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EB 7500 EN

Note on these mounting and operating instructions

These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.

Î

For the safe and proper use of these instructions, read them carefully and keep them for
later reference.

Î

If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department ([email protected]).

The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] field to look for a document.

Definition of signal words

Hazardous situations which, if not avoided,
will result in death or serious injury

Hazardous situations which, if not avoided,
could result in death or serious injury

Property damage message or malfunction

Additional information

Recommended action

DANGER

!

WARNING

!

NOTICE

!

Note

Tip

Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very high
concern on the candidate list of the REACH regulation, this circumstance is indicated on the
SAMSON delivery note. Information on safe use of the part affected,
see

u

http://www.samson.de/reach-en.html.

WARNING

!

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Summary of Contents for Series 420

Page 1: ...trol System Type 3416 Indicator Type 3421 Compact Controller with Type 3422 Controller Station and Type 3423 Controller Module Type 3417 Pneumatic Control Unit Type 3427 Manual Control Station Type 3425 Pneumatic Controller control room installation Type 3425 Pneumatic Controller field unit ...

Page 2: ... on our website www samson de Product documentation You can enter the document number or type number in the Find field to look for a document Definition of signal words Hazardous situations which if not avoided will result in death or serious injury Hazardous situations which if not avoided could result in death or serious injury Property damage message or malfunction Additional information Recomm...

Page 3: ...nal modules 12 4 4 1 Type 3424 4 Manual automatic Transfer 12 4 4 2 Type 3424 5 Control Mode Changeover 12 4 4 3 Type 3424 6 Signal Limiter 13 5 Design and principle of operation 14 5 1 Type 3421 Compact Controller 14 5 2 Type 3427 Manual Control Station 16 5 3 Type 3425 Pneumatic Controller wall mounted and field controller 16 5 4 Type 3416 Indicator 17 5 5 Type 3417 Pneumatic Control Unit 17 5 6...

Page 4: ...1 Pneumatic connections 26 7 2 Electrical connections 28 8 Maintenance 30 8 1 Checking the air supply 30 9 Conversion 30 9 1 Changing the controller function 30 9 2 Operating mode changeover in Type 3424 2 i p Converter 33 9 3 Checking the controller function 34 10 Technical data 35 ...

Page 5: ...applied conformity assessment procedure The EC Declaration of Conformity is available on request According to these mounting and operating instructions trained personnel refers to individuals who are able to judge the work they are assigned to and recognize possible dangers due to their specialized training their knowledge and experience as well as their knowledge of the applicable standards To en...

Page 6: ... The settings for direction of action and air delivery must be performed prior to start up Release the lock 4 in Fig 1 on the front panel of the compact controller and pull the manual control station completely out of the housing to access the controller module 3 1 1 Direction of action The direction of action for the control loop is set at the turnboard A Tshe position of its arrow symbol accordi...

Page 7: ...hanging the air delivery If the control valve that is to be controlled is more than 15 meters away increase the air delivery by turning the position of turnboard B from yA standard to R Fig 1 Turnboards and adjusters 1 Compact controller 2 Control room housing 3 Controller module 3 1 Comparator 3 2 Connecting plate 3 3 Hex screws 3 4 Screws inside 4 Lock 6 Fastening screw 7 Restriction 8 Zero adju...

Page 8: ... 9 determines the controller gain and depends on the con trolled system that is to be tuned see sec tion 4 1 3 1 4 Reset time Tn Controller versions with integral action com ponent require the reset time to be set at the adjuster 10 The setting depends on the controlled system that is to be tuned see sec tion 4 1 3 1 5 Derivative action time Tv Controller versions with derivative action component ...

Page 9: ... can be accessed through the opening on the left hand side Use a 2 5 mm hex screwdriver to slightly loosen the two fastening screws Move the corresponding proximity switch until the indicator points to the required value on the reference scale and a con tact is made over the connected switch ing amplifier or the LED on the front lights up when contact is made Retighten screws and place the marker ...

Page 10: ...Nichols method is a simple way to tune the controller In this method the controller runs in closed loop operation with P action to the point where it is still stable It can only be applied to controlled systems in which the controlled variable can be made to hunt 1 Set manual automatic switch 10 to manual Apply supply pressure 1 4 0 1 bar to Z 2 Set the proportional action coefficient Kp to a low ...

Page 11: ...ght ly change the set point and then return it to its former setting It may be necessary to increase the gain Kp slightly until an harmonic oscillation pattern arises 7 Write down the adjusted value on the Kp scale you have just adjusted as the criti cal proportional action coefficient Kp crit PI and PID controllers Use a stopwatch to time the oscillation time for one entire oscillation to find Tc...

Page 12: ...ut yA must be adjusted at the set point adjuster 11 to match the manual output yH The switch 10 can only be set to automatic after the pointers 4 and 5 in the bottom dis play meet 4 3 Readjusting the controller zero point If deviations arise between the controlled variable and set point during operation the zero point can be readjusted by turning the zero adjuster 8 in Fig 1 until the controlled v...

Page 13: ...he value of the manual output yA reading at the manual control station 0 to 100 cor respond to an output of 0 2 to 1 bar In case of large and frequently changing ref erence variables we recommend setting it to 50 Set point dependent operating point In this version the operating point is auto matically tracked meaning that the system deviation remains at zero The set point ad juster allows however ...

Page 14: ...nnecting plate 1 4 and the plug in unit 1 2 to hold the control ler module 1 3 The plug in unit has self seal push on fittings allowing the device to also function as a control station when no other components are used The controlled variable and set point pointers have metal bellows measuring elements The controlled variable measuring element can optionally be equipped with adjustable in ductive ...

Page 15: ...xt w x Circuit version 9 for ratio control P PI P PI PID PD Z a yA yH yA yH yH e S S yA w Z R e a wext x x y Fig 7 Circuits of Type 3421 Compact Controller Pneumatic connection Self seal push on fitting Supply air Z Venting Pneumatic adjuster End connection Manual automatic switch y Manipulated variable x Controlled variable w Set point wext External set point wint Internal set point R Feedback yA...

Page 16: ...consist of the Type 3426 Control Room or Field Housing and a Type 3423 Controller Module The controller module is connected over self seal push on fittings to the housing and fas tened with a screw 6 See u T 7512 6 P PI P PI PID V wext wint yA yH yA yH yA yH yH w x w wext y w Z y y S x R R w Z yA yA S x wext yA yH yH x w y w Z yA S x R R w Z yA S x S S P PI P PI PID V Fig 8 Pneumatic manual contro...

Page 17: ...on the control task Devices with electric or pneumatic limit con tacts have proximity switches or pick offs with emitter sensor nozzles which are con nected to the limit contact pointers The metal tag connected to the measuring unit pointer triggers a signal when a limit is reached See u T 7526 The listed limit contacts are no longer avail able 5 5 Type 3417 Pneumatic Control Unit The Type 3417 Pn...

Page 18: ...ntil the dis tance between nozzle and flapper is the same as initially and the output pressure yA assumes a value corresponding to the con trolled variable x and the adjusted propor tional action coefficient Kp adjustable over a screw Outside of the controller module the yA is connected to R allowing the pressure yA to be fed back to bellows R1 also over the port R and the adjustable Tn restrictor...

Page 19: ...largely identical to the Type 3423 2 PI Controller Module Type 3423 3 PID Controller Module This module is largely identical to the Type 3423 2 PI Controller Module This module however contains an addition al derivative element providing a deriva tive action gain of approx ten times in the input branch of the controlled variable x The derivative action time can be adjusted at the TV restrictor Fig...

Page 20: ...he same way as the PI and P controller modules The Type 3423 6 PD PID Controller Module with PD PID selector switch can be used ei ther as PD or PID controller The Type 3423 9 P Controller Module with set point dependent operating point is the same as Type 3423 1 P Controller Module except the operating point changes propor tionally to the set point w Type 3423 7 Ratio Relay This device is designe...

Page 21: ...dized pneumatic signal from 0 2 to 1 bar The i p converter which functions according to the force balance principle is mounted di rectly to the controller module of the Type 3421 Compact Controller Type 3424 21 or to the Type 3422 Manual Control Sta tion Type 3424 20 In the delivered state the output pressure is either connected to the signal channel of the controlled variable x or to the external...

Page 22: ...put pressure yA to the maximum pressure adjusted 5 7 3 Type 3424 5 for control mode changeover The control mode changeover switches the connected controller from PI or PID to P action if the control error exceeds an adjustable limit This allows a fast start up of the set point without overshooting 5 7 4 Type 3424 6 for signal limitation The additional module is used to limit the maximum and minimu...

Page 23: ...ed with metal tags which move adjustable proximity switches within a magnetic field The operation of the inductive limit contacts requires switching amplifiers in accordance with EN 60947 5 6 to be connected in the output circuit The corresponding wiring Fig 17 allows the limit contacts to be additionally fitted with LEDs Internal electrical limit contacts with LED are amplified on the internal bo...

Page 24: ... top and bot tom to a rail Type 3421 3422 1089 0036 and Type 3427 1089 0037 in the control panel The tightening torque for the screws depends on the installation situation approx 1 4 Nm On tightening the screws the rail must have direct contact with the housing and the panel must not be bent Pneumatic connections Electrical connections Terminal rail All dimensions in mm Approx 135 mm with Type 342...

Page 25: ... Field Housing 334 165 129 M6 14 15 240 97 A 26 37 105 65 R w Z yA S x All dimensions in mm View A Pneumatic connections Cover open 1 8 NPT 3 Turn scale or replace it with another one and insert it into the scale holder 4 Insert scale holder into its guide and push it into place Type 3426 Control Room or Field Housing Fasten control room housing Type 3426 2 using M4 screws in the control room Fast...

Page 26: ...e manual control station to manual a switching pressure of 1 4 bar is applied to the start up relay to bypass the Tn and Tv restrictors yA Automatic output pressure 0 2 to 1 bar Sealed in Type 3422 open for separate instrumentation with Type 3427 Pneu matic Manual Control Unit Output in Types 3423 and 3425 input in Type 3427 w Reference variable 0 2 to 1 bar Sealed in Type 3422 open in Type 3427 O...

Page 27: ...3416 1 3417 1 Types 3416 2 3417 2 Types 3416 90 91 y Manipulated variable 0 2 to 1 bar Controller output signal to actuate the control valve Output in Type 3427 input in Types 3423 and 3425 Zul Supply air Ports 1 2 3 4 In Type 3416 Indicator and Type 3417 Pneu matic Control Unit Assignment depending on version Type 3416 90 91 Indicators with pneumatic limit contacts have ports designed as con nect...

Page 28: ... no longer available NOTICE Note _ _ _ _ _ _ 3 1 2 6 7 8 9 3 4 5 4 5 1 2 6 7 8 9 _ _ 24V 24V _ _ _ _ _ _ _ _ 3 1 2 6 7 1 2 3 4 5 4 5 1 2 6 7 1 2 _ _24V 24V _ _ Fig 17 Electrical connections of Type 3422 and Type 3427 Type 3427 Type 3422 Top bottom LED Max limit contact Min limit contact Max limit contact Bottom top LED Min limit contact 4 to 20 mA input Self seal push on fittings 24 V DC for limit...

Page 29: ... 9 1 2 3 4 5 6 7 8 9 3 4 5 7 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3 5 6 7 1 2 3 4 5 6 7 8 9 1 2 8 9 1 3 2 1 3 1 3 2 4 3 4 5 3 4 5 3 4 5 3 4 5 3 5 2 1 3 2 1 3 2 Fig 18 Electrical connections of Type 3416 Min max min Limit contacts min Limit contacts min max Limit contacts Max Max Max Max Type 3416 18 With terminals Version with electrical output With pneumatic output Type 3416 18 Type 3416 16 Type 3416 ...

Page 30: ...ules are also fitted with filters They can not be renewed 9 Conversion 9 1 Changing the controller function If a different control behavior is necessary for example after modifying the plant the control behavior of the Type 3423 Controller Module can be altered by converting or up grading components such as adjusters re strictors or a derivative amplifier The required parts are listed in Table 1 o...

Page 31: ...t Attach plate with restriction 15 in place of the adjuster for operat ing point 12 We recommend replacing old O rings with new ones as well as replacing the filter in the restriction 7 in Fig 1 and Fig 19 Note P to PI P to P PI Fig 19 Changing the controller function Filter Restriction 7 10 12 11 14 10 12 13 11 1 11 2 14 1 14 2 P to PD PI to PID Seals in P and PI controllers 10 2 14 4 14 3 Seals ...

Page 32: ...erating point adjuster 1 4 bar 1070 7550 12 1 Operating point adjuster 20 psi 1070 7551 12 1 2 M3 x 8 screws 8333 0479 12 2 4 O rings 1 78 x 1 02 8421 0010 13 1 Selector switch for operating point adjuster 1080 6909 13 1 2 M3 x 30 screws 8333 0482 13 2 4 O rings 1 78 x 1 02 8421 0010 14 1 Derivative amplifier 1080 6924 14 1 1 1 Cover plate 0360 1598 14 2 1 M3 x 16 screw 8333 0476 14 3 1 1 Formed s...

Page 33: ...he location of the O ring and washer on the holes on the inside of the plate as shown in Fig 20 x mode 6 Seal tight the wext input of the compact controller connecting plate Fig 16 with a screw plug with 1 8 NPT thread The wext port at the plug connection of the control station must be sealed wext mode 7 Open the wext port at the plug connection by unscrewing the M4 hexagon socket screw at the wex...

Page 34: ... Perform the following settings Turnboard A to increasing decreasing Fully open Tn restriction 0 03 min Fully close Tv restriction 0 01 min Î Î Turn the set point rotary knob to change the reference variable through its whole range The controlled variable pointer red and the output reading small dial follow the reference variable over the whole range when the controller functions properly ...

Page 35: ...rol parameters Proportional action coefficient Kp 0 2 to 20 or 0 4 to 40 Reset time Tn 0 03 to 50 min Derivative action time Tv 0 01 to 10 min Derivative action gain of x 10 Ratio R a e mechanically adjustable R 0 2 to 20 Operating point adjustment 0 2 to 1 0 bar 3 to 15 psi Input 0 2 to 1 bar 3 to 15 psi Output 0 2 to 1 bar 3 to 15 psi max 0 02 to 1 35 bar 0 3 to 19 psi max air delivery 1 5 mn h ...

Page 36: ... and density Class 3 Oil content Class 2 Pressure dew point Class 3 or at least 10 K below the lowest ambient temperature to be expected Permissible ambient temperature range 20 to 60 C Compliance Weight approx Manual control station without components 2 5 kg Type 3421 with controller module 3 2 kg Type 3421 Controller with controller or additional module 3 6 kg 1 No longer available Technical dat...

Page 37: ...EB 7500 EN 37 ...

Page 38: ...38 EB 7500 EN ...

Page 39: ...EB 7500 EN 39 ...

Page 40: ...SAMSON AG MESS UND REGELTECHNIK Weismüllerstraße 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 7500 EN 2017 07 17 English ...

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