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- Samson
- Valve Positioners
- 3785 series
- Mounting And Operating Instructions
Samson 3785 series Mounting And Operating Instructions
Summary of 3785 series
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Profibus positioner type 3785 pa device profile version 2.0 mounting and operating instructions eb 8382-1 en firmware version r 1.4x/k 1.6x edition july 2004 fig. 1 · type 3785 profibus positioner.
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Contents page 1 design and principle of operation . . . . . . . . . . . . . . . . . . . 8 1.1 optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2 communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2 attaching the positioner . . . . . . . . . . . . . ....
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7 how to implement a class 1 profibus master . . . . . . . . . . . . 36 7.1 device database files (gsd) . . . . . . . . . . . . . . . . . . . . . . 36 7.2 data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 7.3 parameter description . . . . . . . . . . . . . . . . . . . . . . . ...
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Modifications of the firmware compared to the previous version old new control r 1.23 r 1.31 firmware adaptation for a new hardware version hardware version device index .01 control r 1.31 r 1.4 actuator type when the actuator type is switched from "linear actuator" to "rotary actua- tor", the follo...
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Control r 1.41 r 1.42 correction when zero calibration was triggered by communication. Communication k 1.34 k 1.41 firmware adaptation for new hardware version hardware version device index .01 communication 1.41 k 1.51 bit 7 of the checkback parameter indicates the current status of control loop mo...
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Positioner travel direct attachment type 3277 acc. To iec 60534-6 (namur) adjustable 5 mm to 30 mm 5 mm to 255 mm or 30° to 120° for rotary actuators bus connection fieldbus interface according to iec 61158-2 field unit according to fisco (fieldbus intrinsically safe concept) permissible operating v...
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Forced venting input k v coefficient to be activated using switch inside the positioner 6 to 24 v dc, static destruction limit 45 v r i approx. 6 k Ω at 24 v dc (depending on voltage) switching point for "1" signal at ≥ 3 v, switching point for "0" signal only at 0 v 0.17 communication data transmis...
Page 8: Tion
1 design and principle of opera- tion the digital profibus-pa positioner is de- signed for attachment to pneumatic control valves. It is used to assign the valve stem po- sition (controlled variable) to the control sig- nal (reference variable). It compares the digi- tal output signal to the travel ...
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Din en 50170 and din 19245, part 4. Data is transmitted as bit-synchronous cur- rent modulation at a transmission rate of 31.25 kbit/s over twisted-pair cables ac- cording to iec 61158-2. Positioners are gen- erally set up using a pc. One or more positioners are connected to the pc's profibus segmen...
Page 10: Attaching The Positioner
2 attaching the positioner the positioner can be attached either directly to a samson type 3277 actuator or ac- cording to namur (iec 60534-6) to control valves with cast yokes or rod-type yokes. In combination with an intermediate piece, the positioner can also be attached as a ro- tary positioner ...
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Eb 8382-1 en 11 attaching the positioner suppl y 18 17 19 1.2 d2 d1 17 16 15 1.2 16 17 15 fig. 3 · attachment and signal pressure connection for types 3277 (top) and 3277-5 with 120 cm² (bottom) 1.2 clamp d1 lever d2 lever 15 distance plate 16 cover 17 seal 18 cover plate 19 switch plate actuator st...
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240, 350 and 700 cm² actuators 6. Check whether the tongue of the seal (17) is properly aligned at the side of the connection block with the actuator symbol "actuator stem extends" or "actu- ator stem retracts" to match the actuator version used. If it does not match, remove the three fastening scre...
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Table 1 required lever with associated clamp and distance plate actuator size cm² mounting kit order no. D1 (33 mm in length with clamp, 17 mm in height) 120 (g ¼) 120 (¼ npt) 1400-6790 1400-6791 d1 (33 mm in length with clamp, 17 mm in height) 240 and 350 1400-6370 d2 (44 mm in length with clamp, 1...
Page 14: 2.2 Attachment According to
2.2 attachment according to iec 60534-6 for selection of the required mounting parts, refer to tables 4 and 5 on page 17. For positioner attachment according to namur as shown in fig. 4, an adapter housing is required. The valve travel is trans- mitted over the lever (18) and shaft (25) to the brack...
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Eb 8382-1 en 15 attaching the positioner 2 1,5 1 28 26 a b 24 25 22 32 31 20 19 19 21 20 23 18 27b 27a 29 30 fig. 4 · attachment according to iec 60534-6 (namur) mounting position attachment to namur rib attachment to rods 18 lever n1, n2 19 pin 20 plate 21 clamp 22 clamping plate 23 screw 24 pointe...
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5. Measure distance between the center of the shaft (25) and the center of the pin (19). This value must later be entered when configuring the positioner. 2.2.2 presetting the valve travel 1. Adjust shaft (25) in the adapter housing so that the black pointer (24) is aligned with the cast marking on ...
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Table 4 attachment iec 60534-6 control valve travel [mm] with lever order no. Namur mounting kit parts, see fig. 4 valve with cast yoke 7.5 to 60 n1 (125 mm) 1400-6787 30 to 120 n2 (212 mm) 1400-6789 valve with rod-type yoke, rod diame- ter [mm] 20 to 25 n1 1400-6436 20 to 25 n2 1400-6437 25 to 30 n...
Page 18: Roll Lever
2.3 attachment to rotary actuators for selection of the required mounting parts, refer to table 6 on page 21. The positioner can also be attached to rotary actuators in accordance with vdi/vde 3845 using the mounting parts and accessories listed in table 6. In this arrangement, the ac- tuator's rota...
Page 19
Eb 8382-1 en 19 attaching the positioner 33 38 35 39 39 40 34 36 40 34 44 45 42 43 37 fig. 5 · attachment to rotary actuators attachment to samson type 3278 actuator attachment acc. To vdi/vde 3845 vent plug or filter check valve 33 positioner 34 intermediate piece 35 lever with cam follower roll 36...
Page 20: Cam Disk
2.3.3 aligning and mounting the cam disk in rotary actuators with spring-return mecha- nism, the built-in actuator springs determine the fail-safe position and the direction of ro- tation of the control valve (clockwise, counterclockwise). With double-acting, springless rotary actua- tors, the direc...
Page 21
Table 6 rotary actuators (complete mounting parts, but without cam disk) attachment acc. To vdi/vde 3845, level 1 samson type 3278 actuator attachment to masoneilan actuators 160 cm² actuator 320 cm² actuator camflex i dn 25 to 100 camflex i dn 125 to 250 camflex ii order no. 1400-8815 1400-7103 140...
Page 22: Ble-Acting Actuators
2.3.4 reversing amplifiers for dou- ble-acting actuators for the use with double-acting actuators, the positioner must be fitted with a reversing am- plifier. The reversing amplifier is listed as an accessory in table 6 on page 21. The signal pressure of the positioner is sup- plied at output a1 of ...
Page 23
Eb 8382-1 en 23 attaching the positioner 1.3 1.2 1.1 1 output 38 supply 9 a 1 1.5 1.6 z a 2 1.4 a 1 a 2 output 38 supply 9 1.3 1.2 1.1 1.6 z a 1 fig. 7 · mounting a reversing amplifier from the positioner control signals to the actuator 1 reversing amplifier 1.1 special screws 1.2 gasket 1.3 special...
Page 24: Connections
3 connections 3.1 pneumatic connections the air connections are either ¼ npt or g ¼ tapped holes. Common fittings for metal and copper tubes or plastic hoses can be used. Important! The supply air must be dry and free of oil and dust. The maintenance instructions for upstream pressure reducing stati...
Page 25: 3.1.2 Supply Air Pressure
3.1.2 supply air pressure the required supply air pressure depends on the bench range and the operating direction (fail-safe action) of the actuator. The bench range is indicated on the nameplate as a spring range or signal pressure range. Actuator stem extends: required supply air pressure = upper ...
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Note on the selection of cables and wires to run several intrinsically safe circuits in one multi-core cable, observe section 12 of en 60079-14; vde 0165:1998. Note especially that, for commonly used in- sulating materials such as polyethylene, the radial thickness of the conductor insulation must b...
Page 27: 3.2.1 Forced Venting
Refer to profibus-pa user and installation guideline (profibus user organization document 2.091) for further information. At the binary input, a passive floating con- tact can be used. The positioner signals the circuit's state using the bus protocol. Important! The connection of limit switches, bin...
Page 28: 3.2.2 Limit Switches
3.2.2 limit switches switching amplifiers have to be connected in the output circuit to operate limit switches. To ensure operational safety of the positioner, these switching amplifiers must comply with the limits of the control circuit according to namur. Observe the relevant regulations if the po...
Page 29
Eb 8382-1 en 29 connections profibus-dp(e) rs 485 3785 3785 3785 3785 profibus-pa iec 61158-2 profibus-dp rs 485 3785-1 3785-1 3785-1 3785-1 profibus-pa iec 61158-2 profibus-dp(e) rs 485 profibus-dp rs 485 fig. 10 · profibus connection controller/plc/control system (class 1 master) display and contr...
Page 30: Operation
4 operation warning! Before putting the positioner into op- eration, carefully move the control valve to its end position by covering the hole (manually) on the cover plate (fig. 11). Check whether the lever mechanism functions properly. If the maximum angle of rotation is exceeded by selecting the ...
Page 31: 4.2 Write Protection
4.2 write protection a microswitch marked "write protection" is located to the right of the seven bus address selector switches inside the hinged cover. When it is activated (position on), the positioner settings are write-protected so that they cannot be overwritten by the profibus communication pr...
Page 32: 4.4.2 Initialization
4.4.1 adjusting mechanical zero important! Zero must be adjusted with the valve closed (for three-way valves with the actuator stem extended). 4 firmly push the zero point lever, which is located on the cover plate of the positioner, once in the direction indicated by the arrow as far as it will go....
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4 set delay time to at least 30 s. 4 enter tag identification. 4 if necessary, configure the positioner further, e.G. Special characteristics for ro- tary valves. If no communication can be established on the valve , the positioner can also be initial- ized directly on the device itself. 4 connect p...
Page 34: Switches
4.5 adjusting the inductive limit switches the positioner version with inductive limit switches has two adjustable metal tags that are mounted on the shaft of the positioner le- ver and operate the associated proximity switches. Connect appropriate switching amplifiers to the output circuit to opera...
Page 35: Maintenance
5 maintenance the positioner is maintenance free. Pneumatic connection 9/supply contains a filter with a mesh size of 100 µm. Remove and clean the filter, if required. Observe the maintenance instructions for up- stream pressure reducing stations for supply air, if applicable. 6 servicing explosion-...
Page 36: 7.2 Data Exchange
7 how to implement a class 1 profibus master 7.1 device database files (gsd) the device data are provided as a text file (sams3785.Gsd). It is available from samson ag under order no. 1400-7417 on a 3½" 1.44 mb floppy disk or on the internet at http://www.Samson.De or http: //www.Profibus.Com. The d...
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Output value (output) byte 0 1 2 3 4 octet 1 sign, exponent octet 2 exponent, fraction octet 3 fraction octet 4 fraction octet 5 rcas_in, value (floating point, ieee) status variant 3: module = readback + pos_d, sp; 0x96, 0xa4 input value (input) byte 0 1 2 3 4 5 6 octet 1 sign, exponent octet 2 exp...
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Output value (output) byte 0 1 2 3 4 octet 1 sign, exponent octet 2 exponent, fraction octet 3 fraction octet 4 fraction octet 5 sp, value (floating point, ieee) status variant 5: module = readback + pos_d + checkback, sp; 0x99, 0xa4 input value (input) byte 0 1 2 3 4 5 6 7 8 9 octet 1 sign, ex- pon...
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Output value (output) byte 0 1 2 3 4 octet 1 sign, exponent octet 2 exponent, fraction octet 3 fraction octet 4 fraction octet 5 rcas_in, value (floating point, ieee) status variant 7: module = readback + rcas_out + pos_d + checkback, sp + rcas_in; 0x9e, 0xa9 input value (input) byte 0 1 2 3 4 5 6 7...
Page 40: 7.3 Parameter Description
7.3 parameter description sp – set point with status: reference variable w in "auto" operating mode the reference variable w of the positioner is preset by sp in automatic mode (auto). Sp consists of a floating point value (4 bytes) and the associated status (1 byte). Value and status must be transf...
Page 41
11 cb_simulate simulation mode, i.E. Value are not derived from the process 1 12 cb_disturbance error, refer to diagnosis parameter for cause 13 cb_contr_err error in internal positioner control loop (to be con- firmed by class 2 master), indicated by led, reset au- tomatically when control loop mon...
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7.4 coding of measured value status measured value status the following status codes are used by the type 3785 positioner: bad value is valid substatus condition decimal value configuration error error in device configuration, value cannot be determined 4 device failure device error: memory, electro...
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Good (non-cascade) value is valid substatus condition value ok everything ok, no other status available 128 maintenance required transit time monitoring active, zero point error ac- tive or total valve travel exceeded 164 set point status good (non-cascade) substatus condition value ok everything ok...
Page 44: 7.5 Operating Modes
7.5 operating modes possible operating modes the following operating modes are defined in the ao (analog output) profile: 4 automatic (auto) 4 manual (man) 4 remote cascade (rcas) 4 local override (lo) 4 out of service (os) the type 3785 positioner supports the following operating modes: up to firmw...
Page 45
Eb 8382-1 en 45 w_man configuration block diagram start end reference variable range direction of action correction value speed limit travel limit travel adapt. > end pos. At end pos. At end position function supply valve exhaust valve fail-safe position control characteristic fail-safe action "stem...
Page 46
Start-up (warm start) the response of the positioner to a warm start is determined by the fsafe_type parameter (fail-safe action). If fsafe_type is set to "control to fail-safe value", the positioner switches to automatic oper- ating mode and adjusts to the value determined by the fsafe_value parame...
Page 47: List of Parameters
8 list of parameters below is an overview of parameters ordered by their fields of application. The list of parameters following the overview is in alphabetical order and describes all positioner parameters that can be displayed or modified using profibus communication, e.G. On a pc. Manufacturer-sp...
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Start-up security locking . . . . . . . . . . . . . . . . . . . Security_locking cold start . . . . . . . . . . . . . . . . . . . . . . Factory_reset warm start . . . . . . . . . . . . . . . . . . . . . Device_reset_cmd actuator type . . . . . . . . . . . . . . . . . . . . Actuator_type valve type ....
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End pos. When reference variable is below limit value . Setp_cutoff_dec end pos. When reference variable is above limit value . Setp_cutoff_inc selection of characteristic . . . . . . . . . . . . . . Charact type of characteristic . . . . . . . . . . . . . . . . Charact_type control parameters propo...
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List of parameters actuator type actuator_type states: default: identifies the actuator design read-only parameter, determined by actuator 0 = electropneumatic 1 = electric 2 = electrohydraulic 3 = other 0 actuator version actuator_version (m) states: default: specifies the actuator version with/wit...
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Calibration, status self_calib_status states: indicates manufacturer-specific status of calibration procedure started with self_calib_cmd 0 = not determined 2 = canceled 4 = error in mechanics/pneumatics 11 = timeout 17 = initialization status: determining mechanical stops 19 = initialization status...
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Date of last maintenance valve_maint_date indicates when the last maintenance was performed on the field device dead band xtot dead_band default: indicates dead band of the control characteristic between 0.1 and 10.0 % of the rated travel/nominal angle 0.5 % delay time delay_time (m) range: default:...
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Direction of action increase_close (m) states: default: determines the assignment of reference variable to travel/angle 0 = increasing/increasing, valve opens when reference variable increases (for rotary plug valves, the actuator stem retracts) 1 = increasing/decreasing, valve closes when reference...
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Fail-safe value, reference var. Fsafe_value default: functions as replacement value for set point (reference variable w or w_cas) when communication failure was detected 0 firmware version sw_revision firmware version, communication/control hardware version hw_revision hardware version, electronics/...
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Mounting position mounting_position (m) (linear actuator) states: default: an arrow on the positioner's cover plate indicates how to attach the positioner to the actuator. For direct attachment, the arrow must point towards the actuator. For namur attachment, the arrow must point away from the actua...
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Operating mode, current operating mode, desired mode_blk / target_mode (continued) the action determined by the fsafe_type parameter (fail-safe ac- tion) is triggered by the following events: – start-up of the positioner (warm start) – elapsing of dp watchdog by interrupting the cyclic communica- ti...
Page 57
Security locking security_locking default: memory position for a password to be used by the host, serves to check access rights (format: 16 bit unsigned integer) 0x2457 serial no., actuator actuator_ser_num indicates serial number of the actuator associated with the positioner length: 16 characters ...
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Tolerance band tolerance_band (m) range: default: reset criterion for active control loop monitoring. Enter permissible de- viation for control loop monitoring. See also delay_time parameter. 0.1 to 10.0 % 5 % tolerated overshoot tol_overshoot (m) adjustment range: default: if the set point deviatio...
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Transmission code transm_code (m) states: states: default: for linear actuators with integrally attached positioner: determine geometrical dimensions of the travel pick-off with integral attachment 1 = d1, lever length 64 mm 2 = d2, lever length 106 mm for rotary actuators: max. Opening angle of sel...
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Valve type valve_type states: default: specifies the valve design 0 = control valve with linear motion of the connecting element 1 = control valve with rotary or part-turn motion of the element 0 warm start device_reset_cmd states: default: resets the field device (warm start) 0 = no action 1 = rese...
Page 61: Messages and Diagnostics
9 messages and diagnostics the type 3785 profibus-pa positioner provides the best opportunities for diagnostics dur- ing the initialization phase. The positioner automatically conducts detailed tests to check the mounting position and valve response as well as to evaluate them based on the entered o...
Page 62
Zero point error (end position) this message indicates any change that exceeds the value determined during initialization or zero adjustment by more than ±5 %. Possible sources of error: – worn-out valve seat or plug – foreign particles between seat and plug the message is automatically reset when z...
Page 63
Further information available this message indicates that extended diagnostic messages have been generated. 9.2 extended diagnostic messages binary input active this message indicates that the condition for activating the binary input has been fulfilled. Invalid start values for min. Pulses in range...
Page 64: 9.3 Checkback Messages
9.3 checkback messages fail-safe position (mode = out of service) this message indicates that fail-safe position was triggered by the positioner. This can be caused by selecting out of service mode, by activating the optional forced venting function or by a communication failure. The positioner swit...
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Control loop error this message indicates that the positioner fails to control within the adjusted tolerance band for error monitoring within the specified delay time. Possible sources of error: – oscillation caused by the actuator working too fast (small travel volume) remedy: reduce supply pressur...
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9.4 messages during initialization not defined this message indicates that the positioner has not yet been initialized or that a cold start was performed. The message is reset by confirmation. Canceled this message indicates that the initialization routine was aborted by the user. The message is res...
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Incorrect selection of rated travel or transmission this message indicates that the maximum travel determined, which is issued in percent of the rated travel/angle, is smaller than the selected rated travel/angle. Warning! Initialization is not canceled. Possible sources of error: – improper mechani...
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Zero point error this message indicates that the zero point determined is outside the permissible tolerance of max. ±5 % around the absolute internal value for measurement. Initialization is canceled. To remove the error, adjust mechanical zero (see section 4.4.1). After that, make sure that the yel...
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Eb 8382-1 en 69 dimensional drawing 39 35 14 198 78.5 40 86 30.5 164 150 27 14 28 56 58 n1=113 n2=200 39 50 78.5 45 50 82 150 164 27 75 56 50 86 46 28.5 28.5 output 1 (a1) output 2 (a2) supply (z) output (38) supply (9) m20 x1.5 g ¼ or ¼ npt pneumatic connections direct attachment reversing amplifie...
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Samson ag · mess- und regeltechnik weismüllerstraße 3 · 60314 frankfurt am main · germany phone: +49 69 4009-0 · fax: +49 69 4009-1507 internet: http://www.Samson.De eb 8382-1 en s/z 2017-07 ·(version 3785-xxx0...).