9) using a bellows nut wrench. Unscrew plug stem including plug from the plug stem extension and remove bellows intermediate piece from valve body. Before reassembling, replace sealing rings (9.1 and 9.2). In addition, secure bellows intermediate piece (9) or insulating section (9) as well as the valve bonnet using additional anti-rotation devices (11 and 12). The upper anti-rotation devices (2.4 and 12) are secured by the disk (15).
Important! If, on replacing the seat trim (parts 2.1 to 2.4), you wish to install a trim with a different KV value, the old anti-rotation device must also be replaced with the one included in the new trim. On the anti-rotation device as well as on the seat and plug themselves, there is an identification number indicating which trim parts belong together as well as the material, KVS value and characteristic. Never combine seats and plugs belonging to different trims! The seat thread imposes restrictions on replacing trims. Only the KV values of associated seat threads can be exchanged (see table below).
Table seat thread Seat thread KVS value PN max. M10 x 1 0.0001 to 0.4 400 M16 x 1 0.63 to 1.6 100
12
EB 8091 EN
2.4 15 12
1.1 2.2 2.4 Screw Plug Anti-rotation device with trim identification number 5 Valve bonnet 9 Bellows intermediate piece/insulating section 9.1 Sealing ring 9.2 Sealing ring 10 Bellows seal 10.1 Plug stem extension (in version with insulating section without metal bellows) 11 Anti-rotation device 12 Anti-rotation device 13 Screw 15 Disk 16 Test connection (optional)
9.1 13
16
9.2 10 10.1 9
11
1.1
2.2
Fig. 6 Metal bellows version
EB 8091 EN
13
Customer inquiries
6 Customer inquiries
Please include the following details in your inquiry: Order number Type, product and identification number Valve style: globe or angle valve Nominal size and pressure of the valve, additionally KVS value and the identification number of the attached trim Pressure, density, viscosity and temperature of the flow medium Flow rate in m3/h Direction of flow through the valve Bench range (signal pressure range, e.g. 0.2 to 1 bar) of the attached actuator Has a strainer been installed? Installation drawing
For dimensions and weights of the valve versions, refer to Data Sheet T 8091 EN.
14
EB 8091 EN
EB 8091 EN
15
EB 8091 EN
S/Z 2002-07
Pneumatic Control Valves Type 3244-1 and Type 3244-7
Fig. 1 Type 3244 -1 (left) and Type 3244-7 (right)

Edition November 2006
Contents
Contents 1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 4 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.4 6 7 8
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 4 Assembling valve and actuator . . . . . . . . . . . . . . . . . . . . . 6 Assembly and adjustment . . . . . . . . . . . . . . . . . . . . . . . . 6 Option to pretension the springs for actuator version "Actuator stem extends". 7 Installation . . . . . . . . . . . Mounting position . . . . . . . Arrangement of the control valve Signal pressure line. . . . . . . Strainer, bypass . . . . . . . . Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 8 8 8 8 10 11 11 11 12 12 14 15 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance Replacing parts . . . . . . . . . . Standard valve version . . . . . . . . . . . . . Stuffing box packing . . . . . . . . . . . . . . Seat and/or plug . . . . . . . . . . . . . . . . Valve with insulating section or metal bellows seal Stuffing box packing . . . . . . . . . . . . . . Seat and plug . . . . . . . . . . . . . . . . . . Metal bellows . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . .
Material identifying marks . . . . . . . . . . . . . . . . . . . . . . 16 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . 17 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Note! Non-electrical actuators and control valves do not have their own potential ignition source according to the risk assessment in the rare incident of an operating fault, corresponding to EN 13463-1: 2001 paragraph 5.2, and therefore do not fall within the scope of the European Directive 94/9/EC. Refer to paragraph 6.3 of EN 60079-14:1977 VDE 0165 Part 1 concerning connection to equipotential bonding system.
EB 8026 EN
Safety instructions
trained and qualified personnel, observing the accepted industry codes and practices. Make sure employees or third persons are not exposed to any danger. All safety instructions and warnings in these mounting and operating instructions, particularly those concerning assembly, start-up and maintenance, must be observed. The control valves fulfill the requirements of the European Pressure Equipment Directive 97/23/EC. Valves with a CE marking have a declaration of conformity that includes information about the applied conformity assessment procedure. The corresponding declaration of conformity can be viewed and downloaded on the Internet at http://www.samson.de. For appropriate operation, make sure that the control valve is only used in areas where the operating pressure and temperatures do not exceed the operating values which are based on the valve sizing data submitted in the order. The manufacturer does not assume any responsibility for damage caused by external forces or any other external influence! Any hazards which could be caused in the control valve by the process medium, operating pressure, signal pressure or by moving parts are to be prevented by means of the appropriate measures. Proper shipping and appropriate storage of the control valve are assumed.
Caution!
4 For installation and maintenance work on the valve, make sure the relevant 4 4
section of the pipeline is depressurized and, depending on the process medium, drained as well. If necessary, allow the control valve to cool down or warm up to reach ambient temperature prior to starting any work on the valve. Prior to performing any work on the valve, make sure the supply air and control signal are disconnected or blocked to prevent any hazards that could be caused by moving parts. Special care is needed with pneumatic control valves when the actuator springs are pretensioned. These actuators are labeled correspondingly and can also be identified by three long bolts protruding from the bottom of the actuator. Prior to starting any work on the control valve, relieve the compression from the pretensioned springs.
EB 8026 EN
Design and principle of opera- Fail-safe position tion Depending on the arrangement of the compression springs in the actuator, the control valve has two different fail-safe positions: Actuator stem extends When the pressure is relieved or the supply air fails, the springs cause port B (mixing valves) or port A (diverting valves) to close. Ports B or A are opened against the force of the springs when the signal pressure increases. Actuator stem retracts When the diaphragm is relieved of pressure or when the supply air fails, the springs cause port B (mixing valves) or port A (diverting valves) to open. Ports B or A are closed against the force of the springs when the signal pressure increases.
The Type 3244-1 and Type 3244-7 Pneumatic Control Valves consist of a Type 3244 Three-way Valve and either a Type 3271 or a Type 3277 Pneumatic Actuator. Thanks to the modular design, the actuators can be exchanged, and the standard version of the valve can be supplemented to form a version with insulating section or metal bellows seal. Depending on the plug arrangement, the three-way valve operates either as mixing or flow-diverting valve (in DN 15 to 25, the plugs are identical). In mixing valves, the media to be mixed enter through ports A and B. The combined flow leaves at port AB. In diverting valves, the medium enters through port AB and the diverted flows exit at ports A and B. The flow rate from A or B to AB or vice versa is determined by the cross-sectional area released between the seat (2.1, 2.2) and the plug (3), and thus by the position of the plug stem (6). The plug (3) is moved by the changing signal pressure acting on the diaphragm of the actuator. The plug stem (6) and the actuator stem (8.1) are connected over the stem connector (7); they are sealed by a springloaded PTFE ring packing (4.2).
EB 8026 EN
1.1 Nuts 1.2 Gasket 2.1 Top seat ring 2.2 Bottom seat ring 3 Plug 3.1 Plug part 3.2 Screws 4.1 Spring 4.2 Packing 5 Valve bonnet
5.2 Threaded bushing 5.3 Travel indicator scale 6 Plug stem 6.1 Stem connector nut 6.2 Lock nut 7 8 Stem connector Actuator
Type 3277 Actuator
8.1 Actuator stem 8.2 Nut
Type 3271 Actuator
8.1 8.2 7 5 5.3 7 6.1 6.2 5.2 4.2 4.1 AB A 1.1 5
8 8.2 8.1
6.1 6.2 1.2 6 2.1 3 2.2 3.1 B 3.2
1.1 1.2 6 AB A
2.1 3 2.2
Plug arrangement for flow-diverting service DN 15 to DN 25
B
Plug arrangement for mixing service in DN 15 to DN 25 also for flow-diverting service
Fig. 2 Sectional drawings
EB 8026 EN
Instead of the simple pneumatic actuator, it is also possible to attach an actuator with additional handwheel or an electric actuator. A pneumatic actuator (with or without handwheel) can be replaced by a pneumatic actuator in a different size. If the travel range of the actuator exceeds that of the valve in the valve-actuator configuration, the manufacturer will adjust the spring assembly of the actuator such that the travels match.
The lower bench range value (0.2 bar) corresponds to the lower signal pressure range to be adjusted; the upper bench range value (1 bar) corresponds to the upper signal pressure range. In Type 3271 Actuators, the fail-safe action "Actuator stem extends" is indicated by FA and "Actuator stem retracts" by FE on the nameplate. Type 3277 Actuators bear a corresponding symbol on the nameplate. 5. In actuator version "Actuator stem extends", apply a pressure corresponding to the lower bench range value (e.g. 0.2 bar) to the signal pressure connection on the bottom diaphragm case. In actuator version "Actuator stem retracts", apply a pressure corresponding to the upper bench range value (e.g. 1 bar) to the connection on the top diaphragm case. 6. Turn stem connector nut (6.1) by hand until it touches the actuator stem (8.1). Turn it another quarter turn and secure position with the lock nut (6.2). 7. Attach clamps of the stem connector (7) and screw them tightly together. Align travel indicator scale (5.3) with the tip of the stem connector.
2.1
Assembly and adjustment
If the valve and actuator have not already been assembled by the manufacturer, or if the original actuator is replaced by a different actuator size or model, proceed as follows to assemble the valve and actuator: 1. Loosen lock nut (6.2) and stem connector nut (6.1) from the valve. Firmly press the plug with the plug stem into the seat ring. Turn stem connector nut and lock nut downward. 2. Remove clamps of the stem connector (7) and annular nut (8.2) from the actuator (8). Push annular nut over the plug stem. 3. Place actuator on the valve bonnet (5) and screw tight with the annular nut (8.2). 4. Read bench range (or range with pretensioned springs) and fail-safe action from the nameplate of the actuator (e.g. 0.2 to 1 bar and "Actuator stem extends").
EB 8026 EN
Note on disassembling the actuator: When disassembling actuators with fail-safe action "Actuator stem extends" and particularly versions with pretensioned springs, apply a pressure slightly higher than the lower bench range value (see actuator nameplate) to the bottom signal pressure connection before unscrewing the annular nut (8.2).
2.2
Option to pretension the springs for actuator version "Actuator stem extends"
Caution! Actuators with springs that have already been pretensioned by the manufacturer without attachment to a valve are marked by an appropriate label. In addition, such actuators can be identified by three bolts and nuts protruding from the bottom diaphragm case. These bolts and nuts allow you to evenly relieve the compression when disassembling the actuator.
To achieve a greater thrust, the actuator springs can be pretensioned by up to 12.5 % (120 and 240 cm2) or by up to 25 % (350 cm2 and larger) of their travel or their bench range span. Example: If, with a bench range of 0.2 to 1 bar, the springs are to be pretensioned by 0.1 bar, for example, the bench range is shifted by 0.1 bar, resulting in a new bench range of 0.3 to 1.1 bar (0.1 bar corresponds to a compression of 12.5 %). When adjusting the valve, a signal pressure of 0.3 bar is to be set as the lower signal pressure range. The new bench range of 0.3 to 1.1 bar must be marked on the nameplate as bench range with pretensioned springs.
EB 8026 EN
Installation
3 3.1
3.3
Signal pressure line
The valve can be mounted in any desired position. However, vertical installation with the actuator pointing upwards is preferable for valves in DN 100 or larger. Otherwise, wear on the packing may increase. For valves with insulating section or metal bellows seal, or for actuators weighing more than 50 kg, mount a suitable support or suspension for the actuator.
Connect the signal pressure line to the bottom diaphragm case for valves with actuator version "Actuator stem extends" and to the top diaphragm case for valves with actuator version "Actuator stem retracts". In the Type 3277 Actuator, the bottom connection is located at the side of the yoke on the bottom diaphragm case.
3.4
Strainer, bypass
Note! Make sure the valve is mounted free of stress and not exposed to excessive vibration. Flush the pipeline thoroughly before installation.
We recommend to install a SAMSON Type 2 Strainer upstream of the valve body. We also recommend to install a shut-off valve both upstream of the strainer and downstream of the valve, as well as a bypass, so that you do not need to shut down the plant for maintenance.
3.5 3.2 Arrangement of the control valve
Test connection
Arrange the control valve depending on the desired service as illustrated in Fig. 3. The installation examples refer to the standard application using fail-safe action "Actuator stem extends" for heating service and "Actuator stem retracts" for cooling service. When the fail-safe action is triggered, the valve shuts off the heating or cooling media. The plug arrangement for either mixing or diverting service is marked on a plate on the valve body. Valves in sizes DN 15 to 25 have an identical plug arrangement for both mixing and diverting service.
EB 8026 EN
Installation
Mixing service Temperature control Q = constant
Flow-diverting service Flow rate control Q = 0 to 100 %
Fail-safe action: FA = Actuator stem extends, FE = Actuator stem retracts In heating service with FA, the heating medium (flow) is shut off in fail-safe position. In cooling service with FE, cooling is continued when the fail-safe action is triggered.
Heating with mixing valve FA or cooling with mixing valve FE Installation in the flow pipe Installation in the return flow pipe
A AB B A B
Flow
Flow
Return flow
Return flow
AB
Flow
A B
AB
Flow
Return flow
Return flow
AB B
Heating with diverting valve FA or cooling with diverting valve FE Installation in the return flow pipe Installation in the flow pipe
Flow Flow
AB B A AB B A
Return flow
Return flow
Flow
Flow
AB B
Return flow
A B
AB
Return flow
Fig. 3 Typical installations
EB 8026 EN
Operation
Operation
(e.g. reversing the direction of action, etc.) For details, refer to the Mounting and Operating Instructions of the respective pneumatic actuator. EB 8310 EN for Type 3271 and EB 8311 EN for Type 3277.
The control valve is subject to natural wear, especially at the seat, plug and packing. Depending on the application, the valve needs to be checked regularly to prevent against possible failures. If leakage occurs, this could be caused by a damaged packing or a defective metal bellows. If the valve does not seal properly, the tight shut-off may be impeded by dirt or other impurities caught between the seat and plug, or by damaged seating surfaces. Remove the parts, clean them thoroughly and replace them, if necessary.
Note! Before servicing or disassembling the control valve, depressurize the concerned section of the plant and drain it, if necessary, depending on the medium used. Wait until the medium has cooled down, if necessary. As valves are not free of cavities, there might still be residual medium in the valve. This applies, in particular, for valve versions with insulating section or metal bellows seal. We recommend removing the valve from the pipeline. Caution! On performing any work on the valve body, first shut off the supply pressure, disconnect the supply pressure line and remove the actuator.
Disassembling the actuator: 1. Remove stem connector (7) and unscrew annular nut (8.2). To remove the annular nut (8.2), apply a pressure slightly higher than the lower bench range value (see actuator nameplate) before disassembling actuators with fail-safe action "Actuator stem extends" and particularly actuator versions with pretensioned springs. 2. Lift actuator from the valve bonnet.
Note! Suitable seat and special tools as well as the appropriate tightening torques required for installation are listed in EB 029 EN (formerly WA 029 EN), which can be viewed on the Internet at http://www.samon.de/pdf_en/ e00290en.pdf.
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EB 8026 EN
5.1

We recommend you to also replace the packing (4.2) when exchanging the seat and plug. 1. Unscrew stem connector nut and lock nut (6.1, 6.2) from the plug stem. 2. Remove threaded bushing (5.2). 3. Remove nuts (1.1). Lift valve bonnet (5) from the body over the plug stem (6). Mixing valve 4. Unscrew top seat ring (2.1) using a SAMSON seat wrench. 5. Remove plug stem (6) together with the plug (3).

1. Unscrew stem connector nut and lock nut (6.1, 6.2) from the plug stem. 2. Unscrew threaded bushing (5.2). 3. Remove nuts (1.1). Lift valve bonnet (5) from the body over the plug stem. 4. Pull complete packing assembly out of the packing chamber using a suitable tool. Replace damaged parts as necessary. Thoroughly clean the packing chamber. 5. Remove gasket (1.2) and carefully clean the sealing surfaces in the valve body and on the bonnet. 6. Apply lubricant (order no. 8150-0111) to all parts of the packing assembly and the plug stem (6). 7. Place a new gasket (1.2) into the valve body. Place valve bonnet (5) over the plug stem on the valve body and secure with nuts (1.1). 8. Carefully push packing assembly (4.1, 4.3 and 4.2) over the plug stem into the packing chamber, observing the proper order. Screw in threaded bushing (5.2) and tighten. 9. Loosely screw lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 10. Mount actuator and adjust upper and lower bench range values as described in section 2.1.
5.2
4.2
4.1 Spring 4.2 PTFE ring packing 4.3 5 5.2 6 Washer Bonnet Threaded bushing Plug stem
4.3 4.1
5 6
Fig. 4 Packing assembly
EB 8026 EN
11
6. Check seating surfaces of the seat rings. If necessary, unscrew bottom seat ring (2.2) as well and replace it. 7. Apply lubricant and sealant (order no. 8150-0119) to the thread and sealing cone of the seat rings. Also apply lubricant (order no. 8150-0111) to the plug stem. 8. Reassemble in reverse order. Observe tightening torques for seat rings and nuts of the body flanges as specified in EB 029 EN. Flow-diverting valve DN 32 to DN 150 (DN 15 to DN 25 as for mixing valves) 4. Remove screws (3.2). Also remove plug piece (3.1) with its sealing ring from the plug (3). 5. Proceed as described for mixing valves under items 5 to 8. Check sealing ring when mounting the plug piece (3.1) and replace it, if necessary. Mixing and diverting valves 9. Loosely screw lock nut (6.2) and stem connector nut (6.1) onto the plug stem. 10. Mount actuator and adjust upper and lower bench range values as described in section 2.1.
5.2

1. Unscrew stem connector nut and lock nut (6.1, 6.2) from the plug stem extension (6.3). Remove threaded bushing (5.2) of the packing. 2. Remove bolts (5.4). Carefully lift valve bonnet (5) from the body over the plug stem extension. 3. Pull complete packing assembly out of the packing chamber using a suitable tool. Replace damaged parts as necessary. Thoroughly clean the packing chamber. 4. Remove gasket (5.1) in the intermediate piece (12) and carefully clean the sealing surfaces. 5. Apply lubricant (order no. 8150-0111) to all parts of the packing assembly and the plug stem extension (6). 6. Place a new gasket (5.1) into the intermediate piece. Carefully place bonnet (5) over the plug stem extension onto the intermediate piece (12) and tighten with bolts (5.4). (Tightening torques in EB 029 EN). 7. Carefully push packing assembly (4.1, 4.3 and 4.2) over the plug stem into the packing chamber observing the proper order. Screw in threaded bushing (5.2) and tighten. 8. Loosely screw lock nut (6.2) and stem connector nut (6.1) onto the plug stem.
12
EB 8026 EN
1.1 Nuts 3 Plug 3.1 Plug piece 3.2 Screws 4.2 Packing 5 Bonnet 5.1 Sealing ring 5.2 Threaded bushing 5.3 Travel indicator scale 5.4 Bolts 6 Plug stem 6.1 Stem connector nut 6.2 Lock nut 6.3 Plug stem extension 6.4 Lock washers DN 15 to 80, Order no. 8382-231 DN 100 to 150, Order no. 8382-2321 6.5 Nut 6.6 Metal bellows 11 Test connection 12 Intermediate piece
5 6.1 6.2 5.4 5.1 5.2 4.2 4.1 11 6.5 6.6 12 6.3 6.4 6
1.1
AB
2.1 A 3 2.2 3.1
Mixing valve (left) and flow-diverting valve (right)
3.2 B
Fig. 5 Version with bellows seal or insulating section (without welded-on bellows (6.6) for insulating section)
EB 8026 EN
13
9. Mount actuator and adjust upper and lower bench range values as described in section 2.1.
5.2.2 Seat and plug

We recommend also to replace the packing (4.2) when installing a new seat and plug.
Caution! To avoid damage in the metal bellows version (the version with insulating section does not have a bellows), make sure that no torque is applied to the bellows, which is screwed to the intermediate piece. It is recommended to use a SAMSON clamping tool.
1. Unscrew stem connector nut and lock nut (6.1, 6.2) from the plug stem. 2. Remove threaded bushing (5.2). 3. Remove bolts (5.4). Carefully lift bonnet (5) from the intermediate piece (12) over the plug stem extension (6.3). Mixing valves 4. Insert SAMSON plug tool through valve port B to hold the plug stationary. Unscrew nut (6.5) using a socket wrench. 5. Tightly screw stem connector nut (6.1) and lock nut (6.2) onto the free threaded end of the plug stem extension (6.3) to hold the plug stem stationary. 6. Unscrew plug from the plug stem extension using a SAMSON plug tool.
7. Remove nuts (1.1) from the body. Lift intermediate piece (12) together with the plug stem extension (6.3) from the valve body. If necessary, replace the metal bellows together with the plug stem extension (see section 5.2.3). 8. Unscrew top seat ring (2.1) and remove plug from the body. Unscrew bottom seat ring (2.2) as well. Diverting valves DN 32 to DN 150 (DN 15 to DN 25 as for mixing valves) 4. Remove screw (3.2) from the plug through valve port B. Take plug piece (3.1) together with the sealing ring off the plug (3). 5. Remove nuts (1.1). Also remove intermediate piece (12) together with plug stem extension, plug stem and plug (3) from the valve body (1). 6. Tightly screw stem connector nut (6.1) and lock nut (6.2) onto the free threaded end of the plug stem extension (6.3) to hold the plug stem stationary. 7. Unscrew plug (3) from the plug stem extension (6.3). If necessary, replace the metal bellows together with the plug stem extension (see section 5.2.3). 8. Replace seats as described in section 5.2.2. 9. Apply lubricant (order no. 8150-0111) to the plug stem (6) of the new plug. Make sure that both lock washers (6.4) are still located in the plug stem exten-
14
EB 8026 EN
sion. Tightly screw plug stem into plug stem extension (6.3) with a tightening torque of 50 Nm for 10 mm and 80 Nm for 16 mm.
5.2.4 Reassembly
1. Place a new gasket (1.2) into the valve body. Place intermediate piece onto valve body and tighten with nuts (1.1). Observe tightening torques as specified in EB 029 EN. 2. Place a new gasket (5.1) into intermediate piece, place it on the valve bonnet (5) and fasten with nuts and bolts (5.4). Observe tightening torques as specified in EB 029 EN. 3. Tighten threaded bushing (5.2). 4. Loosely screw lock nut (6.2) and stem connector nut (6.1) onto plug stem extension (6.3) or plug stem. 5. Mount actuator and adjust upper and lower bench range values as described in section 2.1.
5.2.3 Metal bellows

Refer to section 5.2.2, item 7 for mixing and flow-diverting valves. 1. Pull plug stem extension with weld-on metal bellows (6.6) out of the intermediate piece. 2. Clean seating surfaces on the intermediate piece. 3. Push new plug stem extension including metal bellows into the intermediate piece (12).
EB 8026 EN
15
Seat The material number is either stamped or engraved on the seat.

The Kvs value and characteristic are engraved on the plug.

engraved "st".
16
EB 8026 EN
SAMSON
1 2 3 -4 7 9 11 12 13 8 14 15
Made in Germany
5 10
SAMSON
H 5 F
1 6
2 V
3 7
1 2 3 4 5 6 7 8 9 10 11 12
CE marking or "Art. 3, Abs.3" (see article 3, 3 of PED), where applicable Identification no. of notified body, fluid group and category, where applicable Type designation Modification index of valve Material Year of manufacture Nominal size: DIN: DN, ANSI: Size Permissible excess pressure at room temperature DIN: PN, ANSI: CL Order number with modification index Position of item in order Flow coefficient: DIN: KVS, ANSI: Cv Characteristic: % equal percentage, Lin linear, DIN: A/Z quick opening, ANSI: O/C Sealing: ME metal, ST stellited, Ni nickel-plated PT soft sealing with PTFE, PK soft sealing with PEEK Pressure-balanced: DIN: D, ANSI: B I or III flow divider
1 2 3 4
SAMSON
Model - No. Serial - No. Pneum. Stellantrieb 3 Pneum. actuator Servo - monteur pneum. Federbereich Spring range Plage des ressorts Stelldruckbereich Signal pressure range Plage avec prcontrainte Hub cm Stroke Course mm bar bar
5 6 7
13
14 15
Zuluft max. 6 bar Begrenzt auf Air supply 90 psi Up to Air d' alimentation Limit
Made in France
bar
Customer inquiries
Please submit the following details:
4 Order number 4 Type, product number, nominal size and

version of the valve
4 Pressure and temperature of the process medium 4 Flow rate in m3/h 4 Bench range of the actuator (e.g. 0.2 to 1 bar) 4 Has a strainer been installed? 4 Installation drawing
EB 8026 EN
17
SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt am Main Germany Phone +49 69 4009-0 Fax +49 69 4009-1507 Internet: http://www.samson.de
EB 8026 EN
S/Z 2006-11
Pneumatic Actuator Type 3271
Type 3271
Type 3271-5
Type 3271 with handwheel
Type 3271-52
Fig. 1 Type 3271 Actuators

Edition October 2004
Contents
Safety instructions
Contents 1 2 2.1 2.1.1 2.1.2 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 3 4
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Reversing the operating direction (fail-safe action) . . . . . . . . . . . . 6 Type 3271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Actuator with handwheel . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacing the diaphragm and stem seal . . . . . . . . . . . . . . . . 10 Adjusting the travel stop . . . . . . . . . . . . . . . . . . . . . . . . 11 Manual operation of Type 3271 with side-mounted handwheel . . . . . 12 Normal operation with the handwheel locked . . . . . . . . . . . . . 12 Actuator stem extends upon air supply failure . . . . . . . . . . . . . 12 Actuator stem retracts upon air supply failure. . . . . . . . . . . . . . 12 Actuator stem extends when supply air is applied . . . . . . . . . . . . 13 Actuator stem retracts when supply air is applied . . . . . . . . . . . . 13 Description of nameplate . . . . . . . . . . . . . . . . . . . . . . . 14 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Assembly, start-up and operation of the device may only be performed by
4 4
trained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the relevant standards. Any hazards which could be caused by the signal pressure and moving parts of the actuator are to be prevented by means of appropriate measures. Proper shipping and appropriate storage are assumed.
EB 8310 EN
principle
of
The Type 3271 Actuators are primarily used for attachment to Series 240, 250, 260 and 280 Valves. Type 3271-5 with a die-cast aluminum casing and effective diaphragm areas of 60 and 120 cm2, is mounted to Type 3510 Valves and Series 240 Valves. The Type 3271 Actuator is made up of two diaphragm cases, a rolling diaphragm and springs. Actuators with manual override additionally
have a handwheel mounted on the top diaphragm case or mounted on the side of the valve yoke. The handwheel moves the actuator stem over a spindle. The Type 3271 Actuator can be equipped in a special version with a mechanically adjustable travel stop (Fig. 7). The signal pressure creates a force at the diaphragm surface which is balanced by the springs (6) arranged in the actuator. The number of springs and their compression determine the bench range (signal pressure range) while taking the rated travel into account which is directly proportional to the signal pressure.
Actuator stem extends FA
Actuator stem retracts FE
3 5 6 8 9
1.1
9 a 3
1 1.1 2 3 4 Nut Nut Actuator stem 6 Springs Vent plug Loading pressure 7 Diaphragm plate 8 Diaphgram connection 5 Top diaphragm 8.1 Hose clamp case Fig. 2 Sectional diagram of Type 3271
12 12.1 15 13 16
9 10 11 12 12.1 13 15 16
8.1 7 10 11
Nuts and bolts Bottom diaphragm case Loading pressure connection Stem seal Dry bearing Wiper Ring nut Stem connector
EB 8310 EN
A maximum of 30 springs can be installed, partly fitted inside one another. In an actuator with the fail-safe action "Actuator stem extends FA", the loading pressure is connected to the loading pressure connection (11) to fill the bottom diaphragm chamber with air which causes the actuator stem to move upwards. In an actuator with the fail-safe action "Actuator stem retracts FE", the loading pressure is connected to the loading pres2 1 1.1 6
sure connection (4) to fill the top diaphragm chamber with air which causes the actuator stem to move downwards. The stem connector (16) connects the actuator stem (2) to the plug stem of the valve. Fail-safe action When the signal pressure fails, the fail-safe action of the actuator depends on whether the springs are installed in the top or bottom diaphragm chamber.
9
5 3 4 8 11 7 7.1
12 12.1 15 13 16
10 20 21 22
2.1
1 1.1 2 2.1 3 3.1 4 5 6
Nut Nut Actuator stem Bushing Vent plug Vent plug Loading press. connection Actuator stem retracts Top diaphragm case Springs
21 Diaphragm plate 22 Metal plate Diaphragm Nuts and bolts Bottom diaphragm case Loading press. connection Actuator stem extends 12 Stem seal 12.1 Dry bearing
7 7.1 8 9 10 11
16
13 Wiper 15 Ring nut 16 20 21 22 Stem connector 2 Screw (60 cm ) 2 Washer (60 cm ) 2 Sleeve (60 cm )
Fig. 3 Type 3271-5 Actuators with 120 cm2 (top) and 60 cm2 (bottom) effective diaphragm area
EB 8310 EN
Actuator stem extends When the signal pressure is reduced or the air supply fails, the springs move the actuator stem downwards and close the valve. The valve opens when the signal pressure is increased enough to overcome the force exerted by the springs. Actuator stem retracts When the signal pressure is reduced or the air supply fails, the springs move the actuator stem upwards and open the valve. The valve closes when the signal pressure is in-
creased enough to overcome the force exerted by the springs. The tandem actuator (Fig. 4) has two diaphragms connected to each other. The signal pressure produces an actuating force double to that of an actuator with just one diaphragm. Actuators with an additional manual override (Fig. 5) have a handwheel that moves the actuator stem over a spindle after the locking mechanism (lock nut) has been disengaged. A side-mounted handwheel (Fig. 8) moves the stem over a bevel or worm gear.
3.1
4.1 4
3 3.1
4.1 15 16
Actuator stem retracts 3 3.1 4 4.1 15 16
3 7
Loading pressure connection Vent plug Loading pressure connection Vent plug Ring nut Stem connector
Fig. 4 Tandem actuator
Note! Refer to the attached valves Mounting and Operating Instructions to mount or remove the actuator from the valve. Actuators with 2800 cm2 diaphragm area weigh 450 kg and cannot be mounted onto the valve on site. Important! The pneumatic actuators are designed for a maximum supply pressure of 6 bar. To prevent the actuator from being damaged, do not let the supply pressure exceed the upper spring range value by more than 3 bar when the actuator is used for flow-switching service (on-off valve) with the fail-safe action "Actuator stem retracts". Label actuators that have a reduced supply pressure with a sticker "max. supply pressure limited to ... bar". The maximum supply pressure for actuators with fail-safe action Actuator stem extends and mechanical travel stops should not exceed the upper spring range value by more than 1.5 bar.
EB 8310 EN
Operation
Operation
2.1.1 Type 3271

Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts" (Fig. 2) 1. Unthread nuts and remove the bolts (9) from the diaphragm cases. 2. Lift off the top diaphragm case (5) and remove the springs (6). 3. Pull the actuator stem (2) with diaphragm plate (7) and diaphragm (8) out of the bottom diaphragm case (10). 4. Unscrew nut (1), while holding the nut (1.1) stationary with a suitable tool. Caution! Proceed carefully to avoid damaging the seals of the actuator stem.
Note! Only apply the loading pressure to the diaphragm chamber that does not contain the springs. It is important for a troublefree operation of the actuator that the vent plug (3) is not blocked. Make sure in versions with a handwheel that the plug stem can move freely when the valve is being positioned by the pneumatic actuator by moving the handwheel into a neutral position (Fig. 5 for 240 to 700 cm2 and Fig. 8 for 1400 and 2800 cm2) .
2.1
Reversing the operating direction (fail-safe action)
The operating direction, i.e. fail-safe action, of pneumatic actuators can be changed. Prior to proceeding, you must remove the actuator from the valve. The fail-safe action "Actuator stem extends" or "Actuator stem retracts" is specified on the nameplate with the initials FA and FE on Type 3271 Actuator or by a symbol on Type 3271-5 Actuator.
Caution! Do not loosen the nut (1.1) on the actuator stem. It is painted over to protect it. If, however, it does become loose, it is essential that the dimension "a" from the top of the nut to the bottom of the actuator stem is kept as shown in Fig. 2 and the table below.
Actuator cm 120
2
Dimension a in mm (Fig. 2) 100.5, or 89 with threaded end 98.25 107.25 125 for 15 mm rated travel (0.4-1.2 bar) 144 for 30 mm and 40 mm rated travel 230 430
Caution! To disassemble an actuator with preloaded actuator springs (recognizable by the long bolts on the diaphragm chambers), always undo the short bolts first and then unthread the long bolts slowly and evenly until the actuator springs are fully decompressed.
240 350
700
1400 2800
EB 8310 EN
Operation
5. Lift off the diaphragm plate with diaphragm and replace them in reverse order. Tighten nut (1). 6. Apply lubricant/sealant (order no. 8152-0043) to the actuator stem. 7. Place the diaphragm plate with diaphragm in the top diaphragm case. Insert the springs (6) and slide the lower diaphragm case over the actuator stem. 8. Screw tight the nuts and bolts of the diaphragm cases. 9. Remove vent plug (3) from top diaphragm case and screw it into the loading pressure connection on the bottom diaphragm case. The actuator springs now press against the diaphragm plate from below and cause the actuator stem to retract. The loading pressure is connected over the connection (4) to the top diaphragm chamber. The actuator stem starts to extend when the signal pressure overcomes the force of the springs. 10. Record the changed fail-safe action on the nameplate! Proceed in the same manner for the Type 3271-5 Actuator, but additionally install the metal plate (7.1). For the version intended for attachment to micro-flow valves, additionally install the bushing (2.1) for the mechanical travel stop. In Type 3271-52 Actuator with 60 cm2 diaphragm area, unthread the screw (20) and then remove the washer (21) and sleeve (22).
Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" (Fig. 2) 1. Unthread nuts and remove the bolts (9) and lift off the top diaphragm case (5). 2. Pull the diaphragm plate (7) and diaphragm with the actuator stem (2) out of the bottom diaphragm case (10). Remove the springs (6). 3. Unscrew nut (1), while holding the nut (1.1) stationary with a suitable tool. Caution! Proceed carefully to avoid damaging the seals of the actuator stem. 4. Remove the diaphragm plate with diaphragm and replace them in reverse order. Screw tight nut (1). 5. Coat the actuator stem with sealant/lubricant (order no. 8152-0043) and insert it into the bottom diaphragm chamber along with the diaphragm plate and diaphragm. 6. Insert springs (6) and place the top diaphragm case back on. 7. Screw tight the nuts and bolts of the diaphragm cases. 8. Remove the vent plug (3) from the bottom loading pressure connection and place it in the top connection. The springs which are now pressed from the top against the diaphragm plate cause the actuator stem to extend. The signal pressure is connected via the connection (11) to the bottom diaphragm chamber. The actuator stem starts to retract when the signal pressure overcomes the force of the springs.
EB 8310 EN
Operation
9. Record the changed fail-safe action on the nameplate! Proceed in the same manner for the Type 3271-5 Actuator, but additionally install the metal plate (7.1). For an actuator intended for a micro-flow valve, install the bushing (2.1) for the travel stop. For Type 3271-52 Actuator with 60 cm2 undo the screw (20) and then remove the washer (21) and sleeve (22).
2.1.2 Actuator with handwheel

240, 350 and 700 cm2 (Fig. 5) only 1. Undo lock nut (20) and relieve the springs (6) by turning the handwheel (17). 2. Loosen threaded pin (26) and unscrew coupling nut (25) from the coupling (22). 3. Knock out the clamping sleeve (23) and remove the ring (24). 4. Unthread the ring nut (28) and lift off the flange part (21). Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts"
4 Proceed as described in section 2.1.1.

After reversing the operating direction:
However, use the word "spindle with nut (27)" in place of "nut (1)".
1. Place the flange part (21) and coupling nut (25). Then fasten the flange part (21) with the ring nut (28). 2. Attach the ring (24) with clamping sleeve (23). 3. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26). Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends"
EB 8310 EN
Operation
After reversing the operating direction: 1. Place the flange part (21) and the coupling nut (25) and then secure flange part (21) with ring nut (28).
2. Attach the ring (24) with clamping sleeve (23). 3. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26).
Actuator stem Vent plug Loading press. connection Top diaphragm case Springs Additional springs Diaphragm plate Diaphragm Nuts and bolts Hose clip Bottom diaphragm case Loading press. connection Stem connector Handwheel Lock nut Flange part Coupling Clamping sleeve Ring Coupling nut Threaded pin Spindle with nut Ring nut
17 20 21
Neutral position Pointer points to groove in coupling (22)
3 4 5 6 6.1 7 8 9 8.1 10 11 16 17 20 21 22 23 24 25 26 27 28
22 23 24 25 3 4 5 6 7
26 28 27 8.1
9 8 6.1 10 2 16
Actuator stem retracts Actuator stem extends
11
Fig. 5 Actuators 240, 350 und 700 cm2 with handwheel
EB 8310 EN
Operation
2.2
Replacing the diaphragm and stem seal
Diaphragm (Fig. 2) 1. Remove the diaphragm plate (7) together with diaphragm (8) and actuator stem (2) from the diaphragm case as described in section 2.1. 2. Remove the hose clamp (8.1) and pull it together with the diaphragm (8) off the diaphragm plate (7) (not necessary with Type 3271-5 as the diaphragm is held in place by the metal plate (7.1)). 3. Stretch the new diaphragm onto the diaphragm plate. Fit the hose clamp (8.1) evenly into the groove intended for it and tighten. Insert a piece of protective wear-resistant rubber between the diaphragm and the worm screw of the hose clamp (jubilee clip) to protect the diaphragm. 4. Reassemble actuator as described in section 2.1. Stem seal (Fig. 6) 1. Remove the diaphragm plate (7) together with the actuator stem (2) from the diaphragm case as described in section 2.1. 2. Coat the new stem seal (12) with lubricant/sealant (order no. 8152-0043) and insert it. 3. If necessary, replace the dry bearing (12.1) and wiper (13) with new ones as well. 4. Reassemble the actuator as described in section 2.1.
2 13
12 12.1
Fig. 6 Actuator stem seal
10
EB 8310 EN
Operation
2.3
Adjusting the travel stop

33 31 32
(Type 3271 in special version only) The travel stop can be adjusted upwards or downwards to 50 % of the travel. Downward travel stop (actuator stem extends) 1. Undo the lock nut (34) and unscrew the cap (33). 2. Undo the lock nut (31) and adjust the nut (32) to set required travel stop. 3. Tighten the lock nut (31) again.
34
Upward travel stop (actuator stem retracts) 1. Undo the lock nut (34) and adjust the cap (33) to set the required travel stop. 2. Tighten the lock nut (34) again.
7 2
Actuator stem retracts 2 7 31 32 33 34 Actuator stem extends
Actuator stem Diaphragm plate Lock nut Nut Cap Lock nut
Fig. 7 Travel stop
EB 8310 EN
11
Operation
2.4
Manual operation of Type 3271 with side-mounted handwheel
4 Pull the locking knob on the side all the 4
Note! To operate the handwheel on actuators with 1400 and 2800 cm2 diaphragm areas, do not use any additional tools such as a lever or wrench.
4 4 4
2.4.1 Normal operation with the handwheel locked

The handwheel is not used. The valve is positioned by the pneumatic signal pressure applied to the valve. To achieve this, the pin next to the actuator stem must be in the neutral position: The pin must sink into the flange so far that its groove is aligned with the top of the flange. If this is not case:
way out and turn it to unlock the handwheel. Turn the handwheel counterclockwise (direction Auf/Open/Ouvert), the pin sinks into the flange. Initially, the handwheel is easy to turn and after a certain point of pressure is reached, the valve starts to open. On reaching the final position at the stop, do not turn the handwheel any further by force. Caution! Risk of damage. After finishing manual operation, turn the handwheel to bring the pin back into the neutral position again. Turn the locking knob until it engages to lock the handwheel again.
2.4.3 Actuator stem retracts upon air supply failure

The manual override must overcome the force of the actuator springs to close the valve.
4 Pull the locking knob on the side all the 4 4
way out and turn it to unlock the handwheel. Turn the handwheel until the pin reaches the neutral position. Turn the locking knob until it engages to lock the handwheel again. The easiest way to adjust the handwheel is with the valve in the fail-safe position.
2.4.2 Actuator stem extends upon air supply failure

The manual override must overcome the force of the actuator springs to open the valve.
way out and turn it to unlock the handwheel. Turn the handwheel clockwise (direction Zu/Close/Ferm), the pin emerges from the flange. Initially, the handwheel is easy to turn and after a certain point of pressure is reached, the valve starts to close. On reaching the final position at the stop, do not turn the handwheel any further by force. Caution! Risk of damage.
12
EB 8310 EN
Operation
4 After finishing manual operation, turn 4
the handwheel to bring the pin back into the neutral position again. Turn the locking knob until it engages to lock the handwheel again.
2.4.5 Actuator stem retracts when supply air is applied

The manual override must overcome the force of the actuator springs to close the valve. Do not open the valve any further than before unlocking the handwheel.
Pin with groove
2.4.4 Actuator stem extends when supply air is applied

The manual override must overcome the force of the actuator springs to open the valve. Do not close the valve any further than before unlocking the handwheel.
way out and turn it to unlock the handwheel. Turn the handwheel counterclockwise (direction Auf/ Open/Ouvert), the pin sinks into the flange. Initially, the handwheel is easy to turn and the pins position does not move anymore. After a certain point of pressure is reached (how long depends on the valve travel), the valve starts to open.
Neutral position
4 On reaching the final position at the 4 4
stop, do not turn the handwheel any further by force. Caution! Risk of damage. After finishing manual operation, turn the handwheel to bring the pin back into the neutral position again. Turn the locking knob until it engages to lock the handwheel again.
Locking knob (locked)
Version in this drawing for 80 mm travel
Fig. 8 Side-mounted handwheel
EB 8310 EN
13
Description of nameplate
4 Pull the locking knob on the side all the 4 4 4 4
way out and turn it to unlock the handwheel. Turn the handwheel clockwise (direction Zu/Close/Ferm), the pin emerges from the flange. After a certain point of pressure is reached, the valve starts to close. On reaching the final position at the stop, do not turn the handwheel any further by force. Caution! Risk of damage. After finishing manual operation, turn the handwheel to bring the pin back into the neutral position again. Turn the locking knob until it engages to lock the handwheel again.
Description of nameplate
SAMSON H 5 F
1 6
2 V
3 7
1 2 3 4
Type designation Modification index Effective diaphragm area Operating direction: Actuator stem extends FA Actuator stem retracts FE Travel Bench range (spring range) Bench range with preloaded springs
5 6 7
Fig. 9 Nameplate
14
EB 8310 EN
Customer inquiries
Customer inquiries
Please specify the following details on making inquires:
4 Type and model number 4 Effective diaphragm area 4 Bench range (spring range) in bar 4 Actuator version and its operating direction
Dimensions and weights Refer to the Data Sheets T 8310-1 EN or T 8310-2 EN for the different actuator versions.
EB 8310 EN
15
SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt am Main Germany Phone +49 69 4009-0 Fax +49 69 4009-1507 Internet: http://www.samson.de
EB 8310 EN
S/Z 2004-11
Pneumatic Actuator Type 3277
Fig. 1 Type 3277 Pneumatic Actuator
Fig. 2 Type 3277-5 Pneumatic Actuator

Edition July 2006
principle
of
The Type 3277 Pneumatic Actuators with an effective diaphragm area of 240, 350 or 700 cm are primarily mounted to control valves from the Series 240, 250 and 280. Type 3277-5 with a die-cast aluminum case and an effective diaphragm area of 120 cm, is mounted to Type 3510 and Series 240 Valves. The actuator is made up of two diaphragm cases, a rolling diaphragm and springs. The lower diaphragm case is permanently fixed to the yoke which allows the direct attachment of either a pneumatic or electropneumatic positioner or a limit switch. Actuators with manual override (Fig. 5) additionally have a handwheel mounted on the diaphragm case. The handwheel moves the
actuator stem over a spindle after the locking mechanism (lock nut) has been disengaged. In addition, the actuator can be equipped in a special version with a mechanically adjustable travel stop. The signal pressure creates a force at the diaphragm surface which is balanced by the springs (6) arranged in the actuator. The number of springs and their compression determine the bench range (signal pressure range) while taking the rated travel into account which is directly proportional to the signal pressure. A maximum of 30 springs can be installed, partly fitted inside one another. The stem connector (16) connects the actuator stem (2) with the plug stem of the control valve.
4 Assembly, start-up and operation of the device may only be performed by
4 4
trained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the relevant standards. Any hazards which could be caused by the signal pressure and moving parts of the actuator are to be prevented by means of appropriate measures. Proper shipping and appropriate storage are assumed.
EB 8311 EN
Fail-safe action When the signal pressure fails, the fail-safe action of the actuator depends on whether the springs are installed in the top or bottom diaphragm chamber. Actuator stem extends When the signal pressure is reduced or the air supply fails, the springs move the actuator stem downwards and close the valve. The valve opens when the signal pressure is increased enough to overcome the force exerted by the springs.
5 1
Actuator stem retracts When the signal pressure is reduced or the air supply fails, the springs move the actuator stem upwards and open the valve. The valve closes when the signal pressure is increased enough to overcome the force exerted by the springs.
4 7
1.1
6.1
1 1.1 2 3 4
Nut Nut Actuator stem Vent plug Loading pressure9 connection 5 Top diaphragm 2 case 6 Springs 7 Diaphragm plate 8 Diaphragm 9 Nuts and bolts 10 Yoke with bottom diaphragm case 11 Loading pressure connection 12 Stem seal 12.1Dry bearing 13 Wiper 15 Ring nut 16 Stem connector
8 12
a
12.1 11 10 12.1
Dimension a 350 cm = 209 mm 700 cm = 246 mm
15 13 16
Fig. 3 Sectional diagram of Type 3277 with 240, 350 and 700 cm effective diaphragm area
EB 8311 EN
Loading pressure connection Type 3277 Actuator (Fig. 3) In the Type 3277 Actuator with fail-safe action "Actuator stem extends", the loading pressure is connected to the loading pressure connection (11) at the side of the yoke to fill the bottom diaphragm chamber which causes the actuator stem (2) to move upwards. In an actuator with the fail-safe action "Actuator stem retracts", the loading pressure is connected the loading pressure connection (4) to fill the top diaphragm chamber which causes the actuator stem to move downwards. Type 3277-5 Actuator (Fig. 4) In the Type 3277-5 Actuator, the loading pressure is connected to a borehole either at the left or right of the yoke. A switchover plate (14, accessories) directs the air to one of the diaphragm chambers, depending on the fail-safe action of the actuator ("Actuator stem extends" or "Actuator stem retracts"), which is determined by how the plate is aligned with the mark (14.4).
4 Turn the connecting plate to align the 4 4
symbol (14.3) for the appropriate fail-safe action "Actuator stem extends" or "Actuator stem retracts" with the mark (14.4). See Fig. 4, bottom right. Make sure that the flat gasket of the connecting plate is correctly inserted. The connecting plate has both NPT and G threaded bores. Seal the bore not required with a rubber gasket and square plug. Accessories: The switchover plate or connecting plate must be ordered separately. Please note that actuators with modification index 01 e.g. 3277-531xxx20.01 (old = .00) are equipped with new plates. Old and new plates are not interchangeable.
Index Switchover plate Connecting plate New Old New Old: G thread Old NPT thread 01 00 01 00 00 Order no. 1400-6822 1400-6819 1400-6823 1400-6820 1400-6821
4 Turn the switchover plate to align the
symbol (14.3) for the appropriate fail-safe action with the mark (14.4). See Fig. 4, bottom left. The operating direction (>>) or (<>) of the positioner determines whether the left or right attachment is to be used. A connecting plate (accessories) is required instead of the switchover plate if the actuator is operated without a positioner. The loading pressure is directly connected to the loading pressure connection (14.8) of the connecting plate to fill the diaphragm chamber.
Note! The pneumatic actuators are designed for a maximum supply pressure of 6 bar. To prevent the actuator from being damaged, do not let the supply pressure exceed the upper spring range value by more than 3 bar when the actuator is used for flow-switching service (on-off valve) with the fail-safe position "Actuator stem retracts". Label actuators that have a reduced supply pressure with a sticker "max. supply pressure limited to bar". Note! Refer to the operating instructions of the corresponding valve on how to mount and remove the actuator from the valve.
EB 8311 EN
1.1
2.1 2
12 12.1
7 8 14 10
7.1 14.1 14.2 14 15 13 16

Actuator with threaded connection for a micro-flow valve Connecting plate
1 1.1 2.1 5 6 7 7.1 8 9 10 12
Nut Nut Bushing Diaphragm case Springs Diaphragm plate 16 Metal plate Diaphragm Nuts and bolts Yoke Switchover plate Stem seal
12.1 Dry bearing 13 Wiper 14 Switchover or connecting plate Air routing: 14.1 for actuator stem extends 14.2 for actuator stem retracts 15 Ring nut 16 Stem connector
14.6
14.3 Symbol 14.4 Marking for signal pressure input 14.5 For left attachment 14.6 For right attachment 14.7 Seal with filter 14.8 Loading pressure connection Actuator stem retracts Left attachment Right attachment Actuator stem extends retracts
14.8 14.3 14.4
14.7 14.5 14.3 14.4

Actuator stem extends Left attachment Right attachment
Dimension a = 188.5 with 15 mm travel and 185.5 with 20 mm travel
Fig. 4 Type 3277-5 Actuators with 120 cm2 effective diaphragm area
EB 8311 EN
Operation
Operation
2.1.1 Standard actuator

Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts"
Note! It is important for a trouble-free operation of the Type 3277 Actuator that the vent plug (3) is not blocked. Make sure in versions with a handwheel that the plug stem can move freely when the valve is being positioned by the pneumatic actuator by moving the handwheel into a neutral position.
Note! Actuators with 700 cm (travel = 30 mm) that are mounted to valves with 15 mm travel, are preloaded by approx. 75 % on mounting them to the valve. The signal pressure range is recorded on the nameplate when the actuators have been preloaded on mounting them to the valve.
1. Unthread nuts and remove the bolts (9) from the diaphragm cases. 2. Lift off the top diaphragm case (5) and remove the springs (6). 3. Pull the actuator stem (2) with diaphragm plate (7) and diaphragm (8) out of the yoke (10). 4. Unscrew nut (1), while holding the nut (1.1) stationary or clamping the actuator stem with a suitable tool. Caution! Proceed carefully to avoid damaging the seals of the actuator stem.
2.1
The operating direction, i.e. fail-safe action, of pneumatic actuators can be changed. Prior to proceeding, you must remove the actuator from the valve. The fail-safe action is represented by a symbol on the nameplate. "Actuator stem extends" "Actuator stem retracts"
Caution! To disassemble an actuator with preloaded actuator springs (recognizable by the long bolts on the diaphragm chambers), always undo the short bolts first and then unthread the long bolts slowly and evenly until the actuator springs are fully decompressed.
EB 8311 EN
Caution! Do not loosen the nut (1.1) on the actuator stem. It is painted over to protect it. If, however, it has been loosened, it is essential that the dimension a (Figs. 3 and 4) measured from the top of the nut to the bottom of the actuator stem is kept.
5. Apply lubricant/sealant (order no. 8152-0043) to the sealing places on the actuator stem. 6. Turn over top diaphragm case (5). Place the actuator stem with diaphragm plate, diaphragm and metal plate (7.1), if applicable in the case. 7. Insert the springs (6) and slide the yoke with bottom diaphragm case over the actuator stem. 8. Screw tight the nuts and bolts of the diaphragm cases. Remove vent plug (3) in Type 3277 Actuator. Proceed in the same manner for the Type 3277-5 Actuator intended for the micro-valve, but additionally attach the bushing (2.1) for the mechanical travel stop. The springs now press from below against the diaphragm plate and cause the actuator stem to retract (fail-safe action). The actuator stem only starts to extend when the signal pressure overcomes the force of the springs. 9. Record the changed fail-safe action on the nameplate!
Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends" 1. Unthread nuts and remove the bolts (9) and lift off the top diaphragm case (5). 2. Pull the actuator stem with diaphragm plate, diaphragm and metal plate (7.1), if applicablethe diaphragm plate (7) out of the yoke and bottom diaphragm case (10). 3. Unscrew nut (1), while holding the nut (1.1) stationary or clamping the actuator stem with a suitable tool. Caution! Proceed carefully to avoid damaging the seals of the actuator stem. 4. Remove the diaphragm plate with diaphragm and replace them in reverse order. Screw tight nut (1). 5. Coat the sealing parts of the actuator stem with sealant/lubricant (order no. 8152-0043). 6. Insert the actuator stem with diaphragm plate, diaphragm and metal plate (7.1), if applicable, into the bottom diaphragm case with yoke. 7. Insert springs (6) and place the top diaphragm case back on. Screw tight the nuts and bolts of the diaphragm cases. 8. Screw the vent plug (3) into the top loading pressure connection of the Type 3277 Actuator. Proceed in the same manner for the Type 3277-5 Actuator intended for the micro-valve, but additionally attach the bushing (2.1) for mechanical travel stop. The springs now press from the top against the diaphragm plate and cause the actuator stem to extend (fail-safe action). The actua-
EB 8311 EN
tor stem only starts to retract when the signal pressure overcomes the force of the springs. 9. Record the changed fail-safe action on the nameplate!
Reversing the fail-safe action "Actuator stem extends" to "Actuator stem retracts"

2.1.2 Actuator with handwheel

Type 3277 (Fig. 5) only 1. Undo lock nut (20) and relieve the springs (6) by turning the handwheel (17). 2. Loosen threaded pin (26) and unscrew coupling nut (25) from the coupling (22). 3. Knock out the clamping sleeve (23) and remove the ring (24). 4. Unthread the ring nut (15) and lift off the flange part (21) together with the coupling nut (25).
1. Replace the flange part (21) with ring nut (15) and coupling nut (25). 2. Tighten ring nut (15). Attach the ring (24) with clamping sleeve (23). 3. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26). Reversing the fail-safe action "Actuator stem retracts" to "Actuator stem extends"

1. Replace the flange part (21) with ring nut (15) and coupling nut (25). 2. Tighten ring nut (15). Attach the ring (24) with clamping sleeve (23). Attach the ring (24) with clamping sleeve (23). 3. Screw coupling nut (25) as far as it will go onto the coupling (22) and secure with threaded pins (26).
EB 8311 EN
17 20
Neutral position Pointer points to groove in coupling (22)
21 22 24 13 15 3 4 6
23 26 25 12 5 27
8 12 10
9 6.1 7 11
2 3 4 5 6 6.1 7 8 9 10 11 15 12 12.1 13 17 20 21 22 23 24 25 26 27
Actuator stem Vent plug Loading press. connection Top diaphragm case Springs Additional springs Diaphragm plate Diaphragm Nuts and bolts Bottom diaphragm case Loading press. connection Ring nut Stem seal Dry bearing Wiper Handwheel Lock nut Flange part Coupling Clamping sleeve Ring Coupling nut Threaded pin Spindle with nut
12.1 13
Fig. 5 Type 3277 Actuator with additional handwheel
EB 8311 EN
2.2

33 31 32 34 5
(with Type 3277 in special version only) The travel stop can be adjusted upwards or downwards to 50% of the travel. Downward travel stop (actuator stem extends) 1. Undo the lock nut (34) and unscrew the cap (33). 2. Undo the lock nut (31) and adjust the nut (32) to set required travel stop. 3. Tighten the lock nut (31) again. Upward travel stop (actuator stem retracts) 1. Undo the lock nut (34) and adjust the cap (33) to set the required travel stop. 2. Tighten the lock nut (34) again.
7 2
Actuator stem retracts 2 5 7 31 32 33 Actuator stem extends
Actuator stem Top diaphragm case Diaphragm plate Lock nut Nut Cap
Fig. 6 Travel stop
10
EB 8311 EN
Replacing the diaphragm and stem seal
3 3.1
(Fig. 3)
Replacing the diaphragm and stem seal Diaphragm
Customer inquiries
Please specify the following details on making inquires:
1. Remove the diaphragm plate (7) together with diaphragm (8) and actuator stem (2) from the diaphragm case as described in section 2.1.1. 2. Remove the hose clamp and pull it together with the diaphragm (8) off the diaphragm plate (7) (not necessary with Type 3277-5 as the diaphragm is held in place by the metal plate (7.1)). 3. Stretch the new diaphragm onto the diaphragm plate. Fit the hose clamp evenly into the groove intended for it and tighten. 4. Reassemble actuator as described in section 2.1.1.
4 Type and model number 4 Effective diaphragm area 4 Bench range (spring range) in bar 4 Actuator version and its operating direction
Dimensions and weights Refer to the Data Sheet T 8310-1 EN dimensions and weights of the different actuator versions.
12
3.2
Stem seal
2 12.1
1. Remove the diaphragm plate (7) together with the actuator stem (2) from the diaphragm case as described in section 2.1.1. 2. Coat the new stem seal (12) with lubricant/sealant (order no. 8152-0043) and insert it. 3. If necessary, replace the dry bearing (12.1) and wiper (13) with new ones as well. 4. Reassemble the actuator as described in section 2.1.1.
13
Fig. 7 Actuator stem seal
EB 8311 EN
11
EB 8311 EN
S/Z 2006-08
Series 3730 Electropneumatic Positioner Type 3730-3

With HART communication
Fig. 1 Type 3730-3
Mounting and Operating Instructions EB 8384-3 EN

Firmware version 1.4x Edition March 2007
Contents
Contents 1 1.1 1.2 1.3 2 2.1 2.1.1 2.1.2 2.2 2.3 2.4 2.5 2.5.1 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.7 2.8 3 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 4 4.1 4.2 4.3 4.3.1 4.3.2 5 5.1 5.2 5.3
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 8 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Attachment to the control valve Mounting parts and accessories . . . Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . Reversing amplifier for double-acting actuators . . . . . . . . . . . . . Pressure gauge attachment . . . . . . . . . . . . . . . . . . . . . . Attaching an external position sensor . . . . . . . . . . . . . . . . . Mounting the position sensor with direct attachment. . . . . . . . . . . Mounting the position sensor with attachment according to IEC 60534-6 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . Mounting the position sensor to rotary actuators . . . . . . . . . . . . Attaching positioners with stainless steel housings. . . . . . . . . . . . Air purging function for single-acting actuators . . . . . . . . . . . . . Connections . . . . . . . Pneumatic connections . . Signal pressure gauges . . Supply pressure . . . . . . Electrical connections . . . Switching amplifiers . . . . Establishing communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 16 16 18 20 22 24 26 26 28 28 30 31 32 34 34 36 36 36 36 38 40 40 42 42 44 45 45 46 46 47 47 47
Operation . . . . . . . . . . . . . . . Operator controls and display . . . . . . Enabling and selecting parameters . . . Operating modes . . . . . . . . . . . . Automatic and manual operating modes . SAFE Fail-safe position . . . . . . . . Start-up and settings . . . . . . Determining the fail-safe position Setting the volume restriction Q . . Adapting the display . . . . . . . . . . . . . . . . . . . . . .
EB 8384-3 EN
Contents
5.4 5.5 5.6 5.6.1 5.7 5.8 5.9 5.10 5.11 6 6.1 6.2 6.3 7 8 8.1 8.2 8.3 8.3.1 8.3.2 8.3.3 9 9.1 9.2 10 11 12 13 13.1 13.2 13.3 13.4 14
Limiting the signal pressure . . . . . . . . . . Checking the operating range of the positioner . Initialization . . . . . . . . . . . . . . . . . Initialization modes . . . . . . . . . . . . . . Fault/failure . . . . . . . . . . . . . . . . . Zero calibration . . . . . . . . . . . . . . . . Reset to default values . . . . . . . . . . . . . Start-up via local interface (SSP) . . . . . . . . Start-up over HART communication . . . . . .
. . . . . . . . .
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. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
48 48 49 51 57 58 59 59 59 60 60 61 61 66 66 67 68 68 68 68
Status and diagnostic alarms . . . . . . . . . . . . . . . Standard EXPERT diagnostics . . . . . . . . . . . . . . . Extended EXPERT+ diagnostics . . . . . . . . . . . . . . . Classification of the status alarms and the condensed status . Quick start-up guide . Mounting . . . . . . . Start-up. . . . . . . . Initialization . . . . . Simplest method (MAX) Precise method (NOM) Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 64
Upgrading options . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 69 Activation of optional EXPERT+ diagnostics . . . . . . . . . . . . . . . 70 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 70 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Setting with TROVIS-VIEW software Parameter list . General . . . . . . . . . . . . . . . . . . . . . . Starting TROVIS-VIEW and performing basic settings . Setting the parameters. . . . . . . . . . . . . . . . Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 87 88 91 92
Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
EB 8384-3 EN
Safety instructions
4 The positioner may only be assembled, started up or operated by trained
4 4 4
and experienced personnel familiar with the product. According to these mounting and operating instructions, trained personnel is referred to as individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training, their knowledge and experience as well as their knowledge of the relevant standards. Explosion-protected versions of this positioner may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas. Refer to section 11 on Servicing explosion-protected versions. Any hazards that could be caused by the process medium, the operating pressure, the signal pressure or by moving parts of the control valve are to be prevented by means of the appropriate measures. If inadmissible motions or forces are produced in the actuator as a result of the supply pressure level, it must be restricted by means of a suitable supply pressure reducing station. Do not operate the positioner with the back of the positioner/exhaust air opening facing upwards. The exhaust air opening must not be sealed when the positioner is installed on site.
4 Proper shipping and appropriate storage are assumed. 4 Note! The device with a CE marking fulfils the requirements of the Directives
94/9/EC (ATEX) and 89/336/EEC (EMC). The declaration of conformity is available on request.
EB 8384-3 EN
Versions
Article code
Type 3730-3 X X X X X 0 0 X 0 X 0 0 X 0 X X 0 1 3 8
Explosion protection Without II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 C acc. to ATEX CSA/FM intrinsically safe/non incendive II 3 G EEx na II T6 / II 3 D IP 65 T 80 C acc. to ATEX Additional equipment Inductive limit switch Solenoid valve SIL 4 Without With Type SJ 2-SN Without 24 V DC
0 1 0 4 0 1 0
Analog Without position transmitter With External Position sensor Diagnostics Housing material Positioner for special applications Without With EXPERT EXPERT+ (extended) Aluminum Stainless steel 1.4581 Without Free of substances that impair painted surfaces Exhaust air with NPT connection Special versions Without IECEx 1
0 1 1 2 0 0 1 0 1 2 0 0 0 0 1 2
EB 8384-3 EN
Firmware modification
Modifications of positioner firmware in comparison to previous versions Previous 1.00 New 1.10 The HART protocol as per HART specification Revision 5 is supported by default setting. The setting can be changed to HART Revision 6 over TROVIS-VIEW. HART tools as well as AMS or handheld communicators are currently not supported by the Revision 6 version. The following additional status indications were implemented: Code 76 - No emergency mode Code 77 - Program loading error Displays number of zero calibrations performed since the last initialization. For initialization of "AIR TO CLOSE" actuators, the direction of action (Code 7) is automatically set to increasing/decreasing. Code 3, the activation period of the enabled configuration function was extended to 120 s. 1.10 1.20 Electronics changed, no new functions added. 1.20 1.30 New EXPERT+ diagnostics functions (Code 48) added Positioner in EXPERT+ version with extended diagnostics features. A running initialization can be canceled by pressing the pushbutton. The position transmitter (Code 37) and solenoid valve (Code 45) options are automatically recognized. 1.30 1.40 All EXPERT+ functions can be used over HART communication in this firmware version and higher.
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/Maintenance demanded condensed status The Function check condensed status is additionally set for Test A1, A2, fault alarm output and position transmitter. The min./max. values of the temperature monitoring can be reset.
1.40
1.41 Internal modifications
1.41
1.42 Internal modifications
EB 8384-3 EN
principle
of
The electropneumatic positioner is mounted to pneumatic control valves and is used to assign the valve position (controlled variable x) to the control signal (reference variable w). The DC control signal received from a control unit is compared to the travel or rotational angle of the control valve and issues a signal pressure (output variable y). The positioner is designed depending on the corresponding accessories for direct attachment to Type 3277 Actuators or for attachment to actuators according to IEC 60534-6 (NAMUR). Additionally, a coupling wheel included in the accessories is required to transfer the rotary motion for rotary actuators according to VDI/VDE 3845. Springless rotary actuators require an accessory reversing amplifier to permit the powered operation in either direction. The positioner basically consists of a travel sensor system that functions proportional to the resistance, an analog i/p module with downstream booster as well as the electronic unit with a microcontroller. The positioner is fitted with three binary contacts as standard: A fault alarm output is used to indicate a fault to the control station and two configurable software limit switches to indicate the valves end positions. The position of the valve is transmitted as linear travel motion or angle of rotation via pick-up lever and travel sensor (2) to an analog PD controller (3). Simultaneously, an A/D converter (4) transmits the position of the valve to the microcontroller (5). The PD
controller compares this actual position to the 4 to 20 mA DC control signal (reference variable) after it has been converted by the A/D converter (4). In case of a system deviation, the operation of the i/p converter (6) is changed so that the actuator (1) is filled or vented via the downstream air capacity booster (7). This causes the closure member of the control valve to move to the position determined by the reference variable. The pneumatic air capacity booster (7) and the pressure regulator (8) are provided with supply air. An intermediate flow regulator (9) with fixed settings is used to purge the positioner and also guarantees trouble-free operation of the pneumatic booster. The output signal pressure supplied by the booster can be limited over the software. The volume restriction Q (10) is used to optimize the positioner by adapting it to the actuator size. Serial interface The positioner is equipped with an interface to allow the SAMSON TROVIS-VIEW Configuration and Operator Interface software to transmit data and parameters over an adapter cable from the RS-232 interface of a computer to the positioner. Refer to section 13. To detect any valve faults at an early stage, the positioner can optionally be equipped with EXPERT+ valve diagnostics. You can access the functions provided by EXPERT+ valve diagnostics over TROVIS-VIEW software and over the DTM file of the device. Refer to Data Sheet T 8388 EN for more details on EXPERT+ valve diagnostics. Instructions on how to operate the software can be found in Operating Instructions EB 8388 EN.
EB 8384-3 EN
1.1
Communication
1.2
Additional equipment
The positioner is equipped with an interface for HART protocol (Highway Addressable Remote Transducer) for communication purposes. Data are transmitted in a superimposed frequency (FSK = Frequency Shift Keying) on the existing signal loop for the 4 to 20 mA reference variable. Either a HART capable handheld communicator or a PC with FSK modem can be used to establish communication and operate the positioner.
As an option, the device can be additionally equipped with a solenoid valve for forced venting, an analog position transmitter, an inductive limit switch or an external position sensor. Version with solenoid valve If the operating voltage for the solenoid valve (12) fails, the supply pressure for the i/p module is vented to the atmosphere. The positioner can no longer operate and the control valve moves to the fail-safe position determined by the actuator, independent of the reference variable.
1 2 3 4 5 6 7 8 9 10 11* 12* 13* 14 15 Control valve Travel sensor PD controller A/D converter Microcontroller i/p converter Air capacity booster Pressure regulator Flow regulator Volume restriction Inductive limit switch Solenoid valve Analog position transmitter Software limit switches Alarm 1/2 Fault alarm output Alarm 3 Display Solenoid valve control Galvanic isolation D/A converter Communication interface HART modulation Optional
Serial 20 Interface 21 FSK
16
mm
13
S
%
A3 15 19 A2 14 A1 14
24V DC
PD
x 17 12 6 9 18 3
11
8 7 Q 10
1 x
Fig. 2 Functional diagram
16 17* 18* 19 20 21 *
EB 8384-3 EN
Positioner with position transmitter The position transmitter (13) is a two-wire transmitter and issues the travel sensor signal as a 4 to 20 mA signal processed by the microcontroller. Since this signal is issued independent of the positioners input signal (min. current 3.8 mA), the actual travel/angle of rotation is controlled in real-time. Additionally, the position transmitter provides the possibility of signaling a positioner fault over a signal current of <2.4 mA or >21.6 mA.
Version with inductive limit switch The rotary shaft of the positioner carries an adjustable tag which actuates the installed proximity switch. The optional inductive limit switch (11) leads to A1 and the software limit switch, which keeps its function, leads to A2. Version with external position sensor In this version, only the sensor is mounted to the control valve. The positioner is located separately from the valve. The connection of x and y signals to the valve is established via cable and piping for air (only without inductive limit switch).
1.3
Technical data
Direct attachment to Type 3277: 3.6 to 30 mm Attachment acc. to IEC 60534-6: 3.6 to 200 mm or 24 to 100 with rotary actuators Adjustable within the initialized travel/angle of rotation; 1 travel can be restricted to 5 at the maximum Signal range 4 to 20 mA, 2-wire unit, reverse polarity protection, min. span 4 mA, static destruction limit 100 mA 3.6 mA for display, 3.8 mA for operation 8.2 V (corresponding to 410 at 20 mA) Supply pressure from 1.4 to 7 bar (20 to 105 psi), Air quality acc. to ISO 8573-1 (2001): Max. particle size and density: Class 4 Oil content: Class 3, pressure dew point: Class 3 or at least 10 K beneath the lowest ambient temperature to be expected 0 bar up to the capacity of supply pressure, limitable to 1.4/2.4/3.7 0.2 bar via software Linear/equal percentage/reverse equal percentage/butterfly valve linear/ butterfly valve eq. percentage/rotary plug valve linear/rotary plug valve eq. percentage/segmented ball valve linear/segmented ball valve eq.percentage Deviation from terminal-based conformity 1 % 0.3 % 0.1 %
Positioner Travel, adjustable Travel range Reference variable w Minimum current Load impedance
Supply air
Signal pressure (output) Characteristic, user-defined adjustable over operating software Hysteresis Sensitivity
10
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Transit time Direction of action Air consumption, steady state Air output capacity Actuator pressurized Actuator vented Permissible ambient temperature Influences Electromagnetic compatability
Separately adjustable up to 240 seconds for supply air and exhaust air Reversible Independent from supply pressure approx. 110 ln/h At p = 6 bar: 8.5 mn3/h, at p = 1.4 bar: 3.0 mn3/h KVmax (20 C) = 0.09 at p = 6 bar: 14.0 mn3/h, at p = 1.4 bar: 4.5 mn3/h KVmax (20 C) = 0.15 20 to +80 C, with metal cable gland 45 to +80 C The limits specified in the EC Type Examination Certificate additionally apply for explosion-protected devices. Temperature: 0.15 %/10 K Supply air: None Vibration: 0.25 % up to 2000 Hz and 4 g acc. to IEC 770 Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21 II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 C or II 3 G EEx nA II T6 / II 3 D IP 65 T 80 C
Explosion protection
IECEx ia IIC T6 / IP 54 and IP 65 T 80 C FM/CSA intrinsically safe Class I, 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 Communication (local) Software requirements Communication (HART)
IP 66 / NEMA 4X SAMSON SSP interface and serial interface adapter TROVIS-VIEW with database module 3730-3 HART field communication protocol Impedance in the HART frequency range: receive 350 to 450 , send: approx. 155 For handheld communicator: device description for 3730-3, For PC: DTM file acc. to Specification 1.2, suitable for integrating the positioner in frame applications that supports the FDT/DTM concept (e.g. PACTware); other integration options (e.g. AMS, PDM) available.
Software requirements (HART) Binary contacts
2 software limit switches, reverse polarity protection, configurable switching characteristics, default settings as per table Signal status: No response: Response: 1 fault alarm contact Signal status: No response/No alarm Response/Fault alarm Operating voltage Without explosion protection: Conductive R = 348 Non-conducting Positioners with model no. ../9000 only for connection to signal converter acc. to EN 60947-5-6. All other versions also for connection to binary input of the PLC acc. to EN 61131, Pmax = 400 mW Exp.-protected version: 2.1 mA 1.2 mA Only for connection to signal converter acc. to EN 60957-5-6 Without explosion protection: Non-conducting Conductive (R = 348 ) Exp.-protected version: 1.2 mA 2.1 mA
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11
Solenoid valve
SIL 4 approval acc. to IEC 61508 24 V DC reverse polarity protection, static destruction limit 40 V; U 5.6 V (corresponding to 4.5 mA at 24 V) 4020
Input
Current consumption I =
Signal Service life Implementation in safety-relevant systems in compliance with IEC 61508 Analog position transmitter Supply voltage Output signal Direction of action Operating range Characteristic Hysteresis and HF influence Other influences Fault indication Inductive limit switch
Signal "0" no pick-up 15 V Signal "1" safe pick-up > 19 V > 5 x 106 switching cycles Probability of failure on demand of safety functions PFD < 2.8 x 107 for a confidence level of 95 %. The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater or equal to 0.99. The valves are therefore suitable for implementation in safety-related systems with a hardware fault tolerance of 1 or 2 up to and including SIL 4. Two-wire transmitter 12 to 30 V DC, reverse polarity protection, static destruction limit 40 V 4 to 20 mA Reversible 0 to 100 % of the travel range, optional also for fault indication over 2.4 or 21.6 mA Linear Same as positioner Same as positioner Can be issued with current signal < 2.4 mA or > 21.6 mA Type SJ 2SN Proximity Switch
For connection to switching amplifier acc. to EN 60947-5-6. Can be used in combination with a software limit switch. External position sensor Nominal travel Cable Adjustable same as positioner 10 m with M12x1 connector, designed for continuous flexing, flame retardant acc. to VDE 0472, reistant to oils, lubricants, coolants as well as other corrosive media Permissible temperature: 60 to +105 C, the limits specified in the EC Type Examination Certificate additionally apply for explosion-protected devices. Vibration immunity: up to 10 g in the range between 10 and 2000 Hz IP 67 Housing: Die-cast aluminum EN AC-AlSi12(Fe) (EN AC 44300) acc. to DIN EN 1706, chromated and powder paint coated Special version: Stainless steel 1.4581 External parts: Stainless steel 1.4571 and 1.4301 Cable gland M20x1.5, black polyamide Approx. 1.0 kg
Ambient conditions Degree of protection
Materials
Weight
12
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Attachment to the control valve Mounting parts and accessories
The positioner can be attached either directly to a SAMSON Type 3277 Actuator or according to IEC 60534-6 (NAMUR) to control valves with cast yokes or rod-type yokes as well as to rotary actuators according to VDI/VDE 3845. For attachment to the various actuators, corresponding mounting parts and accessories are required. These are listed with their order numbers in Tables 1 to 5. On attaching the positioner, it is important to observe the assignment between lever and pin position according to the travels listed in the travel tables. The tables show the maximum adjustment range at the positioner. The travel that can be implemented at the valve is restricted by the pin position used and additionally by the actuator spring compression required. The positioner is standard equipped with the lever M (pin position 35).
Note! If the standard mounted lever M (pin position 35) is replaced, the newly mounted lever must be moved once all the way as far as it will go in both directions to adapt it to the internal measuring lever.
Fig. 3 Lever M with pin position 35
Travel table for direct attachment to Type 3277 Actuator Type 3277-5 and 3277 Actuators Actuator size cm 120 120/240/350 700 Rated travel mm 7.5 15 30 Adjustment range at positioner Min. Travel Max. 5.0 7.0 10.0 25.0 35.4 50.0 Required lever M M M Assigned pin position 25 35 50
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13
Travel table for attachment according to IEC 60534-6 (NAMUR) SAMSON valves cm 60 and 120 with Type 3510 Valve 120 Type 3271 Actuator 120/240/350 700/1400/2800 1400/2800 1400/2800 1400/2800 Rotary actuators Rated travel mm 7.5 7.5 15 15 and 30/30 60 60 120 Other valves/actuators Min. 3.6 5.0 7.0 10.0 14.0 20.0 40.0 Travel Max. 17.7 25.0 35.4 50.0 70.7 100.0 200.0 Required lever S M M M L L XL M Assigned pin position 17 25 35 50 70 100 200 90
Opening angle 24 to 100
Table 1
Direct attachment to Type 3277-5 Actuator, see Fig. 4 1400-7452 1400-6819 1400-6822 1400-6820 1400-6821 1400-6823
Mounting parts For actuators with 120 cm effective diaphragm area Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) Accessories for the actuator Connecting plate for additional attachment of a solenoid valve G 1/8 Connecting plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1/8 NPT Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new)
Note: Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates are not interchangeable.
Connecting plate (6) Accessories for the positioner Table 2 or pressure gauge bracket (7) Pressure gauge mounting kit (8) up to max. 6 bar (output/supply) G : 1400-7461 G : 1400-7458 St. st./Bs: 1400-6950 NPT: 1400-7462 NPT: 1400-7459 St. st./St. st.: 1400-6951
Direct attachment to Type 3277 Actuator, see Fig. 5 Mounting parts for actuators with 240, 350 and 700 cm Required piping with screw fittings for "Actuator stem retracts" or when the top diaphragm chamber is filled with air Connection block with seals and screw Pressure gauge mounting kit up to max. 6 bar (output and supply) cm2 240 350 700 Steel 1400-6444 1400-6446 1400-6448 1400-7453 Stainless steel 1400-6445 1400-6447 1400-6449 NPT: 1400-8812 St.st/St.st.: 1400-6951
Accessories
G : 1400-8811 St.st./Bs: 1400-6950
14
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Table 3 Travel in mm 7.5 5 to 50 14 to 100 40 to 200 30 or 60
Attachment to NAMUR ribs or control valves with rod-type yokes (20 to 35 mm rod diameter) according to IEC 60534-6, see Fig. 6 Lever S Without (lever M on basic model) L XL L For actuators Type 3271-5 with 60/120 cm on Type 3510 Valve (Fig. 7) Actuators from other manufacturers and Type 3271 with 120 to 700 cm Actuators f. other manufacturers and Type 3271, 1400-60 version Actuators from other manufacturers and Type 3271, versions 1400-120 and 2800 cm with 120 mm travel Type 3271, versions 1400-120 and 2800 cm with 30/60 mm travel Order no. 1400-7457 1400-7454 1400-7455 1400-7456 1400-7466 1400-6771
Mounting brackets for Emerson and Masoneilan linear actuators In addition, a mounting kit acc. to IEC 60534-6 is required depending on the travel. See row above. Connecting plate Accessories or pressure gauge bracket (7) Pressure gauge mounting kit up to max. 6 bar (output/supply) Table 4 G : 1400-7461 G : 1400-7458
NPT : 1400-7462 NPT: 1400-7459
St.st./Bs: 1400-6950 St.st./St.st.: 1400-6951
Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 8 and 9 With follower clamp and coupling wheel, CrNiMo steel bracket VDI/VDE 3845 for all sizes of fixing level 2 for Type 3278 Actuator with 160/320 cm2 for Camflex II 1400-7448 1400-7614 1400-9120 1400-9244 1400-9526 1400-9245 NPT: 1400-7462 NPT: 1400-7459
Mounting parts
VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty version Mounting parts for rotary actuators VDI/VDE 3845 (level 1), heavy-duty version SAMSON Type 3278 160 cm / VETEC Type S160 and Type R Connecting plate G : 1400-7461 G : 1400-7458 or pressure gauge bracket (7) Pressure gauge mounting kit up to max. 6 bar (output/supply)
Accessories
St.st./Bs: 1400-6950 St.st./St.st: 1400-6951
Table 5
General accessories Pneumatic reversing amplifier for double-acting actuators Cable gland M20 x 1.5 Nickel-plated brass Adapter M 20 x 1.5 to NPT, aluminum G NPT 1079-1118 1079-1119 1890-4875 0310-2149 1400-7460 German/English (standard) English/Spanish English/French 1990-0761 1990-3100 1990-3142 1400-9318
Accessories
Retrofit kit for inductive limit switch 1x SJ 2-SN Cover plate with list of parameters and operating instructions
EXPERT+ activation code (specify the serial number of the positioner on ordering this option)
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15
2.1
Direct attachment
2.1.1 Type 3277-5 Actuator

Refer to Table 1 on page 14 for the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 13!
Actuator with 120 cm Depending on the type of positioner attachment, the signal pressure is routed either left or right of the yoke through a bore to the actuator diaphragm. Depending on the fail-safe action of the actuator "Actuator stem extends" or "Actuator stem retracts" (valve closes or opens if the supply air fails), the switchover plate (9) must first be attached to the actuator yoke. Align the switchover plate with the corresponding symbol for left or right attachment according to the marking (view looking onto the switchover plate). 1. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges onto the positioner, making sure both seal rings (6.1) are seated properly. 2. Remove screw plug (4) on the back of the positioner and close the signal pressure output "Output 38" on the connecting plate (6) or on the pressure gauge bracket (7) with the stopper (5) included in the accessories. 3. Place follower clamp (3) on the actuator stem, align and screw tight so that the mounting screw is located in the groove of the actuator stem. 4. Mount cover plate (10) with narrow side of the cut-out opening (Fig. 4, on the 5.
6. 7.
8.
left) pointing towards the signal pressure connection. Make sure that the bonded gasket (14) points towards the actuator yoke. 15 mm travel: Keep the follower pin (2) at lever M (1) on the back of the positioner in the pin position 35 (delivered state). 7.5 mm travel: Remove the follower pin (2) from the pin position 35, reposition it in the bore for pin position 25 and screw tight. Insert formed seal (15) in the groove of the positioner casing. Place positioner on the cover plate (10) in such a manner that the follower pin (2) rests on the top of the follower clamp (3). Adjust the lever (1) correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch (Fig. 19). The lever (1) must rest on the follower clamp with spring force. Mount the positioner on the cover plate (10) using the two fixing screws. During the installation make sure that the seal ring (10.1) is inserted in the bore of the intermediate plate. Mount cover (11) on the other side. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off.
16
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1 Symbols Actuator stem extends Attachment left Attachment right Actuator stem retracts Signal pressure input for left attachment Switchover plate (9)
Lever
1.1 Nut 1.2 Disk spring 2 3 4 5 6 Follower pin Follower clamp Screw plug Stopper Connecting plate
6.1 Seal rings 7 Pressure gauge bracket 8 Marking Signal pressure input for right attachment 9 Press. gauge mounting kit Switchover plate for actuator
10 Cover plate 10.1Seal ring 11 Cover
15 14
Lever M
14 Gasket 15 Formed seal
1 2
3 1.1 1.2
Cut-out of cover plate
4 10.1 10 6 9 11
6.1 6 5 Supply 9 Output 38
Note! Always use the connecting plate (6) included in the accessories to connect 7 supply and output. Never screw threaded parts directly 8 into the housing.
Fig. 4 Direct attachment - Signal pressure connection for Type 3277-5 Actuator with 120 cm2
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2.1.2 Type 3277 Actuator

Refer to Table 2 on page 14 or the required mounting parts as well as the accessories with their order numbers. Note the travel table on page 13!
Actuators with 240 to 700 cm The positioner can be mounted either on the left or on the right side of the yoke. The signal pressure is routed to the actuator over the connection block (12), for actuators with fail-safe action "Actuator stem extends" internally through a bore in the valve yoke and for "Actuator stem retracts" through external piping. 1. Place follower clamp (3) on the actuator stem, align and screw tight so that the mounting screw is located in the groove of the actuator stem. 2. Mount cover plate (10) with narrow side of the cut-out opening (Fig. 5, on the left) pointing towards the signal pressure connection. Make sure that the bonded gasket (14) points towards the actuator yoke. 3. For actuators with 700 cm, remove the follower pin (2) at lever M (1) on the back of the positioner from pin position 35, reposition it in the bore for pin position 50 and screw tight. For actuators 240 and 350 cm with 15 mm travel, the follower pin (2) remains in pin position 35. 4. Insert formed seal (15) in the groove of the positioner casing. 5. Place positioner on the cover plate in such a manner that the follower pin (2)
rests on the top of the follower clamp (3). Adjust the lever (1) correspondingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch (Fig. 19). The lever (1) must rest on the follower clamp with spring force. Mount the positioner on the cover plate (10) using the two fixing screws. 6. Make sure that the tip of the gasket (16) projecting from the side of the connection block (12) is positioned above the actuator symbol that corresponds with the actuator with fail-safe action "Actuator stem extends" or "Actuator stem retracts." If necessary, remove the three fixing screws and the cover. Then reposition the gasket (16) turned by 180. The previous version of the connection block (Fig. 5, bottom) requires the switch plate (13) to be turned such that the corresponding actuator symbol points to the marking. 7. Place the connection block (12) with the associated seal rings against the positioner and the actuator yoke. Screw it tight using the fixing screw (12.1). For actuators with fail-safe action "Actuator stem retracts", additionally remove the stopper (12.2) and fit on the external signal pressure piping. 8. Mount cover (11) on the other side. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off.
18
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Lever
12.1 Screw 12.2 Stopper or connection for external piping 13 Switch plate 14 15 16 Gasket Formed seal Gasket
1.1 Nut 1.2 Disk spring 2 Follower pin 3 Follower clamp 10 Cover plate 11 Cover 12 Connection block
15
10 14
11
2
Lever M
Cut-out of cover plate (10)
1.1 1.2
16
Actuator stem retracts extends
16
12
12.1
12.2
SUPPLY
SUPPLY
13 12 Stem retracts
Stem extends Marking
Connection block (old) with switch plate (13)
12 12.1 12.2
Fig. 5 Direct attachment Signal pressure connection for Type 3277 Actuator with 240, 350 and 700 cm
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2.2
Attachment according to IEC 60534-6
The positioner is attached to the control valve with a NAMUR bracket (10).
1. Screw the two bolts (14) to the bracket (9.1) of the stem connector (9), place the follower plate (3) on top and use the screws (14.1) to tighten. Actuator size 2800 cm and 1400 cm (120 mm travel) only: For a travel of 60 mm or smaller, screw the longer follower plate (3.1) directly to the stem connector (9). For a travel exceeding 60 mm, mount the bracket (16) first and then the follower plate (3) to the bracket together with the bolts (14) and screws (14.1). 2. Mount NAMUR bracket (10) to the control valve as follows: For attachment to the NAMUR rib, use an M8 screw (11) and toothed lock washer directly in the yoke bore. For attachment to valves with rod-type yokes, use two U-bolts (15) around the yoke. Align the NAMUR bracket (10) in such a way that the slot of the follower plate (3) is centrally aligned with the NAMUR bracket at mid valve travel. 3. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges
(8) on the positioner, making sure both seal rings (6.1) are seated properly. 4. Select required lever size (1) M, L or XL and pin position according to the actuator size and valve travels listed in the table on page 14. Should you require a pin position other than position 35 with the standard installed lever M, or require a lever size L or XL, proceed as follows: 5. Screw the follower pin (2) in the assigned lever bore (pin position) as listed in the table. Only use the longer follower pin (2) included in the mounting kit. 6. Place lever (1) on the positioner shaft and screw tight using the disk spring (1.2) and nut (1.1).
Note! If you have mounted a new lever (1), you must move it once all the way as far as it will go in both directions.
7. Place positioner on the NAMUR bracket in such a manner that the follower pin (2) rests in the slot of the follower plate (3, 3.1). Adjust the lever (1) correspondingly. Screw the positioner to the NAMUR bracket using both its fixing screws.
20
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Attachment to rod-type yoke Rods with 20 to 35 mm
11 10 9 9.1
Attachment to NAMUR rib
15
3.1 16 Additional bracket for 2 actuators with 2800 cm and travel 60 mm 1 1
Lever XL and L 1 1.1 1.2 2 3 3.1 6 6.1 7 8 9 9.1 10 11 14 Lever Nut Disk spring Follower pin Follower plate Follower plate Connecting plate Seal rings Pressure gauge bracket Pressure gauge mounting kit Stem connector Bracket NAMUR bracket Screw Bolt
14 3 14.1
2 1.1 1.2 1 6.1 6 7 8
14.1 Screw 15 U-bolt 16 Bracket
Note! Always use the connecting plate (6) included in the accessories to connect supply and output. Never screw threaded parts directly into the housing.
Fig. 6 Attachment according to IEC 60534-6 (NAMUR)
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21
2.3
Attachment to Type 3510 Micro-flow Valve
The positioner is attached to the valve yoke using a bracket.
1. Place clamp (3) on the valve stem connector, align at a right angle and screw tight. 2. Screw bracket (10) to the valve yoke using two screws (11). 3. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges to the positioner, making sure both seal rings (6.1) are seated properly. 4. Unscrew the standard installed lever M (1) including follower pin (2) from the positioner shaft. 5. Take lever S (1) and screw follower pin (2) in the bore for pin position 17. 6. Place lever S on the positioner shaft and screw tight using the disk spring (1.2) and nut (1.1). Move lever once all the way as far as it will go in both directions. 7. Place positioner on the bracket (10) in such a manner that the follower pin slides into the groove of the clamp (3). Adjust the lever (1) correspondingly. Screw the positioner to the bracket (10) using both its screws.
22
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1 1.1 1.2 2 3 6 6.1 7 8 10 11
Lever Nut Disk spring Follower pin Clamp Connecting plate Seal rings Pressure gauge bracket Pressure gauge mounting kit Bracket Screw
3 10 11
1.2 6 6.1
Lever S
11 1.1 2 1
Fig. 7 Attachment to Type 3510 Micro-flow Valve
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23
2.4
Attachment to rotary actuators
The positioner is mounted to the rotary actuator using two pairs of double brackets.
Refer to Table 4 on page 15 for the required mounting parts as well as the accessories with their order numbers.
Prior to the attachment of the positioner to the SAMSON Type 3278 Rotary Actuator, you have to mount the associated adapter (5) to the free end of the rotary actuator shaft.
Note! During the installation of the positioner as described below, it is imperative that the actuator's direction of rotation be observed.
1. Place follower clamp (3) on the slotted actuator shaft or the adapter (5). 2. Place coupling wheel (4) with flat side facing the actuator on the follower clamp (3). Refer to Fig. 9 to align slot so that it matches the direction of rotation when the valve is in its closed position. 3. Screw coupling wheel and follower clamp tightly onto the actuator shaft using screw (4.1) and disk spring (4.2). 4. Screw the bottom pair of brackets (10.1) with the bends pointing either to the inside or to the outside (depending on the actuator size) to the actuator case. Position top pair of brackets (10) and screw tight.
5. Mount connecting plate (6) or pressure gauge bracket (7) with pressure gauges to the positioner, making sure both O-rings are seated properly. For double-acting, springless rotary actuators, a reversing amplifier is required to attach the positioner to the actuator, see section 2.5. 6. Unscrew the standard follower pin (2) from the positioner's lever M (1). Use the metal follower pin (5) included in the mounting kit and screw tight into the bore for pin position 90. 7. Place positioner on the top pair of brackets (10) and screw tight. Considering the actuator's direction of rotation, adjust lever (1) so that it engages in the slot of the coupling wheel (4) with its follower pin (see Fig. 9). It must be guaranteed that the lever (1) is parallel to the long side of the positioner when the actuator is at half its angle of rotation. 8. Stick scale plate (4.3) on the coupling wheel so that the arrow tip indicates the closed position, and it can be easily read when the valve is installed.
1.2 1.1 4.1 4.2 5
2 3
Actuator flange
Fig. 8 Mounting the coupling wheel with Type 3278
24
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6.1 6 (7, 8)
10
10.1
1 1.2 1.1 2 4.3 4 5
Control valve opens counterclockwise 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 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
Control valve opens clockwise
Slot
Fig. 9 Attachment to rotary actuators
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25
2.5
Reversing amplifier for double-acting actuators
For the use with double-acting actuators, the positioner must be fitted with a reversing amplifier. The reversing amplifier is listed as an accessory in the Table 5 on page 15. The output signal pressure of the positioner is supplied at the output A1 of the reversing amplifier. An opposing pressure, which equals the required supply pressure when added to the pressure at A1, is applied at output A2. The rule A1 + A2 = Z applies. Mounting 1. Mount the connecting plate (6) from the accessories in Table 5 to the positioner. Make sure that both O-rings (6.1) are seated correctly. 2. Thread the special nuts (1.3) from the accessories of the reversing amplifier into the boreholes of the connecting plate. 3. Insert the gasket (1.2) into the recess of the reversing amplifier and push both the hollowed special screws (1.1) into the connecting boreholes A1 and Z. 4. Place the reversing amplifier onto the connecting plate (6) and screw tight using both the special screws (1.1). 5. Use a screwdriver (8 mm wide) to screw the enclosed filters (1.6) into the connecting boreholes A1 and Z.
Note! The sealing plug (1.5) in the Type 3730 Positioner should not be unscrewed out of the reversing amplifier. The rubber seal (1.4) is not required and can be removed when the sealing plug is used.
Signal pressure connections A1: Output A1 leading to the signal pressure connection at the actuator which opens the valve when the pressure increases A2: Output A2 leading to the signal pressure connection at the actuator which closes the valve when the pressure increases
4 Set slide switch on positioner to

AIR TO OPEN. 6. After the initialization is completed, set Code 16 (Pressure limit) to OFF.
2.5.1 Pressure gauge attachment

The mounting sequence shown in Fig. 10 remains unchanged. Screw a pressure gauge bracket onto the connections A1 and Z. Pressure gauge bracket: G NPT 1400-7106 1400-7107
Pressure gauges for supply air Z and output A1 as listed in Tables 1 to 4.
26
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From the positioner

Output 38 Supply 9
A1
A2
A1
Control signals to the actuator
1.3 A2
1.1 1.2
1.4
1 1.1 1.2 1.3 1.4 1.5 1.6
1.5
1.6
6 Connecting plate 6.1 O-rings 6.2 Screws
6.1
6.2
Reversing amplifer Special screws Gasket Special nuts Rubber seal Sealing plug Filter
Supply 9
Output 38
A1
1.3
1.2
1.1
1.6
Fig. 10 Mounting a reversing amplifier
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27
2.6
Attaching an external position sensor
Refer to Table 6 on page 33 for a list of the mounting parts as well as the accessories required for mounting the position sensor. Accessories for the pneumatic connection to the positioner housing can be found in Table 7.
In the positioner version with an external position sensor, the sensor placed in a separate housing is attached over a plate or bracket to the control valve. The travel pick-off corresponds to that of a standard device. The positioner unit can be mounted as required to a wall or a pipe. For the pneumatic connection either a connecting plate (6) or a pressure gauge bracket (7) must be fixed to the housing, depending on the accessory chosen. Make sure the seal rings (6.1) are correctly inserted (see Fig. 6, bottom right). For the electrical connection a 10 m connecting lead with M12x1 connectors plug is included. Note! In addition, the instructions in section 3.1 and 3.2 apply for the pneumatic and electrical connection. Operation and setting are described in sections 4 and 5.
Fig. 11 Positioner unit with sensor mounted on a micro-flow valve
2.6.1 Mounting the position sensor with direct attachment

Type 3277-5 Actuator with 120 cm The signal pressure from the positioner is routed over the signal pressure connection of the connecting plate (9, Fig. 12 left) to the actuator diaphragm chamber. To proceed, first screw the connecting plate (9) included in the accessories onto the actuator yoke.
4 Turn the connecting plate (9) so that the 4 4
correct symbol for the fail-safe position "Actuator stem extends" or "Actuator stem retracts" is aligned with the marking (Fig. 12, below). Make sure that the gasket for the connecting plate (9) is correctly inserted. The connecting plate has boreholes with NPT and G threads. Seal the threaded connection that is not used with the rubber seal and square plug.
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Type 3277 Actuator with 240 to 700 cm: The signal pressure is routed to the connection at the side of the actuator yoke for the version "Actuator stem extends". For the fail-safe position "Actuator stem retracts" the connection on the top diaphragm case is used. The connection at the side of the yoke must be fitted with a venting plug (accessories). Mounting the position sensor 1. Place the lever (1) on the sensor in mid-position and hold it in place. Unthread the nut (1.1) and remove the lever together with the disk spring (1.2) from the sensor shaft.
1
2. Screw the position sensor (20) onto the mounting plate (21). 3. Depending on the actuator size and rated travel of the valve, determine the required lever and position of the follower pin (2) from the travel table on page 14. The positioner is delivered with lever M in pin position 35 on the sensor. If necessary, remove the follower pin (2) from its pin position and move it to the borehole for the recommended pin position and screw tight. 4. Place the lever (1) and disk spring (1.2) on the sensor shaft.
2 3
11 1.1 1.2 20 21 9
Signal pressure Vent plug 1 1.1 1.2 2 3 9 11 20 21 Lever Nut Disk spring Follower pin Follower clamp Connecting plate Cover Position sensor Mounting plate
Signal pressure
Symbol
Actuator stem extends retracts
Marking
Fig. 12 Mounting for Type 3277-5 Actuator (left) and Type 3277 Actuator (right)
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29
Place the lever (1) in mid-position and hold it in place. Screw on the nut (1.1). 5. Place the follower clamp (3) on the actuator stem, align and fasten it, making sure that the fastening screw rests in the groove of the actuator stem. 6. Place the mounting plate (21) together with the sensor onto the actuator yoke so that the follower pin (2) rests on the top of the follower clamp (3). It must rest on it with spring force. Screw tight the mounting plate (21) onto the actuator yoke using both fixing screws. 7. Mount cover (11) on the other side. Make sure that the vent plug points downwards when the control valve is installed to allow any condensed water that collects to drain off.
20 21 1.1, 1.2 14.1 3 14 9.1
2.6.2 Mounting the position sensor with attachment according to IEC 60534-6
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) on the sensor in mid-position and hold it in place. Unthread the nut (1.1) and remove the lever together with the disk spring (1.2) from the sensor shaft. 2. Screw the position sensor (20) onto the bracket (21). The standard attached lever M with the follower pin (2) at position 35 is designed for 120, 240 and 350 cm actuators with 15 mm rated travel.
1 1.1 1.2 2 3 9 9.1 14 14.1 20 21

2
Lever Nut Disk spring Follower pin Follower plate Stem connector Bracket Bolt Screws Position sensor Bracket
Fig. 13 Mounting according to IEC 60534-6 (NAMUR)
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For other actuator sizes or travels, select the lever and pin position from the travel table on page 14. Lever L and XL are included in the mounting kit. 3. Place the lever (1) and disk spring (1.2) on the sensor shaft. Place the lever (1) in mid-position and hold it in place. Screw on the nut (1.1). 4. Screw both bolts (14) to the bracket (9.1) of the stem connector (9). Attach 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 follower plate (3), then screw the bracket using its fixing screws onto the valve.
Place the lever (1) in mid-position and hold it in place. Screw on the nut (1.1). 4. Place the follower clamp (3) on the stem connector, align it at a right angle and screw tight. 5. Position the bracket (21) with the position sensor on the valve yoke and screw tight, making sure the follower pin (2) slides into the groove of the follower clamp (3).
2.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve

20 21
1.1 1.2
1 1.1 1.2 2 3 20 21
Lever Nut Disk spring Follower pin Follower clamp Position sensor Bracket
1. Place the lever (1) in mid-position and hold it in place. Unscrew the nut (1.1) and remove the standard attached lever M (1) together with the disk spring (1.2) from the sensor shaft. 2. Screw the position sensor (20) onto the bracket (21). 3. Select the lever S (1) from the accessories 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.
1 2
Fig. 14 Mounting a micro-flow valve
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2.6.4 Mounting the position sensor to rotary actuators

1. Place the lever (1) in mid-position and hold it in place. Unscrew the nut (1.1) and remove the standard attached lever 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 attached to the lever (1) with the metal follower pin ( 5) from the accessories and screw it into the hole for pin position 90.
4. Place the lever (1) and disk spring (1.2) on the sensor shaft. Place the lever (1) in mid-position and hold it in place. Screw on the nut (1.1). Follow the instructions describing attachment to the standard positioner in section 2.4 Instead of the positioner, attach the position sensor (20) with its mounting plate (21).
20 21
1.1, 1.2
1 1.1 1.2 2 20 21
Lever Nut Disk spring Follower pin Position sensor Mounting plate
Fig. 15 Positioner unit with sensor mounted on rotary actuators
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Table 6 Direct attachment
Mounting parts for position sensor Mounting parts for actuators with 120 cm see Fig. 12 left Connecting plate (9, old) for Actuator Type 3277-5xxxxxx.00 G 1/8 1/8 NPT
Order no. 1400-7472 1400-6820 1400-6821 1400-6823
Accessories for actuator 120 cm
Connecting plate (new) for Actuator Type 3277-5xxxxxx.01 (new)
Note: Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates are not interchangeable.
Direct attachment NAMUR attachment Attachment to micro-flow valves Mounting parts for actuators with 240, 350 and 700 cm, see Fig. 12 right Mounting parts for attachment to NAMUR rib w. lever L and XL, see Fig. 13 Mounting parts for Type 3510 Micro-flow Valve, see Fig. 14 VDI/VDE 3845 for all sizes of fixing level 2 Mounting parts with follower clamp and coupling wheel CrNiMo steel bracket, see Fig. 15 VDI/VDE 3845 for all sizes of fixing level 2, heavy-duty version SAMSON Type 3278 160 cm2 / VETEC Type S160 and Type R, heavy-duty version Table 7 Postioner accessories Connecting plate (6) or pressure gauge bracket (7) Accessories Pressure gauge mounting kit (8) up to max. 6 bar (output and supply) G NPT G NPT St. steel/Brass St.st./St. steel 1400-7471 1400-7468 1400-7469
1400-7473 1400-9384 1400-9385 Order no. 1400-7461 1400-7462 1400-7458 1400-7459 1400-6950 1400-6951 0309-0111
Bracket to mount the positioner on a wall Note! The other fastening parts are to be provided at the site of installation as wall foundations vary from site to site.
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2.7
Attaching positioners with stainless steel housings
2.8
Air purging function for single-acting actuators
Positioners with stainless steel housings require mounting parts that are completely made of stainless steel or free of aluminum.
The exhaust air from the positioner is diverted to the actuator spring chamber to provide corrosion protection inside the actuator. The following must be observed: Direct attachment to Type 3277-5 (stem extends FA/stem retracts FE) The air purging function is automatically provided. Direct attachment to Type 3277, 240 to 700 cm FA: Remove the stopper 12.2 (Fig. 5 on page 19) at the connection block and make a pneumatic connection to the spring chamber on the vented side. FE: The air purging function is automatically provided. Attachment acc. to IEC 60534-6 (NAMUR rib or attachment to rod-type yokes) and to rotary actuators The positioner requires an additional port for the exhaust air that can be connected over piping. An adapter available as an accessory is used for this purpose: Threaded bushing G (M20 x 1.5): NPT 0310-2619 0310-2550
Note! The pneumatic connecting plate and pressure gauge bracket are available made of stainless steel (order numbers listed below). A stainless steel version of the pneumatic reversing amplifier is not available.
Connecting plate (stainless steel): G NPT 1400-7476 1400-7477 1400-7108
Pressure gauge Only in bracket (st. steel): NPT
The Tables 1 to 5 (pages 14 and 15) apply for attaching positioners with stainless steel housings with the following restrictions: Direct attachment All mounting kits from Tables 1 and 2 can be used. The connection block is not required. The stainless steel version of the pneumatic connecting plate routes the air internally to the actuator. Attachment according to IEC 60534-6 (NAMUR rib or attachment to rod-type yokes) All mounting kits from Table 3 can be used. Connecting plate in stainless steel. Attachment to rotary actuators All mounting kits from Table 4 can be used except for the heavy-duty version. Connecting plate in stainless steel.
Note! The adapter uses one of the M20 x 1.5 connections in the housing which means just one cable gland can be installed.
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Should other valve accessories be used which vent the actuator (e.g. solenoid valve, volume booster, quick exhaust valve), this exhaust air must also be included in the purging function. The connection over the adapter at the positioner must be protected with a check valve mounted in the piping. Otherwise the pressure in the positioner housing would rise above the ambient pressure and damage the positioner when the exhausting components respond suddenly.
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Connections
3 3.1
Connections Pneumatic connections
3.1.1 Signal pressure gauges

To monitor the supply air (Supply) and signal pressure (Output), we recommend that pressure gauges be attached (see accessories in Tables 1 to 5).
Caution! The threads in the positioner housing are not designed for direct air connection!
The screw glands must be screwed into the connecting plate, the pressure gauge mounting block or the connection block from the accessories. The air connections are optionally designed as a bore with NPT or G thread. The customary fittings for metal and copper pipes or plastic hoses can be used.
3.1.2 Supply pressure

The required supply air pressure depends on the bench range and the actuator's operating direction (fail-safe action). The bench range is registered on the nameplate either as spring range or signal pressure range depending on the actuator. die The direction of action is marked FA or FE, or by a symbol. Actuator stem extends FA (Air to open ATO) Fail-safe position "Valve Closed" (for globe and angle valves): Required supply pressure = Upper bench range value + 0.2 bar, minimum 1.4 bar. Actuator stem retracts FE (Air to close ATC)
Note! The supply air must be dry and free from oil and dust. The maintenance instructions for upstream pressure reducing stations must be observed. Blow through all air tubes and hoses thoroughly prior to connecting them.
If the positioner is attached directly to the Type 3277 Actuator, the connection of the positioner's output pressure to the actuator is fixed. For attachment according to IEC 60534-6 (NAMUR), the signal pressure can be routed to either the top or bottom diaphragm chamber of the actuator, depending on the actuator's fail-safe action "Actuator stem extends" or "Actuator stem retracts". For rotary actuators, the manufacturer's specifications for connection apply.
Fail-safe position "Valve Open" (for globe and angle valves): For tight-closing valves, the maximum signal pressure pstmax is roughly estimated as follows: d2 p [bar] 4A
pstmax = F +
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Connections
d = Seat diameter [cm] p = Differential pressure across the valve [bar] A = Actuator diaphragm area [cm] F = Upper bench range of the actuator [bar] If there are no specifications, calculate as follows: Required supply pressure = Upper bench range value + 1 bar
Note! The signal pressure at the output (Output 38) of the positioner can be limited to 1.4, 2.4 or 3.7 bar over Code 16 or the pressure limit can be deactivated (MAX).
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Connections
3.2
Electrical connections
For electrical installation, you are required to observe the relevant electrotechnical regulations and the accident prevention regulations that apply in the country of use. In Germany, these are the VDE regulations and the accident prevention regulations of the employers' liability insurance association.
The following standards apply for assembly and installation in hazardous areas: EN 60079-14: 2003 (VDE 0165 Part 1/ 8.98) "Electrical apparatus for explosive gas atmospheres" and EN 50281-1-2: 1999 (VDE 0165 Part 2/11.99) "Electrical apparatus for use in the presence of combustible dust". For the interconnection of intrinsically safe electrical equipment, the permissible maximum values specified in the EC type examination certificate apply (Ui or Uo; Ii or Io; Pi or Po; Ci or Co, and Li or Lo). The following applies for equipment with type of protection EEx nA (non-sparking apparatus) according to the standard EN 50021 (1999): Connecting, interrupting, or switching circuits while energized is only allowed during installation, maintenance or repair work. The following applies for equipment connected to energy-limited circuits with type of protection EEx nL (energy-limited apparatus) according to the standard EN 50021 (1999): This type of equipment may be switched under normal operating conditions.
For the interconnection of equipment to energy-limited circuits with type of protection EEx nL IIC, the permissible maximum values specified in the statement of conformity or the addenda to the statement of conformity apply. Caution! The terminal assignment specified in the certificate must be adhered to. Reversing the assignment of the electrical terminals may cause the explosion protection to become ineffective! Do not tamper with enameled screws inside or on the housing. Note on the selection of cables and wires: To install intrinsically safe circuits, observe section 12 of the standard EN 60079-14: 2003 (VDE 0165 Part 1). To run multi-core cables or lines with more than one intrinsically safe circuit, section 12.2.2.7 of this standard applies. An additional cable gland can be installed when connecting the device over two separate cables. Cable entries left unused must be sealed with blanking plugs. Devices used at ambient temperatures down to 20 C must have metal cable entries.
Cable entries The cable entry with M20 x 1.5 cable gland, 6 to 12 mm clamping range. There is a second M20 x 1.5 threaded bore in the housing that can be used for additional connection, when required. The screw terminals are designed for wire cross-sections of 0.2 to 2.5 mm. Tighten by at least 0.5 Nm.
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Connections
The wires for the reference variable must be connected to the terminals 11 and 12 located in the housing. Only use a current source! If the reference variable exceeds 22 mA, OVERLOAD appears on the LC display to warn the user.
Caution! The erroneous connection of a voltage source of just around 7 V (or around 2 V when connected to the wrong pole) can damage the positioner.
In general, it is not necessary to connect the positioner to a bonding conductor. Should this be required, however, this conductor can be connected inside the device. Depending on the version, the positioner is equipped with inductive limit switches and/or a solenoid valve.
The position transmitter is operated on a two-wire circuit. The usual supply voltage is 24 V DC. Considering the resistance of the supply leads, the voltage at the position transmitter terminals can be between 12 V and 30 V DC. Refer to Fig. 16 or the label on the terminal strip for terminal assignment. Note! The minimum permissible reference variable should not fall below 3.8 mA for operating the positioner. Accessories: Plastic cable gland M20 x 1.5: Black Order no. 8808-1011 Blue Order no. 8808-1012 Nickel-plated brass Order no. 1890-4875 Adapter M20 x 1.5 to NPT Aluminum, powder-coated Order no. 0310-2149
Optional
Optional
A3
A2
A1
+81 -82
+11 -12
+83 -84
+51 -52
+41 -42
+31 -32 A
Switching amplifier acc. to EN 60947-5-6 24 V DC solenoid valve mA Control signal A3 Fault indication Limit switches A2 A1 Software Software or inductive
2-wire transmitter supply unit for optional position transmitter only
Fig. 16 Electric connections
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Connections
3.2.1 Switching amplifiers

For operation of the limit switches, switching amplifiers must be connected in the output circuit. To ensure the operating reliability of the positioner, the amplifiers should comply with the limit values of the output circuits conforming to EN 60947-5-6. If the positioner is to be installed in hazardous areas, the relevant regulations must be observed.
3.2.2 Establishing communication

Communication between PC and positioner (via FSK modem or handheld communicator, if necessary, using an isolation amplifier) is based on the HART protocol. Type Viator FSK modem RS 232 EExia Order no. 8812-0129 RS 232 not ex Order no. 8812-0130 PCMCIA not ex Order no. 8812-0131 USB not ex Order no. 8812-0132 If the supply voltage of the controller or control station becomes too low because it has been reduced by the load in the circuit, an isolation amplifier is to be connected between controller and positioner (interfacing
Connection in non-hazardous area
Handheld communicator or second FSK modem 4 to 20 mA

3730-30
Controller/control station
Hazardous area Connection in hazardous area Safe area

3730-31
Ex isolating amplifier
Handheld communicator or second FSK modem (explosion-protected)
Fig. 17 Connection with a FSK modem
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Connections
as for positioner connected in hazardous areas, see Fig. 17). If the positioner is used in hazardous areas, an explosion-protected isolation amplifier is to be used. By means of the HART protocol, all control room and field devices connected in the loop are individually accessible through their address via point-to-point or standard bus (Multidrop). Point-to-point: The bus address/polling address must always be set to zero (0). Standard bus (Multidrop): In the standard bus (Multidrop) mode, the positioner follows the analog current signal (reference variable) as for point-to-point communication. This operating mode is, for example, suitable for split-range operation of positioners (series connection). The bus address/polling address has to be within a range of 1 to 15. Note: Communication errors may occur when the process controller/control station output is not HART-compatible. For adaptation, the Z box (order no. 1170-2374) can be installed between output and communication interface. At the Z box a voltage of 330 mV is released (16.5 at 20 mA). Alternatively, a 250- resistor can be connected in series and a 22-F capacitor can be connected in parallel to the analog output. Note that in this case, the controller output load will increase.
22 F
250
Fig. 18 Adapting the output signal
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Operation
Operation
Note! A summary about operating and start up can be found in section 8 on page 66. A leaflet including the same summary is also enclosed with the positioner.
The switch position is prompted prior to an initialization. After an initialization has been completed, changing the switch position does not have any effect on the operation of the positioner. Volume restriction Q The volume restriction is used to adapt the air delivery to the actuator size. Two fixed settings are possible depending on how the air is routed at the actuator (section 5.2 in page 47). Displays A self test is performed automatically (tEStinG runs across the display) when the positioner starts up for the first time after the electrical auxiliary power has been connected. Symbols appear on the LC display that are assigned to parameters, codes, and functions. The bar graph in the operating modes Manual and Automatic indicates the system deviation that depends on the sign (+/) and the value. One bar graph element appears per 1 % system deviation. If the device has not yet been initialized (see section 4.3.1), the lever position in degrees in relation to the longitudinal axis is indicated instead of the system deviation. One bar graph element corresponds to approximately a 5 angle of rotation. If the fifth element blinks (value displayed > 30), the permissible angle of rotation has been exceeded. Lever and pin position must be checked.
4.1
Operator controls and display
Rotary pushbutton The positioner is mainly operated with the rotary pushbutton. Turn the button to select and set codes, parameter and values. Press it to confirm them. Slide switch AIR TO OPEN or AIR TO CLOSE
4 AIR TO OPEN applies when the increasing signal pressure opens the valve 4 AIR TO CLOSE applies when the increasing signal pressure closes the valve The signal pressure is the air pressure at the output of the positioner which is transferred to the actuator. For positioners with an attached reversing amplifier for double-acting rotary actuators (section 2.5): switch position AIR TO OPEN. For checking purposes: After successfully completing initialization, the positioner display should read 0 % when the valve is closed and 100 % when the valve is open. If this is not the case, change the slide switch position and re-initialize the positioner.
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Operation
Displays and their meaning
AUO CL CCL Err ESC HI LO LOW MAN
Automatic mode Clockwise Counterclockwise Error Escape ix greater than 21.6 mA ix smaller than 2.4 mA w too low Manual mode
MAX NO NOM ON OVERLOAD OFF RES RUN SAFE
Maximum range Not available Nominal travel ON w > 22 mA OFF Reset Start Fail-safe position
SUb tEStinG TunE YES ZP
Substitute calibration Test function active Initialization in progress Available Zero calibration Increasing/increasing Increasing/decreasing
Blinking Controlled operation Blinking Not initialized
Failure/fault Manual operation Control operation Code Bar graph for system deviation or lever position
Designation Position Parameter
Limit switch Alarm 1
Configuration enabled Initialization key
Fig. 19 Display and controls
mm
Units Limit switch Alarm 2
mm
S
Maintenance required/ Maintenance demanded
Fail-safe position active Metal tag of proximity switch SSP interface

SERIAL INTERFACE
Cap or rotary switch
Switch for fail-safe action of the actuator
INIT
CAUTION VALVE ACTUATES
AIR TO OPEN
CLOSE
mm
mm
Volume restriction
MIN BACK MAX SIDE MAX BACK MIN SIDE
Rotary pushbutton
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Operation
4.2
Enabling and selecting parameters
The codes which are marked with an asterisk (*) in section 12 on page 71 onwards must be enabled with Code 3 before the associated parameters can be configured as described below.
Code 3 Configuration not enabled
Note! To cancel a value that you have just entered under a code, turn the button until ESC appears on the display and press to confirm.
Canceling the setting
Configuration enabled
Note! If no settings are entered within 120 seconds, the enabled configuration function becomes invalid and the display resets to Code 0.
The code list on page 71 onwards in section 12 shows all parameters that can be adjusted, including their description and their default settings.
4 From the current display, turn the rotary
pushbutton until Code 3 and OFF appear on the display. Confirm Code 3 by pressing the button, the code number blinks.
4 Turn
button until ON appears. Confirm setting by pressing the button.
Configuration is enabled and is indicated by symbol appearing on the display. Now you can adjust the codes, parameters and values for the control valve in any desired order by turning the button. Confirm settings by pressing the button.
Note! After attaching the positioner to the valve as well as setting the fail-safe position and the volume restriction, it is sufficient for standard operation to press the initialization key in order to ensure optimum positioner operation (section 5.6 on page 49). For this purpose, the positioner must be operated with its default values. If necessary, a reset must be carried out (section 5.9 on page 59).
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Operation
4.3
Operating modes
Switching to manual operating mode Over Code 0, press the button, AUtO appears in the display, Code 0 blinks. Turn button until MAN appears.
4.3.1 Automatic and manual operating modes

Prior to initialization: If the positioner has not been initialized yet, the automatic operating AUtO cannot be selected. The valve can only be positioned manually with the positioner. To proceed, turn button clockwise until Code 1 appears, then confirm Code 1 by pressing the button.
Press button to switchover to the manual operating mode . The switchover is smooth since the manual operating mode starts up with the set point last used during automatic operating mode. The current position is displayed in %. Adjusting the manual set point
If both the code number and the hand symbol are blinking, the valve can be manually positioned by turning the button. After initialization: After successful initialization in the MAX, NOM or MAN mode (section 5.6.1), the positioner is in the automatic control operation mode . Turn
button until Code 1 appears.
Default
Press button to confirm, Code 1 blinks. While Code 1 is blinking, you can move the valve to the position required by turning the button. To proceed, turn the button until enough the positioner has built up enough pressure and the control valve starts to react. The positioner automatically returns to manual mode with Code 0 if the button is not activated within two minutes. Switching from manual to automatic operating mode works in the same manner. First, you must reset the positioner to Code 0 and set it to automatic mode AUtO and confirm.
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Start-up and settings
4.3.2 SAFE Fail-safe position

If you want to move the valve to fail-safe position, proceed as follows: Select Code 0, press the button, AUtO or MAN appears on the display, Code 0 blinks. Turn the button until SAFE appears.
Note! A summary about start-up and operation can be found in section 8 on page 66. A leaflet including the same summary is also enclosed with the positioner.
4 Connect pneumatic supply air 4 4
Press the
button to confirm this setting.
(Supply 9), making sure the pressure is correct as described in section 3.1. Apply an electrical reference variable of 4 to 20 mA (terminals 11 and 12). The voltage supply >19 V DC for version with a solenoid valve must be connected at terminals 81 (+) und 82 ().
Operating mode SAFE has been selected, symbol S for the fail-safe position appears. Caution! The valve moves to the fail-safe position.
Once the positioner is initialized, the current valve position is indicated on the digital display in %. 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.
Warning! The signal pressure supplied may cause the actuator stem to move. Risk of injury! Note! The positioner performs a test in the start-up phase while following its automation task at the same time. During the start-up phase, operation on site is unrestricted, yet write access is restricted.
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5.1
Determining the fail-safe position
The SIDErestriction position always applies for actuators from other manufacturers.
Overview Position of the volume restriction Q* Signal pressure Transit time <1s MIN SIDE MIN BACK 1 s MAX SIDE MAX BACK
To adapt the positioner to the operating direction of the actuator, set slide switch to AIR TO OPEN or AIR TO CLOSE. AIR TO OPEN = Signal pressure opens the valve, for fail-safe position: actuator stem extends/valve closed AIR TO CLOSE = Signal pressure closes the valve, for fail-safe position: actuator stem retracts/valve open. The switch position is prompted prior to an initialization. After an initialization has been completed, changing the switch position does not have any effect on the operation of the positioner.
Connection at the side Connection at the back
* Intermediate positions are not permitted.
Note! The positioner needs to be initialized again after the position of the restriction has been changed.
5.3
Adapting the display
5.2
Setting the volume restriction Q
The data representation on the positioner display can be turned by 180. If the displayed data appear upside down, proceed as follows:
Reading direction for right attachment of pneumatic connections
The volume restriction Q is used to adapt the air delivery to the size of the actuator:
4 Actuators with a transit time < 1 s, e.g. 4
linear actuators with an effective area smaller than 240 cm, require a restricted air flow rate (MIN). Actuators with a transit time 1 s do not require the air flow rate to be restricted (MAX).
Reading direction for left attachment of pneumatic connections
4 The SIDE position applies for actuators 4 4

with a loading pressure connection at the side, e.g. Type 3271-5. The BACK position applies for actuators with a loading pressure connection at the back, e.g. in Type 3277-5.
The position of volume restriction Q also depends on how the signal pressure is routed at the actuator in SAMSON actuators:
4 Turn the
button until Code 2 appears, and press the button to confirm Code 2, Code 2 blinks. Turn button until the display is adjusted to the desired direction, then confirm reading direction by pressing the button.
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5.4
Limiting the signal pressure
If the maximum actuator force may cause damage to the valve, the signal pressure must be limited. Select Code 3 to enable configuration and then access Code 16 to set the pressure limit to 1.4, 2.4 or 3.7 bar. The required signal pressure limit is only automatically recognized on initialization when the fail-safe position AIR TO OPEN is set.
5.5
Checking the operating range of the positioner
To check the mechanical attachment and the proper functioning, the valve should be moved through the operating range of the positioner in the manual operating mode with the manual reference variable.
Code 0 Select manual operation Default MAN
3. Turn the button until Code 1 appears, confirm Code 1 by pressing button. The hand symbol and Code 1 blink. 4. Position control valve by turning the button several times until pressure builds up, and the control valve moves to its final positions so that the travel/angle of rotation can be checked. The permissible range has been exceeded when the displayed angle is higher than 30, and the outer right or left bar graph element blinks. If this is the case, it is absolutely necessary to check lever and pin position as described in section 2.
Note! If the selected pin position is smaller than intended for the respective travel range, the positioner switches to the SAFE mode, the valve moves to the fail-safe position (see section 4.3.2 on page 44).
5. Initialize positioner as described in section 5.6.
Code 1 Position valve using the rotary pushbutton, the current angle of rotation is indicated
1. Turn the button until Code 0 appears, then confirm Code 0 by pressing the button. 2. Turn the button until MAN appears in the display, i.e. manual operating mode, confirm selected operating mode by pressing the button.
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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 = 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.
5.6
Initialization
During initialization the positioner adapts itself optimally to the friction conditions and the signal pressure demand of the control valve. The type and extent of self-adaptation depends on the set initialization mode (see section 5.6.1). MAX is the default setting for initialization based on the maximum nominal range. If configuration is enabled via Code 3, Code 6 can be used to change to other initialization modes. If the positioner has been initialized once already, it will automatically go to the operating mode used last after the electrical reference variable is applied, Code 0 appears on the display.
On initializing the positioner for the first time, the hand symbol appears on the display.
Note! Every time you re-initialize the positioner, it should be reset to its basic setting including the default values. Refer to section 5.9 on page 59.
4 Start the initialization process by pressing the INIT key with a suitable tool. The time required for an initialization process depends on the transit time of the actuator and take several minutes. Positioners with EXPERT+ diagnostic functions start plotting the reference graphs after
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the initialization process has been completed. See note at the end of this section.
The control position in % predetermined by the reference variable appears on the display. A malfunctioning leads to the process being interrupted. The initialization error appears on the display according to how it has been classified by the condensed status. See section 5.7 on page 57. If the slide switch is set to AIR TO CLOSE, the positioner automatically switches to the direction of action increasing/decreasing () on successful completion of initialization. This results in the following assignment between reference variable and valve position:
Fail-safe position Actuator stem extends FA AIR TO OPEN Actuator stem retracts FE AIR TO CLOSE Direction of action Valve Closed at Open at 4 mA 20 mA
Warning! During the initialization, the control valve moves through its entire travel/angle of rotation range. Therefore, do not start initialization while a process is running, but only during start-up, when all shut-off valves are closed. Note! The initialization procedure can be interrupted while running by pressing . StOP appears three seconds long and the positioner then moves to the fail-safe position.
Alternating displays Initialization running
20 mA
4 mA
Bar graph display indicating the progress of the initialization
The tight-closing function is activated. Set Code 15 (final position w>) to 99 % for three-way valves. Further settings relevant for the valve can be entered subsequently. Note! Positioner with integrated EXPERT+ diagnostics automatically start to plot the reference graphs (drive signal y d1 and hysteresis d2) after initialization has been completed. TEST d1 and d2 appear on the display in an alternating sequence. An unsuccessful plotting of the reference graphs is indicated on the display by Code 81 (see error code list).
Initialization successful, positioner in automatic operating mode
After a successful initialization, the positioner runs in control operation indicated by the control symbol.
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After the initialization has been successfully completed, the positioner still works properly, even though the reference graph plotting has not been completed successfully. The reference graphs are required for the extended diagnostic functions of EXPERT+.
After enabling:
Default MAX
5.6.1 Initialization modes

After enabling configuration with Code 3 and accessing Code 6, you can choose one of the initialization modes MAX, NOM, MAN or SUb to start initialization. ZP, the zero calibration is described in section 5.8 on page 58. MAX Initialization based on maximum range Initialization mode for simplified start-up for valves with two clearly defined mechanical travel stops, e.g. three-way valves. The positioner determines travel/angle of rotation of the closing member from the CLOSED position to the opposite side and adopts this travel/angle of rotation as the operating range from 0 to 100 %. Enable configuration:
Turn turn
Code 6, press MAX, press .
4 Press INIT key to start initialization!

The initialization procedure may take several minutes, depending on the actuator size, as the valve moves through its entire travel/angle of rotation range.
Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. See the note on page 50.
Note! For MAX initialization, the positioner cannot indicate nominal travel/angle of rotation in mm/, Code 5 remains disabled. In addition, the lower (Code 8) and the upper (Code 9) x-range value can only be displayed and modified in %. During MAX initialization, an increased system deviation (undefined final position of the actuator) in the upper control range may occur with some control valves due to the pneumatic actuator design.
Default OFF
Turn turn
Code 3, press ON, press .
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If you want the display to indicate mm/, proceed as follows after configuration has been enabled: Turn Code 4, press , turn Select pin position entered during installation, press . If you now switch to Code 5, the nominal range appears in mm/. The lower and upper x-range values for Code 8 and 9 are displayed in mm/ and can be adapted accordingly. NOM Initialization based on nominal range Initialization mode for globe valves, especially for valves with maximum ranges that are clearly greater than the required nominal range. For this initialization mode, the following parameters must be entered: pin position (Code 4), nominal travel/angle (Code 5) and, if required, the direction of action (Code 7). The calibrated sensor enables the effective valve travel to be preset very accurately. During the initialization procedure, the positioner checks whether the control valve 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 lower x-range and upper x-range values as the operating range.
Note! The maximum possible travel must always be greater than the nominal travel entered. If this is not the case, the initialization is interrupted (error indication Code 52) because the nominal travel is not achieved.
Enable configuration:
Default OFF
Turn turn
After enabling:
mm
Default OFF
Turn
Code 4, press
turn Select pin position entered during installation, press .
mm
Default 15
Turn turn press
Code 5, press .
Enter nominal valve travel,
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Default MAX
it as the operating range with the lower x-range value and upper x-range value being the limits. Enable configuration:
Turn turn
Code 6, press NOM, press .
,
Default OFF

Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. See note on page 50. MAN Initialization based on a manually selected range (with default upper x-range value by means of manual adjustment). Initialization mode just as NOM, however, for starting up valves with unknown nominal range. In this mode, the positioner expects the control valve to be moved manually to the desired OPEN position prior to enabling the initialization procedure. The upper range travel/angle of rotation value is adjusted using the rotary pushbutton. The positioner uses this OPEN position and the CLOSED position to calculate the differential travel/angle and accepts
Turn turn Turn
After enabling: Code 4, press , turn Select pin position entered during installation, press . Turn turn Code 6 , press MAN, press . ,
Default MAX
Turn turn
Code 0, press MAN, press .
Default MAN
Turn Code 1, press Code 1 blinks.
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sure signal which is routed to the actuator externally. The blocking position ensures that the plant continues to operate with this valve position. The spare positioner should not be initialized. If necessary, reset the spare positioner using Code 36. After the old positioner has been replaced with a new one, the following parameters must be entered: pin position (Code 4), nominal range (Code 5), direction of action (Code 7) and closing direction (Code 34). The default travel limit of 100 % (Code 11) must be disabled with OFF. In addition, the blocking position (Code 35) must be adjusted with the button so that it matches the position of the previously blocked valve. The parameters KP (Code 17), TV (Code 18) and the pressure limit (Code 16) should remain set to their default values. If the configuration data of the new positioner are known, it is recommended to accept its KP and TV values. After setting the AIR TO OPEN/CLOSE switch for the fail-safe position, setting the volume restriction and pressing the INIT key, the positioner calculates its configuration data on the basis of the blocking position and the closing direction as well as the other entered data. The positioner switches to manual operation, subsequently the blocking position should be canceled as described on page 56.
Turn until the valve reaches its OPEN position, press .

Positioners with EXPERT+ diagnostic functions automatically start plotting the reference graphs after the initialization process has been completed. See note on page 50. SUb (substitute configuration, without initialization) This initialization mode is an emergency mode. The positioner parameters are estimated and not determined by an initialization procedure, so that a high stationary accuracy cannot be expected. You should always select a different initialization mode if the plant allows it. The initialization mode SUb is used to replace a positioner while the process is in operation. For this purpose, the control valve is usually fixed mechanically in a certain position, or pneumatically by means of a pres-
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Enable configuration:
Default Default OFF
Turn Turn turn Code 3, press ON, press . ,
Code 7, press
turn Retain direction of action or select . Press .
After enabling:
mm
Default OFF
Default 100.0
Turn
Code 4, press
Turn turn press
Code 11, press .
press Select pin position entered during installation, press .
Deactivate travel limit,
Default OFF
mm
Default 15
Turn Turn turn press Code 5, press . , Enter nominal travel/angle,
Code 16,
Retain default value for pressure limit, change value only if necessary.
Default 7 Default MAX
Turn Turn turn Code 6, press SUb, press . ,
Code 17
Retain default. Proceed as follows only if known: Press ,
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turn press
Select KP, .
4 Set switch for fail-safe position AIR TO 4 Set volume restriction as described in
section 5.2 on page 45.
OPEN or AIR TO CLOSE as described in section 5.1 on page 44.
Default 2
Turn
Code 18,
4 Press INIT key!

The positioner switches to manual operating mode!
Retain default TV, change only if known.
Default CCL The adjusted blocking position is indicated
mm
Turn turn
Code 34, press
, As initialization has not been carried out completely, the error code 76 (no emergency mode) and possibly also error code 57 may appear on the display. These alarms do not influence the positioners readiness for operation. Canceling the blocking position For the positioner to follow its reference variable again, the blocking position must be canceled and the positioner must be set to automatic operation AUtO as follows: Press Code 1, press , , turn in order to move the valve slightly past the blocking position, then cancel mechanical blocking. Press . , Turn Code 0, press Code 0 blinks.
Select closing direction.
CCL = counterclockwise and CL = clockwise.

Direction of rotation which causes the valve to move to the CLOSED position (view onto the rotary switch movement while positioner cover is open). Press .
mm
Default 0.0
Turn
Code 35, press
turn Enter blocking position, e.g. 5 mm (read off at travel indicator scale of the blocked valve or measure with a ruler). Press .
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Turn Press
until AUtO appears on the display. to confirm the operating mode.
5.7
Fault/failure
The positioner switches to automatic operating mode! The current valve position is indicated in %.
All status and fault alarms are assigned a classified status in the positioner. To provide a better overview, the classified alarms are summarized in a condensed status for the positioner (see section 6). The condensed status appears on the display with the following symbols:
Condensed status Maintenance alarm Maintenance requested/Maintenance demanded Function check No alarm Text Display
Note! If the positioner shows a tendency to oscillate in automatic operating mode, the parameters KP and TV must be slightly corrected. Proceed as follows: Set TV to 4 (Code 18). If the positioner still oscillates, the gain KP (Code 17) must be decreased until the positioner shows a stable behavior.
Zero point correction Finally, if process operations allow it, the zero point must be adjusted according to section 5.8 on page 58.
Caution! The positioner automatically moves to zero point.
If the positioner has not been initialized, the fault symbol appears on the display as the positioner cannot follows its reference variable. Additionally, a signal is issued over the fault alarm contact when certain faults occur (see error code list). To access the error codes, turn the button past the Code 50. Err appears on the display with the respective error code. For the cause of the fault and its remedy, refer to the codes listed in section 12 on page 71 onwards.
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5.8
Display indicating an error code
Zero calibration
After an error code has occurred, you should first try to confirm it as follows: Enable configuration: Turn turn Code 3 , press ON, press . ,
In case of discrepancies with the closing position of the valve, e.g. with soft-sealed plugs, it may become necessary to recalibrate the zero point. Enable configuration:
Default OFF
Turn until the error code number appears, then press to confirm it. Should the error occur again, read the remedy instructions in the error code list. Occurrences such as when the total valve travel is exceeded or when the temperature leaves the permissible temperature range affect the condensed state and cause a fault alarm to be displayed depending on its classification. The optional EXPERT+ diagnostics generates additional diagnostic alarms which are included in the condensed status with their corresponding status classification. When a diagnostic alarm is issued by EXPERT+, this is displayed by Code 79 (see error code list).
Turn turn
After enabling:
Default MAX
Turn turn
Code 6, press ZP, press .
4 Press INIT key!

Zero calibration is started, the positioner moves the control valve to the CLOSED position and readjusts the internal electrical zero point.
The valve briefly moves from the current travel/angle of rotation position to the closed position.
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5.9
Reset to default values
This function resets all parameters to the factory default values (see code list in section 12). Enable configuration:
5.10 Start-up via local interface (SSP)

The positioner must be supplied with at least 4 mA. The positioner can be connected directly to the PC via the local serial interface and the serial interface adapter. Use the TROVIS-VIEW software with 3730-3 device module installed. Refer to section 13 for more details. For start-up and settings, proceed as described in section 5, 5.1 to 5.4 and then proceed as described in section 13.
Default OFF
Turn turn
After enabling:
Default OFF
Turn turn
Code 36, press RUN, press .
Note! Depending on the firmware installed in the positioner, a certain minimum version of the TROVIS-VIEW device module is required for communication. If you have already installed the software, you can download updates at www.samson.de (Support & Downloads TROVIS VIEW Updates).
All parameters are reset and can be reconfigured.
5.11 Start-up over HART communication
The positioner must be supplied with at least 4 mA current. The FSK modem must be connected in parallel to the current loop. A DTM file (Device Type Manager) conforming to the Specification 1.2 is available for communication. This allows the device, for example, to be run with the PACTware operator interface. All the positioner's parameters are then accessible over the DTM and the operator interface.
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Status and diagnostic alarms
For start-up and settings, proceed as described in section 5, 5.1 to 5.4. Refer to the code list in section 12 as well as section 13.4 for the parameters necessary for the operator interface.
The Type 3730-3 Positioner contains an integrated diagnostic approach to generate classified status and diagnostic alarms. There are two different on-board diagnostics available: the standard integrated diagnostics (EXPERT) and the optional extended EXPERT+ diagnostics.
Note! The write access for HART communication can be disabled over Code 47. You can only disable or enable this function locally at the positioner. The write access is enabled by default. The on-site operation including the INIT key can be locked over HARTcommunication. The word "HART" then blinks on the display when Code 3 is selected. This locking function can only be disabled over HART communication. On-site operation is enabled by default.
Note! In the case, complex functions are started in the positioner, which require a long calculation time or lead to a large quantity of data being stored in the volatile memory of the positioner, the alert busy is issued by the DTM file. This alert is not a fault alarm and can simply be confirmed.
6.1
Standard EXPERT diagnostics
The standard EXPERT diagnostics provides information about positioner states such as operating hours counter, process monitoring, number of zero calibrations and initializations, total valve travel, temperature, initialization diagnostics, zero/control loop errors, logging of the last 30 alarms, etc. In addition, the standard EXPERT diagnostics generates diagnostic and status alarms which allow faults to be pinpointed quickly when a fault occurs. Alarms are classified in the following main groups:
4 Status 4 Operation 4 Hardware 4 Initialization 4 Data memory 4 Temperature
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6.2
Extended EXPERT diagnostics
In addition to the standard EXPERT diagnostic features, the optional EXPERT+ extended diagnostics provides the following online and offline test functions which enable significant statements on the condition of the entire control valve. Online test functions (monitoring functions)
the positioner. Additionally, it is possible to activate EXPERT+ at a later point in time in an existing positioner. For this purpose, an activation code can be ordered, specifying the serial number of the positioner.
6.3
Classification of the status alarms and the condensed status
4 Data logger 4 Histogram 4 Cycle counter 4 Valve end position trend 4 Y = f (X) diagram (drive signal) 4 Hysteresis test
Offline test functions (manual functions)
The alarms are assigned a classification status in the positioner. The following states are differentiated between: Maintenance alarm The positioner cannot perform its control task due to a functional fault in the device or in one of its peripherals or an initialization has not yet been successfully completed. Maintenance required The positioner still performs its control task (with restrictions). A maintenance demand or above average wear has been determined. The wear tolerance will soon be exhausted or is reducing at a faster rate than expected. Maintenance is necessary in the medium term. Maintenance demanded The positioner still performs its control task (with restrictions). A maintenance demand or above average wear has been determined. The wear tolerance will soon be exhausted or is reducing at a faster rate than expected. Maintenance is necessary in the short term.
4 Y = f (X) diagram over the entire valve 4 Hysteresis test over the entire valve travel 4 Static characteristic 4 Step response test
The diagnostic tests are completely integrated in the positioner. Further status alarms are generated from the extensive information gained in the diagnostic tests of EXPERT+ which provide the user with information covering the whole control valve. The required reference curves are automatically plotted after initialization and saved in the positioner if EXPERT+ is activated. The optional diagnostic functions provided by EXPERT+ can be selected when ordering range travel range
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Function check Test or calibration procedures are being performed. The positioner is temporarily unable to perform its control task until this procedure is completed. Classification process in the positioner An alarm is assigned to one of following classified states in the table:
Status alarm Alarm inactive Alarm active Classified as No alarm Alarm active Classified as Maintenance required/ Maintenance demanded Alarm active Classified as Function check Alarm active Classified as Maintenance alarm Engineering tool
Condensed status To provide a better overview, the state of the positioner is summarized in a condensed status which is made up from a summary of all classified positioner alarms. If an event is classified as No alarm, this event does not have any affect on the condensed status of the positioner. The condensed status is displayed in the engineering tool as well as on the positioner display as in the following table:
Status alarm Maintenance alarm Maintenance required "Maintenance demanded Function check No alarm Text Engineering tool Positioner display
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Status modification The classification of the status alarms can be changed as required. They can be modified using TROVIS-VIEW software over the local SSP interface. In addition, the classification can be modified over the parameters in DD or easily entered over the DTM.
Note! All additional alarms generated by EXPERT+ have the status No alarm by default.
Logging and displaying diagnostic functions/alarms The last 30 alarms are logged in the positioner. However, it is important to note that the same alarm is only logged once when it first occurs. The alarms and the condensed states appear on the display as described in the code list (section 12). In addition, the diagnostic parameters are issued over the communication interface of the positioner. The diagnostic functions can easily be displayed and configured using the TROVIS-VIEW software connected over the local interface (SSP) or over the DTM.
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Adjusting the limit switch
The positioner version with inductive limit switch has one adjustable tag (1) mounted on the shaft which operates the proximity switch (3). For operation of the inductive limit switch, the corresponding switching amplifier (see section 3.2.1) must be connected to the output. If the tag (1) is inside the field of the switch, the switch assumes a high resistance. If the tag is outside of the field, the switch assumes a low resistance. Normally, the limit switch is adjusted such that it will provide a signal in both end positions of the valve. The switch, however, can also be adjusted to indicate intermediate valve positions.
The desired switching function, i.e. whether the output relay shall be picked up or released when the tag has entered the field, has to be determined, if necessary, at the switching amplifier.
Note! The inductive limit switch replaces the software limit switch A1 with terminal assignment +41/42. Each switching position can optionally be set to indicate when the tag has entered the field, or when it has left the field. The second software limit switch remains effective, the function of the software limit switch A1 is disabled.
Adjustment screw (2)
Tag (1) Proximity switch (3)
Fig. 20 Adjustment of the limit switch
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Software adaptation Code 38 (inductive alarm is set to YES). The inductive limit switch is connected to the terminals +41/42. The device is set up accordingly when delivered ex works SAMSON. Setting the switching point:
For OPEN position: 1. Initialize positioner. 2. Use the MAN function to move the positioner to 95 % (see LC display). 3. Adjust the tag (1) using the yellow adjustment screw (2) until the tag enters or leaves the field of the proximity switch (3). You can measure the switching voltage as an indicator.
Note! During adjustment or testing, the switching point must always be approached from mid-position (50 %).
To ensure safe switching under any ambient conditions, the switching point should be adjusted to a value of approx. 5 % before the mechanical stop (OPEN CLOSED). For CLOSED position: 1. Initialize positioner. 2. Use the MAN function to move the positioner to 5 % (see LC display). 3. Adjust the tag using the yellow adjustment screw (2) until the tag enters or leaves the field and the switching amplifier responds. You can measure the switching voltage as an indicator. Contact function: Tag leaving the field > contact is made. Tag entering the field > contact is opened.
Contact function: Tag leaving the field > Contact is made. Tag entering the field > Contact is opened.
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Quick start-up guide
8 8.1
Quick start-up guide Mounting
4 Secure the positioner to the NAMUR
bracket, making sure that the follower pin is in the slot of the follower plate. Make sure the lever can still move.
Direct attachment to SAMSON Type 3277 Actuator

Travel mm 7.5 15 15/30 Actuator cm 120 120/240/350 700 Pin position 25 35 50
4 Lever M pin position 90 4 Put the valve into the closed position, determine the opening direction. 4 Place the follower plate on the slotted ac4
Note! Standard delivery includes lever M ready assembled with the follower pin on 35 mm pin position for 15 mm travel!
To mount the positioner, lift the lever so that the follower pin rests on the follower clamp of the actuator stem. NAMUR attachment
tuator shaft and fasten it to the coupling wheel. Attach the top pair of brackets and the bottom pair of brackets to the actuator. Place the positioner on the brackets and screw tight, making sure that the lever with its follower pin engages the slot of the coupling wheel, while taking into account the opening direction. It is important to make sure that the lever's mid position corresponds to the mid travel of the valve (lever's mid position = the lever is parallel to the long side of the positioner casing).
4 Determine the maximum travel range of 4 4 4
the control valve from the closed position to as far it will go in the other direction. Select the lever to match the maximum travel range as well the next largest pin position and screw onto the shaft of the positioner. Lever option/pin distance: see pin position table (Code 4) or cover plate on the positioner. Screw the NAMUR bracket onto the valve yoke so that it is aligned centrally to the slot of the follower plate when the travel position is at 50 %.
Pneumatic connections
4 Screw the threaded connections only into

the attached connection block, connecting plate or pressure gauge block from the accessories.
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8.2
Start-up
Operation Selecting the parameters or values Each parameter has a code number which is shown in the display. Use the button to select. Turn the button to select parameters or values and then push to confirm. Select and confirm ESC to prevent an entered value from being accepted. Enabling parameters Parameters that have a code marked with an asterisk (*) can only be changed when they are enabled beforehand using Code 3. The configuration mode is shown in the display with the symbol. See the code list on page 71 onwards or cover plate of the positioner for a description of the menu codes.
Connect pneumatic supply air (1.4 to 6 bar). Apply an electrical reference variable (4 to 20 mA). Set the fail-safe position Position the slide switch according to fail-safe position of the control valve: AIR TO OPEN or AIR TO CLOSE. Adapt the volume restriction Q to the actuator size Only set the restriction for actuators < 240 cm to: MIN SIDE for connection at the side or MIN BACK for connection at the back.
Note! After each change of the volume restriction setting, the positioner must be re-initialized.
Changing the reading direction of the display (if necessary) Turn turn Code 2, press Display ok, press , .
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8.3
Initialization
turn Code 4, Select pin position, turn turn Code 5, Code 6, Enter nominal travel/range, select NOM, Press INIT key!
Note! Perform a reset (Code 36) prior to each initialization

Turn turn turn Code 3, ON, Code 36,
8.3.3 Manual method (MAN)

Initialization mode same as NOM, but for start-up of control valves with unknown nominal ranges. The final position of travel/angle of rotation (valve open) is entered manually. Mount and start up the positioner, then proceed as follows: Turn turn turn turn turn turn turn Code 0, , select MAN, Code 1, , valve open position, Code 3, , ON, Code 6, , select MAN,
select RUN,
Caution! During initialization, the valve runs through its whole range of travel/angle of rotation.
8.3.1 Simplest method (MAX)

Mount and start up the positioner and press the INIT key! READY! The positioner adapts itself automatically to the maximum travel/angle of rotation range of the control valve.
8.3.2 Precise method (NOM)

Positioner adapts itself precisely to the nominal travel/rotational angle of the control valve! Mount and start up the positioner, then proceed as follows: Turn Code 3, turn ON,
Press INIT key!
Note! After imposing the electrical reference variable, the positioner is in the last used operating mode. Code 0 appears in the display. If the positioner has not yet been initialized, the fault symbol appears on the display and the symbol blinks.
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Upgrading options
9 9.1
Upgrading options Retrofitting an inductive limit switch
1 2 4 3
Required retrofit kit: Limit switch Order no. 1400-7460
Note! For explosion-protected devices, the requirements in section 11 need to be kept.

5 1. Take off the rotary pushbutton (3) and cap (1), unthread the five fixing screws (2) and lift off the plastic cover (9). 2. Use a knife to cut an opening at the marked location (4). 3. Push the connector (11) with cable through the opening and secure the proximity switch (7) on the cover with a dot of glue. 4. Remove the jumper at the socket ST1 of the top board and insert the cable connector (11). 5. Guide the cable in such a manner that the plastic cover can be placed back onto the positioner. Insert the fixing screws (2) and screw tight. Attach the clamping plate (8) onto the proximity switch. 6. Attach the rotary switch (5). Make sure the flattened side of the positioner shaft is turned so that the rotary switch (5) can be attached with the metal tag next to the proximity switch. 7. Note! On start-up of the positioner, set the option "inductive alarm" under Code 38 from NO to YES. 8 7 6 9 7
Socket ST1(11) 1 2 3 4 5 Cap Screws Rotary pushbutton Marking Rotary switch 6 7 8 9 11 Metal tag Proximity switch Clamping plate Plastic cover Connector
Fig. 21 Retrofitting an inductive limit switch
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Maintenance
9.2
Activation of optional + EXPERT diagnostics
11
Servicing explosion-protected devices
The optional extended EXPERT+ diagnostics can be activated subsequently. The required activation code is order number 1400-9318. On ordering this option, specify the serial number of the positioner (see nameplate or in the software). Enter the activation code in Code 48 d8 EXPERT+ activation. Plot reference curve with Code 48 d7 Start reference run (see also Code 48 in code list).
If a part of the positioner on which the explosion protection is based needs to be serviced, the positioner must not be put back into operation until an expert has inspected the device according to explosion protection requirements, has issued a certificate stating this or given the device a mark of conformity. Inspection by an expert is not required if the manufacturer performs a routine test on the device prior to putting it back into operation. The passing of the routine test must be documented by attaching a mark of conformity to the device. Explosion-protected components may only be replaced by original, checked components from the manufacturer. Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future must comply with the safety demands placed on repaired devices. Prior to operation, they must be tested according to the specifications stipulated for "Repairing explosion-protected devices".
10
Maintenance
The positioner does not require any maintenance. There are filters with a 100 m mesh size in the pneumatic connections for supply and output which can be removed and cleaned, if required. The maintenance instructions of any upstream supply air pressure reducing stations must be observed.
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Code list
12
Code list
Description
Code Parameter Display, values no. [default setting]
Note! Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
Operating mode [MAN] AUtO SAFE ESC
AUtO SAFE
= Automatic mode = Fail-safe position
MAN = Manual mode ESC = Escape
Switchover from automatic to manual mode is smooth. In fail-safe mode, the symbol S appears on the display. In MAN and AUtO mode, the system deviation is represented by the bar graph elements. When the positioner is initialized, the numerical display indicates the valve position or the angle of rotation in %, otherwise the position of the sensor in relation to the central axis is displayed in degrees . Adjust the manual set point with the rotary pushbutton, the current travel/angle is displayed in % when the positioner is initialized, otherwise the sensor position in relation to the central axis is indicated in degrees . The reading direction of the display is turned by 180.
Manual w 0 to 100 [0] % of the nominal range
Reading direction Normal or upside down ESC
Enable configuration [OFF] ON ESC
Enables the option to modify data (automatically deactivated when the rotary pushbutton has not been operated for 120 s.) HART blinks on the display when the on-site operation is locked. Codes marked with an asterisk (*) can only be read and not overwritten. Likewise, codes can only read over the SSP interface.
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Code list
4*
Pin position [OFF] 17, 25, 35, 50 mm 70, 100, 200 mm, 90 with rotary actuators ESC
For initialization using NOM or SUb, the follower pin must be inserted into the correct pin position according to the valve travel/angle of rotation. Pin position Code 4 Standard Code 5 7.5 7.5 15.0 30.0 40.0 60.0 120.0 90.0 Adjustment range Code 5 3.6 to 17.7 5.0 to 25.0 7.0 to 35.4 10.0 to 50.0 14.0 to 70.7 20.0 to 100.0 40.0 to 200.0 24.0 to 110.0
17 25 35 Note! 50 If you select a pin position in 70 Code 4 that is too small, the 100 positioner switches to SAFE 200 mode for reasons of safety 90 5* Nominal range [15.0] mm or angle ESC
For initialization using NOM or SUb, the nominal travel/angle of rotation of the valve must be entered. The permissible adjustment range depends on the pin position according to the table. After initialization has been successfully completed, the maximum nominal travel/angle reached on initialization is displayed. Select the initialization mode MAX: Maximum range of the control valve, the travel/angle of the closure member from the CLOSED position to the opposite stop in the actuator. NOM: Nominal range of the control valve, the travel/angle of the closure member measured from the CLOSED position to the indicated OPEN position. MAN: Manual adjustment: upper x-range value SUb: No self-adjustment (emergency mode) ZP: Zero calibration Direction of action of the reference variable w in relation to the travel/angle of rotation x (increasing/increasing or increasing/decreasing) Automatic adaptation: AIR TO OPEN: On completing initialization, the direction of action remains increasing/increasing (), a globe valve opens as the mA signal increases. AIR TO CLOSE: On completing initialization, the direction of action changes to increasing/decreasing ( ), a globe valve closes as the mA signal increases.
6*
Init mode [MAX] NOM MAN Sub ZP ESC
7*
w/x [] ESC
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Code list
8*
Lower x-range value 0.0 to 80.0 [0.0] % of the nominal range,

Specified in mm or angle provided Code 4 is set
ESC
Lower range value for the travel/angle of rotation in the nominal or operating range. The operating range is the actual travel/angle of the control valve and is limited by the lower x-range value (Code 8) and the upper x-range value (Code 9). Usually, the operating range and the nominal range are identical. 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! Upper range value for the travel/angle of rotation in the nominal or operating range. Value is displayed or must be entered. The characteristic is adapted. Example: The operating range is modified, for example, to limit the range of a control valve which has been sized too large. For this function, the entire resolution range of the reference variable is converted to the new limits. 0 % on the display corresponds to the set lower limit and 100 % to the set upper limit. Limitation of the travel/angle of rotation downwards to the entered value, the characteristic is not adapted. The characteristic is not adapted to the reduced range. See also example in Code 11. Limitation of the travel/angle of rotation upwards to the entered value, the characteristic is not adapted. Example: In some applications, it makes sense to limit the valve travel, e.g. if a certain minimum medium flow is required or a maximum flow must not be reached. 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.
9*
Upper x-range value 20.0 to 100.0 [100.0] % nominal range,

Specified in mm or angle provided Code 4 is set
ESC
10*
Lower x-limit [OFF] 0.0 to 49.9 % of the operating range ESC
11*
Upper x-limit [100 %] 50.0 to 120.0 [100] % of the operating range or OFF ESC
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Code list
12*
w-start 0.0 to 75.0 [0.0] % of the reference variable range ESC
Lower range value of the applicable reference variable range must be smaller than the final value w-end, 0 % = 4 mA The reference variable range is the difference between w-end and w-start, and must be w 25 % = 4 mA. 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 reference 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*
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 w-end ESC Final position w < 0.0 to [1.0] % of the span adjusted via Code 12/13 OFF ESC If w approaches the percentage adjusted towards the final value that causes the valve to close, the actuator is immediately completely vented (with AIR TO OPEN) or filled with air (with AIR TO CLOSE). This action always lead to maximum tight-closing of the valve. Codes 14/15 have priority over Codes 8/9/10/11.
14*
15*
Final position w > [OFF] 50.0 to 100.0 % of the span adjusted via Code 12/13 ESC
If w approaches the percentage adjusted towards the final value that causes the valve to open, the actuator is immediately completely filled with air (with AIR TO OPEN) or vented (with AIR TO CLOSE). This action always lead to the valve being completely opened. Codes 14/15 have priority over Codes 8/9/10/11. Example: Set the final position w > to 99 % for three-way valves. The signal pressure can adopt the value of the applied supply pressure at the maximum [OFF] or it can be limited in stages of 1.4, 2.4 or 3.7 bar. This pressure limitation is already effective during the initialization. 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.
16*
Pressure limit [OFF] 1.4 ESC 2.4 3.7 bar
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Code list
17*
KP step 0 to 17 [7] ESC
Displaying or changing KP Note on changing the KP and TV steps: During the initialization of the positioner, the KP and TV values are optimized. Should the positioner show a tendency for impermissibly high post-pulse oscillation due to additional interference, the KP and TV steps can be adapted after the initialization. For this, either the TV step can be increased in increments until the desired response behavior is reached or, when the maximum value of 4 is reached, the KP step can be decreased in increments. CAUTION! Changing the KP step influences the system deviation. This effect decreases as the KP step increases.
18*
TV step [2] 1 2 3 4 ESC OFF
Displaying or changing TV, See note under KP step A change of the TV step has no effect on the system deviation. Used for error monitoring Determination of the tolerance band in relation to the operating range. Associated lag time [30] s is a reset criterion. If, during initialization, a transit time is determined which is 6 times > 30 s, the 6fold transit time is accepted as lag time. Select the characteristic: 0: Linear 1: Equal percentage 2: Reverse equal percentage 3: Butterfly valve linear 4: Butterfly valve eq. percentage 5: Rotary plug valve linear 6: Rotary plug valve eq. perc. 7: Segmented ball valve linear 8: Segmented ball valve eq. p. 9: User-defined *
19*
Tolerance band 0.1 to 10.0 [5] % of the operating range ESC
20*
Characteristic 0 to 9 [0] ESC
* Definition over SAMSON TROVIS-VIEW software or HART communication
21*
w-ramp Open 0 to 240 s [0] ESC
The time required to pass through the operating range when the valve opens. Limitation of the transit time (Code 21 and 22): For some applications it is recommendable to limit the transit time of the actuator to prevent it from engaging too fast in the running process.
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Code list
22*
w-ramp Closed 0 to 240 s [0] ESC
The time required to pass through the operating range when the valve closes.
23*
Total valve travel 0 to 99 10 [0]

Exponential reading from 9999 travel cycles onwards 7
Totaled double valve travel. Can be reset to 0 by Code 36 RUN.
RES ESC 24* LV total valve travel 1000 to 99 10 [1 000 000]

7
Limit value of total valve travel. If the limit value is exceeded, the fault symbol and the wrench symbol appear.
Exponential reading from 9999 travel cycles onwards
ESC 25* Alarm mode 0 to 3 [2] ESC Switching mode of software limit switches alarm A1 and A2 in responding state (when positioner has been initialized). 1) Explosion-protected version according to EN 60947-5-6 0: A1 2.1 mA 1: A1 1.2 mA 2: A1 2.1 mA 3: A1 1.2 mA A2 1.2 mA A2 1.2 mA A2 2.1 mA A2 2.1 mA
2) Version without explosion protection 0: A1 R = 348 A2 Non-conducting 1: A1 Non-conducting A2 Non-conducting 2: A1 R = 348 A2 R = 348 3: A1 Non-conducting A2 R = 348 When a positioner has not been initialized, the software limit switches always register the signal as in the state of no response. If there is no mA signal at the terminals 11/12, the software limit switches both switch to 1.2 mA signal (Ex) or non-conducting (without explosion protection). Note! The fault alarm output always switches to 1.2 mA/ non-conducting in case of fault arises; it has 1.2 mA/R = 348 when there is no fault.
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Code list
26*
Limit value A1 OFF 0.0 to 100.0 [2.0] % of the operating range ESC
Alarm A1 goes into the state of response when the value exceeds the limit. Displaying or changing the software limit value A1 in relation to the operating range. Setting has no effect when an inductive limit switch has been installed.
27*
Alarm A2 goes into the state of response when the value falls below the limit. OFF 0.0 to 100.0 [98.0] % of the Displaying or changing the software limit value A2 in relation to the operating range. operating range Limit value A2 ESC Alarm test Reading direction: Standard [OFF] RUN 1 RUN 2 RUN 3 ESC Turned [OFF] 1 RUN 2 RUN 3 RUN ESC Testing the software limit switches alarm A1 and A2 in addition to the fault alarm contact A3. If the test is activated, the respective limit switches five times. RUN1/1 RUN: Software limit switch A1 to 2.1 mA RUN2/2 RUN: Software limit switch A2 to 2.1 mA RUN3/3 RUN: Fault alarm contact A3 to 1.2 mA
28*
29*
Position transmitter x/ix [] ESC
3)
Operating direction of the position transmitter; indicates how the travel/angle position is assigned to the output signal i, based on the closed position. 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.
30*
Fault alarm ix [OFF] HI ESC
3)
LO
Used to select whether faults causing the fault alarm contact to switch should also be signaled by the position transmitter output and how they should be signaled HI ix > 21.6 mA or LO ix < 2.4 mA
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Code list
31*
Position transmitter test
3)
10.0 to 110.0 [default value is last indicated value of the position transmitter] % of the operating range ESC
3)
Testing the position transmitter. Values can be entered in relation to the operating range. The current actual value is used in initialized positioners locally as the start value (bumpless changeover to the test mode). On testing over software, the entered simulation value is issued as the position feedback signal for 30 seconds.
Analog position transmitter: Code 29/30/31 can only be selected if the position transmitter (optional) is installed.
32*
Fault alarm with Function check condensed status NO ESC [YES]
Determines whether a fault alarm is to be issued when Function check condensed status occurs.
33*
Fault alarm with Maintenance alarm or Maintenance required condensed status NO [YES] ESC
NO: Fault alarm only with Maintenance alarm condensed status YES: Fault alarm only with Maintenance alarm condensed status and with Maintenance required condensed status
34*
Closing direction CL ESC [CCL]
CL: Clockwise, CCL: Counterclockwise Turning direction in which the valve is moved to the CLOSED position (view onto the rotary switch motion when the positioner cover is open). Needs only be entered in initialization mode SUb (Code 6). Entering the blocking position. Distance up to the CLOSED position. Only necessary in initialization mode SUb. Resets all start-up parameters to default (factory setting). Note: After setting RUN, the positioner must be re-initialized. Display only, indicates whether the position transmitter option is installed. Indicates whether the inductive limit switch option is installed or not. Display only, indicates the deviation from the set point position (e = wx).
35*
Blocking position [0] mm/ /% ESC
36*
Reset [OFF] ESC RUN
37 38*
Position transmitter Yes No Inductive alarm [NO] ESC YES
39
System deviation e info 99.9 to 999.9 % ,
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Code list
40 41 42
Transit time Open info 0 to 240 s [0] Transit time Closed info 0 to 240 s [0] Auto-w info 0.0 to 100.0 % of the span 4 to 20 mA
Display only, minimum opening time is determined during initialization Display only, minimum closing time is determined during initialization Display only, indicates the supplied automatic reference variable corresponding 4 to 20 mA. Display only, indicates the device type and the current firmware version of the positioner in alternating sequence. Display only. The control signal y is displayed in % in relation to the travel range determined on initialization. MAX: The positioner builds up its maximum output pressure (refer to description for Codes 14 and 15). 0 P: The positioner vents the actuator completely (refer to description for Codes 14 and 15). : The positioner has not been initialized. Display only, indicates whether a solenoid valve is installed. If a voltage supply is connected at the terminals of the installed solenoid valve, YES and HIGH appear on the display in alternating sequence. If a voltage supply is not connected (actuator vented, fail-safe position indicated on the display by the S symbol), YES and LOW appear on the display in alternating sequence. Select bus address
43
Firmware info Xxxx
44
y info [0] OP 0 to 100 % MAX
45
Solenoid valve info Yes No
46*
Polling address 0 to 63 [0] ESC Write protection HART YES [NO] ESC
47*
When the write protection function is activated, device data can only be read, but not overwritten over HART communication.
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Code list
48
Diagnostics d d0 Current temperature 55 to 125 d1 Minimum temperature [20] d2 Maximum temperature [20] d3 Number of zero calibrations The number of zero calibrations since the last initialization. The highest temperature above 20 C that has ever occurred. The lowest temperature below 20 C that has ever occurred. Diagnostic parameters Operating temperature [C] inside the positioner
d4 Number of initializations The number of initializations that have been performed. d5 Zero point limit [5 %] 0.0 to 100.0 % d6 Condensed status Limit for the zero point monitoring.
Condensed status, made up from the individual states. OK: Okay, C: Maintenance required, CR: Maintenance demanded, B: Maintenance alarm, I: Function check. Triggering of a reference run for the functions: Drive signal y steady-state and drive signal y hysteresis. The reference run can only be activated in manual operation as the valve moves through its entire travel range. If EXPERT+ is activated at later point in time, the reference graphs must be plotted in order to activate the diagnostic functions.
d7 Start reference run [OFF] ON ESC 1
d8 EXPERT activation
Enter the activation code for EXPERT . After the activation procedure has been successfully completed, YES appears under d8.
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Code list
Error codes Remedy
Condensed status alarm active, when prompted, Err appears.
Initialization error (indicated on the display by the condensed status with the corresponding classification) 50 x < range The value supplied by the measuring signal is either too high or too low, the measuring sensor is close to its mechanical limit. Pin positioned incorrectly. Bracket slipped in case of NAMUR attachment or positioner is not central. Follower plate incorrectly attached. Remedy Check attachment and pin position, set operating mode from SAFE to MAN and re-initialize the positioner. 51 x > range The measuring span of the sensor is too low. Pin positioned incorrectly. Wrong lever. A rotational angle smaller than 11 at the positioner shaft creates just an alarm. An angle below 6 leads to the initialization being canceled. Remedy Check attachment and re-initialize the positioner. 52 Attachment Positioner attachment incorrect. Nominal travel/angle (Code 5) could not be achieved on initialization under NOM or SUB (no tolerance downwards permissible) Mechanical or pneumatic error, e.g. wrong lever selected or supply pressure too low to move to the required position or pneumatic fault Remedy Check attachment and supply pressure. Re-initialize the positioner. Under certain circumstances, it may be possible to check the maximum travel/angle by entering the actual pin position and then performing an initialization under MAX. After initialization has been completed, the Code 5 indicates the maximum achieved travel or angle. 53 Init time > The initialization routine lasts too long. The positioner returns to its previous operating mode. No pressure on the supply line or there is a leak. Supply air failure during initialization. Remedy Check attachment and supply pressure. Re-initialize the positioner.
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Code list
54
Init Solenoid valve
1) A solenoid valve is installed (Code 45 = YES) and was not or not properly connected so that an actuator pressure could not be built up. The message appears when you attempt to initialize the positioner. 2) If you attempt to initialize the device from the fail-safe position (SAFE). Remedy Re. 1) Check connection and supply voltage of the solenoid valve. Code 45 High/Low Re. 2) Set the MAN operating mode over Code 0. Then initialize the positioner.
55
Transit time <
The actuator transit times determined during the initialization are so short that the positioner cannot adapt itself optimally. Remedy Check the volume restriction setting as described in section 5.2, re-initialize the positioner.
56
Pin pos.
Initialization was canceled because you are required to enter the pin position for the selected initialization modes NOM and SUb. Remedy Enter pin position over Code 4 and nominal travel/angle over Code 5. Re-initialize the positioner.
Operational error (indicated on the display by the condensed status with the corresponding classification) 57 Control loop
Additional alarm at the fault alarm contact!
Control loop error, the control valve does not react within the tolerable times of the controlled variable (tolerance band alarm Code 19). Actuator mechanically blocked. Attachment of the positioner subsequently postponed. Supply pressure not sufficient.
Remedy Check attachment. 58 Zero point Zero point incorrect. Error may arise when the mounting position/linkage of the positioner moves or when the valve seat trim is worn, especially with soft-sealed plugs. Remedy Check valve and mounting of the positioner. If OK, perform a zero calibration over Code 6 (see section 5.8 on page 58). 59 Autocorrection Should an error occur in the data range of the positioner, the self-monitoring function recognizes it and automatically corrects it. Remedy Automatic
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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 disturbances. The control valve moves to its fail-safe position.
Remedy Reset over Code 36. Re-initialize the positioner. Hardware error (indicated on the display by the condensed status with the corresponding classification) 62 x signal
Determination of the measured value for the actuator has failed. Conductive plastic element is defective. The positioner continues to run in emergency mode, but should 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.
Note on the control: If the measuring system has failed, the positioner is still in a reliable state. The positioner switches to emergency mode where the position cannot be accurately controlled anymore. However, the positioner continues operation according to its reference variable signal so that the process remains in a safe state. Remedy Return the positioner to SAMSON AG for repair. 63 w too small The reference variable is much smaller than 4 mA (0 %); occurs 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.
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Code list
Error appendix 65 Hardware

A hardware error has occurred, the positioner moves to the fail-safe position SAFE.
Remedy Confirm error and return to the automatic operating mode, or perform a reset and re-initialize the device. If this is not successful, return device to SAMSON AG for repair. 66 Data memory
The writing of data to the data memory does not work anymore, e.g. when the written data deviate from the read data. Valve moves to the fail-safe position.
Remedy Return the positioner to SAMSON AG for repair. 67 Test calculation

The hardware positioner is monitored by means of a test calculation.
Remedy Confirm error. If this is not possible, return the positioner to SAMSON AG for repair. Data error 68 Control parameter
Control parameter error.
Remedy Confirm error, perform reset and re-initialize the positioner. 69 Poti parameter
Parameter error of the digital potentiometer.
Remedy Confirm error, perform reset and re-initialize the positioner. 70 Calibration
Error in the production calibration data. Subsequently, the device runs on default values
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.
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Code list
72
Start-up parameters
Start-up parameter errors Remedy Confirm error, perform reset and re-initialize the positioner.
73
Internal device error 1
Internal device error
Remedy Return the positioner to SAMSON AG for repair. 74 HART parameters Error in the HART parameters that are not critical for the control function. Remedy Confirm error. Check and, if necessary, reset required parameters. 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-monitoring function (see Code 62). A controlled emergency mode is not available on certain actuators, 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 signal has been applied, it carries out a self-test (tEStinG runs 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. 78 79 Options parameter Diagnostic alarms Errors in options parameters. Alarms are generated in the EXPERT extended diagnostics if EXPERT+ has been successfully activated in Code 48.
+
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Code list
80
Diagnostic parameters
Error which is not critical for control.
Remedy Confirm error. Check and, if necessary, start new reference run. 81 Reference graphs Error on plotting the reference graphs of drive signal y steady-state or drive signal y hysteresis. Reference run was interrupted Reference line y steady-state or y hysteresis was not adopted.
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Setting with TROVIS-VIEW software Parameter list
13
13.1 General
A CD-ROM containing the program for installing the TROVIS-VIEW Configuration and Operator Interface is provided by SAMSON. Insert the installation CD-ROM to start the installation program. Once inserted, the CD-ROM usually starts the installation program automatically depending on the configuration of the operating system. If the program does not start automatically, double-click setup.exe in the root directory of the CD-ROM in order to install TROVIS-VIEW. Follow the on-screen prompts and instructions of the installation program. The system requirements are specified in the readme.txt file in the root directory of the CD-ROM. The TROVIS-VIEW Operator Interface can be used for different SAMSON devices. Note that the installation program also offers you the option of installing a demo module. To use the software without restrictions, the software needs to be activated as described below: After installation, a dialog box will appear, prompting you to enter the CD key, which you will find on the cover of the original CD-ROM. Once you have entered the correct CD key and initiated the activation process, a request code will be automatically generated. The Activation dialog box will come up displaying the generated request code and an Internet link to SAMSONs ac-
tivation server where a unique activation code will then be generated and displayed. Enter this activation code into TROVIS-VIEWs Activation dialog box. The software is now ready for use without any restrictions in the purchased scope. To enable communication with the PC, connect the serial interface to the serial interface (5-pole female socket) of the positioner using a SAMSON connecting cable with serial interface adapter (order no. 1400-7700). The positioner settings configured in TROVIS-VIEW can be directly transferred over the SAMSON connecting cable to the positioner on site. This online connection enables you to read any entered settings as well as providing a diagnostic function.
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13.2 Starting TROVIS-VIEW and performing basic settings

Settings may be entered into the TROVIS-VIEW operator interface when either the positioner is connected or not connected. When the positioner is connected, the data uploaded from the positioner can be overwritten. When the positioner is not connected, the default settings appear on the operator interface display or, alternatively, a stored TROVIS-VIEW file (*.tro) can be loaded and written over in the File menu by selecting Open. Connection to the positioner is established by clicking the symbols on top right on the button bar: Upload data from the positioner and displayed in the operator interface Download the complete set of data from the operator interface onto the positioner. To download individual parameters onto the positioner, open the corresponding drop-down menu. Select Write to just download the selected parameter (see section 13.3) The positioner is in online mode, indicated by the TROVIS-VIEW 3 logo on the top right in the blue bar The positioner is in offline mode.
You can also activate the listed functions in the Device menu.
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1. Start TROVIS-VIEW
Make required settings in View menu by activating or deactivating functions. When the Trend Viewer is activated, all operating data are uploaded cyclically from 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.
2. Select required language in Options menu. The selected language can be changed at any time except in online mode.
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3. Select Communication from the Options menu and choose. communication settings.
4. Click on Port settings and select port as well as server setting.
5. Select Convert in the File menu to select the firmware version of the positioner. It must match the version specified in the bar at the top.
6. Enter more details about the plant, if necessary, in Customer Data in the Edit menu.
7. Select Load Factory Defaults in Edit menu to upload default settings to the operator interface.
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13.3 Setting the parameters

Click on one of the folders listed in the left column to open a window listing the settings of the corresponding parameters. Place the mouse arrow on the parameter name to open a tool tip providing information about that particular parameter.
Double-click on a parameter to open a window to enable the parameter to be modified. Right-click on the parameter to open a drop-down menu providing further editing options.
The parameters in all the folders are listed in the following parameter list.
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13.4 Parameter list

Parameter Values Default setting Description Refer to section 12 for the description of the codes Tag identification of operation unit
Identification Operation unit TAG Long TAG Bus address Description Message Text field 1 to 5 Positioner serial number Positioner product number Firmware version Diagnosis level Final assembly number Date (day) Date (month) Date (year) Certification Number of preambles Required number of 5...20 preambles HART revision 5 5 5 Designates the version of the HART specification which is supported by the positioner 1900...2155 0...16777215 1...31 3730-3 xxx x.xx EXPERT 0 1 January 2003 Date that can be entered. Stored in the positioner Indicates whether the positioner can be used in hazardous area Number of required synchronization bytes Any number assignable to clearly identify the entire field device Serial number of the positioner Manufacturer model number of the positioner Current firmware version of device, Code 43 0 Code 46 Freely available text fields Max. 32 characters
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Identification Positioner Device type Identification Positioner Actuator Type identification actuator Actuator type Attachment Booster Actuator size Signal pressure lower value Signal pressure upper value Supply pressure Type identification valve Direction of flow Flow-to-open (FTO)/ Flow-to-close (FTC) Adjustable/ Self-adjusting/ Bellows seal Single-acting Double-acting Integral/ NAMUR Not present/ present 60...5600 0.0...6 0.0...6 0.0...6 Manufacturer ID number of the actuator that the positioner is mounted upon Single-acting Actuator with or without spring return mechanism Integral Not present 240 cm 0.2 bar 1.0 bar 6.0 bar Defines the attachment of the positioner on the control valve Pneumatic volume booster Effective diaphragm or piston area of the actuator Initial value of the actuator bench range Final value of the actuator bench range Supply pressure of compressed air network Manufacturer ID number of the valve that the positioner is mounted upon Flow-to-open Indicates in which direction the process medium (FTO) flows to the valve plug. 3730-3 Indicates exact model designation
Identification Positioner Valve
Packing
Selfadjusting
Sealing of the plug stem to the atmosphere
Seating surface (leakage class)
Metal sealing Type of sealing between seat and plug Metal sealing/ Lapped-in metal/ Soft sealing/ Nickel sealing Without/ With (PTFE)/ With (graphite) Without Plug with pressure balancing to compensate for forces
Pressure balancing
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Flow characteristic
Linear 30:1/ Eq. perc. 30:1/ Linear 50:1/ Eq. perc. 50:1/ Other DIN/ANSI 8...2100 0.0001... 20000.0000 Kv/cv
Linear 50:1
Valve characteristic: Flow to valve travel
Valve dimensions standard Nominal size DN Kvs coefficient Kvs unit
DIN 50 1.0000 Kv Kv 6.0 mm
Valve dimensions according to DIN or ANSI Nominal size in mm (DIN) or inch (ANSI) Valve flow coefficient Flow coefficient, metric unit (Kvs) or US American units (cv) Diameter of valve seat bore
Seat diameter of the 2.0...500.0 valve Solenoid valve Position transmitter Inductive limit switch Operation unit HART write protection Start with default settings Positioner Operating mode Current operating mode Target operating mode Installed/ Not installed
Identification Positioner Additional components Code 45 Not installed Code 37 Code 38
Not write protected
Code 47 Code 36
Indicated the current operating mode used by the device Automatic Automatic/ Manual/Fail-safe position Code 0
Positioner Process data Reference variable w Controlled variable x System deviation e Manipulated variable y Displays current process variables Code 42 Current position Deviation from target position (e = wx) Indicates the control signal y in % in relation to the travel range found on initialization after the device has been initialized.
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Status Condensed state Summarized state of the positioner. The condensed status is made up from the various states. The condensed status can take on the following states: No alarm Maintenance required Maintenance demanded Maintenance alarm Function check The condensed states Maintenance required and Maintenance demanded are also indicated on the positioner display by . The condensed status Maintenance alarm causes the fault alarm symbol to appear on the display. Fault exists (fault alarm contact) Status of limit switch A1 x falls below A1 Status of limit switch A2 x exceeds A2 Operational status Temperature Display and alarm Status of the fault alarm contact Status of the switching output for limit switch A1 Indicates whether the controlled variable x has fallen below the limit for A1 Status of the switching output for limit switch A2 Indicates whether the controlled variable x has exceeded the limit for A2 Indicates the current operational status of the internal control Current temperature in the positioner
EB 8384-3 EN
95
Positioner Reference variable Direction of action Increasing/ increasing >> Incr./decr. <> Lower reference range value Upper reference range value 0.0...75.0 % 25.0...100.0 % 0.0 % 100.0 % On 1.0 % Off 100.0 % 0s 0s Code 12 Code 13 Code 14 Code 14 Code 15 Code 15 Code 21 Code 22 Increasing/ Code 7 increasing >>
Enable final posiOn/Off tion smaller than w Final position when 0.0...49.9 % w is smaller Enable final posiOn/Off tion greater than w Final position when 50.0...100.0 % w is greater Required transit time OPEN Required transit time CLOSED 0...240 s 0...240 s
Positioner Working range 0.0...12.0 mm Initial value of travel range/angle of rotation range Final value of travel 3.0...15.0 mm range/angle of rotation range Enable travel/angle On/Off of rotation lower limit Travel/angle of rotation lower limit 0.0...49.9 % 0.0 % Code 8
100.0 %
Code 9
Off
Code 10
0.0 % On
Code 10 Code 11
Enable travel/angle On/Off of rotation upper limit Travel/angle of 50.0...120.0 % rotation upper limit
100.0 %
Code 11
96
EB 8384-3 EN
Positioner Characteristic Characteristic selection Linear Equal percentage Eq. perc. reverse SAMSON butterfly valves linear eq. perc. VETEC rotary plug valves linear eq. perc. Segmented ball valves linear eq. perc. User defined Characteristic type Linear Code 20
Graphs of the user-defined characteristics, loading and saving characteristics. See example on the next page. Free text for describing the user-defined characteristic
EB 8384-3 EN
97
Example for user-defined characteristic
Select User defined characteristic in Characteristic selection parameter. Double-click on Edit, open or save characteristic to open a window where the characteristic can be edited. Click on Characteristic button on the bottom right to open and save a characteristic.
98
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Parameter
Values
Default 7
Description Code 17
Positioner Performance characteristics Required propor0...17 tional-action coefficient KP (step) Proportional-action coefficient KP (step) Required derivative-action time TV (step) Derivative-action time TV (step) Positioner Fail-safe action Fail-safe position Closing Fail-safe action of the actuator upon air/auxiliary power failure or device start-up. 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 Error control Tolerance band Delay time 0.1...10.0 % 0...9999 s 5.0 % 30 s Code 19 Reset criterion for running control loop monitoring. A control loop error is issued when the delay time is exceeded and the system deviation is not within the tolerance band. Code 23 Code 24 Off/1/2/3/4 2
Code 17 Code 18
Code 18
Total valve travel Limit of the total valve travel Alarm mode 1000... 990 000 000
1 1 000 000
Code 25 A1 Conducting/high A1 A2 Non-conduc./low Conducting/

A1 Non-conduc./low high A2 Non-conduc./low A2 A1 Conducting/high Conducting/ high A2 Conduc./high A1 Non-conduc./low A2 Conducting/high
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99
Enable limit value A1 Limit value A1 Enable limit value A2 Limit value A2 Fault alarm with Function check condensed status Fault alarm with Maintenance alarm or Maintenance required condensed status Zero point limit
On/Off 0.0...100.0 % On/Off 0.0...100.0 % Yes/No
On 2.0 % On 98.0 % No
Code 26 Code 26 Code 27 Code 27 Code 32
Maintenance alarm only and Maintenance required only
Maintenance Code 33 alarm
0.0...100.0 %
5.0 %
Limit for zero point monitoring
Positioner Error control Classification report Condensed status error alarms Note! Each fault alarm has a status assigned to it. The possible states are placed in order starting with the lowest priority: Maintenance required Maintenance demanded Maintenance alarm Function check Highest priority Lowest
No alarm
Alarm is not added to the condensed status
The fault alarm present in the device with the highest priority determines which condensed status is displayed. The condensed states Maintenance required and Maintenance demanded are also indicated on the positioner display by . The condensed status Maintenance alarm causes the play. fault alarm symbol to appear on the dis-
100
EB 8384-3 EN
x > range Delta x < range Attachment Initialization time exceeded Initialization/ solenoid valve Transit time not achieved Pin position Control loop Zero point Autocorrection x signal w too small Control parameter Poti parameter Calibration parameter General parameters Internal device error 1 HART parameter Parameter info No emergency mode Options parameter Total valve travel exceeded Temperature < 40 C Temperature > 80 C or symbol for function check Symbol for maintenance required and maintenance demanded Symbol Determines the individual status for each alarm with symbol an alarm is not added to the condensed status
Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 57 Code 58 Code 59 Code 62 Code 63 Code 68 Code 69 Code 70 Code 71 Code 73 Code 74 Code 75 Code 76 Code 78 Determines the condensed status when a fault occurs Temperature fell below 40 C during operation Temperature exceeded +80 C during operation
for maintenance alarm
EB 8384-3 EN
101
Positioner Start-up Reading direction Pneumatic connection right/left Pneumatic connection right Code 2
Pin position
Off Off 17/25/35/50/ 70/100/200 mm 90 Nominal range Maximum range Manual adjustment Substitution Maximum range
Code 4
Initialization mode
Code 6
Pressure limit Determined nominal range Minimum transit time OPEN Minimum transit time CLOSED Fail-safe action
Off /2.4/3.7/ 1.4 bar
Off
Code 16 Code 5 Code 40 Code 41 Fail-safe action of the actuator upon air/auxiliary power failure or device start-up. 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 range Manual adjustment Substitution Device initialized Initialization Status of device initialization Starting of initialization procedure. The initialization mode parameter must be first set to the required initialization procedure. Maximum range Code 6
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102
Initialization status Initialization canceled Target operating mode Current operating mode Initialization error x > range Delta x < range Attachment Initialization time exceeded Initialization/solenoid valve Transit time too short Pin position No emergency mode Positioner Start-up Substitution Initialized in Sub mode Closing direction Blocking position Positioner Maintenance Start zero calibration Zero calibration Initialization status Initialization canceled Target operating mode Current operating mode Automatic Manual SAFE Automatic Counterclockwise 0.0 % Alarm Automatic Manual SAFE Automatic
Status of the running initialization procedure Running initialization procedure has been canceled. The control valve moves to its fail-safe position. Code 0
Indicates current operating mode of positioner
Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 76
Indicates whether the substitute configuration (sub mode) has been performed Code 34 Code 35
Starts zero calibration Status of running initialization procedure Running initialization procedure has been canceled. The valve moves to fail-safe position. Code 0
Indicates current operating mode of positioner
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103
Positioner Simulation Alarm test A1 Alarm test A2 Alarm test A3 (alarm fault output) Diagnosis Diagnosis level setting Current operating mode Diagnosis Status alarms Status Condensed status Operating hours counter Device in closed loop Device switched on since last initialization Device in closed loop since last initialization Error occurred (fault alarm output) Solenoid valve status Fail-safe position Display or status Alarm symbol Summarized condensed status. Made up from various states. Time elapsed since first initialization Time elapsed in closed loop since first initialization Time elapsed since last initialization Expert Automatic Indicates current operating mode of positioner Code 28 Code 28 Code 28
Time elapsed in closed loop since last initialization Status of fault alarm output Status of optional solenoid valve Fail-safe action of actuator upon air supply/auxiliary power failure or device start-up. Determined during initialization. Status of device initialization Indicates whether a start has been performed with default settings. Local operation is active Status of device status bit configuration changed.
Device initialized Start performed with default settings Local operation active Configuration changed
104
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Number of zero calibrations Number of initializations Zero point limit Operation Control loop Zero point Autocorrection Fatal error w too small Total valve travel exceeded Temperature exceeded Hardware x-signal i/p converter Hardware Data memory Control calculation Program load error Initialization x range Delta x < range Attachment Initialization time exceeded Initialization/ solenoid valve Transit time too short Pin position No emergency mode Alarm Alarm Alarm
Number of zero calibrations performed since last initialization Number of initializations performed Limit for zero point monitoring Code 57 Code 58 Code 59 Code 60 Code 63 Status of total valve travel limit Status alarm resulting from diagnosis analysis
Code 62 Code 64 Code 65 Code 66 Code 67 Code 77 Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 Code 56 Code 76
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105
Data memory Control parameter Poti parameter Calibration parameter General parameters Internal device error 1 HART parameter Info parameter Option parameter Diagnostic parameters Temperature Min. temperature Max. temperature Min. temperature (time) Max. temperature (time) Diagnosis Status messages Data logger Alarms (1) to (30) Operating hours since first initialization Diagnosis Status alarms Reset Reset absolute total travel Reset default values flag Reset device setting changed Resetting corresponding alarms Reset counter for absolute total valve travel back to 0 Set back default values flag to 0 Reset device status bit device setting changed. Alarm Recorded alarms issued by the positioner Operating hours counter logging of each alarm Display Lowest temperature recorded in the positioner Highest temperature recorded in the positioner Operating hours counter logging when the lowest temperature was recorded in the positioner Operating hours counter logging when the highest temperature was recorded in the positioner Alarm Code 68 Code 69 Code 70 Code 71 Code 73 Code 74 Code 75 Code 78 Code 80
106
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Reset initialization error Reset x > range Reset Delta x < range Reset attachment Reset initialization exceeded Reset initialization/ solenoid valve Reset transit time too short Reset pin position Reset operational error Reset zero point Reset autocorrection Reset hardware error Reset hardware Reset control calculation Reset data error Reset control parameter Reset poti parameter Reset general parameters HART parameter Reset options parameter Reset diagnostic parameters Reset statistical information Reset data logger Measured data in the data logger buffer memory are deleted Code 68 Code 69 Resetting corresponding alarms Code 71 Code 74 Code 78 Code 80 Resetting corresponding alarms Code 65 Code 67 Resetting corresponding alarms Code 58 Code 59 Resetting corresponding alarms Code 50 Code 51 Code 52 Code 53
Code 54
Code 55
Code 56
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107
108
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Dimensions in mm
14
Dimensions in mm
or connecting plate
Pressure gauge bracket
Attachment acc. to IEC 60534-6 External position sensor Lever mm

S = 17 M = 50 L = 100 XL = 200
28 70
70 28 164 Output (38) Supply (9)
A1 Z A2
Schild
15
70
46
58
34
Direct attachment
210
M20 x 1.5
34
40
58
Attachment to rotary actuators VDI/VDE 3845

for all sizes of fixing level 2
86
50
Output A1 Supply (9)
79 59 49
Connecting plate G or NPT

50
58 80 130
Reversing amplifier (option)
76
Output A2
14
80
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109
110
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111
112
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113
114
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115
116
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117
118
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119
120
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121
122
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123
124
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NEMA 4x
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125
126
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127
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S/Z 2007-05
Inductive Limit Switch Type 3768
Fig. 1 Type 3768

Edition April 2004
Contents
Contents 1 1.1 1.2 2 2.1 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 3 3.1 4 5 6
Page Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Attachment to control valve . . . . . . . . . Direct attachment . . . . . . . . . . . . . . Attachment according to IEC 60534-6 . . . . Mounting sequence . . . . . . . . . . . . . Presetting the travel . . . . . . . . . . . . . Attachment to rotary actuators . . . . . . . . Mounting the follower roll lever . . . . . . . . Mounting the intermediate piece . . . . . . . Adjusting the cam disk . . . . . . . . . . . . Reversing amplifier for double-acting actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . 6 . 8 . 8 . 8 . 10 . 10 . 10 . 12 . 14
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Pneumatic connections for versions with solenoid valve . . . . . . . . . . . . 19 Operation Adjusting the limit contacts . . . . . . . . . . . . . . . . . . . 20 Servicing explosion-protected versions . . . . . . . . . . . . . . . . . . . . 22 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EB 8356 EN
Safety instructions
Assembly, start-up and operation of the device may only be performed by trained and experienced personnel familiar with this product. According to these mounting and operating instructions, trained personnel is referred to individuals who are able to judge the work they are assigned to and recognize possible hazards due to their specialized training, their knowledge and experience as well as their knowledge of the applicable standards. Explosion-protected versions of this device may only be operated by personnel who have undergone special training or instructions or who are authorized to work on explosion-protected devices in hazardous areas (for more details, refer to section 5). Any hazards which could be caused by the process medium, the signal pressure and moving parts of the control valve are to be prevented by means of appropriate measures. If inadmissible motions or forces are produced in the pneumatic actuator as a result of the level of the supply air pressure, this must be restricted by means of a suitable pressure reducing station. Proper shipping and appropriate storage are assumed. Note! The device with a CE marking fulfils the requirements of the Directives 94/9/EC (ATEX) and 89/336/EEC. The declaration of conformity can be viewed and downloaded on the Internet at http://www.samson.de.
EB 8356 EN

The Type 3768 Limit Switch is designed for attachment to pneumatic control valves. It is equipped with inductive switching elements that issue a limit signal whenever the valve travel exceeds or falls below a certain preset limit, especially when the valve has reached one of its end positions. The limit signal is transmitted to an alarm or indicating unit. The limit switch is also available with a solenoid valve which is used to move the control valve to fail-safe position. The limit switch is designed for either direct attachment to SAMSON Type 3277 Actuators or for attachment to control valves complying with IEC 60534-6 (NAMUR) by means of an adapter housing. The valve travel and, hence, the valve position is transmitted via the pin (1.1) to the lever (1), thus converting the linear travel into a rotary motion. The shaft (2) transmits
the rotary motion to two adjustable tags (4) which, in return, operate the associated proximity switches (5). The operation of the inductive limit switches requires that switching amplifiers be connected in the output circuit (see section 3). Version with solenoid valve The solenoid valve is used to move the control valve to its fail-safe position regardless of the output signal issued by the control unit. When a control signal which corresponds to the binary signal 0 (OFF) is applied to the input, the signal pressure pst is shut off and the actuator vented. As a result, the springs installed in the actuator force the valve to move to its fail-safe position. Whereas a control signal corresponding to the binary signal 1 (ON) causes the signal pressure pst to be transmitted to the actuator, resulting in activation of the control valve.
7 3 2 1 1.1 supply
u[V]
pst
1 1.1 2 3
Lever Pin Shaft Spring
4 5 6 7
Tag Proximity switch Adjustment screw Pressure regulator
Fig. 2 Functional diagram
EB 8356 EN
Technical data
1.1 Versions
Model Without Ex II 2 G EEx ia IIC T6 acc. ATEX Ex ia FM/CSA Ex II 3 G EEx nA II T6 acc. ATEX Solenoid valve Without 6 V DC 12 V DC 24 V DC Pneumatic connections Without 1/4-NPT ISO 288/1-G 1/4 Electrical connections M20 x 1.5 blue M20 x 1.5 black Plug connector HAN 7D (not with CSA/FM) Explosion protection 37680 1 3 8 0 2 3 4 0 1 2 1 2 4 2 0 0
1.2 Technical data

Travel range 2 proximity switches Differential gap Degree of protection Perm. ambient temp. EMC Solenoid valve Nominal signal Signal 0 (no pick-up) , DC signal at 25 C Signal 1 (safe pick-up), DC signal at +80 C Maximum permissible signal Coil resistance Ri at 20 C Air consumption in steady state, Kvs= 0.14 m3/h Closing time for For rated travel and signal pressure range Type 3277 Actuator cm2 0.2 to 1 bar 0.4 to 2 bar 0.6 to 3 bar 0.5 s 120 Direct attachment: 7.5 to 30 mm; Attachment acc. to IEC 60534-6: 5.5 to 120 mm; angle of rotation: 0-90 Type SJ 2-SN; Control circuit: values must match the downstream switching amplifiers 1% at rated travel IP 65 w/o solenoid valve, IP 54 with solenoid valve (special version IP 65 w. filter check valve) 20 to +80 C Requirements as per EN 50081/50082 are met Input Air supply Binary DC signal Supply air 1.4 to 6 bar (20 to 90 psi) 6 V DC 1.2 V 5.4 V 28 V 2909 12 V DC 2.4 V 9.6 V 25 V 5832 240 1 s 2 s 1 s 24 V DC 4.7 V 18 V 32 V 11714 350 1.5 s 2.5 s 1.5 s 700 4 s 8 s 5 s
"Off" 60 ln/h; "On" 10 ln/h
EB 8356 EN
Attachment to control valve
2 Attachment to control valve

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

1. Screw the clamp (1.2) to the actuator stem. Make sure the fastening screw rests in the groove of the actuator stem. 2. Screw the associated lever D1 or D2 to the lever of the limit switch. 3. Secure the distance plate (15) together with the gasket facing towards the actuator yoke. 4. Position the limit switch such that the lever D1 or D2 slides in line over the pin (1.1) of the clamp (1.2). 5. Mount cover (18).
EB 8356 EN
Type 3277
18 1.2 D2 D1
Adapter block only for version with solenoid valve
15
View onto the signal pressure connection < Attachment left Attachment right> Actuator stem < extends retracts > Signal pressure connection < internal over pipe connection > With switch plate (old)
SUPPLY
Side view of adapter block with gasket (new)
Symbol for actuator stem extends retracts Tip of gasket (16) Cover plate Marking
Actuator stem retracts extends
Switch plate (13)
Type 3277-5 with 120 cm2

Signal pressure input for right attachment Clamp Signal pressure input for left attachment Symbol for actuator stem retracts extends Marking Switchover plate only for version with solenoid valve
15
Fig. 3 Direct attachment Mounting of bracket, signal pressure connection
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2.2 Attachment according to IEC 60534-6

For limit switch attachment according to NAMUR, you require an adapter housing. The valve travel is transmitted via the lever (18) and shaft (25) to the bracket (28) of the adapter housing and then passed on to the pin (27a) located on the limit switch lever. For the limit switch attachment you require the mounting parts listed in Table 4. The rated travel of the control valve determines which lever must be used. You can attach the limit switch either to the left or to the right of the control valve.
Control valve with rod-type yoke: 1. Screw the plate (20) to the carrier of the plug stem. 2. Screw the studs (29) into the adapter housing. 3. Place the housing with the mounting plate (30) on either the right or left side of the valve stem and screw tight using nuts (31). Make sure that the lever (18) to be mounted subsequently is in horizontal position when the valve is at midtravel. 4. Screw the pin (19) into the center row of holes on the plate (20) and lock it in a position above the correct lever marking (1 to 2), as indicated in Table 5. 5. Clamp the clip (21) onto the lever (18). Only when connecting versions with solenoid valve and air connection pointing to the front, must the clip be clamped onto the lever with the open side pointing downwards. 6. Attach the lever (18) including clamping plate (22) to the shaft (25). The clip must clasp the pin (19).
2.2.1 Mounting sequence

Choose the required mounting parts from Tables 4 and 5 on pages 16 and 17. Control valve with cast yoke: 1. Screw the plate (20) to the stem connector of the actuator and plug stem using the countersunk screws. For 2100 and 2800 cm2 actuator versions, use an additional mounting bracket (32). 2. Remove the rubber plug from inside the adapter housing and fasten the housing to the left or right side of the Namur rib using a hexagon screw.
2.2.2 Presetting the travel

1. Move the valve to 50 % travel. 2. Adjust the shaft (25) in the adapter housing so that the black pointer (24) meets the cast mark on the adapter housing. 3. Screw the clamping plate (22) tight in this position using the screw (23). 4. Screw in the pin (27a) at the limit switch lever on the side of the press nut and lock with a hex nut (27b) on the other side. Observe the mounting posi-
EB 8356 EN
27b
Mounting position
26
27a 28
Attachment to NAMUR rib
1,5
24 25
22 23 19
21 20
18
32
18 19 20 21 22 23 24 25 26 27a 27b 28 29 30 31 32 Lever N1, N2 Pin Plate Clip Clamping plate Screw Pointer Shaft Lever positioner Pin Lock nut Bracket Studs Plate Nuts Mounting bracket
Attachment to rods
31 29 30
20
19
Fig. 4 Attachment according to NAMUR (shown for attachment to the left side)
EB 8356 EN
tion A or B according to Table 5 and Fig. 4. 5. Place the limit switch on the adapter housing, observing the operating direction. Make sure that the pin (27a) rests against the bracket (28). Caution! The pin must not slip out of the bracket once installed.
2.3.2 Mounting the intermediate piece

SAMSON Type 3278 Actuator 1. Screw the adapter (36) to the free end of the rotary actuators shaft. 2. Screw intermediate piece (34) with two screws to the actuator case. For versions with solenoid valve, make sure that you place the intermediate piece in such a manner that the air connections of the limit switch point towards the side of the diaphragm case. 3. Align the cam disk and scale as described in section 2.3.3, and fasten with screws. Actuators according to VDI/VDE 3845 1. Place the entire intermediate piece (34, 42, 44 and 45) onto the mounting bracket included in the scope of actuator delivery (fixing level 1 acc. to VDI/VDE 3845) and screw tight. 2. Align the cam disk (40) and scale as described in section 2.3.3 and fasten with screws.
2.3 Attachment to rotary actuators

You have the possibility of attaching the limit switch to rotary actuators according to VDI/VDE 3845. For this purpose, you require the accessories and mounting parts listed in Table 6 on page 17. The rotary motion of these actuators is transferred to the metal tags via the cam disk installed on the actuator shaft and a follower roll on the limit switch lever.
2.3.1 Mounting the follower roll lever

1. Place the follower roll lever (35) on the side where the transmission lever (37) is located (opposite of the press nuts). Secure with the supplied screws (38) and washers.
10
EB 8356 EN
33
Attachment to SAMSON Type 3278
37
35 38
Attachment acc. to VDI/VDE 3845
39 40
Vent plug or filter check valve
39 40
34 34 36 44
45
33 34 35 36 37 38 39 40 41 42 43 44 45 Limit switch Intermediate piece Lever with follower roll Adapter Transmission lever Screws Scale Cam disk Actuator shaft Disk Mounting bracket Coupling Seal
42 43
Fig. 5 Attachment to rotary actuators
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11
2.3.3 Adjusting the cam disk

The adjustment of the cam disk depends on the valves direction of rotation, i.e. whether it opens clockwise or counterclockwise. Important! Starting position is the closed valve. The starting point (bore) of the cam must be positioned so that the fulcrum of the cam disk and the 0-position on the scale as well as the arrow on the inspection glass form a horizontal line. When aligning the cam disk, the doublesided scale disk must be clipped on the cam disk in such a way that the value on the scale matches the control valves direction of rotation. Secure the cam disk using the fastening screw.
Securing the aligned cam disk To additionally prevent the cam disk from being turned, drill a hole into the adapter (36) or the coupling (44) and install a 2 mm dowel pin. Four bore holes are available on the cam disk, and they are located centrically around the center bore hole. Select the suitable bore to secure.
12
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Follower roll Starting point
Starting point
30
30
Insert clip and press the tongues outwards
Control valve opens counterclockwise

Fig. 6 Adjusting the cam disk
Control valve opens clockwise
60
90
90
60
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13
2.3.4 Reversing amplifier for double-acting actuators

Limit switches fitted with solenoid valves which are intended for use with double-acting actuators must be equipped with a reversing amplifier. The reversing amplifier is listed as an accessory in Table 7 on page 21. The output signal pressure of the solenoid valve is supplied at output A1 of the reversing amplifier. An opposing pressure, which equals the required supply pressure when added to the pressure at A1, is supplied at output A2. A1 + A2 = Z applies. Assembly Important! Remove the sealing plug (1.5) before installing the reversing amplifier. The rubber seal (1.4) must remain installed. 1. Screw the special nuts (1.3) included in the accessories of the reversing amplifier into the threaded connections of the limit switch. 2. Insert the gasket (1.2) into the recess of the reversing amplifier and push the two hollowed special screws (1.1) into the connecting bore holes A1 and Z. 3. Place the reversing amplifier onto the limit switch and screw tight using the two special screws (1.1).
Signal pressure connections A1: Connect output A1 to the signal pressure connection on the actuator that opens the valve when the pressure increases. A2 : Connect output A2 to the signal pressure connection on the actuator that closes the valve when the pressure increases.
14
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From the limit switch
Output 38
Supply 9
A1
A2
To the actuator
1.3 1.1 1.2 1.4 1.5 A2

1 1.1 1.2 1.3 1.4 1.5 Reversing amplifier Special screws Gasket Special nuts Rubber seal Sealing plug
A1
Vent plug or filter check valve
Supply 9
Output 38
A1
1.3 1.2
Fig. 7 Mounting a reversing amplifier
1.1
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15
Mounting parts table
Table 1
Direct attachment (Fig. 3)
Actuator size cm2 120 240 and 350 700 Actuator Type 3277-5xxxxxx. 00 (old) Actuator with index 3277-5xxxxxxxx. 00 (old) Actuator with index . 01or higher (new) G 1/8 1/8 NPT .01or higher (new)
Attachment kit Order no. 1400-6790 1400-6791 1400-6370 1400-6371 Order no. 1400-6819 1400-6822 1400-6820 1400-6821 1400-6823
Required lever with associated clamp and distance plate D1 with sealing plug for output (38) for version with solenoid valve G 1/4 1/4 NPT
D1 (33 mm long with 17-mm high bracket) D2 (44 mm long with 13-mm high bracket) Table 2 (only for versions with solenoid valve) Switchover plate for 120 cm2 actuators Switchover plate new Connection plate for additional attachment of, e.g. a solenoid valve Connection plate new
Note! Only new switchover and connecting plates can be used for new actuators (index 01). Old and new plates are not interchangeable. Required connection block for 240, 350 and 700 cm2 actuator (including seals and mounting screws) Table 3 (only for version with solenoid valve) Required tube connection including screw joint For actuator: Actuator stem retracts or when filling the top diaphragm chamber with air Accessories Pressure gauge mounting kit for supply air and signal pressure Actuator size in cm2 240 240 350 350 700 700 G 1/4 1/4 NPT Material Steel Stainless steel Steel Stainless steel Steel Stainless steel Stainless steel/Br SS/SS 1400-8811 1400-8812 Order no. 1400-6444 1400-6445 1400-6446 1400-6447 1400-6448 1400-6449 1400-6950 1400-6951 1790-7408
Filter check valve, replaces the vent plug and raises the degree of protection to IP 65
16
EB 8356 EN
Mounting parts table
Table 4 Attachment IEC 60534-6 (Fig. 4) NAMUR attachment kit Parts, see Fig. 4
Control valve Valve with cast yoke 20 to 25 20 to 25 25 to 30 25 to 30 30 to 35 30 to 35
Travel in mm 7.5 to 60 22.5 to 120
With lever N1 (125mm) N2 (212 mm) N1 N2 N1 N2 N1 N2
Order no. 1400-6787 1400-6789 1400-6436 1400-6437 1400-6438 1400-6439 1400-6440 1400-6441
Valve with rodtype yoke with rod diameter mm
Attachment to Fisher and Masoneilan linear actuators (one each of both attachment kits are required per actuator) Accessories (w. sol. valve) Press. gauge mount. block Press. gauge mount. kit for supply and signal pressure G 1/4: St. steel/brass: 1400-7098 1400-6950
1400-6771and 1400-6787 1/4 NPT: St. st./st. st.: 1400-7099 1400-6951 1790-7408
Filter check valve, replaces the vent plug and raises the degree of protection to IP 65 Table 5 Attachment acc. to IEC 60534-6 Travel in mm *) Pin on lever marking *) Distance between pin/lever fulcrum With lever Transmission pin (27a) in position
*)
7.5 1 42
15 2 84
15 1 42
30 2 84
30 1 42
60 2 84
30 1 84
60 2 168
60 1 84
120 2 168
N1 (125 mm long) A A B
N2 (212 mm long) A B
Interpolate intermediate values Rotary actuator for mounting parts (Fig. 5) 160 cm2 1400-7103 Camflex I DN 25...100 1400-7118 320 cm2 1400-7104 Camflex I DN 125...250 1400-7119 VDI/VDE 3845 1400-7105 Camflex II 1400-7120 1400-6664 1079-1118 1079-1119 1400-6950 1400-6951 1790-7408
Table 6 Order no.
SAMSON Type 3278 Actuator
Attachment Masoneilan Order no.
Cam disk with accessories cam disk, linear characteristics (0050-0072) angle of rotation 0 to 90 Reversing amplifier (Fig. 7) for double-acting springless actuators G threaded connection NPT threaded connection Accessories (only for versions with solenoid valves) Press. gauge mount. kit for supply air and signal pressure Stainless steel/brass Stainless steel/st. steel
Filter check valve, replaces the vent plug and raises the degree of protection to IP 65
EB 8356 EN
17
Electrical connections
3 Electrical connections
As far as the electrical installation of the device is concerned, the relevant national regulations governing the installation of electrical equipment and the national accident prevention regulations of the country of destination must be adhered to. In Germany, these are the VDE regulations and accident prevention regulations of the employers liability insurance. For installation in hazardous areas, the following standards apply: EN 60079-14: 1997; VDE 0165 Part 1/8.98 "Electrical apparatus for explosive gas areas" and EN 50281-12: VDE 0165 Part 2/11.99 "Electrical apparatus for use in the presence of combustible dust". For intrinsically safe electrical apparatus that are certified according to the Directive 79/196/EEC, the data specified in the certificate of conformity apply for connection of intrinsically safe circuits. For intrinsically safe electrical apparatus that are certified according to the Directive 94/9/EC, the data specified in the EC type examination certificate apply for connection of intrinsically safe circuits. Note: It is absolutely necessary to keep to the terminal plan specified in the certificate. Reversal of the electrical connections may cause the explosion protection to be ineffective! Do not tamper with any painted screws inside or on the case.
Switching amplifier To operate the inductive limit switches, switching amplifiers complying with EN 60947-5-6 must be connected in the output circuit. When the limit switch is installed in hazardous areas, you are required to observe the relevant regulations. Note on the selection of cables and wires! To run several intrinsically-safe circuits in a multi-core cable, observe paragraph 12 of EN 60079-14; VDE 0165/8.98 standards. Note especially that for commonly used insulating materials, such as polyethylene, the radial thickness of the conductor insulation must be minimum 0.2 mm. The diameter of a single wire of a flexible conductor must not be smaller than 0.1 mm. The conductor ends must be protected against unlaying, e.g. by using wire end ferrules. Any unused openings on the limit switch must be closed with plugs. Devices used in ambient temperatures down to 40 C must be fitted with metal cable glands.
For the terminal assignment, refer to Fig. 8 or to the label on the terminal strip.
18
EB 8356 EN
Pneumatic connections for versions with solenoid valve
Accessories: Model code 3768-x...x. 03 and lower Cable gland PG 13.5: Black Order no. 1400-6781 Blue Order no. 1400-6782 Adapter PG 13.5 on 1/2" NPT: Metallic Order no. 1400-7109 Blue finish Order no. 1400-7110 Model code 3768-x...x. 04 and higher Cable gland M20 x 1.5: Black Order no. 1400-6985 Blue Order no. 1400-6986 Nickel-plated brass Order no. 1400-4875 Adapter M20 x 1.5 on 1/2" NPT: Aluminum powder-coated Order no. 0310-2149
3.1 Pneumatic connections for versions with solenoid valve

The air connections are either 1/4 NPT or G 1/4 tapped holes. The customary screw joints for metal and copper tubes or plastic hoses can be used. Important! Make sure that the supply air is dehumidified and free of oil and dust. You are required to observe the maintenance instructions for upstream pressure reducing stations. Thoroughly flush the pneumatic lines prior to installation. When attaching the Type 3277 Actuator directly, the signal pressure connection is fixed. When using NAMUR attachment, the signal pressure line is connected to either the upper or lower diaphragm chamber of the actuator, depending on the actuators fail-safe action, i.e. "Actuator stem retracts" or "Actuator stem extends". Exhaust air: Models with the index 3768-x...x. 03 and higher are equipped with a hinged cover without a venting hole. The exhaust air connections for these models are included in the mounting accessories. For direct attachment, the vent plug is located on the plastic cover of the actuator, whereas for NAMUR attachment, it is located on the adapter housing and for attachment to rotary actuators on the intermediate piece. Note! If you intend to replace older models with model indices 3768-x...x. 02 or lower, the mounting parts need replacing, too.
Rear connections
(B) A +41 42 +51 52
(A) B +81 82 + 6 to 24 V DC solenoid valve (optional)
Switching amplifier acc. to EN 60947-5-6
Fig. 8 Electrical connections
EB 8356 EN
19
Operation Adjusting the limit contacts
4 Operation Adjusting the limit contacts

On the rotary axis, there are two adjustable tags (51) which operate the associated proximity switches (50). To operate the inductive limit switches, corresponding switching amplifiers must be connected in the output circuit (see section 3). When the tag (4) is in the inductive field of the switch, the switch assumes a high resistance. When it is no longer in the field, the switch assumes a low resistance. The limit contacts are usually adjusted to issue a signal for both limit positions. The switches, however, can also be adjusted to signalize intermediate positions. The assignment of the switches A and B must be determined according to Tables 7 and 8. It depends on the mounting position
of the limit switch and the limit position of the valve (either valve Open or Closed). The switches A and B are optionally assigned to the terminal pairs 41/42 and 51/52 by turning the associated name plate on the terminal block (see also Fig. 8). Important! Since the tags of the limit switches cannot be turned by 360, correct assignment of the switches A and B to the valve positions Open and Closed must be observed, especially when the limit switches are to be connected in fail-safe circuits. The desired switching function, i.e. whether the output relay must be picked up or released when the tag has entered the field, must be determined by means of jumpers for either working current or closed circuit current at the switching amplifier.
Fig. 9 Limit contacts
20
EB 8356 EN
Operation Adjusting the limit contacts
Setting the switching point Move the valve to the switching position and adjust the tag by turning the adjustment screw (53) so that the switching point is reached and indicated by the LED on the switching amplifier. To ensure safe switching under any condition, the switching point should be adjusted to stop approx. 2 % before the mechanical stop (Open Closed) is reached.
Table 7
Direct attachment to Type 3277 Actuator (Fig. 3) Attachment left Switch Attachment right
Valve position Closed Open Table 8
Tag OUT B A
Tag IN A B
Tag OUT A B
Tag IN B A
NAMUR attachment (Fig. 4) Attachment left
Mounting position of adapter housing when looking onto the lever (18) Attachment right
Cable gland points towards
Valve position OUT
Switch Tag IN A B B A
Cable gland points towards
Valve position OUT
Switch Tag IN B A A B
Front Back
Closed Open Closed Open
B A A B
Front Back
Closed Open Closed Open
A B B A
EB 8356 EN
21
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 inspected the device according to the explosion protection requirements, issued a certificate 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 performs a routine check test on the device prior to taking it into operation again, and the success of the routine check test is documented by attaching a mark of conformity to the device. Parts used in explosion-protected versions should only be exchanged for original detail inspected parts from the manufacturer.
22
EB 8356 EN
Dimensions in mm
6 Dimensions in mm
185
19.5
68
M20 x 1.5
164
29
14 Output (38)
37
76
150
Reversing amplifier (optional)
28
Supply (9)
39
35
68
44
19.5
50
110 56 58
50
82
46
Fulcrum of the actuator shaft
56
Pneumatic connection reversing amplifier Output 1 (A1) 28.5
66
164
Output 2 (A2)
28.5
76
50
Supply (Z)
N1=113 N2=200
36
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
SAMSON AG MESS- UND REGELTECHNIK Weismllerstrae 3 60314 Frankfurt Germany Phone: +49 69 4009-0 Fax: +49 69 4009-1507 Internet: http://www.samson.de
EB 8356 EN
S/Z 2004-05
B73G
Filter/Regulator B73G - 555 - 555 - 555
Port 2 ....1/4" 3 ....3/8" 4 ....1/2" Adjustment Thread Form K....Knob A....PTF B....ISO Rc taper T ....T-bar G....ISO G parallel Drain Bowl A....Automatic D....Metal with liquid level indicator Q....Manual, 1/4 turn P....Transparent with guard T ....Transparent Diaphragm Element 1 ....5 m N....Non-relieving 2 ....25 m R....Relieving 3 ....40 m
Installation & Maintenance Instructions
Spring (Outlet Pressure Range) * F ....0,3 to 4 bar (5 to 60 psig) M...0,3 to 10 bar (5 to 150 psig) S....0,7 to 17 bar (10 to 250 psig)
Gauge G....With N....Without
* 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. TECHNICAL DATA Fluid: Compressed air Maximum pressure: Transparent bowl: 10 bar (150 psig) Metal bowl: 17 bar (250 psig) Operating temperature*: Transparent bowl: -20 to +50C (0 to +125F) Metal bowl: -20 to +80C (0 to +175F) * Air supply must be dry enough to avoid ice formation at temperatures below +2C (+35F). Particle removal: 5 m, 25 m, or 40 m filter element Air quality: Within ISO 8573-1, Class 3 and Class 5 (particulates) Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar (90 psig) set pressure and 1 bar (15 psig) droop from set: 50 dm3/s (106 scfm) Nominal bowl size: 0,1 litre (3.5 fluid ounce) Manual drain connection: 1/8" Automatic drain connection: 1/8" Automatic drain operating conditions (float operated): Bowl pressure required to close drain: Greater than 0,3 bar (5 psig) Bowl pressure required to open drain: Less than 0,2 bar (3 psig) Minimum air flow required to close drain: 0,1 dm3/s (0.2 scfm) Manual operation: Depress pin inside drain outlet to drain bowl Gauge ports: 14 PTF with PTF main ports Rc1/4 with ISO Rc main ports Rc1/8 with ISO G main ports Materials: Body: Aluminum Bonnet: Aluminum Valve: Brass Bowl: Transparent: Polycarbonate Transparent with guard: Polycarbonate, steel guard Metal: Aluminum Metal bowl liquid level indicator lens: Transparent nylon Element: Sintered polypropylene Elastomers: Neoprene and nitrile REPLACEMENT ITEMS Service Kit (includes items circled on exploded view): Relieving.............................................................4383-600 Nonrelieving .......................................................4383-601 Liquid level lens kit (43, 45, 46, 47) ......................4380-020 Filter element, 5m (50) ..........................................4438-01 Filter element, 25m (50) ........................................4438-02 Filter element, 40m (50) ........................................4438-03 Manual drain (18, 19, 20) ..........................................619-50 Automatic drain (21, 22, 23) .................................4000-51R Tamper resistant cover (knob adjustment only).......4455-51 PANEL MOUNTING DIMENSIONS Panel mounting hole diameter: 48 mm (1.89") Panel thickness: 2 to 6 mm (0.06" to 0.24") INSTALLATION 1. Shut off air pressure. Install filter/regulator in air line q vertically (bowl down), q with air flow in direction of arrow on body, q upstream of lubricators and cycling valves, q as close as possible to the device being serviced. 2. Connect piping to proper ports using pipe thread sealant on male threads only. Do not allow sealant to enter interior of unit. 3. Push bowl, or bowl with guard, into body and turn fully clockwise before pressurizing. 4. Install a pressure gauge or plug the gauge ports. Gauge ports can also be used as additional outlets for regulated air.
Norgren 1998
ADJUSTMENT 1. Before applying inlet pressure to filter/regulator, turn adjustment (1 or 7) counterclockwise to remove all force on regulating spring (12). 2. Apply inlet pressure, then turn adjustment (1 or 7) clockwise to increase and counterclockwise to decrease pressure setting. 3. Always approach the desired pressure from a lower pressure. When reducing from a higher to a lower setting, first reduce to some pressure less than that desired, then bring up to the desired pressure. NOTE With non-relieving filter/regulators, make pressure reductions with some air flow in the system. If made under no flow (dead-end) conditions, the filter/regulator will trap the over-pressure in the downstream line. 4. KNOB ADJUSTMENT. Push knob down to lock pressure setting. Pull knob up to release. Install tamper resistant cover (see Replacement Items) to make setting tamper resistant. 5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock pressure setting. SERVICING 1. Open manual drain to expel accumulated liquids. Keep liquids below baffle (49). 2. Clean or replace filter element when dirty. DISASSEMBLY 1. Filter/regulator can be disassembled without removal from air line. 2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero. 3. Turn adjustment (1 or 7) fully counterclockwise. 4. Remove bowl - push into body and turn counterclockwise. 5. Disassemble in general accordance with the item numbers on exploded view. Do not remove the drains unless replacement is necessary. Remove and replace drains only if they malfunction. CLEANING 1. Clean plastic bowl (25, 35) with warm water only. Clean other parts with warm water and soap. 2. Rinse and dry parts. Blow out internal passages in body (16) with clean, dry compressed air. Blow air through filter element (50) from inside to outside to remove surface contaminants. 3. Inspect parts. Replace those found to be damaged. Replace plastic bowl with a metal bowl if plastic bowl shows signs of cracking or cloudiness. ASSEMBLY 1. Lubricate the following items with o-ring grease. 4 (Thrust washer) - outer circumference and both sides. 5, 7 (Adjusting screw) - threads and tip. 18, 28, 37 (Manual drain body) - the portion of the body that contacts the bowl, and the hole that accommodates the stem of drain valve (19, 29, 38). 53 (Valve) - stem. 26, 34, 47, 54 (O-rings) 2. Assemble the unit as shown on the exploded view. Push bowl, or bowl with guard, into body and turn fully clockwise. 3. Torque Table Item Torque in Nm (Inch-Pounds) 2, 9 (Screw) 2,3 to 3,4 (20 to 30) 22, 32, 41 (Nut) 2,3 to 2,8 (20 to 25) 43 (Screw) 1,7 to 3,4 (15 to 30) 49 (Baffle), 51 (Louver) 1,1 to 2,2 (10 to 20)
12
3 2
13 16
15
5 14 53 6 7 8 10 9 54 52
51
50 11 49
26 18 21
25
17 20 19
23
24
22
28
34 31 35 33 30
27
29 32 47 37 36 42 39 38 41 44 40 48 46 45 43
IM-180.300.01 (4/98)
a subsidiary of IMI plc
Supersedes 12/97
B73G
Installation & Maintenance Instructions
CAUTION Water vapor will pass through these units and could condense into liquid form downstream as air temperature drops. Install an air dryer if water condensation could have a detrimental effect on the application. WARNING These products are intended for use in industrial compressed air systems only. Do not use these products where pressures and temperatures can exceed those listed under Technical Data. Polycarbonate plastic bowls can be damaged and possibly burst if exposed to such substances as certain solvents, strong alkalies, compressor oils containing esterbased additives or synthetic oils. Fumes of these substances in contact with the polycarbonate bowl, externally or internally, can also result in damage. Clean with warm water only. Use metal bowl in applications where a plastic bowl might be exposed to substances that are incompatible with polycarbonate. If outlet pressure in excess of the filter/regulator pressure setting could cause downstream equipment to rupture or malfunction, install a pressure relief device downstream of the filter/regulator. The relief pressure and flow capacity of the relief device must satisfy system requirements. The accuracy of the indication of pressure gauges can change, both during shipment (despite care in packaging) and during the service life. If a pressure gauge is to be used with these products and if inaccurate indications may be hazardous to personnel or property, the gauge should be calibrated before initial installation and at regular intervals during use. Before using these products with fluids other than air, for non industrial applications, or for life-support systems consult Norgren.
Norgren 1998
IM-180.300.02 (4/98)
a subsidiary of IMI plc
Supersedes 12/97
No.IL01OM00006
OPERATION MANUAL
BOOSTER
RELAY
CORPORATION
NoFSM027-1
CONTENTS
Page Instructions for your safety 12
1. Outline 2. Specification 3. Structure and the Operation Principle 4. Transportation and Storage 5. Precautions in Using 6. Maintenance 7. Countermeasures for Failure 8. Spare Parts List Drawings IL100
3 3 34 5 6 78 9 10 1112
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) (Note 2)
Caution Warning Danger
: : :
Operator error could result in injury or equipment damage.
Operator error could result in serious injury or loss of life.
In extreme conditions, there is a possibility of serious injury or loss of life
ISO 4414 JIS B 8370
Pneumatic fluid power-Recommendations for the application of equipment to transmission and control system. Pneumatic system axiom
!
1.
Warning
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. 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. Do not service machinery / equipment or attempt to remove component until safety is confirmed. 1. Inspection and maintenance of machinery / equipment should only be performed after confirmation of safe locked-out control positions. 2. When equipment is removed, confirm the safety process as mentioned above. Cut the supply pressure for this equipment and exhaust all residual compressed air in the system. Before machinery / equipment is restarted, take measures to prevent shooting out of cylinder piston rod etc.
2.
3.
3. 4.
Contact SMC if the product is to be used in any of the following conditions . 1. Conditions and environments beyond the given specifications, or if product is used outdoors. 2. Installation on equipment in conjunction with atomic energy, railway, air navigation, vehicles, medical equipment, food and beverage, recreation equipment, emergency stop circuits, press applications, or safety equipment. An application which has the possibility of having negative effects on people, property, or animals requiring special safety analysis.
3.
1. Outline
Increase the operating speed of controlling part when the piping between the instruments and the controlling part is very long, or the controlling part capacity is large.
2. Specification
Supply pressure InputOutput pressure Output flow Air consumption Linearity Hysteresis Effective orifice (Cv factor) Ambient temperature and operating fluid temperature Port size Mass MAX.1.0MPa MAX.0.7MPa Max. 1MPa (Note 1) 0.140.7MPa (Note 1) Within 1% Within 1% 1.1 560 PT 1/43/8 560g
3. Structure and the operation principle

Input force from the instrument enters to the input chamber and act to diaphragm A. This works against the force generated by diaphragm B. When the force generated by the input is strong, the internal valve is pressed down and the supply air flows to the output side. When not strong, the internal valve is closed and the exhaust port opens for exhaust. This is how the force generated by diaphragm A and B is balanced. Opening of the needle valve connect the air path of the input and the output. The adjustment of the throttle valve, the stability of the closed loop including the booster relay is improved.
4. Transportation and Storage
Warning
(1) Handle the product with care. (2) Do not expose to rain. (3) The product is packed in a vinyl bag for shipment to prevent from dust. Avoid taking out of the bag just before piping even after unpacking. (4) If the product is kept unpacking for a certain period, select a place where there is no moisture nor corrosive gas. While the product shipped has been applied specified paint and surface treatment, take care that inappropriate storing environment may cause generating rust.
5. Precautions in using
Warning
Operation
(1) Do not operate the booster relay out of the specifications, because it causes malfunction. (2) If booster relay failure affecting the system is expected, provide a safety circuit for the system to avoid danger.
Warning
Handling
(1) Excess vibration and impact on the booster relay cause failure, may cause failure, so that take care in handling during transportation and operation. (2) Mount the filter to the pressure supply line. Use the mist separator when the oil mist and carbon are contained. (3) Flush the air piping before connecting the booster relay. (4) Mind the arrow direction of the air flow when piping. (5) The needle valve is opened for 3/4 turn and locked. No adjustment is necessary except when the control system is unstable. (6) Opening the needle valve delays the response, closing quickens the response.
Warning
Air supply
(1) Please use the filter to the supply line. Where contained oil mist and carbon, please use the mist separator. (2) Avoid using compressed air compressed air containing chemicals, synthetic fluid including organic solvent, salinity, and corrosive gas as it may cause malfunction.
Warning
Environment
(1) Do not use in environment where the product is exposed to corrosive gas, chemicals, salt water, water or steam. (2) Do not operate the product in a location where it is subject to strong vibration and/or shock. For vibration, it should be within IG 60Hz.
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.
Part description Diaphragm (2,10) Oring (11,12) Check items Confirmation Countermeasure
No crack or flaw on Visual inspection the surface No crack or flaw on Visual inspection the surface
Part replacement if abnormality is found.
Valve stem spring No crack due to hold Visual inspection (6) Without lock nut Main valve (3) Hand or tool If loosen, retighten. loosen *( ) shows booster relay disassemble drawing part no.
To re-assemble, ensure no foreign matter inside product and pay attention for air path position of each part. (2) Product replacement (recommended : once / 3 years) This product rubber part is recommended to replace once per 3 years. Part replacement adjustment (valve seat centering, main valve length adjustment etc.) make effects on property. Product replacement is recommended by whole product per 3 years if it is used on extremely important point.
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 251mm.
7. Countermeasures for failure
Warning
Avoid use when failure is not solved. Phenomenon Too much exaust port flow Cause Countermeasures
Disassemble and clean. Dust attach supply port or (If flawed, replace the from exaust port part.) Broken diaphragm Pressure leak loosen screw due to Replace diaphragm Tighten screw Decrease open degrees of restrictor, and lock. Replace diaphragm optimum
No signal even if input Restrictor open too much signal is applied Broken diaphragm
Bad characteristic
Valve stem length is Readjust into changed due to loosen lock valve, and lock. nut Plugged restrictor Deformed diaphragm
Disassemble and clean Replace diaphragm
10
11
12

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Pneumatic Control Valve Type 3241-1 and Type 3241-7

Type 3241-1 Type 3241-7

Mounting and Operating Instructions EB 8015 EN

Page Design and principle of operation . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 7 8 9 9 9 9 9 10 11 11 12 13 13 13 15 15 16 16

Material identifying marks . . . . . . . . . . . . . . . . . . . . . . 18 Description of nameplates . . . . . . . . . . . . . . . . . . . . . . . 19 Customer inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General safety instructions

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

Design and principle of operation

Design and operation

Assembling valve and actuator

Assembly and adjustment

Assembling valve and actuator

4.1 Spring 4.2 Packing 5 Valve bonnet

6.2 6 5.2 4.2

Type 3241 Valve

Fig, 2 Sectional drawings

Assembling valve and actuator

Type 3277 Actuator

8 Actuator 8.1 Actuator stem 8.2 Nut

Assembling valve and actuator

Pretensioning springs in actuator version Actuator stem extends

Assembling valve and actuator

Valve and actuator with different rated travels

Actuator version "Actuator stem retracts"

Actuator version "Actuator stem extends"

Installation Mounting position

Signal pressure line

Maintenance Replacing parts

Maintenance Replacing parts

Maintenance Replacing parts

Standard valve version

5.1.1 Stuffing box packing

4.2 4.3 4.1 4.2

4.3 4.1 6 6.3 5

Fig. 4 Stuffing box packing

Maintenance Replacing parts

4 Unscrew the seat (2) using the appropri-

5.1.2 Seat and/or plug

4 Remove the old plug and replace it with

Seat bore 12 24...48 6...80

x [mm] 0.5 1.0 2.0 2.5

Reworking the plug

4 Slight damage at the sealing edges of

Fig. 5 Plug with soft sealing

Maintenance Replacing parts

Valve with insulating section or metal bellows seal

5.2.1 Stuffing box packing

Maintenance Replacing parts

Fig. 6 Versions with metal bellows seal and insulating section

Maintenance Replacing parts

5.2.4 Metal bellows

Caution! Do not twist the metal bellows!

Maintenance Replacing parts

Replacing the collar or seal

Maintenance Replacing parts

3 3.1 3.2 3.3 3.4 6 DN 100 to 150

Fig. 7 Pressure-balanced plug

Material identifying marks

Material identifying marks

4 Stellited seats are marked by a

the material number or its designation is engraved on the plug.

4 Stellited plugs are marked by an

Fig. 8 Valve nameplate (left) and actuator nameplates (right)

If you encounter any problems, please submit the following details:

Proper shipping and appropriate storage are assumed.