Samson TROVIS 3731-3 Service manual

Series 3731
Type 3731-3 Electropneumatic Ex d
Positioner
with HART®communication
Mounting and
Operating Instructions
EB 8387-3 EN
Firmware version 1.61
Edition May 2017
Fig. 1 · Type 3731-3
EB + CD

2EB 8387-3 EN
DANGER!
indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING!
indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
NOTICE
indicates a property damage message.
Note: Supplementary explanations,
information and tips
Definitions of the signal words used in these instructions

Contents
1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8
3.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 10
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Attachment to the control valve – Mounting parts and accessories . . . 15
4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 22
4.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 24
4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 26
4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 28
4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 28
4.6 Required mounting parts and accessories. . . . . . . . . . . . . . . . 30
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 40
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 42
6.1 Rotary pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3 Readings on display . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4 HART®communication . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.1 Dynamic HART®variables . . . . . . . . . . . . . . . . . . . . . . . 45
7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.1 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Checking the operating range of the positioner . . . . . . . . . . . . . 48
7.4 Allocating the closed position . . . . . . . . . . . . . . . . . . . . . 49
7.5 Positioner initialization. . . . . . . . . . . . . . . . . . . . . . . . . 49
EB 8387-3 EN 3
Contents

7.5.1 Initialization based on MAX maximum range . . . . . . . . . . . . . 51
7.5.2 Initialization based on NOM nominal range . . . . . . . . . . . . . . 52
7.5.3 Initialization based on MAN manually selected range . . . . . . . . . 53
7.5.4 SUB substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 55
7.6 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.7 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 59
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 60
8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2.1 Automatic (AUTO) and manual (MAN) modes . . . . . . . . . . . . . 61
8.2.2 Fail-safe position (SAFE) . . . . . . . . . . . . . . . . . . . . . . . . 62
8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 62
8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 63
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10 Servicing explosion- protected devices. . . . . . . . . . . . . . . . . 64
11 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 86
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
13.1 Selecting the valve characteristic . . . . . . . . . . . . . . . . . . . . 87
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4EB 8387-3 EN
Contents

Modifications to positioner firmware compared to the previous version
1.41 (old) 1.42 (new)
After performing a reset to default values, the allocation of the closing position AIR
TO OPEN (AtO) /AIR TO CLOSE (AtC) is not reset to the default setting. The setting is
kept.
1.42 (old) 1.51 (new)
All EXPERTplus diagnostic functions are available in the positioner without having to
activate them first (refer to EB 8389 on EXPERTplus valve diagnostics)
Optional binary input with following actions:
– Transfer switching state
– Set local operation write protection
– Switch between AUTO/MAN
– Various diagnostic functions (refer to EB 8389 on EXPERTplus valve diagnostics).
The pressure limit (Code 16) is no longer automatically set during initialization.
1.51 (old) 1.52 (new)
Internal modifications
1.52 (old) 1.53 (new)
Internal modifications
1.53 (old) 1.61 (new)
Default values of the step response test have been adapted to the positioner series.
Optimizations made to the step response test.
A positioner not yet initialized generates the NAMUR status "Out of specification"
(previously "Maintenance alarm").
Code 4: the 300 mm setting has been added to the pin positions.
EB 8387-3 EN 5
Modifications to positioner firmware
Note:
–The functions of EXPERTplus valve diagnostics are described in the Mounting and Opera-
ting Instructions EB 8389.

1 Important safety instructions
For your own safety, follow these instructions concerning the mounting, start up and opera-
tion of the positioner:
4The positioner is to be mounted, started up or operated only by trained and
experienced personnel familiar with the product.
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 relevant standards.
4Explosion-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 10.
4Any 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.
4If inadmissible motions or forces are produced in the actuator as a result of the supply
pressure, the supply pressure must be restricted by means of a suitable supply
pressure reducing station.
To avoid damage to any equipment, the following also applies:
4Do not operate the positioner with the back of the positioner/vent opening facing
upwards.
The vent opening must not be sealed or restricted when the positioner is installed on
site.
4Proper shipping and appropriate storage are assumed.
4Do not ground electric welding equipment near to the positioner.
Note: The device with a CE marking fulfills the requirements of the Directives 2014/30/EU
and 2004/108/EC.
The Declaration of Conformity is available on request.
6EB 8387-3 EN
Important safety instructions
Vent opening

2 Article code
Positioner Type 3731 - 3 x x x x x x x 0 0 x 1 x 0 0 0
With LCD, autotune, HART®communication
Explosion protection
ATEX: II 2G Exd IIC T6, T5, T4 Gb; II 2G Exde IIC T6, T5, T4 Gb;
II 2D Extb IIIC T80°C DB IP 66
2 1
FM: Class I, Div. 1+2, Groups B, C, D; Class I, Zone 1, Groups IIB+H2;
Class I, Div. 1+2 Groups E, F, G; Class III
2 3
CSA: Class I, Zone 1, Group IIB+H2 T4...T6; Class I, Div. 1+2, Groups B, C, D T4...T6;
Class II, Div. 1, Groups E, F, G
JIS: Ex d IIC T6 2 7
Options (additional equipment)
Without 0 0
Position transmitter 0 1
Binary input 0 3
Forced venting 0 5
Binary output (NAMUR/PLC) 0 6
Diagnostics
EXPERTplus for control valves 4
Electrical connections
2x M20 x 1.5 1
2x ½ NPT 2
Emergency shutdown
Emergency shutdown with the reference variable of 0 mA* 0
Emergency shutdown when the reference variable is smaller than 3.85 mA 1
Explosion-protection certificates
As specified in Explosion protection 0
NEPSI: Exd IIC T6~T4; Exde IIC T6~T4 (on request) 2 1 1
IECEx: Exd IIC T6, T5, T4 Gb; Exd e IIC T6, T5, T4 Gb; Ex tb IIIC T80°C Db IP66 2 1 2
GOST: 1Exd IIC T6/T5/T4 Gb X; 1Exd e IIC T6/T5/T4 Gb X; Ex tb IIIC T80°C Db X 2 1 3
Special applications
None 0
Positioner compatible with paint (IP 41/NEMA 1) 1
Special version
Without 0 0 0
* Version no longer available
EB 8387-3 EN 7
Article code

3 Design and principle of
operation
The electropneumatic Ex d positioner is
mounted on pneumatic control valves. It is
used to assign the valve stem position (con-
trolled variable x) to the control signal (ref-
erence variable w). The electric control sig-
nal received from a control system is com-
pared to the travel or rotational angle of the
control valve, and a signal pressure (output
variable y) is produced for the pneumatic
actuator.
The positioner basically consists of an elec-
trical travel sensor system (2), an analog i/p
converter (6) with downstream air capacity
booster (7) and the electronic unit with a
microcontroller (5).
In case of a system deviation, the actuator is
either vented or filled with more air. The sig-
nal pressure supplied to the actuator can be
limited to 1.4 bar, 2.4 bar or 3.7 bar by
8EB 8387-3 EN
Design and principle of operation
%
S
mm
%
mm
w
x
G
PD
Serial
Interface 16
22
20
13
23
BE
4
21
17
FSK
519
3
6
7
81
w
9
x
y
Fig. 2 · Functional diagram
1 Control valve
2 Travel sensor
3 PD controller
4 A/D converter
5 Microcontroller
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
13* Analog position
transmitter
16 LCD
17* Control of forced venting
19 D/A converter
20 Serial interface (SSP)
21* HART®modulation
22 Rotary pushbutton
23* Binary input
* Optional
Ex d enclosure

software or on site at the positioner. A con-
stant air stream to the atmosphere is created
by the flow regulator (9) with a fixed set
point. The air stream is used to purge the in-
side of the housing as well as to optimize
the air capacity booster (7). The i/p con-
verter (6) is supplied with a constant up-
stream pressure by the pressure regulator
(8) to make it independent of the supply
pressure.
All parts are enclosed in an Ex d housing.
The electrical wires are connected over a
separate terminal compartment which is also
designed with Ex d protection.
The extended EXPERTplus diagnostics are in-
tegrated into the positioner. It provides infor-
mation on the positioner and generates di-
agnostic and status messages, which allow
faults to be pinpointed quickly.
The positioner is suitable for the following
types of attachment using the corresponding
accessories:
4Direct attachment to SAMSON
Type 3277 Actuator: section 4.1
4Attachment to actuators acc. to
IEC 60534-6 (NAMUR): section 4.2
4Attachment to Type 3510 Micro-flow
Valve: section 4.3
4Attachment to rotary actuators acc. to
VDI/VDE 3845: section 4.4
3.1 Additional equipment
Forced venting
The i/p converter stops working if the oper-
ating voltage supply to the relevant terminals
is interrupted. The positioner can no longer
operate and the control valve moves to the
fail-safe position (SAFE) determined by the
actuator, independent of the reference vari-
able.
Binary contact
The positioner has three internal binary sig-
nals which can be analyzed over terminals
A/B/C. Two of these signals are intended
for the valve end positions and one signal
for a collective fault alarm. The assignment
of these signals to the A/B/C terminals is
determined over Code 25.
Position transmitter
The position transmitter (13) is a two-wire
transmitter and issues the travel sensor sig-
nal as a 4 to 20 mA signal processed by the
microcontroller. Since this signal is issued in-
dependent of the positioner’s input signal
(min. current 3.8 mA), the actual travel/an-
gle of rotation is controlled in real-time. Ad-
ditionally, the position transmitter provides
the possibility of signaling a positioner fault
over a signal current of 2.4 mA or
21.6 mA.
Binary input
The positioner has an optional binary input.
The following actions can be performed over
the binary input:
EB 8387-3 EN 9
Design and principle of operation

4Transfer switching state [default]
The switching state of the binary input is
logged.
4Set local operation write protection
Settings cannot be changed at the
positioner while the binary input is ac-
tive. The configuration enabled function
in Code 3is not active.
4Switch between AUTO/MAN
The positioner changes from automatic
mode (AUTO) mode into manual
mode (MAN) and vice versa.
No action is started if the positioner is in
the fail-safe position (SAFE).
4Various diagnostic functions (refer to
EB 8389 EN on EXPERTplus valve diag-
nostics).
Note: The optional binary output can only
be configured using the TROVIS-VIEW soft-
ware and over the DD parameters (refer to
EB 8389 on EXPERTplus valve diagnostics).
The default switching state is with an open
switch.
Connection to terminals A-B: Binary input
for DC voltage signals
Connection to terminals B-C: Contact input
for an external contact
3.2 Communication
The positioner is equipped with an interface
for HART®protocol (Highway Addressable
Remote Transducer) for communication pur-
poses. Data are transmitted in a superim-
posed frequency (FSK = Frequency Shift
Keying) on the existing signal loop for the 4
to 20 mA reference variable.
Either a HART®capable handheld commu-
nicator or a computer with FSK modem can
be used to establish communication and op-
erate the positioner.
3.2.1 Configuration using
TROVIS-VIEW software
Refer to Table 5 on page 33 for order num-
bers.
The positioner can be configured using the
TROVIS-VIEW software.
The positioner is equipped for this purpose
with an additional digital SERIAL INTERFACE
to allow a computer to be connected over an
adapter cable from the RS-232 or USB port
of the computer to the positioner.
The TROVIS-VIEW software enables the user
to easily set parameters in the positioner
and view process parameters online.
Note: The TROVIS-VIEW software is a com-
mon operator interface for various smart
SAMSON devices. The software together
with a device-specific module allow the con-
figuration and parameterization of the de-
vice.
The device-specific module for Type 3731-3
can be downloaded free of charge from the
SAMSON website (Services > Software >
TROVIS-VIEW).
Additional information on TROVIS-VIEW
(e.g. system requirements) can found on the
SAMSON website and in the Data Sheet
T 6661.
10 EB 8387-3 EN
Design and principle of operation

3.3 Technical data
EB 8387-3 EN 11
Design and principle of operation
Type 3731-3 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Rated travel Adjustable Direct attachment to Type 3277: 3.6 to 30 mm
Attachment acc. to IEC 60534-6 (NAMUR): 3.6 to 300 mm
Attachment to rotary actuators (VDI/VDE 3845): 24° to 100°
Travel range Adjustable Adjustable within the initialized travel/angle of rotation;
travel can be restricted to 15at the maximum
Reference variable w Signal range 4 to 20 mA, 2-wire unit, reverse polarity protection,
min. span 4 mA, static destruction limit 40 V, internal current limit 60 mA
Shutdown action Type 3731-3xxxxxx000x1x00: Emergency shutdown at 0 mA
Type 3731-3xxxxxx100x1x00: Emergency shutdown at 3.85 mA ± 0.05 mA
Minimum current 3.6 mA for display
Voltage compliance ≤9 V corresponds to 450 Ωat 20 mA
Communication
Local communication SAMSON SSP interface and serial interface adapter
Software requirements TROVIS-VIEW with device-specific module for Type 3731-3
HART®communication HART®field communication protocol
Impedance in HART®frequency range: Receiving approx. 455 Ω, sending 185 Ω
Software requirements For handheld communicator: device description for Type 3731-3
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);
integration into AMS™ Suite available.
Supply air Pressure Type 3731-321, Type 3731-327: 1.4 to 7 bar (20 to 105 psi)
Type 3731-323: 1.4 to 6 bar (20 to 90 psi)
Air quality acc. to
ISO 8573-1
edition 2004
Max. particle size and density: Class 4 · Oil content: Class 3
Moisture and water: Class 3
Pressure dew point: At least 10 K beneath the lowest ambient temperature to be
expected
Signal pressure (output) 0 bar up to supply pressure · Limitable to 1.4/2.4/3.7 ±0.2 bar via software
Characteristic Linear/equal percentage/reverse equal percentage
Butterfly valve/Rotary plug valve/Segmented ball valve: linear/equal percentage
User-defined (over operating software and communication)
Deviation from terminal-based conformity ≤1 %
Hysteresis ≤0.3 %
Sensitivity ≤0.1%
Transit time Separately adjustable up to 240 seconds for supply air and exhaust air
Direction of action Reversible
Air consumption, steady-state Independent from supply pressure < 110 ln/h

12 EB 8387-3 EN
Design and principle of operation
Type 3731-3 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Air
output
capacity
to fill actuator
with air
At ∆p = 6 bar: 8.5 mn³/h · At ∆p = 1.4 bar: 3.0 mn³/h · KVmax(20 °C) = 0.09
to vent
actuator
At ∆p = 6 bar: 14.0 mn³/h · At ∆p = 1.4 bar: 4.5 mn³/h · KVmax(20 °C) = 0.15
Permissible ambient
temperature
–40 to 80 °C
The limits in the test certificate additionally apply.
Influences Temperature: ≤0.2/10 K · Supply air: None
Vibration: ≤0.25 % up to 2000 Hz and 4 g acc. to IEC 770
EMC Complying with the requirements of EN 61000-6-2, EN 61000-6-3, EN 61326-1 and
NAMUR Recommendation NE 21
Electrical connections Two threaded connections with ½ NPT thread, optionally with M20 x 1.5
Screw terminals for 2.5 mm² wire cross-section
Explosion protection See "Summary of explosion-protection certificates"
Degree of protection IP 66/NEMA 4 X
Use in safety-
instrumented systems (SIL)
Observing the requirements of IEC 61508, the systematic capability of the control valve
for emergency venting as a component in safety-instrumented systems is given.
Use is possible on observing the requirements of IEC 61511 and the required hardware
fault tolerance in safety-instrumented systems up to SIL 2 (single device/HFT = 0) and SIL
3 (redundant configuration/HFT = 1).
Compliance ·
Materials Housing Die-cast aluminum EN AC-AlSi10Mg(Fe) (EN AC-44300) acc. to DIN EN 1706
chromated and powder paint coating
External parts Stainless steel 1.4301/1.4305/1.4310
Weight Approx. 2.5 kg

EB 8387-3 EN 13
Design and principle of operation
Additional equipment
Optional binary output,
software limit switch, galvanically isolated
Connection: Optionally NAMUR EN 60947-5-6 or PLC, configurable as a limit switch or fault alarm output
Signal status Terminals B-C
Switching output AC/DC (PLC)
Terminals A-B
Conductive/remaining voltage < 1.7 V ≥2.2 mA
Non-conducting/high resist. I < 100 µA ≤1.0 mA
Operating voltage Switch. capacity: 40 V DC/28 V/AC 0.3 A
Static destr. limit: 45 V DC/32 V/AC 0.4 A
Only for connection to NAMUR signal
converter acc. to EN 60947-5-6
Optional forced venting, galvanically isolated
Input 0 to 40 V DC/0 to 28 V AC, static destruction limit 45 V DC/32 V AC,
input resistance ≥7 kΩ
Signal Fail-safe position at an input voltage ≤3 V
Normal operation at an input voltage > 5.5 V
Optional analog position transmitter, two-wire transmitter
Supply voltage 11 to 35 V DC, reverse polarity protection, static destruction limit 45 V
Output signal 4 to 20 mA
Direction of action Reversible
Operating range –1.25 to 103 % of the travel range, corresponding to 3.8 to 20.5 mA, optionally also for
fault alarm over 2.4 or 21.6 mA acc. to NAMUR Recommendation NE 43
Characteristic Linear
Hysteresis and
HF influence Same as positioner
Other influences Same as positioner
Fault alarm Can be issued with current signal 2.4 mA or 21.6 mA
Optional binary input, galvanically isolated, optionally for detection of an externally applied voltage or for operation
of an external floating contact · Switching behavior configured as required, default setting (see below)
Voltage input function,
polarity insensitive, 0 to 24 V DC voltage to be applied, input resistance 6.5 kΩ
Static destruction limit 40 V
Voltage > 6 V: Switching state ON · < 4 V: Switching state OFF
Contact input function,
for external switch (floating contact)
Electrical data Open-circuit voltage when contact is open: 10 V, pulsed DC current, peak value 100 mA
Contact Closed: Switching state ON · Open: Switching state OFF

Summary of explosion-protection certificates
Type
3731 Certificate Type of protection/comments
-321
EC-Type
Examination
Certificate
Number PTB11 ATEX 1014 X II 2G Ex d IIC T6,T5,T4 Gb;
II 2G Ex de IIC T6,T5,T4 Gb;
II 2D Ex tb IIIC T80°C DB IP66
Date 2012-07-26
Number RU C-DE-GB08.B.00697 1Exd IIC T6/T5/T4 Gb X;
1Exd e IIC T6/T5/T4 Gb X;
Ex tb IIIC T80°C Db X
Date 2014-12-15
Valid until 2019-12-14
IECEx
Number IECEx PTB11.0084X Exd IIC T6, T5, T4 Gb;
Exd e IIC T6, T5, T4 Gb;
Ex tb IIIC T80°C Db IP66
Date 2011-09-14
INMETRO
Number IEx 13.0193X
Ex d IIC T* Gb;
Ex de IIC T* Gb
Date 2016-10-14
Valid until 2019-08-28
KCS
Number 13-KB4BO-0036
Exd IIC T6/T5/T4Date 2013-01-31
Valid until 2018-01-31
NEPSI
Number GYJ16.1083X
Ex d IIC T6~T4;
Ex de IIC T6~T4
Date 2016-01-24
Valid until 2023-01-23
STCC Number 973 1Exd IIC T4...T6;
1Exde IIC T4...T6
Valid until 2017-10-01
-323
CSA
Number 1709815 Class I, Zone 1, Group IIB+H2 T4...T6;
Class I, Div. 1+2, Groups B, C, D T4...T6;
Class II, Div. 1, Groups E, F, G
Date 2005-10-04
FM
Number 3024956 Class I, Div. 1+2, Groups B, C, D;
Class I, Zone 1, Groups IIB+H2;
Class I, Div. 1+2 Groups E, F, G; Class III
Date 2006-01-30
-324
Number RU C-DE-GB08.B.00697
1Exd IIC T6/T5/T4 Gb X;
Ex tb IIIC T80°C Db X
Date 2014-12-15
Valid until 2019-12-14
-327 JIS
Number TC17747
Exd IIC T6Date 2015-09-12
Valid until 2018-09-11
14 EB 8387-3 EN
Design and principle of operation

4 Attachment to the control
valve – Mounting parts and
accessories
WARNING!
Attach the positioner, keeping the following
sequence:
1. Mount the positioner on the control valve
2. Connect the supply air
3. Connect the electrical power
4. Perform the start-up settings
The positioner is suitable for the following
types of attachment:
4Direct attachment to SAMSON
Type 3277 Actuator
4Attachment to actuators according to
IEC 60534-6 (NAMUR)
4Attachment to Type 3510 Micro-flow
Valve
4Attachment to rotary actuators
NOTICE
Attach the positioner to the control valve,
observing the following instructions to avoid
damaging the positioner.
–Use only the mounting parts/accessories
listed in the Tables 1 to 5 (pages 30 to
33) to mount the positioner. Observe the
type of attachment!
–The positioner is fitted with pneumatic
connections with ¼ NPT threads. If you
need G ¼ threads, attach the connecting
plate (6) listed in the accessories.
–Observe the assignment between lever
and pin position (see travel tables on
page 16).
–Fit a signal pressure restriction (Table 5
on page 33) for actuators with di-
aphragm areas smaller than 240 cm².
Lever and pin position
The positioner is adapted to the actuator
and to the rated travel by the lever on the
back of the positioner and the pin inserted
into the lever.
The travel tables on page 16 show the maxi-
mum adjustment range at the positioner. The
travel that can be implemented at the valve
is additionally restricted by the selected
fail-safe position and the required compres-
sion of the actuator springs.
The positioner is standard equipped with the
lever M(pin position 35).
Note: If the standard mounted lever M is re-
placed, 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.
EB 8387-3 EN 15
Attachment to the control valve – Mounting parts and accessories
Fig. 3 · Lever M with pin position 35 (delivered state)

16 EB 8387-3 EN
Attachment to the control valve – Mounting parts and accessories
Travel tables
Note: The lever Mis included in the scope of delivery.
Levers S,L,XL for attachment according to IEC 60534-6 (NAMUR) are available as accesso-
ries (see Table 3 on page 32).
Direct attachment to Type 3277-5 and Type 3277 Actuators
Actuator size Rated travel Adjustment range at positioner 1) Required
lever
Assigned
pin position
[cm²] [mm] Min. Travel Max.
120 7.5 5.0 to 25.0 M 25
120/175/240/350 15 7.0 to 35.0 M 35
355/700/750 30 10.0 to 50.0 M 50
Attachment according to IEC 60534-6 (NAMUR)
SAMSON valves/Type 3271 Actuator Adjustment range at positioner 1)
Other valves/actuators Required
lever
Assigned
pin position
Actuator size Rated travel
[cm²] [mm] min. Travel max.
60 and 120 with
Type 3510 Valve 7.5 3.6 to 18.0 S 17
120 7.5 5.0 to 25.0 M 25
120/175/240/350 15 7.0 to 35.0 M 35
700/750 7.5
355/700/750 15 and 30 10.0 to 50.0 M 50
1000/1400/2800 30 14.0 to 70.0 L 70
1000/1400/2800 60 20.0 to 100.0 L 100
1400/2800 120 40.0 to 200.0 XL 200
See manufacturer's
specifications 200 See manufacturer's specifications 300
Attachment to rotary actuators according to VDI/VDE 3845
Rotary actuators Required
lever
Assigned
pin position
Min. Opening angle Max.
24 to 100° M 90°
1) Values are based on the NOM initialization mode

4.1 Direct attachment
4.1.1 Type 3277-5 Actuator
Refer to Table 1 on page 30 for required
mounting parts and accessories.
Actuator with 120 cm²
NOTICE
If a solenoid valve or similar is additionally
mounted to the actuator, observe the follow-
ing instructions which differ from the instruc-
tions otherwise described:
–The switchover plate (9) is omitted.
–The signal pressure must be routed from
the signal pressure output over the con-
necting plate (accessories order no.
1400-6820) to the actuator.
–The hole for the signal pressure output
must be fitted with the screw restriction
(accessories order no. 1400-6964/item
no. 0390-1424).
–Do not remove the screw plug (4) at the
back of the positioner.
Depending on the type of positioner attach-
ment, the signal pressure is routed either left
or right of the yoke through a bore to the
actuator diaphragm.
1. Refer to Fig. 4 to select the symbol to
match the required fail-safe position
and how the positioner is attached:
Fail-safe position:
Actuator stem extends = Fail-close
Actuator stem retracts = Fail-open
Positioner attachment: Left or right with
view looking onto the switchover plate
2. Align the marking of the switchover
plate (9) to the corresponding symbol
and mount the plate on the actuator
yoke.
3. If applicable, mount pressure gauge
bracket (7) with pressure gauges or, in
case G ¼ threaded connections are re-
quired, the connecting plate (6), mak-
ing sure both seal rings (6.1) are
seated properly.
4. Remove screw plug (4) on the back of
the positioner and seal the signal pres-
sure output "Output 38" on the con-
necting plate (6) or on the pressure
gauge bracket (7) with the stopper (5)
included in the accessories.
5. Place follower clamp (3) on the actua-
tor stem, align and screw it tight so that
the mounting screw is located in the
groove of the actuator stem.
6. Press brass restriction (accessories or-
der no. 1400-6964/item no.
0390-1423) into the seal of the signal
pressure input at the actuator yoke.
7. Mount cover plate (10) with the narrow
side of the cut-out opening (Fig. 4, left)
pointing towards the signal pressure
connection. Make sure that the bonded
gasket (14) points towards the actuator
yoke.
8. 15 mm travel: Keep the follower pin
(2) at lever M(1) on the back of the
positioner in the pin position 35 (deliv-
ered state).
7.5 mm travel: Remove the follower pin
(2) from the pin position 35, reposition
EB 8387-3 EN 17
Attachment to the control valve – Mounting parts and accessories

it in the hole for pin position 25 and
screw tight.
9. Insert formed seal (15) into the groove
of the positioner housing, pressing the
four retaining rings over the housing
screws and both fittings into the hous-
ing recesses.
10. Thread the bias spring (17) through the
crosspiece underneath the lever (1) and
push into the hole in the housing. Push
the lever (1) until it engages into place.
Place positioner on the cover plate (10)
and fasten it using the three fixing
screws.
Check to make sure that the follower
pin (2) rest on top of the follower clamp
(3). The lever (1) must rest on the fol-
lower clamp with spring force.
Make sure that the seal ring (10.1) is
inserted in the borehole of the cover
plate.
11. Mount cover (11) on the other side.
Make sure that the vent plug (11.1)
points downwards when the control
valve is installed to allow any con-
densed water that collects to drain off.
18 EB 8387-3 EN
Attachment to the control valve – Mounting parts and accessories

EB 8387-3 EN 19
Attachment to the control valve – Mounting parts and accessories
911
Supply 9 Output 38
5
6
4
17
7
6
10
10.1
3
2
1
15
6.1
1.1
1.2
14
8
11.1
A
A-A
A
Fig. 4 · Direct attachment for Type 3277-5 Actuator with 120 cm²
Switchover plate (9)
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
3 Follower clamp
4 Screw plug
5 Stopper
6 Connecting plate for G ¼
6.1 Seal rings
7 Pressure gauge bracket
8 Press. gauge mounting kit
9 Switchover plate
for actuator
10 Cover plate
10.1 Seal ring
11 Cover
11.1 Vent plug
14 Gasket
15 Formed seal
17 Bias spring (only with
direct attachment)
Signal pressure input
for right attachment
Symbols
Actuator stem
extends
Left attachment Right attachment
Actuator stem
retracts
Signal pressure
input for left
attachment
Signal pressure input
with brass restriction
Cut-out of
cover plate
Marking

4.1.2 Type 3277 Actuator
Refer to Table 2 on page 31 for the required
mounting parts and accessories.
Actuators with 175 to 750 cm²
Mount the positioner onto the yoke as shown
in Fig. 5. 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 re-
tracts" through external piping.
1. Place follower clamp (3) on the actua-
tor stem, align and screw it tight so that
the mounting screw is located in the
groove of the actuator stem.
2. Mount cover plate (10) with the narrow
side of the cut-out (Fig. 5, left) pointing
towards the signal pressure connection.
Make sure that the bonded gasket (14)
points towards the actuator yoke.
3. Actuators with 355, 700 and 750 cm²:
Remove the follower pin (2) at lever M
(1) on the back of the positioner from
pin position 35, reposition it in the hole
for pin position 50 and screw tight.
Actuators 175 to 350 cm² with 15 mm
travel: The follower pin (2) remains in
pin position 35 (delivered state).
4. Insert formed seal (15) into the groove
of the positioner housing, pressing the
four retaining rings over the housing
screws and both fittings into the hous-
ing recesses.
5. Thread the bias spring (17) through the
crosspiece underneath the lever (1) and
push into the hole in the housing. Push
the lever (1) until it engages into place.
Place positioner on the cover plate (10)
and fasten it using three fixing screws.
Check whether the follower pin (2) rests
on top of the follower clamp (3).
The lever (1) must rest on the follower
clamp with spring force.
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 corre-
sponds with the actuator with fail-safe
action "Actuator stem extends" or "Ac-
tuator stem retracts." If necessary, re-
move the three fixing screws and the
cover plate. Then reposition the gasket
(16) turned by 180°. The previous ver-
sion 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. Actuators with 175 cm²: Unscrew the
filter from the signal pressure input and
first screw the screw restriction (acces-
sories order no. 1400-6964/item no.
0390-1424) into the input and then the
filter.
8. 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 "Ac-
tuator stem retracts", additionally re-
move the stopper (12.2) and attach the
external signal pressure line.
20 EB 8387-3 EN
Attachment to the control valve – Mounting parts and accessories