Samson Type 3766 Service manual

Translation of original instructions
EB 8355-1 EN
Edition October 2018
Type3766 Pneumatic Positioner

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
Department (aftersalesser[email protected]).
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.samson.de > 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 8355-1 EN

Contents
EB 8355-1 EN 3
1 General safety instructions.............................................................................5
2 Design and principle of operation ..................................................................6
2.1 Versions and article code................................................................................9
2.2 Technical data .............................................................................................10
2.3 Additional equipment...................................................................................12
2.4 Summary of explosion protection approvals...................................................13
3 Mounting on control valves..........................................................................14
3.1 DirectattachmenttoType3277Actuator .......................................................14
3.2 AttachmentaccordingtoIEC60534-6...........................................................21
3.2.1 Mounting sequence......................................................................................22
3.2.2 Initial adjustment of travel.............................................................................22
3.3 Attachment to rotary actuators ......................................................................25
3.3.1 Mounting the lever with feeler roll..................................................................26
3.3.2 Mounting the intermediate piece ...................................................................26
3.3.3 Basic setting of the cam disk .........................................................................28
3.3.4 Reversingamplierfordouble-actingactuators ..............................................32
4 Connections ................................................................................................34
4.1 Pneumatic connections..................................................................................34
4.1.1 Pressure gauges...........................................................................................34
4.1.2 Supply pressure ...........................................................................................34
4.2 Electrical connections ...................................................................................36
4.2.1 Switchingamplier ......................................................................................37
5 Operation...................................................................................................38
5.1 Tuningthepositionermountedontothecontrolvalve.......................................38
5.1.1 AdjustingtheproportionalbandXpandairdeliveryQ ..................................39
5.1.2 Settingsforactuatorwith“actuatorstemextends”fail-safeaction.....................39
5.1.3 Settingsforactuatorwith“actuatorstemretracts”fail-safeaction .....................40
5.2 Changingtheoperatingdirection..................................................................41
5.3 Adjustingthelimitcontacts ...........................................................................42
5.4 Adjustingthepositiontransmitter...................................................................44
6 Upgrading the positioner.............................................................................47

Contents
4 EB 8355-1 EN
7 After-sales service .......................................................................................49
7.1 Servicingexplosion-protecteddevices............................................................49
7.2 Maintenanceandcalibration ........................................................................49
8 Dimensions in mm.......................................................................................50
Test certicates............................................................................................51

EB 8355-1 EN 5
General safety instructions
1 General safety instructions
For your own safety, follow these instructions concerning the mounting, start up and opera-
tion of the device:
−The device 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 applicable standards.
−Any hazards that could be caused in the valve by the process medium, the signal pres-
sure or by moving parts are to be prevented by taking appropriate precautions.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of
the supply pressure level, it must be restricted using a suitable supply pressure reducing
station.
−Explosion-protected versions of this device are to be operated only by personnel who has
undergone special training or instructions or who is authorized to work on explosion-
protected devices in hazardous areas.
To avoid damage to any equipment, the following also applies:
−Proper shipping and storage are assumed.
The device with a CE marking fullls the requirements of the Directive 2014/34/EU and the
Directive 2014/30/EU. The Declaration of Conformity is available on request.
Models with index 3766-x...x.03 and higher are equipped with a hinged cover without their
own exhaust air port.
The required exhaust air connection is now included in the mounting accessories.
If these positioners are mounted on older actuator models, make sure that there is an exhaust
air connection. If necessary, replace the mounting accessories as well.
Note
NOTICE
!

6 EB 8355-1 EN
Design and principle of operation
2 Design and principle of oper-
ation
The pneumatic positioner is used to assign
the valve position (controlled variable) to the
input signal (reference variable). The posi-
tioners compare the control signal of a con-
trol system to the travel of the control valve
and issues a signal pressure (output variable)
for the pneumatic actuator.
The positioner consists of a lever for travel
pick-up, a measuring diaphragm and the
pneumatic control system with nozzle, dia-
phragmlever(apperplate)andbooster.
The positioner is designed either for direct
attachmenttoSAMSONType3277Actua-
tors or for attachment according to NAMUR
(IEC60534-6-1)withanadapterhousing.
The positioner can be additionally equipped
with either inductive limit contacts and/or a
solenoid valve or position transmitter.
The positioner operates according to the
force-balance principle. The valve travel, i.e.
the valve position, is transmitted to the pick-
up lever (1) over the pin (1.1) and deter-
mines the force of the range spring (4). This
force is compared to the positioning force
generated by the pressure peat the measur-
ingdiaphragm(5).
If either the control signal or the valve posi-
tion changes, the diaphragm lever (3)
moves, altering the distance to the nozzle
(2.1 or 2.2), depending on the adjusted di-
rection of action of the positioner.
The supply air is supplied to the booster (10)
and the pressure regulator (9). The controlled
supplyairowsthroughtheXprestriction(8)
and the nozzle (2.1, 2.2) and hits the dia-
phragmlever(apperplate).
Any change in the reference variable or the
valve position causes the pressure to change
upstream or downstream of the booster.
The air controlled by the booster (signal
pressure pst)owsthroughthevolumerestric-
tion (11) to the pneumatic actuator, causing
the plug stem to move to a position corre-
sponding to the reference variable.
TheadjustableXprestriction(8)andvolume
restriction (11) are used to optimize the posi-
tioner control loop.
The pick-up lever (1) and the range spring
(4) must be selected to match the rated valve
travel and the nominal span of the reference
variable.
Positioner with inductive limit contacts
In this version, the rotary shaft of the posi-
tioner carries two adjustable tags which ac-
tuate the built-in proximity switches.
Positioner with solenoid valve
When the positioner is equipped with a sole-
noid valve, the valve can be moved to the
fail-safe position, regardless of the position-
er's output signal. If a control signal corre-
sponding to the binary signal '0' (OFF) is ap-
plied to the input, the signal pressure pst is
shut off and the actuator is vented. The actu-
ator springs move the valve to its fail-safe po-
sition.
When a control signal corresponding to the
binary signal '1' (ON) is applied to the in-
put, the signal pressure pst is applied to the
actuator, allowing the valve to move accord-
ing to the input signal issued by the control
equipment.

EB 8355-1 EN 7
Design and principle of operation
789101112
6.1 46.2
2.1
3
2.2
5
1
1.
11
.2
Pe
Supply
9
V
Pst
Q
Xp
e
p
1 Lever
1.1 Pin
1.2 Clamp
2.1 Nozzle >>
2.2 Nozzle <>
3 Diaphragm lever
4 Range spring
5Measuring
diaphragm
6.1 Span adjuster
6.2 Zero adjuster
7Turnboard
8Xprestriction
9 Pressure regulator
10 Booster
11 Volume restriction
12 Solenoid valve
(option)
4
6.1 6.2
378 9 11
Travel
Fig.1: Functional diagram and inside view

8 EB 8355-1 EN
Design and principle of operation
Positioner with position transmitter
A positioner containing a position transmit-
ter cannot be equipped with integrated limit
contacts or an integrated solenoid valve
since the position transmitter requires most of
the space inside.
The position transmitter is used to assign the
valve position, i.e. the valve travel, to an out-
putsignalof4to20mA.
The tuning of the position transmitter ensures
that both end positions "valve CLOSED" or
"valve OPEN" as well as all intermediate po-
sitions can be signalized. Since the valve po-
sition is signalized independently of the in-
put signal to the positioner, the position
transmitter is a suitable option for checking
the actual valve position.

EB 8355-1 EN 9
Design and principle of operation
2.1 Versions and article code
Pneumatic positioner Type3766- x x x 0 1 x x x x 1 x 0 x 0
Explosion protection
Without 0 2
II2GExiaIICT6accordingtoATEX 1
CSA/FM intrinsically safe/non incendive 3
Exia/ExnI/IICT6IP65IECExTSAAustralia 6
II3GExnAIIT6acc.toATEX 8
Additional equipment
Without 0
Inductive limit contacts 2x SJ2-SN 2
(Analogpositiontransmitter4to20mA)1) 60 0
3/2-way solenoid valve
Without 0
6VDC 2
12VDC 3
24VDC 4
Pneumatic connections
¼-18NPT 1
ISO228/1-G¼ 2
Electrical connections
Without (no additional equipment or solenoid valve) 0 0 0 0
PlasticcableglandM20x1.5,blue 1 0 0
PlasticcableglandM20x1.5,black 2 0 0
CableglandM20x1.5,nickel-platedbrass 2 1 3
Housing version
Die-cast aluminum 0
CrNiMo steel 2
Temperature range
Standard 0
Low-temperature version
Tmin ≥–50°C;optionallimitcontacts,solenoidvalve 2 1 3
Special versions
Without 0 0 0
GOSTExapproval0ExiaIICT8X 1 0 1 0
1) Available until March 2011
Devicefunctioningonlyasanalogpositiontransmitter:3766-x60000xxx000000

10 EB 8355-1 EN
Design and principle of operation
2.2 Technical data
Type3766 Positioner
Travel range 7.5to30mm DirectattachmenttoType3277Actuator
7.5to120mm Attachmentacc.toIEC60534(NAMUR)
Opening angle 70°,75°or90°dependingonthecamdisk
Reference
variable w
Signal range 0.2to1bar(3to15psi)
Span 0.4to0.8bar(6to12psi)
Overloadable Max. 2bar(29psi)
Supply air 1.4to6bar(20to90psi)
Air quality acc. to
ISO8573-1,
edition 2001-02
Maximum particle size and density: Class 4 · Oil content: Class 3
Pressuredewpoint:Class3oratleast10Kbelowthelowestambient
temperature to be expected.
Signal pressure pst (output) Can be limited between:
0toapprox.2.5barand0to6bar(0toapprox.35psiand0to90psi)
Characteristic Linearcharacteristic·Deviationfromterminal-basedconformity:≤1%
Hysteresis ≤0.6%
Sensitivity ≤0.1%
Direction of action Reversible
ProportionalbandXp 0.5to2.5%(proportional-actioncoefcientKp:>200to40)
Air consumption At1.4barsupplypressure At6barsupplypressure
≤230In/h ≤230In/h 1)
Air output
capacity
Tollactuatorwithair 3.0mn³/h·KVmax(20°C) = 0.09 8.5mn³/h·KVmax(20°C) = 0.09
To vent actuator 4.5mn³/h·KVmax(20°C)=0.15 14.0mn³/h·KVmax(20°C)=0.15
Permissible
ambient
temperature 2)
Standard –20to80°C: Optional limit contacts/solenoid valve/position
transmitter with plastic cable gland
–40to80°C: Optional limit contacts/solenoid valve with metal
cable gland
Low-temperature
version
–50to80°C: Optional limit contacts/solenoid valve with metal
cable gland
Technicaldataintestcerticatesadditionallyapplytoexplosion-
protected devices
Inuence Temperature:≤0.3%/10K
Supplyair:≤1%between1.4and6bar
Electromagnetic compatibility AccordingtoEN61000-6-2,EN61000-6-3andNAMUR
RecommendationNE21

EB 8355-1 EN 11
Design and principle of operation
Effect of vibration Nonebetween10and150Hzand4g
Explosion protection Refer to article code or list of approvals in Data Sheet uT8355
Degree of protection IP54(IP65andNEMA4Xpossiblebyttingaltercheckvalve.See
tableonaccessoriesonpage19)
Compliance ·
Weight Approx.1kg
1) With lowest setting of pressure regulator
2) Thelimitsinthetypeexaminationcerticateadditionallyapplytoexplosion-protectedversions.

12 EB 8355-1 EN
Design and principle of operation
2.3 Additional equipment
Limit contacts
2 inductive proximity switches SJ2-SN
Control circuit Values according to downstream transistor relay
Hysteresis at rated travel ≤1%
Solenoid valve
Input Binary DC voltage signal
Nominal signal 6VDC 12VDC 24VDC
Signal '0' (no response) 2) ≤1.2V ≤2.4V ≤4.7V
Signal '1' (response) 3) ≥5.4V ≥9.6V ≥18.0V
Maximum permissible signal 28V 25V 32V
Coil resistance Riat20°C 2909Ω 5832Ω 11714Ω
Air consumption in steady state Inadditiontothatofthepositioner:OFF≤60ln/h·ON≤10ln/h 1)
Closing time for
rated travel and
signal pressure
range(KVS 0.13)
Type3277Actuator ≤120cm² 240cm² 350cm² 700cm²
0.2to1bar ≤0.5s ≤0.8s ≤1.1s ≤4s
0.4to2bar ≤0.5s ≤2s ≤2.5s ≤8s
0.6to3bar 5) ≤1s ≤1.5s ≤5s
Analog position transmitter6)
Output Two-wireconnection4to20mA
Auxiliary power Minimumterminalvoltage:12V,
max.:45V
The position transmitter must
onlybeconnectedtoacertied
intrinsically safe circuit. 4)
1) With lowest setting of pressure regulator
2) DCvoltagesignalat25°C
3) DCvoltagesignalat+80°C
4) e.g.usingaSAMSOMATICType994-0103-KFD2-STC4-Ex1LoopIsolator
5) 120cm²actuatorinallsignalpressureranges:≤0.5s
6) Available until March 2011

EB 8355-1 EN 13
Design and principle of operation
2.4 Summary of explosion protection approvals
Type Certication Type of protection
3766-1
ATEX Number PTB01ATEX2171 II2GExiaIICT6
Date 2001-11-26
EAC
Number RUCDE.08.00697 Type3766-1:
1ExiaIICT6/T5/T4GbX
Type3766-8:
2ExnAIICT6/T5/T4GcX
Date 2014-12-15
Valid until 2019-12-14
3766-3
CSA
Number 1607848 ExiaIICT6;ClassIZone0;
ClassI,II,Div.1,GroupsA,B,C,D,E,F,G;
ClassI,II,Div.2,GroupsA,B,C,D,E,F,G;
Date 2005-09-16
FM
Number 3020228 ClassI,Zone0AExiaIIC
Class I, II, III, Div. 1, Groups A, B, C, D, E, F, G
ClassI,Div.2,GroupsA,B,C,D;
ClassII,Div.2GroupsF,G;ClassIII;
Date 2005-02-28
3766-6 IECEx Number IECExTSA05.0004X ExiaI/IICT6IP65,
ExnI/IICT6IP65
Date 2005-05-24
3766-8
EAC
Number RUCDE.08.00697 Type3766-1:
1ExiaIICT6/T5/T4GbX
Type3766-8:
2ExnAIICT6/T5/T4GcX
Date 2014-12-15
Valid until 2019-12-14
ATEX Number PTB01ATEX2195X II3GExnAIIT6
Date 2002-03-07

14 EB 8355-1 EN
Mounting on control valves
3 Mounting on control valves
The positioner can be mounted either directly
toSAMSONType3277Actuatorortocon-
trol valves with cast yokes or rod-type yokes
accordingtoIEC60534-6(NAMUR).
Combined with an intermediate piece, the
positioner can also be mounted on rotary
actuators. The standard positioner is deliv-
ered without accessories. Any additionally
required accessories are listed together with
their order numbers in the following tables.
Do not remove the protective cover on the
back of the positioner until you actually start
to attach the positioner.
Mounting position and operating direction
The operating direction of the positioner also
determines its mounting position on the actu-
atorasillustratedinFig.2,Fig.3andFig.5.
Theturnboard(7inFig.1)atthepositioner
must be mounted correspondingly.
For an increasing input signal (reference
variable), the signal pressure pst can either
be increasing (direct action >>) or decreas-
ing (reverse action <>). Similarly, as the ref-
erence variable decreases, the signal pres-
sure can either decrease (direct action >>) or
increase (reverse action <>).
Ontheturnboard(7),theoperatingdirection
is indicated by symbols (direct >>, reverse
<>). Depending on the position of the turn-
board, the adjusted operating direction and
the associated symbol become visible.
If the required operating direction does not
correspond to the visible symbol or if you
want to change the operating direction, re-
move the fastening screw at the turnboard,
turntheboardby180°andrefastenthe
turnboard. Make sure the three rubber gas-
kets inserted in the housing remain in posi-
tion.
When any subsequent changes are made,
e.g. reversing the operating direction of the
positioner control loop or changing the actu-
ator fail-safe action from “actuator stem ex-
tends” to “actuator stem retracts” or vice ver-
sa, the positioner's mounting position must
be changed accordingly.
3.1 Direct attachment to
Type3277 Actuator
The required accessories are listed in Table1
to Table4 on page18.
The attachment of the positioner either on the
left or right side of the actuator (always look-
ing onto the signal pressure connection or
switchover plate) is determined by the re-
quired operating direction of the positioner,
i.e. >> or <>.
NOTICE
!
Note

EB 8355-1 EN 15
Mounting on control valves
SUPPLY
Actuator stem extends
Actuator stem retracts
Internal signal
pressure connection
Side view of connection block
Signal pressure
connection over piping
Connection block
Tipofgasket(16)
Operating
direction >> Left
attachment
Operating
direction <> Left
attachment
With gasket (new) With switch plate (old)
Switch plate (13)
Gasket(16)
Cover
Switchover plate Signal pressure input
Signal pressure
input for left
attachment
Seal with
lter
With right
attachment
Marking
Marking
Symbol
Actuator stem extends
Actuator stem retracts
Operating
direction <> Right
attachment
Actuator stem extends
>> Operating direction <>
Left attachment Right attachment
Actuator stem retracts
<> Operating direction >>
Left attachment Right attachment
Operating
direction >> Right
attachment
Fig.2: Mounting position and connection of signal pressure for Type3277 Actuator (top) and Type3277-
5 Actuator (120cm²) (bottom)

16 EB 8355-1 EN
Mounting on control valves
1. Fasten the clamp (1.2) to the actuator
stem, making sure that the fastening
screw rests in the groove of the actuator
stem.
2. Fasten the associated pick-up lever D1 or
D2(with355/700cm²actuators)tothe
feedback lever of the positioner.
3. Securetheintermediateplate(15)with
the gasket facing towards the actuator
yoke.
4. Position the positioner such that the pick-
up lever slides in line over the pin (1.1)
of the clamp (1.2). Fasten the positioner
totheintermediateplate(15).
5. Mountcover(16).
6. Check whether the correct range spring
hasbeeninstalledaslistedinTable4!
Range spring 1 is installed as standard.
If necessary, replace it with range spring
2includedintheaccessoriesandxitat
the outer hook-in holes.
Actuators with 240, 350, 355 and 700cm²
diaphragm areas
7. Makesurethatthetipofthegasket(16)
projecting from the side of the connec-
tionblock(Fig.2,middle)ispositioned
to match the actuator symbol for the ac-
tuator's fail-safe action "actuator stem
extends" or "actuator stem retracts".
If this is not the case, unscrew the three
fastening screws and lift off the cover.
Turnthegasket(16)by180°andre-in-
sert it.
The old connection block version requires
the switch plate (13) to be turned to align
the actuator symbol with the arrow mark-
ing.
8. Place the connection block with the asso-
ciated gaskets against the positioner and
the actuator yoke. Fasten it using the
screw.
For actuators with fail-safe action "actua-
tor stem retracts", additionally mount the
external signal pressure pipe.
Actuator (120cm²)
The signal pressure is transmitted to the dia-
phragm chamber over the switchover plate
(Fig.2andFig.3,bottom).
7. Removescrewplugonthebackofthe
positioner(Fig.4)andsealtheside
signal pressure output with the stopper
included in the accessories.
8. Mount the positioner so that the hole in
theintermediateplate(15)coversthe
seal in the hole of the actuator yoke.
9. Align the switchover plate with the corre-
sponding actuator symbol. Fasten it to
the actuator yoke.
If a solenoid valve or a similar device is ad-
ditionally mounted onto a 120cm² actuator,
do not remove the M3 screw plug at the
back of positioner. In this case, the signal
pressure must be transmitted from the signal
pressure output to the actuator over an addi-
tional connecting plate (Table2). The swi-
tchover plate is not used in this case.
NOTICE
!

EB 8355-1 EN 17
Mounting on control valves
Air purging of the spring chamber
If the spring chamber of the actuator is to be
purged with the exhaust air from the
positioner,usepiping(Table3)toconnect
the spring chamber (with "actuator stem
extends" version) to the connection block. To
do so, remove the stopper from the
connection block. For an actuator with fail-
safe action "actuator stem retracts" and in
Type3277-5Actuatorswithaneffective
diaphragmareaof120cm²,theexhaustair
from the positioner is connected to the spring
chamber over an internal hole.
When the valve is installed, the side cover of
the actuator must be mounted such that the
vent plug points downward.
NOTICE
!
1.2
D2
D1
15
Vent plug
Vent plug must point
downward when the
valve is installed
View onto the signal pressure connection
Left attachment Right attachment
Cover
Switchover plate
Intermediateplate(15)
Clamp (1.2)
Signal pressure
borehole
240cm²
350cm²
355cm²
700cm²
120cm²
Type3277
Type3277-5
Fig.3: Mounting the clamp

18 EB 8355-1 EN
Mounting on control valves
Table1: Lever (see Fig.3) Mounting kit
Actuator size Lever with associated clamp and intermediate plate Order no.
120cm² D1 lever with stopper for output (38) Standard version 1400-7116
Version compatible with paint 1402-0944
240/350cm² D1lever(33mmlongwith17mmclamp) Standard version 1400-6370
Version compatible with paint 1402-0942
355/700cm² D2lever(44mmlongwith13mmclamp) Standard version 1400-6371
Version compatible with paint 1402-0943
Table2: Switchover plates and connecting plates Order no.
Switchoverplate(for120cm²actuator) Type3277-5xxxxxx.00 Actuator (old) 1400-6819
New switchover plate Type3277-5xxxxxx.01 Actuator (new) or higher 1400-6822
Connecting plate for additional attachment
of, e.g. a solenoid valve
Type3277-5xxxxxx.00Actuator(old),G
1
/
8
Type3277-5xxxxxx.00 Actuator (old),
1
/
8
NPT
1400-6820
1400-6821
New connecting plate Type3277-5xxxxxx.01 Actuator (new) or higher
G
1
/
8
and
1
/
8
NPT 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,355and700cm²
actuator (including gaskets and fastening screw)
G¼ 1400-8819
¼ NPT 1402-0901
Table3: Pipe connection Material Actuatorsize[cm²] Order no.
Requiredpipeconnectionincludingscrewtting
For actuator with "actuator stem retracts" or
with air purging of the top diaphragm chamber
Steel 240 1400-6444
Stainless steel 240 1400-6445
Steel 350 1400-6446
Stainless steel 350 1400-6447
Steel 355/700 1400-6448
Stainless steel 355/700 1400-6449
Table4: Range spring Travel[mm] Actuatorsize[cm²] Order no.
2(4.5coils) 7.5 120, 240 1400-6443
1(9.5coils,installedasstandard) 10to15 120,240and350 1400-6442
215 355/700 1400-6443
1 30 355/700 1400-6442

EB 8355-1 EN 19
Mounting on control valves
Accessories Order no.
Pressuregaugemountingblock(onlyfor120cm²) G¼ 1400-7458
¼ NPT 1400-7459
Pressure gauge mounting kit for supply pressure and signal pres-
sure
Stainless steel/brass 1400-6950
Stainless steel/stainless steel 1400-6951
Filtercheckvalve,replacesventplugandincreasesthedegreeofprotectiontoIP65
FiltercheckvalveinhousingwithG¼thread
Polyamide,
IP65degreeofprotection 1790-7408
1.4301,IP65degreeof
protection 1790-7253
Polyamide,
NEMA 4 degree of protection 1790-9645
1.4301,
NEMA 4 degree of protection 1790-9646
Assortment of spare parts including gaskets and diaphragms 1400-9895

20 EB 8355-1 EN