3766 positioner

8/11/2019 3766 positioner

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Pneumatic PositionerType 3766

Mounting andOperating Instructions

EB 8355-1 ENEdition November 2011

Fig. 1 Type 3766 Pneumatic Positioner


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2 EB 8355-1 EN

Safety instructions

Safety instructions

The positioner is to be mounted, started up or operated only by trained andexperienced personnel familiar with the product.

According to these Mounting and Operating Instructions, trained personnelrefers to individuals who are able to judge the work they are assigned toand recognize possible dangers due to their specialized training, theirknowledge and experience as well as their knowledge of the applicablestandards.

Explosion-protected versions of this positioner may only be operated by per-sonnel who have undergone special training or instructions or who are aut-

horized to work on explosion-protected devices in hazardous areas. 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 tobe prevented by means of the appropriate measures.

If inadmissible motions or forces are produced in the actuator as a result ofthe supply pressure, the supply pressure must be restricted by means of asuitable supply pressure reducing station.

Proper shipping and appropriate storage are assumed.

Note:The device with a CE marking fulfils the requirements of the Directives94/9/EC (ATEX) and 2004/108/EC (EMC).The declaration of conformity is available on request.

Note on modification:

Positioners with model index 3766-x...x.03 and higher are equipped with ahinged cover without venting connection.The required exhaust air connection is now included in the mounting accesso-ries. If these positioners are mounted on older actuator models, make absolutelysure that there is a vent connection. If necessary, replace the mounting accesso-ries as well.


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Contents Page

1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 4

1.1 Versions (article code). . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Attachment to control valve . . . . . . . . . . . . . . . . . . . . . . 102.1 Direct attachment to Type 3277 Actuator . . . . . . . . . . . . . . . . 102.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 152.2.1 Mounting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 162.2.2 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 162.3 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 192.3.1 Mounting the cam follower lever . . . . . . . . . . . . . . . . . . . . 20

2.3.2 Mounting the intermediate piece . . . . . . . . . . . . . . . . . . . . 202.3.3 Default setting of the cam disk . . . . . . . . . . . . . . . . . . . . . 222.3.4 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26

3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.1 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 293.2.1 Switching amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324.1 Setting the positioner at the valve. . . . . . . . . . . . . . . . . . . . 324.1.1 Adjusting the proportional band Xp and air delivery Q . . . . . . . . . 334.1.2 Settings for actuator: "Actuator stem extends". . . . . . . . . . . . . . 334.1.3 Settings for actuator: "Actuator stem retracts" . . . . . . . . . . . . . . 344.2 Changing the operating direction . . . . . . . . . . . . . . . . . . . 354.3 Adjusting the limit switches . . . . . . . . . . . . . . . . . . . . . . . 364.4 Adjusting the position transmitter . . . . . . . . . . . . . . . . . . . . 38

5 Converting the positioner . . . . . . . . . . . . . . . . . . . . . . . 40

6 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426.1 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 426.2 Maintenance, calibration and work on equipment. . . . . . . . . . . . 42

7 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EB 8355-1 EN 3

Contents


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1 Design and principle ofoperation

The positioners ensure a fixed assignmentbetween the valve stem position (controlled

variable x) and the pneumatic or electric in-put signal (reference variable w). They com-pare the input signal received from the con-trol unit with the travel of the control valveand, issue the corresponding output signalpressure pst(output variable).

The positioner consists of a lever for travelpick-up, a measuring diaphragm and thepneumatic control system with nozzle, dia-phragm lever (flapper plate) and booster.

The positioner is designed either for directattachment 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 switches and/or asolenoid valve or a position transmitter.

The positioner operates according to theforce-balance principle. The valve travel, i.e.the valve position, is transmitted to thepick-up lever (1) over the pin (1.1) and de-termines the force of the measuring spring(4). This force is compared to the positioningforce generated by the pressure pe at the

measuring 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 set operatingdirection of the positioner.

The air is supplied to the booster (10) andthe pressure regulator (9). The controlledsupply air flows through the Xp restriction

(8) and the nozzle (2.1, 2.2) to finallystream on the diaphragm lever (flapper

plate). Any change in the reference variableor the valve stem position cause the pressureto change upstream or downstream of thebooster.

The air controlled by the booster (signalpressure pst) flows through the volume re-striction (11) to the pneumatic actuator,causing the plug stem to move to a positioncorresponding to the reference variable.

The adjustable Xp restriction (8) and volumerestriction Q (11) are used to optimize thepositioner control loop.

The pick-up lever (1) and the range spring(4) must be selected to match the rated valvetravel and the nominal span of the reference

variable.

Positioner with inductive limit switches

In this version, the rotary shaft of thepositioner carries two adjustable tags whichactuate the built-in proximity switches.

Positioner with solenoid valve

When the positioner is equipped with a so-lenoid valve, the valve can be moved to thefail-safe position regardless of thepositioner's output signal. If a control signal

corresponding to the binary signal '0' (off)is applied to the input, the signal pressurepstis shut off and the actuator is vented. Theactuator springs move the valve to itsfail-safe position. If a control signal corre-sponding to the binary signal '1' (on) is ap-plied to the input, the signal pressure pstissupplied to the actuator. The valve is inclosed-loop operation.

4 EB 8355-1 EN

Design and principle of operation


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Positioner with position transmitter

A positioner containing a position transmit-

ter cannot be equipped with integrated limitswitches or an integrated solenoid valvesince the position transmitter requires mostof the space inside.

The position transmitter is used to establish acertain relationship between the valve posi-tion, i.e. the valve travel, and a controlleroutput signal of 4 to 20 mA.

1.1 Versions (article code)

The position transmitter setting ensures thatboth end positions "valve CLOSED" or

"valve OPEN" as well as all intermediatepositions can be signalized. Since the valveposition is signalized independently of theinput signal to the positioner, the positiontransmitter is a suitable option for checkingthe current valve position.

6 EB 8355-1 EN


Pneumatic positioner Type 3766- x x x 0 1 x x x x 1 x 0 x 0

Explosion protection

Without 0 2

II 2 G EEx ia IIC T6 acc. to ATEX 1

FM/CSA intrinsically safe/non incendive 3

Ex ia / Ex n I/IIC T6 IP 65 IECEx TSA Australia 6

II 3 G EEx nA II T6 acc. to ATEX 8

Additional equipment

Without 0

Limit switch, inductive 2x SJ2 SN 2

(Analog position transmitter 4 to 20 mA * 6 0 0)

3/2-way solenoid valve

Without 0

6 V DC 2

12 V DC 3

24 V DC 4


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EB 8355-1 EN 7


Pneumatic positioner Type 3766- x x x 0 1 x x x x 1 x 0 x 0

Pneumatic connections

-18 NPT 1

ISO 228/1 - G 2

Electrical connections

Without (no additional equipment or solenoid valve) 0 0 0 0

Cable gland

M20 x 1.5, blue (plastic) 1 0 0

M20 x 1.5, black (plastic) 2 0 0

M20 x 1.5 (nickel-plated brass) 2 1 3

Housing version

Die-cast aluminum 0

Stainless steel (CrNiMo) 2

Temperature range

Standard 0

Low temperatureTmin 50 C; optional limit switches, solenoid valve

2 1 3

Special version

Without 0 0 0

GOST Ex approval 0Ex ia IIC T8 X 1 0 1 0

* Available until March 2011

Device functioning only as analog position transmitter: 3766-x60 000xxx00 000 0


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1.2 Technical data

8 EB 8355-1 EN


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 60534-6 (NAMUR)

Opening angle 70, 75 or 90 depending on the cam disk

Referencevariable 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 Auxiliary power 1.4 to 6 bar (20 to 90 psi)

Air quality acc. toISO 8573-1,edition 2001-02

Max. particle size and density: Class 4,Oil content: Class 3, pressure dew point: Class 3 or at least 10 Kbelow 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 characteristicDeviation from terminal-based conformity: 1 %

Hysteresis 0.3 %

Sensitivity 0.1 %

Operating direction ReversibleProportional band Xp 0.5 to 2.5 % (proportional-action coefficient Kp: > 200 to 40)

Air consumption With 1.4 bar supply air With 6 bar supply air

230 In/h 230 In/h 1)

Air delivery Actuator filled with air 3.0 mn/h 8.5 mn/h

Actuator vented 4.5 mn/h 14.0 mn/h

Permissibleambienttemperature 2)

Standard 20 to 80 C: Optional limit switches/solenoid valve/positiontransmitter with plastic cable gland

40 to 80 C: Optional limit switches/solenoid valve with

metal cable gland

Low temperature version 50 to 80 C: Optional limit switches/solenoid valve withmetal cable gland

The technical data of the test certificate also apply for explosion-pro-tected versions.

Influences Temperature: 0.3 %/10 KSupply air: 1 % between 1.4 and 6 bar

Vibrations: None between 10 and 150 Hz and 4 g


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EB 8355-1 EN 9


Electromagnetic compatibility Complying with requirements specified in EN 61000-6-2,EN 61000-6-3 and NAMUR Recommendation NE 21

Explosion protection Refer to article code or list of approvals in Data Sheet T 8355 ENDegree of protection IP 54 (special version IP 65)

Weight Approx. 1 kg

Additional equipment

Limit switches

Two inductive proximity switches Type SJ 2-SN

Control circuit Ratings according to downstream transistor relay

Hysteresis at rated travel 1 %

Solenoid valveInput Binary direct current signal

Nominal signal 6 V DC 12 V DC 24 V DC

Signal 0 (no pick-up) 3) 1.2 V 2.4 V 4.7 V

Signal 1 (safe pick-up) 4) 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 5832 11714

Air consumption in steady state In addition to that of the positioner:

'Off' 60 ln/h 'On' 10 ln/h1)

Closing time forrated travel andsignal pressurerange (KVS 0.14)

Type 3277 Actuator 120 cm 240 cm 350 cm 700 cm

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 6) 1 s 1.5 s 5 s

Analog position transmitter 7)

Output signal Two-wire circuit 4 to 20 mA

Auxiliary power Min. terminal voltage:

12 V, max.: 45 V

The position transmitter must only

be connected to a certifiedinstrinsically safe circuit5)

1) With lowest setting of pressure regulator2) The limits of the EC-Type Examination Certificate additionally apply3) DC voltage at 25 C4) DC voltage at +80 C5) e.g. using a SAMSOMATIC Type 994-0103-KFD2-STC4-Ex1 Loop Isolator6) Actuator 120 cm in all signal pressure ranges: 0.5 s7) Available until March 2011


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EB 8355-1 EN 11

Attachment to control valve

Fig. 3 Mounting position and connections of Type 3277 (top) and Type 3277-5 120 cm2(bottom) Actuators

Actuator stem extends

Actuator stem retracts

Internal signal pressureconnection

Connection block

Tip of gasket (16)

Op. direction >>Attachment left

Signal pressure connectionover piping

With gasket(new) With switch plate (old)

Side view ofconnection block

Cover plate

Actuator stem extends

Actuator stem retracts

Marking

Gasket (16)

Switch plate (13)

Switchover plate Signal pressure inputfor attachment

Symbol

Marking

Signal pressure

input for attach-ment left

Sealwith filter

Actuator stem extends>> Operating direction

Attachment left Attachment right

Actuator stem retracts Operating direction >>


Operatingdirection >>

Attachment right

Op. direction Attachment left

Op. direction Attachment right


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2. Screw the associated lever D1 or D2 (for700 cm actuator) to the pick-up lever of

the positioner.3. Fasten the distance plate (15) with the

seal pointing towards the actuator yoke.4. Attach the positioner such that the lever

D1 or D2 slides centrically over the pin(1.1) of the clamp (1.2). Screw thepositioner to the distance plate (15).

5. Mount the cover (16).6. Check whether the correct measuring

spring has been installed as listed in Ta-ble 4.Range spring 1 is installed as standard.If necessary, replace it with range spring2 included in the accessories and fix it atthe outer slot.

Actuators with 240, 350 and 700 cm di-aphragm area

7. Make sure that the tip of the gasket (16)projecting from the side of the connec-tion block (Fig. 3, middle) is positionedto match the actuator symbol that corre-sponds to the actuator's fail-safe action"Actuator stem extends" or "Actuatorstem retracts."If necessary, remove the three fixing

screws and the cover. Reposition thegasket (16) turned by 180.The old connection block version re-quires the switch plate (13) to be turnedsuch that the corresponding actuatorsymbol points to the marking.

8. Place the connection block with its sealson the positioner and the actuator yokeand screw tight using the fastening

screw.Actuators with "Actuator stem retracts"

require the ready-made signal pressureline to be installed.

Actuators with 120 cm diaphragm area

The signal pressure is transmitted to the dia-phragm chamber over the switchover plate(Figs. 3 and 4, bottom).

7. Remove the screw in the rear cover of

the positioner (Fig. 5) and seal the sidesignal pressure output with the plug con-tained in the accessories kit.

8. Mount the positioner such that the borein the distance plate (15) mates with theseal in the bore of the actuator yoke.

9. Align the switchover plate with the corre-sponding symbol and fasten it to the ac-tuator yoke.

NOTICEWhen a solenoid valve or a similar device isattached to the 120 cm actuator in additionto the positioner, do not remove the rear M3screw plug. In this case, the signal pressuremust be transmitted from the signal pressureoutput to the actuator over an additionalconnecting plate(Table 2). The switchover

plate (Figs. 3 and 4) is not used.

Filling the actuator with air

If the spring chamber of the actuator mustbe filled with the positioner's exhaust air,use piping (Table 3) to connect the springchamber (with version "Actuator stem ex-tends") to the connection block. To do so, re-

move the plug from the connection block.

12 EB 8355-1 EN



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14 EB 8355-1 EN


Table 1 Mounting kit

Required lever with associated clamp and distance plate Actuator size [cm] Order no.

D1 with vent plug for output (38)Connecting thread

G NPT

120 1400-67901400-6791

D1 (33 mm long with 17-mm-high clamp) 240 and 350 1400-6370

D2 (44 mm long with 13-mm-high clamp) 700 1400-6371

Table 2 Order no.

Swichover plate for actuators 120 cm Actuator 3277-5xxxxxx.00 (old) 1400-6819

Swichover plate new Actuator 3277-5xxxxxx.01 or higher (new) 1400-6822

Connecting plate for additional attachment of,e.g. a solenoid valve

Actuator 3277-5xxxxxx.00 (old), G 18Actuator 3277-5xxxxxx.00 (old), 18 NPT

1400-68201400-6821

Connecting plate new Actuator 3277-5xxxxxx.01 or higher (new) 1400-6823

Note!Only the new switchover and connecting plates can be used for new actuators (model index01). Old and newplates cannot be interchanged.

Connection block required for actuators with 240, 350 and 700 cm2

diaphragm area (including seals and fastening screw)G 1400-8819

NPT 1400-8812

Table 3 Material Actuator size [cm] Order no.

Piping requiredincluding screw fitting

For actuator:Actuator stem retractsor

when the top diaphragm case is filled with ex-haust air from the positioner

Steel240

1400-6444

Stainless steel 1400-6445

Steel 350 1400-6446Stainless steel 1400-6447

Steel700

1400-6448

Stainless steel 1400-6449

Table 4 Range spring required Travel [mm] Actuator size [cm] 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

2 15 700 1400-6443

1 30 700 1400-6442

Accessories Order no.

Pressure gauge build-on block (only for 120 cm2) G 1400-7458

NPT 1400-7459

Pressure gauge kit for supply pressure and signal pressure Stainl. steel/Brass 1400-6950

Stainl. steel/St. steel 1400-6951

Filter check valve, replaces the vent plug and increases the degree of protection to IP 65 1790-7408

Assortment of spare parts including seals and diaphragms 1400-9895


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2.2 Attachment according toIEC 60534-6

Note:Required mounting parts are listed inTable 5. The rated travel of the valve deter-mines which lever and range spring (Table 6)are required.

An adapter housing (Fig. 7) is required forNAMUR attachment. The valve travel is

transmitted over the lever (18) and shaft(25) to the bracket (28) of the adapter hous-ing and then passed on to the pin (27a) lo-cated on the positioner lever.Fix the spring included in the accessories atthe back of the positioner housing as illus-trated in Fig. 5 to ensure that the pin (27a)is properly located in the bracket (28).

The positioner can be attached either to theleft or the right of the control valve (Figs. 6and 7). Turn the positioner at the adapterhousing by 180 to set or change the oper-ating direction of the positioner/control

valve unit.

EB 8355-1 EN 15


Fig. 5 Installing the spring on the back of the

housing

Spring Plug screw

20

20


Mounting position on the plate looking onto the travel pick-up (20), actuator facing upward (see also Fig. 7)Actuator with fail-safe action Actuator stem extends (FA)

Direct op. direction >> Reverse op. direction Direct op. direction >> Reverse op. direction

Actuator with fail-safe action Actuator stem retracts (FE)Direct op. direction >> Reverse op. direction Direct op. direction >> Reverse op. direction

Fig. 6 Attachment to the left or right of the valve when NAMUR attachment is used

Input

Input Output and supplyOutput and supply

InputOutput and supply


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2.2.1 Mounting sequence

Choose the required mounting parts andrange spring from Table 4 or 5 and installthem as illustrated in Fig. 7.

Control valve with cast yoke

1. Screw the plate (20) to the stem connec-tor connecting the actuator and plugstems using countersunk screws.For 2100 and 2800 cm actuators, use

an additional mounting bracket (32).2. Remove the rubber plug from inside the

adapter housing. Fasten the housing tothe left or right side of the NAMUR rib(as shown in Fig. 6) using a hexagonscrew.

Control valve with rod-type yoke

1. Screw the plate (20) to the followerclamp of the plug stem.

2. Screw the studs (29) into the adapterhousing.

3. Place the housing with the mountingplate (30) on either the right or left side(Fig. 6) of the plug stem and fasten it

with the nuts (31). Make sure that the le-ver (18) to be mounted subsequently is

in horizontal position when the valve isat mid-travel.

4. Screw the pin (19) into the center row ofholes in the plate (20) and lock it in aposition approximately above the correctlever marking (1 to 2) as in Table 6.

5. Attach the clip (21) to the lever (18). Ifthe actuator is attached with its air con-nection pointing to the front (Fig. 6), the

clip must be attached to the lever (18)with the open side pointing downward.

6. Plug the lever (18) together with theclamping plate (22) on the shaft (25).The clip must clasp the pin (19).

2.2.2 Presetting the travel

1. Move the valve to 50 % travel.2. Adjust the shaft (25) in the adapter

housing such that the black pointer (24)

matches the cast mark on the adapterhousing.

3. Fasten the clamp (22) tightly in this posi-tion using the screw (23).

4. Screw in the pin (27a) at the positionerlever on the side of the insert nut and se-cure it with a hex nut (27b) on the oppo-site side. Observe the mounting position

AorB according to Table 6 and Fig. 7.

5. Place the positioner on the adapterhousing, observing the operating direc-tion. Make sure that the pin (27a) restsagainst the bracket (28) and screw ittight.

CAUTION!The pin must not slip out of the bracket onceit has been installed.

6. Hang the required range spring (Table6) between the diaphragm lever (3) andspan adjuster screw (6.1) using the outerslot.

7. Adjust positioner as described in section4.1.

16 EB 8355-1 EN



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EB 8355-1 EN 17


21,51

24 25 22

32

31

20 19

19 21 2023 18

2930

2826

A B

27b

27a

Fig. 7 Attachment according to IEC 60534-6 (NAMUR)

Mounting position

18 Lever N1, N2

19 Pin

20 Plate

21 Clip

22 Clamping plate

23 Screw

24 Pointer

25 Shaft

26 Lever of the positioner27a Pin

27b Lock nut

28 Bracket

29 Studs

30 Plate

31 Nuts

32 Mounting bracket

Attachment toNAMUR rib

Attachment torod-type yoke


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18 EB 8355-1 EN


Table 5 Control valve Travel [mm] With lever Order no.

NAMUR mounting kit

Refer to Fig. 7concerning parts

Valve with cast yoke 7.5 to 60 N1 (125 mm) 1400-6787

22.5 to 120 N2 (212 mm) 1400-6789

Valve withrod-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

(one each of both mounting kits is required per actuator)

1400-6771

and1400-6787

Additional range spring acc. to Table 6 Range spring 1 (9.5 coils, installed as standard)Range spring 2 (4.5 coils)

1400-64421400-6443


Pressure gauge build-on block G 1400-7458

NPT 1400-7459

Pressure gauge kit Stainless steel/Brass 1400-6950

Stainless steel/Stainless steel 1400-6951



Table 6

Travel [mm]* 7.5 15 15 30 30 60 30 60 60 120

Pin on marking* 1 2 1 2 1 2 1 2 1 2

Distance pin/fulcrum of the lever 42 to 84 mm 84 to 168 mm

With lever N1 (125 mm long) N2 (212 mm long)

Pin (27a) on position A A B A B

Range spring required (see Table 5) 2 1 1 1 1

* Intermediate values must be interpolated


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2.3 Attachment to rotaryactuators

The positioner can also be attached to rotaryactuators according to VDI/VDE 3845 (Sep-tember 2010) when the mounting kits andaccessories listed in Table 7 are used.

The rotary motion of these actuators is con-verted into a linear motion required by the

pneumatic control unit of the positioner us-ing the cam disk of the actuator shaft and acam follower roll on the positioner lever.

EB 8355-1 EN 19


Table 7 Complete mounting parts, including range spring 2, but excluding the cam disk Order no.

Attachment acc. to VDI/VDE 3845 (September 2010), level 1 1400-8815

SAMSON Type 3278 Actuator 160 cm 1400-7103

VETEC Type S 320 cm 1400-7104VETEC Type R R 100 to R 250 1400-7117

Attachment to Masoneilan actuators Camflex I, DN 25 to 100 1400-7118

Camflex I, DN 125 to 250 1400-7119

Camflex II 1400-7120

Range spring required Order no.

Standard operation of reference variable, range spring 2 (4.5 coils) 1400-6443

Split-range operation, range spring 1 (9.5 coils, installed as standard) 1400-6442

Cam disk with accessories Order no.

Linear basic characteristic 3) (0050-0072), op. angle 0 to 70, also for Type 3310 1400-6664

Equal percentage basic characteristic 3 (0050-0073), opening angle 0 to 90 1400-6665

Linear1) (0050-0080), op. angle 0 to 70, for control butterfly valves 1400-6774

Equal percentage 2) (0050-0081), op. angle 0 to 70, for control butterfly valves 1400-6775

Linear1) (0050-0074, VETEC), opening angle 0 to 75 1400-6666

Equal percentage 2) (0050-0075, VETEC), opening angle 0 to 75 1400-6667

Linear1) (0059-0007, Camflex) set to between 0 and 55 1400-6637

Equal percentage 2) (0059-0008, Camflex) set to between 0 and 55 1400-6638

1) Linearizes the flow characteristic 2) Creates an equal percentage flow characteristic 3) Based on opening angle


Pressure gauge build-on block G 1400-7458

NPT 1400-7459

Pressure gauge kit St. steel/Brass 1400-6950

St. steel/St. steel 1400-6951




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NOTICEUse the correct range spring (1 or2)!

Range spring1 is installed as standard.

Double-acting springless rotary actuators re-quire the use of a reversing amplifier on theconnection side of the positioner housing(see section 2.3.4).

When using a reversing amplifier, the pres-sure regulator (9, Fig. 2) must be turned

clockwise as far as it will go (also see sec-tion 3.1.2).

When attaching the positioner to theSAMSON Type 3278 Rotary Actuator(Fig. 8, left), the actuator's inside and theunused reverse side of the diaphragm arefilled with the positioner's exhaust air. Addi-tional piping is not required. When attach-ing the positioner to actuators from other

manufacturers (Fig. 8, right), the reverseside of the diaphragm can be filled with airover a pipe connection installed between theactuator and the intermediate piece.

2.3.1 Mounting the cam followerlever

1. Place the lever with the cam follower roll

(35) on the side of the feedback lever(37) opposite the insert nuts. Fasten withthe supplied screws (38) and washers.

NOTICETo ensure a close physical contact betweenthe cam follower roll and the cam disk, fixthe spring contained in the accessories kit

(order no. 1400-6660) at the back of thepositioner housing (see Fig. 5).

2.3.2 Mounting the intermediatepiece

SAMSON Type 3278 Actuator

1. Screw the adapter (36) to the free end ofthe actuator shaft.

2. Attach the intermediate piece (34) to theactuator housing using two screws.Align the intermediate piece to ensurethat the air connections of the positionerpoint towards the diaphragm housing.

3. Align the cam disk (40) and scale (39)as described in section 2.3.3 and fasten

with screws.

Actuators according to VDI/VDE 3845(September 2010)

(fixing level 1)

1. Place the complete intermediate piece(34, 44, 45 and 42) onto the mountingbracket that came with the actuator andfasten with screws.

2. Align the cam disk (40) and scale (39)as described in section 2.3.3 and fastenwith screws.

20 EB 8355-1 EN



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EB 8355-1 EN 21


33

3835

39

39

40

34

36

40

34

44

45

42

43

37

Fig. 8 Attachment to rotary actuators

Attachment to SAMSONType 3278

Attachment acc. to

VDI/VDE 3845(September 2010)

Vent plug orfilter check valve

33 Positioner34 Intermediate piece35 Lever with cam follower roll

36 Adapter 37 Feedback lever38 Screws39 Scale40 Cam disk41 Actuator shaft42 Plate43 Mounting bracket44 Coupling

45 Seal


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2.3.3 Default setting of the camdisk

The valve model used determines the defaultsetting of the cam disk.

NOTICECam disks tailored to the special character-istic of a valve cause the valve to open in anon-linear or non-equal percentage way.The visible difference between the set point

(4 to 20 mA) and the actual value (openingangle) does not constitute a system deviationof the positioner.

Figs. 9 and 10 show linear cam disks.

Fig. 9 illustrates a control valve assemblywith a spring-loaded rotary actuator thatopens counterclockwise. The arrangement ofthe springs in the actuator determines thefail-safe position of the valve.

Fig. 10 shows how to adjust the cam diskwhen a double-acting springless rotary actu-ator is used. The direction of rotation, eithercounterclockwise or clockwise, depends onthe actuator and valve model used. The camdisk must be set when the valve is closed.

Use the turnboard (7) to adjust the operating

direction of the positioner, i.e. whether thevalve opens or closes when the referencevariable increases (direct >> or reverse ).

Each cam disk carries two cam sectionswhose starting points are indicated by smallbores. Depending on the operating directionof the rotary actuator signal pressureopens or closes the valve the starting pointof the cam, either marked N (standard char-

acteristic) orI (reverse characteristic), must

point towards the cam follower roll. Whenthe starting point is located on the back of

the cam disk, turn over the cam disk.

NOTICEThe starting point (bore) of the selected camsection must be aligned with the fulcrum ofthe cam disk, the 0 position of the scale,and the arrow symbol on the inspectionglass.

When aligning the cam disk, the double-sided scale disk must be clipped on the camdisk such that the value on the scale corre-sponds to the control valve's direction of ro-tation.

NOTICEMake sure the 0 position of the scale al-ways corresponds to CLOSED position.

For actuators with fail-safe position "ValveOPEN" and for springless actuators, it istherefore necessary to apply the maximumsupply pressure to the actuator before align-ing the cam disk.

22 EB 8355-1 EN



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EB 8355-1 EN 23


90

60

30 0

90

60

30 0

90

60

30 0

90

60

30 0

Cam follower rollStarting point I

Starting pointN

Position at max. signal pressure

Starting pointIStarting pointNHoles to securethe cam disk

Insert clip and presstongue outwards

Cam follower roll

Single-acting spring-loaded rotary actuator

Linear cam disk(equal percentage cam disk is represented by a broken and dotted line)

Valve opens counterclockwiseFor valves that open clockwise, the cam disk must be turned over so that the cam follower roll movesover the same disk segments as shown in the figures below, but with the cam disk turning clockwise.

Fail-safe position:Valve CLOSED without supply air

Direct operating direction >> Reversible operating direction

Referencevariable

Signalpressure

Valve Charact-eristic

Referencevariable

Signalpressure


increases increases opens N decreases increases opens I

Fail-safe position:Valve OPEN without supply air


Referencevariable

Signalpressure


Referencevariable

Signalpressure


decreases decreases opens I increases decreases opens N

Fig. 9 Setting the cam disk for single-acting rotary actuators


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24 EB 8355-1 EN


90

60

30 0

90

60

30 0

Cam follower rollStarting pointN

Starting pointI

Insert clip and press tongue out-wards

0

90

60

30

0

90

60

30

Starting pointICam follower rollStarting pointN

Double-acting springless rotary actuator with reversing amplifier

Linear cam disk(equal percentage cam disk is represented by a broken and dotted line)

View from the positioner onto the actuator shaftValve opens counterclockwise Starting position: valve CLOSED


Referencevariable

Signalpressure


Referencevariable

Signalpressure


increases A1 increases,A2 decreases

opens N decreases A1 increases,A2 decreases

opens I

View from the positioner onto the actuator shaft

Valve opens clockwise Starting position: valve CLOSEDDirect operating direction >> Reversible operating direction

Referencevariable

Signalpressure


Referencevariable

Signalpressure


increases A1 increases,A2 decreases

opens N decreases A1 increases,A2 decreases

opens I

Fig. 10 Setting the cam disk for double-acting actuators

Holes to securethe cam disk


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Securing the aligned cam disk

To additionally prevent the cam disk from

being turned, drill a hole into the adapter(36) or the coupling (44) and install a 2 mmdowel pin.

Four bore holes are located centricallyaround the center hole on the cam disk. Se-lect a suitable hole to install the pin.

EB 8355-1 EN 25



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2.3.4 Reversing amplifier fordouble-acting actuators

For the use with double-acting actuators, thepositioner must be fitted with a reversingamplifier.

Type 3710

Refer to the Mounting and Operating In-structions EB 8392 EN for the mounting ofthe SAMSON Type 3710 Reversing Ampli-

fier.

1079-1118 or 1079-1119

If a different reversing amplifier (item no.1079-1118 or 1079-1119) is used, followthe mounting instructions described below:

The output signal pressure of the positioneris supplied at the outputA1 of the reversingamplifier. An opposing pressure, whichequals the required supply pressure whenadded to the pressure atA1, is applied atoutputA2.The ruleA1 +A2 = Z applies.

On using the reversing amplifier, make surethat the adjuster of the pressure regulator (9in Fig. 2) is turned as far as it will go in theclockwise direction. Refer also to section3.1.2.

Mounting

Note:Remove the sealing plug (1.5) beforeinstalling the reversing amplifier. The rubberseal (1.4) must remain installed.

1. Thread the special nuts (1.3) from theaccessories of the reversing amplifier

into the threaded holes of the positioner.2. Insert the gasket (1.2) into the recess of

the reversing amplifier and push boththe special hollow screws (1.1) into theconnecting boreholesA1 and Z.

3. Place the reversing amplifier onto thepositioner and screw tight using both thespecial screws (1.1).

Signal pressure connections

A1: Connect output A1 to the signal pressureconnection on the actuator that opens the

valve when the pressure increases.

A2: Connect output A2 to the signal pressureconnection on the actuator that closes the

valve when the pressure increases.

Pressure gauge attachment

The mounting sequence shown in Fig. 11 re-mains unchanged. Screw a pressure gaugebracket onto the connectionsA1 and Z.

Pressure gauge G 1400-7106bracket: NPT 1400-7107

Pressure gauges for supply air Z and outputA1 as listed in Tables 4, 5 and 7.

26 EB 8355-1 EN



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EB 8355-1 EN 27


1.3 1.2 1.1 1

Output38

Supp

ly9

A1

1.5 1.6

Z

A2

1.4

A1 A2

Output 38 Supply 9

1.3 1.21.1

1.6

Z

A1

Fig. 11 Mounting a reversing amplifier

From the positioner

1 Reversing amplifier

1.1 Special screws

1.2 Gasket

1.3 Special nuts1.4 Rubber seal

1.5 Sealing plug

Control signals tothe actuator


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3 Connections

3.1 Pneumatic connectionsThe pneumatic connections are designed astapped holes with NPT or G thread.The conventional male connections for metaland copper pipes (or plastic hoses) can beused.

NOTICE

The supply air must be dry and free of anyoil and dust.Always observe the maintenance instructionsapplicable to the connected pressure reduc-ing stations. Blow out air lines thoroughlybefore connecting them.

When attaching the Type 3277 Actuator di-rectly, the signal pressure connection is

fixed. When using NAMUR attachment, thesignal pressure line is connected to either theupper or lower diaphragm chamber of theactuator depending on the actuator'sfail-safe action, i.e. "Actuator stem retracts"or "Actuator stem extends".

Exhaust air

Positioners with model index 3766-x...x.03

or higher are equipped with a hinged coverwithout a vent connection. The required ex-haust air connection for these models arenow included in the mounting accessories.

For direct positioner attachment, the ventplug is located on the plastic cover of the ac-tuator; for NAMUR attachment, it is locatedon the adapter housing, and for attachmentto rotary actuators the vent plug can be

found on the intermediate piece or the re-versing amplifier.

Note:When using older models with index3766-x...x. 02or lower, mounting parts willhave to be replaced as well.

3.1.1 Pressure gauge

To monitor the positioner, we recommend toinstall pressure gauges for the supply air

and the signal pressure.

The required parts are listed as accessoriesin Tables 4, 5 or 7.

3.1.2 Supply pressure

The required supply pressure is determinedby the bench range and the operating direc-tion (fail-safe action) of the actuator.

The bench range is written on the nameplateas spring range or signal pressure rangedepending on the type of actuator. FA(actu-ator stem extends) orFE (actuator stem re-tracts) or a symbol indicates the operatingdirection.

Actuator stem extends (FA):Fail-safe position "Valve CLOSED"

(for globe and angle valves)

Required supply pressure =Upper bench range value + 0.2 bar,minimum 1.4 bar.

28 EB 8355-1 EN

Connections


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Actuator stem retracts (FE):Fail-safe position "Valve OPEN"

(for globe and angle valves)The required supply pressure for atight-closing valve is roughly estimated fromthe maximum signal pressure pstmax:

pstmax= F +d p

A

4[bar]

d = Seat diameter [cm]p = Differential pressure at the valve [bar]

A = Actuator diaphragm area [cm]F = Upper range value of the actuator

In the absence of such specifications, pro-ceed as follows:

Required supply pressure =Upper bench range value + 1 bar

Pressure regulatorAfter tilting the cover plate back, the pres-sure regulator (9) can be continuously ad-justed. When the adjuster is turned counter-clockwise as far as it will go, signal pres-sures for spring ranges up to 2.5 bar arecontrolled. When the adjuster is turnedclockwise all the way, signal pressures forspring ranges up to 6.0 bar are controlled.

If the signal pressure must not exceed a cer-tain value, this limit can be adjusted using apressure gauge (accessories).

3.2 Electrical connections

DANGER!Risk of electric shock and/or theformation of an explosive atmo-sphere!

For electrical installation, observe the rel-evant electrotechnical regulations andthe accident prevention regulations thatapply in the country of use.

The following regulations apply to

mounting and installation in hazardousareas: EN 60079-14: 2008Explosiveatmospheres Part 14: Electrical instal-lations design, selection and erection(orVDE 0165 Part 1).

NOTICE Adhere to the terminal assignment! Switching the assignment of the electrical

terminals may cause the explosion pro-tection to become ineffective! Do not loosen enameled screws in or on

the housing. The maximum permissible values speci-

fied in the national EC type examinationcertificates apply when interconnectingintrinsically safe electrical equipment (Uior Uo; Iior Io; Pior Po; Cior Co, and LiorLo).

Depending on the version use, the positioneris equipped with inductive limit switchesand/or a solenoid valve.

Versions with position transmitter do notpermit the connection of this additionalequipment.

EB 8355-1 EN 29

Connections


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The position transmitter is operated on atwo-wire circuit. The usual supply voltage is

24 V DC. Considering the resistance of thesupply leads, the voltage at the positiontransmitter terminals can be between 12 and45 V DC.

For terminal assignment, refer to Fig. 12 orthe label on the terminal strip.

Selecting cables and wires:ObserveClause 12 of EN 60079-14: 2008

(VDE 0165 Part 1) when installing intrinsi-cally safe circuits. The Subclause 12.2.2.7applies when running multi-core cables con-taining more than one intrinsically safe cir-cuit.In particular, the radial thickness of the con-ductor insulation for common insulation ma-terials, such as polyethylene, must have aminimum radial thickness of 0.2 mm.The diameter of an individual wire in afine-stranded conductor must not be smallerthan 0.1 mm. Protect the conductor endsagainst splicing, e.g. by using wire-end fer-rules.When two separate cables are used for con-

nection, an additional cable gland can beinstalled.

Seal cable entries left unused with plugs.Devices used at ambient temperatures be-low 20 Cmust be fitted with metal cableglands.

Equipment for use in zone 2/zone 22

In equipment operated with type of protec-tion Ex nA II (non-sparking equipment) ac-

cording to EN 60079-15: 2003, circuitsmay be connected, interrupted or switchedwhile energized only during installation,maintenance or repair.

Equipment connected to energy-limited cir-cuits with type of protection Ex nL (en-ergy-limited equipment) according toEN 60079-15: 2003 may be switched un-der normal operating conditions.

The maximum permissible values specifiedin the Statement of Conformity or its ad-denda apply when interconnecting theequipment with energy-limited circuits intype of protection Ex nL IIC.

30 EB 8355-1 EN

Connections

+41 42 +51 52 +81 82 +31 32

GEi

+

+

(B)A (A)B

A

+11 12 +11 12

Ei/

Ei/ AA

Fig. 12 Electrical connections

Switching amplifieracc. to EN 60947-5-6

Voltage supply for transmitter,only for position transmitter

On the rear Version with position transmitter

6 to 24 V DCsolenoid valve


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Accessories

Cable gland M20 x 1.5Black plastic Order no. 1400-6985Blue plastic Order no. 1400-6986Nickel-plated brass Order no. 1890-4875

Adapter M20 x 1.5 to NPT:Aluminum, powder-coated 0310-2149

3.2.1 Switching amplifier

For operation of the limit switches, switching

amplifiers must be connected in the outputcircuit. To ensure the operating reliability ofthe positioner, the amplifiers should comply

with the limit values of the output circuitsconforming to NAMUR.If the positioner is to be installed in hazar-dous areas, the relevant regulations must beobserved.

EB 8355-1 EN 31

Connections


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4 Operation

4.1 Setting the positioner at thevalve

Starting point and reference variable

When adjusting the positioner directly at thecontrol valve, the travel (opening angle)must be adapted to the reference variable.

With a reference variable, for example, 4 to

20 mA, the valve must pass through its en-tire travel range from 0 to 100 % (Fig. 13,left).

For rotary positioners, an opening angle, forexample, 0 to 70 must be assigned to thereference variable.

The starting point refers to CLOSED positionof the valve.

Depending on the actuator version (Actuatorstem extends or Actuator stem retracts) andthe operating direction of the positioner (>>or ), this starting point can be representedby either the lower or upper range value(0.2 or 1 bar) of the reference variable.

The reference variable range and thus theupper range value determine the travel ofthe valve.

In split-range operation (Fig. 13, bottom),the control valves operate on smaller refer-ence variables. The controller output signalis used to control two control valves, divid-ing it such that the valves pass through theirentire travel range at half the input signalrange each (e.g. first valve set to 0.2 to0.6 bar, second valve set to 0.6 to 1 bar).To avoid overlapping, allow for a deadband of0.05 bar as shown in Fig. 13.

The starting point(zero) is adjusted at thezero adjuster screw (6.2); the span, i.e. the

upper range value, is adjusted at the spanadjuster screw (6.1).

When adjusting, connect a suitable pressureadjuster to the signal input and apply supplypressure to the supply air input.

32 EB 8355-1 EN

Operation

100%

0%

0.2 1 bar 0.6

0.2 1 bar

100%

0%

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3766 positioner