Samson 430 Series Service manual

Translation of original instructions
EB 7030 EN
Type3430 Pneumatic Indicating Controllers
Series430
Edition May 2018
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
The version with lockable door and installed Type3436
Transmitter Module for temperature is shown.
Type3431 Controller Station
- for standardized signals

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samsongroup.com > Service & Support > Downloads >
Documentation.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
2 EB 7030 EN
WARNING!
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of
very high concern on the candidate list of the REACH regulation, this circumstance is
indicated on the SAMSON delivery note.
Information on safe use of the part affected uwww.samsongroup.com/en/about-
samson/material-compliance/reach-regulation.html.

Contents
EB 7030 EN 3
1 General safety instructions.............................................................................5
2 Application ...................................................................................................6
3 Operation.....................................................................................................6
3.1 Settings at the controller modules ....................................................................6
3.1.1 Direction of action ..........................................................................................6
3.1.2 Air output capacity ........................................................................................7
3.1.3 Proportional-action coefcient KP ....................................................................8
3.1.4 Reset time Tn .................................................................................................8
3.1.5 Derivative-action time Tv .................................................................................8
3.1.6 Operating point .............................................................................................8
3.2 Adjusting the limit contacts .............................................................................9
4 Start-up and settings ...................................................................................10
4.1 Tuning the controller .....................................................................................10
4.2 Adjusting the operating point in P and PD controllers ......................................11
4.3 Bumpless automatic/manual mode changeover ..............................................12
4.4 Bumpless changeover between internal or external set point ............................12
4.5 Readjusting the controller zero point ..............................................................12
5 Design and principle of operation ................................................................13
5.1 Transmitter modules ......................................................................................14
5.2 Controller station .........................................................................................16
5.3 Controller modules .......................................................................................16
5.3.1 Type3433 Controller Modules ......................................................................16
5.3.2 Type3434 Controller Module .......................................................................20
5.4 Diaphragm seal ...........................................................................................21
5.4.1 Mounting with diaphragm seal......................................................................21
5.4.2 Diaphragm seal for general use ....................................................................22
5.4.3 Diaphragm seals for use with oxygen ............................................................22
5.4.4 Diaphragm seals for use with ammable gases ..............................................22
5.5 Additional units ...........................................................................................25
5.5.1 Type6112 i/p Converter ..............................................................................25
5.5.2 wint/wext selector switch................................................................................25
5.5.3 Supply pressure regulator .............................................................................25
5.5.4 Inductive limit contacts ..................................................................................26
6 Installation..................................................................................................26
6.1 Mounting ....................................................................................................26
6.1.1 Changing scales ..........................................................................................33
6.2 Installing the temperature sensor ...................................................................33

Contents
4 EB 7030 EN
7 Connections ................................................................................................36
7.1 Pneumatic connections..................................................................................36
7.1.1 Connection examples ...................................................................................36
7.1.2 Adjusting the supply air in supply pressure regulators .....................................37
7.2 Electrical connections ...................................................................................38
8 Maintenance ...............................................................................................40
8.1 Checking the air supply ................................................................................40
9 Conversion..................................................................................................41
9.1 Changing the controller function ....................................................................41
9.2 Exchanging the transmitter module ................................................................44
9.3 Checking the controller function ....................................................................44
10 Use in hazardous areas...............................................................................45
10.1 Servicing explosion-protected devices ............................................................46
11 Technical data .............................................................................................47
12 Certicates..................................................................................................51

EB 7030 EN 5
General safety instructions
1 General safety instructions
−The device must be mounted, started up or serviced by fully trained and
qualied personnel only; the accepted industry codes and practices are to
be observed. Make sure employees or third persons are not exposed to any
danger.
−All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up and mainte-
nance, must be strictly observed.
−Devices with a CE marking have an EU declaration of conformity, which
includes information about the applied conformity assessment procedure.
The EU Declaration of Conformity is available on request.
−According to these mounting and operating instructions, trained personnel
refers to 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.
−To ensure appropriate use, only use the device in applications where the op-
erating pressure and temperatures do not exceed the specications used for
sizing the device at the ordering stage.
−The manufacturer does not assume any responsibility for damage caused by
external forces or any other external factors.
−Proper transport, storage, installation, operation and maintenance are as-
sumed.

6 EB 7030 EN
Application
2 Application
The Series430 Pneumatic Controllers are
used for the automation of process and in-
dustrial plants.
The controllers measure directly the
controlled variable (pressure, temperature,
electric or pneumatic standardized signal),
compare the measured value with the set
point and issue a pneumatic control signal of
0.2 to 1bar (3 to 15psi).
A supply pressure of 1.4bar ±0.1bar
(20psi ±1.5psi) or an operating air pres-
sure of 2 to 12bar (30 to 180psi) with an
installed supply pressure regulator is re-
quired.
3 Operation
3.1 Settings at the controller
modules
The controller module in the station can be
accessed after releasing the lock (4, Fig.1)
and opening the indicating unit (5).
The settings for direction of action (turnboard
A) and air delivery (turnboard B) must be
performed prior to start-up.
Unscrew the fastening screw (6) at the con-
troller module, pull the module off its self-
seal push-on ttings and lift it out of the con-
troller station.
3.1.1 Direction of action
The direction of action for the control loop is
set at the turnboard A, where the position of
its arrow symbol according to the arrow
symbol on the controller module determines
the direction of action of the controller
(Fig.1).
 Arrow tips facing opposite directions:
Direction of action: increasing/
decreasing
As the controlled variable x
increases, the output pressure y falls.
 Arrow tips facing the same direction:
Direction of action: increasing/
increasing
As the controlled variable x
increases, the output pressure y
increases.
Setting or changing the direction of action:
Undo the screw in turnboard A (Fig.1) and
lift it off together with the turnboard. If nec-
essary, lever the board at the side. Do not
lose the rubber seal.
Î Turn the board by 90° so that the re-
quired arrow is aligned with the arrow
on the base plate.
ÎInsert board and tighten the screw.
ÎRemount the controller module and
fasten it in the controller station.

EB 7030 EN 7
Operation
3.1.2 Air output capacity
(Type3433 Controller Module only)
The position of turnboard B (Fig.1) with its
arrow symbol determines the air delivery to
the feedback bellows. It can only be ac-
cessed after removing the comparator (3.1).
yA Normal air delivery
Approx. 1mn³/h per % of the system
deviation
RHigh air delivery
approx. 3mn³/h per % of the system
deviation (not with P or PD controller
modules)
Direction of
action
A
8
B
1.1
1.4
1.3
5
4
1
10
11
12
7
83.4
3.2 A
3.3
9
1 Controller station (Type3432)
1.1 Dial plate
1.3 Controlled variable pointer
1.4 Set point adjuster
2Transmitter module or 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 Fastening screw
7Restriction with lter
8 Zero adjuster
9Kp adjuster
10 Tn adjuster
11 Tv adjuster (PD or PID
controller only)
12 Operating point adjuster (P
or PD controller only)
Turnboard
ADirection of action
BAir output capacity
91036
Type3433-3 Controller Module (PID)Type3433 Controller Module
View from the side without
comparator
Type3434-2 Controller Module (PI)
2
3
6
Fig.1: Turnboards and adjusters

8 EB 7030 EN
Operation
ÎUndo screws (3.3) and pull off the
connecting plate (3.2) together with
square nuts and bolts from the controller
module.
ÎUnscrew the hexagonal socket head
screws (3.4) at the side and lift the com-
parator (3.1) off the controller module.
Setting or changing the air delivery
ÎUndo the screw in turnboard B and lift it
off together with the turnboard. If neces-
sary, lever the board at the side. Do not
lose the rubber seal.
ÎTurn the board so that the arrow is
aligned with yAor R on the controller
module. Insert board and tighten the
screw.
ÎRemount the controller module and fas-
ten it in the controller station.
3.1.3 Proportional-action coef-
cient Kp
The setting of the Kp (adjuster 9) determines
the controller gain and depends on the con-
trolled system that is to be tuned (see sec-
tion4.1).
3.1.4 Reset time Tn
Controller versions with integral-action
component require the reset time to be set at
the adjuster (10). The setting depends on the
controlled system that is to be tuned (see
section4.1).
3.1.5 Derivative-action time Tv
Controller versions with derivative-action
component require the derivative-action time
Tv to be set at the adjuster (11). The setting
depends on the controlled system that is to
be tuned (see section4.1).
3.1.6 Operating point
Controller modules without integral-action
component, such as P or PD controllers, have
an operating point.
This can be adjusted at the operating point
adjuster (12) between 0 and 100%, which
corresponds to 0.2 to 1bar in Types3433-
1/-4/-5/-6 Controller Modules.
The setting depends on the output pressure y
(see section4.1).
The operating point of the Type3434-1
Controller Module is xed at 0.6bar.

EB 7030 EN 9
Operation
3.2 Adjusting the limit contacts
Only with controller station that have the op-
tional inductive limit contacts.
Before adjustment, release the lock (4,
Fig.1) and open the indicating unit (5). The
contacts can be accessed on the back of the
device.
Use a screwdriver to move the proximity
switches in the holders between 0 and
100% on the scale until contact is made with
the aid of a connected switching amplier.
Fig.2: Limit contacts
Holder with proximity switch

10 EB 7030 EN
Start-up and settings
4 Start-up and settings
Before start-up of the control loop, check all
devices to make sure that they are connected
correctly, do not leak and function properly.
Release the lock (4) and open the indicating
unit (5) to access the operating controls on
the controller.
Check the turnboard to make sure the correct
direction of action is set at the controller (see
section3.1.1).
4.1 Tuning the controller
The controller needs to be tuned to the
characteristics of the controlled system using
the Kp and Tn and/or Tv adjusters at the
controller module (Fig.1). This ensures that
the controller can maintain any system
deviations for all set points caused by the
disturbance variables to zero or at least
minimize them.
The system must be started up manually
when a controller station is tted with a
manual/automatic switch (1.6).
In most cases, a tuning test following the
Ziegler and Nichols method is sufcient to
tune the controller:
1. Apply supply air (1.4±0.1bar).
2. Set the proportional-action coefcient Kp
to a low value at the comparator.
3. Set the Tn restrictor to its maximum value
and Tv to its lowest value (PI and PID
controllers only).
1.6
1.7
1.5
1.8
1.4
1.3
5
4
Fig.3: Front view
Setting for manual mode:
4. Set manual/automatic switch to manual.
5. Move the adjuster (1.7) for the control
signal until the controlled variable (con-
trolled variable pointer, 1.3) slowly starts
to settle to the adjusted set point (set
point adjuster, 1.4).
After the differential pressure indicator
(1.8) reads zero, set the switch (1.6) to
automatic.
Proceed as described in steps 6 to 7.
Setting for automatic mode:
4. Turn the adjuster (1.4) on the indicating
unit to set the set point to the required
value.
1.3 Controlled variable pointer (red)
1.4 Set point adjuster (green)
1.5 Output pressure display
1.6 Manual/automatic switch
1.7 Manual output pressure adjuster
1.8 Differential pressure indicator
4 Lock
5 Indicating unit