Samson 3785 series Service manual

PROFIBUS Positioner
Type 3785
PA Device Profile Version 3.0
Mounting and
Operating Instructions
EB 8382-2 EN
Firmware version R 1.42/K 2.12
Edition May 2007
Fig. 1 · Type 3785

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 8
1.1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Attaching the positioner. . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Direct attachment to Type 3277 Actuator. . . . . . . . . . . . . . . . 12
2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 16
2.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Presetting the valve travel . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . 20
2.3.1 Mounting the cam follower roll lever . . . . . . . . . . . . . . . . . . 20
2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . 20
2.3.3 Aligning and mounting the cam disk . . . . . . . . . . . . . . . . . . 22
2.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 24
2.4 Fail-safe action of the actuator . . . . . . . . . . . . . . . . . . . . . 24
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Supply air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.1 Forced venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.2 Limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.3 Establishing communication (bus address) . . . . . . . . . . . . . . . 30
3.2.4 Local interface (SSP). . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 LED controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Write protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Activating/deactivating the forced venting function . . . . . . . . . . . 33
4.4 Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.1 Adjusting mechanical zero . . . . . . . . . . . . . . . . . . . . . . 34
4.4.2 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Adjusting the inductive limit switches . . . . . . . . . . . . . . . . . . 36
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 37
7 How to implement the PROFIBUS Master Class 1. . . . . . . . . . . . 38
7.1 Device Database Files (GSD). . . . . . . . . . . . . . . . . . . . . . 38
7.2 Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2EB 8382-2 EN
Contents

7.3 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.1 Measured value status . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.2 Set point status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5.1 Start-up (warm start) . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5.2 Monitoring function FSAVE_TIME, FSAVE_TYPE, FSAVE_VALUE . . . . 48
8 List of parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Summary of parameters . . . . . . . . . . . . . . . . . . . . . . . . 51
8.2 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9 Messages and diagnosis . . . . . . . . . . . . . . . . . . . . . . . 69
9.1 Diagnosis messages . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.2 CHECK_BACK messages . . . . . . . . . . . . . . . . . . . . . . . 71
9.3 Initialization messages. . . . . . . . . . . . . . . . . . . . . . . . . 73
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . 75
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
EB 8382-2 EN 3
Contents

4EB 8382-2 EN
Safety instructions
General safety instructions
4
The positioner 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 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.
4
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.
4
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.
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.

Modifications in the positioner firmware compared to earlier version
Old New
Control R 1.23 R 1.31
Firmware adaption for new hardware version
Hardware version device index .01
Control R 1.31 R 1.4
Actuator type When the actuator type is set from "linear actuator" to "rotary ac-
tuator", the following applies:
Initialization method . . . . . . Based on maximum range
Transmission code. . . . . . . . S90
Nominal angle . . . . . . . . . . 90
Final position for w < . . . . . 1 %
Final position for w > . . . . . 99 %
Rotat. angle range begins . . 0°
Rotational angle range ends 90°
When the actuator type is set from "linear actuator" to "rotary ac-
tuator", the following applies:
Attachment. . . . . . . . . . . . . Integral . . . . . . . . . . . . . . . According to NAMUR
Type of initialization . . . . . . Based on nominal range . . . Based on nominal range
Mounting position . . . . . . . . Arrow towards actuator. . . . Arrow away f. actuator
Transmission code. . . . . . . . D1. . . . . . . . . . . . . . . . . . . –
Pin position . . . . . . . . . . . . – . . . . . . . . . . . . . . . . . . . . A
Rated travel . . . . . . . . . . . . 15 mm . . . . . . . . . . . . . . . . 15 mm
Final position for w < . . . . . 1 % . . . . . . . . . . . . . . . . . . 1 %
Final position for w > . . . . . 125 % . . . . . . . . . . . . . . . . 125 %
Lower travel range value . . . 0 mm. . . . . . . . . . . . . . . . . 0 mm
Upper travel range value. . . 15 mm. . . . . . . . . . . . . . . . 15 mm
Lever length . . . . . . . . . . . . – . . . . . . . . . . . . . . . . . . . . 42 mm
Type of initialization When the initialization method is set from "maximum range" to
"nominal range", the following applies:
Final position for w < 1 % . . Final position for w > 125 %
When the initialization method is set from "maximum range" to
"nominal range", the following applies:
Final position for w < 1 % . . Final position for w > 99 %
Desired transit time
Open/Closed
The adjustment range of the desired transit times was limited to
75 seconds.
EB 8382-2 EN 5
Firmware modifications

Initialization During initialization, the minimum control signals from 20 % to
80 % of the range of the manipulated variable are determined
and saved in the EEPROM.
Proportional-action
coefficients
KP_Y1 and KP_Y2
The coefficients are adapted to the selected actuator type and the
measured transit times.
Control R 1.41 R 1.4.2
Correction in case of zero adjustment triggered via communica-
tion.
Communication K 1.34 K 1.41
Firmware adaption for new hardware version
Hardware version device index .01
Communication K 1.41 K 1.51
The current status of control loop monitoring is indicated by bit 7
of the CHECK_BACK parameter.
Contrary to bit 13, bit 7 is automatically reset when no further er-
ror is detected by control loop monitoring. The function of bit 13
remains unchanged. Messages are only issued by bit 7 if control
firmware version R 1.41 or higher is used.
The message "Warm start" indicated by bit 11 of the DIAGNOSIS
parameter is automatically reset after 10 sec.
In operating mode "Local override", bit 2 of the CHECK_BACK
parameter is set.
Communication K 1.51 K 1.60
In operating mode "Manual", the out value is preset by the pa-
rameter OUT.
6EB 8382-2 EN
Firmware modifications

Communication K 1.60 K 2.00
This firmware version implements the PROFIBUS PA Profile 3.0,
Class B for control valves according to PROFIBUS PA Profile for
Process Control Devices Version 3.0-Actuator.
The positioner can be connected to the TROVIS-VIEW Configura-
tion and Operator Interface via the serial interface for adjustment
and operation.
Communication K 2.00 K 2.10
When a zero point error or self-resetting control loop error (transit
time exceeded) is detected, or when the limit value for the total
valve travel is exceeded, the status of the parameters READBACK
or POS_D is set to GOOD_MAINTENANCE_REQUIRED.
EB 8382-2 EN 7
Änderungen der Firmware
Positioner Type 3785 XXXXX3X
Not explosion protected
II 2 G EEx ia IIC T6 /II 2 D IP 65 T 80 °C acc. to ATEX
Ex ia FM/CSA
0
1
3
Additional accessories
Inductive limit switch without
with Type SJ 2-SN
0
22
with forced venting without
24 V DC
0
12
PA device profile Version 2.0
Version 3.0
0
1
Pneumatic connections NPT ¼ - 18
ISO 228 / - G ¼
1
2
Electrical connections Cable gland M20 x 1.5 with
Shielding, nickel-plated brass
Quantity 1
Quantity 2
1
2

1 Design and principle of
operation
The digital PROFIBUS PA positioner is at-
tached to pneumatic control valves. It as-
signs the valve position (controlled variable)
to the control signal (reference variable).
The positioner compares the digital control
signal transmitted from the control equip-
ment to the travel of the control valve and is-
sues a pneumatic signal pressure (output
variable). To achieve this, a supply air pres-
sure of 1.4 to 6 bar is required. The electric
power is supplied by the bus connection of
the PROFIBUS PA segment in accordance
with IEC 61158-2 regulations. The
positioner consists of an inductive,
frictionless displacement sensor system and
an electrically controlled valve block with
two on-off valves, as well as the electronics
including the two microcontrollers to edit the
control algorithm and manage PROFIBUS
communication.
When a system deviation occurs while com-
paring set point and actual value, the
microcontroller returns binary
pulse-pause-modulated signals which are
used to control two on-off valves with subse-
quent boosters. One valve controls the ex-
haust air, the other the supply air. The sup-
ply air valve (3) connects the supply air (7,
supply air pressure 1.4 to 6 bar) and the
actuator (filling). The exhaust air valve (4)
connects the actuator and the atmosphere
(venting). These on-off valves can either
have the switching states continuously open
or continuously closed, or they can generate
single pulses of variable width. Controlling
the two valves causes the actuator of the
valve to move the plug stem to a position
corresponding to the reference variable. If
there is no system deviation, both the ex-
haust and supply air valves are closed. By
default, the positioner is equipped with a bi-
nary input for floating contacts, which serves
to signalize the switching state of an addi-
tional field device via PROFIBUS. The write
protection switch in the hinged cover (lo-
cated near the bus address adjustment) pre-
vents that positioner settings are overwritten
via PROFIBUS communication on activation.
Positioner with forced venting function:
The positioner is controlled by a 6 to 24 V
signal, causing the signal pressure to be ap-
plied to the actuator. When this voltage sig-
nal decreases, the signal pressure is shut off
and the actuator is vented. Additionally, the
control valve is moved to its fail-safe posi-
tion by the integrated springs. All
positioners are equipped with the forced
venting function, which can be activated
and deactivated using a switch (also see
section 4.3).
1.1 Options
The standard positioner version can be sup-
plemented with limit switches. Two proximity
switches suitable for fail-safe circuits can be
used to signalize the valve's final positions.
1.2 Communication
The positioner is completely controlled via
digital signal transmission according to
PROFIBUS PA Profile Class B based on
DIN EN 50170 and DIN 19245 Part 4.
Data is transmitted as bit synchronous cur-
rent modulation with a transfer rate of
31.25 kbps using twisted-pair cables as
specified in IEC 61158-2. The positioner
8EB 8382-2 EN
Design and principle of operation

settings are usually made on a computer. By
using a segment coupler, one or more
positioners can be connected to the PC's
PROFIBUS segment. After mechanically set-
ting the positioner to zero, it can be auto-
matically started up by an initialization pro-
cedure. During this initialization, zero is ad-
justed automatically and the preset span is
checked. The positioner is delivered with a
standard configuration for a control valve
with a rated travel of 15 mm, designed for
integral positioner attachment. The
positioner can be individually configured to
adapt it to other actuators only by means of
communication.
Configuration
The positioner is configured and operated
from the computer via the SSP interface (13)
using TROVIS-VIEW. Alternatively, a seg-
ment coupler can be used together with, for
example, the COMMUWIN II interface by
Endress + Hauser or the SIMATIC PDM soft-
ware by SIEMENS.
During configuration, you can enter param-
eters such as characteristic, operating direc-
tion, travel limitation, travel range, transit
time and fault alarms.
EB 8382-2 EN 9
Design and principle of operation
Fig. 2 · Functional diagram
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 bus address
and write protection
7 Binary input
8 Forced venting
9 IEC 61158-2
interface module
10 Actuator stem
11 Lever
12 Clamp
13 SSP interface
Binary input
Forced venting
Exhaust air
Supply air

1.3 Technical data
Positioner
Travel,
adjustable
Direct attachment to Type 3277: 5 to 30 mm
Attachment acc. to IEC 60534 (NAMUR): 5 to 255 mm
or 30° to 120° for rotary actuators
Bus connection Fieldbus interface as per IEC 61158-2
Field device acc. to FISCO (Fieldbus intrinsically safe concept)
Permissible operating voltage 9 to 32 V DC; The limits specified in the EC Type Examination Certificate addi-
tionally apply for explosion-protected devices. Supplied over the bus line
Destruction limit 35 V
Maximum operating current 10 mA
Fault current 0 mA
Supply air Supply pressure from 1.4 to 6 bar (20 to 90 psi),
Air quality acc. to ISO 8573-1 Edition 2001: Max. particle size and density:
Class 4; Oil content: Class 3, pressure dew point: Class 3 or at least 10 K be-
neath the lowest ambient temperature to be expected
Signal pressure (output) 0 bar up to supply pressure
Characteristic, adjustable Linear, equal percentage, reverse equal percentage, user-definable
Deviation from terminal-based conformity ≤1 %
Dead band
(related to rated travel/angle) Adjustable from 0.1 to 10.0 %, predefined 0.5 %
Resolution < 0.05 % (internal measured data recording)
Required transit time Separately adjustable up to 75 seconds for supply air and exhaust air
Direction of action Reversible, adjustable over software
Air consumption Independent from supply pressure < 90 ln/h
Air capacity output Actuator pressurized: at Δp = 6 bar 9.3 mn3/h, at Δp = 1.4 bar 3.5 mn3/h
Actuator vented: at Δp = 6 bar 15.5 mn3/h, at Δp = 1.4 bar 5.8 mn3/h
Permissible ambient
temperature
–40 to 80 °C; The limits specified in the EB Type Examination Certificate addi-
tionally apply for explosion-protected devices.
Influences Temperature: ≤0.15 %/10 K, supply air: None,
Vibration: None up to 250 Hz and 4 g
Explosion protection II 2 G SEX ia IIC T6 /II 2 D IP 65 T 80 °C
Degree of protection IP 65 on using enclosed filter check valve
Electromagnetic comparability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation
NE 21
10 EB 8382-2 EN
Design and principle of operation

Binary input Internal supply 5 V DC, Ri = 100 kW
for alarm function e.g. connection to a pressure switch
Forced venting,
activated over internal switch
Input: 6 to 24 V DC, static destruction limit 45 V, Ri approx. 6 kΩwith 24 V DC
(voltage dependent, switching point “1” signal at ≥3 V, “0” signal only at 0
V, Kv 0.17)
Communication Data transmission as per PROFIBUS-PA, Profile Class B Version 3.0 acc. to
DIN EN 50170 and DIN 19245 Part 4 (Version 2.0 is also available)
Local interface SAMSON SSP interface for configuration and start-up
Bus address Adjustable over software or microswitch, delivered state: 126
Additional equipment
Inductive limit switch Two SJ 2SN Proximity Switches
for connection to switching amplifier acc. to EN 60947-5-6
Materials
Housing Die-cast aluminum, chromated and plastic coated,
external parts: Stainless steel 1.4571 und 1.4301
Weight Approx. 1.3 kg
EB 8382-2 EN 11
Design and principle of operation

2 Attaching the positioner
The positioner can be attached either di-
rectly to the SAMSON Type 3277 Actuator,
or according to IEC 60534-6 (NAMUR) to
control valves with cast or rod-type yokes.
In combination with an intermediate piece,
the device can also be attached to rotary ac-
tuators as rotary positioner.
As the positioner unit is delivered without
accessories, refer to the appropriate tables
for the order numbers of the required
mounting parts.
Note!
For faster control valves with small travel
volumes (transit time <0.6 sec.), replace the
filter in the signal pressure output (output
38) with a screw-in throttle (see Accessories
table), if necessary, to improve the control
properties. See also sections 2.1, 2.2 and
2.3.
Important!
The positioner does not have its own vent
plug. The air is exhausted via vent plugs lo-
cated on the accessories (also see Figs. 3, 5
and 7).
Each positioner comes with a filter check
valve for the exhaust air located below the
transparent protective cap on the back of
the positioner.
The standard vent plug available as an ac-
cessory must be replaced with this filter
check valve to achieve degree of protection
IP 65 protecting the device against dirt and
moisture.
2.1 Direct attachment to
Type 3277 Actuator
Refer to Tables 1, 2 and 3 on page 15 for
the required mounting parts.
When looking onto the signal pressure con-
nection or the switchover plate (120 cm² ac-
tuator) from the top, the positioner is to be
attached to the left side of the actuator. The
arrow on the black case cover (Fig. 11)
must point towards the diaphragm cham-
ber.
Exception: Control valves in which the plug
only closes the seat area when the actuator
stem retracts. In this case, the positioner has
to be attached to the right side of the yoke
with the arrow pointing 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 associated lever D1 or D2 (for
700 cm² actuator) to the transmission le-
ver of the positioner.
3. Attach distance plate (15) with the seal
pointing towards the actuator yoke.
4. Place positioner onto the plate so that
the lever D1 or D2 slides centrically over
the pin of the clamp (1.2). Screw
positioner to distance plate (15).
5. Mount the cover (16).
12 EB 8382-2 EN
Attaching the positioner

EB 8382-2 EN 13
Attaching the positioner
Actuator stem extends Actuator stem retracts
Internal signal pressure connection
Connection block
Signal pressure
connection over
external piping
with seal (new) with switch plate (old) Venting
Actuator stem
extends
Actuator stem extends
Symbol
Switchover plate
Switchover plate
Signal pressure input
Signal pressure hole
Marking
Signal pressure input
with brass throttle
Side view of connection block
Actuator stem
retracts
Actuator stem retracts
1.2 Clamp
D1 Lever
D2 Lever
15 Distance plate
16 Cover
17 Gasket
18 Cover plate
19 Switch plate
Fig. 3 · Attachment - Signal pressure connection for Type 3277 (top) and Type 3277-5 with 120 cm
2
(bottom)

240, 350 and 700 cm² actuators
6. Check whether the tongue of the seal
(17) is properly aligned at the side of
the connection block with the actuator
symbol "actuator stem extends" or "ac-
tuator stem retracts" to match the actua-
tor version used. If not, remove the three
fastening screws and the cover plate
(18), turn the seal (17) by 180° and re-
insert it.
When the old connection block is used,
turn the switch plate (19) to align the ac-
tuator symbol with the arrow.
7. Place the connection block with its seal-
ing rings against the positioner and ac-
tuator yoke, and screw it tight using the
fasting screw. For actuators with fail-safe
action "Actuator stem retracts" addition-
ally install the prefabricated signal pres-
sure tube between connection block and
actuator.
Actuator with 120 cm²
For Type 3277-5 Actuators with 120 cm²,
the signal pressure is transmitted to the dia-
phragm chamber via the switchover plate
(Fig. 3, bottom).
For a rated travel of 7.5 mm, a brass throttle
(see Accessories table on page 15) must be
pressed into the seal located in the signal
pressure input on the actuator yoke.
With 15 mm rated travel, this is only re-
quired if the supply pressure exceeds 4 bar.
6. Remove the screw at the back of the
positioner and close the signal pressure
output (output 38) at the side with the
associated plug included in the acces-
sory kit.
7. Mount the positioner so that the bore in
the distance plate (15) is aligned with
the seal located in the bore of the actua-
tor yoke.
8. Align the switchover plate with the cor-
responding symbol for attachment on
the left side, and screw the plate to the
actuator yoke.
Note!
If, in addition to the positioner, a solenoid
valve or a similar device is attached to the
120 cm² actuator, the rear M3 screw must
not be removed. In this case, the signal
pressure has to be fed from the signal pres-
sure output to the actuator via the required
connecting plate (see Table 2). The
switchover plate is no longer required.
Note!
For faster control valves with a transit time
<0.6 sec., replace the filter in the signal
pressure output (output 38) with a screw-in
throttle (see Accessories table), if necessary.
Air purging function
If the spring chamber of the Type 3277 Ac-
tuator must be filled with the air exhausted
from the positioner, the spring chamber
(version "Actuator stem extends") can be
connected to the connection block by means
of a tube (Table 3). To do so, remove the
vent plug on the connecting block.
With Type 3277-5, version "Actuator stem
retracts", the air exhausted from the
positioner is constantly applied to the spring
chamber via an internal bore.
14 EB 8382-2 EN
Attaching the positioner

EB 8382-2 EN 15
Attaching the positioner
Table 1 Mounting kit
Required lever with associated clamp and distance plate Actuator size [cm2] Order no.
D1 with stopper for Output (38)
threaded connection
G ¼
¼ NPT
120 1400-6790
1400-6791
D1 (33 mm in length with clamp 17 mm in height) 240 and 350 1400-6370
D2 (44 mm in length with clamp 13 mm in height) 700 1400-6371
Table 2 Order no.
Switchover plate for actuator 120 cm2Actuator 3277-5xxxxxx.00 (old) 1400-6819
Switchover plate new Actuator Type 3277-5xxxxxx.01 and larger (new) 1400-6822
Connecting plate for additional attachment of a
solenoid valve
Actuator Type 3277-5xxxxxx.00 (alt), G 18
Actuator Type 3277-5xxxxxx.00 (alt), 18NPT
1400-6820
1400-6821
Connecting plate new Actuator Type 3277-5xxxxxx.01 and larger (new) 1400-6823
Note: Only new switchover and connecting plates can be used with new actuators (Index 01).
Old and new plates are not interchangeable.
Required connection block for 240, 350, 700 cm2actuator
(including seals and screw)
G ¼ 1400-8811
¼ NPT 1400-8812
Table 3 Actuator size [cm2]Material Order no.
Required piping with screw fittings
for "Actuator stem retracts" or when the top
diaphragm chamber is filled with air
240 Steel 1400-6444
240 Stainless steel 1400-6445
350 Steel 1400-6446
350 Stainless steel 1400-6447
700 Steel 1400-6448
700 Stainless steel 1400-6449
Accessories Order no.
Pressure gauge mounting kit (output and supply)
Order with every pressure gauge kit: 2 restrictions (1790-6121)
Stainless steel/Brass 1402-0938
Stainless steel/Brass 1402-0939
Signal pressure throttles (screw-in and brass throttles) 1400-6964
Filter check valve, replacing the exhaust plugs and increasing the degree of protection to IP 65
(one valve is included in the scope of delivery)
1790-7408

2.2 Attachment according to
IEC 60534-6
Refer to Tables 4 and 5 on page 19 for re-
quired accessories.
For positioner attachment according to
NAMUR as shown in Fig. 4, an adapter
housing is required. The valve travel is
transmitted via the lever (18) and the shaft
(25) to the bracket (28) of the adapter hous-
ing and then to the pin (27) located at the
positioner lever.
To attach the positioner, the mounting parts
listed in Table 4 are required. Which lever is
to be used depends on the rated valve
travel.
The positioner must be attached with the ar-
row on the black case cover pointing away
from the diaphragm actuator towards the
valve.
Exception: Control valves in which the plug
only closes the seat area when the actuator
stem retracts. In this case, the arrow has to
point towards the diaphragm actuator.
If the adapter housing cannot be mounted
between the actuator and the valve (e.g. ac-
tuators by other manufacturers), the arrow
on the case cover must point towards the
control valve.
Note!
For faster control valves with a transit time
<0.6 sec., replace the filter in the signal
pressure output (output 38) with a screw-in
throttle (see Accessories table), if necessary.
2.2.1 Mounting sequence
Note!
Before you mount the parts, apply a signal
pressure to the actuator so that the valve is
set to 50 % of its travel. This will ensure the
exact alignment of the lever (18) and the
bracket (28).
Control valve with cast yoke
1. Use countersunk screw to attach the
plate (20) to the coupling which con-
nects the plug and actuator stems. With
2100 cm² and 2800 cm² actuators, use
additional mounting bracket (32).
2. Remove rubber plug from the adapter
housing and fasten the housing to the
NAMUR rib using hexagon head screw.
Control valve with rod-type yoke
1. Screw plate (20) to the follower clamp of
the plug stem.
2. Screw studs (29) into the adapter hous-
ing.
3. Place the housing with the plate (30) on
either the right or the left side of the
valve rod and screw the housing tight
using nuts (31). Be sure to align the
housing in such a way that the lever to
be mounted subsequently is in a hori-
zontal position.
4. Move the clamp (21) to surround the pin
(19). Screw pin into the center row of
bores in the plate (20) and lock it such
that it will be located above the correct
lever marking (1 to 2) for the assigned
travel (see Table 5).
16 EB 8382-2 EN
Attaching the positioner

EB 8382-2 EN 17
Attaching the positioner
Fig. 4 · Attachment according to IEC 60534-6 (NAMUR)
18 Lever N1, N2
19 Pin
20 Plate
21 Clamp
22 Clamping plate
23 Screw
24 Pointer
25 Shaft
26 Lever of positioner
27a Transmission pin
27b Counter nut
28 Bracket
29 Studs
30 Plate
31 Nuts
32 Mounting bracket
Mounting position
Attachment to
NAMUR rib
Attachment to
rods

Intermediate values must be calculated.
5. Measure the distance between the center
of the shaft (25) and the center of the
pin (19). You will be prompted for this
value later during the configuration of
the positioner.
2.2.2 Presetting the valve travel
1. Adjust the shaft (25) in the adapter
housing so that the black pointer (24) is
aligned with the cast marking on the
adapter housing.
2. Screw clamping plate (22) tight in this
position using a screw (23).
3. Screw in the pin (27) at the positioner
lever (26) on the side of the insert nuts
and secure it with a hex nut on the op-
posite side. Note the mounting position
A or B respectively according to Table 5
and Fig. 5.
4. Put the positioner to the adapter housing
such that the pin (27) lies properly
within the arms of the bracket (28). To
do so, insert a 2.5 mm Allen key or a
screwdriver from the front into the bore
located below the oblong hole on the
cover plate, and push the positioner le-
ver in the required position.
5. Screw the positioner to the adapter
housing.
6. Relieve the actuator from the signal pres-
sure.
18 EB 8382-2 EN
Attaching the positioner

EB 8382-2 EN 19
Attaching the positioner
Table 4 NAMUR
attachment
Valve Travel [mm] With lever Order no.
NAMUR mounting kit,
see Fig. 4 for parts
Valve with cast yoke 7.5 to 60 N1 (125 mm) 1400-6787
30 to 120 N2 (212 mm) 1400-6789
Valve with
rod-type yoke,
rod diameter
[mm]
20 to 25 N1 1400-6436
20 to 25 N2 1400-6437
25 to 30 N1 1400-6438
25 to 30 N2 1400-6439
30 to 35 N1 1400-6440
30 to 35 N2 1400-6441
Attachment to Fisher and Masoneilan linear actuators
(both mounting kits are required for one actuator)
1400-6771
and
1400-6787
Accessories Order no.
Pressure gauge mounting block G ¼ 1400-7458
¼ NPT 1400-7459
Pressure gauge kit Stainless steel/Brass 1400-6957
Stainless steel/Stainless steel 1400-6958
Signal pressure throttles (screw-in and brass throttles) 1400-6964
Filter check valve, replacing the exhaust plugs and increasing the degree of protection to IP 65
(one valve is included in the scope of delivery)
1790-7408
Table 5 NAMUR attachment
Lever [mm]* 7.5 15 15 30 30 60 30 60 60 120
Pin on marking* 1212121212
Corresponding distance between pin/rotation
point of lever [mm]
42 84 42 84 84 168 84 168
With lever N1 (125 mm long) N2 (212 mm long)
Transmission pin (27a) on position A ABAB
* Intermediate values need to be calculated

2.3 Attachment to rotary
actuators
Refer to Table 6 on page 23 for required
accessories.
The positioner can also be attached to ro-
tary actuators according to VDI/VDE 3845
by using the mounting parts and accessories
in Table 6. In this arrangement, the actua-
tor's rotary motion is converted via the cam
disk on the actuator shaft and the follower
roll of the positioner lever into a linear mo-
tion required by the positioner's inductive
displacement sensor system.
Each cam disk is suitable for two curves: for
angles of rotation from 0 to 90° and for 0 to
120°.
For double-acting, springless rotary actua-
tors, it is necessary that a reversing amplifier
be attached to the connected side of the
positioner (see section 2.3.4).
If the positioner is attached to SAMSON
Type 3278 Rotary Actuator, the air ex-
hausted from the positioner is transferred to
the inside of the actuator and the chamber
behind the diaphragm. No additional tub-
ing is required. If the positioner is attached
to actuators by other manufacturers
(NAMUR), the air is applied to the chamber
behind the diaphragm through a tube as-
sembly with tee, connected between actua-
tor and intermediate piece.
Note! For faster control valves with a transit
time <0.6 sec., replace the filter in the signal
pressure output (output 38) with a screw-in
throttle (see Accessories table), if necessary.
2.3.1 Mounting the cam follower
roll lever
1. Place lever with the attached roll (35) on
the transmission lever (37) and secure it
with the enclosed screws (38) and wash-
ers.
2.3.2 Mounting the intermediate
piece
SAMSON Type 3278 Actuator:
11.Screw adapter (36) to the free end of the
rotary actuator shaft using two screws.
2. Position intermediate piece (34) on the
actuator case and secure it with two
screws. Align the positioner's intermedi-
ate piece so that the air connections of
the positioner face towards the dia-
phragm case side.
Actuators by other manufacturers:
1. Position complete intermediate piece
(34, 42, 44 and 45) on the bracket (fix-
ing level 1, VDI/VDE 3845) delivered
with the actuator and fasten with screws.
2. Align cam disk (40) and scale (39) as
described in section 2.3.3. Fasten with
screws.
With springless actuators, a reversing am-
plifier (45) must be screwed to the side of
the positioner case. See section 2.3.4 for
more details.
20 EB 8382-2 EN
Attaching the positioner