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Samson 3785 series, Mounting And Operating Instructions

The Samson 3785 series provides comprehensive Mounting and Operating Instructions manual for easy installation and use. Users can download the free manual from our website for a hassle-free experience. Ensure optimal performance by following the guidelines outlined in the manual. Download your copy now at 88.208.23.73:8080.

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Contents

Page

1.

Design and principle of operation

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8

1.1

Option  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8

1.2

Communication  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  8

2.

Attaching the positioner

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10

2.1

Direct attachment to Type 3277 Actuator  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10

2.2

Attachment acc. to IEC 60534-6  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 14

2.2.1

Mounting sequence  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 14

2.2.2

Presetting the valve travel .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 16

2.3

Attachment to rotary actuators  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 18

2.3.1

Mounting the cam follower roll lever  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 18

2.3.2

Mounting the intermediate piece  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 18

2.3.3

Aligning and mounting the cam disk  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 20

2.3.4

Reversing amplifier for rotary actuators  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 22

2.4

Fail-safe position of the actuator  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 22

3.

Connections

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 24

3.1

Pneumatic connections  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 24

3.1.1

Pressure gauge  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 24

3.1.2

Supply air pressure  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 25

3.2

Electrical connections  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 25

3.2.1

Forced venting  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 27

3.2.2

Limit switches  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 28

3.2.3

Establishing communication (bus address) .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 28

3.2.4

Local interface (SSP)  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 28

4.

Operation

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 30

4.1

LED controls  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 30

4.2

Write protection  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 31

4.3

Activate/deactivate forced venting function  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 31

4.4

Default setting  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 31

4.4.1

Adjusting mechanical zero  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 32

4.4.2

Initialization  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 32

4.5

Adjusting the inductive limit switches  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 34

5.

Maintenance

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 35

6.

Servicing ex-proof versions

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 35

7.

How to implement the PROFIBUS Master Class 1

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 36

Contents

2

EB 8382-1 EN

Summary of Contents for 3785 series

Page 1: ...PROFIBUS Positioner Type 3785 PA device profile version 2 0 Fig 1 Type 3785 Mounting and operating instructions EB 8382 1 EN Firmware R 1 42 K 1 60 Edition January 2003...

Page 2: ...ctuators 22 2 4 Fail safe position of the actuator 22 3 Connections 24 3 1 Pneumatic connections 24 3 1 1 Pressure gauge 24 3 1 2 Supply air pressure 25 3 2 Electrical connections 25 3 2 1 Forced vent...

Page 3: ...special knowledge of the relevant standards Explosion proof versions of this device may only be operated by personnel who have undergone special training or instructions or who are authorized to work...

Page 4: ...ge Mounting position arrow toward actuator arrow away from actuator Transmission code D1 Transmission pin position A Rated travel 15 mm 15 mm End position for w 1 1 End position for w 125 125 Lower tr...

Page 5: ...s are detected by means of control loop monitoring The function of bit 13 remains unchanged Messages are only indicated by bit 7 if Control Firmware R 1 41 or higher is used The message warmstart indi...

Page 6: ...ion 0 05 internal measurement Transit time Up to 240 s separately adjustable for exhaust and supply air Moving direction Reversible adjustment via software Air consumption Independent of supply air 90...

Page 7: ...according to EN 60947 5 6 Materials Case Die cast aluminum chromized and plastic coated External parts Stainless steel 1 4571 and 1 4301 Weight Approx 1 3 kg Positioner versions Type 3785 X X X X X 3...

Page 8: ...g These on off valves can either have the switching states permanently open permanently closed or generate single pulses of changing widths With the two valves being controlled the plug stem moves to...

Page 9: ...ositioner is configured and operated at the PC over the SSP interface 13 using TROVIS VIEW Alternatively it can be con figured via a segment coupler for example by the COMMUWIN II user interface by En...

Page 10: ...d moisture from entering the device 2 1 Direct attachment to Type 3277 Actuator For the selection of the required mounting parts refer to tables 1 2 and 3 on page 13 When looking at the signal pressur...

Page 11: ...ssure connection over piping 1 2 Clamp D1 Lever D2 Lever 15 Distance plate 16 Cover Signal pressure bore Side view of connection block with switch plate Connection block Marking Symbol actuator stem e...

Page 12: ...e with the associated plug included in the acces sory kit 7 Mount the positioner so that the bore in the distance plate 15 is aligned with the seal located in the bore of the actua tor yoke 8 Align th...

Page 13: ...n only be used with the new actuators Index 01 Old and new plates are not interchangeable Connection block required for actuator sizes 240 350 and 700 cm2 including seals and fastening screw G thread...

Page 14: ...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 casted yoke 1 Use countersunk screws to screw the plate 20 to th...

Page 15: ...ounting position Attachment to rods 18 Levers N1 N2 19 Pin 20 Plate 21 Clamp 22 Clamping plate 23 Screw 24 Pointer 25 Shaft 26 Lever of positioner 27a Transmission pin 27b Lock nut 28 Bracket 29 Studs...

Page 16: ...nut on the op posite side Note the mounting position A or B respectively according to Table 5 and Fig 5 4 Put the positioner to the adapter hous ing such that the pin 27 lies properly within the arms...

Page 17: ...no Pressure gauge mounting block G 1 4 NPT 1 4 1400 7106 1400 7107 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...

Page 18: ...f the positioner is attached to actuators of other manufacturers NAMUR the air is applied to the chamber behind the diaphragm through a tube as sembly and a tee connected between actua tor and interme...

Page 19: ...e piece 35 Lever with cam follower roll 36 Adapter 37 Transmission lever 38 Screws 39 Scale 40 Cam disk 41 Actuator shaft 42 Plate 43 Bracket turned 90 44 Coupling 45 Reversing amplifier Attachment ac...

Page 20: ...the closing position must not be below the 0 position In actuators with fail safe position Control valve open OPEN the actuator must therefore be loaded with max signal press ure prior to aligning th...

Page 21: ...3 1400 7104 1400 7105 1400 7118 1400 7119 1400 7120 Piping kit 8 x 1 stainl steel G 1400 6670 1400 6672 NPT 1400 6669 1400 6671 Accessories Order no Reversing amplifier for double acting actuators wit...

Page 22: ...hollowed special screws 1 1 into the connecting boreholes A1 and Z 4 Place the reversing amplifier onto the positioner and screw tight using both the special screws 1 1 5 Replace the venting plug in...

Page 23: ...1 2 1 1 1 A A A A Z A2 1 4 A1 A2 Z A1 Output 38 Supply 9 Output 38 Supply 9 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 Pl...

Page 24: ...ither Actuator stem retracts or stem extends Exhaust air The exhaust air connection of the positioner is located at the mounting kit For direct attachment of the positioner a vent plug is located at t...

Page 25: ...accident preven tion regulations of the country of destination must be adhered to In Germany these are the VDE regu lations and accident prevention regulations of the employer s lia bility insurance F...

Page 26: ...minals The shield which is placed over the clamping insert is connected over a large area to the gland and housing 1 To connect the bus line loosen the coup ling nut and the clamping insert from the p...

Page 27: ...orced venting function a voltage of 6 to 24 V DC must be applied to the relevant terminals The forced venting function can be acti vated or deactivated over an internal switch See chapter 4 3 for more...

Page 28: ...located on the inside of the positioner hinged cover serve to enter the bus address as binary information The ad dress is made up with one switch directly as per numbers 1 2 4 etc or by adding up sev...

Page 29: ...C Control system Master Class 1 Segment coupler Display and control element Master Class 2 Termination Termination Controller PLC Control system Master Class 1 Display and control element Master Class...

Page 30: ...ror recognized control operation possible For details refer to the table below Description LED Device start up Red lights up No fault Device on the bus coldstart executed initialization required Initi...

Page 31: ...o desired position 1 ENABLED Function activated 2 DISABLED Function deactivated 4 4 Default setting All parameters are set to default values See chapter 8 on description of parameters NOTE Manual oper...

Page 32: ...During that time the valve changes its position There fore never initialize the positioner during a running process but only during the start up cycle when the shut off valves in the plant are closed...

Page 33: ...nly starts a zero calibration A new initialization routine can only be started after this when communication is connected A completed initialization can be cancelled via the communication with the com...

Page 34: ...he tag has entered the field has to be determined at the switching ampli fier if required Adjusting the switching point The limit switches are marked GW1 and GW2 on the inside of the case cover Yel lo...

Page 35: ...osion protection is based must be serviced the positioner must not be taken into operation again unless an ex pert has inspected the device according to the explosion protection requirements has issue...

Page 36: ...ave unit in this case the Type 3785 Positioner 7 2 DATA EXCHANGE According to the PROFIBUS PA device profile for electropneumatic actuators a total of 7 different cyclic parameter combinations is avai...

Page 37: ...action Octet 3 Fraction Octet 4 Fraction Octet 5 Octet 1 Octet 2 READBACK Value Floating Point IEEE Status POS_D Value POS_D Status Output value Output Byte 0 1 2 3 4 Octet 1 Sign Exponent Octet 2 Exp...

Page 38: ...loating Point IEEE Status POS_D Value POS_D Status CHECK_ BACK 0 CHECK_ BACK 1 CHECK_ BACK 2 Output value Output Byte 0 1 2 3 4 Octet 1 Sign Exponent Octet 2 Exponent Fraction Octet 3 Fraction Octet 4...

Page 39: ...ctet 3 Fraction Octet 4 Fraction Octet 5 READBACK Value Floating Point IEEE Status RCAS_OUT Value Floating Point IEEE Status Byte 10 11 12 13 14 Octet 1 Octet 2 Octet 1 Octet 2 Octet 3 POS_D Value POS...

Page 40: ...emains in the fail safe position determined by the actuator NOTE The RCAS operating mode is implemented in version K1 60 and higher READBACK Current position with status Controlled variable x The posi...

Page 41: ...standard diagnosis messages the positioner can provide more messages as Ext_Diag_Data These are encoded bit wise encoded as well and correspond to the PROFIBUS PA Diagnosis profile parameter Bit no N...

Page 42: ...Out of Service no valid value since the block is out of service Uncertain 64 Non specific value uncertain without more details 68 Last Usable Value value uncertain device operates with the last usabl...

Page 43: ...sitioner follows the acyclic set point entered via the par ameter OUT correction value according to the scale and unit mm or degrees entered via OUT_SCALE travel angle of rotation range With the chara...

Page 44: ...ameter Monitoring parameters FSAFE_TIME FSAFE_TYPE FSAFE _VALUE The action determined by the FSAFE_TYPE fail safe action parameter is triggered by the fol lowing events Start up of the positioner warm...

Page 45: ...tem extends Speed limit Transit time End position function End position at End position at Correction value Direction of action stem retracts Travel range relation Start End Reference variable range I...

Page 46: ...er DEVICEMAN_ID Valve manufacturer VALVE_MAN Actuator manufacturer ACTUATOR_MAN Type number positioner DEVICE_ID Serial number positioner DEVICE_SER_NUM Serial number of the corresponding actuator ACT...

Page 47: ...ransmission length TRANSM_LENGTH M Transmission pin position TRANSM_PIN_POS M Initialization method INIT_METHOD M Device setting Configuration Write protection WRITE_PROTECT_SWITCH M Reference variabl...

Page 48: ...BLK TARGET MODE Controlled variable x READBACK Reference variable w SP Reference variable w_rcas RCAS_IN RCAS_OUT Valve position feedback discrete POS_D Set point deviation e SETP_DEVIATION Correction...

Page 49: ...more details on attachments see also Chapters 2 1 and 2 2 States Default 0 Integral attachment in combination with a SAMSON Type 3277 Linear Actuator 1 NAMUR attachment according to DIN IEC 534 NAMUR...

Page 50: ...linear 7 Vetec rotary plug valve equal percentage 0 Characteristic type CHARACT_TYPE Text field 32 characters for a description of the adjusted characteristic Coldstart FACTORY_RESET States Default Co...

Page 51: ...lue Higher increments cause an increased deceleration before reaching the reference variable 0 0 to 1 00 0 12 Description DESCRIPTOR Available space for entering texts on the description of the applic...

Page 52: ...ariable falls below the entered limit the valve moves in the end position corresponding to 0 of the reference variable Hysteresis 1 When the value is 2 5 the function is deactivated 1 Caution Since th...

Page 53: ...variable entered under rated travel nominal angle is considered e g globe valve with mechanical stop on one side When the maximum range is initialized the maximum permissible range of the manipulated...

Page 54: ...With the characteristic deactivated this value corresponds to the actual valve position in mm or degrees The parameter INCREASE_CLOSE direction of action however is not processed Communication monito...

Page 55: ...tion for version K 1 30 and higher Positioner manufacturer DEVICE_MAN_ID Clearly identifies the manufacturer of the field device Read only Product number positioner DEVICE_PRODUCT_NUM M Manufacturer s...

Page 56: ...to use the host serves to check the access rights 16 bit unsigned integer format 0x2457 Serial no actuator ACTUATOR_SER_NUM Serial number of the positioner s corresponding actuator Length 16 character...

Page 57: ...control loop See also DELAY_TIME 0 1 to 10 0 5 Tolerated overshoot TOL_OVERSHOOT M Default If the set point deviation e exceeds the overshoot the pulse adaptation reduces the minimum pulses in the mov...

Page 58: ...4 mm 2 D2 lever 106 mm For rotary actuator Maximum opening angle of the selected cam disk segment installed 3 S90 90 degree segment 4 S120 120 degree segment 1 Transmission length TRANSM_LENGTH M Rang...

Page 59: ...feedback discrete POS_D States Discrete valve position feedback with status 0 Not initialized 1 Closed x 0 5 2 Open x 99 5 3 Intermediate Valve travel limit value TOT_VALVE_TRAV_LIM Default Total val...

Page 60: ...error mechanics This message is issued if during cyclic check a defect is detected in the mechanics module Repair required Memory checksum error This message is issued if the cyclic check determines t...

Page 61: ...Warmstart restart completed This message is displayed if the device was RESET via warmstart This RESET is carried out following a coldstart after an electrical power failure or by indicat ing DEVICE_...

Page 62: ...n fulfilled Invalid start values for min pulses range 1 The pulse search for the range 0 to 20 relative to the rated travel nominal angle has not been completed yet by adaption of the pulse pause rati...

Page 63: ...ls 81 and 82 is smaller than 3 V The control valve moves to fail safe position regardless of the control loop Automatic reset when a 6 V DC to 24 V DC signal is applied to terminals 81 and 82 Static d...

Page 64: ...fer to table on pages 38 39 Bit 7 is automatically reset whereas bit 13 is reset by means of the SELF_CALIB_CMD 10 command reset control loop fault Positioner inactive MODE out of service This message...

Page 65: ...hung For NAMUR attachment lever not correctly secured to the shaft of the adapter housing Connecting cable between logic and displacement sensor board disengaged Timeout The initialization routine ca...

Page 66: ...ac tion and zero by completely venting and exhausting the actuator In addition the routine checks whether the positioner can pass 100 rated travel nominal angle Initialization status Determining mini...

Page 67: ...sure too high Missing signal pressure throttle for actuators with small volumes Fault in the mechanics particularly with attachment according to IEC 60534 6 NAMUR In case a booster valve has been moun...

Page 68: ...Output 2 A2 Supply Z Output 38 Supply 9 M20 x1 5 Fulcrum of the driving shaft Reversing amplifier optional formerly PG 13 5 Dimensional diagram Attachment with intermediate piece for rotary actuators...

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Page 79: ...EB 8382 1 EN 79...

Page 80: ...SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de S Z 2003 03 Model 3785 xxx0 EB 8382 1 EN...

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