Samson foundation 3787 Service manual

FOUNDATIONTM FIELDBUS Positioner
Type 3787
Fig. 1 ⋅Type 3787
Mounting an
Operating Instructions
EB 8383-1 EN
Firmware R 1.4x/K 1.4x
Edition November 2004

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Optional limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Attachment to the control valve . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . . . . 10
2.2 Attachment acc. to I C 60534-6 . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.2 Presetting the valve travel . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Mounting the lever with feeler roll . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 Aligning and mounting the cam disk . . . . . . . . . . . . . . . . . . . . . 20
2.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . . . . 22
2.4 Fail-safe action of the actuator . . . . . . . . . . . . . . . . . . . . . . . . 22
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2 Supply air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 lectrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.1 stablishing communication . . . . . . . . . . . . . . . . . . . . . . . . . 28
4Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 L Ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Write protection and simulation switches . . . . . . . . . . . . . . . . . . . 30
4.3 Activate/deactivate forced venting function . . . . . . . . . . . . . . . . . . 30
4.4 Default setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.1 Adjusting mechanical zero . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.2 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Operation via TROVIS-VI W . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.1 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.2 Testing the control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6 Setting the inductive limit switches . . . . . . . . . . . . . . . . . . . . . . 34
Contents
2EB 8383-1 EN

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 ervicing explosion-protected versions . . . . . . . . . . . . . . . . . . . 35
7 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Device Description (DD) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Notes on the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.1 Legends assigned to the parameters . . . . . . . . . . . . . . . . . . . . . 37
7.3.2 Notes on parameter storage classes S, N and D . . . . . . . . . . . . . . . 37
7.4 Block structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.1 Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Transducer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.3 Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4.3.1 Analog Output Function Block . . . . . . . . . . . . . . . . . . . . . . . 57
Parameters of the Analog Output Function Block . . . . . . . . . . . . . . . 59
7.4.3.2 PID Function Block (PID controller) . . . . . . . . . . . . . . . . . . . . . . 65
Parameters of the PID Function Block . . . . . . . . . . . . . . . . . . . . 67
7.5 Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.1 Stale counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.2 Link objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5.3 LAS capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8Diagnostic messages
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1 Messages of the XD_ RROR_ XT parameter (Transducer Block) . . . . . . . 79
8.2 Messages of the XD_ RROR parameter (Transducer Block) . . . . . . . . . . 80
8.3 Messages of the S LF_CALIB_STATUS parameter (Transducer Block) . . . . . 81
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
C Type xamination Certificate . . . . . . . . . . . . . . . . . . . . . . 83
CSA/FM certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents
EB 8383-1 EN 3

Safety instructions
The device may only be assembled, started up, and operated by experienced
personnel familiar ith this product.
In these mounting and operating instructions, the term "experienced person-
nel" refers to individuals ho are able to evaluate the responsibilities assigned
to them as ell as recognize potential hazards due to their specialized train-
ing, kno ledge, and experience as ell as their special kno ledge of the rele-
vant standards.
Explosion-protected versions of this device may only be operated by person-
nel ho have undergone special training or instructions, or ho are auth-
orized to ork on explosion-protected devices in hazardous areas.
Any hazards hich could be caused by the process medium, the operating
pressure, the signal pressure and moving parts of the control valve, must be
prevented by means of appropriate measures.
Should inadmissible motions or forces be produced in the pneumatic actuator
as a result of the level associated ith the supply air pressure, these must be
restricted by means of a suitable pressure reducing station.
Proper shipping and appropriate storage of the device are assumed.
Note: Devices ith the CE mark meet the requirements specified in the Directive
94/9/EC and the Directive 89/336/EEC.
The Declaration of Conformity can be vie ed and do nloaded from the
SAMSON ebsite at .samson.de.
Modifications of positioner firmware in comparison to previous versions
Previous New
Positioner R 1.41 R 1.42
Correction in the zero calibration activated over software
communication
4EB 8383-1 EN

Firmware modifications
Communication
K1.00 K1.20
Version compatible with user interface software version number:
Fisher-Rosemount DeltaV in version 5.1 or higher
National Instruments Fieldbus Configurator in version 2.3 or
higher.
All host systems certified by the Fieldbus Foundation
Alteration to default values of the following parameters:
AO Function Block CHANN L, PID Function Block GAIN,
PID Function Block R S T, PID Function Block BYPASS
Resource Block parameter extended:
BLOCK_ RROR, page 40
Transducer Block parameters changed/extended:
BLOCK_ RR, page 46.
Communication
K 1.00 K1.31
The output parameters of the function blocks can be
interconnected within a device and with blocks in other devices at
the same time. In the previous version, it was only possible to
either interconnect function blocks within a device or with blocks
in other devices.
An Output Failure in BLOCK_ RR of the AO Function Block
generates a Block Alarm.
The automatic resetting control loop monitor (previously not
automatic resetting) is evaluated for the control loop error
indication via L D or the message "Calibration rror". This means
this alarm or message is automatically reset as soon as the control
loop monitor cannot find an error anymore.
Communication
K 1.31 K1.40
The default value for R S T in the PID Block has been changed
from 0 to 3402823466 x 1038 (maximum possible value). The
integral-action component of the PID is ineffective at this value as
well as at 0. On switching over the operating mode from MAN to
AUTO, a smooth switchover is achieved.
EB 8383-1 EN 5

Tec nical data
Positioner
Travel
Direct attachment to Type 3277
Attachment acc. to I C 60534-6
Adjustable
5 to 30 mm
5 to 255 mm or 30 to 120° for rotary actuators
Bus connection Fieldbus interface as per I C 61158-2, bus-powered
Physical Layer Class: 113 (not explosion-protected version) and 111 ( x-version)
Field device according to FM 3610 entity and FISCO.
Permissible operating voltage 9 to 32 V DC; The specifications in the C Type xamination Certificate additionally
apply for explosion-protected devices. Power supply over bus cable
Max. operating current 13 mA
Additional current in case of fault 0 mA
Supply air Supply air from 1.4 to 6 bar (20 to 90 psi);
Air quality as per ISO 8573-1: Max. particle size and density: Class 4;
Oil contents: Class 3; Pressure dew point: Class 3
Signal pressure (output) 0 bar up to the pressure of the supply air
Characteristic, adjustable
Deviation
Globe valve: linear, equal percentage, reverse equal percentage,
SAMSON butterfly valve: linear, equal percentage
V T C plug rotary valve: linear, equal percentage
≤1 %
Dead band
(based on rated travel/angle
Adjustable from 0.1 to 10.0 % , default 0.5 %
Resolution (internal measurement) < 0.05 %
Transit time required For valve transit time up to 75 s
Set point ramp for exhaust and supply air separately adjustable
Operating direction Reversible, setting by software
Air consumption Independent of supply air <90l
n
/h
Air supply Actuator filled: when Δp = 6 bar 9.3 m
n3
/h, when
Δp = 1.4 bar 3.5 m
n3
/h
Actuator vented: when Δp = 6 bar 15.5 m
n3
/h, when Δp = 1.4 bar 5.8 m
n3
/h
Permissible ambient temperature 40 to 80 °C
The specifications in the C Type xamination Certificate additionally apply for
explosion-protected devices
ffects Temperature: ≤0.15 %/10 K, supply air: none,
Vibrations: none up to 250 Hz and 4 g
Degree of protection IP 65 using filter check valve included
lectromagnetic compatibility Requirements acc. to N 61000-6-2, N 61000-6-3 and
NAMUR Recommendations N 21 are met
Binar y input Internal power supply 5 V DC, R
i
= 100 kΩ for alarm function
Forced venting
(activated over an internal switch)
Input 6 to 24 V DC, R
i
approx. 6 kΩ at 24 V DC (depending on voltage)
Switching point for "1" signal
≥ 3 V, switching point for "0" signal only at 0 V,
K
V
0.17
6EB 8383-1 EN

Versions
Accessories
Inductive limit switches Two Type SJ 2 SN Proximity Switches for connection to a switching amplifier acc. to
N 60947-5-6
Communication
Data transmission In accordance with FOUNDATION
TM
Fieldbus specification
Communication Profile Class: 31 PS, 32: Interoperability Test System (I TS) Revision 4.0
Materials
Case Die-cast aluminum, chromized and plastic-coated
xternal parts Stainless steel 1.4571 and 1.4301
Weight Approx 1.3 kg
Versions of the positioner
Model 3787 - XXX0X3X
xplosion protection Without
II 2 G x ia IIC T6/
II 2 D IP 65 T 80 °C acc. to AT X
x ia FM/CSA
II 3 G x ia IIC T6/
II 3 D IP 54 T 80 °C acc. to AT X
0
1
3
8
Accessories Limit switches Without
2 inductive
0
22
Forced venting Without (deactivated)
With (activated)
0
12
Pneumatic
connections
NPT 1/4- 18
ISO 228/1-G 1/4
1
2
lectric connections Cable gland M20 x 1.5
Nickel-plated brass
Quantity: 1
2
1
2
EB 8383-1 EN 7

1 Design and principle of operation
The digital positioner compares the refer-
ence variable, which is cyclically trans-
mitted over the FOUNDATIONTM Fieldbus,
with the travel or opening angle of the con-
trol valve. It then delivers a corresponding
signal pressure. It is suitable for attachment
to linear and rotary actuators.
The Type 3787 Positioner communicates as
per FOUNDATIONTM Fieldbus specification
with field devices, programmable logic con-
trollers and process management systems.
An integrated PID Function Block allows the
control of required process variables di-
rectly in the field.
The travel of the control valve is picked up
by the inductive displacement sensor (1)
and supplied to the microcontroller (2) via a
converter.
The microcontroller compares the travel
with the reference variable and controls the
two pneumatic 2/2-way on-off valves (3, 4)
when a system deviation occurs. The on-off
valves fill (3) or vent (4) the pneumatic actu-
ator via corresponding amplifiers corre-
sponding to the system deviation.
Two L Ds on the inside of the cover indicate
the operating status of the positioner.
The positioner is equipped with a standard
binary input over which any process infor-
mation can be signaled via the FOUNDA-
TIONTM Fieldbus.
The write protection switch (6) located on
the inside of the cover prevents stored con-
figuration data from being overwritten.
Forced venting:
The positioner is controlled over a 6 to 24 V
signal which causes the corresponding sig-
nal pressure to be applied to the actuator. If
the voltage signal drops, the signal pressure
is shut off and the actuator is vented. The
control valve moves to its fail-safe position
regardless of the output variable issued by
the microcontroller.
1.1 Optional limit switches
Limit switches can be retrofitted to the stand-
ard positioner.
Two proximity switches can be used for fail-
safe circuits to indicate the valves end posi-
tions.
1.2 Communication
The positioner is completely controlled via
digital signal transmission according to the
FOUNDATIONTM Fieldbus specification
based on the N 50170/A1 draft. Data
is transmitted as bit synchronous current
modulation at a transmission rate of
31.25 kbit/s over twisted pairs according
to I C 61158-2.
Configuration with TROVI -VIEW
The positioner can be configured using the
SAMSON Configuration and Operator In-
terface, TROVIS-VI W.
To configure the positioner, connect its addi-
tional ERIAL INTERFACE to the RS-232 in-
terface of a PC using an adapter cable.
After adapting the positioner to the process
requirements, TROVIS-VI W enables the
process to be controlled online.
8EB 8383-1 EN
Design and principle of operation

Configuration with NI-FBU TM Configurator
The positioner can also be configured using
the NI-FBUSTM Configurator from National
Instruments.
An interface card installed in a PC is re-
quired to connect it to FOUNDATIONTM
Fieldbus.
The NI-FBUSTM Configurator can be used to
configure the whole FOUNDATIONTM
Fieldbus network.
Fig. 2 ⋅Functional diagram
ep
3
4
2
9
7
8
61
G
μC
&
IEC 61158-2
ep
G
Fieldbus
Foundation
8
TROVIS
VIEW
11 10
1
12
u
13
Forced
venting
Binary
input
Supply
air
xhaust
air
Serial Interface
1 Inductive displacement sensor
2 Microcontroller
3 On-off valve for supply air
4 On-off valve for exhaust air
5 Microcontroller
6 Switches for write protection and
simulation mode
7 Binary input
8 Forced venting
9 I C 61158-2 interface module
10 Actuator stem
11 Lever
12 Clamp
13 Configuration interface
EB 8383-1 EN 9
Design and principle of operation

2 Attachment to the control valve
The positioner can be attached either di-
rectly to a SAMSON Type 3277 Actuator
or to control valves with cast yokes or rod-
type yokes according to I C 60534-6
(NAMUR).
In connection with an intermediate piece,
the positioner can also be attached to rot-
ary actuators.
Since the standard positioner is delivered
without accessories, please refer to the
tables for required mounting parts and their
order numbers.
Note!
For fast control valves ith small travel vol-
umes (transit time < 0.6 sec.), replace the fil-
ter in the signal pressure output ith a
scre -in throttle, if necessary, to improve
the control properties. See also sections
2.1, 2.2 and 2.3.
Important!
The positioner does not have its o n vent-
ing plug, instead vented air has to escape
through venting plugs located on the mount-
ing parts (see Figs. 3, 5 and 7).
A filter check valve for the vented air is in-
cluded in every positioner delivery (under
the transparent protective cap on the back
of the positioner). Replace the standard vent-
ing plug included in the accessories ith
this filter check valve. This is the only ay to
achieve the degree of protection IP 65 by
preventing dirt and moisture from entering
the device.
2.1 Direct attachment to Type
3277 Actuator
The necessary accessories are listed in the
Tables 1, 2 and 3 on page 13.
When looking at the signal pressure connec-
tion or the switchover plate (actuator 120
cm2), the positioner must be attached to the
left side of the actuator.
The arrow on the black cover of the case
(Fig. 11) should point towards the dia-
phragm chamber.
Exception: Control valves in which the plug
closes the seat area when the actuator stem
retracts. In this case, the positioner has to
be attached to the right side of the actuator
and the arrow points away from the dia-
phragm chamber.
1. Screw the clamp (1.2) to the actuator
stem, ensuring that the fastening screw
is located in the groove of the actuator
stem.
2. Screw the assigned pick-up lever D1 or
D2 to the transmission lever of the posi-
tioner.
3. Fasten the distance plate (15) with seal
pointing towards the actuator yoke.
4. Place the positioner on the plate so that
the lever D1 or D2 slides centrally over
the pin of the clamp (1.2). Then screw
tight to the distance plate (15).
5. Mount cover (16).
Actuators with 240, 350 and 700 cm2
6. Check whether the tongue of the seal
(17) is properly aligned at the side of
the connection block (Fig. 3, center)
10 EB 8383-1 EN
Attac ment to t e control valve