Samson 3780 series Mounting And Operating Instructions Download Page 1

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Positioner with HART

communication

Type 3780

Mounting and

Operating Instructions

EB 8380-1 EN

Firmware R 2.22/K 2.23
Edition June 2004

Fig. 1

⋅

Type 3780

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Summary of Contents for 3780 series

Page 1: ...r with HART communication Type 3780 Mounting and Operating Instructions EB 8380 1 EN Firmware R 2 22 K 2 23 Edition June 2004 Fig 1 Type 3780 All manuals and user guides at all guides com a l l g u i d e s c o m ...

Page 2: ...l safe action of the actuator 26 3 Connections 28 3 1 Pneumatic connections 28 3 1 1 Pressure gauge 28 3 1 2 Supply air pressure 29 3 2 Electrical connections 29 3 2 1 Switching amplifiers 31 3 2 2 Establishing communication 32 4 Operation 34 4 1 Write protection 34 4 2 Activate deactivate forced venting function 34 4 3 Default setting 35 4 3 1 Adjusting mechanical zero point 35 4 3 2 Initializati...

Page 3: ...owing applies live circuits may only be connected interrupted and switched for installation maintenance or repair purposes Devices that have already been used outside of hazardous areas and are intended for use in hazardous areas in future shall com ply with the safety demands placed on serviced devices Prior to operation they shall be tested according to paragraph 26 Re pairing explosion protecte...

Page 4: ...t time open closed The measured time is not referenced to filling venting the actuator but to the opening and closing the valve Required transit time filling venting Required transit time open closed The actuating time is not referenced to filling venting the actuator but to the opening and closing the valve Cycle time factor K_IS Omitted Initialization For version R2 02 or higher an alarm message...

Page 5: ...ngle of rotation or transmission is displayed as alarm message but does not cause abortion of initialization anymore Positioner 2 11 R 2 21 Type of actuator Change over type of actuator from linear actuator to rotary actuator Initialization type Based on maximum range Transmission code S90 Nominal angle 90 End position when w 1 End position when w 99 Rotational angle range start 0 Rotational angle...

Page 6: ...icient KP_Y1 and KP_Y2 These factors are adapted to the type of actuator chosen and the transit times measured Positioner 2 21 R 2 22 Correction in manual operating mode and direction of action Correction in zero calibration started via communication Communication K 1 00 K 2 01 Characteristic type Free space for entering information on the description of the user defined characteristic saved in th...

Page 7: ...HART communication See section 4 1 for more details on the write protection switch Model index 3780 x x 03 or higher are suitable for the extended valve diagnosis using the TROVIS EXPERT software Positioner versions Model 3780 X X X X X Explosion protection Without Ex II 2 G EEx iA IIC T6 as per ATEX CSA FM Ex II 3 G EEx nA II T6 as per ATEX 0 1 3 8 Additional accessories Limit switches Without 2 ...

Page 8: ... 4 bar 5 8 m h Perm ambient temperature 20 to 80 C with metal cable gland 40 to 80 C Devices with position transmitter only 20 to 80 C For explosion protected devices see type examination certificate in appendix Effects Temperature 0 15 10 K supply none vibrations none up to 250 Hz and 4 g Explosion protection EEx ia IIC T6 see type examination certificate Degree of protection IP 65 by using the f...

Page 9: ...s for connection to switching amplifier acc to EN 60947 5 6 Switching hysteresis 1 static destruction limit 16 V Analog position transmitter Two wire transmitter output 4 to 20 mA Supply terminal voltage 12 to 35 V DC static destruction limit 40 V Direction of action reversible characteristic linear operating range 10 to 114 DC current signal ripple content 0 6 at 28 Hz IEC 381 T1 Resolution 0 05 ...

Page 10: ...l room Activating the write protection switch lo cated in the hinged cover prevents the posi tioner settings from being overwritten by the HART protocol Forced venting function The positioner is controlled via a 6 to 24 V signal causing the signal pressure to be applied to the actuator If this volt age signal decreases the signal pressure is shut off and the actuator is vented The springs containe...

Page 11: ...ally resetting the positioner to zero it can be automatically started up via initialization procedure During this in itialization procedure zero is automatically adjusted and the preset span is checked Fig 2 Functional diagram 11 10 1 12 e p 3 4 2 5 1 G μC FSK e p G μC 6 7 8 1 Inductive displacement sensor 2 Microcontroller 3 2 2 way valve for supply air 4 2 2 way valve for exhaust air 5 Microcont...

Page 12: ...owing parameters control characteristic direction of action limitation of travel travel range transit time to travel and fault messages Operating software TROVIS VIEW for devices with firmware K 2 11 or higher Data Sheet T 6661 EN IBIS DOS based no longer runs on Windows 2000 ME XP NT see EB 8380 2 EN for more details DMT 1 2 and PACTware Integration e g Fisher AMS Siemens PDM etc Handheld communi...

Page 13: ...ace the filter installed in the output pressure bore with a screw in throttle to obtain good control properties For further information refer to sections 2 1 2 2 and 2 3 Caution The positioner does not have a venting plug Instead the air is exhausted via vent ing plugs on the mounting parts see also Fig 3 5 and 7 A filter check valve for the exhaust air is sup plied with every positioner located u...

Page 14: ...es spe cified in Table 3 Actuator with 240 350 and 700 cm2 6 Check whether the tongue of the seal 17 is aligned on the side of the connection block such that the actuator symbols for Actuator stem extends or Actuator stem retracts match the actu ator design Otherwise remove the three fixing screws remove the cover plate 18 and reinsert the seal 17 turned by 180 When using an old connection block t...

Page 15: ...over 17 Seal 18 Cover plate 19 Switch plate Signal pressure hole Side view of connection block Connection block Mark Mark Actuator stem extends symbol Switchover plate Switchover plate Signal pressure input Signal pressure input if necessary with brass throttle Actuator stem extends Actuator stem extends Fig 3 Attachment and signal pressure connection for Type 3277 top and Type 3277 5 with 120 cm ...

Page 16: ...ot used Note For quick acting control valves transit time 0 6 s it is necessary to replace the filter installed in the output pressure bore Output 38 with a screw in throttle accessories spe cified in Table 3 Filling the spring chamber with air If the spring chamber of the Type 3277 Ac tuator must be filled with the air exhausted from the positioner the spring chamber ver sion Actuator stem extend...

Page 17: ...1 Order with every pressure gauge kit 2 restrictions 1790 6121 1 1402 0938 1402 0939 All manuals and user guides at all guides com ...

Page 18: ... sequence NOTE Before you mount the parts load the actua tor with air pressure so that the valve is set to 50 of its travel This will ensure the exact alignment of the lever 18 and the bracket 28 Control valve with cast yoke 1 Use countersunk screws to screw the plate 20 to the coupling which con nects the plug and actuator stem With 2100 and 2800 cm2 actuators use ad ditional mounting bracket 32 ...

Page 19: ...Lever N1 N2 19 Pin 20 Plate 21 Clamp 22 Clamping plate 23 Screw 24 Pointer 25 Shaft 26 Lever of positioner 27a Coupling pin 27b Lock nut 28 Bracket 29 Studs 30 Plate 31 Nuts 32 Mounting bracket Attachment to NAMUR rib Attachment to rod type yoke EB 8380 1 EN 19 Attachment to the control valve All manuals and user guides at all guides com ...

Page 20: ...in the pin 27 at the positioner lever 26 and secure it with a hex nut on the opposite side Note the mount ing position A or B respectively accord ing to Table 5 and Fig 5 4 Put the positioner to the adapter hous ing such that the pin 27 will lie properly within the arms of the bracket 28 To do so insert a 2 5 mm Allen key or a screwdriver from the front into the hole located below the oblong hole ...

Page 21: ...G 1 4 1 4 NPT 1400 7458 1400 7459 Pressure gauge set St st Brass St st St st 1400 6957 1400 6958 Signal pressure throttles screw in type and brass throttle 1400 6964 Filter check valve replaces venting plug and increases the degree of protection to IP 65 one included with the delivered positioner 1790 7408 Table 5 Attachment according to IEC 60534 6 Travel in mm 7 5 15 15 30 30 60 30 60 60 120 Pin...

Page 22: ... the chamber behind the diaphragm through a tube assembly and a tee con nected between actuator and intermediate piece Note For quick acting control valves transit time 0 6 s it is necessary to replace the filter installed in the output pressure bore Output 38 with a screw in throttle accessories spe cified in Table 6 2 3 1 Mounting the cam follower roll lever 1 Place lever with the attached roll ...

Page 23: ... to VDI VDE 3845 Vent plug or filter check valve 33 Positioner 34 Intermediate piece 35 Lever w cam follower roll 36 Adapter 37 Transmission lever 38 Screws 39 Scale 40 Cam disk 41 Actuator shaft 42 Plate 43 Bracket 44 Coupling 45 Seal EB 8380 1 EN 23 Attachment to the control valve All manuals and user guides at all guides com ...

Page 24: ... closed should not under any circumstances be below the 0 position With actuators with fail safe position Valve OPEN the maximum signal pressure must be applied to the actuator before aligning the cam disk With springless actuators the supply air must be connected 2 In aligning the cam disk clip on the double sided scaled disk in such a way that the valve on the scale will corre spond to the direc...

Page 25: ...am disk 0050 0089 especially for VETEC adjustable to 0 to 75 via software 1400 6960 Cam disk 0050 0090 especially for Camflex adjustable to 0 to 50 via software 1400 6961 Pressure gauge mounting block G 1 4 1400 7458 1 4 NPT 1400 7459 Pressure gauge set St st Br 1400 6957 St st St st 1400 6958 Signal pressure throttles screw in type and brass throttle 1400 6964 Filter check valve replaces venting ...

Page 26: ...into the connecting boreholes A1 and Z 3 Place the reversing amplifier onto the positioner and screw tight using both the special screws 1 1 4 Screw the enclosed filter 1 6 into the connecting boreholes A1 and Z using a screwdriver 8 mm wide Signal pressure connections A1 Output A1 leading to the signal press ure connection at the actuator which opens the valve when the pressure increases A2 Outpu...

Page 27: ...ig 7 Mounting a reversing amplifier Control signals to the actuator 1 Reversing amplifier 1 1 Special screws 1 2 Gasket 1 3 Special nuts 1 4 Rubber seal 1 5 Plug 1 6 Filter From the positioner EB 8380 1 EN 27 Reversing amplifier for double acting actuators All manuals and user guides at all guides com ...

Page 28: ...r the upper or lower diaphragm chamber of the actua tor depending on the actuator s fail safe po sition Exhaust air The exhaust air connection of the positioner is located in the mounting kit If the positioner is attached directly a vent plug is located in the plastic cover of the ac tuator For Namur attachment it is in the adapter housing and for attachment to rot ary actuators it will either be ...

Page 29: ...ions of the country of destina tion must be adhered to In Germany these are the VDE regu lations and accident prevention regu lations of the employer s liability in surance For installation in hazardous areas the following standards apply EN 60079 14 1997 VDE 0165 Part 1 8 98 Electrical apparatus for ex plosive gas areas and EN 50281 1 2 VDE 0165 Part 2 11 99 Electri cal apparatus for use in the p...

Page 30: ...0x1 5 cable gland in the housing that can be used for additional connection if required The screw terminals are designed for wire cross sections of 0 2 to 2 5 mm2 Tighten by at least 0 5 Nm The wires for the reference variable are to be connected to the terminals 11 and 12 lo cated in the case as shown in Fig 9 Make sure to connect the appropriate poles The voltage applied must not exceed 15 V Cau...

Page 31: ... V and not higher than 35 V DC Terminal assignment is shown in Fig 9 and is indicated on the cover plate inside the case cover Accessories Model index 3780 x x 01 Cable gland PG 13 5 Black Order no 1400 6781 Blue Order no 1400 6782 Adapter PG 13 5 on 1 2 NPT Metallic Order no 1400 7109 Blue finish Order no 1400 7110 Model index 3780 x x 02 or higher Cable gland M20 x 1 5 Black plastic Order no 140...

Page 32: ...ed Connection of an FSK bus always re quires interfacing of isolating amplifiers By means of the HART protocol all control room and field devices connected in the loop are accessible through their address via point to point or standard bus multi drop Point to point The bus address polling address must al ways be set to zero 0 Standard bus multidrop In the standard bus multidrop mode the positioner...

Page 33: ... the process controller control station output is not HART compatible For adaptation the Z box order no 1170 2370 can be in stalled between output and communication interface At the Z box a voltage of approx 330 mV is released 16 5 Ω at 20 mA Alternatively a 250 Ω resistor can be con nected in series and a 22 μF capacitor can be connected in parallel to the analog out put Note that in this case th...

Page 34: ... posi tion 4 2 Activate deactivate forced venting function Model index 03 or higher 1 Remove cover inside the positioner s lid by unscrewing the four screws 2 Loosen the screw in the center of the board and swivel out the board 3 Set switch to desired position 1 ENABLED Function activated 2 DISABLED Function deactivated Arrow for mounting position Manual adjustment Zero point lever Pointer Adjustm...

Page 35: ...uently the zero point lever can be oper ated 4 3 2 Initialization After the electric reference variable and the auxiliary supply pressure have been con nected to the positioner the initialization process can be started In this process the positioner adapts itself optimally to the mechanical conditions friction and signal pressure requirements of the control valve See list of parameters on page 48 ...

Page 36: ...on by pressing the Init Zero key on the positioner hinged cover using a suitable tool The initialization is completed when the po sitioner takes on the position predetermined by the reference variable Note After the positioner has been initialized suc cessfully for the first time pressing the Init Zero key subsequently only starts a zero calibration A new initialization routine can only be started...

Page 37: ...l be picked up or re leased when the tag has entered the field has to be selected if necessary at the switching amplifier Adjusting the switching point The limit switches are marked GW1 and GW2 on the inside of the case cover Yel low tags and the associated adjustment screws Fig 12 are located below these markings Each switching position can optionally be sig nalized when the tag has entered the f...

Page 38: ...t be put back into operation again until an ex pert has inspected the device according to explosion protection requirements has is sued a certificate stating this or given the device a mark of conformity Inspection by an expert does not have to be carried out if the manufacturer performs a routine check test on the device prior to tak ing it into operation again and the success of the routine chec...

Page 39: ...ommunication control HART universal revision field device revision Number of required preambles Bus address polling address Message loop tag identification numbers Description plant identification Date Type of protection Identification of the options forced venting contacts position transmitter Ident number actuator Ident number valve Text field not allocated Start up Actuator type Attachment Mode...

Page 40: ...istic with 11 co ordinates Required transit time on off Limit values for software limit switches GW1 GW2 GW1 GW2 on when the respective limit value is exceeded not attained Operating direction position transmitter Write protection Parameters Dead band Xtot Proportional action coefficient KP_Y1 KP_Y2 Derivative action coefficient KD Tolerated overshoot Operation Operating mode Reference variable w_...

Page 41: ...tolerance band lag time Fault message in case of communication fault Fault message with controller in special function Fault message if limit value for total valve travel is exceeded Test of fault indication output Test of position transmitter Test of software limit switches GW1 GW2 Zero adjustment EB 8380 1 EN 41 Summary of parameters All manuals and user guides at all guides com a l l g u i d e ...

Page 42: ...minal angle The working range may not be selected 1 4 less than the nominal angle Range Default coldstart value 0 0 degrees to 120 0 degrees 0 0 degrees Attachment Defines the positioner attachment to the control valve with a linear actuator For a rotary motion actuator only attachment according to VDI VDE 3845 NAMUR is possible States Default coldstart value Integral Type of attachment in combina...

Page 43: ...according to the European date format DD MM YYYY can be stored in the field device The date can be entered as required Dead band Xtot Maximum tolerated deviation between set point value and actual value specified as a percentage of the travel range A small dead band means a high degree of control accuracy The smallest possible dead band is determined by the quality of the control valve high fricti...

Page 44: ...ion in Error monitoring of delay time Reset criterion for active control loop monitoring A control loop fault is reported when an entered delay time is exceeded and the deviation error does not lie within the entered tolerance band The delay time is determined from the minimum transit time during the initialization process when the detected value exceeds the preset value Range Default coldstart va...

Page 45: ...entification States Default coldstart value Not installed Installed Not installed Initialization special function Automatic start up Prerequisite Mechanical zero point adjustment must have been carried out once Valid initialization data must have been entered Initialization alarm Message concerning initialization States Unknown Ok Air leakage of pneumatic system Wrong selection of rated travel or ...

Page 46: ... text can be used by the user in any way Each field device is recommended to be assigned a unique loop tag number Length 32 characters For non IBIS devices message Manufacturer Manufacturer s id code Clearly identifies the manufacturer of the field device Message Unassigned text stored in the field device Length 32 characters For IBIS devices loop tag number Minimum control pulses Shortest pulse s...

Page 47: ... travel Nominal working range of the valve Range Default coldstart value 0 0 mm to 255 0 mm 15 0 mm Number of request preambles Number of preambles required from the control station requested by the field device Operating direction of position transmitter Determines the operating direction of the optional position transmitter States Default coldstart value Increasing controlled variable causes inc...

Page 48: ...when the positioner is initialized for the first time The initialization values listed in the table below may possibly have to be adapted to the changed operating conditions in order to attain the best control response Type of actuator Nom travel angle Transit time KD KP_Y1 Filling KP_Y2 Venting Min Effect of spring Open Close Rotary actuator 0 7 s 0 7 s 0 12 0 5 0 5 Closes 0 7 s 0 7 s 0 12 0 5 0 ...

Page 49: ...riable in mA adjustable in Manual mode via communication Range 3 8 mA to 22 mA Required transit time filling venting The transit time is defined as the time required by the system comprising positioner actuator and valve to pass through the complete rated travel nominal range The actual transit time is extended to the entered value If the required transit time is less than the minimum transit time...

Page 50: ...dead band xtot but remains within the overshoot range the pulse adaptation only reduces the minimum pulses in both moving directions after two complete oscillations within the overshoot range Range Default coldstart value 0 01 to 10 00 of the nominal travel nominal angle 0 5 Total valve travel Sum of nominal duty cycles Maximum value 16 500 000 The value is indicated in double in up and down trave...

Page 51: ...ar characteristic the characteristic is adapted to the reduced travel If the maximum range has been initialized the travel range is always related to the entered nominal travel The working range may not be selected 1 4 less than the nominal angle Range Default coldstart value 0 0 mm to 255 9 mm 0 0 mm Type of initialization Type of initialization related to the nominal or maximum range For initial...

Page 52: ...be overwritten The only way to activate the write protection is using the switch installed on the device States Activated deactivated Zero calibration special function Zero correction with valid mechanical zero point 52 EB 8380 1 EN List of parameters All manuals and user guides at all guides com ...

Page 53: ... range 57 9 2 9 Erroneous characteristic 58 9 2 10 Erroneous characteristic monotony 58 9 2 11 Erroneous characteristic inclination 58 9 2 12 Time out 58 9 2 13 Application data invalid 58 9 2 14 Control data memory erroneous 58 9 2 15 Checksum error control data memory 58 9 2 16 Communication data memory erroneous 59 9 2 17 Checksum error communication data memory 59 9 2 18 Checksum error device ...

Page 54: ... Reset Device setup modified 9 1 2 Insufficient power supply The parameter is set when the power supply exceeds 3 6 mA It is automatically reset when the current exceeds 3 6 mA again 9 1 3 Warmstart completed This message is displayed when the power supply was 3 2 mA informing about a possible power supply failure The device is automatically reset after the message has been acknow ledged 9 1 4 Col...

Page 55: ...tically signals that the valve needs to be maintained so that possible failure is prevented Reset via Diagnostics Device status 9 1 8 Zero adjustment aborted Zero adjustment was aborted by the user Automatic reset after acknowledgement The previous zero point is maintained if zero adjustment has already been carried out successfully Initialization status 9 1 9 Initialization aborted Initialization...

Page 56: ... are adjusted via Device data Specialist Extension Configuration Possible sources of error Oscillation caused by actuator being operated too fast small travel volume Remedy Reduce the supply air pressure as described in section 3 1 2 and install a sig nal pressure throttle see chap 2 Supply air failure supply air insufficient Filter clogged Solenoid valves oiled up Actuator diaphragm torn Actuator...

Page 57: ...ults in values which are not within the permissible measuring range Possible sources of error Reference variable exceeded power supply 22 5 mA This message is automatically reset when the power supply decreases below 22 5 mA 9 2 7 Controlled var x out of range The internal A D conversion results in values which are not within the permissible measuring range Possible sources of error Improper mecha...

Page 58: ...nter too high an inclination value 16 It is automatically reset after a correct characteristic has been transmitted 9 2 12 Timeout This message is generated when a specified time frame is exceeded during certain tests Acknowledge this message to reset 9 2 13 Application data invalid This message is generated in case an internal communication fault or a HART communica tion fault occurs It is reset ...

Page 59: ...ation without abortion Error message without abortion of the initialization procedure Error message with abortion of the initialization procedure After the error has been eliminated initialization must be restarted 9 3 1 Wrong selection of rated travel or transmission The maximum determined travel which is read out as value of the rated travel angle is smaller than the selected rated travel angle ...

Page 60: ...between 6 and 24 V DC be ap plied to terminal 81 and 82 9 4 2 Determining the mechanical end stops The initialization routine recognizes the spring action and zero during determination of the mechanical end stops by completely venting and exhausting the actuator In addition the routine checks whether the positioner can pass 100 rated travel angle 9 4 2 1 Defective mechanics pneumatic section when ...

Page 61: ...trol loop error If the system cannot travel through the entire rated travel angle the supply air pressure is usually too low 9 4 4 Messages during determination of minimum pulses 9 4 4 1 Proportional band restricted too much Even the smallest permissible pulses still cause too large changes in travel Initialization is aborted Possible sources of error Supply pressure too high Missing signal pressu...

Page 62: ... Supply Z Output 38 Supply 9 M20 x1 5 Fulcrum of actuator shaft Dimensional diagram Pneumatic connections G 1 4 or NPT 1 4 Attachment with intermediate piece for rotary actuators Attachment acc to IEC 60534 6 w adapter housing Pneum connection of reversing amplifier Direct attachment 62 EB 8380 1 EN All manuals and user guides at all guides com ...

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