Professional Documents
Culture Documents
Mounting and
Operating Instructions
EB 8394 EN
Firmware version 1.12
Edition June 2014
NOTICE
Property damage message or malfunction
Note:
Additional information
Tip:
Recommended action
EB 8394 EN
Contents
Article code....................................................................................................7
3.1
Technical data..............................................................................................10
4.1
Mounting sequence.......................................................................................12
4.2
4.3
4.3.1
4.3.2
Direct attachment..........................................................................................14
Type 3277-5 and Type2780-2 Actuators.......................................................14
Type3277 Actuator......................................................................................18
4.4
4.5
4.6
4.6.1
4.6.1
4.7
Connections.................................................................................................33
5.1
5.1.1
Pneumatic connections..................................................................................33
Supply pressure............................................................................................33
5.2
5.2.1
5.2.2
5.2.3
5.2.4
Electrical connections....................................................................................34
Electric power supply....................................................................................35
Selecting cables and wires.............................................................................35
Equipment for use in zone 2..........................................................................35
Cable entry..................................................................................................35
Operation....................................................................................................36
6.1
6.1.1
6.1.2
6.1.3
Operating elements.......................................................................................36
Capacitive keys.............................................................................................36
Volume restriction Q......................................................................................36
Display........................................................................................................37
Start-up.......................................................................................................38
Settings........................................................................................................39
8.1
8.2
EB 8394 EN
Contents
8.3
8.4
8.5
8.6
8.7
8.8
8.8.1
Initialization.................................................................................................43
Canceling initialization..................................................................................44
8.9
8.9.1
Zero calibration............................................................................................44
Canceling zero calibration.............................................................................45
8.10
Manual mode...............................................................................................45
8.11
Reset............................................................................................................46
8.12
8.12.1
Fault............................................................................................................47
Resetting error codes.....................................................................................48
Code list......................................................................................................49
9.1
Parameter codes...........................................................................................49
9.2
Error codes...................................................................................................52
10
Maintenance................................................................................................54
11
12
Dimensions in mm........................................................................................55
12.1
EB 8394 EN
Contents
Firmware revisions
1.02 (old)
1.03 (new)
Internal revisions
1.03 (old)
1.10 (new)
Setting of the travel in steps of 0.5mm (P4 parameter code)
Monitoring of the end stops only during initialization and in manual mode
To suppress common-mode interference on the signal lines, the D
component of the positioner is switched off when the actuator is
at a standstill.
1.10 (old)
1.11 (new)
Internal revisions
1.11 (old)
EB 8394 EN
Note:
Devices with a CE marking fulfill the requirements of the Directive 2004/108/EC. The
Declaration of Conformity is available on request.
EB 8394 EN
Article code
2 Article code
Positioner
Type3725- x
Without
1)
Certificate
Type of protection
Number
STCC
No. 2860
Number
Date
2011-08-25
Number
RU C-DE.GB08.B.00697
Date
2014-12-15
EC type
examination
certificate
3725-113
0 Ex ia IIC T4 X
II 2 G Ex ia IIC T4
1Ex ia IIC T4 Gb X
EB 8394 EN
Number
2703735 X
Date
2014-06-03
Ex ia IIC T4;
Class I, Zone 0, AEx ia IIC T4;
Class I, Div. 1, Groups A, B, C, and D
EB 8394 EN
11
S
mm
%
mm
w
3
9
10
8
7
1
2
3
4
5
6
Valve
Sensor
A/D converter
Microcontroller
D/A converter
i/p converter
7
8
9
10
11
1
x
EB 8394 EN
3.75 to 30mm
6/12/15mm
15/30mm
3.75 to 50mm
24 to 100
Reference variable w
(reverse polarity
protection)
33V
Minimum current
3.8mA
Load impedance
Max. 6.3V
Supply air
Air quality acc. to
ISO8573-1
0 bar up to the capacity of the supply pressure Can be limited to approx. 2.3bar by
software
Characteristic
Hysteresis
0.3%
Sensitivity
0.1%
Transit time
Direction of action
w/x reversible
Air consumption
100 ln/h with a supply pressure up to 6bar and a signal pressure of 0.6bar
1)
At p = 1.4bar: 3.0mn/h,
At p = 1.4bar: 4.5mn/h,
KVmax(20 C) = 0.09
KVmax(20 C) = 0.15
20 to +80 C
25 to +80 C with metal cable gland
The limits in the test certificates additionally apply for explosion-protected versions
For faster actuators, a volume restriction must be used. Otherwise, the initialization cannot be performed
successfully.
10
EB 8394 EN
Safety
Influences
Temperature:
Effect of vibration:
Supply air:
Electromagnetic
compatibility
Explosion protection 1)
Degree of protection
IP66
Compliance
0.15 %/10 K
0.25 % up to 2000 Hz and 4 g according to IEC770
None
Materials
Housing
Polyphthalamide (PPA)
Cover
Polycarbonate (PC)
External parts
Cable gland
Venting
Weight
Approx. 0.5kg
1)
EB 8394 EN
11
Vent opening
12
Bottom
stop
EB 8394 EN
Travel tables
Note:
The M lever is included in the scope of delivery.
Rated travel
[cm]
[mm]
Travel
Max.
Required
lever
Assigned
pin position
120
7.5
5.0mm
to
16.0mm
25
120/240/350
15
7.0mm
to
22.0mm
35
355/700
30
10.0mm
to
32.0mm
50
Required
lever
Assigned
pin position
Rated travel
[cm]
[mm]
Min.
Travel
Max.
120
6/12
5.0mm
to
16.0mm
25
120
15
7.0mm
to
22.0mm
35
Required
lever
Assigned
pin position
Size [cm]
Rated travel
[mm]
Min.
Max.
120
7.5
3.5mm
11.0mm
17
120
7.5
5.0mm
16.0mm
25
7.0mm
22.0mm
35
10.0mm
32.0mm
50
120/240/350
15
700
7.5
700/355
15/30
Opening angle
Max.
24
to
100
EB 8394 EN
Required
lever
Assigned
pin position
90
13
14
7. Mount the positioner on the actuator using the two fixing screws.
8. Mount cover (11) on the other side.
Make sure that the vent plug is located at
the bottom when the control valve is installed to allow any condensed water
that collects to drain off (Fig.4).
EB 8394 EN
Symbols
1 Lever
1.1 Nut
1.2 Disk spring
2 Follower pin
3 Follower clamp
4 Screw plug
5 Stopper
6 Connecting plate
6.1 Seals
7 Pressure gauge
bracket
8 Pressure gauge
mounting kit
9 Switchover plate
(actuator)
11 Cover
15 Formed seal
16 Vent plug
Actuator stem
extends
Left attachment
Right attachment
Actuator stem
retracts
Signal pressure
input for left
attachment Marking
Signal pressure
input for right
attachment
15
1
2
3
1.1
1.2
16
4
6.1
6
5
Supply 9
Output 38
11
7
8
Fig.4: Direct attachment Signal pressure connection for Type3277-5 Actuator (120cm)
EB 8394 EN
15
Cover
Vent plug
Note:
The switchover plate and connecting
plate are accessories for the actuator
(120 cm). They are listed in section4.7 on page29.
16
EB 8394 EN
Fig.6: Signal pressure port and park position for screw plug
EB 8394 EN
17
18
EB 8394 EN
10 15 1 2 3
11
2
1
1.1
1.2
Ansicht A
16
SUPPLY
12
12.1 12.2
16
1
1.1
1.2
2
3
11
12
12.1
12.2
15
16
M lever
Nut
Disk spring
Follower pin
Follower clamp
Cover
Connection block
Screw
Stopper or connection for
external piping
Formed seal
Gasket
1.
1.
Ansicht A
16
16
Fig.7: Direct attachment Signal pressure connection for Type3277 Actuator with 240 to 700cm
EB 8394 EN
19
20
EB 8394 EN
16
15
11
10
9
9.1
14
3
1
1.1
1.2
2
3
6
6.1
7
Lever
Nut
Disk spring
Follower pin
Follower plate
Connecting plate
Seals
Pressure gauge
bracket
8
Pressure gauge
9
Stem connector
9.1 Bracket
10
NAMUR bracket
11
Screw
14
Pin
14.1 Screws
15
Travel indicator
scale
16
U-bolt
14.1
2
1.1
1.2
6.1
EB 8394 EN
21
22
EB 8394 EN
EB 8394 EN
23
24
EB 8394 EN
6
6.1
7
8
1
1.1
1.2
1
1.1
1.2
2
3
4
4.1
4.2
5
Lever
Nut
Disk spring
Follower pin
Follower clamp
Coupling wheel
Screw
Disk spring
Actuator shaft
6
6.1
7
8
Connecting plate
Seals
Pressure gauge bracket
Pressure gauge
mounting kit
10 Mounting bracket
10.1 Screws
13 Adapter
6
6.1
7
8
2
4.1
4.2
4
1
1.1
1.2
10.1
4.1
4.2
4
3
80
50
10
10.1
10.1
80
10
50
13
30
60
5
5
30
Attachment according to
VDI/VDE3845, level 1
EB 8394 EN
25
seals (6.1) are seated properly. Double-acting springless rotary actuators require the use of a reversing amplifier on
the connection side of the positioner
housing (refer to section4.6.1).
7. For actuators with a volume of less than
300 cm, fit the restriction (order no.
1400-6964) into the signal pressure output of the positioner (or the output of the
pressure gauge bracket or connecting
plate).
8. Fasten the positioner onto the adapter
plate (12).
9. Place the positioner together with the
adapter plate on the housing (10) and
screw it tight. Taking the actuator's direction of rotation into account, adjust lever
(1) so that it engages in the correct slot
with its follower pin (Fig.12).
Counterclockwise
1
10
Clockwise
EB 8394 EN
Lever
5.1
Nut
6
Disk spring
6.1
Follower pin
7
Adapter
8
Coupling wheel
Screw
10
Disk spring
10.1
Adhesive label
Actuator shaft or adapter 11
12
6
6.1
7
8
Adapter
Connecting plate (only
for G)
Seals
Pressure gauge bracket
Pressure gauge mounting
kit
Adapter housing
Screws
Distance piece
Adapter plate
1
1.1
1.2
2
12
4.1
4.2
4
4.3
4.1
4.2
4
4.3
5.1
10.1
5
10.1
10
11
10
5
EB 8394 EN
27
Note:
The screws supplied with the connecting plate have a TORX PLUS profile
(size 25 IP) and must be tightened
using a suitable tool.
28
EB 8394 EN
Order no.
Mounting parts
For actuators up to 120cm
1402-0239
Accessories for actuator
1400-6822
1400-6823
1/8
1402-0235
NPT
1402-0236
1402-0237
NPT
1402-0238
Stainless steel/brass
1400-6950
Stainless steel/
stainless steel
1400-6951
Order no.
1402-0240
Accessories
EB 8394 EN
G
NPT
1402-0241
1402-0242
Stainless steel/brass
1400-6950
Stainless steel/
stainless steel
1400-6951
29
Actuator size
Material
Steel
175cm
Stainless
steel
Steel
240cm
Stainless
steel
Steel
350cm
Piping with screw fittings
for "actuator stem retracts" fail-safe action
with air purging of the top diaphragm chamber
Stainless
steel
Steel
355cm
Stainless
steel
Steel
700cm
Stainless
steel
Steel
750cm
30
Stainless
steel
Connection
Order no.
G / G3/8
1402-0930
NPT/ 3/8NPT
1402-0958
G / G3/8
1402-0950
NPT/
NPT
3/8
G / G3/8
NPT/
1402-0927
NPT
3/8
G / G3/8
NPT/
1402-0964
1402-0959
1402-0951
NPT
3/8
1402-0965
G / G3/8
1402-0928
NPT/ 3/8NPT
1402-0960
G / G3/8
1402-0952
NPT/ 3/8NPT
1402-0966
G / G3/8
1402-0956
NPT/ 3/8NPT
1402-0961
G / G3/8
1402-0953
NPT/ 3/8NPT
1402-0967
G / G3/8
1402-0929
NPT/ 3/8NPT
1402-0962
G / G3/8
1402-0954
NPT/
NPT
3/8
G / G3/8
NPT/
1402-0957
NPT
3/8
G / G3/8
NPT/
1402-0963
1402-0955
NPT
3/8
1402-0968
1402-0969
EB 8394 EN
Order no.
1402-0330
1402-0235
NPT
1402-0236
1402-0237
NPT
1402-0238
Stainless steel/brass
1400-6950
1400-6951
Order no.
1402-0243
1402-0244
1402-0294
1402-0295
Heavy-duty version
VDI/VDE3845, AA1 to AA4 size, level 1 1)
1402-1097
1402-1099
1)
1402-1098
Accessories
Connecting plate
Pressure gauge bracket
Pressure gauge mounting kit up to max. 6bar
(output/supply)
Connecting plate for Type3710 Reversing Amplifier
1)
1402-0235
NPT
1402-0236
1402-0237
NPT
1402-0238
Stainless steel/brass
1400-6950
1400-6951
1402-0512
EB 8394 EN
31
Order no.
8808-1011
Blue plastic
8808-1012
Nickel-plated brass
1890-4875
8808-0160
Adapter M20x1.5 to NPT
Powder-coated aluminum
0310-2149
Stainless steel
1400-7114
Brief instructions inside cover
German
0190-6173
English
0190-6174
32
EB 8394 EN
Connections
5 Connections
5.1 Pneumatic connections
The pneumatic connections are optionally
designed as a bore with NPT or G
thread. The customary fittings for metal and
copper pipes or plastic hoses can be used.
Points that apply concerning the pneumatic
connections:
Only screw the screw fittings into the
connecting plate, pressure gauge mounting block or connection block from the
accessories. Do not screw them directly
into the positioner housing.
Keep the length of the line as short as
possible to avoid delays in control signal
transmission.
NOTICE
Dirty supply air will cause the positioner to malfunction.
Only use supply air that is dry and
free of oil and dust.
Blow through all air pipes and hoses
thoroughly before connecting them.
EB 8394 EN
33
Connections
d p
4A
[bar]
p =
34
Note:
The signal pressure at the output (38)
of the positioner can be restricted to
approx. 2.3bar by setting P9 parameter code to ON.
EB 8394 EN
Connections
The minimum radial thickness of the conductor insulation must be suitable for the
conductor diameter and type of insulation and must not be smaller than
0.2mm.
The diameter of an individual wire in a
fine-stranded conductor must not be
smaller than 0.1mm.
Protect the conductor ends against splicing, e.g. by using wire-end ferrules.
Cable glands available:
See Table7 on page32
+11
+11
-12
-12
+11/12: mA control
signal
35
Operation
6 Operation
6.1 Operating elements
Three capacitive keys are used to operate the positioner and allow the user to navigate within the menu on the display (Fig.16). Additionally, the volume restriction allows the air output
capacity to be adapted to the size of the actuator.
or
to change to Code P0 or
Note:
The
icon on the display indicates that the changed parameter settings have not
yet been saved in the non-volatile memory.
The selected parameter code remains active until you change the setting or exit the
parameter code.
After changing settings in P2, P4 and P8 parameter codes, the positioner must be
re-initialized.
36
EB 8394 EN
Operation
6.1.3 Display
Icons which are assigned to certain codes and functions are indicated on the display
(Fig.16). The bar elements indicate the set point deviation that depends on the sign (+/)
and the value. One bar element appears per 1% set point deviation.
If the positioner has not yet been initialized, the lever position in degrees in relation to the
mid-axis is indicated. One bar element corresponds to approximately a 7 angle of rotation.
If the fault indication icon is displayed, press
E0 to E15 error codes (see section9.2).
or
Confirm
Down
Up
Operation locked
S
mm
Unit
mm
Parameter/error code
Manual mode
Reading
ESC
Err
LOW
MAN
MAX
RST
INIT
ON/OFF
ZERO
Meaning
Cancel
Error
w too low
Manual mode
Maximum range
Reset
Initialization
Activated/deactivated
Zero calibration
Closed-loop control
EB 8394 EN
37
Start-up
7 Start-up
Before start-up, mount the positioner following the sequence described in section4.1. Apply
the electric reference variable to start up the positioner. Refer to section5.2.
Note:
LOW on the display indicates that the reference variable is lower than 3.8mA.
The positioner is ready for operation with its default settings for most applications.
38
EB 8394 EN
Settings
8 Settings
8.1 Adapting the display
The display reading direction can be rotated by 180. If the displayed data appear upside
down, proceed as follows:
1. Touch
2. Press
3. Touch
4. Press
or
or
to enable configuration.
Note:
If no settings are entered within three minutes, the enabled configuration function becomes invalid.
EB 8394 EN
39
Start-up
Volume restriction
40
EB 8394 EN
Start-up
or
to confirm setting.
Note:
The changed operating direction first becomes effective after the positioner has been
re-initialized.
or
to confirm setting.
CLOSED
OPEN
0%
100%
4mA
20mA
20mA
4mA
Reading
EB 8394 EN
41
Start-up
or
2. Press
3. Touch
or
until ON appears.
to confirm setting.
4. Press
1)
P0
Status indication
P11
P1
Reading direction
P12
P2 1)
ATO/ATC [ATO]
P13
P3
1)
P14
P4
1)
P15
P5
Characteristic [0]
P16
P6
P17
P7
P18
RST Reset
P8 1)
Gain Kp [50]
P19
Enable configuration
P9
P20
Firmware version
P10
42
EB 8394 EN
Start-up
8.8 Initialization
During initialization the positioner adapts itself optimally to the friction conditions and the
signal pressure required by the control valve.
WARNING!
Risk of injury due to the actuator stem extending or retracting.
Do not touch or block the actuator stem.
NOTICE
The process is disturbed by the movement of the actuator stem.
Do not initialize the positioner while the process is running and only after isolating
the plant by closing the shut-off valves.
The type and extent of self-adaptation depends on the preset parameters. MAX applies as
the default setting for the nominal range (Code P4). During the initialization process, the positioner determines the total travel range or rotational range of the valve (from the CLOSED
position to the opposite end position).
Alternatively, a different travel can be selected in Code P4 (see code list in section9).
Note:
The travel set in Code P4 is only limited during initialization. However, it might be exceeded in closed-loop control when the control signal is higher than 20mA.
or
EB 8394 EN
Start-up
Note:
This code must be confirmed by pressing
Initial state 1:
The positioner is not initialized.
The positioner goes to the fail-safe position after the initialization process has been canceled.
Initial state 2:
The positioner is initialized.
On canceling a new initialization process, the positioner returns to closed-loop operation.
The settings of the previous initialization are used.
A new initialization can be started directly afterwards.
or
44
EB 8394 EN
Start-up
Note:
This code must be confirmed by pressing
1. Touch
or
or
Initialized positioner
The manual mode starts using the last set point used in closed-loop operation, ensuring a
bumpless changeover.
The bar elements on the display indicate the set point deviation between the manual set point
and set point used for closed-loop control while manually moving the valve in Code P17.
The manual set point is adjusted in steps of 0.1 %. You can move the valve controlled within its
range.
EB 8394 EN
45
Start-up
or
The valve is only moved in one direction uncontrolled. The bar elements on the display indicate the change in direction.
Touch
8.11 Reset
A reset causes an initialization to be undone and all parameters settings are reset to the default settings (see code list in section9).
Enable configuration as described in section8.2.
1. Touch
or
46
Note:
The fault indication icon is displayed after a reset since the positioner needs to be
re-initialized. The error code E2 is also activated (see section9.2).
EB 8394 EN
Start-up
8.12 Fault
In case of a fault, the fault indication icon is displayed. Switch past Code P0 or P20 to display the respective error code E0 to E15 together with ERR appear on the display. Refer to
the error code list in section9.2 for the cause of the errors and the recommended action.
Example:
If, for instance, a travel has been entered in Code P4 (nominal range) which is larger than
the maximum valve travel possible, the initialization process would be interrupted (E2 error
code) because the rated travel would not have been reached (E6 error code). The valve
moves to the fail-safe position (S indicated on the display).
S
appears
The nominal range (Code P4) must be changed and the positioner re-initialized to remedy
this problem.
EB 8394 EN
47
Start-up
or
2. Touch
to confirm the error code. ESC is displayed and the error code blinks.
3. Touch
4. Press
or
48
when ESC
EB 8394 EN
Code list
9 Code list
9.1 Parameter codes
Code
Display, values
[default setting]
Description
Note: Codes marked by an asterisk (*) indicate that the positioner needs to be re-initialized afterwards
P0
P1
Reading direction
P2*
ATO/ATC
[ATO]
P3*
Pin position
17/25/[35]/50/90
P4*
Nominal range
[MAX]
Values with
default setting [35]:
e.g.
7.5/8.92/10.6/12.6/
15.0/17.8/21.2mm
From 3.75
From 5.3
From 7.5
From 10.6
to
to
to
to
10.6mm
15.0mm
21.2mm
30.0mm
EB 8394 EN
49
Code list
P4*
Nominal range
[MAX]
From 3.5
From 5.0
From 7.0
From 10.0
to
to
to
to
Characteristic
0 to 8
[0]
Select characteristic:
0, 1, 2 for globe valves, 0 to 8 with rotary actuators (P3 = 90)
P6
Reference variable
[4 to 20mA]
SRLO/SRHI
P7
w/x
[>>]/<>
Direction of action of the reference variable w to the travel/rotational angle x (increasing/increasing or increasing/decreasing)
P8*
Gain KP
30/[50]
P9
Pressure limitation
ON/[OFF]
The signal pressure can take on the same pressure as the supply air
at the maximum [OFF] or, in the case that the maximum actuator
force can damage the valve, the pressure is limited to approx.
2.3bar.
P10
50
0
1
2
3
4
5
6
7
8
Linear
Equal percentage
Reverse equal percentage
SAMSON butterfly valve, linear
SAMSON butterfly valve, equal percentage
VETEC rotary plug valve, linear
VETEC rotary plug valve, equal percentage
Segmented ball valve, linear
Segmented ball valve, equal percentage
EB 8394 EN
Code list
P11
P14
Info w
Initialized Indicates the internally adjusted set point in the positioner (adjusted
set point in 0 to 100% according to the settings in P6 and P7).
Touch
to display external set point (applied set point in 0 to
100% according to the 4-20mA signal).
Not initialized
P15
Start initialization
. The
The initialization process can be interrupted by pressing
control valve moves to the fail-safe position. After a power supply
failure during initialization, the positioner starts with the settings
from the last initialization (if they exist).
P16
Manual mode
Press
P18
Reset
P19
Enable configuration
[LOCK]/OPEN
P20
Firmware version
EB 8394 EN
or
51
Code list
is displayed.
The errors listed in the following table are assigned to error classes:
Error class 1: No operation possible
Error class 2: Manual operation only possible
Error class 3: Manual operation and closed-loop control possible
Code
E0
Description
Zero error
(operational error)
Recommended action
Class
If the positioner is mounted correctly, perform a zero calibration over Code P16 (see section8.9).
Error code can be reset (see section8.12.1).
E1
E2
E3
KP setting
(initialization error)
Recommended action
E4
52
EB 8394 EN
Code list
E5
Standstill detection is
not possible
(initialization error)
Recommended action
E6
E7
E8
E9
to
E15
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1/3
53
Maintenance
10 Maintenance
The positioner does not require any maintenance.
There are filters with a 100m mesh size in the pneumatic connections for supply and output
which can be removed and cleaned, if required.
Observe the maintenance instructions of any upstream supply air pressure reducing stations.
Note:
Devices that have already been used outside hazardous areas and are intended for
future use inside hazardous areas must comply with the safety requirements placed
on serviced devices. Before being operated inside hazardous areas, test the devices
according to the specifications for servicing explosion-protected devices.
54
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Dimensions in mm
12 Dimensions in mm
42
108
14
87
22
M20 x 1.5
21
25
157.5
62.50
42
EB 8394 EN
55
Maintenance
25
M6
C
Mmin
D 1)
AA0
50
25
15
5.5 for M5
66
50
AA1
80
30
20
5.5 for M5
96
50
AA2
80
30
30
5.5 for M5
96
50
AA3
130
30
30
5.5 for M5
146
50
AA4
130
30
50
5.5 for M5
146
50
AA5
200
50
80
6.5 for M6
220
50
1)
56
Size
EB 8394 EN
58
EB 8394 EN
EB 8394 EN
59
60
EB 8394 EN
EB 8394 EN
61
62
EB 8394 EN
EB 8394 EN
63
EB 8394 EN
2015-11-12 English