Samson 3430 User manual

Series 430
Pneumatic Indicating Controllers
Type 3430
Fig. 1 · Controller stations
Mounting and
Operating Instructions
EB 7030 EN
Edition October 2010
Type 3432 Controller Station
– with Type 3435 Transmitter Module for Pressure
– with Type 3436 Transmitter Module for Temperature
– with Type 3438 Transmitter Module for Temperature (Pt 100)
– for standardized signals
Version shown with lockable door and integrated
Type 3436 Transmitter Module for Temperature
Type 3431 Controller Station
– for standardized signals

Contents Page
1 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Settings at the controller modules . . . . . . . . . . . . . . . . . . . . 4
2.1.1 Operating action . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.2 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.3 Proportional-action coefficient Kp . . . . . . . . . . . . . . . . . . . . 6
2.1.4 Reset time Tn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.5 Rate time Tv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.6 Operating point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Setting the limit switches. . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Tuning the controller . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1 Setting the operating point in P and PD controllers . . . . . . . . . . . . 9
3.2 Smooth automatic/manual mode changeover . . . . . . . . . . . . . 10
3.3 Smooth changeover between the internal and external reference variable 10
3.4 Readjusting the controller’s zero point . . . . . . . . . . . . . . . . . 10
4 Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Transmitter modules . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Controller station . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Controller modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3.1 Type 3433 Controller Modules . . . . . . . . . . . . . . . . . . . . . 14
5.3.2 Type 3434 Controller Modules . . . . . . . . . . . . . . . . . . . . . 17
5.4 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.1 Type 6112 i/p Converter . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.2 wint/wext selector switch . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.3 Supply pressure regulators . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.4 Inductive limit switches . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.1 Changing scales. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Installing the temperature sensor . . . . . . . . . . . . . . . . . . . . 22
7 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.1 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.2 Adjusting the supply air for version with supply pressure regulator. . . . 25
7.2 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2EB 7030 EN
Contents

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Checking the air supply . . . . . . . . . . . . . . . . . . . . . . . . 27
9 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.1 Changing the controller function . . . . . . . . . . . . . . . . . . . . 28
9.2 Exchanging the transmitter module . . . . . . . . . . . . . . . . . . . 30
9.3 Checking the controller function . . . . . . . . . . . . . . . . . . . . 30
10 Use in hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . 31
10.1 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 31
11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EB 7030 EN 3
Contents
General safety instructions
4
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 relevant
standards.
4
Explosion-protected versions 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.
4
Any hazards that could be caused by the signal pressure are to be
prevented by means of the appropriate measures.
4
Proper shipping and appropriate storage of the device are assumed.

1 Application
The Series 430 Pneumatic Indicating Con-
trollers are used for applications in process
automation and industrial plants.
The controllers directly measure the con-
trolled variables (pressure, temperature,
electric or pneumatic standardized signal)
and display the value. They compare the
measured variable with the set point and is-
sue a corresponding pneumatic control sig-
nal from 0.2 to 1 bar (3 to 15 psi).
A supply pressure of 1.4 bar ±0.1 bar
(20 psi ±1.5 psi) is required or an operat-
ing pressure of 2 to 12 bar (30 to 180 psi)
when a supply pressure regulator is in-
stalled.
2 Operation
2.1 Settings at the controller
modules
The controller module in the station can be
accessed after the lock (Fig. 2) has been re-
leased and the indicating unit (5) has been
opened out.
The settings for operating action (turnboard
A) and air supply (turnboard B) must be
performed prior to commissioning.
4Unscrew the mounting screw (6) on the
controller module. Pull it off its self-seal-
ing hose fittings and lift out of the con-
troller station.
2.1.1 Operating action
The operating action for the control loop is
set at the turnboard A(Fig. 2), where the
position of its arrow symbol according to the
arrow symbol on the controller module de-
termines the operation action of the control-
ler.
34Arrow tips facing opposite
directions:
Operating direction:
Increasing/decreasing =
As the controlled variable x increases,
the output signal pressure y
decreases.
44Arrow tips facing the same direction:
Operating direction:
Increasing/increasing
As the controlled variable x increases,
the output signal pressure y
increases.
4EB 7030 EN
Application

Fig. 2 · Turnboards and adjusters
1 Controller station (Type 3432)
1.1 Scale
1.3 Actual value pointer (red)
1.4 Set point adjuster
2 Transmitter module
or connecting base
3 Controller module
3.1 Comparator
3.2 Connecting plate
3.3 Hex screws
3.4 Screws (inside)
4 Lock
5 Indicating unit
6 Mounting screw
7 Restriction
8 Zero adjuster
9 Kp adjuster
10 Tn adjuster
11 Tv adjuster (only in
PD or PID controller)
12 Operating point adjuster
(only in P or PD controller)
Type 3432 Contr. Module
Side view without comparator
1
1.3
1.1
4
1.4
5
2
B
10
12
11
3.3
3
6
7
A3.2 3.4 8 9 3.1
A
8
63109
Oper. action
Type 3433-2 (PI) Controller Module Type 3434-2 (PI) Controller Module
Air supply Oper. action
Setting or modifying the operating direction:
Unfasten the screw in turnboard A(Fig. 2)
and lift it off together with the turnboard. If
necessary, lever the board at the side.
Do not lose the rubber seal.
4Turn the board by 90° so that the re-
quired arrow is aligned with the arrow
on the base plate.
4Insert board and tighten screw.
4Reassemble the controller module in the
controller station.
2.1.2 Air supply
(only with Type 3433 Controller Module)
The position of the turnboard B(Fig. 2) with
its arrow symbol determines the air supply
to the feedback bellows. It can be accessed
after the comparator (3.1) has been re-
moved.
4yA Normal air supply, approx. 1 mn³/h
per % of the system deviation
4RLarge air supply, approx. 3 mn³/h
per % of the system deviation
(not with P or PD controller modules)
EB 7030 EN 5
Operation

4Unfasten screws (3.3) and pull off the
connecting plate (3.2) together with nuts
and bolts from the controller module.
4Unscrew the hexagonal socket-head
screws (3.4) at the side and lift the com-
parator (3.1) out of the controller mod-
ule.
Setting or modifying the air supply:
4Unfasten screw in turnboard Band lift it
off together with the turnboard. If neces-
sary, lever the board at the side.
Do not lose the rubber seal.
4Turn the board so that the arrow is
aligned with the mark yA or Ron the
controller module. Insert board and
tighten screw.
4Reassemble the controller module in the
controller station.
2.1.3 Proportional-action
coefficient Kp
The setting of the KP(adjuster 9) determines
the controller gain and is related to the con-
trolled system that is being tuned (section
3.1).
2.1.4 Reset time Tn
Controller versions with integral-action com-
ponent require the reset time to be set at the
restriction (10). The setting depends on the
controlled system that is being tuned
(section 3.1).
2.1.5 Rate time Tv
For Type 3433 Controller versions with de-
rivative-action component, the rate time Tv
needs to be set at the restriction (11). The
setting depends on the controlled system that
is being tuned (section 3.1).
2.1.6 Operating point
Controller modules without integral-action
component such as P or PD controllers have
an operating point. In Type 3433 Controller
Module, it can be adjusted between 0 and
100 % which corresponds to 0.2 to 1 bar by
an operating point adjuster (12). The setting
depends on the manipulated variable y (sec-
tion 3.1.1).
In Type 3434 P Controller Module, the oper-
ating point is fixed at 0.6 bar.
6EB 7030 EN
Operation

2.2 Setting the limit switches
Only applies to controller stations with the
limit switch option:
To set the limit switches, first release the lock
(4, Fig. 2) and open out the indicating unit
(5). The contacts can be accessed at the
back.
Adjust proximity switches by placing a
screwdriver in the clamps between 0 and
100 % of the reference scale and move until
a contact is made over the connected switch-
ing amplifier.
EB 7030 EN 7
Operation
Fig. 3 · Limit switches
Clamps with proximity switch

3 Commissioning
Prior to commissioning the control loop,
check all devices to make sure they are con-
nected correctly, do not leak and function
properly.
Release lock (4) and open out the indicating
unit (5) to enable easy access to the operat-
ing controls at the controller.
Check the turnboard to make sure the cor-
rect operating action is set at the controller
(see section 2.1.1).
3.1 Tuning the controller
The controller needs to be tuned to the char-
acteristics of the controlled system using the
KPand Tnand/or Tvadjusters at the control-
ler module to ensure that the controller can
keep any system deviations for all set points
caused by the disturbance variables to zero
or at least to minimize them.
In case of controller stations which have a
manual/ automatic switch (1.6), the plant
must be started up manually.
We recommend to determine the settings by
using a tuning test (following the Ziegler and
Nichols method) which produces sufficient
results in most cases:
1. Apply supply air (1.4 ±0.1 bar).
2. Set the proportional-action coefficient KP
to a low value at the comparator.
3. Set Tnrestrictor to its maximum value
and Tvto its lowest value (applies only to
PI and PID controllers).
Setting in manual mode:
4. Set manual/automatic switch to Manual.
5. Operate manual adjuster (1.7) for the
control signal so that the controlled vari-
able (actual value pointer 1.3) slowly
settles on the adjusted set point (set point
pointer 1.4).
Should the differential pressure indicator
(1.8) move to zero, set the manual/auto-
matic switch (1.6) to Automatic.
Proceed as described in points 6 and 7.
Setting in automatic mode:
4. Set the set point to the required value at
the rotary knob (1.4) on the indicating
unit.
5. Set the Tnrestriction briefly to its lowest
value (completely open) to move the red
8EB 7030 EN
Commissioning
Fig. 4 · Front view
1.8
1.6
1.5
1.7
1.3
1.4
4
5
1.3 Actual value pointer (red)
1.4 Set point adjuster with green pointer
1.5 Signal pressure display
1.6 Manual/automatic switch
1.7 Adjuster for signal pressure (manual)
1.8 Differential pressure indicator
4 Lock
5 Indicating unit

actual value pointer to the green set
point pointer. Close the Tnrestriction
again.
6. Starting from a low value, increase the
proportional-action coefficient KPuntil
the actual value pointer displays an har-
monic oscillation pattern (uniform oscil-
lation amplitudes as shown in Fig. 5) of
the controlled variable.
If oscillations do not arise with a large
KPsetting, turn the rotary knob to
change the set point slightly and then re-
turn it to its former setting. It may be
necessary to increase the gain (KP)
slightly until an harmonic oscillation pat-
tern arises.
7. Write down the adjusted value of the KP
scale you have just adjusted as the criti-
cal proportional-action coefficient KPkrit.
Use a stopwatch to time the oscillation
time for one entire oscillation as Tkrit (PI
and PID controller only).
Multiply both values with the values in
the table (Fig. 5) and set as the favor-
able settings for KP, Tn, and Tvat the
controller.
Should oscillations still occur despite these
settings, slightly reduce KPand increase Tn.
Repeat these steps, if necessary, until the
control loop shows a satisfactory perfor-
mance. Leave enough time in between set-
ting to allow the controller to stabilize.
3.1.1 Setting the operating point in
P and PD controllers
(Type 3433 Controller Module only)
After setting the proportion-action coefficient
KPas described previously, set the operating
point for P and PD controllers instead of the
reset time Tn.
4Read off the controlled variable yA of the
controller at the display (1.5) when the
plant is in a steady-state condition and
set this value directly at the operating
point adjuster (12, Fig. 2). (Setting 0.2 to
1 bar = 0 to 100 %).
4Recorrect slightly until the system devia-
tion is zero. In case the signal pressure
display deviates, average the value.
Note!
On changing set point or reference variable,
the operating point must be set again as de-
scribed above.
If the reference variable is changed more of-
ten, set the operating point to 0.6 bar =
50 % (average value).
EB 7030 EN 9
Commissioning
Fig. 5 · Harmonic oscillation, settings
Cntr. KPTnTv
P 0.50 · KP,krit
PI 0.45 · KP,krit 0.85 · Tkrit
PID 0.59 · KP,krit 0.50 · Tkrit 0.12 · Tkrit
Controlled variable
(actual value)
Tkrit
Tkrit
–
+

Note!
The T
n
restriction must be completely opened
with a P/PI controller is switched over to P
action to allow the operating point adjuster
to work without delay.
Version with w-dependent operating point
This version does not need to be adjusted
since the operating point automatically fol-
lows the set point w.
3.2 Smooth automatic/manual
mode changeover
(only for controller station with manual/au-
tomatic changeover, Fig. 4)
The smooth switchover ensures that no pres-
sure surges can reach the valve when the
manual/automatic switch is activated as fol-
lows:
Changeover from automatic to manual
Use the manual adjuster (1.7) to adjust
signal pressure manual yH until the differen-
tial pressure indicator (1.8) is zero. Switch
over to manual at the switch.
Changeover from manual to automatic
If the plant is to be controlled manually to
the required value, the automatic signal
pressure yA must be matched to the manual
signal pressure yH by adjusting the set point
adjuster (1.4).
The switch (1.6) can only be set to automatic
after the differential pressure indicator (1.8)
is at zero.
Set the set point again to the required value.
3.3 Smooth changeover between
the internal and external re-
ference variable
When combining the fixed set point control
and follower control, the Type 3432 Con-
troller Station is equipped with a wint/wext
switch, a pressure adjuster and a differential
pressure indicator (Fig. 10).
The differential pressure indicator must first
be brought to zero by activating the pres-
sure adjuster in order to switch between the
reference variables.
3.4 Readjusting the controller’s
zero point
Should deviations arise between the actual
value and set point during operation, the
zero point adjustment can be readjusted by
turning the zero screw at the back of the dis-
play unit (5) until the actual value and set
point on the front display are the same
again.
Deviations between the actual value and set
point can also be corrected at the zero point
adjuster (8, Fig. 2) of the controller module.
10 EB 7030 EN
Commissioning
Differential pressure indicator
With Without deviation