Type 3766 Pneumatic Positioner

Fig. 1: Type 3766 Pneumatic Positioner

Mounting and
Operating Instructions

EB 8355-1 EN
Edition November 2011
Definition of the signal words used in these mounting and operating instructions

DANGER! NOTICE
indicates a hazardous situation which, indicates a property damage mes-
if not avoided, will result in death or sage.
serious injury.
Note:
WARNING!  Supplementary explanations, informa-
indicates a hazardous situation which, tion and tips
if not avoided, could result in death or
serious injury.

2 EB 8355-1 EN
 Contents

1 General safety instructions..............................................................................5

2 Design and principle of operation...................................................................6
2.1 Versions and article code.................................................................................9
2.2 Technical data..............................................................................................10
3 Mounting on control valves...........................................................................12
3.1 Direct attachment to Type 3277 Actuator........................................................12
3.2 Attachment according to IEC 60534-6 (NAMUR)............................................19
3.2.1 Mounting sequence.......................................................................................20
3.2.2 Initial travel adjustment..................................................................................20
3.3 Attachment to rotary actuators.......................................................................23
3.3.1 Mounting the lever with feeler roll...................................................................24
3.3.2 Mounting the intermediate piece....................................................................24
3.3.3 Basic setting of the cam disk..........................................................................26
3.3.4 Reversing amplifier for double-acting actuators...............................................30
4 Connections.................................................................................................32
4.1 Pneumatic connections..................................................................................32
4.1.1 Pressure gauge.............................................................................................32
4.1.2 Supply pressure............................................................................................32
4.2 Electrical connections....................................................................................34
4.2.1 Switching amplifier.......................................................................................35
5 Operation....................................................................................................36
5.1 Tuning the positioner mounted on the control valve..........................................36
5.1.1 Adjusting the proportional band Xp and air delivery Q...................................37
5.1.2 Settings for actuator with “actuator stem extends” fail-safe action......................37
5.1.3 Settings for actuator with “actuator stem retracts” fail-safe action......................38
5.2 Changing the operating direction...................................................................39
5.3 Adjusting the limit switches............................................................................40
5.4 Adjusting the position transmitter...................................................................42
6 Upgrading the positioner..............................................................................44
7 Service........................................................................................................46
7.1 Servicing explosion-protected devices.............................................................46
7.2 Maintenance and calibration.........................................................................46
8 Dimensions in mm........................................................................................47

EB 8355-1 EN 3
 General safety instructions

1 General safety instructions

For your own safety, follow these instructions concerning the mounting, start up and opera-
tion of the positioner:
−− The positioner is to be mounted, started up or operated only by trained and experienced
personnel familiar with the product. According to these mounting and operating instruc-
tions, trained personnel refers to individuals who are able to judge the work they are as-
signed to and recognize possible dangers due to their specialized training, their knowledge
and experience as well as their knowledge of the applicable standards.
−− Any hazards that could be caused in the valve by the process medium, the signal pressure
or by moving parts are to be prevented by taking appropriate precautions.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure level, it must be restricted using a suitable supply pressure reducing station.
−− Explosion-protected versions of this device are to be operated only by personnel who has
undergone special training or instructions or who is authorized to work on explosion-pro-
tected devices in hazardous areas.
To avoid damage to any equipment, the following also applies:
−− Proper shipping and storage are assumed.

Note:
 Devices with a CE marking fulfill the requirements of the Directives 94/9/EC and
2004/108/EC. The Declaration of Conformity is available on request.

NOTICE
Models with index 3766-x...x.03 and higher are equipped with a hinged cover with-
out its own exhaust air hole.
The required exhaust air connection is now included in the mounting accessories.
If these positioners are mounted on older actuator models, make sure that there is an
exhaust air connection. If necessary, replace the mounting accessories as well.

EB 8355-1 EN 5
 Design and principle of operation

2 Design and principle of oper- and the nozzle (2.1, 2.2) and then hits the di-
aphragm lever (flapper plate).
ation
Any change in the reference variable or the
The pneumatic positioner is used to assign the valve position causes the pressure to change
valve position (controlled variable) to the in- upstream and downstream of the booster.
put signal (reference variable). The positioner
The air controlled by the booster (signal pres-
compares the control signal of a control sys-
sure pst) flows through the volume restriction
tem to the travel of the control valve and is-
(11) to the pneumatic actuator, causing the
sues a signal pressure (output variable) for the
plug stem to move to a position correspond-
pneumatic actuator.
ing to the reference variable.
The positioner consists of a lever for trav-
The adjustable Xp restriction (8) and volume
el pick-up, a measuring diaphragm and the
restriction (11) are used to optimize the posi-
pneumatic control system with nozzle, dia-
tioner control loop.
phragm lever (flapper plate) and booster.
The pick-up lever (1) and the range spring
The positioner is designed either for direct
(4) must be selected to match the rated valve
attachment to SAMSON Type 3277 Actua-
travel and the nominal span of the reference
tors or for attachment according to NAMUR
variable.
(IEC 60534-6-1) with an adapter housing.
The positioner can be additionally equipped Positioner with inductive limit switches
with either inductive limit switches and/or a In this version, the rotary shaft of the position-
solenoid valve or position transmitter. er carries two adjustable tags which actuate
the built-in proximity switches.
The positioner operates according to the
force-balance principle. The valve travel, i.e. Positioner with solenoid valve
the valve position, is transmitted to the pick- When the positioner is equipped with a so-
up lever (1) over the pin (1.1) and determines lenoid valve, the valve can be moved to the
the force of the range spring (4). This force fail-safe position regardless of the positioner's
is compared to the positioning force gener- output signal. If a control signal correspond-
ated by the pressure pe at the measuring di- ing to the binary signal '0' (OFF) is applied to
aphragm (5). the input, the signal pressure pst is shut off and
If either the control signal or the valve position the actuator is vented. The actuator springs
changes, the diaphragm lever (3) moves, al- move the valve to its fail-safe position.
tering the distance to the nozzle (2.1 or 2.2), When a control signal corresponding to the
depending on the adjusted operating direc- binary signal '1' (ON) is applied to the in-
tion of the positioner. put, the signal pressure pst is applied to the
The supply air is supplied to the booster (10) actuator, allowing the valve to move accord-
and the pressure regulator (9). The controlled ing to the input signal issued by the control
supply air flows through the Xp restriction (8) equipment.

6 EB 8355-1 EN
 Design and principle of operation

2.1
3

2.2

5 Travel
1

1.1 1.2
4 Pe
6.1 6.2
Supply
9
1 Lever 6.2 Zero adjuster
e
p V 1.1 Pin 7 Turnboard
1.2 Clamp 8 Xp restriction
Xp Q 2.1 Nozzle >> 9 Pressure regulator
Pst
2.2 Nozzle <> 10 Booster
3 Diaphragm lever 11 Volume restriction
4 Range spring 12 Solenoid valve (option)
7 8 9 10 11 12 5 Measuring diaphragm
6.1 Span adjuster

4 3 7 8 9 11

6.1 6.2

Fig. 2: Functional diagram and inside view

EB 8355-1 EN 7
 Design and principle of operation

Positioner with position transmitter The tuning of the position transmitter ensures
A positioner containing a position transmit- that both end positions "valve CLOSED" or
ter cannot be equipped with integrated limit "valve OPEN" as well as all intermediate po-
switches or an integrated solenoid valve since sitions can be signalized. Since the valve po-
the position transmitter requires most of the sition is signalized independently of the input
space inside. signal to the positioner, the position transmit-
ter is a suitable option for checking the actu-
The position transmitter is used to assign the
al valve position.
valve position, i.e. the valve travel, to an out-
put signal of 4 to 20 mA.

8 EB 8355-1 EN
 Design and principle of operation

2.1 Versions and article code

Pneumatic Positioner Type 3766- x x x 0 1 x x x x 1 x 0 x 0

Explosion protection
Without 0 2
II 2G Ex ia IIC T6 acc. to ATEX 1
CSA/FM intrinsically safe/non incendive 3
Ex ia/Ex n I/IIC T6 IP 65 IECEx TSA Australia 6
II 3G Ex nA II T6 acc. to ATEX 8
Additional equipment
Without 0
Inductive proximity switches 2x SJ 2-SN 2
(Analog position transmitter 4 to 20 mA) 1) 6 0 0
3/2-way solenoid valve
Without 0
6 V DC 2
12 V DC 3
24 V DC 4
Pneumatic connections
¼-18 NPT 1
ISO 228/1-G ¼ 2
Electrical connections
Without (no additional equipment or solenoid valve) 0 0 0 0
Plastic cable gland M20 x 1.5, blue 1 0 0
Plastic cable gland M20 x 1.5, black 2 0 0
Cable gland M20 x 1.5, nickel-plated brass 2 1 3
Body version
Die-cast aluminum 0
CrNiMo steel 2
Temperature range
Standard 0
Low-temperature version
 Tmin ≥ –50 °C; optional limit switches, solenoid valve 2 1 3
Special versions
Without 0 0 0
GOST approval 0Ex ia IIC T8 X 1 0 1 0

1)
Available until March 2011
Device functioning only as analog position transmitter: 3766-x60 000xxx00 000 0

EB 8355-1 EN 9
 Design and principle of operation

2.2 Technical data

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 angles 70°, 75° or 90° depending on the cam disk
Reference Signal range 0.2 to 1 bar (3 to 15 psi)
variable w
Span 0.4 to 0.8 bar (6 to 12 psi)
Overloadable Max. 2 bar (29 psi)
Supply air Supply air 1.4 to 6 bar / 20 to 90 psi
Air quality acc. to Maximum particle size and density: Class 4 · Oil content: Class 3
ISO 8573-1 Pressure dew point: Class 3 or at least 10 K below the lowest ambient
(edition 2001-02) 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 characteristic
Deviation of characteristic from terminal-based conformity: ≤ 1 %
Hysteresis ≤ 0.3 %
Sensitivity ≤ 0.1 %
Operating direction Reversible
Proportional band Xp 0.5 to 2.5 % (proportional-action coefficient Kp: > 200 to 40)
Air consumption At 1.4 bar supply pressure At 6 bar supply pressure
≤ 230 In/h ≤ 230 In/h 1)
Air output Actuator filled with air 3.0 mn3/h 8.5 mn3/h
capacity
Actuator vented 4.5 mn /h
3
14.0 mn3/h
Permissible Standard –20 to 80 °C: Optional limit switches/solenoid valve/position
ambient transmitter with plastic cable gland
temperature 2)
–40 to 80 °C: Optional limit switches/solenoid valve with metal cable
gland
Low-temperature –50 to 80 °C: Optional limit switches/solenoid valve with metal cable
version gland
Technical data in test certificates additionally apply to explosion-protected
devices
Influence Temperature: ≤ 0.3 %/10 K
Supply air: ≤ 1 % between 1.4 and 6 bar

10 EB 8355-1 EN
 Design and principle of operation

Electromagnetic compatibility According to EN 61000-6-2, EN 61000-6-3 and NAMUR Recommenda-

tion NE 21
Influence of vibrations None between 10 and 150 Hz and 4 g
Explosion protection Refer to article code or list of approvals in Data Sheet u T 8355 EN
Degree of protection IP 54 (IP 65 and NEMA 4X possible by fitting a filter check valve.
See table on accessories on page 17)
Weight Approx. 1 kg
Additional equipment
Limit switch
Two inductive proximity switches SJ 2-SN
Control circuit Values according to downstream transistor relay
Hysteresis at rated travel ≤1%
Solenoid valve
Input Binary DC voltage signal
Nominal signal 6 V DC 12 V DC 24 V DC

Signal '0' (no response) 3)

≤ 1.2 V ≤ 2.4 V ≤ 4.7 V

Signal '1' (response) 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 Ω 5832 Ω 11714 Ω

Air consumption in steady state In addition to that of the positioner: OFF ≤ 60 ln/h · ON ≤ 10 ln/h 1)
Closing time Type 3277 Actuator ≤ 120 cm² 240 cm² 350 cm² 700 cm²
for rated travel
0.2 to 1 bar ≤ 0.5 s ≤ 0.8 s ≤ 1.1 s ≤4s
and signal
pressure range 0.4 to 2 bar ≤ 0.5 s ≤2s ≤ 2.5 s ≤8s
(KVS 0.14)
0.6 to 3 bar 6)
≤1s ≤ 1.5 s ≤5s
Analog position transmitter 7)
Output Two-wire connection 4 to 20 mA
Power supply Minimum terminal voltage: 12 V, The position transmitter must
max.: 45 V only be connected to a certified
intrinsically safe circuit. 5)
1)
With lowest setting of pressure regulator
2)
The limits in the type examination certificate additionally apply for explosion-protected versions
3)
DC voltage signal at –25 °C
4)
DC voltage signal at +80 °C
5)
e.g. using a SAMSOMATIC Type 994-0103-KFD2-STC4-Ex1 Loop Isolator
6)
120 cm² actuator in all signal pressure ranges: ≤ 0.5 s
7)
Available until March 2011

EB 8355-1 EN 11
 Mounting on control valves

3 Mounting on control valves If the required operating direction does not

correspond to the visible symbol, or if you
The positioner can be mounted either directly want to change the operating direction, re-
to SAMSON Type 3277 Actuator or to control move the fastening screw at the turnboard,
valves with cast yokes or rod-type yokes ac- turn the board by 180° and refasten the turn-
cording to IEC 60534-6 (NAMUR). board. Make sure the three rubber gaskets in-
Combined with an intermediate piece, the po- serted in the housing remain in position.
sitioner can also be mounted on rotary ac-
tuators. The standard positioner is delivered NOTICE
without accessories. Any additionally required When any subsequent changes are
mounting parts are listed together with their made, e.g. reversing the operating
order numbers in the tables on the following direction of the positioner control loop
pages. or changing the actuator fail-safe ac-
Do not remove the protective cover on the tion from “actuator stem extends” to
back of the positioner until you actually start “actuator stem retracts” or vice ver-
to attach the positioner. sa, the positioner's mounting position
must be changed accordingly.
Mounting position and operating direction
The operating direction of the positioner also
determines its mounting position on the actu- 3.1 Direct attachment to
ator as illustrated in Fig. 3, Fig. 4 and Fig. 6. Type 3277 Actuator
The turnboard (7 in Fig. 2) at the positioner
must be mounted correspondingly. Note:
For an increasing input signal (reference vari-
 The required accessories are listed in
able), the signal pressure pst can either be in- Table 1 to Table 1 on page 16.
creasing (direct action >>) or decreasing (re-
verse action <>). Similarly, as the reference The attachment of the positioner either on
variable decreases the signal pressure can ei- the left or right side of the actuator (always
ther decrease (direct action >>) or increase looking onto the signal pressure connection
(reverse action <>). or switchover plate) is determined by the re-
quired operating direction of the positioner,
On the turnboard (7), the operating direction
i.e. >> or <>.
is indicated by symbols (direct >>, reverse
<>). Depending on the position of the turn-
board, the adjusted operating direction and
the associated symbol become visible.

12 EB 8355-1 EN
 Mounting on control valves

Actuator stem extends

Internal signal
Operating Operating
pressure connection
direction >> direction <>
Left attachment Connection block Right attachment
Tip of gasket (16)

Actuator stem retracts

Signal pressure
connection over piping

Operating
direction <> Operating
Left attachment direction >>
Right attachment

Side view of connection block

With gasket (new) With switch plate (old)

Cover
SUPPLY

Actuator stem extends

Marking Switch plate (13)

Gasket (16) Actuator stem retracts

Switchover plate Signal pressure input

With right
attachment

Actuator stem extends

Signal pressure >> Operating direction <>
input for left Left attachment Right attachment
attachment

Actuator stem retracts

Seal with <> Operating direction >>
filter Symbol Left attachment Right attachment
Marking

Fig. 3: Mounting position and connection of signal pressure for Type 3277 Actuator (top) and
Type 3277-5 Actuator (120 cm²) (bottom)

EB 8355-1 EN 13
 Mounting on control valves

1. Fasten the clamp (1.2) to the actuator and the actuator yoke. Fasten it using the
stem, making sure that the fastening screw screw.
rests in the groove of the actuator stem. For actuators with "actuator stem retracts"
2. Fasten the associated pick-up lever D1 or fail-safe action, additionally mount the ex-
D2 (with 355/700 cm² actuators) to the ternal signal pressure pipe.
feedback lever of the positioner. Actuator with 120 cm² diaphragm area
3. Secure the intermediate plate (15) with the The signal pressure is transmitted to the di-
gasket facing towards the actuator yoke. aphragm chamber over the switchover plate
4. Position the positioner such that the pick- (Fig. 3 and Fig. 4, bottom).
up lever slides in line over the pin (1.1) of 7. Remove screw plug on the back of the po-
the clamp (1.2). Fasten the positioner to sitioner (Fig. 5) and seal the side signal
the intermediate plate (15). pressure output with the stopper included
in the accessories.
5. Mount cover (16).
8. Mount the positioner so that the hole in the
6. Check whether the correct range spring
intermediate plate (15) covers the seal in
has been installed as listed in Table 4!
the hole of the actuator yoke.
Range spring 1 is installed as standard. If
necessary, replace it with range spring 2 9. Align the switchover plate with the corre-
included in the accessories and fix it at the sponding actuator symbol. Fasten it to the
outer hook-in holes. actuator yoke.

Actuators with 240, 350, 355 and 700 cm² NOTICE

diaphragm areas If a solenoid valve or a similar de-
vice is additionally mounted onto a
7. Make sure that the tip of the gasket (16)
120 cm² actuator, do not remove the
projecting from the side of the connec-
M3 screw plug at the back of posi-
tion block (Fig. 3, middle) is positioned
tioner. In this case, the signal pressure
to match the actuator symbol for the ac-
must be transmitted from the signal
tuator's fail-safe action "actuator stem ex-
pressure output to the actuator over an
tends" or "actuator stem retracts".
additional connecting plate (Table 2).
If this is not the case, unscrew the three
The switchover plate is not used in this
fastening screws and lift off the cover. Turn
case.
the gasket (16) by 180° and re-insert it.
The old connection block version requires
the switch plate (13) to be turned to align
the actuator symbol with the arrow mark-
ing.
8. Place the connection block with the as-
sociated gaskets against the positioner

14 EB 8355-1 EN
 Mounting on control valves

Air purging of the spring chamber effective diaphragm area of 120 cm², the ex-
If the spring chamber of the actuator is to be haust air from the positioner is connected to
purged with the exhaust air from the position- the spring chamber over an internal hole.
er, use piping (Table 3) to connect the spring
NOTICE
chamber (with "actuator stem extends" ver-
When the valve is installed, the side
sion) to the connection block. To do so, remove
cover of the actuator must be mounted
the stopper from the connection block. For an
such that the vent plug points down-
actuator with "actuator stem retracts" fail-safe
ward.
action and in Type 3277-5 Actuators with an

Type 3277 15
240 cm²
Vent plug
350 cm²
355 cm²
700 cm²

1.2
D2

D1

Cover

Left attachment Right attachment

View onto the signal pressure connection

Type 3277-5
Vent plug must point
120 cm²
downward when the
valve is installed
Intermediate plate (15)

Clamp (1.2)

Signal pressure
borehole

Switchover plate
Fig. 4: Mounting the clamp

EB 8355-1 EN 15
Mounting on control valves

Table 1:  Lever and dimensions Mounting kit

Actuator size Lever with associated clamp and intermediate plate Order no.
Standard version 1400-7116
120 cm² D1 lever with stopper for output (38)
Version compatible with paint 1402-0944

D1 lever Standard version 1400-6370

240/350 cm²
(33 mm long with 17 mm clamp) Version compatible with paint 1402-0942

D2 lever Standard version 1400-6371

355/700 cm²
(44 mm long with 13 mm clamp) Version compatible with paint 1402-0943
Table 2:  Switchover plates and connecting plates Order no.
Switchover plate (for 120 cm² actuator) Type 3277-5xxxxxx.00 Actuator (old) 1400-6819
New switchover plate Type 3277-5xxxxxx.01 Actuator (new) or higher 1400-6822
Connecting plate for additional attachment of Type 3277-5xxxxxx.00 Actuator (old), G 1/8 1400-6820
e.g. a solenoid valve Type 3277-5xxxxxx.00 Actuator (old), 1/8 NPT 1400-6821
Type 3277-5xxxxxx.01 Actuator (new) or higher,
New connecting plate 1400-6823
G 1/8 and 1/8 NPT
Note: Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates
are not interchangeable.
Required connection block for 240, 350, 355 and 700 cm² G¼ 1400-8819
actuator (including gaskets and fastening screw)
¼ NPT 1400-8812
Table 3:  Pipe connection Material Actuator size [cm²] Order no.
Required pipe connection including screw fitting Steel 240 1400-6444
Stainless steel 240 1400-6445
For actuator:
Steel 350 1400-6446
with "actuator stem retracts" fail-safe action
or Stainless steel 350 1400-6447
with air purging of the top diaphragm chamber
Steel 355/700 1400-6448
Stainless steel 355/700 1400-6449
Table 4:  Range spring Travel [mm] Actuator size [cm²] 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 15 355/700 1400-6443
1 30 355/700 1400-6442

16 EB 8355-1 EN
 Mounting on control valves

Accessories Order no.

G¼ 1400-7458
Pressure gauge mounting block (only for 120 cm²)
¼ NPT 1400-7459
Stainless steel/brass 1400-6950
Pressure gauge mounting kit for supply pressure and signal pressure Stainless steel/
1400-6951
stainless steel
Filter check valve, replaces vent plug and increases the degree of protection to IP 65
Polyamide,
1790-7408
IP 65 degree of protection
1.4301,
1790-7253
IP 65 degree of protection
Filter check valve in housing with G ¼ thread
Polyamide,
1790-9645
NEMA 4 degree of protection
1.4301,
1790-9646
NEMA 4 degree of protection
Assortment of spare parts including gaskets and diaphragms 1400-9895

EB 8355-1 EN 17
Mounting on control valves

18 EB 8355-1 EN
 Mounting on control valves

3.2 Attachment according to

IEC 60534-6 (NAMUR)
Required mounting parts are listed in Table 5.
The rated travel of the valve determines which
lever and range spring (Table 6) are required.
An adapter housing (Fig. 7) is required for at-
tachment. The valve travel is transmitted over
the lever (18) and shaft (25) to the bracket Spring Screw plug
(28) of the adapter housing and then passed
Fig. 5: Installing spring on the back of the housing
on to the pin (27a) located on the position-
er lever. To ensure that the pin (27a) is prop- The positioner can be mounted either on the
erly located in the bracket (28), fix the spring left or right side of the control valve (Fig. 6
included in the accessories at the back of the and Fig. 7). Turn the positioner at the adapt-
positioner housing as illustrated in Fig. 5. er housing by 180° to determine or change
the operating direction of the positioner/con-
trol valve unit.
Left attachment Right attachment
Mounting position on the plate looking onto the travel pick-up (20), actuator facing upward (see also Fig. 7)
Actuator with “actuator stem extends” (FA) fail-safe action
Direct operating Reverse operating Direct operating Reverse operating
direction >> direction <> direction >> direction <>

20

Input Output and supply Input

Actuator with “actuator stem retracts” (FE) fail-safe action

Direct operating Reverse operating Direct operating Reverse operating
direction >> direction <> direction >> direction <>

20

Output and supply Input Output and supply

Fig. 6: Attachment to the left or right of the valve for NAMUR attachment (IEC 60534-6)

EB 8355-1 EN 19
 Mounting on control valves

3.2.1 Mounting sequence when the positioner is attached with the

air connection at the front (Fig. 6).
Select the required mounting parts and range
6. Attach the lever (18) including clamping
spring from Table 4 or Table 5 and install
plate (22) to the shaft (25), making sure
them as illustrated in Fig. 7:
that the clip clasps the pin (19).
Valve with cast yoke
1. Screw the plate (20) to the stem connector 3.2.2 Initial travel adjustment
of the actuator and plug stems using the 1. Move the valve to 50 % travel.
countersunk screws.
2. Move the shaft (25) in the adapter hous-
Use the additional bracket (32) for 2100
ing so that the black pointer (24) matches
and 2800 cm² actuators.
the cast marking on the adapter housing.
2. Remove the rubber stopper from the
3. Fasten the clamping plate (22) in this po-
adapter housing and fasten the adapt-
sition using the screw (23).
er housing either on the left or right of
the NAMUR rib using the hexagon head 4. Screw the pin (27a) into the positioner le-
screw as shown in Fig. 6. ver on the side where the press nut is lo-
cated. Lock it in position with the hex nut
Valve with rod-type yoke on the other side, observing the mount-
1. Screw the plate (20) to the follower clamp ing position A or B according to Table 6
of the plug stem. and Fig. 7.
2. Screw the studs (29) into the adapter 5. Place the positioner on the adapter hous-
housing. ing, taking into account the mounting di-
3. Place the adapter housing with the plate rection. Fasten it, making sure that the pin
(30) onto either the left or right valve rod (27a) rests against the bracket (28).
and screw tight using the nut (31). Make NOTICE
sure that the adapter housing is at the The pin must not slip out of the brack-
correct height to mount the lever (18) so et once installed!
that it is in a horizontal position when the
valve is at mid-travel. 6. Check whether the correct range spring
4. Screw the pin (19) into the middle row of has been installed as listed in Table 5.
holes on the plate (20) and lock it into po- Range spring 1 is installed as standard. If
sition over the correct lever marking (1 or necessary, replace it with range spring 2
2) as indicated in Table 6. included in the accessories and fix it at the
5. Clamp the clip (21) onto the lever (18). outer hook-in holes.
The clip must be clamped onto the lever 7. Perform positioner settings as described in
(18) with the open side facing downward section 5.1.

20 EB 8355-1 EN
 Mounting on control valves

Mounting position

27b
A B

26 27a 28 Attachment to
NAMUR rib

1,5 2
1

24 25 22 23 19 21 20 18

32
18 Lever N1, N2
19 Pin
Attachment to
20 Plate
21 Clip
rods
22 Clamping plate
23 Screw
24 Pointer 31
25 Shaft 29
26 Lever of positioner 30
27a Pin
27b Lock nut
28 Bracket
29 Studs
30 Plate
31 Nuts
32 Mounting bracket
20 19

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

EB 8355-1 EN 21
 Mounting on control valves

Table 5:  Mounting kits Control valve Travel [mm] With lever Order no.
7.5 to 60 N1 (125 mm) 1400-6787
Valve with cast yoke
22.5 to 120 N2 (212 mm) 1400-6789
20 to 25 N1 1400-6436

NAMUR mounting kit 20 to 25 N2 1400-6437

Refer to Fig. 7 for parts. Rod diameter 25 to 30 N1 1400-6438
[mm] of rod-type
yoke 25 to 30 N2 1400-6439
30 to 35 N1 1400-6440
30 to 35 N2 1400-6441
1400-6771
Attachment to Fisher and Masoneilan linear actuators
and
(one of each mounting kits is required per actuator)
1400-6787
Additional range spring acc. to Range spring 1 (9.5 coils, installed as standard) 1400-6442
Table 6 Range spring 2 (4.5 coils) 1400-6443
Accessories Order no.
G¼ 1400-7458
Pressure gauge mounting block
¼ NPT 1400-7459
Stainless steel/brass 1400-6950
Pressure gauge kit
Stainless steel/stainless steel 1400-6951
Filter check valve, replaces vent plug and increases the degree of protection to IP 65
Polyamide,
1790-7408
IP 65 degree of protection
1.4301, IP 65 degree of protection 1790-7253
Filter check valve in housing with G ¼ thread Polyamide,
1790-9645
NEMA 4 degree of protection
1.4301,
1790-9646
NEMA 4 degree of protection
Assortment of spare parts including gaskets and diaphragms 1400-9895

Table 6:  Mounting position

Travel [mm] 1) 7.5 15 15 30 30 60 30 60 60 120
Pin at marking 1)
1 2 1 2 1 2 1 2 1 2
Distance between pin and lever fulcrum 42 to 84 mm 84 to 168 mm
With lever N1 (125 mm long) N2 (212 mm long)
Pin (27a) at position A A B A B
Required range spring (see Table 5) 2 1 1 1 1

1)
Calculate intermediate values

22 EB 8355-1 EN
 Mounting on control valves

3.3 Attachment to rotary actuators

The positioner can also be mounted on rotary pneumatic control unit of the positioner using
actuators according to VDI/VDE 3845 (Sep- the cam disk of the actuator shaft and a feel-
tember 2010) using the mounting parts list- er roll on the positioner lever.
ed in Table 7.
The rotary motion of these actuators is con-
verted into a linear motion required by the

Table 7:  Complete mounting parts, including range spring 2, but not including the cam disk Order no.
Actuator acc. to VDI/VDE 3845 (September 2010), level 1 1400-8815

SAMSON Type 3278 Actuator 160 cm² 1400-7103

VETEC Type S 320 cm² 1400-7104
VETEC Type R R 110 to R 250 1400-7117
Camflex I, DN 25 to 100 1400-7118
Attachment Masoneilan Camflex I, DN 125 to 250 1400-7119
Camflex II 1400-7120
Required range spring 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), 0 to 90° opening angle, also for
~, equal percentage basic characteristic 3) Type 3310
1400-6664
~, linear 1) (0050-0073), 0 to 90° opening angle
1400-6665
~, equal percentage 2) (0050-0080), 0 to 70° opening angle, for control
1400-6774
~, linear 1) butterfly valves
1400-6775
~, equal percentage 2) (0050-0081), 0 to 70° opening angle, for control
1400-6666
~, linear 1) butterfly valves
1400-6667
~, equal percentage 2) (0050-0074, VETEC), 0 to 75° opening angle
1400-6637
(0050-0075, VETEC), 0 to 75° opening angle
1400-6638
(0059-0007, Camflex) to be set between 0 and 55°
(0059-0008, Camflex) to be set between 0 and 55°
Accessories
See list on page 22

Linearizes the flow characteristic

1)

Creates an equal percentage flow characteristic

2)

Based on opening angle

3)

EB 8355-1 EN 23
 Mounting on control valves

NOTICE 3.3.1 Mounting the lever with

Check whether the correct range spring feeler roll
has been installed as listed in Table 7! 1. Place the lever with feeler roll (35) on the
Range spring 1 is installed as stan- side of the lever (37) opposite to where
dard. If necessary, replace it with the press nuts are located and secure it us-
range spring 2 included in the acces- ing the supplied screws (38) and washers.
sories and fix it at the outer hook-in
holes. NOTICE
To ensure a close physical contact be-
Double-acting springless rotary actuators re- tween the lever with feeler roll and the
quire the use of a reversing amplifier on the cam disk, attach the spring contained
connection side of the positioner housing (see in the accessories kit (order no. 1400-
section 3.3.4). 6660) to the back of the positioner
When using a reversing amplifier, the pres- housing (see Fig. 5).
sure regulator (9, Fig. 2) must be turned
clockwise as far as it will go (also see sec- 3.3.2 Mounting the intermedi-
tion 4.1.2).
ate piece
When attaching the positioner to the
SAMSON Type 3278 Rotary Actuator (Fig. 8, SAMSON Type 3278 Actuator
left), the inside of the actuator and the unused 1. Fasten the adapter (36) to the free shaft end
reverse side of the diaphragm are purged of the rotary actuator.
with the positioner's exhaust air. Additional 2. Fasten the intermediate piece (34) to the
piping is not required. actuator housing using two screws.
When attaching the positioner to actuators Align the intermediate piece so that the air
from other manufacturers (Fig. 8, right), the connections of the positioner point toward
reverse side of the diaphragm can be purged the diaphragm case side.
with air over a pipe connection installed be- 3. Align the cam disk (40) and scale (39) as
tween the actuator and intermediate piece. described in section 3.3.3 and fasten.

Actuators according to VDI/VDE 3845

(09/2010) (fixing level 1)
1. Place the assembled intermediate piece
(34, 44, 45 and 42) onto the mounting
bracket included in the scope of actuator
delivery and fasten.
2. Align the cam disk (40) and scale (39)
as described in section 3.3.3 and fasten.

24 EB 8355-1 EN
 Mounting on control valves

33

Attachment to
SAMSON Type 3278

37 35 38

Attachment according
to VDI/VDE 3845
39
(09/2010)
40
39 Vent plug or filter
40 check valve

34
34

36
44

45

42
33 Positioner
34 Intermediate piece 43
35 Lever with feeler roll
36 Adapter
37 Lever
38 Screws
39 Scale
40 Cam disk
42 Washer
43 Mounting bracket
44 Coupling
45 Seal

Fig. 8: Attachment to rotary actuators

EB 8355-1 EN 25
 Mounting on control valves

3.3.3 Basic setting of the cam Each cam disk carries two cam sections whose
starting points are indicated by small holes.
disk Depending on the operating direction of the
The valve model used determines the basic rotary actuator (air-to-open or air-to-close),
setting of the cam disk. the starting point of the cam, either marked
N (standard characteristic) or I (reverse char-
NOTICE acteristic), must point towards the lever with
Cam disks tailored to the special char- feeler roll. When the starting point is locat-
acteristic of a valve cause the valve to ed on the back of the cam disk, turn over the
open in a non-linear or non-equal cam disk.
percentage way.
The visible difference between the set NOTICE
point (4 to 20 mA) and the actual po- The starting point (hole) of the select-
sition (opening angle) does not con- ed cam must be aligned so that the
stitute a system deviation of the po- fulcrum of the cam disk and 0° po-
sitioner. sition on the scale as well as the ar-
row on the window are in line with
Fig. 9 and Fig. 10 show linear cam disks. each other.
Fig. 9 illustrates a control valve assembly with
a spring-loaded rotary actuator that opens When aligning the cam disk, clip the double-
counterclockwise. The arrangement of the sided scale disk on the cam disk, while mak-
springs in the actuator determines the fail- ing sure that the value on the scale matches
safe position of the valve. the valve's direction of rotation.

Fig. 10 shows how to adjust the cam disk NOTICE

when a double-acting springless rotary ac- Make sure the 0° position of the scale
tuator is used. The direction of rotation (ei- always corresponds to CLOSED posi-
ther counterclockwise or clockwise) depends tion.
on the actuator and valve model used. The Therefore, for fail-open actuators and
cam disk must be set when the valve is closed. for springless actuators, the maximum
Use the turnboard (7) to adjust the operat- supply pressure needs to be applied to
ing direction of the positioner, i.e. whether the the actuator before aligning the cam
valve opens or closes when the reference vari- disk.
able increases (direct >> or reverse <>).

26 EB 8355-1 EN
 Mounting on control valves

Single-acting rotary actuator with spring-return mechanism

Linear cam disk (equal percentage cam disk is represented by a broken and dotted line)
Control valve opens counterclockwise
For valves that open clockwise, the cam disk must be turned over so that lever with feeler roll moves
over the same disk segments as shown in the images below, but with the cam disk turning clockwise.
Fail-safe position: Fail-close valve
Direct operating direction >> Reverse operating direction <>
Reference Signal Reference Signal
Valve Characteristic Valve Characteristic
variable pressure variable pressure

increases increases opens N decreases increases opens I

Feeler roll Starting point I

Starting point N
Hole to secure the cam disk

90˚
90˚

60
60

Insert clip and press the flaps

˚
˚

30 30
˚ 0˚ outwards ˚ 0˚

Fail-safe position: Fail-open valve

Direct operating direction >> Reverse operating direction <>
Reference Signal Reference Signal
Valve Characteristic Valve Characteristic
variable pressure variable pressure

decreases decreases opens I increases decreases opens N

Feeler roll
Starting point I
Starting point N
90˚
90˚

60
60

˚
˚

30 30
˚ ˚ 0˚
0˚
Alignment at max. signal pressure

Fig. 9: Cam disk settings for single-acting actuators

EB 8355-1 EN 27
Mounting on control valves

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 shaft
Control valve opens counterclockwise – Based on a closed valve
Direct operating direction >> Reverse operating direction <>
Reference Charac- Reference Charac-
Signal pressure Valve Signal pressure Valve
variable teristic variable teristic
A1 increases, A1 increases,
increases opens N decreases opens I
A2 decreases A2 decreases

Feeler roll Starting point I

Starting point N
Hole to secure the cam disk

90˚
90˚

60
60

Insert clip and press the flaps

˚
˚

30 30
˚ 0˚ outwards ˚ 0˚

View from the positioner onto the actuator shaft

Control valve opens counterclockwise – Based on a closed valve
Direct operating direction >> Reverse operating direction <>
Reference Charac- Reference Charac-
Signal pressure Valve Signal pressure Valve
variable teristic variable teristic
A1 increases, A1 increases,
increases opens N decreases opens I
A2 decreases A2 decreases

Feeler roll Starting point I

Starting point N
90˚
90˚

60˚
60˚

˚ ˚
0˚ 30 0˚ 30

Fig. 10: Cam disk settings for double-acting actuators

28 EB 8355-1 EN
 Mounting on control valves

Securing the aligned cam disk

To prevent the cam disk from turning, drill a
hole into the adapter (36) or coupling (44) to
allow a 2 mm dowel pin to be inserted.
Select one of the four holes located around the
center hole of the cam disk to secure the cam
disk in position.

EB 8355-1 EN 29
 Mounting on control valves

3.3.4 Reversing amplifier for 3. Place the reversing amplifier onto the po-
sitioner and screw tight using the two spe-
double-acting actuators
cial screws (1.1).
For the use with double-acting actuators, the 4. Use a screwdriver (8 mm wide) to screw
positioner must be fitted with a reversing am- the enclosed filters (1.6) into the connec-
plifier, e.g. the SAMSON Type 3710 Revers- tion boreholes A1 and Z.
ing Amplifier (see Mounting and Operating
Instructions u EB 8392 EN). Signal pressure connections

The signal pressure of the positioner is sup- A1: Connect output A1 to the loading pressure
plied at the output A1 of the reversing ampli- connection on the actuator which causes the
fier. An opposing pressure, which equals the valve to open when the pressure rises.
required supply pressure when added to the A2: Connect output A2 to the loading pressure
pressure at A1, is applied at output A2. The connection on the actuator which causes the
rule A1 + A2 = Z applies. valve to close when the pressure rises.
If a different reversing amplifier (item no. Pressure gauge attachment
1079-1118 or 1079-1119) is used, follow
The mounting sequence shown in Fig. 11 re-
the mounting instructions described below:
mains unchanged. Screw a pressure gauge
Mounting bracket onto the connections A1 and Z.
Pressure gauge bracket G ¼ 1400-7106
NOTICE
¼ NPT 1400-7107
When using a reversing amplifier, the
pressure regulator (9) must be turned Pressure gauges for supply air Z and output
as far as it will go in the clockwise di- A1 as listed in Table 4, Table 5 and Table 7.
rection.
Remove the sealing plug (1.5) before
mounting the reversing amplifier. The
rubber seal (1.4) must remain installed.

1. Screw the special nuts (1.3) from the ac-

cessories of the reversing amplifier into the
threaded connections of the positioner.
2. Insert the gasket (1.2) into the recess of the
reversing amplifier and slide both the hol-
lowed special screws (1.1) into the con-
necting boreholes A1 and Z.

30 EB 8355-1 EN
 Mounting on control valves

From the positioner

Output 38 Supply 9

A1 Z

A2

Control signals to the actuator

1.3 1.1 1.2 1.4 1.5 1.6
A1 A2
1 Reversing amplifier
1.1 Special screws
1.2 Gasket
1.3 Special nuts
1.4 Rubber seal
1.5 Sealing plug
1.6 Filter
Supply 9

Z
Output 38

A1

1.3 1.2 1.1 1 1.6

Fig. 11: Mounting a reversing amplifier

EB 8355-1 EN 31
 Connections

4 Connections the intermediate piece or reversing amplifier

for attachment to rotary actuators.
4.1 Pneumatic connections NOTICE
The pneumatic connections are optionally de- If you intend to replace older mod-
signed as tapped holes with ¼ NPT or G ¼ els with index 3766-x...x.02 or low-
thread. Customary fittings for metal or copper er, the mounting parts may need to be
tubing or plastic hoses can be used. replaced as well.

NOTICE
The supply air must be dry and free 4.1.1 Pressure gauge
from oil and dust. The maintenance in- To precisely tune the positioner, we recom-
structions for upstream pressure reduc- mend installing pressure gauges for the sup-
ing stations must be observed. ply air and signal pressure.
Blow through all air pipes and hos-
The required parts are listed as accessories in
es thoroughly before connecting them.
Table 4, Table 5 and Table 7.

If the positioner is attached directly to the

Type  3277 Actuator, the connection of the
4.1.2 Supply pressure
positioner's output pressure to the actua- The required supply air pressure depends on
tor is fixed. For attachment according to the bench range and the actuator's operating
IEC 60534-6 (NAMUR), the signal pressure direction (fail-safe action).
can be routed to either the top or bottom di- The bench range is written on the nameplate
aphragm chamber of the actuator, depend- either as spring range or signal pressure
ing on the actuator's fail-safe action "actua- range. The operating direction is marked FA
tor stem extends" or "actuator stem retracts". or FE, or by a symbol.
Exhaust air Actuator stem extends (FA):
Models with index 3766-x...x.03 and high- Fail-close (for globe and angle valves):
er are equipped with a hinged cover without Required supply pressure =
its own exhaust air hole. The exhaust air con- Upper bench range value + 0.2 bar,
nections for these models are included in the at least 1.4 bar.
accessories.
The vent plug is located on the plastic cover
of the actuator for direct attachment, where-
as for NAMUR attachment, it is located on the
adapter housing. The vent plug is located on

32 EB 8355-1 EN
 Connections

Actuator stem retracts (FE):

Fail-open (for globe and angle valves):
For tight-closing valves, the maximum signal
pressure pstmax is roughly estimated as follows:
d² · π · ∆p
pstmax = F + [bar]
4·A

d = Seat diameter [cm]

∆p = Differential pressure across the valve
[bar]
A = Actuator diaphragm area [cm²]
F = Upper bench range value of the
actuator
If there are no specifications, calculate as fol-
lows:
Required supply pressure =
Upper bench range value + 1 bar
Pressure regulator
After tilting the cover plate back, the pressure
regulator (9) can be continuously adjusted.
When the adjuster is turned counterclockwise
as far as it will go, signal pressures for spring
ranges up to 2.5 bar are controlled. When the
adjuster is turned clockwise all the way, sig-
nal pressures for spring 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 a
pressure gauge (accessories).

EB 8355-1 EN 33
 Connections

4.2 Electrical connections The radial thickness of the insulation of a

conductor for common insulating materials
DANGER! (e.g. polyethylene) must not be smaller than
For electrical installation, observe the 0.2 mm.
relevant electrotechnical regulations The diameter of an individual wire in a fine-
and the accident prevention regula- stranded conductor must not be smaller than
tions that apply in the country of use. 0.1 mm. Protect the conductor ends against
In Germany, these are the VDE reg- splicing, e.g. by using wire-end ferrules.
ulations and the accident prevention When two separate cables are used for con-
regulations of the employers’ liability nection, an additional cable gland can be in-
insurance. stalled.
The following regulations apply to Seal cable entries left unused with plugs.
installation in hazardous areas: Fit equipment used in ambient temperatures
EN  60079-14: 2008 (VDE 0165, below –20 °C with metal cable entries.
Part 1) Explosive Atmospheres – Elec- Zone 2/zone 22
trical Installations Design, Selection
In equipment operated according to type of
and Erection.
protection Ex nA II (non-sparking equipment)
Adhere to the terminal assignment!
according to EN  60079-15: 2003, circuits
Switching the assignment of the elec-
may be connected, interrupted or switched
trical terminals may cause the explo-
while energized only during installation,
sion protection to become ineffective.
maintenance or repair.
Do not loosen enameled screws in or
Equipment connected to energy-limited cir-
on the housing. The maximum permis-
cuits with type of protection Ex nL according
sible values specified in the EC-type
to EN 60079-15: 2003 may be switched un-
examination certificates apply when
der normal operating conditions.
interconnecting intrinsically safe elec-
trical equipment (Ui or U0, li or I0, Pi or The maximum permissible values specified in
P0, Ci or C0 and Li or L0). the statement of conformity or its addenda
apply when interconnecting the equipment
with energy-limited circuits in type of pro-
Selecting cables and wires
tection Ex nL IIC.
Observe clause 12 of EN 60079-14: 2008
(VDE 0165, Part 1) for installation of the in-
trinsically safe circuits.
Clause 12.2.2.7 applies when running multi-
core cables and wires with more than one in-
trinsically safe circuit.

34 EB 8355-1 EN
 Connections

The wires for the reference variable must be Accessories:

connected to the terminals 11 and 12 locat- Cable gland M20 x 1.5
ed in the housing. Black plastic Order no. 1400-6985
In general, it is not necessary to connect the Blue plastic Order no. 1400-6986
positioner to a bonding conductor. Should this Nickel-plated brass Order no. 1890-4875
be required, however, this conductor can be Adapter M20x1.5 to ½ NPT:
connected inside the device or outside on the Powder-coated aluminum
device. Order no. 0310-2149
Depending on the version, the positioner is
4.2.1 Switching amplifier
equipped with inductive limit switches and/or
a solenoid valve. The operation of the inductive limit switches
Versions with position transmitter do not per- requires switching amplifiers in accordance
mit the connection of additional equipment. with EN 60947-5-6 to be connected in the
output circuit. Observe the relevant regula-
The position transmitter is operated on a
tions for installation in hazardous areas.
two-wire circuit. The usual supply voltage is
24 V DC.
Taking the resistance of the supply leads into
account, the voltage at the position transmitter
terminals can be between 12 and 45 V DC.
Refer to Fig. 12 or to the label on the termi-
nal block.

On the back Version with position transmitter

Ei (B) (A) Ei G
/A /A Ei
A B

+11 –12 +41 –42 +51 –52 +81 –82 +11 –12 +31 –32

+ – mA control A
Switching amplifier 6 to 24 V DC signal
acc. to EN 60947-5-6 solenoid valve + –
Transmitter supply voltage
for position transmitter only

Fig. 12: Electrical connections

EB 8355-1 EN 35
 Operation

5 Operation The reference variable range and thus the up-

per range value determine the travel of the
valve.
5.1 Tuning the positioner mount-
In split-range operation (Fig.  13, right), the
ed on the control valve control valves work with smaller reference
Starting point and reference variable variable ranges. The controller output signal
is used to control two control valves, dividing
When adjusting the positioner directly at the
it such that the valves move through their en-
control valve, the travel (opening angle) must
tire travel range at half the input signal range
be adapted to the reference variable.
each (e.g. first valve set to 0.2 to 0.6 bar, sec-
With a reference variable, for example, 0.2 ond valve set to 0.6 to 1 bar). To avoid over-
to 1 bar, the valve must move through its en- lapping, allow for a dead band of ± 0.05 bar
tire travel range from 0 to 100 % (Fig. 13, left). as shown in Fig. 13.
For positioners for rotary actuator, an opening The starting point (zero) is adjusted at the
angle, for example, 0 to 70° must be assigned zero adjuster (6.2); the span, i.e. the upper
to the reference variable. range value, is adjusted at the span adjust-
The starting point is based on the CLOSED po- er (6.1).
100%
<> <<
sition of the valve. During the adjustment, connect a suitable
Depending on the actuator version ("actuator pressure adjuster to the signal input and ap-
stem extends" or "actuator stem retracts") and ply air to the supply air input.
the operating direction of the positioner (>> or
<>), this starting point can be either the lower 0%
or upper range value (0.2 or 1 bar) of the ref- 0.2 1 bar
erence variable.

100% 100%
<> << <> <<
Open Open

Travel Travel

Closed Closed Valve 2 Valve 1

0% 0%
0.2 1 bar 0.2 0.6 1 bar
Reference variable Dead
Input signal band

Fig. 13: Normal

100%or split-range operation
<> <<

36 EB 8355-1 EN

0%
 Operation

5.1.1 Adjusting the proportion- 5.1.2 Settings for actuator with

al band Xp and air deliv- “actuator stem extends”
ery Q fail-safe action
1. Close the volume restriction (11) as far as NOTICE
the required positioning speed permits. To allow the valve to close with full
Check the positioning speed by pushing force, the diaphragm chamber must
the diaphragm lever (3) as far it will go. be fully vented when the reference
2. Adjust the reference variable at the input variable reaches its lower value (op-
to approx. 50 % of its range. erating direction <<) or upper value
3. Turn the zero adjuster (6.2) until the valve (operating direction <>).
has reached approx. mid-travel. As a result, adjust the input signal to
a slightly increased starting point of
4. Use the adjuster (8) to set the proportion-
0.23 bar for direct operating direction
al band Xp to a value half way (half turn).
<<; for reverse operating direction <>,
5. Check the valve's tendency to hunt and adjust the input signal to a slightly re-
the positioning speed by briefly tapping duced starting point of 0.97 bar.
the diaphragm lever (3).
The Xp value is to be adjusted to be as Starting point (e.g. 0.23 bar)
small as possible, without considerable 1. Adjust the input signal to 0.2 bar at the
overshooting occurring. pressure adjuster.
2. Turn the zero adjuster (6.2) until the valve
NOTICE
just starts to move from its initial position.
Always adjust the Xp restriction before
3. Reduce the input signal to 0 bar and slow-
setting the starting point.
ly increase it again. Check whether the
Changing it later will cause the zero
valve starts to move at exactly 0.23 bar.
point to be shifted!
Correct any deviation at the zero adjust-
er (6.2).

Upper range value (e.g. 1 bar)

1. Once the starting point has been set, in-
crease the input signal to 1  bar at the
pressure adjuster.
At exactly 1 bar, the plug stem must stand still,
having moved through 100 % travel (watch
the travel indicator at the valve).

EB 8355-1 EN 37
 Operation

If the upper range value is incorrect, turn the Starting point (e.g. 1 bar)
span adjuster (travel). Four turns correspond 1. Adjust the input signal to 1  bar at the
to a travel change of 10 % in standard opera- pressure adjuster.
tion. In split-range operation, this value is re-
2. Turn the zero adjuster (6.2) until the valve
duced by half.
just starts to move from its initial position.
Turn the adjuster clockwise to reduce the travel
3. Increase the input signal and slowly re-
and counterclockwise to increase it.
duce it again to 1 bar. Check whether the
2. After correction has been completed, re- valve starts to move at exactly 0.1 bar.
duce the input signal to 0 bar and slowly
4. Correct any deviation at the zero ad-
increase it again.
juster (6.2). Turning the adjuster coun-
Check the starting point and the upper
terclockwise causes the valve to move
range value.
from its end position earlier; turning
Repeat the correction procedure until both
clockwise causes the valve to move from
values are correct.
its end position later.

5.1.3 Settings for actuator with Upper range value (e.g. 0.2 bar)
“actuator stem retracts” 1. Once the starting point has been set, in-
fail-safe action crease the input signal to 0.2 bar at the
pressure adjuster.
NOTICE At exactly 0.2  bar, the plug stem must
When using an actuator with "ac- stand still, having moved through 100 %
tuator stem retracts" fail-safe ac- travel (watch the travel indicator at the
tion, the diaphragm chamber must valve).
be pressurized with a signal pressure 2. If the upper range value is incorrect, turn
high enough to tightly close the valve the span adjuster (travel). Four turns corre-
against the upstream pressure in the spond to a travel change of 10 % in stan-
plant. This applies to an upper range dard operation. In split-range operation,
value of the reference variable (1 bar) this value is reduced by half.
with operating direction >> as well as Turn the adjuster clockwise to reduce the
a lower range value of the reference travel and counterclockwise to increase it.
variable (0.2 bar) with operating di-
3. After the correction has been completed,
rection <>.
set the input signal to 1 bar again.
The required signal pressure is either indicat- 4. Turn the zero adjuster (6.2) again until the
ed on the positioner label or the required sup- pressure gauge indicates the required sig-
ply pressure can be roughly calculated as de- nal pressure (see section 4.1.2).
scribed in section 4.1.2.

38 EB 8355-1 EN
 Operation

5. If no pressure gauge has been installed, 5.2 Changing the operating di-
set the starting point to 0.97 bar instead.
rection
NOTICE If the operating direction of directly attached
After attaching and tuning of the po- positioners (Fig. 3) is to be changed after
sitioner, make sure that the vent plug they have been installed, turn the turnboard
of the housing cover faces downward (7) and change the position of the connection
when the valve is installed. block, positioner and clamp (1.2).
For attachment according to IEC  60534-6
(NAMUR), turn the turnboard (7) and the po-
sitioner on the adapter housing (Fig. 6).
In positioners for rotary actuators, reassign
the cam disk as shown in Fig. 9 and Fig. 10.
For details on changing the turnboard (7), re-
fer to section 3.

EB 8355-1 EN 39
 Operation

5.3 Adjusting the limit switches The terminals 41/42 and 51/52 can option-
ally be assigned to the switches A and B by
The positioner version with inductive limit turning the associated label on the terminal
switches has two adjustable tags mounted on block (also see Fig. 12).
a rotary shaft which operate the associated
proximity switches (50). NOTICE
The operation of the inductive limit switches The tags of the limit switches cannot
requires switching amplifiers to be connect- be turned by 360°. As a result, it is
ed in the output circuit. Refer to section 4.2.1. important to observe the correct as-
signment of switches A and B to the
When the tag (51) is located in the inductive
valve positions (valve CLOSED and
field of the switch, the switch assumes a high
valve OPEN), especially when the lim-
resistance. When it moves outside the field,
it switches are to be connected in safe-
the switch assumes a low resistance.
ty circuits.
The limit switches are usually adjusted to issue
a signal for both end positions. The switching The required switching function, i.e. wheth-
points can also be adjusted to indicate inter- er the output relay is to be picked up or re-
mediate positions. leased when the tag enters the field, must be
The switches A and B must be assigned to the determined by jumpers for either load current
end positions of the control valve (valve OPEN or no-load current at the isolating switch am-
or CLOSED) depending on the operating di- plifier.
rection and the mounting position according
to Table 8 and Table 9.

Fig. 14: Limit switches

40 EB 8355-1 EN
 Operation

Adjusting the switching point

Move the valve to the switching point and ad-
just the tag by turning the adjustment screw
(53) so that the switching point is reached and
indicated by the LED on the switching ampli-
fier.
To guarantee the switching under all ambi-
ent conditions, adjust the switching point ap-
prox. 2 % before the mechanical stop (OPEN
– CLOSED).

NOTICE
After tuning the positioner, make sure
that the vent plug of the housing cov-
er faces downward when the valve is
installed.

Table 8:  Direct attachment to Type 3277 Actuator (Fig. 3)

Left attachment Right attachment

Switch
Valve position Tag outside inductive Tag inside inductive Tag outside inductive Tag inside inductive
field field field field
Closed B A A B
Open A B B A

Table 9:  Right or left attachment according to NAMUR (Fig. 6) and attachment to rotary actuators (Fig. 8)
Actuator stem extends (FA) Actuator stem retracts (FE)
Operat- Switch Switch
Valve
ing di- Tag Tag
position
rection
Outside inductive Outside inductive
Inside inductive field Inside inductive field
field field
>> Closed B A A B
Open A B B A
<> Closed A B B A
Open B A A B

EB 8355-1 EN 41
 Operation

5.4 Adjusting the position Zero point

transmitter Use the switches 1 and 2 to roughly set the ze-

ro point and the ZERO potentiometer for fine-
NOTICE tuning. The adjusted value is always based on
The starting point (zero) and upper a 4 mA signal.
range value (span) must be set before Span
calibrating the position transmitter.
Use the switches 3 and 4 to roughly set the
span, i.e. the upper range value, and the
Depending on the position of the four-pin con-
SPAN potentiometer for fine-tuning. The ad-
nector (symbol on connector: >> or <>), the
justed value is always based on a 20 mA sig-
feedback signal can be set to either a range
nal.
of 4 to 20 mA or 20 to 4 mA for 0 to 100 %
travel.
Example:
Move the valve to the open position while ob-
serving the position transmitter signal.
If the signal does not move in the desired di-
rection, change the position of the multi-pin
connector.
Adjust the zero point (4  mA) and span
(20 mA) for the valve positions according to
Table 10.
Fig. 15: Position transmitter

Table 10:  Position transmitter

Valve movement Observed feedback signal Direction of signal Set zero/span to

20 mA Valve OPEN
OK
  4 mA Valve CLOSED
Signal increases á Not OK   4 mA Valve OPEN
à Change connector's   20 mA Valve CLOSED
Open
position
á
  4 mA Valve OPEN
Closed OK
  20 mA Valve CLOSED
Signal drops â Not OK 20 mA Valve OPEN
à Change connector's   4 mA Valve CLOSED
position

42 EB 8355-1 EN
 Operation

Zero point adjustment

Note:
1. Use the input signal of the positioner to
move the valve to closed position (valve
 The following applies to positioners
with adapter housing for NAMUR at-
CLOSED – travel 0 %).
tachment:
2. The ammeter must now indicate approx. When the positioner and the position
4 mA. transmitter signal have different oper-
3. Correct smaller deviations at the ZERO po- ating directions (<< and <>), it may
tentiometer until the meter shows exactly be impossible to adjust the zero point
4 mA. of the transmitter signal due to the
For larger deviations that cannot be cor- additional deflection caused by the
rected using the potentiometer (adjustment bracket (28) of the adapter housing.
range of approx. 20 turns), set the switch- In this case, readjust the black pointer
es 1 and 2 to indicate an mA signal which (section 3.2.2 on page 20) so that
is within the adjustment range of the ZERO the sensor of the position transmitter
potentiometer. reaches the control range.
4. Set the zero point to exactly 4 mA using the Unscrew the clamp. For “actuator stem
ZERO potentiometer. extends” (FA), shift the pointer up-
ward towards the actuator; for "actu-
Adjusting the span ator stem retracts" (FE), shift the point-
1. Use the input signal of the positioner to er downward towards the valve. For
move the valve to closed position (valve valves with rod-type yoke, slightly shift
CLOSED – travel 100 %). the positioner on the rod in the down-
2. The ammeter must now indicate approx. ward (FE) or upward (FA) direction.
20 mA.
3. Correct smaller deviations at the SPAN po- NOTICE
tentiometer until the meter shows exactly Every time you make a change as de-
20 mA. scribed above, the zero point and span
If deviations are too high, set the switches of the positioner must be readjusted
3 and 4 to indicate an mA signal which is before adjusting the position transmit-
within the adjustment range of the SPAN ter.
potentiometer. After tuning the positioner, make sure
that the vent plug of the housing cov-
4. Turn the SPAN potentiometer until the am-
er faces downward when the valve is
meter shows exactly 20 mA.
installed.
Since the zero point and span have a mu-
tual influence on each other, repeat the cor-
rection procedure at both potentiometers
until both values are correct.

EB 8355-1 EN 43
 Upgrading the positioner

6 Upgrading the positioner Note:

The pneumatic positioner (3766-x...x.04 and
 For details on Type 3767 Positioners,
higher) can be converted to form a Type 3767 refer to Mounting and Operating In-
Electropneumatic Positioner. structions u EB 8355-2 EN.

NOTICE
Upgrade of explosion-protected ver-
sions only on request.

Besides the Type 6112 i/p Module (see Ta- 1 2 3 4

ble 11 ), the associated conversion kit (includ-
ing cable gland, fastening screw, clamps and
cables) must be ordered.
1. Remove the holder with the terminal block
(if used).
2. Unscrew the connecting plate (3) and re-
move the silicone hose (2).
Remove the guard plate (4) and pneumat- 5 6 7 8
ic screw fitting (1).
3. Connect the connecting cable to the ter-
minal block and the i/p module (6). Lead
the blue cable to the minus side and the
red cable to the plus side. Fasten the ca-
bles with terminal screws.
4. Check whether the seals (7, 8) are prop-
erly inserted on the bottom section of the
i/p module. When the module is installed
(broken line in Fig. 16), the seal including
restriction and filter must be located on the
right above the inner hole (supply). Fig. 16: Upgrading the positioner

5. Fasten the i/p module and terminal block

holder each with two screws.
6. Seal the housing on the side using the ca-
ble gland (5) or a stopper with seal.
7. Change model index on the nameplate to
Type 3767 i/p Positioner.

44 EB 8355-1 EN
 Upgrading the positioner

Table 11:  Conversion kits

Required input signal Required i/p module Required upgrade kit
(reference variable) (order no.) (order no.)
4 to 20 mA 6112-041110 1400-7574
0 to 20 mA 6112-042110
1 to 5 mA 6112-043110

EB 8355-1 EN 45
 Service

7 Service 7.2 Maintenance and calibra-

tion
7.1 Servicing explosion-pro-
Interconnection with intrinsically safe circuits
tected devices to check or calibrate the equipment inside or
If a part of the device on which the explosion outside hazardous areas is to be performed
protection is based needs to be serviced, the only with intrinsically safe current/voltage cal-
device must not be put back into operation un- ibrators and measuring instruments to rule out
til a qualified inspector has assessed it accord- any damage to components relevant to explo-
ing to explosion protection requirements, has sion protection.
issued an inspection certificate or given the Observe the maximum permissible values
device a mark of conformity. specified in the certificates for intrinsically
Inspection by a qualified inspector is not re- safe circuits.
quired if the manufacturer performs a routine
test on the device before putting it back into
operation. Document the passing of the rou-
tine test by attaching a mark of conformity to
the device.
Replace explosion-protected components on-
ly by original, routine-tested components pro-
vided by the manufacturer.
Devices that have already been used outside
hazardous areas and are intended for fu-
ture use inside hazardous areas must comply
with the safety requirements placed on ser-
viced devices. Before being operated inside
hazardous areas, test the devices according
to the specifications for servicing explosion-
protected devices. Observe EN  60079-17
during servicing.

46 EB 8355-1 EN
 Dimensions in mm

8 Dimensions in mm

Pneumatic connections
185

G ¼ or ¼ NPT

M20 x 1.5
68

19.5
164 29 14 Output (38)
76
37

Input signal 150 28 Supply (9)

Reversing amplifier
(optional)
68
35
39

36
44

50
19.5

N1=113
Ø110 N2=200
56 58
Attachment IEC 60534-6
(NAMUR) with adapter housing
Attachment with intermediate
piece for rotary actuators Pneumatic connection
reversing amplifier
50 82
Fulcrum of
actuator shaft Output 1 (A1)
28.5
46

56

28.5
76
50

66

164 Output 2 (A2)

Supply (Z)

EB 8355-1 EN 47
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EB 8355-1 EN
Ptb15 Ex n.doc Ptb15 Ex n.doc
EB 8355-1 EN 53
54 EB 8355-1 EN
 ,transm itter

EB 8355-1 EN 55
56 EB 8355-1 EN
EB 8355-1 EN 57
 ,transm itter

58 EB 8355-1 EN
EB 8355-1 EN 59
SAMSON AG · MESS- UND REGELTECHNIK
2014-03-28

Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany

Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de EB 8355-1 EN