EB 7500 EN
Translation of original instructions

Type 3421 Compact Controller with Type 3422
Controller Station and Type 3423 Controller
ModuleType 3427 Manual Control
StationSeries 420
Pneumatic Control System

Edition July 2017

Type 3417 PneumaticControl Unit

Type 3425 PneumaticController (control room
installation)

Type 3416 IndicatorType 3425 PneumaticController (field unit)

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎÎ For the safe and proper use of these instructions, read them carefully and keep them forlater reference.
ÎÎ If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesservice@samson.de).

The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.

! WARNING
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very highconcern on the candidate list of the REACH regulation, this circumstance is indicated on the
SAMSON delivery note. Information on safe use of the part affected,
see u http://www.samson.de/reach-en.html.

Definition of signal words! DANGER
Hazardous situations which, if not avoided,
will result in death or serious injury! WARNING
Hazardous situations which, if not avoided,
could result in death or serious injury

2! NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action

EB 7500 EN

Contents

1

General safety instructions..............................................................................52

Application....................................................................................................63

Operation......................................................................................................6

3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6

Settings at the controller modules.....................................................................6
Direction of action...........................................................................................6
Air delivery....................................................................................................7
Proportional-action coefficient KP.....................................................................8
Reset time Tn..................................................................................................8
Derivative-action time Tv..................................................................................8
Operating point..............................................................................................8

3.2

Adjusting the limit contacts..............................................................................94

Start-up and settings....................................................................................10

4.1

Tuning the controller......................................................................................10

4.2

Bumpless automatic/manual mode changeover...............................................12

4.3

Readjusting the controller zero point...............................................................12

4.4
4.4.1
4.4.2
4.4.3

Additional modules.......................................................................................12Type 3424-4 Manual/automatic Transfer........................................................12Type 3424-5 Control Mode Changeover.........................................................12Type 3424-6 Signal Limiter............................................................................13

5

Design and principle of operation.................................................................14

5.1

Type 3421 Compact Controller......................................................................14

5.2

Type 3427 Manual Control Station.................................................................16

5.3

Type 3425 Pneumatic Controller (wall-mounted and field controller)..................16

5.4

Type 3416 Indicator......................................................................................175.5Type 3417 Pneumatic Control Unit.................................................................17

5.6

Type 3423 Controller Modules.......................................................................18

5.7
5.7.1
5.7.2
5.7.3
5.7.4

Additional modules.......................................................................................21
Type 3424-2x for i/p conversion...................................................................21
Type 3424-4 for bumpless manual/automatic switchover.................................22
Type 3424-5 for control mode changeover.....................................................22
Type 3424-6 for signal limitation...................................................................22

5.8

Optional electrical limit contacts.....................................................................23

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3

Contents

6

Installation...................................................................................................24

6.1

Changing scales...........................................................................................25

7

Connections.................................................................................................26

7.1

Pneumatic connections..................................................................................26

7.2

Electrical connections....................................................................................28

8

Maintenance................................................................................................30

8.1

Checking the air supply.................................................................................30

9

Conversion...................................................................................................30

9.1

Changing the controller function.....................................................................30

9.2

Operating mode changeover in Type 3424-2 i/p Converter.............................33

9.3

Checking the controller function.....................................................................34

10

Technical data..............................................................................................35

4

EB 7500 EN

General safety instructions

1 General safety instructions−− The device must be mounted, started up, or serviced by fully trained andqualified personnel only; the accepted industry codes and practices are tobe observed. Make sure employees or third persons are not exposed to any
danger.
−− All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up, and maintenance, must be strictly observed.
−− Devices with a CE marking have an EC declaration of conformity, which includes information about the applied conformity assessment procedure. TheEC Declaration of Conformity is available on request.
−− According to these mounting and operating instructions, trained personnel
refers to individuals who are able to judge the work they are assigned toand recognize possible dangers due to their specialized training, theirknowledge and experience as well as their knowledge of the applicablestandards.
−− To ensure appropriate use, only use the device in applications where the operating pressure and temperatures do not exceed the specifications used forsizing the device at the ordering stage.
−− The manufacturer does not assume any responsibility for damage caused byexternal forces or any other external factors.
−− Proper transport, storage, installation, operation, and maintenance are assumed.

EB 7500 EN

5

Application

2 Application
The Series 420 Control System is used in automation applications in process engineeringand industrial plants. It can be used for applications with P, PI, PID, and PD controls, forcontrol loops with control mode changeoveror signal limitation, for fixed set point, ratio,cascade, or slave control.
The output signals of a connected transmitteror master controller are measured as pneumatic standardized signals between 0.2 and1 bar or, in case of i/p additional modules,
0/4 to 20 mA signals.
The integrated controller modules compare
the measured variable with the set point andissue a corresponding pneumatic control signal of 0.2 to 1 bar (2 to 15 psi).
The controller requires a supply pressure of
1.4 bar (20 psi).

3 Operation
3.1 Settings at the controller
modules! NOTICE
The settings for direction of action and air
delivery must be performed prior to start-up.
Release the lock (4 in Fig. 1) on the front
panel of the compact controller and pull the
manual control station completely out of the
housing to access the controller module.

3.1.1

Direction of action

The direction of action for the control loop isset at the turnboard A. Tshe position of its
arrow symbol according to the arrow symbolon the controller module determines the
direction of action of the controller (Fig. 1).
< > Arrow tips facing opposite directions:
Direction of action increasing/decreasing
As the controlled variable x increases,
the output pressure y falls.
>> Arrow tips facing the same direction:
Direction of action increasing/increasing
As the controlled variable x increases,
the output pressure y increases.
Setting or changing the direction of action:
Unscrew the screw in turnboard A and lift it
off together with the turnboard. If necessary,lever the board at the side. Do not lose therubber seal.

6

EB 7500 EN

Operation−− Turn the board by 90° so that the required arrow is aligned with the arrowon the base plate.

>yA Normal air delivery,
approx. 1 mn³/h per % of the system deviation (default setting)−− Insert board and tighten the screw.

>R High air delivery,
approx. 3 mn³/h per % of the system deviation (not with P or PD controller modules)

3.1.2

Air delivery(only with Type 3423 Controller Module)

Setting or changing the air delivery
If the control valve that is to be controlled ismore than 15 meters away, increase the airdelivery by turning the position of turnboard
B from yA (standard) to R.

The position of turnboard B with its arrowsymbol determines the air delivery to the
feedback bellows.

1

4

2

3

B

3.2

6 3.3 3.2 3.4 A

7

3

3.1 8

9

Compact controller

2

Control room housing

3

Controller module

3.1

Comparator

3.2

Connecting plate

3.3

Hex screws

3.4

Screws (inside)

4

Lock

6

Fastening screw

7

Restriction

8

Zero adjuster9

Kp adjuster

10

Tn adjuster

11

Tv adjuster (only in PD or PID
controller)

12

Operating point adjuster(only in P or PD controller)

Turnboard

10
12
11

View from the side without
comparator (3.1)

1

A

Direction of action

B

Air delivery

Type 3423-2 Controller Module (PI)Fig. 1: Turnboards and adjusters

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7

Operation

1. Unscrew the fastening screw (6) at thecontroller module and pull the module off
its self-seal push-on fittings.
2. Unscrew screws (3.3) and pull off theconnecting plate (3.2) together withsquare nuts and bolts from the controller
module.
3. Unscrew the hexagonal socket headscrews (3.4) at the side and lift the comparator (3.1) off the controller module.
4. Unscrew the screw in turnboard B and lift
it off together with the turnboard. If necessary, lever the board at the side. Do
not lose the rubber seal.
5. Turn the board so that the arrow isaligned with yA or R on the controller
module. Insert board and tighten thescrew.

3.1.4

Reset time Tn

Controller versions with integral-action component require the reset time to be set at theadjuster (10). The setting depends on thecontrolled system that is to be tuned (see section 4.1).

3.1.5

Derivative-action time Tv

Controller versions with derivative-action
component require the derivative-action time
Tv to be set at the adjuster (11). The setting
depends on the controlled system that is tobe tuned (see section 4.1).

3.1.6

Operating point

6. Remount the controller module and fasten it in the controller station.

Controller modules without integral-action
component (e.g. P or PD, controllers) havean operating point.

3.1.3

This can be adjusted at the operating point
adjuster (12) between 0 and 100 %, whichcorresponds to 0.2 to 1 bar.

Proportional-action coefficient Kp

The setting of the Kp (adjuster 9) determines
the controller gain and depends on the controlled system that is to be tuned (see section 4.1).

8

The setting depends on the output pressure ythat is to be tuned (see section 4.1).
The Type 3423-9 Controller Module does nothave an operating point adjuster. The operating point is dependent on the set point.

EB 7500 EN

Operation

3.2 Adjusting the limit contacts

Adjustment screw

Indicator withproximity switch

Note
The listed limit contacts are no longer available.
Inductive contacts in Type 3422 ManualControl Station and Type 3427 ManualControl Unit−− Release lock on the front panel and pullout the indicating unit.
The proximity switches with min. andmax. contacts can be accessed throughthe opening on the left-hand side.
−− Use a 2.5 mm hex screwdriver to slightly
loosen the two fastening screws.
−− Move the corresponding proximity switch
until the indicator points to the required
value on the reference scale and a contact is made over the connected switching amplifier or the LED on the front
lights up when contact is made.
−− Retighten screws and place the marker
on the main scale at the corresponding
place.
Inductive and pneumatic contacts in
Type 3416 Pneumatic Indicator−− Release lock on the front panel and pullout the indicating unit.

Limit adjuster in
Type 3416
Lock

Fig. 2: Indicator with limit contacts−− Move adjuster at the side until contact is
made.

EB 7500 EN

9

Start-up and settings

4 Start-up and settings
Before start-up of the control loop, check all
devices to make sure that they are connected
correctly, do not leak, and function properly.
Release lock (7) and pull out the plug-in unitof the compact controller station for easieraccess to the operating controls at the controller.
Check the turnboard to make sure the correct
direction of action is set at the controller (seesection 3.1.1). Set arrow symbol (6) for
valve position at 100 % signal pressure accordingly:
Arrow symbol facing:
Upward: valve OPEN
Downward: valve CLOSED

2. Set the proportional-action coefficient Kp
to a low value (0.2) at the comparator.
PI and PID controllers only: set Tn restrictor to its maximum value (50 min) and Tv
to its lowest value (0.01 min).
3. Adjust the set point at the top rotaryknob (11) until the green pointer (2)points to the required value on the scale.
PI and PID controllers:
4. Adjust the manual output yH at the bottom rotary knob (9) to start up the control loop until the controlled variable indicated by the red pointer (3) slowly approaches the adjusted set point (green
pointer).
121
11

4.1 Tuning the controller
The controller needs to be tuned to the characteristics of the controlled system using theKp and Tn and/or Tv adjusters at the controller module (Fig. 1) to ensure that the controller can keep any system deviations for all set
points caused by the disturbance variables tozero or at least minimize them.
The tuning test following the Ziegler andNichols method is a simple way to tune thecontroller. In this method, the controller runs
in closed-loop operation with P action to thepoint where it is still stable. It can only beapplied to controlled systems in which thecontrolled variable can be made to hunt.
1. Set manual/automatic switch (10) to
manual. Apply supply pressure(1.4 ±0.1 bar) to Z.
10

2
3

4
5
1 Front panel
2 Set point pointer
3 Controlled variable
pointer
4 Control signal yA
5 Control signal yH
6 Valve CLOSED/OPEN

10

9
8
7
6
7 Lock8 LED
9 Manual adjuster for yH
10 Manual/automatic
switchover
11 Set point adjuster
12 Label

Fig. 3: Front view

EB 7500 EN

Start-up and settings

When the pointers meet, wait until also
the automatic output (4) on the bottom
scale reaches the manual output (5).

PI and PID controllers:
Use a stopwatch to time the oscillation
time for one entire oscillation to find Tcrit.

If necessary, slightly adjust the set point
to allow the automatic output to matchthe manual output more quickly. Afterthey match, set the set point back to thecontrolled variable. Continue as described in 5.

Tcrit

P and PD controllers with operating point
adjuster:−− Set the manual/automatic switch to automatic.
−− Adjust the operating point at the operating point adjuster in the range between
0 and 100 % until the controlled variable(red pointer) is identical with the adjusted set point (green pointer). Continue as
described in 6.
5. Change the manual/automatic switch toautomatic.
6. Starting from a low value, increase theproportional-action coefficient Kp until
the red controlled variable pointer showsan harmonic oscillation pattern of thecontrolled variable (uniform oscillation
amplitudes as shown in Fig. 4).
If oscillations do not arise with a large
Kp setting, turn the rotary knob to slightly change the set point and then return it
to its former setting. It may be necessary
to increase the gain (Kp) slightly until anharmonic oscillation pattern arises.
7. Write down the adjusted value on the Kp
scale you have just adjusted as the critical proportional-action coefficient Kp,
crit.
EB 7500 EN

Controlled
variable (actual value)

+
–
Tcrit
Controller
P

Kp

Tn

Tv

0.50 · Kp, critPI

0.45 · Kp, crit0.85 · Tcrit

PID

0.59 · Kp, crit

0.50 · Tcrit

0.12 · Tcrit

Fig. 4: Harmonic oscillation, settings

8. Multiply value for Kp, crit and value for
Tcrit (with PI/PID controller) with the values in the table (Fig. 4) and set them as
the favorable settings for Kp, Tn, and Tv
at the controller.
Should oscillations still occur despite thesesettings, slightly reduce Kp and increase Tn.
Repeat these steps, if necessary, until thecontrol loop shows a satisfactory performance.
Leave enough time in between settings to allow the controller to stabilize.
Note
If the set point (reference variable) of the P or
PD controller is changed, readjust the operating point. When the reference variable isoften changed, adjust the operating point toan average value (e.g. 50 %).

11Start-up and settings

Note
If a P/PI controller is switched to P action,completely open the Tn restrictor to ensure
the operating point adjuster can take effectwithout delay.
Version with set-point-dependent operating
pointThis version does not need to be adjusted
since the operating point automatically follows the set point w.

4.2 Bumpless automatic/
manual mode changeover
The bumpless switchover ensures that nopressure surges can reach the valve whenthe manual/automatic switch (10) is activated as follows:
Changeover from automatic to manual
Use the adjuster (9) to adjust the manual output yH until the pointers (4 and 5) in the bottom display meet. Change the switch over tomanual.
Changeover from manual to automatic
If the system is to be controlled manually tothe required value, the automatic output yA
must be adjusted at the set point adjuster(11) to match the manual output yH.
The switch (10) can only be set to automatic
after the pointers (4 and 5) in the bottom display meet.

12

4.3 Readjusting the controller
zero point
If deviations arise between the controlled
variable and set point during operation, thezero point can be readjusted by turning thezero adjuster (8 in Fig. 1) until the controlled
variable and set point on the front display
are the same again.

4.4 Additional modules
Note
The Type 3424 Additional Module is no longer available.

4.4.1

Type 3424-4 Manual/automatic Transfer

Switchover is performed automatically byactivation of the manual/automatic switch(10, Fig. 3). See u T 7523.

4.4.2

Type 3424-5 Control
Mode Changeoveru T 7523
Adjusting the direction of action
Set the direction of action at the turnboard of
the control mode changeover device tomatch the direction of action of turnboard Aof the controller module. To proceed, unfasten the screw on the turnboard and turn theboard as follows:

EB 7500 EN

Start-up and settings<>

Increasing/decreasing:

Position>>(x-w) </= 0
Increasing/increasing:

Position(x-w) >/= 0

Setting the control error
The setting depends on the system and must
be determined by experimenting.
Starting with a high value, perform the setting in steps with an increasingly smaller
control error.
To ensure that the switchover point for P and
PI or PD and PID control mode is not continuously exceeded, set the control error (x–w),
keeping the error deviations that occur in thesystem due to constant disturbances within
the adjusted (x–w) range.
It is often recommendable to set the control
error (x–w) to be double the Kp value set atthe controller module.
Setting the operating point
When the system is in a steady-state condition, move the operating point adjuster to thevalue of the manual output yA (reading at
the manual control station) (0 to 100 % correspond to an output of 0.2 to 1 bar).
In case of large and frequently changing reference variables, we recommend setting it to
50 %.
Set-point-dependent operating point
In this version, the operating point is automatically tracked, meaning that the systemdeviation remains at zero. The set point adjuster allows, however, a proportional shiftof ±20 %.

EB 7500 EN

Feedback limitation
The additional feedback limitation allows theoutput pressure yA to be limited. In this case,the 0 to 100 % scale of the adjuster corresponds to a limitation signal of 0.2 to 1 bar.
Operating point

SystemdeviationyA limiter

Direction ofaction of
turnboard

Fig. 5: Type 3424-5 Control Mode
Changeover

4.4.3

Type 3424-6 Signal
Limiter

Use the corresponding adjusters to performthe minimum or maximum signal limitation(Fig. 13). In this case, the 0 to 100 % scaleof the adjuster corresponds to a limitation
signal of 0.2 to 1 bar. See u T 7523.

13

Design and principle of operation

5 Design and principle of operation
The pneumatic control system has a modular
design. As a result, the compact control
equipment can be combined with various
controller modules and additional modules
and adapted to a wide range of applications.

5.1 Type 3421 Compact Controller
The Type 3421 Pneumatic Compact Controller consists of the Type 3422 Manual Control
Station and the Type 3423 Controller Module.
The manual control station consists mainly ofthe housing (1.1) with connecting plate (1.4)
and the plug-in unit (1.2) to hold the controller module (1.3). The plug-in unit has selfseal push-on fittings, allowing the device toalso function as a control station when noother components are used.
The controlled variable and set point pointers
have metal bellows measuring elements. The
controlled variable measuring element can
optionally be equipped with adjustable inductive limit contacts or LEDs.
Three versions of the Type 3422 ManualControl Station are available, which areadapted to the control task. Depending on
the circuit version 1, 2 or 9, the device does
not have the set point adjuster (11), set point
pointer (2), or selector switch (14) for internal (wint) or external (wext) reference variable.
All circuit versions have the ports R (feedback) and y (output pressure) connected internally to the connecting plate of the compact controller.
In case y and R are to be routed separately
out of the device, proceed as described in
section 7.1 by relocating the O-rings on theconnecting plate.
1.1 Housing
1.2 Plug-in unit
1.3 Controller module
1.4 Connecting plate

11
10
2
3
4
5

9

14

1.2

1.3

1.1

1.4

2

Set point pointer (green)3

Controlled variable pointer (red)4Control signal yA

5Control signal yH

9Manual adjuster for yH

10Manual/automatic switchover

11

Set point adjuster

14

Selector switch (wext/wintern)

Fig. 6: Type 3421 Compact Controller

14

EB 7500 EN

Design and principle of operation

Circuit version 1 for fixed
set point and slave control

x w

wint

w

wext

w
S

S

R

Z
yA

yA
yH

S

yA
P/PI
P
PI
PID
PD

Circuit version 2 for slave
control

Z
R
wext
x

x

yH
yA
yH

w

y

S

R
x w

w
S

Z
yA

yA
yH

S

yA
P/PI
P
PI
PID
PD

Z
R
wext
x

x

yH
yA
yH

w

y

Circuit version 9 for ratio
control
Pneumaticconnection

S
yA

x

Self-seal push-on
fitting

S

Supply air Z

a

yA
yH

Venting

e

yH
yA
yH

Pneumatic adjuster
End connection
Manual/automatic
switchZyManipulated
variablex

Controlled variablew

Set point

P/PI
P
PI
PID
PD

w
Z
R
wext
x

e

y

a

wext External set point

yH Manual output

wint Internal set point

S

Switching pressure

R

Feedbacka

Output pressure

yA Output pressureeInput pressure

Fig. 7: Circuits of Type 3421 Compact Controller

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15

Design and principle of operation

5.2 Type 3427 Manual Control
Station

5.3 Type 3425 Pneumatic Controller (wall-mounted andfield controller)

The Type 3427 Manual Control Station isused in combination with the Type 3425
Pneumatic Controller (in a Type 3426 Control Room or Field Housing).

The pneumatic controllers for control room orfield installation consist of the Type 3426
Control Room or Field Housing and aType 3423 Controller Module.

The three different versions (Type 3427-1,
Type 3427-2, and Type 3427-9) are adapted to control tasks and corresponds to thecircuits of Type 3422 Manual Control Station. See u T 7511.

The controller module is connected over selfseal push-on fittings to the housing and fastened with a screw (6). See u T 7512.

6Type 3427 Manual Control Station Type 3426-2 Control Room
Housing with Type 3423
Controller Module

x

w

wint

w

y

Type 3426-3 Field Housing with Type 3423
Controller Module

wext
y
w

S

6

wext

yA
yH

yH
yA
yH

Z
yA

P/PI
P
PI
PID
w
V
Z
yA
R

S *) Sx

x

R

Type 3427-1 Manual Control Unit (circuit 1) connected
to Type 3425 Pneumatic Controller (for control room
P/PI
wext
and field installation)
x

w

y

R

Z
yA

Z
yA

Fig. 8: Pneumatic manual control unit with controllers for control room and field installation
w
w
S

yA
y

16

yH
yA
yH

yH

P
PI
PID
V

S *) Sx
Rx

EB 7500 EN

Design and principle of operation

5.4 Type 3416 Indicator
The pneumatic indicators are used whenconnected to control equipment to display
measured variables (e.g. temperature orpressure) in standardized pneumatic signals
from 0.2 to 1 bar.
The devices are fitted with double or quadruple indicators depending on the control task.
Devices with electric or pneumatic limit contacts have proximity switches or pick-offs
with emitter sensor nozzles, which are connected to the limit contact pointers. The metal
tag connected to the measuring unit pointertriggers a signal when a limit is reached. Seeu T 7526.

5.5 Type 3417 PneumaticControl Unit
The Type 3417 Pneumatic Control Unit isused to adjust, link, and feedback pneumatic
signals in standardized range from 0.2 to
1 bar.
The set-up of the individual versions varies inthe equipment of remote adjusters, signal selector switches, and indicators which are installed in the housing depending on the control task. See u T 7527.

Note
The listed limit contacts are no longer available.

Type 3417 Pneumatic Control Unit
with signal adjuster, selector switch,and indicators
Type 3416 Indicator in double andsingle versions

Fig. 9: Type 3416 Indicator and Type 3417 Pneumatic Control Unit

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17

Design and principle of operation

5.6 Type 3423 Controller
Modules
See u T 7521. The controller modules areplug-in units which are inserted onto the selfseal push-on fittings of a manual control station, manual control unit, or control room orfield housing. The controller modules areheld in place by a screw.
The controller modules consist of a comparator fitted with four metal bellows arranged ina square and a base plate with self-sealpush-on fittings.
The base plate accommodates the components required for the chosen function, suchas relays and restrictors. The components
can be exchanged or upgraded, allowing
the function to be changed at a later point intime (see section 9.1).
Type 3423-2 PI Controller (Fig. 10, top)
The controlled variable x and the reference
variable w (set point) are transferred aspneumatic signals between 0.2 and 1 bar
via turnboard A to the metal bellows w andx. When x is greater than w, the controlled
variable bellows tilts the pivoted swashplate
toward the set point bellows, causing thepressure downstream of the nozzle connected to the swashplate over a pin to rise. As aresult, the output pressure yA of the booster
increases. The pressure yA is fed back immediately via turnboard B to the bellows R2 onto the swashplate.
The position of the swashplate and the output pressure yA keep changing until the distance between nozzle and flapper is thesame as initially and the output pressure yA
18

assumes a value corresponding to the controlled variable x and the adjusted proportional-action coefficient Kp adjustable over ascrew.
Outside of the controller module, the yA is
connected to R, allowing the pressure yA to
be fed back to bellows R1 also over the port
R and the adjustable Tn restrictor. As a result, the effects of the pressures in bellows R1
and R2 balance themselves out and the error
deviation is eliminated.
A switchover to manual mode at the controller station causes a switching pressure to be
applied to port S. The Tn start-up relay is activated and bypasses the Tn restrictor.
The turnboard A determines the direction ofaction of the controller. The direction of action can be changed by turning the turnboard (see section 3.1.1).
The turnboard B determines the air delivery
to the feedback bellows.
In the delivered state, the turnboard B is set
to yA, i.e. the output pressure yA is directly
fed back to bellows R2. Whereas, it is fed
via connection R to bellows R1. With this circuit arrangement, the controller provides
normal air delivery and output pressure
damping.
In the switching position to R, the output
pressure yA is fed back via port R to the bellows R1 and R2. As a result, the controller
has a higher air delivery. Practical application for long distances to the control valve,large connecting volumes and for fast controlled systems.
See section 3.1.2 on how to set or change
the air delivery by turning the turnboard B.
EB 7500 EN

Design and principle of operation

Type 3423-2 PI Controller Module
The following controller module versions arealmost identical to the Type 3423-2 PI Controller Module, except they are fitted with, forexample, an operating point adjuster, a derivative element or a selector switch, depending on the application.

Type 3423-1 P Controller ModuleThis module is largely identical to theType 3423-2 PI Controller Module.

Type 3423-3 PID Controller ModuleThis module is largely identical to theType 3423-2 PI Controller Module.
This module, however, contains an additional derivative element providing a derivative-action gain of approx. ten times in the
input branch of the controlled variable x.
The derivative-action time can be adjusted at
the TV restrictor.
R

Feedback

Feedback
R1/R2
bellowsyA

S

Switchingpressure

Turnboards

1.4 bar supplyA
air

Direction ofactionOutput pressure B

Air delivery

Fig. 10: Type 3423 Controller Modules

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19

Design and principle of operation

The Type 3423-4 PD Controller Module issimilar to Type 3423-4.
This module, however, contains a derivative
element providing a rate gain of the input
branch of the controlled variable x. It has aderivative-action gain of approx. ten times
and a derivative-action time that can be adjusted at the TV restrictor.
The Type 3423-5 P/PI Controller Modulewith P/PI selector switch can be used either
as P controller with operating point setting or
PI controller.
This module is designed in the same way as
the PI and P controller modules.
The Type 3423-6 PD/PID Controller Modulewith PD/PID selector switch can be used either as PD or PID controller.
The Type 3423-9 P Controller Module with
set-point-dependent operating point is thesame as Type 3423-1 P Controller Module,
except the operating point changes proportionally to the set point w.

Type 3423-7 Ratio Relay
This device is designed as the Type 3423-1 P
Controller Module. The constant pressure of
the operating point adjuster, however, is fed
to the R1 and w bellows. The output pressure
a is proportional to the input pressure e (a =e x Kp). In ratio control applications, thispressure is the reference variable for a slave
controller.
Fig. 11: Type 3423 Controller Module20

EB 7500 EN

Design and principle of operation

The ratio V = a/e is adjusted in the same
way as the proportional-action coefficient Kp(gain) for P controllers.

5.7 Additional modules
Note
The Type 3424 Additional Module is no longer available.
The additional modules upgrade the control
equipment especially concerning processing
engineering requirements. They are mounted
between the controller module and the controller module assigned to the connector
strip.

5.7.1

Type 3424-2x for i/p
conversion

See u T 7523. The i/p additional module isused to link electric systems to the manualcontrol station. It is used to convert a standardized 4 to 20 mA DC signal into a standardized pneumatic signal from 0.2 to
1 bar.
The i/p converter, which functions according
to the force-balance principle, is mounted directly to the controller module of theType 3421 Compact Controller (Type 342421) or to the Type 3422 Manual Control Station (Type 3424-20).

The Type 3424-2 i/p Converter is no longer
available. Instead, the external mounting ofa Type 6111, 6116 or 6126 i/p Converter
is possible. Further details are available on
request.
Type 3424-23
mounted onto Type 3423-2 Controller
ModuleType 3424-21
with terminal plate forpneumatic self-seal push-on
fittings

Type 3424-4 Manual/automatic Transfer

Fig. 12: Type 3424-2x and Type 3424-4
Additional Modules

In the delivered state, the output pressure iseither connected to the signal channel of thecontrolled variable x or to the external reference variable wext depending on the orderspecifications.

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21

Design and principle of operation

5.7.2

Type 3424-4 for bumpless manual/automatic
switchover

A bumpless transfer from manual to automatic mode is only possible when the controller output pressure yA and the manual
output pressure yH are the same. The transfer from yA to yH is performed manually inmost instruments.

Type 3424-5
Control Mode
Changeover

The Type 3424-4 Additional Module connected between controller and manual control station performs this switchover automatically.
The module can be equipped optionally witha pressure limiter. This limits the controller
output pressure yA to the maximum pressureadjusted.

5.7.3

Type 3424-5 for control
mode changeover

The control mode changeover switches theconnected controller from PI or PID to P
action if the control error exceeds anadjustable limit. This allows a fast start-up of
the set point without overshooting.

5.7.4

Type 3424-6Signal Limiter

Type 3424-6 for signal
limitation

The additional module is used to limit the
maximum and minimum controller output
pressure yA, the feedback signal R or thereference variable w.

Fig. 13: Type 3424-5 and Type 3424-6
Additional Modules

More details on Type 3424-4 Manual/automatic Switchover, Type 3424-5 Control Mode
Changeover, and Type 3424-6 Signal Limitercan be found in Data Sheet u T 7524.
22

EB 7500 EN

Design and principle of operation

5.8 Optional electrical limit
contacts
Note
The listed limit contacts and LEDs are no longer available.
The limit contacts indicate when the controlled variable x falls below and/or exceeds
an adjustable limit.
The version with inductive limit contacts has
a controlled variable pointer fitted with metaltags which move adjustable proximity
switches within a magnetic field.
The operation of the inductive limit contacts
requires switching amplifiers in accordancewith EN 60947-5-6 to be connected in the
output circuit.
The corresponding wiring (Fig. 17) allows
the limit contacts to be additionally fittedwith LEDs.
Internal electrical limit contacts with LED are
amplified on the internal board and onlyused to actuate LEDs. These contacts requirea 24 V DC power supply.
See section 3.2 on how to adjust the limit
contacts.

EB 7500 EN

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Installation

6 Installation

The devices are fastened at the top and bottom to a rail (Type 3421/3422: 1089-0036
and Type 3427: 1089-0037) in the control
panel.

Panel-mounted devices (Type 3421,
Type 3422, Type 3427, Type 3416, andType 3417)

The tightening torque for the screws depends
on the installation situation (approx.
1.4 Nm). On tightening the screws, the rail
must have direct contact with the housing
and the panel must not be bent.

All devices have the front dimensions
72 x 144 mm and require a control panel
cut-out of 138+1 x 68+0.7 mm.

Devices for panel mounting

Mid distance
between devices:min. 73 mm
horizontally and
170 mmvertically.

Terminal rail

100

ca.157

144

70
60
40
30
20
10
0

Pneumaticconnections

Electricalconnections
51
72

Control room housing

137,5

90
80

Terminal rail
1)

Approx. 135 mm with Type 3423...,
approx. 170 mm withType 3423... + Type 3424

u T 7506,
u T 7526,
u T 7527.
1)

320/18025
180 mm: Types 3427, 3416-1.../-90, 3417-1...
320 mm: Types 3421, 3422, 3416-2.../-91, 3417-2...

21

R
w
21

Ø4,5

21

124
86

Z
yA

21

Ø4,5

13,5

22
44

Type 3424

55
77,5

x

9,5

17,3

21

S

All dimensions in mm
Fig. 14: Installation dimensions of panel-mounted devices and Type 3426-2 Control Room Housing

24

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Installation

Type 3423 Controller Modules andType 3424 Additional Modules
Push the controller and additional modules
into the self-seal push-on fittings and screw
them tight.

Type 3426 Control Room or Field Housing
Fasten control room housing (Type 3426-2)
using M4 screws in the control room.
Fasten the field housing (Type 3426-3) using
brackets to a wall.

165
129
M6

334

R

w

Z

yA

S

x

65

240

14

Cover open

15

105

A

1/8

NPT

37

View A
Pneumatic connections

26
97

All dimensions in mm
Fig. 15: Installation dimensions of Type 3426-3 Field Housing

6.1 Changing scales
The large scales for the manual control stations, pneumatic indicators, and pneumatic
control units can be replaced with otherscales.

3. Turn scale or replace it with another one
and insert it into the scale holder.
4. Insert scale holder into its guide andpush it into place.

To replace or turn the scales, proceed as follows:
1. Release lock and pull out the plug-in unit.
2. Reach into the top opening and pull up
the scale holder. Bend the scale slightly
and pull it out.

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25

Connections

7 Connections
7.1 Pneumatic connections
The pneumatic connections are designed asa bore with 1/8 NPT thread. Customary fittings for tubing or plastic hoses can be used.
! NOTICE
Make sure the supply air is dry as well as
free of oil and dust.
Read the maintenance instructions for upstream pressure reducing stations.
Blow through all air pipes and hoses thoroughly before connecting them.
The threaded holes on the connecting plate(depending on the type and circuit version)
which are not used must be sealed with stoppers with 1/8 NPT thread.

The port labeling is as follows:S

Switching pressure (0/1.4 bar)
Sealed in Type 3422 Manual Control
Station, open in Type 3427 Pneumatic
Manual Control Unit when used with
controller for control room or field installation (except with P and V controller
module)Output in Type 3427, input in
Types 3423 and 3425.

On switching the manual control station to
manual, a switching pressure of 1.4 bar isapplied to the start-up relay to bypass the Tn
and Tv restrictors.

26

yA Automatic output pressure (0.2 to
1 bar)
Sealed in Type 3422, open for separate
instrumentation with Type 3427 Pneumatic Manual Control Unit
Output in Types 3423 and 3425, input
in Type 3427.
w

Reference variable (0.2 to 1 bar)
Sealed in Type 3422, open in
Type 3427.
Output in Type 3427, input in
Types 3423 and 3425.

Z

Supply air
Supply air 1.4 ±0.1 bar.

R

Feedback (input 0.2 to 1 bar)
Sealed in Type 3422 in delivered state(R and y are internally connected on theconnecting plate).

If R and y ports are to be connected externally (Fig. 16, top), unfasten the connecting
plate and move the O-ring to the feedback
port (y and R are then separated from one
another). Remove the stopper at the R port
and replace it with a screw fitting.
wext External reference variable(input 0.2 to 1 bar)
To feed forward the reference variable
externally when selector switch is set to
wext.
xControlled variable (input 0.2 to 1 bar)
Input signal, output signal from transmitter

EB 7500 EN

Connectionsy

Zul Supply air

Manipulated variable (0.2 to 1 bar)Controller output signal to actuate thecontrol valve

Ports 1, 2, 3, 4
In Type 3416 Indicator and Type 3417 Pneumatic Control Unit. Assignment dependingon version.

Output in Type 3427, input in
Types 3423 and 3425.

Type 3416-90/91 Indicators with pneumatic
limit contacts have ports designed as connecting grommets for a 1.8x1 hose.

S

yA

w

Z Pneumatic

R

wext

x

y

connecting plate

Inside of connecting plate:Move O-ring to separate y and R.

Zul
Zul
4

1

3

2

Types 3416-1.../3417-1...

4

1

3

2

Types 3416-2.../3417-2...

Zul

Zul

3

2

Types 3416-90/-91

Fig. 16: Pneumatic connections on the connecting plate

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27

Connections

7.2 Electrical connections! NOTICE
For electrical installation, observe the relevant electrotechnical regulations and the accident prevention regulations that apply inthe country of use.

In Germany, these are the VDE regulations
and the accident prevention regulations of
the employers’ liability insurance.
Note
The listed limit contacts, LEDs, and i/p converters are no longer available.

Type 3422

Type 3427

3 4 5

6

7

1

8

9

2

+ _
4 to 20 mA input

Min. limit contact

Max. limit
contact_ +Top/bottom
LED
_+_
*
24V–

Self-seal push-on fittings_+
Min. limit contact

2

3

4

5

6

7

8

1

2

(1)

6

7

3 4 5

(2)

*_ + _ 24V–_+

Max. limit contact

Top/bottom Max. limitLEDcontact
_+ _
_+
*
24V–

1

( )
_ *+

_

+

Bottom/top
LED

Max. limit
contact
+_

(*)
_+

9

Terminal connections
1+_
4 to 20 mA input_+
Min. limit contact

2

3

4

6

7

(1) (2)_ + _ 24V–+_
Min. limit contact

5

Bottom/top
LED*) 24 V DC for limit contacts with integrated

Fig. 17: Electrical connections of Type 3422 and Type 3427 LED actuation

28

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Connections

Electrical connection only applies to devices
with additional i/p modules or electricalequipment, such as limit contacts or LEDs.
Fast-on connectors (6.3 mm socket) or terminals are used depending on the version. The
Version with fast-on connector

With terminals

Type 3416-18

Type 3416-18

Type 3416-16
Limit contacts
min.
+ _

Min.
_ +

1

2

8

9

3

4

5

7

Type 3416-16
Limit contacts
min. max. max. min.
+_ +_ _ + _+operation of the inductive limit contacts requires switching amplifiers in accordancewith EN 60947-5-6 to be connected in the
output circuit.
Version with electrical
outputWith pneumatic output

Types 3416-90/-91

Type 3416-90/-91
Contact

Max.

Max.

1

1

3

1

2

3

4

5

6 7

8

_ +
Max.
Max.
_ +

3

5

6

7

1

2

8

9

Contact
1 32

3

4 5

6

7

8

_ +

+_ + _ _+ _+

Min.

Max.

min. max. max. min.

Type 3416-28

5
3

5

4

Min.

5

Min.
3
4 5

9

+ _

Type 3416-26

4

2

Min.

Limit contacts

2

4

3

3

2

Min.

1

2

3
5

9
3

+ _
Max.
Max.
+ _

4

1

1

Max.

3

3

2

Max.

Type 3416-26
Type 3416-28

Fig. 18: Electrical connections of Type 3416

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29

Maintenance

8 Maintenance

9 Conversion

8.1 Checking the air supply

9.1 Changing the controller
function

The modules of the pneumatic controllers
normally do not require any maintenance.
However, the air supply must be checked atregular intervals.
To guarantee trouble-free operation of thedevice, make sure that the supply air is always clean.
Check the air filter and separator installed in
the upstream air reducing station regularly. If
necessary, if the performance worsens, clean
or replace the appropriate filters.
If a controller module does not control properly or the output signal is missing, unscrew
the restriction with filter (7 in Fig. 2 andFig. 19) located on left-hand side underneath the comparator. It may be necessary tounscrew and clean the filter or to replace it(order no. 0550-0183).
In addition, all the ports have filters withplastic rims (order no. 0550-0189) on theback connecting plate of the devices. Thesefilters can be unscrewed and removed forcleaning.
The self-seal push-on fittings of the controller
modules are also fitted with filters. They cannot be renewed.

If a different control behavior is necessary,for example, after modifying the plant, thecontrol behavior of the Type 3423 Controller
Module can be altered by converting or upgrading components, such as adjusters, restrictors or a derivative amplifier.
The required parts are listed in Table 1 on
page 32.
1. Unscrew the fastening screw (6) at thecontroller module and pull the module off
its self-seal push-on fittings. Lift it out of
the control station (control room or fieldhousing).
2. Unscrew screws (3.3) and pull off theconnecting plate (3.2) together withsquare nuts and bolts from the controller
module.
3. Unscrew inside M3 hexagon socket
screws. Remove and/or install the coverplates and adjusters as described below
depending on the version.
4. P to PI: Remove adjuster for operating
point (12) and replace it with Tn restrictor (10).
P to P/PI: Remove adjuster for operating
point (12) and replace it with selector
switch with adjuster for operating point(13) and Tn restrictor (10).
P to PD: Unscrew cover plate (14.1). Remove formed seal (14.3) and insert two
O-rings (14.4) in its place. Fasten deriv-30

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Conversion

ative amplifier (14) in place. Unscrew
cover plate (11.1) and mount Tv restrictor(11).
PI to PID: Same as for P to PD.
P to PID: Same as for P to PD. In addition, replace adjuster (12) with Tn restrictor (10).

(15) in place of the adjuster for operating point (12).
Note
We recommend replacing old O-rings withnew ones as well as replacing the filter in the
restriction (7 in Fig. 1 and Fig. 19).

P controller with set-point-dependent operating point: Attach plate with restriction
P to PI

P to P/PI
13
10
12

6
3.2

10
12
(15)

3.3

14.1, 14.2

14.1, 14.2

11.1, 11.2

P to PD, PI to PID

1012

11.1, 11.2

11FilterRestriction (7)Seals in P and PI
controllers

14.3 14.4 10.2
Fig. 19: Changing the controller function

EB 7500 EN

Seals in PD and PID
controllers

14.4

14

10.2

31

Conversion

Table 1: Spare parts
Part

Qty.

Designation

Order no.

7

1

Restriction with filter

1390-0183

8

Filter in the connecting plate of the manual control unit

0550-0189

10

1

Tn restrictor

1070-4584

10.1

2

M3 x 6 screws

8333-0476

10.2

3

O-rings 1.78 x 1.02

8421-0010

11

1

Tv restrictor

1070-4585

11.1

1

Cover plate0360-1597

11.2

2

M3 x 8 screws

8333-0479

11.3

4

O-rings 2 x 1.5

8421-0023

12

1

Operating point adjuster 1.4 bar

1070-7550

121Operating point adjuster 20 psi

1070-7551

12.1

2

M3 x 8 screws

8333-0479

12.2

4

O-rings 1.78 x 1.02

8421-0010

13

1

Selector switch for operating point adjuster

1080-6909

13.1

2

M3 x 30 screws

8333-0482

13.2

4

O-rings 1.78 x 1.02

8421-0010

141

Derivative amplifier1080-6924

1

Cover plate0360-1598

14.1

1)

14.2

1

M3 x 16 screw

8333-0476

14.3 1)1Formed seal for plate0430-0992

14.4

4 (2)

O-rings 2 x 1.5

8421-0023

15

1

Plate with restriction for set-point-dependent operating point

1590-1089

1)

32

Required for P and PI controller. Not required for PD and PID controller.

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Conversion

9.2 Operating mode changeover in Type 3424-2 i/p
Converter

8. Reinstall converter and plug on the cableconnector.

The i/p module is in the x input in x mode
and in the wext input in wext mode.
1. Release lock and completely pull out theplug-in unit.
2. Pull the three-pin cable connector for themA signal off the converter board.
3. Unscrew the fastening screw (6) at thecontroller module and pull the module off
together with the i/p converter from theself-seal push-on fittings. Lift it out of thecontrol station.
4. Pull the three-pin cable connector for themA signal off the terminal plate.
5. Swap the location of the O-ring andwasher on the holes on the inside of theplate as shown in Fig. 20.
x mode6

5Washer for x mode
O-ring for wext mode

O-ring for wext mode
Washer for x mode

6. Seal tight the wext input of the compact
controller connecting plate (Fig. 16) witha screw plug with 1/8 NPT thread.
The wext port at the plug connection of
the control station must be sealed.
wext mode
7. Open the wext port at the plug connection
by unscrewing the M4 hexagon socket
screw at the wext port and insert 4 x 2
O-ring included.
Seal tight the wext input of the compact
controller connecting plate (Fig. 16) withthe 1/8 NPT screw.

EB 7500 EN

Self-seal push-on
fittings
Blankingplug wext

Fig. 20: Operating mode changeover of i/p
converter33

Conversion

9.3 Checking the controller
function
To check the controller, the controlled variable x and the output y must be bypassed at
ports x and y on the controller station.
Perform the following settings:−− Turnboard A to increasing/decreasing ><,−− Fully open Tn restriction (0.03 min),−− Fully close Tv restriction (0.01 min).
ÎÎ Turn the set point rotary knob to change
the reference variable through its whole
range.
The controlled variable pointer (red) andthe output reading (small dial) follow thereference variable over the whole range
when the controller functions properly.

34

EB 7500 EN

Technical data

10 Technical data
Type 3421 Compact ControllerType 3422 Manual Control Station
Circuit1 and 2

9

Set point/
controlled
variable display

Measuring range 0.2 to 1.0 bar (3 to 15 psi) · Accuracy class 1 (synchronism 0.6) · Scale 0 to
100 %, (linear, square root or special inscription) · Scale length 100 mm

Output display

Output 0 to 1.2 bar (0 to 18 psi) · Accuracy class 2.5 × Scale: 0 to 1.2 bar (0 to 18 psi), length
36 mm

Adjuster for
manual mode

Output 0.2 to 1.0 bar (3 to 15 psi) · Max. 0.02 to 1.35 bar
Max. air delivery >1.5 mn³/h · Air consumption depending on adjuster: 0.1 mn³/hLimit contacts 3)

1 or 2 adjustable limit contacts with proximity switch SJ 3,5-N-Y according to EN 60947-5-6Type 3422 Manual Control Station equippable with ...
Type ... Module3423-1

Controller action

P

3)

PID

3423-53423-63423-9PD

P/PI

PD/PIDP

2)3423-7
Ratio module
Ratio R = a/emechanicallyadjustable,
R = 0.2 to 20

Input

0.2 to 1 bar (3 to 15 psi)

Output

0.2 to 1 bar (3 to 15 psi), max. 0.02 to 1.35 bar (0.3 to 19 psi)
max. air delivery: >1.5 mn³/h · Air delivery with yA setting: approx. 1 mn³/h per % of the systemdeviation · With R setting: approx. 3 mn³/h per % of the system deviation

Air consumption
in steady state in
mn³/h

2)

PI

3423-4

Proportional-action coefficient Kp = 0.2 to 20 or 0.4 to 40
Reset time Tn = 0.03 to 50 min
Derivative-action time Tv = 0.01 to 10 min
Derivative-action gain of x »10
Operating point adjustment: 0.2 to 1.0 bar (3 to 15 psi)

Controlparameters

1)3423-2 1) 3423-3 1)

<0.1

<0.05

<0.13

<0.1

<0.05

<0.05

<0.05

<0.1
Hysteresis <0.4 %(1 % at R >2)

Alignment offset<0.5 %

Tracking error<0.5 %

Dead band<0.01 %

Derivative
element

Deviation of controlled variable x: <1 %(0.4 % at V = 0.5
to 2)

Influence of
supply air at 1.4±0.1 bar<±0.1 % (D element additionally: <±0.2 %)<±1 % (<±0.4 % at
V <2)Temperature
influence/K<0.01 % (D element additionally: <0.01 %)<0.05 % (<0.02 %when V = 0.5 to 2)

Deviation fromterminal-based
linearity <1 %Optionally with maximum feedback limitation
With set-point-dependent operating point
No longer available

EB 7500 EN

35

Technical data

Type 3424-2 ...
Additional Module 1)

i/p converter, 4 to 20 mA or 0 to 20 mA input, 0.2 to 1 bar (3 to 15 psi) output
Input impedance approx. 200 Ω and 4 mH

Type 3424-4

Manual/automatic transfer
Input: 0.2 to 1.0 bar (3 to 15 psi)
Output: 0.2 to 1.0 bar (3 to 15 psi), max. 0.02 to 1.35 bar (0.3 to 19 psi)

Type 3424-5

Control mode changeover · Output: switching pressure approx. 1.4 bar (only for
Types 3423-2/-3)

Type 3424-6Signal limiter for yA, R or w · Limitation adjustable between 0.2 and 1.0 bar (3 and 15 psi)

Supply air

Supply air 1.4 ±0.1 bar (20 ±1.5 psi) · Air consumption per unit <0.15 mn³/hMedium for supply
air and inputs

Instrument air, free from corrosive substances

Air quality acc. toISO 8573-1: 2001

Max. particle size and density: Class 3 · Oil content: Class 2 · Pressure dew point: Class 3 orat least 10 K below the lowest ambient temperature to be expected

Permissible ambient
temperature range–20 to +60 °C

Compliance
Weight (approx.)·
Manual control station (without components): 2.5 kg · Type 3421 with controller module:
3.2 kgType 3421 Controller with controller or additional module: 3.6 kg

No longer available

1)

Technical data for the devices can be found in the following data sheets:
Device designation (Type)

Further details in data sheet

Type 3421 Pneumatic Compact Controller

u T 7506

Type 3422 Manual Control Stationu T 7506

Type 3427 Manual Control Stationu T 7511

Type 3425 Pneumatic Controller (wall-mounted and field
controller)

u T 7512

Type 3416 Indicatoru T 7526

Type 3417 Pneumatic Control Unitu T 7527

Types 3423-1/-2/-3/-4/-5/-6/-7/-9 Controller
Modulesu T 7521

Types 3424-4/-5/-6 Additional Modules

u T 7524

Type 3424-2 Additional Moduleu T 7523

36

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37

38

EB 7500 EN

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39

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samson.de · www.samson.de

2019-04-12 · English

EB 7500 EN