EB 8493S EN
Translation of original instructions

TROVIS SAFE 3793 Smart Positioner (HART®) for on/off valves insafety-instrumented systems

Firmware version 1.00.05
Edition August 2021

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

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.samsongroup.com > Service & Support > Downloads >Documentation.

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 8493S EN

Contents

1
1.1
1.2
1.3

Safety instructions and measures....................................................................7
Notes on possible severe personal injury........................................................10
Notes on possible personal injury..................................................................10
Notes on possible property damage...............................................................11

2
2.1
2.2
2.3
2.4

Markings on the device................................................................................13
Nameplate...................................................................................................13
Option modules............................................................................................14
Electronic module..........................................................................................14
Article code..................................................................................................15

3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9

Design and principle of operation.................................................................18
Versions.......................................................................................................22
Types of attachment.......................................................................................22
Configuration using the TROVIS-VIEW software..............................................22
Device overview and operating controls..........................................................23
Accessories..................................................................................................24
Travel tables.................................................................................................29
Technical data..............................................................................................30
Dimensions in mm.........................................................................................36
Fixing levels according to VDI/VDE 3845 (September 2010)...........................40

4
4.1
4.2
4.3

Measures for preparation.............................................................................41
Unpacking...................................................................................................41
Transporting.................................................................................................41
Storage........................................................................................................41

5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2

Mounting and start-up..................................................................................42
Mounting position.........................................................................................42
Lever and pin position...................................................................................42
Type 3277 Actuator......................................................................................44
Attachment according to IEC 60534-6............................................................46
Rotary actuators (heavy-duty version).............................................................48
Air purging function for single-acting actuators...............................................50
Direct attachment to Type 3277, 240 to 750 cm².............................................50
Attachment according to IEC 60534-6 (NAMUR rib or attachment to rod-type
yokes) and to rotary actuators........................................................................50
Attachment according to VDI/VDE 3847........................................................51
Preparing the positioner for attachment...........................................................52
Mounting on Type 3277 Actuator...................................................................54
Attachment according to IEC 60534-6 (NAMUR)............................................56

5.7
5.7.1
5.7.2
5.7.3

EB 8493S EN

3Contents

5.8
5.9
5.9.1
5.9.2
5.9.3
5.10
5.10.1
5.10.25.10.35.10.4

Pneumatic connections..................................................................................58
Connecting the supply air..............................................................................61
Signal pressure connection............................................................................61
Signal pressure gauges.................................................................................61
Supply pressure............................................................................................62
Electrical connections....................................................................................63
Cable entry with cable gland.........................................................................64
Connecting the electrical power.....................................................................64
Establishing communication...........................................................................65
Switching amplifier according to EN 60947-5-6.............................................66

6
6.1
6.1.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.3.1
6.3.2
6.3.3
6.4

Optional modules.........................................................................................67
Pneumatic modules.......................................................................................68
Installing and removing pneumatic/dummy modules........................................69
Optional additional functions.........................................................................72
Option modules............................................................................................74
Slots for option modules................................................................................75
Dummy option module..................................................................................76
Inserting or removing option modules.............................................................78
Hardware limit switches.................................................................................82
Inserting hardware limit switches....................................................................82
Adjusting the switching points........................................................................85
Shaft locking................................................................................................85
Forced venting..............................................................................................86

7
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1

Operation....................................................................................................87
Rotary pushbutton.........................................................................................87
Initialization key (INIT)...................................................................................88
Switch for forced venting...............................................................................88
Display........................................................................................................89
Menu structure..............................................................................................90
Display icons................................................................................................91
Changing the display's reading direction........................................................92
HART® communication..................................................................................93
Dynamic HART® variables..............................................................................93

8
8.1
8.2
8.3

Operating the positioner...............................................................................95
First start-up.................................................................................................95
Start-up settings............................................................................................96
Enabling configuration..................................................................................96

4

EB 8493S EN

Contents

8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
8.5
8.6
8.7

Start-up menu...............................................................................................97
Setting the actuator type................................................................................97
Specifying the pin position.............................................................................97
Setting the nominal range..............................................................................98
Selecting the initialization mode.....................................................................98
Setting the initialization mode........................................................................99
Defining the fail-safe position.......................................................................102
Assigning the pneumatic primary output.......................................................103
Adjusting the software restriction..................................................................103
Initializing the positioner.............................................................................104
Performing zero calibration.........................................................................105
Resetting the positioner................................................................................106

9
9.1
9.2
9.3

Servicing...................................................................................................108
Cleaning the window in the cover................................................................108
Preparation for return shipment....................................................................108
Firmware update........................................................................................108

10
10.1

Malfunctions..............................................................................................109
Emergency action.......................................................................................112

11
11.1
11.2
11.3

Decommissioning and removal...................................................................112
Decommissioning........................................................................................112
Removing the positioner..............................................................................112
Disposal.....................................................................................................113

12
12.1
12.2
12.3
12.3.112.3.212.3.312.3.412.3.512.3.6

Annex.......................................................................................................114
After-sales service.......................................................................................114
Structure of the main display........................................................................114
Menu structure and parameters (menu level).................................................115
Parameters for on-site operation...................................................................115
Parameters of option modules......................................................................121
Readable process data................................................................................123
Diagnosis: status messages..........................................................................125
Reset functions............................................................................................129
Wizard......................................................................................................129

EB 8493S EN

5

6

EB 8493S EN

Safety instructions and measures

1 Safety instructions and measures
Intended use
The SAMSON TROVIS SAFE 3793 Positioner is mounted onto on/off valves in safetyinstrumented systems for discrete control of the set point. The device can be upgraded byadding pneumatic modules and/or option modules and is designed to operate under exactly
defined conditions (e.g. operating pressure, temperature). Therefore, operators must ensurethat the positioner is only used in applications where the operating conditions correspond to
the technical data. In case operators intend to use the positioner in applications or conditions
other than those specified, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the device for its intended purpose or for damage caused by external forces or any other external
factors.
Î Refer to the technical data for limits and fields of application as well as possible uses.
Reasonably foreseeable misuse
The TROVIS SAFE 3793 Positioner is not suitable for the following applications:− Use outside the limits defined during sizing and by the technical data
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts− Performing maintenance activities not described in these instructions
Qualifications of operating personnel
The positioner must be mounted, started up and serviced by fully trained and qualified
personnel only; the accepted industry codes and practices must be observed. According tothese mounting and operating instructions, trained personnel refers to individuals who areable to judge the work they are assigned to and recognize possible hazards due to their
specialized training, their knowledge and experience as well as their knowledge of theapplicable standards.
Explosion-protected versions of this device must be operated only by personnel who has undergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

EB 8493S EN

7

Safety instructions and measures

Personal protective equipment
No personal protective equipment is required for the direct handling of the positioner. Workon the control valve may be necessary when mounting or removing the device.
Î Observe the requirements for personal protective equipment specified in the valve documentation.
Î Check with the plant operator for details on further protective equipment.
Revisions and other modifications
Revisions, conversions or other modifications of the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Furthermore, the product may no longer meet the requirements for its intended use.
Safety features
Upon failure of the air supply, the positioner vents the actuator, causing the valve to move tothe fail-safe position determined by the actuator. Upon failure of the electrical signal, thepneumatic outputs of the positioner are either vented or filled with air depending on the combination of the pneumatic modules (see Table 14 on page 69). An automated step response test is started to retain the valve's ability to move when the set point is between thepredefined upper and lower test limits.
Warning against residual hazards
The positioner has direct influence on the control valve. To avoid personal injury or property
damage, plant operators and operating personnel must prevent hazards that could becaused in the control valve by the process medium, the operating pressure, the signal pressure or by moving parts by taking appropriate precautions. Plant operators and operating
personnel must observe all hazard statements, warnings and caution notes in these mounting
and operating instructions, especially for installation, start-up and service work.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure, it must be restricted using a suitable supply pressure reducing station.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Operators are obliged to provide these mounting and operating instructions to the operating personnel and to instruct them in proper operation. Furthermore, operators must ensure that operating personnel or third parties are not exposed to any danger.

8

EB 8493S EN

Safety instructions and measures

Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions aswell as the specified hazard statements, warnings and caution notes. Furthermore, the operating personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.
Servicing explosion-protected devices
If a part of the device on which the explosion protection is based needs to be serviced, thedevice must not be put back into operation until a qualified inspector has assessed it according to explosion protection requirements, has issued an inspection certificate or given the device a mark of conformity. Inspection by a qualified inspector is not required if the manufacturer performs a routine test on the device before putting it back into operation and the passing of the routine test is documented by attaching a mark of conformity to the device. Replace explosion-protected components only with original, routine-tested components by the
manufacturer.
Devices that have already been operated outside hazardous areas and are intended for future use inside hazardous areas must comply with the safety requirements placed on serviced
devices. Before being operated inside hazardous areas, test the devices according to thespecifications for servicing explosion-protected devices.
Maintenance, calibration and work on equipment
Î Only use intrinsically safe current/voltage calibrators and measuring instruments for interconnection with intrinsically safe circuits to check or calibrate the equipment inside oroutside hazardous areas.
Î Observe the maximum permissible values specified in the certificates for intrinsically safe
circuits.
Referenced standards, directives and regulations
Devices with a CE marking fulfill the requirements of the Directives 2014/30/EU and2014/34/EU. The declarations of conformity are included at the end of these instructions.

EB 8493S EN

9

Safety instructions and measures

Referenced documentation
The following documents apply in addition to these mounting and operating instructions:− Operating instructions for valve diagnostics: u EB 8389-2S− The mounting and operating instructions of the components on which the positioner ismounted (valve, actuator, valve accessories etc.).

1.1 Notes on possible severe personal injury! DANGER
Risk of fatal injury due to the formation of an explosive atmosphere.
Incorrect installation, operation or maintenance of the positioner in potentially explosive
atmospheres may lead to ignition of the atmosphere and ultimately to death.
Î The following regulations apply to installation in hazardous areas: EN 60079-14(VDE 0165, Part 1).
Î Installation, operation or maintenance of the positioner is to be performed only by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.

1.2 Notes on possible personal injury! WARNING
Risk of personal injury due to moving parts on the valve.
During initialization of the positioner and during operation, the valve moves through its
entire travel range. Injury to hands or fingers is possible if they are inserted into thevalve.
Î During initialization, do not insert hands or fingers into the valve yoke and do nottouch any moving valve parts.

10

EB 8493S EN

Safety instructions and measures

1.3 Notes on possible property damage! NOTICE
Risk of damage to the positioner due to incorrect mounting position.
Î Do not mount the positioner with the back of the device facing upward.
Î Do not seal or restrict the vent opening when the device is installed on site.
Risk of malfunction due to incorrect sequence during start-up.
The positioner can only work properly if the mounting and start-up are performed in theprescribed sequence.
Î Perform mounting and start-up as described in section 5 on page 42.
An incorrect electric signal will damage the positioner.
A current source must be used to power the positioner.
Î Only use a current source and never a voltage source.
Incorrect assignment of the terminals will damage the positioner and will lead to malfunction.
For the positioner to function properly, the prescribed terminal assignment, especially atthe option modules used, must be observed.
Î Connect the electrical wiring to the positioner and option modules according to theprescribed terminal assignment.
Electrostatic discharge will damage the option modules.
Components at risk can be destroyed by even small electrostatic discharge.
Î Observe the ESD requirements according to IEC 61340-5-1.
Î Only store option modules in their original packaging.
Risk of damage of the positioner and option modules due to incorrectly assigned slots.
The slots for the option modules are predesignated (see section 6.2.2).
Î Only insert option modules in their designated slots.

EB 8493S EN

11

Safety instructions and measures

Malfunction due to initialization not yet completed.
The initialization causes the positioner to be calibrated to adapt it to the mounting situation. After initialization is completed, the positioner is ready for use.
Î Initialize the positioner on first start-up.
Î Re-initialize positioner after changing the mounting position.
Î Initialize positioner after replacing or adding pneumatic or option modules.
Risk of positioner damage due to incorrect grounding of the electric welding equipment.
Î Do not ground electric welding equipment near the positioner.
Incorrect cleaning will damage the window.
The window is made of Makrolon® and will be damaged when cleaned with abrasive
cleaning agents or agents containing solvents.
Î Do not rub the window dry.
Î Do not use any cleaning agents containing chlorine or alcohol or abrasive cleaning
agents.
Î Use a non-abrasive, soft cloth for cleaning.

12

EB 8493S EN

Markings on the device

2 Markings on the device
2.1 Nameplate
Explosion-protected version

Version without explosion protection

SAMSON TROVIS SAFE 3793

SAMSON TROVIS SAFE 3793

HART

R

Positioner

1
SupplyInput 4 ... 202mA DC
Pneumatic 3 Single or double acting
output4 Independent single acting

0044

5 A
6 B

II 2 G Ex ia IIC T6 Gb*
II 2 D Ex13
ia IIIC T 80 °C Db*
PTB 15 ATEX XXXX
* See EU Type Exam. Certificate for further values
14£+80 °C-40 °C £ Ta*
Firmware 8 Hardware 9
Model 3793 - 11010
11Var.-ID
Serial no. 12

1
2
3
4
5
6
7
8
9
10
11
12
13
14

R

Positioner

1
SupplyInput 4 ... 202mA DC
Pneumatic 3 Single or double acting
output4 Independent single acting

5 A
6 B

Pressure sensor 7

Pressure sensor 7

SAMSON AG D-60314 Frankfurt

HART

See technical data for ambient temperature
8
HardwareFirmwareModel 3793 - 00010
11
Var.-ID
Serial no.

SAMSON AG D-60314 Frankfurt

912Made in Germany

Made in Germany

Supply pressure
Signal range
Single and double-acting pneumatic module (yes/no)
2x independent, single-acting pneumatic module (yes/no)
Slot A occupied (yes/no)
Slot B occupied (yes/no)
Pressure sensor (yes/no)
Firmware version
Hardware version
Model number
Configuration ID
Serial number
Type of protection for explosion-protected devices
Temperature limits in the test certificates for explosion-protected
devicesEB 8493S EN

13

Markings on the device

2.2 Option modules
If option modules (see section 6.2) are installed into the TROVIS SAFE 3793 Positioner, a label to identify each module is affixed to the device.
SAMSON Z3799 Option module [ 1 ]Inductive limit switch 1 / 2, NO
2Forced venting

1
2

ID code of the option module
Function of the option module See Table 15 on page 74

2.3 Electronic module

SERIAL INTERFACE

Slot

D

SignalSAMSON Module 3793
E3793-000 10
Var.-ID 11
Serial no. 12

14R-12 +11

Electronic HARTC

Slot labelingfor option module(see section 6.2.2)

Terminal assignment forelectrical signal(see section 5.10.2)
10
11
12

Model number
Configuration ID
Serial number

EB 8493S EN

Markings on the device

2.4 Article code
Positioner

TROVIS SAFE 3793- x x x 5 x x x x x x x x 0 0 0 x 0 x 0 x 0 0 9 9 x x

With LCD, autotune, HART® communication
Explosion protection
Without

ATEX

EAC

IECEx

FM

NEPSI

0 0 0

II 2 G Ex ia IIC T4/T6 Gb
II 2 D Ex ia IIIC T 85 °C Db

1 1 0

II 2 D Ex tb IIIC T 85 °C Db

5 1 0

II 3 G Ex nA IIC T4/T6 Gc
II 2 D Ex tb IIIC T 85 °C Db

8 1 0

II 3 G Ex nA IIC T4/T6 Gc

8 5 0

1Ex ia IIC T4/T6 Gb X
Ex ia IIIC T85°C Db X

1 1 3

2Ex nA IIC T4/T6 Gc X
Ex tb IIIC T85°C Db X

8 1 3

Ex ia IIC T4/T6 Gb
Ex ia IIIC T 85 °C Db

1 1 1

Ex tb IIIC T 85 °C Db

5 1 1

Ex nA IIC T4/T6 Gc
Ex tb IIIC T 85 °C Db

8 1 1

Ex nA IIC T4/T6 Gc

8 5 1

IS Class I, II, III, Division 1,
Groups A, B, C, D, E, F, G; Type 4X
NI Class I, II, III, Division 2,
1 3 0
Groups A, B, C, D, E, F, G; Type 4X
Class I, Zone 1, AEx ia IIC; Type 4X
Ex ia IIC T6...T4 Gb
Ex iaD 21 T85

1 1 2

Ex tD A21 IP66 T85°C

5 1 2

Ex nA IIC T6...T4 Gc
Ex tD A21 IP66 T85°C

8 1 2

Ex nA IIC T4...T6 Gc

8 5 2

Pneumatics
Single/double acting, KV = 0.35

0 1Single/double acting, KV = 0.70

0 2Single acting, 2x independent KV = 0.35

0 3

EB 8493S EN

15

Markings on the device

Positioner

TROVIS SAFE 3793- x x x 5 x x x x x x x x 0 0 0 x 0 x 0 x 0 0 9 9 x x

Option module 1 (slot C)
Without/dummy module

0 0Software limit switches + binary output (NAMUR), [N]1 0Software limit switches + binary output (PLC), [X] 1)

1 1

Position transmitter + binary input/output (NAMUR), [T]4 0Forced venting + Binary input/output (NAMUR), [V]

8 0

Option module 2 (slot D)
Without/dummy module

0 0Software limit switches + binary output (NAMUR), [N]1 0Software limit switches + binary output (PLC), [X]

1 1

1)

Inductive limit switches + binary output (NAMUR), [P]; –50
to +85 °C

1 5Mechanical limit switches, [M]; –40 to +85 °C

3 0Position transmitter + binary input/output (NAMUR), [T]4 0Pressure sensors
Without

0Standard (Supply 9, Output 138, Output 238); –40 to +85 °C

1Electrical connection
M20x1.5 (1x cable gland, 3x blanking plugs)

1½-14 NPT (1x cable gland, 3x blanking plugs)

4

Enclosure material
Aluminum (standard)0

Special applications
Without

0

Additional certification
Without

0

Permissible ambient temperatureStandard: –20 to +85 °C, plastic cable gland0–40 to +85 °C metal cable gland

1–55 to +85 °C, low-temperature version with metal cable gland2

Display text in different languages
Standard (English and German)

16

0

EB 8493S EN

Markings on the device

Positioner

TROVIS SAFE 3793- x x x 5 x x x x x x x x 0 0 0 x 0 x 0 x 0 0 9 9 x x

Special version
Without

0

Cover without window

1

Hardware version
1.00.00

9 9

Firmware version
1.00.05
1)

9 6

The option module for Software limit switches + Binary output (PLC), [X] is not available in the explosion-protection
version.

EB 8493S EN

17

Design and principle of operation

3 Design and principle of operation
Î Refer to Fig. 1
The TROVIS SAFE 3793 Electropneumatic
Positioner is mounted on pneumatic control
valves and used to assign the valve position(controlled variable x) to the control signal(set point w). The discrete analysis of the set
point w is performed in automatic mode. The
positioner moves the valve to the operating
point or fail-safe position (see Fig. 2 on
page 20) depending on the definedswitching thresholds. An automated step response test is started (see Fig. 3 onpage 21) when the set point is between
the predefined upper and lower test limits.
The positioner mainly consists of a non-contact travel sensor system (2), pneumatics andthe electronics with the microcontroller (4).
The output of the standard version is either
single or double acting; which means both
the Output 138 and Output 238 can provide
the output variable and route the signal pressure to the actuator.
The positioner can be configured to meetrequirements of an application by adding amaximum of two pneumatic modules (A, B)
and electronic option modules (C, D). The
pneumatic modules mainly consist of a
microcontroller, which operates an i/pconverter with downstream spool valve.
Depending on the actuator used, an outputof the positioner can be sealed to achieve asingle-acting function. The option modules
additionally provide individual functions,18e.g. recognition of the end positions. A list
can be found in section 6.2.1.
The valve position is transmitted either as anangle of rotation or linear travel to the pickup lever, from there to the travel sensor (2)and forwarded to the microcontroller (4).
The PID algorithm in the microcontroller compares the valve position measured by thetravel sensor (2) to the 4 to 20 mA DC control signal issued by the control system after
it has been converted by the A/D converter(3). In case of a set point deviation, thepneumatic module (A, B) causes the actuator(1) to be either vented or supplied with air.
As a result, the closure member of the valve(e.g. plug) is moved to the position determined by the set point.
The pneumatic module is supplied with air.
The flow rate of the module's output can be
restricted by software.
The positioner is operated by a rotary pushbutton (9) for menu navigation on the plaintext display (8).
The extended EXPERTplus diagnostics areintegrated into the positioner. They provide
information on the control valve andpositioner and generate diagnostic andstatus messages, which allow faults to be
pinpointed quickly.

EB 8493S EN

Design and principle of operation

Serial 6
Interface

9

7 FSK

8

#

#

M.1

4

3 E

w

M

µC

#

C

M.2
I

M.3

&

A

D

B

2

M.4
M.5
M.6

p/#
p/#
p/#

Exh

Exhaust 79

Control valve
Travel sensor
A/D converter
Microcontroller
Pressure sensors
Communication interface
HART® connection
Display
Rotary pushbutton

Output 238

Output 138

1
2
3
4
5
6
7
8
9

Supply 9

y

M
M.1
M.2
M.3
M.4
M.5
M.6

5

1
x

A
B
C
D

Slot for pneumatic module A
Slot for pneumatic module B
Slot for option module C
Slot for option module D

Available option modules (see section 6.2 on page 72)
Software limit switches with binary output (NAMUR)
Software limit switches with binary output (PLC)
Inductive limit switches with binary output (NAMUR)
Mechanical limit switches
Position transmitter with binary input and output
Forced venting with binary input and output

Fig. 1: Block diagram

EB 8493S EN

19

Design and principle of operation

On/off valve with ATO setting

On/off valve with ATC setting

If the set point (w, ) is below 75 % when theautomatic mode starts, the valve (x, ) closes.
If the set point rises and exceeds 75 %, thevalve fully opens. If the set point continues todrop under 12.5 %, the valve closes.

If the set point (w, ) is above 12.5 % when
the automatic mode starts, the valve (x, ) fully
opens. If the set point drops below 12.5 %, thevalve closes. If the set point continues to riseand exceeds 75 %, the valve fully opens.

x [%]
w [%]

x [%]
w [%]

x

100

100

w

w

12,5
0

t [s]

If the set point (w, ) is above 75 % when theautomatic mode starts, the valve (x, ) fully
opens. If the set point continues to drop under
12.5 %, the valve closes.
x [%]
w [%]

100
75

x

75

75

12,5
0

t [s]

If the set point (w, ) is below 12.5 % when
the automatic mode starts, the valve (x, )closes. If the set point continues to rise andexceeds 75 %, the valve fully opens.
x [%]
w [%]

x

100

w

12,5
0

75

t [s]

12,5
0

w
x
t [s]

Further information on EXPERTplus Valve Diagnostics u EB 8389-2S.
Fig. 2: Discrete set point analysis

20

EB 8493S EN

Design and principle of operation

On/off valve with ATO setting

On/off valve with ATC setting

Triggering the step response test (PST)

Triggering the step response test (PST)

A step response test is started when the set
point (w, ) moves into the range between 25
and 50 % of the travel (x, ) and remains
there for longer than six seconds.

A step response test is started when the set
point (w, ) moves into the range between 25
and 50 % of the travel (x, ) and remains
there for longer than six seconds.

After the step response test is completed, thevalve moves back to its previous position (openor closed).

After the step response test is completed, thevalve moves back to its previous position (openor closed).

Canceling the step response test

Canceling the step response test

The step response test is canceled whenever theset point (w, ) leaves the range between 25
and 50 %. After the step response test is canceled, the valve (x, ) moves back to its previous position (open or closed).

The step response test is canceled whenever theset point (w, ) leaves the range between 25
and 50 %. After the step response test iscanceled, the valve (x, ) moves back to its
previous position (open or closed).
x [%]
w [%]

x [%]
w [%]
100

x

100

w

w
50

50
25
0

25

w
t>6s

PST

t [s]

0

w

x
t>6s

PST

t [s]

Further information on EXPERTplus Valve Diagnostics u EB 8389-2S.

Fig. 3: Step response test

EB 8493S EN

21

Design and principle of operation

3.1 Versions
The TROVIS SAFE 3793 Electropneumatic
Positioner can be used as a single or double-acting positioner, depending on the combination of the available pneumatic modules.
The modular design also allows diverse optional additional functions to be added andadapt the positioner on site to the specific requirements.
Details to the optional modules:
Î See section 6 on page 67.

3.2 Types of attachment
The TROVIS SAFE 3793 Positioner is suitable
for the following types of attachment using
the corresponding accessories (see section 3.5):− Direct attachment to Type 3277 Actuator:
The positioner is mounted on the yoke.
The signal pressure is connected to theactuator over a connection block: internally over a hole in the valve yoke for"actuator stem extends" fail-safe action
and through an external signal pressureline for "actuator stem retracts" fail-safe
action.
Î See section 5.3− Attachment to actuators according toIEC 60534-6:
The positioner is mounted to the control
valve using a NAMUR bracket.
Î See section 5.4

22− Attachment to rotary actuators according to VDI/VDE 3845:
The positioner is mounted to the rotaryactuator using the corresponding accessories.
Î See section 5.5− Attachment according to VDI/
VDE 3847:
Attachment according to VDI/VDE 3847
using the corresponding accessories allows the positioner to be replaced quickly while the process is running.
Î See section 5.7

3.3 Configuration using the
TROVIS-VIEW software
The positioner can be configured with
SAMSON's TROVIS-VIEW Software(version 4). For this purpose, the positioner
has a digital interface (SSP) to allow the USB
port of a computer to be connected to it
using an adapter cable.
The TROVIS-VIEW software enables the user
to easily configure the positioner as well asview process parameters online.
Note
TROVIS-VIEW can be downloaded free ofcharge from our website at www.
samsongroup.com > Service & Support >Downloads > TROVIS-VIEW.

EB 8493S EN

Design and principle of operation

3.4 Device overview and operating controls

6

5

4

2

3

1
1

6
8

7

1
2
3
4
5
6
7
8

Grounding connection
SSP interface
Signal input terminal
Switch for forced venting
Display
Rotary pushbutton
Initialization key (INIT)
Shaft locking

Fig. 4: Operating controls

EB 8493S EN

23

Design and principle of operation

3.5 Accessories
Table 1: General accessories
Designation

Order no.

Aluminum dummy plate for pneumatic connections
Stainless steel dummy plate for pneumatic connections

1402-1079
1402-1438

M20x1.5 cable gland

Adapter M20x1.5 to ½ NPTBlack plastic (6 to 12 mm clamping range)

8808-1011

Blue plastic (6 to 12 mm clamping range)

8808-1012

Nickel-plated brass (6 to 12 mm clamping range)

1890-4875

Nickel-plated brass (10 to 14 mm clamping range)

1992-8395

Stainless steel 1.4305 (8 to 14.5 mm clamping range)

8808-0160

Powder-coated aluminum

0310-2149

Stainless steel

1400-7114

M lever

0510-0510

L lever

0510-0511

XL lever0510-0512

XXL lever

0510-0525

TROVIS-VIEW 6661
Isolated USB interface adapter (SAMSON SSP interface to USB port on a computer) including TROVIS-VIEW CD-ROM

1400-9740

Set of spare parts, consisting of:− 2x Molded seal for pneumatic interface− 4x Filter− 2x Cover hinge clip

1402-1582

24

EB 8493S EN

Design and principle of operation

Table 2: Direct attachment to Type 3277 (section 5.3)
Mounting parts/accessories

Order no.

Standard mounting kit for direct attachment to actuators (240, 350, 355, 700, 750 cm²)
Connection block with seals and screw
Pressure gauge mounting kit up to max. 6 bar (output/supply)G¼

1400-8819¼ NPT

1402-0901

Stainless steel/brass1402-0938

Stainless steel/stainless steel

1402-0939

G ¼/G 3/8

1400-6444

Order no.

Piping with screw fittings 1)
Actuator (240 cm²), steel
Actuator (240 cm²), stainless steel
Actuator (350 cm²), steel
Actuator (350 cm²), stainless steel
Actuator (355 cm²), steel
Actuator (355 cm²), stainless steel
Actuator (700 cm²), steel
Actuator (700 cm²), stainless steel
Actuator (750 cm²), steel
Actuator (750 cm²), stainless steel
1)1400-7453¼ NPT/3/8 NPT

1402-0911

G ¼/G 3/8

1400-6445¼ NPT/3/8 NPT

1402-0912

G ¼/G 3/8

1400-6446¼ NPT/3/8 NPT

1402-0913

G ¼/G 3/8

1400-6447¼ NPT/3/8 NPT

1402-0914

G ¼/G 3/8

1402-0972¼ NPT/3/8 NPT

1402-0979

G ¼/G 3/8

1402-0973¼ NPT/3/8 NPT

1402-0980

G ¼/G 3/8

1400-6448¼ NPT/3/8 NPT

1402-0915

G ¼/G 3/8

1400-6449¼ NPT/3/8 NPT

1402-0916

G ¼/G 3/8

1402-0974¼ NPT/3/8 NPT

1402-0981

G ¼/G 3/8

1402-0975¼ NPT/3/8 NPT

1402-0982

For "actuator stem retracts" direction of action;with air purging of the top diaphragm chamber;
air purging of the spring chamber for "actuator stem extends" direction of action

EB 8493S EN

25

Design and principle of operation

Table 3: Attachment to NAMUR rib or attachment to rod-type yokes 1) according toIEC 60534-6 (section 5.4)
Travel inmm

Lever For actuator

Order no.

5 to 50

M2)

Actuators from other manufacturers and Type 3271 with 240 to 750 cm²
effective areas

14 to 100

L

Actuators from other manufacturers and Type 3271 with 1000 and 140060 cm²

1400-7455

Type 3271, 1400-120 and 2800 cm² versions with 30/60 mm travel

1400-7466

Mounting brackets for Emerson and Masoneilan linear actuators (in addition, amounting kit according to IEC 60534-6 is required depending on the travel). See
rows above.

1400-6771

Valtek Type 25/50

1400-9554
1400-7456
1402-0806

30 or 60

L

40 to 200

XL

Actuators from other manufacturers and Type 3271 with 1400-120 and
2800 cm² and with 120 mm travel

60 to 300

XXL

Actuators from other manufacturers and Type 3271, 1400-250 cm² with
250 mm travel
Accessories

Connecting plate, aluminum
Connecting plate, stainless steel
Pressure gauge bracket, two pressure gauges, aluminum
Pressure gauge bracket, two pressure gauges, stainless steel
Pressure gauge bracket, three pressure gauges, aluminum
Pressure gauge bracket, three pressure gauges, stainless steel
Pressure gauge mounting kit, with two pressure gauges up to 6 bar

1400-7454

Order no.
G¼

1402-1434¼ NPT

1402-1435

G¼

1402-1436¼ NPT

1402-1437

G¼

1402-1599¼ NPT

1402-1600

G¼

1402-1601¼ NPT

1402-1602

G¼

1402-1578¼ NPT

1402-1579

G¼

1402-1580¼ NPT

1402-1581

Stainless steel/brass1402-0938

Stainless steel/stainless steel

1402-0939

Pressure gauge mounting kit, with two pressure gauges up to 10 bar

1402-1583

Pressure gauge mounting kit, with three pressure gauges up to 10 bar

1402-1528

1)
2)

26

20 to 35 mm rod diameter
M lever is mounted on basic device (included in the scope of delivery)

EB 8493S EN

Design and principle of operation

Table 4: Attachment according to VDI/VDE 3847
Mounting parts

Order no.

Interface adapter VDI/VDE 3847 for TROVIS SAFE 3793

1402-1527

Pressure gauge mounting kit, with three pressure gauges up to 10 bar

1402-1528

Interface adapter 1) VDI/VDE 3847 for Type 3730

1402-0257

Mounting kit for attachment to SAMSON Type 3277 Actuator with 175 to 750 cm²1402-0868

Mounting kit for attachment to SAMSON Type 3271 Actuator or third-party actuators

1402-0869

Travel pick-off for valve travel up to 100 mm

1402-0177

Travel pick-off for 100 to 200 mm valve travel (SAMSON Type 3271 Actuator only)

1402-0178

1)

No air purging function, single-acting function only

EB 8493S EN

27

Design and principle of operation

Table 5: Attachment to rotary actuators (section 5.5)
Mounting parts/accessories

Order no.

Attachment according to VDI/VDE 3845 (September 2010), actuator surface corresponds to fixing
level 1Size AA1 to AA4, heavy-duty version

1400-9244

Size AA5, heavy-duty version (e.g. Air Torque 10 000)

1400-9542

Bracket surface corresponds to fixing level 2, heavy-duty version

1400-9526

Attachment to SAMSON Type 3278 with 160 cm² and to VETEC Type S160, Type R and Type M,
heavy-duty version

1400-9245

Attachment to SAMSON Type 3278 with 320 cm² and to VETEC Type S320, heavy-duty version

1400-5891
and
1400-9526

Attachment to Camflex II

1400-9120
G¼

1402-1434¼ NPT

1402-1435

G¼

1402-1436¼ NPT

1402-1437

G¼

1402-1599¼ NPT

1402-1600

Pressure gauge bracket, two pressure gauges, stainless
steel

G¼

1402-1601¼ NPT

1402-1602

Accessories Pressure gauge bracket, three pressure gauges, aluminumG¼1402-1578¼ NPT

1402-1579

Pressure gauge bracket, three pressure gauges, stainless
steel

G¼

1402-1580¼ NPT

1402-1581

Pressure gauge mounting kit, with two pressure gauges
up to 6 bar

Stainless steel/brass1402-0938

Stainless steel/stainless steel

1402-0939

Connecting plate, aluminum

Connecting plate, stainless steel

Pressure gauge bracket, two pressure gauges, aluminum

28

Pressure gauge mounting kit, with two pressure gauges
up to 10 bar

1402-1583

Pressure gauge mounting kit, with three pressure gauges
up to 10 bar

1402-1528

EB 8493S EN

Design and principle of operation

3.6 Travel tables
Note
The M lever is included in the scope of delivery.
L, XL, XXL levers for attachment according to IEC 60534-6 (NAMUR) are available as accessories (see Table 3 on page 26).
Table 6: Direct attachment to Type 3277 Actuator
Actuator size
[cm²]

Rated travel[mm]

Adjustment range at positioner
Travel [mm]Required
lever

Assigned pin
position

240/35015

7.0 to 35.0M35355/700/750

3010.0 to 50.0

M

50

Table 7: Attachment according to IEC 60534-6 (NAMUR)SAMSON valves with Type 3271
Actuator

Adjustment range at positioner
Other control valves

Actuator size
[cm²]

Rated travel[mm]

Min. travel[mm]

Max. travel[mm]

Required
lever

Assigned pin
position

240/350/355/
700/750

7.5 and 15

7.0

35.0

M

35

355/700/750

30

10.0

50.0

M

50

30

14.0

70.0

L

70

1000/1400/2800

60

20.0

100.0

L

100

1400/2800

120

40.0

200.0

XL

200

1400

250

60.0

300.0

XXL

300

Table 8: Attachment to rotary actuators
Opening angle

Required lever

Assigned pin position

24 to 100°

M

90°

EB 8493S EN

29

Design and principle of operation

3.7 Technical data
Table 9: TROVIS SAFE 3793 Electropneumatic Positioner
TravelAdjustable travel for

Direct attachment to Type 3277:
Attachment according to IEC 60534-6 (NAMUR):
Attachment according to VDI/VDE 3847
Attachment to rotary actuators:

3.6 to 30 mm
5 to 300 mm
5 to 300 mm
24 to 100° (170° 1))

Set point w
Signal range

4 to 20 mA
Two-wire device, reverse polarity protection,
split-range operation (can be configured as required, minimum span
4 mA)

Static destruction limit

40 V, internal current limit approx. 40 mA

Minimum current

3.75 mA for display/operation (HART® communication and configuration)
3.90 mA for pneumatic function

Load impedance≤ 9.9 V (corresponds to 495 Ω at 20 mA)

SupplySupply air

2.5 to 10 bar/30 to 150 psi

Air quality acc. toISO 8573-1

Max. particle size and density:
Oil content:
Pressure dew point:

Signal pressure (output)

0 bar up to supply pressure

Hysteresis≤0.3 %

Sensitivity≤0.1 %, adjustable by software

Start-up time

After interrupted operation < 300 ms: 100 ms
After interrupted operation > 300 ms: ≤2 s

Transit time

Up to 10000 s separately adjustable for exhaust and supply by software

Class 4
Class 3
Class 3 or at least 10 K below the lowest ambient temperature to be expected

Direction of action

Reversible

Air consumption≤300 ln/h with 6 bar supply pressure, depending on module

1)
2)

30

2)

On request
Based on temperature range –40 to +85 °C

EB 8493S EN

Design and principle of operation

Air output capacity (when ∆p = 6 bar)
Actuator (supply)

32 mn³/h with one pneumatic module (KV max (20 °C) = 0.34)
60 mn³/h with two pneumatic modules of the same sort (KV max (20 °C) = 0.64)

Actuator (exhaust)

37 mn³/h with one pneumatic module (KV max (20 °C) = 0.40)
70 mn³/h with two pneumatic modules of the same sort (KV max (20 °C) = 0.75)

Environmental conditions and permissible temperatures
Permissible environmental conditions according to EN 60721-3
Storage

1K6 (relative humidity ≤95 %)Transport

2K4
4K4

Operation–20 to +85 °C: All versions–40 to +85 °C: With metal cable glands–55 to +85 °C: Low-temperature versions with metal cable glands
Observe the limits in the test certificate for explosion-protected versions.

Resistance to vibration
Vibrations (sinusoidal)

According to DIN EN 60068-2-6:
0.15 mm, 10 to 60 Hz; 20 m/s², 60 to 500 Hz per axis
0.75 mm, 10 to 60 Hz; 100 m/s², 60 to 500 Hz per axis

Bumps (half sine)

According to DIN EN 60068-2-29:
150 m/s², 6 ms; 4000 bumps per axis

Noise

According to DIN EN 60068-2-64:
10 to 200 Hz: 1 (m/s²)²/Hz
200 to 500 Hz: 0.3 (m/s²)²/Hz
4 h/axis

Recommended
continuous duty

≤20 m/s²

Influences
Temperature≤0.15 %/10 K

Supply air

None

EB 8493S EN

31

Design and principle of operation

Requirements
EMC

Complying with EN 61000-6-2, EN 61000-6-3, EN 61326-1 andNAMUR Recommendation NE 21

Degree of protection

IP 66

Conformity
Electrical connections
Cable glands

Max. four, M20x1.5 or ½ NPT

Terminals

Screw terminals for 0.2 to 2.5 mm² wire cross-section(max. 1.5 mm² with the option modules)

Explosion protection
Refer to Table 10
Materials
Enclosure and coverDie-cast aluminum EN AC-AlSi12 (Fe) (EN AC-44300) acc. to
DIN EN 1706, chromate and powder coating

Window

Makrolon® 2807

Cable glands

Polyamide, nickel-plated brass, stainless steel 1.4305

Other external parts

Stainless steel 1.4571 and 1.4404 (316 L)

Weight
1.4 to 1.6 kg (depending on version)

32

EB 8493S EN

Design and principle of operation

Table 10: Summary of explosion protection approvals
TROVIS SAFE 3793

Certification

Type of protection
Number BVS 16 ATEX E117

-110

Date

2016-12-01

Number BVS 16 ATEX E117

-510

ATEX
-810

Date

2016-12-01

Number BVS 16 ATEX E117
Date

2016-12-01

Number BVS 16 ATEX E123

-850

Date

2016-12-01

II 2 G Ex ia IIC T4/T6 Gb
II 2 D Ex ia IIIC T 85 °C Db
II 2 D Ex tb IIIC T 85 °C Db
II 3 G Ex nA IIC T4/T6 Gc
II 2 D Ex tb IIIC T 85 °C Db
II 3 G Ex nA IIC T4/T6 Gc

Number TC RU C-DE.PB.B.00127
2018-06-28
Date

1Ex ia IIC T4/T6 Gb X
Ex ia IIIC T85°C Db X

Number TC RU C-DE.PB98.B.00127
2018-06-28

2Ex nA IIC T4/T6 Gc X
Ex tb IIIC T85°C Db X

-111

Number IECEx BVS 16.0084
2016-12-07
Date

Ex ia IIC T4/T6 Gb
Ex ia IIIC T 85 °C Db-511

Number IECEx BVS 16.0084
2016-12-07
Date

Ex tb IIIC T 85 °C Db

Number IECEx BVS 16.0084
2016-12-07
Date

Ex nA IIC T4/T6 Gc
Ex tb IIIC T 85 °C Db

Number IECEx BVS 16.0084
2016-12-07
Date

Ex nA IIC T4/T6 Gc

-113
-813

-811

EAC

Date

IECEx

-851

Number FM16CA0218X
2018-01-06
Date

IS Class I, II, III, Division 1,
Groups A, B, C, D, E, F, G; Type 4X
NI Class I, II, III, Division 2,
Groups A, B, C, D, E, F, G; Type 4X
Class I, Zone 1, AEx ia IIC; Type 4X-112

Number GYJ17.1245X
2017-11-21
Date

Ex ia IIC T6...T4 Gb
Ex iaD 21 T85-512

Number GYJ17.1245X
2017-11-21
Date

Ex tD A21 IP66 T85°C

Number GYJ17.1245X
2017-11-21
Date

Ex nA IIC T6...T4 Gc
Ex tD A21 IP66 T85°C

Number GYJ17.1245X
2017-11-21
Date

Ex nA IIC T4...T6 Gc

-130

-812
-852

EB 8493S EN

FM

NEPSI

33

Design and principle of operation

Table 11: Optional additional functions (see section 6.2 on page 72)
Analog position transmitter
VersionTwo-wire system, galvanic isolation, reverse polarity protection, reversible direction of action

Supply10 to 30 V DC

Output signal

4 to 20 mA

Error indication

2.4 or 21.6 mA

No-load current

1.4 mA

Static destruction limit

38 V DC · 30 V AC

Software limit switches

NAMUR

PLC

Galvanic isolation, reverse polarity
protection, switching output acc. to
EN 60947-5-6

Galvanic isolation, reverse polarity
protection, binary input of a PLC
acc. to EN 61131-2, Pmax =400 mW

Non-conducting≤1.0 mA

BlockedConductive≥2.2 mA

Conductive (R = 348 Ω)

VersionSignalstate

Static destruction limit

32 V DC/24 V AC

Binary output

PLC

Galvanic isolation, reverse polarity
protection, switching output acc. to
EN 60947-5-6

Galvanic isolation, reverse polarity
protection, binary input of a PLC
acc. to EN 61131-2,
Pmax = 400 mW

Non-conducting≤1.0 mA

BlockedConductive≥2.2 mA

Conductive (R = 348 Ω)

32 V DC/24 V AC

32 V DC/50 mA

VersionSignalstate

16 V DC/50 mA

NAMUR

Static destruction limit
Binary input
Version

Galvanic isolation, reverse polarity protection

Voltage input

0 to 24 V DC

Input resistance≥7 kΩON switching state

Ue >15 V

OFF switching state

Ue <11 V

Static destruction limit

38 V DC/30 V AC

34

EB 8493S EN

Design and principle of operation

Forced venting
Version

Galvanic isolation, reverse polarity protection

Voltage input

0 to 24 V DC

Input resistance≥7 kΩ

Signalstate

ActiveUe <11 V

Not active

Ue >15 V

Static destruction limit

38 V DC/30 V AC

Inductive limit switches
VersionFor connection to switching amplifier according to EN 60947-5-6,
SJ2-SN proximity switches, reverse polarity protection

Measuring plate notdetected≥3 mA

Measuring plate detected≤1 mA

Static destruction limit

20 V DC

Permissible ambient temperature–50 to +85 °C

Mechanical limit switches
Floating contact

NC contact/NO contact

Static destruction limit

38 V DC · 30 V AC · 0.2 A

Permissible ambient
temperature–40 to +85 °C

Table 12: Pressure sensors
Pressure sensors
Pressure range

0 to 14 bar

Permissible ambient
temperature–40 to +85 °C

EB 8493S EN

35

Design and principle of operation

40

28

58

14

24

44

102

277

3.8 Dimensions in mm

87

10...17

16

212

70

Attachment according to IEC 60534-6 (NAMUR)

34

36

EB 8493S EN

Design and principle of operation

Pressure gauge bracket, twopressure gauges

46

Pressure gauge bracket, threepressure gauges

100

72

46

Connecting plate

15

EB 8493S EN

37

Design and principle of operation

13

62

24

278

211

Attachment according to VDI/VDE 3847
onto Type 3277 Actuator

164

13

62

38

278

211

Attachment according to VDI/
VDE 3847 to a NAMUR rib

164

38

EB 8493S EN

Design and principle of operation

86

56

Attachment to rotary actuators according to VDI/VDE 3845
Fixing level 1, AA1 to AA4 size, see section 3.9

80
130

30
86
Ø101

166

Lever
z
y
x

EB 8493S EN

Lever

x

y

z

M

25 mm

50 mm

66 mm
116 mm

L

70 mm

100 mm

XL

100 mm

200 mm

216 mm

XXL

200 mm

300 mm

316 mm39

Design and principle of operation

3.9 Fixing levels according to VDI/VDE 3845 (September 2010)
Mmin
Fixing level 2 (bracket surface)

25

M6
C

Fixing level 1 (actuator surface)
Actuator

Dimensions in mm

Ød

B

ØD
A

1)

40

Size

A

B

C

Ød

Mmin

D1)

AA0

50

25

15

5.5 for M5

66

50

AA1

80

30

20

5.5 for M5

96

50

AA2

80

30

30

5.5 for M5

96

50

AA3

130

30

30

5.5 for M5

146

50

AA4

130

30

50

5.5 for M5

146

50

AA5

200

50

80

6.5 for M6

220

50

Flange type F05 acc. to DIN EN ISO 5211

EB 8493S EN

Measures for preparation

4 Measures for preparation
After receiving the shipment, proceed as follows:
1. Check the scope of delivery. Compare
the shipment received with the deliverynote.
2. Check the shipment for transportation
damage. Report any transportation damage.

4.1 Unpacking! NOTICE
Risk of positioner damage due to foreign
particles entering it.
Do not remove the packaging and protective
film/protective caps until immediately before
mounting and start-up.
1. Remove the packaging from the positioner.
2. Dispose of the packaging in accordancewith the valid regulations.

4.2 Transporting− Protect the positioner against external influences (e.g. impact).

4.3 Storage! NOTICE
Risk of positioner damage due to improper
storage.
− Observe the storage instructions.
− Avoid long storage times.
− Contact SAMSON in case of different storage conditions or longer storage times.
Storage instructions− Protect the positioner against external influences (e.g. impact, shocks, vibration).
− Do not damage the corrosion protection(coating).
− Protect the positioner against moistureand dirt. In damp spaces, prevent condensation. If necessary, use a drying
agent or heating.
− Observe storage temperature dependingon the permissible ambient temperature(see technical data in section 3.7).
− Store the positioner with the coverclosed.
− Seal pneumatic and electrical connections.

− Protect the positioner against moistureand dirt.
− Observe transport temperature depending on the permissible ambient temperature (see technical data in section 3.7).

EB 8493S EN

41

Mounting and start-up

5 Mounting and start-up! NOTICE
Risk of malfunction due to incorrect sequence of mounting, installation andstart-up.
Observe the prescribed sequence.

5.2 Lever and pin position
The positioner is adapted to the actuator andto the rated travel by the lever on the back of
the positioner and the pin inserted into thelever.

1. Remove the protective caps from thepneumatic connections.

The travel tables on page 29 show the
maximum adjustment range at the positioner. The travel that can be implemented at thevalve is additionally restricted by the selected
fail-safe position and the required compression of the actuator springs.

2. Mount the positioner on the valve.
Î Section 5.3 onwards

The positioner is equipped with the M lever(pin position 50) as standard (see Fig. 7).

Î Sequence:

3. Perform pneumatic installation.
Î Section 5.8 onwards
4. Perform electrical installation.
Î Section 5.10 onwards
5. Perform settings.
Î Section 8 onwards

5.1 Mounting position! NOTICE
Risk of damage to the positioner due to incorrect mounting position.
− Do not mount the positioner with the backof the device facing upward.
− Do not seal or restrict the vent opening
when the device is installed on site.
Î Observe mounting position (see Fig. 6).
Î Do not seal or restrict the vent opening(see Fig. 5) when the device is installedon site.

42

Note
The M lever is included in the scope of delivery.
L, XL, XXL levers for attachment according toIEC 60534-6 (NAMUR) are available as accessories (see Table 3 on page 26).
If a pin position other than position 50 withthe standard M lever is required or an L or
XL lever size is required, proceed as follows(see Fig. 8):
1. Remove the follower pin (2) from its pin
position and move it to the hole for therecommended pin position (according totravel tables on page 29) and screw
tight. Only use the longer follower pin included in the mounting kit.
2. Place the lever (1) on the shaft of the positioner and fasten it tight using the disk
spring (1.2) and nut (1.1).

EB 8493S EN

Mounting and start-up

Vent opening

Fig. 5: Vent opening(back of the positioner)







!

Fig. 6: Permissible mounting
positions2Fig. 7: M lever with pin position 50
1.1
1.2
1

1
1.1
1.2
2

Lever
Nut
Disk spring
Follower pin

Fig. 8: Mounting the leverand follower pin

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Mounting and start-up

5.3 Type 3277 ActuatorÎ Actuators with 240 to 750 cm² (Fig. 9)
Î Required mounting parts and accessories: Table 2 on page 25.
Î Observe travel tables on page 29.
1. Place follower clamp (3) on the actuator
stem, align it and screw tight so that themounting screw is located in the grooveof the actuator stem.
2. Mount cover plate (10) with narrow sideof the cut-out pointing towards the signal
pressure connection. Make sure that theglued-on flat gasket (14) points towards
the actuator yoke.
3. Check the pin position of the follower pin(2) on M lever (1). Refer to travel tables
for type of attachment. If necessary,change the pin position (see section 5.2).
4. Insert molded seal (15) into the groove of
the positioner housing.
5. Turn the lever counterclockwise until thespring force can be felt (position 1). Continue to turn the lever further to position 2 (see Fig. 9, bottom right).

8. Make sure that the tip of the gasket (16)projecting from the side of the connection block is positioned to match the actuator symbol for the actuator's fail-safe
action "actuator stem extends" or "actuator stem retracts". If this is not the case,
unscrew the three fastening screws andlift off the cover. Turn the gasket (16) by
180° and re-insert it.
9. Place the connection block (12) with theassociated seals against the positioner
and the actuator yoke and fasten using
the screw (12.1). For actuators with failsafe action "actuator stem retracts", additionally remove the blanking plug(12.2) and mount the external signal
pressure pipe.
10. Mount cover (11) on the other side.
Make sure that the vent plug is located at
the bottom when the control valve is installed to allow any condensed waterthat collects to drain off.
Î The ports 238 and 79 must be sealedwith the dummy plate (see section 5.8).

Î If limit switches are installed, read section 6.3.2.

NoteThis type of attachment is not recommended
when two pneumatic modules are used as
the connection block reduces the KV coefficient (see section 6.1).

7. Place positioner on the cover plate insuch a manner that the follower pin (2)rests on the top of the follower clamp (3).
The lever (1) must rest on the follower
clamp with spring force.
Fasten the positioner on the cover plate(10) using the three fastening screws.

Note− If two pneumatic modules are required,perform pneumatic connections as described for attachment according toIEC 60534-6 (see section 5.4).

6. Press the shaft lock (see Fig. 9, bottom
left) to hold the lever in position 2.

44

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1
1.1
1.2
2
3
10
11
11.1
12
12.1

Lever
Nut
Disk spring
Follower pin
Follower clamp
Cover plate
Cover
Vent plug
Connection block
Screw

12.2
14
15
16

Blanking plug or connection
for external piping
GasketMolded seal
Seal
15

14

1

3

2

11

10
11.1

2
Cut-out ofcover plate (10)1.1/1.2

50
90°
35
25

M

View A

View B

G

B

G 3/8

SUPPLY

16

12

12.1

12.2

A

Position 2

M

25

35

°
90

50

Actuator stem
retracts
extends

Position 1
Shaft locking

Lever position for attachment(view to the back of the device)

Fig. 9: Direct attachment to Type 3277 Actuator (240, 350, 355 and 750 cm²)

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45

Mounting and start-up− When two pneumatic modules are used, fit
an additional exhaust port 79 and seal
port 238 (see section 5.8).
− Accessories: see Table 1 on page 24.

5.4 Attachment according toIEC 60534-6
Î Refer to Fig. 10
Î Required mounting parts and accessories: Table 3 on page 26.
Î Observe travel tables on page 29.
1. Screw the two bolts (14) to the bracket(9.1) of the stem connector (9), place thefollower plate (3) on top and use thescrews (14.1) for fastening.
Actuator sizes 2800 cm² and 1400 cm²
with 120 mm travel:− For a travel of 60 mm or smaller,
screw the longer follower plate (3.1)
directly to the stem connector (9).
− For a travel exceeding 60 mm, mountthe bracket (16) first and then the follower plate (3) to the bracket together with the bolts (14) and screws(14.1).

range to the NAMUR bracket (theslot of the follower plate is centrallyaligned with the NAMUR bracket at
mid valve travel).
3. Mount connecting plate (6) or pressuregauge bracket (7) with pressure gauges(8) on the positioner. Make sure that thetwo seals (6.1) are seated properly.
4. Select required lever (1) M, L or XL andpin position according to the actuator
size and valve travel (see travel tables on
page 29 and section 5.2).
5. Place positioner on the NAMUR bracket
in such a manner that the follower pin(2) rests in the slot of the follower plate(3, 3.1). Adjust the lever (1) correspondingly.
Screw the positioner to the NAMUR
bracket using the three fastening screws.

2. Mount the NAMUR bracket (10):− For attachment to the NAMUR rib,use an M8 screw (11) and toothed
lock washer directly in the yoke hole.
− For attachment to valves with rodtype yokes, use two U-bolts (15)around the yoke. Align the NAMUR
bracket (10) according to the embossed scale so that the follower
plate (3) is shifted by half the angle

46

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Mounting and start-up

Attachment to rod-type
yoke
Rods with 20 to 35 mm
diameter

10
9

Attachment to
NAMUR rib

15

9.1
11

16

Additional bracket for actuators with
2800 cm² and travel ≥60 mm
3.1

1
1.1
1.2
2
3
3.1
6
6.1
7
8
9
9.1
10
11
14
14.1
15
16

Lever
Nut
Disk spring
Follower pin
Follower plate
Follower plate
Connecting plate
Seals
Pressure gauge
bracketPressure gauge
Stem connector
Bracket
NAMUR bracket
Screw
Bolt
ScrewsU-boltBracket14

XL and L lever

14.1

3

2
1.1

6.1

6

7

1.2
1

or

8

Fig. 10: Attachment according to IEC 60534-6 (NAMUR)

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Mounting and start-up

5.5 Rotary actuators (heavyduty version)Î Refer to Fig. 12! NOTICE
Risk of positioner damage due to incorrect
direction of rotation of the rotary actuator.
Observe the actuator's direction of rotation
on attaching the positioner as described below.
Î Required mounting parts and accessories: Table 5 on page 28.
Î Prepare actuator and mount possibly required adapter supplied by the actuator
manufacturer.
1. Mount the housing (10) onto the rotaryactuator. In case of VDI/VDE attachment,
place spacers (11) underneath, if necessary.
Details and dimensions for the fixing levels with VDI/VDE 3845 can be found insection 3.9 on page 40.
2. For SAMSON Type 3278 and VETECS160 Rotary Actuators, fasten theadapter (5) onto the free end of the shaft
and for VETEC R Actuator, place on theadapter (5.1). For Type 3278, VETEC S160 and VETEC R Actuators, placeon the adapter (3). For Type 3278, VETEC S160 and VETEC R Actuators, placeon the adapter (3). For VDI/VDE version,
this step depends on the actuator size.
3. Stick adhesive label (4.3) onto the coupling wheel in such a manner that theyellow part of the sticker is visible in the48

window of the housing when the valve is
OPEN (adhesive labels with explanatory
symbols are enclosed and can be stuckon the housing, if required).
4. Fasten coupling wheel (4) on the slotted
actuator shaft or adapter (3) using screw(4.1) and disk spring (4.2).
5. Unscrew the standard follower pin (2)from the positioner's M lever (1).
Attach the follower pin (Ø5 mm) included in the mounting kit to pin position90°.
6. Place positioner on housing (10) andscrew it tight. Taking the actuator's direction of rotation into account, adjust lever(1) so that it engages in the correct slotwith its follower pin (see Fig. 11).
Actuator turning counterclockwise

1

10
4

Actuator turning clockwise

Fig. 11: Direction of rotation

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1
2
3
4
4.1
4.2
4.3

Lever
5
Actuator shaft oradapter
Follower pin
5.1 Adapter
AdapterStem connector10 Adapter housing
10.1 Screws
Screw
11 Spacer
Disk spring
Adhesive label

1

4.1

2

4.2

4.1

4

4.2

4.3
3

4

5.1

4.3
3

5
10.1
10.1

10

10

11

5

SAMSON Type 3278,
VETEC S160,
VETEC R

Attachment according to VDI/
VDE 3845 (Sept. 2010)
Fixing level 1, AA1 to AA4 size

Fig. 12: Attachment to rotary actuators (heavy-duty version)

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Mounting and start-up

5.6 Air purging function for
single-acting actuators
The instrument air leaving the positioner is diverted to the actuator spring chamber to provide corrosion protection inside the actuator.

5.6.1

Direct attachment toType 3277, 240 to
750 cm²

Direction of action: actuator stem extends
Remove blanking plug (12.2, Fig. 9 on
page 45) at the connection block andmake a pneumatic connection to the actuatorchamber on the vented side.
Tip
The corresponding pipe fittings to establish
the air connections are listed in Table 2 on
page 25.

5.6.2 Attachment according toIEC 60534-6 (NAMUR
rib or attachment to rodtype yokes) and torotary actuators
1. Mount the connecting plate and connect
port 79 to the actuator's spring chamber.
2. Seal port 238 in single-acting actuators.
Should other valve accessories be usedwhich vent the actuator (e.g. solenoid valve,volume booster, quick exhaust valve), this exhaust air must also be included in the purging function. The connection at the positioner
must be protected with a check valve (e.g.
check valve G ¼, order no. 8502-0597)
mounted in the piping. Otherwise the pressure in the positioner housing would rise
above the ambient pressure and damage thepositioner when the exhausting components
respond suddenly.

Î If an obsolete connection block that is nolonger available is used (order no.
1400-8811 or 1400-8812), read the attachment instructions described in section 5.6.2.
"Actuator stem retracts" direction of action:
The air purging function is automaticallyprovided.

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Mounting and start-up

5.7 Attachment according to
VDI/VDE 3847
Attachment according to VDI/VDE 3847 allows the positioner to be replaced quickly
while the process is running by blocking the
air in the actuator.
Note
This type of attachment is not recommended
when two pneumatic modules are used as
the connection block reduces the KV coefficient (see section 6.1).

Tip
To monitor the supply air and signal pressure, we recommend mounting pressuregauges (see accessories in section 3.5).
Procedure to block the actuator in place(see Fig. 13):
1. Unscrew the red retaining screw (20).
2. Turn the air blocker (19) on the bottom of
the adapter block according to the inscription.
19

20

Note
If the top pneumatic connections of thepositioner are sealed with the dummy plate,
it must be unfastened before attaching thepositioner.
Details on the pneumatic connections: seesection 5.8.
Note
The adapter bracket (1402-0257) for
Series 3730 Positioners can also be used for
mounting the TROVIS SAFE 3793 Positioner
according to VDI/VDE 3847 with thefollowing restrictions:− Air purging of the actuator's spring chamber is not possible.
− Only single-acting function can be implemented.
− The top ports (238 and 79, see section 5.8) must be sealed with the dummy
plate.

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20
19
Fig. 13: Adapter block for attachment according to VDI/VDE 3847

51

Mounting and start-up

5.7.1

Preparing the positioner
for attachment

1. Unfasten the turnboard (7) from theadapter bracket (6).
2. Place the adapter bracket (6) on the positioner and mount using the screws(6.1).
Î Make sure that the O-rings (9) are correctly seated.
3. Fasten the turnboard (7) to the adapter
bracket (6). Select the required switching
function from Fig. 14 by turning the turnboard.

Double acting

Single acting

Reverse acting

9 138 238 79

9 138 238 79

9 138 238 79

Supply Y1Y2 Supply Y1

Y2

Supply Y1

Y2

Fig. 14: Label on the adapter bracket

Î Make sure that the O-rings are correctlyseated.
Î An arrow on the turnboard points to thecorresponding switching function:
4. Insert the molded seal (6.2) in the grooveof the adapter bracket (6).
5. Select required lever (1) M, L or XL andpin position according to the actuator
size and valve travel (see travel tables on
page 29 and section 5.2).

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1
2
1.1
1.2

9

6

6.2

6.1

7

6.3
8

1
1.1
1.2
2
6
6.1
6.2
6.3
6.4
7
8
9

6.4

Lever
Nut
Disk spring
Follower pin
Adapter bracket
Screws
Molded seal
ScrewsScrewsTurnboard
Blanking plugs
O-rings

Fig. 15: Mounting the adapter bracket on the positioner

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Mounting and start-up

5.7.2

Mounting on Type 3277
ActuatorÎ Required mounting parts and accessories: Table 4 on page 27.
Mount the positioner on the yoke as shownin Fig. 16. The signal pressure is routed tothe actuator over the connecting plate (12),for actuators with fail-safe action "actuator
stem extends" internally through a bore in
the valve yoke and for "actuator stem retracts" through external piping.
Only the Y1 port is required for positioner
attachment. The Y2 port can be used for air
purging of the spring chamber.
1. Place follower clamp (3) on the actuator
stem, align it and screw tight so that themounting screw is located in the grooveof the actuator stem.
2. Insert the molded seal (17.1) into theturnboard (17) and mount the turnboard
to the adapter block (13) using thescrews (17.2).
3. Mount the dummy plate (18) to the turnboard (17) using the screws (18.1).
Make sure that the seals are correctlyseated.
Note
A solenoid valve can also be mounted inplace of the dummy plate (18). The
orientation of the turnboard (17) determines
the mounting position of the solenoid valve.
Alternatively, a restrictor plate can bemounted (u AB 11).

54

4. Insert the screws (13.1) through the middle holes of the adapter block (13).
5. Place the connecting plate (12) together
with the seal (12.1) onto the screws(13.1) corresponding to the fail-safe action "actuator stem extends" or "actuator
stem retracts". The fail-safe action thatapplies is determined by aligning thegroove of the adapter block (13) with thegroove of the connecting plate (12).
6. Mount the adapter block (13) together
with the connecting plate (12) to theactuator using the screws (13.1).
7. Insert the vent plug (11.1) into the Exh.
connection.
8. For fail-safe action "actuator stem extends", seal the Y1 port with a blanking
plug.
For fail-safe action "actuator stem retracts", connect the Y1 port to the signal
pressure connection of the actuator.
9. Press the shaft lock of the positioner prepared as described in section 5.7.1 (seeFig. 9, bottom left) and hold the lever inposition 2.
10. Place positioner in such a manner thatthe follower pin (2) rests on the top of thefollower clamp (3). The lever (1) must reston the follower clamp with spring force.
11. Fasten the positioner to the adapter block(13) using the two fastening screws (6.3).
Make sure the molded seal (6.2) is properly seated (see Fig. 15).
12. Mount cover (11) on the other side.
Make sure that the vent plug is located at
the bottom when the control valve is in-

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1.1
1.2

1
3
11
Exh.

11.1

20
19

13.1
13

12

17.1 17 17.2

1
1.1
1.2
2
3
11
11.1
12
12.1
13
13.1
17
17.1
17.2
18
18.1
19
20

18 18.1

Actuator stem
extends
retracts

12.1

Lever
Nut
Disk spring
Follower pin
Follower clamp
Cover
Vent plug
Connecting plate
Seal
Adapter block
ScrewsTurnboard
Molded seal
ScrewsDummy plate
ScrewsAir blocker
Retaining screw

Z
12

13

Z

Fig. 16: Attachment to Type 3277 Actuator according to VDI/VDE 3847

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Mounting and start-up

stalled to allow any condensed waterthat collects to drain off.

5.7.3

Attachment according toIEC 60534-6 (NAMUR)

Î Required mounting parts and accessories: Table 4 on page 27.
Î Observe travel tables on page 29.
1. Series 240 Valves, actuator size up to
1400-60 cm²: Screw the two bolts (14)to the bracket of the stem connector or
directly to the stem connector (dependingon the version), place the follower plate(3) on top and use the screws (14.1) tofasten it.
Type 3251 Valve, 350 to 2800 cm²:
Screw the longer follower plate (3.1) tothe bracket of the stem connector or directly to the stem connector (dependingon the version).
Type 3254 Valve, 1400-120 to 2800
cm²: Screw the two bolts (14) to thebracket (16). Fasten the bracket (16) onto the stem connector, place the follower
plate (3) on top and use the screws(14.1) to fasten it.
2. For attachment to the NAMUR rib, fasten the NAMUR connection block (10)directly into the existing yoke bore using
the screw and toothed lock washer (11).
Align the marking on the NAMUR valve
connection (on the side marked '1') to
50 % travel.
For attachment to valves with rod-type
yokes using the formed plate (15), which56

is placed around the yoke: screw the four
studs into the NAMUR connection block(10). Place the NAMUR connection blockon the rod and position the formed plate(15) on the opposite side. Use the nuts
and toothed lock washers to fasten theformed plate onto the studs. Align themarking on the NAMUR valve connection (on the side marked '1') to 50 %travel.
3. Insert the molded seal (17.1) into theturnboard (17) and mount the turnboard
to the adapter block (13) using thescrews (17.2).
4. Mount the dummy plate (18) to the turnboard using the screws (18.1). Make
sure that the seals are correctly seated.
Note
A solenoid valve can also be mounted inplace of the dummy plate (18). The
orientation of the turnboard (17) determines
the mounting position of the solenoid valve.
Alternatively, a restrictor plate can bemounted (u AB 11).
5. Fasten the adapter block (13) to the
NAMUR connection block using thescrews (13.1).
6. Insert the vent plug into the Exh. connection.
7. Place the positioner on the adapter block(13) in such a manner that the followerpin (2) rests on the top of the follower
plate (3, 3.1). Adjust the lever (1) correspondingly.

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Mounting and start-up

Exh.

20
19

3

13

13.1

17.1

17

17.2
15

18

18.1
11
10

14.1
2
3
3.1
10
11
13

Follower pin
Follower plate
Follower plate
NAMUR connection block
Screw with toothed lockwasher
Adapter block

13.1
14
14.1
15
16
17

ScrewsBolt
ScrewsFormed plate
BracketTurnboard

3

16

3.1

17.1
17.2
18
18.1
19
20

Molded seal
ScrewsDummy plate
ScrewsAir blocker
Retaining screw

14

Fig. 17: Attachment according to IEC 60534-6 (NAMUR) and VDI/VDE 3847

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Mounting and start-up

8. Select required lever (1) M, L or XL andpin position according to the actuator
size and valve travel (see travel tables on
page 29 and section 5.2).
9. Fasten the positioner to the adapter block(13) using the two fastening screws (6.3).
Make sure the molded seal (6.2) is properly seated.
10. For single-acting actuators without air
purging, connect the Y1 port of theadapter block to the signal pressure connection of the actuator. Seal the Y2 portwith a blanking plug.
For double-acting actuators and actuators with air purging, connect the Y2
port of the adapter block to the signal
pressure connection of the second actuator chamber or spring chamber of theactuator. Seal the Exh. connection in theadapter block with a blanking plug.

5.8 Pneumatic connections! WARNING
Risk of injury by possible movement of exposed parts (positioner, actuator or valve)
after connecting the signal pressure.
Do not touch or block exposed moving parts.
! NOTICE
Incorrect connection of the supply air will
damage the positioner and will lead tomalfunction.
Screw the screw fittings into the connecting
plate, pressure gauge mounting block orconnection block from the accessories.
The four pneumatic ports are located on theback of the positioner (see Fig. 18).
The availability of the Outputs 138 and 238
depends on the pneumatic module combination (see section 6.1).
Î Seal Output 238 and Exhaust 79 with adummy plate (see Fig. 19) if only one
pneumatic output is available.

58

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Mounting and start-up

Exhaust 79

Exhaust 79

Output 238

Output 138

Supply 9

Output 238

Supply 9

Output 138

Fig. 18: Pneumatic connections

Exhaust 79

Output 238

Output 138

Supply 9

Fig. 19: Output 238 and Exhaust 79 sealed with dummy plate

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Mounting and start-up

Note
If one pneumatic module is used, the entire
air passage (screw fitting, pipe, mounting
plate etc.) must have a minimum inside diameter of 5.9 mm.
If two pneumatic modules are used, the entire air passage (screw fitting, pipe, mounting plate etc.) must have a minimum inside
diameter of 7 mm.
We recommend using a larger inside diameter as the air capacity is further reduced
by any turns and kinks in the air passage.
! NOTICE
Risk of malfunction due to failure to comply
with air quality requirements.
Only use supply air that is dry and 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.

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5.9 Connecting the supply air! NOTICE
Risk of malfunction due to incorrect sequence of mounting, installation andstart-up.
Observe the following sequence.
1. Remove the protective caps from thepneumatic connections.
2. Mount the positioner on the valve.
3. Connect the supply air.
4. Connect the electrical power.
5. Perform settings.
The pneumatic connections in the connecting
plate, pressure gauge mounting block andconnection block are optionally designed asa bore with ¼ NPT or G ¼ thread. Customary fittings for metal or copper tubing or
plastic hoses can be used.

Î For "actuator stem extends" fail-safe action: connect the signal pressure to theconnection on bottom of the actuator.
Rotary actuators (heavy-duty version)Î For rotary actuators, the manufacturer's
specifications for connection apply.

5.9.2

Signal pressure gauges

Tip
To monitor the supply air and signal pressure, we recommend mounting pressuregauges (see accessories in section 3.5).
Mounting the pressure gauges:
Î See sections 5.4 and Fig. 10

Î Read instructions in section 5.8.

5.9.1

Signal pressure connection

The signal pressure connection depends on
how the positioner is mounted onto the actuator:
Type 3277 ActuatorÎ The signal pressure connection is fixed.
Attachment according to IEC 60534-6(NAMUR)Î For "actuator stem retracts" fail-safe action: connect the signal pressure to theconnection on top of the actuator.

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Mounting and start-up

5.9.3

Supply pressure

The required supply air pressure depends on
the bench range and the actuator's directionof action (fail-safe action).
The bench range is written on the nameplate
either as the bench range or signal pressure
range depending on the actuator. The direction of action is marked FA or FE or by a symbol.
Actuator stem extends FA (AIR TO OPEN)
Fail-close (for globe and angle valves):
Î Required supply pressure = Upper benchrange value + 0.2 bar, at least 2.5 bar.
Actuator stem retracts FE (AIR TO CLOSE)
Fail-open (for globe and angle valves):
For tight-closing valves, the maximum signal
pressure pstmax is roughly estimated as follows:
pstmax = F +d² · π · ∆p
4·A

[bar]

d = Seat diameter [cm]∆p = Differential pressure across thevalve [bar]A = Actuator area [cm²]F= Upper bench range value of theactuator [bar]If there are no specifications, calculate as
follows:
Î Required supply pressure = Upper benchrange value + 1 bar, at least 2.5 bar.

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5.10 Electrical connections! DANGER
Risk of fatal injury due to the formation of an explosive atmosphere.
For installation in hazardous areas, observe the relevant standards that apply in the countryof use.
Standard applicable in Germany: EN 60079-14 (VDE 0165, Part 1) Explosive Atmospheres – Electrical Installations Design, Selection and Erection.
! WARNING
Incorrect electrical connection will render the explosion protection unsafe.
− Adhere to the terminal assignment.
− Do not undo the enameled screws.
− Do not exceed the maximum permissible values specified in the EC type examination certificates when interconnecting intrinsically safe electrical equipment (Ui or U0, li or I0, Pi or P0,
Ci or C0 and Li or L0).
Selecting cables and wires
Î Observe the relevant clauses of
EN 60079-14 for installation of intrinsically safe circuits.
Î Seal cable entries left unused with plugs.
Î Fit equipment used in ambient temperatures below –20 °C with metal cable entries.
Equipment with type of protection Ex nA
In equipment operated according to type ofprotection Ex nA (non-sparking equipment),
circuits may be connected, interrupted or
switched while energized only during installation, maintenance or repair.
Use certified cable glands and blanking
plugs with appropriate type of protection

EB 8493S EN

and IP rating ≥ 6X and suitable for the certified temperature range.
The signal circuit is connected using screw
terminals (terminal 11/12) for electrical conductors with a wire cross-section from 0.2 to
2.5 mm². The tightening torque is 0.5 to
0.6 Nm.
The option modules’ circuits are connectedusing screw terminals for electrical conductors with a wire cross-section from 0.14 to
1.5 mm². The tightening torque is 0.5 to
0.6 Nm.
Equipment with type of protection Ex t
In equipment operated according to type ofprotection Ex t (protection by enclosure), circuits may be connected, interrupted or
switched while energized only during installation, maintenance or repair.

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Mounting and start-up

Opening the enclosure cover in potentiallyexplosive dust atmospheres during operation
may cause the explosion protection to become ineffective.
Use certified cable glands and blanking
plugs with appropriate type of protection
and IP rating ≥ 6X and suitable for the certified temperature range.
The signal circuit is connected using screw
terminals (terminal 11/12) for electrical conductors with a wire cross-section from 0.2 to
2.5 mm². The tightening torque is 0.5 to
0.6 Nm.
The option modules’ circuits are connectedusing screw terminals for electrical conductors with a wire cross-section from 0.14 to
1.5 mm². The tightening torque is 0.5 to
0.6 Nm.

5.10.1 Cable entry with cablegland
The enclosure of the TROVIS SAFE 3793 Positioner has four threaded boreholes, which
can be fitted with cable glands as required.

connected inside or outside of the device(see Fig. 4 on page 23).

5.10.2 Connecting the electricalpower! NOTICE
Risk of malfunction due to incorrect sequence of mounting, installation andstart-up.
Observe the following sequence.
1. Remove the protective caps from thepneumatic connections.
2. Mount the positioner on the valve.
3. Connect the supply air.
4. Connect the electrical power.
5. Perform settings.
Î Connect the electrical power (mA signal)as shown in Fig. 20.

–12

+11

Î The cable gland version depends on theambient temperature range. See technical data in section 3.7 on page 30.
Î The screw terminals are designed forwire cross-sections of 0.2 to 2.5 mm²(tightening torque 0.5 Nm).

Fig. 20: Terminal assignment

Î Connect one current source at the maximum.
In general, it is not necessary to connect thedevice to a bonding conductor. Should thisbe required, however, this conductor can be64

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Mounting and start-up

Accessories
Cable glands M20x1.5

Order no.

Black plastic(6 to 12 mm clamping range)

8808-1011

Blue plastic(6 to 12 mm clamping range)

8808-1012

Nickel-plated brass(6 to 12 mm clamping range)

1890-4875

Nickel-plated brass(10 to 14 mm clamping range)

1992-8395

Stainless steel 1.4305(8 to 14.5 mm clamping range)

8808-0160

Adapter M20x1.5 to ½ NPT
Powder-coated aluminum

0310-2149

Stainless steel

1400-7114

5.10.3 Establishing communication
Communication between computer andpositioner using an FSK modem or handheld
communicator (if necessary, using an
isolation amplifier) is based on the HART®
protocol.
Viator FSK modem− RS-232

No
Order no. 8812-0130
explosion
protection

− USB

No
Order no. 8812-0132
explosion
protection

If the load impedance of the controller orcontrol station is too low, an isolation amplifier must be connected between controller
Connection in safe area

Handheld communicator orsecond FSK modem
TROVIS SAFE 3793

4 to 20 mA
Controller/
control station
Connection in hazardous area

Safe range

Hazardous area

TROVIS SAFE 3793
Controller/control station

Explosion-protectedisolation amplifier
Handheld communicator or second
FSK modem (explosion-protected)

Fig. 21: Connection with FSK modem

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65

Mounting and start-up

and positioner (interfacing as for positioner
connected in hazardous areas). See Fig. 21.
If the positioner is used in hazardous areas,an explosion-protected isolation amplifiermust be used.
Using the HART protocol, all connected
control room and field units can be addressed individually with their address using
a standard bus.
®

Standard bus:
In the standard bus mode, the positioner follows the analog set point. The bus address/
polling address has to be within a range of
1 to 15.
When communication errors occur:
Communication errors may occur when theprocess controller/control station output is
not HART®-compatible.

5.10.4 Switching amplifieraccording to EN 609475-6
For operation of the limit switches, switching
amplifiers must be connected in the output
circuit. They must comply with the limit values of the output circuits conforming to
EN 60947-5-6.
Î Observe the relevant regulations for installation in hazardous areas.
For applications in safe areas (non-hazardous areas), software limit switches can be directly interconnected to the binary input of
the PLC in accordance with IEC 61131. Thisapplies to the standard operating range for
digital inputs according to Clause 5.2.1.2 of
IEC 61131-2 with the rated voltage of
24 V DC.

Alternatively, a 250 Ω resistor can be connected in series and a 22 μF capacitor canbe connected in parallel to the analog output
of positioners without explosion protection
and positioners with type of protection Ex tb(Fig. 22). The load for the controller output
will increase as a result.
250 Ω
22 µF
Controller/control station

Fig. 22: Adapting the output signal

66

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Optional modules

6 Optional modules
The modular design of the TROVIS SAFE 3793 Positioner allows it to be adapted to specificrequirements. The air capacity and direction of action can be varied by the installation of different pneumatic modules (see section 6.1). Optional additional functions are available byusing option modules (see section 6.2).
If the positioner is ordered with additional pneumatic modules (Fig. 23) and/or option modules (Fig. 24, Fig. 25), they are ready installed and connected upon delivery.

Fig. 23: Pneumatic module

Fig. 24: Option module

Fig. 25: Option module with hardware limit switches (connected with each other over signal lines)

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67

Optional modules

6.1 Pneumatic modules
The air capacity and direction of action in the TROVIS SAFE 3793 Positioner can be varied
by using and combining different pneumatic modules. A maximum of two pneumatic modules can be used in a positioner.
Table 13: Available pneumatic modules for the TROVIS SAFE 3793 Positioner
Article code

Function of the pneumatic module

P3799-0000

Dummy module (seals the slot connections and must be used when only one pneumatic module is installed)

P3799-0001

Output 138 and Output 238 module (single and double acting)

P3799-0002

Output 138 module (single acting)

P3799-0003

Output 238 module (single acting)

P3799-0001
3
2

4

µC

P3799-0002
n

5

3
2

4

µC

6

Output1 Spool valve
2 Travel sensor
3 Microcontroller

n

3
2

4

µC

6

1

SupplyP3799-0003
5Output5

6

1

1

SupplynSupplyOutput4 Safety control circuit
5 i/p converter
6 Pressure reducer

Fig. 26: Design of pneumatic modules! NOTICE
Risk of malfunction due to the incorrect combination of pneumatic modules.
Do not combine modules P3799-0001 and P3799-0003.

68

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Optional modules

Table 14: Combinations of pneumatic modules
Fail-safe position

Slot A

Slot B

Function

Air capacity

Output 138

Output 238

P3799-0001

P3799-0000

Single/double acting

KVS 0.35

ExhaustSupplyP3799-0001

P3799-0001

Single/double acting

KVS 0.70

ExhaustSupplyP3799-0002

P3799-0003

Single acting, 2x independent

KVS 0.35

ExhaustExhaust

6.1.1

Installing and removing pneumatic/dummy modules! WARNING
Risk of injury due to high pressure inside device.
Only install or replace pneumatic modules when the positioner is depressurized.
! NOTICE
Incorrect installation or removal of pneumatic modules will damage the positioner.
Disconnect the electrical power before installing or removing the pneumatic modules.
Two slots are available for the pneumatic modules in the positioner:

Pneumatic modulein slot A

Dummy modulein slot B

Inscription for
slot A

Inscription for
slot B

Fig. 27: Pneumatic module slots

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69

Optional modules

Note
Either two pneumatic modules must be installed or one pneumatic module together
with a dummy module must be installed. A
slot without an installed module is not permissible.

Note
If the changes have been made to the pneumatic modules, the positioner must re-initialized. See section 8.5.

Removing the pneumatic/dummy module
1. Unscrew the fastening screw using a flatblade screwdriver (15 turns of thescrew).
2. Push the module towards the display andcarefully pull it out.
3. Store the module in its packaging.
Installing the pneumatic/dummy module
1. Observe permissible combinations ofpneumatic modules specified in Table 14
on page 69.
2. Check that the seal on the module isproperly seated (see Fig. 29): the sealmust not protrude out of the groove.
3. Turn the screw to push the wedge downward as far as it will go (see Fig. 28).
4. Insert the module as shown in Fig. 30.
Press the module toward the display andinsert it along the wedge.
5. Lightly push the module downward,
while tightening the fastening screw using a suitable flat-blade screwdriver.
Tighten it with a torque of 0.7 ± 0.1 Nm.

70

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Optional modules

Fastening screw

Seal

Wedge
Fig. 28: Wedge for fastening

Fig. 29: Seal of the pneumatic module

Fig. 30: Inserting/exchanging the pneumatic module

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71

Optional modules

6.2 Optional additional
functions
Additional functions are available for the
TROVIS SAFE 3793 Positioner, which can be
added to the positioner as option modules:
Hardware limit switches
Limit contacts with mechanical position pickup issue a signal to a control system whenthe valve reaches one of the two adjustable
limits.
− Inductive limit switches: inductive proximity switches are operated by adjustable tags. The operation of the inductive
limit switches requires switching amplifiers to be connected in the output circuit(see section 5.10.4).
− Mechanical limit switches: microswitches
are operated by rollers with adjustableswitching point.
Software limit switches
The software limit switches signalize that thevalve has reached one of the two adjustable
limits.
− When limit 1 is not reached− When limit 2 is exceeded
The following versions are available:− Connection of a PLC according toIEC 61131-2, Pmax = 400 mW− Connection to NAMUR switching amplifier according to EN 60947-5-6 (see section 5.10.4)

72

Analog position transmitter
The position transmitter is a two-wire transmitter and issues the travel sensor signal as a
4 to 20 mA signal processed by the microcontroller. This signal is issued independentof the positioner's input signal. Additionally,
the position transmitter allows positioner
faults to be indicated over a signal current of<2.4 mA or >21.6 mA.
Forced venting
If the voltage falls below 11 V at the terminals of the option module, the pneumatic
outputs of the positioner are either vented orfilled with air depending on the combinationof the pneumatic modules (see Table 14 on
page 69). This occurs regardless of the set
point. A voltage above 15 V keeps theforced venting function inactive.
Binary input
The binary inputs can be floating or
non-floating (0 to 24 V) and can be configured to provide the following functions:− Switching state: the switching state of thebinary input is logged.
− On-site write protection: after the firstinitialization, a local write protection canbe activated. While the binary input isactive, no settings can be changed at thepositioner. The positioner cannot be
re-initialized.
− PST (partial stroke test): test to check thevalve's ability to move and assess its dynamic control response (PST: partial
stroke test/FST: full stroke test).

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Optional modules–

Start PST: perform a step response
test in an adjustable range.

–

Start FST: perform a step response
test over the entire travel range following configurable parameters.

− Move valve to fixed value: move thevalve to a defined position (valve position in %).
In addition, a binary input can be deactivated.
Binary output
A fault alarm output signalizes a fault to thecontrol station. The following versions areavailable:− Connection of a PLC according toIEC 61131-2, Pmax = 400 mW− Connection to NAMUR switching amplifier according to EN 60947-5-6 (see section 5.10.4)

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73

Optional modules

6.2.1

Option modules

Table 15 lists all available option modules with the combinations of additional functions.
Table 15: Available option modules for the TROVIS SAFE 3793 Positioner
Function
Inductive limit switches
Mechanical limit switches
Software limit switches (NAMUR)
Software limit switches (PLC)
Analog position transmitter
Forced venting

Option module
Article code

Binary input
ID codeZ3799-00000

Dummy module

Z3799-xxx10[N]

Z3799-xxx11[X]

Z3799-xxx15 1)[P]

Z3799-xxx30

[M]

1)

Z3799-xxx40[T]

Z3799-xxx80[V]

Description

Binary output

Sec. 6.2.3

•
•
•

•

Sec. 6.2.4•

Sec. 6.2.4•

Sec. 6.3•

Sec. 6.3

•
•

•

•

Sec. 6.2.4••

Sec. 6.2.4

Consisting of an option module and a mechanical assembly unit

1)

! NOTICE
Risk of malfunction due to the incorrect combination of option modules.
Do not use option modules with the identical ID code together in one positioner.
Table 16: Explosion protection certification for the option modules
Article code of option module

Z3799-

x

x

x

x

x

Explosion protection
Without

0

0

0

Ex ia

1

1

0

Ex t

5

1

0

Ex t/Ex nA

8

1

0

Ex nA

8

5

0

74

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Optional modules

6.2.2

Slots for option modules

A maximum of two option modules can be used in a positioner (Fig. 31).
− Slot C (top slot)− Slot D (bottom slot)
Î Select slots as listed in Table 17 on page 80.
! NOTICE
Incorrect installation of option modules will damage the positioner.
Do not insert the hardware limit switches into slot C.

Option module inserted
into slot C
Option module inserted
into slot D
Inscription at the side:

Slot

R

-12 +11

Electronic HARTCSERIAL INTERFACE

D

SignalSAMSON Module 3793
E3793-000 10
Var.-ID 11
Serial no. 12

Fig. 31: Slots for option modules

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75

Optional modules

6.2.3

Dummy option module

A dummy module is inserted into slot D toprotect the slot's contacts upon delivery of
the positioner without option modules.
! NOTICE
Risk of electronics damage due tounprotected contacts.
Seal empty slots with dummy modules.
Depending on which slot remains free, thedummy module must be adapted to the slotby breaking off the corresponding edges.
Break off the edges with a pair of pliers at
the predetermined breaking points as shownin Fig. 33 and Fig. 34.
Removing the dummy module
1. Take hold of the dummy module at thetabs.
2. Press the tabs and carefully pull the dummy module out of the slot.
Inserting the dummy module
1. Select the right slot for the dummy module.
2. Take hold of the dummy module at thetabs.
3. Press the tabs and carefully push thedummy module into the slot until thelatches engage into the recesses intended
for them.
4. Release the tabs to allow the latches toengage with a clicking sound.

76

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Optional modules

Latch

Tab
Predetermined
breaking points

Fig. 32: Dummy module in the delivered state, inserted into slot D,both slots are sealed.

Fig. 33: Dummy module adapted, top and bottom edges snapped off, inserted into slot C, slot C issealed.

Fig. 34: Dummy module adapted, top edge snapped off, inserted into slot D, slot D is sealed.

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77

Optional modules

6.2.4

Inserting or removing
option modules! DANGER
Risk of fatal injury due to ineffective explosion protection as a result of impermissible
use of the option modules.
Only install option modules with the same
explosion protection as that of the positioner.
! NOTICE
Incorrect installation and removal of option
modules will damage the positioner.
Before inserting or removing the option modules, disconnect the power supply.
! NOTICEElectrostatic discharge will damage theoption modules.
− Observe the ESD requirements according
to IEC 61340-5-1.
− Only store option modules in their original
packaging.
Î Before inserting the option modules,
check their type of explosion protection
according to the article code in Table 16
on page 74.

Inserting the option module
1. Select the slot for option module as listed
in Table 17.
2. Take hold of the option module at thetabs.
3. Press the tabs and carefully push the option module into the slot until the latches
engage into the recesses intended forthem.
4. Release the tabs to allow the latches toengage.
5. Check to ensure the option module isproperly seated.
6. Connect the wiring as shown in Table 17.
Note
After inserting the option module, stick thecorresponding labels (see section 2.2) next
to the positioner's nameplate on the housing.
 Take the label out of the packaging.
Removing the option module
1. Disconnect the connecting lines.
2. Take hold of the option module at thetabs.
3. Press the tabs and carefully pull the option module out of the slot.
4. Store the option module in its packaging.
5. Remove the label from the positioner
housing.

78

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Optional modules

Observe the ESD requirements.

Tab

Tab

Latch

Fig. 35: Inserting the option module

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79

Optional modules

Table 17: Slot position and terminal assignment of the option modules
Z3799-xxx10 [N] · Software limit switches with binary output (NAMUR)
Slot

Terminal assignment

C or D
Description

Terminal

Software limit switch (NAMUR 1)

N

Software limit switch (NAMUR 2)
Binary output (NAMUR)

N
N

+45
–46
+55
–56
+83
–84

Z3799-xxx11 [X] · Software limit switches with binary output (PLC)
Slot

Terminal assignment

C or D
Description

Terminal

Software limit switch (PLC 1)

X

Software limit switch (PLC 2)
Binary output (PLC)

X
X

+91
–92
+93
–94
+95
–96

Z3799-xxx15 [P] · Inductive limit switches with binary output (NAMUR)
Slot

Terminal assignmentD
NOTICE!
Do not insert themodule into slot C.
The option module
will be damaged.

Description

Terminal

Binary output (NAMUR)

P

Inductive limit switch 1
Inductive limit switch 2

80

P
P

+83
–84
+41
–42
+51
–52

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Optional modules

Z3799-xxx30 [M] · Mechanical limit switches
Slot

Terminal assignmentD
NOTICE!
Do not insert themodule into slot C.
The option module
will be damaged.

Description

Switching
function

Mechanical limit
switch 1 (changeover contact)
Mechanical limit
switch 2 (changeover contact)

Terminal
47

NC
M

C

48

NO

49

NC

57
M

C

58
59

NO

Z3799-xxx40 [T] · Position transmitter with binary input (24 V) and binary output (NAMUR)
Slot

Terminal assignment

C or D
Description

Terminal

Position transmitter 4 to 20 mA

T

Binary input 24 V
Binary output (NAMUR)

T
T

+31
–32
+87
–88
+83
–84

Z3799-xxx80 [V] · Forced venting with binary input (24 V) and binary output (NAMUR)
Slot

Terminal assignment

C or DNOTICE!
Set switch forforced venting
function accordingly. See section 6.4.

Description

Terminal

Forced venting

V

Binary input 24 V
Binary output (NAMUR)

EB 8493S EN

V
V

+81
–82
+87
–88
+83
–84

81

Optional modules

6.3 Hardware limit switches
For the hardware limit switches, the mechanical assembly unit must be installed in addition to the option module (limit switches andoption module are connected with each other over signal lines).
! NOTICE
Incorrect installation and removal of option
modules will damage the positioner.
Before inserting or removing the option modules, disconnect the power supply.
! NOTICEElectrostatic discharge will damage the option modules.
− Observe the ESD requirements according
to IEC 61340-5-1.
− Only store option modules in their original
packaging.

6.3.1

Inserting hardware limit
switches

Î Insert the option module for hardware
limit switches only into slot D (bottomslot).
1. Check that the connector on the bottomof the option module is properly seated.
2. Take hold of the option module at thetabs.

4. Release the tabs to allow the latches toengage with a clicking sound.
5. Check to ensure the option module isproperly seated.
6. Guide the mechanical assembly over the
display and insert as shown in Fig. 36.
Make sure that the pinion shaft engages
with the gear wheel for transmission of
the position pick-up.
Î If it cannot be inserted because the gear
wheels are in the way, slightly turn thepinion shaft.
7. Carefully push the mechanical assembly
unit down as far as it will go.
8. Use a suitable screwdriver to tighten thescrews using a tightening torque of
1.2 ± 0.2 Nm.
Note
If the hardware limit switches are installed in
the positioner for the first time, the screws
tap a thread into the boreholes. In this case,it will be more difficult to screw in the screws.
If the hardware limit switches have been
removed, proceed as follows to re-installthem:− Briefly turn the fastening screws counterclockwise with the screwdriver to engage
them into the ready-tapped thread.
− Tighten the screws applying a tightening
torque of 1.2 ± 0.2 Nm.

3. Press the tabs and carefully push the option module into slot D until the latches
engage into the recesses intended for
them.

82

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Optional modules

Observe the ESD
requirements.

2.

1.

3.

Fig. 36: Installing the hardware limit switches

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83

Optional modules

9. Clamp the two connecting lines between
the electronic module and the positioner
housing and push them downward (asshown in Fig. 37).
Î Make sure that the wires do not projectout of the housing and get caught when
closing the housing cover.

Electronic module

10. Connect the wiring as shown in Table 17.
11. Adjust the switching points as describedin section 6.3.2.

Connecting cable

Connecting cable

Fig. 37: Routing the connecting lines

84

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Optional modules

6.3.2

Adjusting the switching
points

The switching points of the limit switches areusually adjusted so that a signal is issued in
the travel/angle end positions. Optionally,
the switching point can also be adjusted toany position within the travel/angle range,e.g. if an intermediate position is to be indicated.

proximity sensor and the output signal
changes.
3. Turn the adjustment screw in the opposite
direction to compensate for the switching
point shift due to temperature changes.
Refer to the following table to determine
how many times the screw must be
turned.
Switching point shift

Both switching points are adjusted at slotted-head screws on the top of the mechanical assembly (Fig. 38):

Limit switch 1
1
2

Limit switch 2
Groove to lock the shaft usinga screwdriverFig. 38: Adjusting the switching points

1. Move the valve to the position at which
the switching point is to be activated.
2. Adjust the switching points as follows:
Mechanical limit switches:
Turn the adjustment screw until the camof cam disk reaches the roller of the microswitch and the output signal changes.
Inductive limit switches:
Turn the adjustment screw until the metal
tag moves out of the magnetic field of theEB 8493S EN

Travel≤ 2°≤ 0.8 mmTurns of the adjustment screw− Limit switch 1 (screw 1)− Limit switch 2 (screw 2)

Opening angle

1/16

1/16

4. Move the valve away from the switchingposition and check whether the output
signal changes.
5. Move the valve back to the switching position and check the switching point.

6.3.3

Shaft locking

To lock the positioner shaft on mounting thepositioner on the valve (see sections 5.3 andFig. 9 on page 45), insert a flat-blade
screwdriver into the groove of the limit switch
assembly (see Fig. 38) and hold the shaft inposition 2.
! NOTICE
Impermissible turning of the positioner
shaft will damage the positioner.
Only adjust the positioner shaft with a flatblade screwdriver to lock it in place duringattachment to the valve.

85

Optional modules

6.4 Forced venting
The switch for the forced venting function (see Fig. 39) is set to the required switch position
upon delivery of the TROVIS SAFE 3793 Positioner. If the option module with forced venting
function is installed later or removed, the switch must be set as shown in Table 18.
Switch for forced
venting

Fig. 39: Switch for forced ventingÎ Set the switch as shown in Table 18 using a flat-blade screwdriver.
Table 18: Switch position
Option module for forced venting function
Slot CNot used

Used

Not used

Used

Slot D

Not usedNot used

Used

Used

0

Switch position

3

1
2

Note
The positioner changes to the fail-safe position if the switch position does not match the option module configuration.

86

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Operation

7 Operation

SSP connection

Display

Switch for forced venting

Rotary pushbutton

Initialization key (INIT)

Fig. 40: Operating controls of TROVIS SAFE 3793 Positioner

7.1 Rotary pushbutton
The rotary pushbutton for on-site operation is located next to the display (right or left, depending on the mounting position).
Turn: select menu item, parameters or values.
Press: confirm setting.
Keep pressed down for two seconds: return to menu level(ESC with progress bar appears).

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87

Operation

7.2 Initialization key (INIT)! WARNING
Risk of injury by exposed moving parts on the positioner, actuator or valve.
Do not touch or block exposed moving parts.
! NOTICE
The process is disturbed by the movement of the actuator or valve.
Do not perform the initialization while the process is running. First isolate the plant by closing
the shut-off valves.
For normal operation, simply start initialization by pressing the INIT key after mounting thepositioner on the valve. In this case, the initialization is performed using the MAX initialization mode (see section 8.4.4) with the ATO fail-safe position (see section 8.4.6). Additionally, the default settings in the parameter list (see section 12.3.1) apply.
Proceed as follows for fast initialization:
1. Mount the positioner on the valve.
2. Connect the supply air.
3. Connect the electrical power.
Î During the first start-up, the wizard is displayed (see section 8.1).
4. Adjust the software restriction as described in section 8.4.8.
5. Use a thin object to press the initialization key (INIT).

7.3 Switch for forced ventingÎ See section 6.4

88

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Operation

7.4 Display
Note
The display's operating range is from –30 to +65 °C. The readability of the display is restricted outside this temperature range.
As soon as the electrical power (mA control signal) is connected, the wizard is displayed
during the first start-up (see section 8.1) and, in all other cases, the main display (Fig. 41,
left) appears, which is marked by the display numbering 0-0 to 0-10 (at the top right-handcorner of the display). Displayed icons provide information on the operating mode, statusetc. (see section 7.4.2). Press the
key to go from the main display to the menu level(Fig. 41, right). All settings can be made and functions executed in the menu level. Section 8.2 contains a description of the basic start-up settings. A list of the menu structure andparameters for on-site operation is included in the Annex (section 12.3 on page 115 onwards).
Main display

Menu level

Display numbering

Operating mode, status,
messages etc.

Display numbering

Display of menus, submenus,
parameters etc.

Fig. 41: Main display and menu level of the TROVIS SAFE 3793 Positioner

Î Turnclockwise to scroll through from display 0-0 to 0-10. Displays 0-0 to 0-10 are
hidden or shown depending on the positioner's operating mode, configuration, statusetc.
Î Press

EB 8493S EN

to go from the main display to the menu level.

89

Operation

7.4.1

Menu structure

Main display
Start screen: Valve position in %See section 7.4.

Valve position in degrees

See section 7.4.

Set point in %See section 7.4.

Set point deviation in %See section 7.4.

Supply pressure in bar

See section 7.4.

Status of pneumatic module in slot A 1)

See section 7.4.

Status of pneumatic module in slot B

See section 7.4.

1)

Status of option module in slot C 1)

See section 7.4.

Status of option module in slot D 1)

See section 7.4.

Messages 2)

See section 7.4.

Press

See section 7.4.

to go to the menu level.

Menu level

90

Target operating mode

See page 115

Set point (open-loop control)

See page 115

Manual set point (MAN)See page 115

Reason for fail-safe position

See page 115

Change reading direction

See section 7.4.3.

User level

See section 8.3.

Start-up

See section 8.4 and page 116

Configuration

See page 118

Set point processing

See page 118

Identification

See page 119

HART® communication

See page 120

EB 8493S EN

Operation

1)
2)

Control parameters

See page 120

Slot options

See page 121

Pneumatic modules

See page 121

Process data

See page 123

Diagnosis/maintenanceSee page 124

Reset functions

See section 8.7.

WizardSee section 8.1.

Reading only in the event of an error
Some of the messages can be confirmed: in this case, select the message and press
ble when the configuration is enabled, see section 8.3).

7.4.2(only possi-

Display icons

Table 19: Operating modes
Icon

1)

Operating mode

Description

Automatic mode

The positioner is in closed-loop operation and follows the mA
signal.

Manual mode

The positioner follows the manual set point instead of the mA signal.

SAFE(fail-safe position)

The pneumatic outputs of the positioner are either vented or
supplied with air depending on the combination of the pneumatic
modules (see Table 14).

Open-loop control
mode 1)The open-loop control mode allows the valve position to be adjusted
manually (even when the positioner has not been initialized).

Function mode

The positioner is being initialized or a test is in progress.

The open-loop control mode cannot be directly selected. It acts the same as the manual mode when
the positioner has not yet been initialized.

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Table 20: NAMUR status
Icon

Meaning
FailureFunction check
Out of specification
Maintenance demanded
OK

Table 21: Other icons
Icon

Meaning
Configuration enabled (on-site write protection is deactivated)
Write protection
Option module in slot C
Option module in slot D
Binary contact 1 active
Binary contact 2 active
Binary contact 3 active

7.4.3

Changing the display's reading direction

The reading direction of the display can be adapted to the mounting situation (turned 180°)at any time.
1. Press(in start screen) to go to the main menu.

2. Turn

until 'Change reading direction' appears.

3. Pressto change reading direction.

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7.5 HART® communication
Conditions for HART® communication:
Î Supply the positioner with at least 3.6 mA.
Î Connect the FSK modem in parallel to the current loop.
A DTM file (Device Type Manager) conforming to the Specification 1.2 is available for communication. This allows the device, for example to be run with the PACTware user interface.
All the positioner's parameters are accessible over the DTM and the user interface.
Î For start-up, first proceed as described in section 8.
Note
If complex functions are started in the positioner, which require a long calculation time orlead to a large quantity of data being saved in the volatile memory of the positioner, the alert'busy' is issued by the DTM file. This alert is not an error message and can be simply confirmed.
Locking HART® communication
The write access for HART® communication can be locked. This function can be enabled or
disabled locally at the positioner (Configuration [8]/HART communication [8.3]/Locked[8.3.1]) (setting options: Yes/No, default setting: No, see parameter list on page 120).
Locking on-site operation
The on-site operation can be locked over HART® communication. This locking function can
only be disabled over HART® communication. On-site operation is enabled by default.
Note
The access over TROVIS-VIEW is also locked through the locking of on-site operation over
HART® communication.

7.5.1

Dynamic HART® variables

The HART® specification defines four dynamic variables consisting of a value and an engineering unit. These variables can be assigned to device parameters as required. The universal HART® command 3 reads the dynamic variables out of the device. This allows manufacturer-specific parameters to also be transferred using a universal command.

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In the TROVIS SAFE 3793 Positioner, the dynamic variables can be assigned as follows in
the Configuration folder (> HART communication):
Table 22: Dynamic HART® variables assignment
VariableUnit, description

Set point at the input%

Valve position%

Set point deviation%

Condensed state

Current state active/not active

Slot C.1: binary input

Current state active/not active 1)

Slot D.1: binary input

Current state active/not active 1)

Slot C.2: binary input

Current state active/not active 1)

Slot D.2: binary input

Current state active/not active 1)

Slot C.3: binary input

Current state active/not active 1)

Slot D.3: binary input

Current state active/not active 1)

Total valve travel

Current total valve travel

Current temperature

Reading of current temperature

PST outcome

Not performed/successful/test-specific error message

FST outcome

Not performed/successful/test-specific error message

Discrete valve position

Positioner not initialized, Closed, Open, Intermediate position

Supply pressure

bar

1)

Parameter assessment depends on the optional equipment used in the positioner

Note
The 'OUTPUT 138: pressure' and 'OUTPUT 238: pressure' parameters are also listed in
TROVIS-VIEW. These parameters are currently not assessed.

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8 Operating the positioner! NOTICE
Risk of malfunction due to incorrect sequence of mounting, installation and start-up.
Observe the following sequence.
1. Remove the protective caps from the pneumatic connections.
2. Mount the positioner on the valve.
3. Connect the supply air.
4. Connect the electrical power.
5. Perform settings.
Once the mounting and start-up activities have been completed, you can start with the settings (see section 8.2). The positioner can be operated immediately after the electrical power
supply (mA control signal) has been connected.

8.1 First start-up
After the TROVIS SAFE 3793 Positioner is put into operation for the first time after shipment,
the wizard starts automatically after the electrical power is connected. It assists users to set
the display's reading direction and the menu language (English upon first start-up). The
reading direction of the display depends on the mounting position (position of the pneumatic
modules, right or left of the display).
1. Turn: determine the reading direction of thedisplay (mounting position with pneumatic modules on the right or left of the display).
2. Press

twice: confirm reading direction.

3. Turn: select language.

4. Pressthree times: confirm language.

Î Afterwards, the display automatically changes to the main display (see Fig. 41).
Î When ESC is selected in the wizard, you can navigate through the displays of the
wizard 1/3 (mounting position), 2/3 (language) and 3/3 (exit wizard) by selecting
forward (>) and back (<).
Î If no settings are entered within five minutes, the positioner automatically returns to themain display (see Fig. 41).

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8.2 Start-up settings
Î Perform the start-up settings, keeping the following sequence:
ActionSection

1. Enable configuration

8.3

2. Select 'Start-up' menu

8.4

3. Set the actuator type

8.4.1

4. Specify pin position

8.4.2

5. Setting the nominal range

8.4.3

6. Select initialization mode

8.4.4

7. Set initialization mode

8.4.5

8. Defining the fail-safe position

8.4.6

9. Assign the pneumatic output

8.4.7

10. Adjust the software restriction

8.4.8

11. Initialize the positioner

8.5

8.3 Enabling configuration
1. Press(in start screen) to change to the main menu.

2. Turn

until User level [6] appears.

3. Press and turn

until On-site: write appears.

4. Pressto confirm.

5. Keep

pressed down for two seconds to return to the start screen.

Î Configuration is enabled: indicated by

icon.

Note
Configuration is locked again if no settings are entered within 5 min.

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8.4 Start-up menu
1. Press(in start screen) to change to the main menu.

2. Turn

until Start-up [7] appears.

3. Pressto go to the Start-up menu.

8.4.1

Setting the actuator typeThree different parameters are available for selection:− Linear actuator− Rotary actuator− Linear actuator (expert) with separate setting options for pin position and nominal range
1. Turn(within Start-up [7] menu) until Actuator [7.1] appears.

2. Press and turn
3. Press

8.4.2

to set the actuator type.

to confirm the setting.

Specifying the pin position

The setting options depend on the entered actuator type:− For linear actuator: Pin position [7.2] 'None', 17, 25, 35, 50, 70, 100, 200 or 300 mm− For rotary actuator: pin position [7.3]: 90° and 'No lever'− For linear actuator (expert): Pin position [7.4]: 10 to 9999 mm
1. Turn(within Start-up [7] menu) until Pin position [7.2/7.3/7.4] appears.

2. Press and turn
3. Press

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to enter the pin position to match how the actuator is mounted.

to confirm the setting.

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Operating the positioner

Note
A pin position needs to be entered for the NOM and SUB initialization modes. See section 8.4.5.

8.4.3

Setting the nominal range

The possible adjustment range depends on the entered pin position.
1. Turn(within Start-up [7] menu) until Nominal range [7.5/7.6/7.7] appears.

2. Press and turn
3. Pressto set the nominal range.

to confirm the setting.

Note
If no pin position has been entered, Nominal range is only available for the Linear actuator(expert) actuator type.

8.4.4

Selecting the initialization mode

During initialization, the positioner adapts itself optimally to the friction conditions and the signal
pressure required by the control valve. The type and extent of autotuning depends on the initialization mode selected. The following initialization modes are available:
MAX: Maximum range
The positioner determines travel/angle of rotation of the closing member from the CLOSED
position to the opposite travel stop and adopts this travel/angle of rotation as the operating
range from 0 to 100 %.
NOM: Nominal range · Initialization mode for all globe valves
The calibrated sensor allows the exact valve travel to be measured very accurately. Duringinitialization, the positioner checks whether the control valve can move through the indicatednominal range (travel or angle) without collision. If this is the case, the indicated nominal
range is adopted as the operating range.

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MAN: Manually selected end positions · Initialization mode for globe valves
Before starting initialization, move the control valve manually to the end positions. The positioner calculates the travel/angle difference from the two positions that the valve moved toand adopts it as the operating range. This initialization mode can only be started when thevalve position differs in the end positions and the positioner has not yet been initialized.
SUB: Substitute calibration · To replace a positioner while the plant is running
A complete initialization procedure takes several minutes and requires the valve to movethrough its entire travel range several times. In the SUB initialization mode, the control parameters are estimated and not determined by an initialization procedure. As a result, a highlevel of accuracy cannot be expected. A different initialization mode should be selected if theplant allows it.
The substitute calibration is used to replace a positioner while the process is running. For thispurpose, the control valve is usually blocked mechanically in a certain position or pneumatically by means of a pressure signal which is routed to the actuator externally. The blocking
position ensures that the plant continues to operate with this valve position. The blocking position can also be the fail-safe position when this condition is beneficial for the temporary
phase.
Perform a reset before re-initializing the positioner if the substitute positioner has alreadybeen initialized. Refer to section 8.7.

8.4.5

Setting the initialization mode

Note
Configuration is locked again if no settings are entered within 5 min. Enable configuration:see 8.3.
Setting the MAX and NOM initialization modes:
1. Turn(within Start-up [7] menu) until Initialization mode [7.10] appears.

2. Press and turn
3. Press

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to set the MAX or NOM initialization mode.

to confirm the setting.

99Operating the positioner

Note
A pin position needs to be entered for the NOM initialization mode. See section 8.4.2.
Setting the MAN initialization mode
Note
The MAN initialization mode can only be started when the valve position differs in the end
positions and the positioner has not yet been initialized.
1. Turn(within Start-up [7] menu) until Initialization mode [7.10] appears.

2. Press and turnto set the MAN initialization mode.

3. Pressto confirm the setting.

4. Turn

until Set point (open-loop control) [7.12] appears.

5. Press and turn90°.

to move the valve to the first end position. Enter a value from –90 to

6. Pressto confirm the value (first end position).

7. Turn

until Adopt valve position 1 [7.13] appears.

8. Pressto confirm the entered first valve position as valve position 1.

9. Turn

until Set point (open-loop control) [7.12] appears.

10. Press and turnto 90°.

to move the valve to the second end position. Enter a value from –90

11. Press

to confirm the value (second end position).

12. Turn

until Adopt valve position 2 [7.15] appears.

13. Press

to confirm the entered second valve position as valve position 2.

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Setting the SUB initialization mode
Note
The SUB initialization mode is a substitute calibration, which can be selected to replace a positioner while the process is running. In this mode, the control parameters are estimated andnot determined by an initialization procedure. As a result, a high level of accuracy cannot be
expected. A different initialization mode should be selected if the plant allows it.
The SUB initialization mode can only be started when the positioner has not yet been initialized.
1. Write down the current valve position in %.
2. Turn(within Start-up [7] menu) until Initialization mode [7.10] appears.

3. Press and turnto set the SUB initialization mode.

4. Pressto confirm the setting.

5. Turn

until Pin position [7.2/7.3/7.4] appears.

6. Press and turnto enter the pin position to match how the actuator is mounted.

7. Pressto confirm the setting.

8. Turn

until Nominal range [7.5/7.6/7.7] appears.

9. Press and turnto set the actuator's nominal range.

10. Press

to confirm the setting.

11. Turn

until Current valve position [7.17] appears.

12. Press and turnto set the current valve position in % (see step 1), at which the valve iscurrently blocked.
13. Turn

until Direction of rotation [7.18] appears.

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14. Press and turnto set the direction of rotation so that the lever's direction of rotation
matches the valve's closing direction.
Example:The valve closes when the plug stem moves downward. This action causes the positioner's lever to turn counterclockwise (when looking at the display).
Î Setting: Counterclockwise

Note
After performing the SUB initialization, the control parameters can be changed (Configuration [8]/Control parameters [8.4], see section 12.3.1).

8.4.6

Defining the fail-safe position

Define the fail-safe position of the valve taking the valve type and the actuator's direction ofaction into account:
Fail-safe position

Description

AIR TO OPEN
(closing)

Signal pressure opens the valve, e.g. for a fail-close valve

AIR TO CLOSE(opening)

Signal pressure closes the valve, e.g. for a fail-open valve

1. Turn(within Start-up [7] menu) until Fail-safe position [7.11] appears.

2. Press

and turn it to set the fail-safe position AIR TO OPEN or AIR TO CLOSE.

3. Pressto confirm the setting.

For checking purposes: after initialization is completed, the positioner display must read 0 %when the valve is closed.

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8.4.7

Assigning the pneumatic primary output

Which pneumatic signal on which the diagnostics are to be based upon must be defined.
OUTPUT 138 is set by default.
1. Turn(within Start-up [7] menu) until Output P3799 (primary) [7.19] appears.

2. Press and turn
3. Press

8.4.8

to assign OUTPUT 138 or OUTPUT 238.

to confirm the setting.

Adjusting the software restriction

The software restriction serves to adapt the air output capacity to the size of the actuator. The
software restriction can be set for the supply or exhaust:
1. Turn(within Start-up [7] menu) until Software restriction (supply) [7.21] appears.

2. Press and turnto set the value (100, 75, 50 or 25 %).

3. Pressto confirm the setting.

4. Turn

until Software restriction (exhaust) [7.22] appears.

5. Press and turn
6. Pressto set the value (100, 75, 50 or 25 %).

to confirm the setting.

Note
The positioner must be re-initialized if the software restriction settings are changed after initialization.
Tip
We recommend setting the software restriction for supply and exhaust for actuators with diaphragm areas ≤ 240 cm² as specified in Table 23.

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Table 23: Recommended settings for supply and exhaust in actuators with diaphragm areas≤240 cm²
Actuator area

175 cm²

240 cm²

Number of pneumatic modules

1

1

Value for software restriction

25 %

50 %

8.5 Initializing the positioner
Once all settings have been made according to section 8.4, the positioner initialization canbe started.
! WARNING
Risk of injury by exposed moving parts on the positioner, actuator or valve.
Do not touch or block exposed moving parts.
! NOTICE
The process is disturbed by the movement of the actuator or valve.
Do not perform the initialization while the process is running. First isolate the plant by closing
the shut-off valves.
Note
The initialization can only be started over the menu after configuration has been enabled.
1. Turn(within Start-up [7] menu) until Start initialization [7.24] appears.

2. Pressto start initialization.

3. Confirm warning with OK.
4. Wait until the initialization process is completed.
After initialization, the positioner remains in the Start initialization [7.24] menu item.
Î Keep104

pressed down for two seconds to return to the main menu.

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Operating the positioner

Î Keeppressed down again for two seconds to return to the start screen.

The valve position appears in % on the display. The positioner is in the automatic mode (icon), the NAMUR status is OK ( icon) and configuration is still enabled ( icon).
Î The positioner is ready for use.

Tip
Initialization can also be started by pressing the initialization key (INIT). See section 7.2.

8.6 Performing zero calibration
In case of inconsistencies in the closed position of the valve, e.g. with soft-seated plugs, it
might be necessary to recalibrate zero. During zero calibration, the valve moves once to theclosed position.
! WARNING
Risk of injury by exposed moving parts on the positioner, actuator or valve.
Do not touch or block exposed moving parts.
! NOTICE
The process is disturbed by the movement of the actuator or valve.
Do not perform the zero calibration while the process is running. First isolate the plant byclosing the shut-off valves.
Note
A zero calibration is not possible if there is zero point shift of more than 5 %.

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1. Turn(within Start-up [7] menu) until Start zero calibration [7.25] appears.

2. Pressto start zero calibration.

3. Confirm warning with OK.
4. Wait until zero calibration is completed.
After zero calibration, the positioner remains in the Start zero calibration [7.25] menu item.
Î Keeppressed down for two seconds to return to the main menu.

Î Keeppressed down again for two seconds to return to the start screen.

8.7 Resetting the positioner
A reset allows the positioner to be reset to the default settings. The TROVIS SAFE 3793 Positioner has the following reset options:
Reset function

Description

Sample application

Reset diagnosis

Resets all diagnostic functions including graphs and histograms.

Diagnosis analyses of operating
hours in the past are no longer relevant.

Reset (standard)

Resets the positioner to the state as
upon delivery. Actuator andvalve-specific settings remain unchanged.

Positioner has been repaired or
modified. The diagnosis data are
no longer relevant. The positioner
must be re-initialized.

Reset (advanced)

All parameters will be reset to theirdefaults adjusted upon delivery.

Positioner is mounted on anotheractuator/valve.

Restart

The positioner is shut down and restarted.

Putting the device back into operation after failure

Reset initialization

All parameters for the start-up settings (see section 8.2) are reset.
The positioner needs to be re-initialized afterwards.

Changes to the start-up settings arenecessary.

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1. Turn(within main menu) until Reset functions [11] appears.

2. Pressto go to the menu.

3. Turn

to select a reset function.

4. Pressto perform the reset function.

5. Confirm warning with OK.
6. Wait until the reset function is completed.

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Servicing

9 Servicing

Proceed as follows to return devices to
SAMSON:Note
The positioner was checked by SAMSON
before it left the factory.
− The product warranty becomes void ifservice or repair work not described inthese instructions is performed without
prior agreement by SAMSON's After-sales
Service.
− Only use original spare parts by
SAMSON, which comply with the original
specifications.

1. Put the control valve out of operation.
See associated valve documentation.

9.1 Cleaning the window inthe cover! NOTICE
Incorrect cleaning will damage the window.
The window is made of Makrolon® and will
be damaged when cleaned with abrasive
cleaning agents or agents containing solvents.
− Do not rub the window dry.
− Do not use any cleaning agents containing
chlorine or alcohol or abrasive cleaning
agents.
− Use a non-abrasive, soft cloth for cleaning.

9.2 Preparation for return shipment

2. Fill in the Declaration on Contamination.
The declaration form can be downloaded from our website atu www.samsongroup.com > Service >After Sales Service.
3. Remove the positioner (see section 11).
4. Send the positioner to your nearest
SAMSON subsidiary. SAMSON subsidiaries are listed on our website atu www.samsongroup.com > About
SAMSON > Sales offices.

9.3 Firmware update
Contact your local SAMSON engineeringand sales office or subsidiary(u www.samsongroup.com > About
SAMSON > Sales offices) to request afirmware update.
Required specifications
Please submit the following details on requesting a firmware update:− Type− Serial number− Configuration ID− Current firmware version− Required firmware version

Defective positioners can be returned to
SAMSON for repair.

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10 Malfunctions
Malfunctions are indicated on the display by error messages in conjunction with an icon for
status classification (see Table 24) and an error ID. Table 25 lists possible error messages andrecommended action.
Note− Contact SAMSON's After-sales Service for malfunctions not listed in the table.
− The status classification of error messages can be changed in SAMSON's TROVIS-VIEW
software.
Table 24: Icon showing status classification
Icon

Meaning
FailureFunction check
Out of specification
Maintenance demanded

Table 25: Troubleshooting
Error ID

StatusMessage

Recommended action

1

Init: rated travel not achievedÎ Check attachment and pin position.

3

Valve does not moveÎ Check positioner mounting, pin positionand supply air. Check piping and configuration of the mounting parts. Movethe positioner out of the fail-safe position.

21

Pin position incorrect

Î Check pin position.

27

Positioner not initializedÎ Perform an initialization.

31

Initialization canceled (external)

Î Check power supply/electrical signal.
Î Check whether the forced venting is active.

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Malfunctions

Message

Recommended action

100

Error ID

StatusP3799: combination

Î Check configuration. Install correction
pneumatic modules.

101

No pneumatic module installedÎ Install pneumatic module (at least one
pneumatic module must be installed).

144

Temperature below minimum
temperatureÎ Check the ambient temperature.

145

Temperature above maximum
temperatureÎ Check the ambient temperature.

146

Function check active

The positioner is in the test mode (e.g. initialization process, step response test etc.).
Î Wait until the test is completed or cancel
it.

149

BrownoutÎ Check power supply/electrical signal.

153

Current too low

Î Check power supply/electrical signal.

154

Current too highÎ Check power supply/electrical signal.

155

Dynamic stress factor exhausted.

Î We advise ordering the spare part soon.

156

Total valve travel exceededÎ Check the control valve to ensure it functions properly.

157

Forced venting

Î Check supply voltage. Search for thereason why the forced venting was triggered.

162

Combination Z3799

Î Remove the option module and, if necessary, replace it with another option
module.

194

Tolerance band (set point deviation)

Î Check positioner attachment and supply
pressure.

195

Lower end position shiftedÎ Check seat and plug.

196

Upper end position shiftedÎ Check seat and plug.

201

Switch position for forced venting
function incorrect

Î Set correct switch position.

207

No supply pressureÎ Check the supply pressure.

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Malfunctions

Message

Recommended action

208

Error ID

StatusSupply pressure > 10 bar

Î Check the supply pressure.

209

Pressure sensors failed

Î Check the supply pressure.
Î Check power supply/electrical signal.

211

Emergency mode active

Î Check travel measurement.

212

Friction change (mid-position)

The friction conditions have changed.

213

Friction change (open position)

Î Check the positioner's mechanical functions and set-up.

214

Friction change (closed position)

Table 26: Further troubleshooting
Error description

Tasks

No reading on the display

Î Check electrical connection and power supply.
Î Check the ambient temperature (the display's operating range is from –30 to +65 °C).

Actuator moves too slowly

Î Check the supply pressure.
Î Deactivate software restriction.
Î Correct setting for filter (transit time).
Î Insert second pneumatic module.
Î Check the cross-section of the piping and screw fittings.
Î Check the configuration of the mounting parts.

Actuator moves in the wrong direction.

Î Check the characteristic setting.
Î Check the setting for OUTPUT.
Î Check piping.
Î Check the configuration of the mounting parts.

Air leaks from the positioner.

Î Check the installation of the pneumatic modules.
Î Seal ports 79 and 238 with a dummy plate.
Î Check the seals in the connecting plate.

Limit switch does not work properlyÎ Check the mounting and cabling.
Î Check polarity of signal wires.

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10.1 Emergency action
Upon failure of the air supply, the positioner
vents the actuator, causing the valve to moveto the fail-safe position determined by theactuator. Upon failure of the electrical signal,
the pneumatic outputs of the positioner are
either vented or filled with air depending on
the combination of the pneumatic modules(see Table 14 on page 69).
Plant operators are responsible for emergency action to be taken in the plant.
Tip
Emergency action in the event of valve failure is described in the associated valve documentation.

11 Decommissioning andremoval! DANGER
Risk of fatal injury due to ineffective explosion protection.
The explosion protection becomes ineffective
when the positioner cover is opened.
The following regulations apply to installation in hazardous areas: EN 60079-14(VDE 0165, Part 1).
! NOTICE
The process is disturbed by interrupting
closed-loop control.
Do not mount or service the positioner while
the process is running and only after isolating the plant by closing the shut-off valves.

11.1 Decommissioning
To decommission the positioner before removing it, proceed as follows:
1. Disconnect and lock the air supply andsignal pressure.
2. Open the positioner cover and disconnect the wires for the control signal.

11.2 Removing the positioner
1. Disconnect the wires for the control signal from the positioner.
2. Disconnect the lines for supply air andsignal pressure (not required for direct
attachment using a connection block).

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3. To remove the positioner, loosen the threefastening screws on the positioner.

11.3 Disposal
We are registered with the German national register for waste
electric equipment (stiftung ear)as a producer of electrical andelectronic equipment,
WEEE reg. no.: DE 62194439

Î Observe local, national and international refuse regulations.
Î Do not dispose of components, lubricantsand hazardous substances together withyour other household waste.
Tip
On request, we can appoint a service provider to dismantle and recycle the product.

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Annex12 Annex

Addresses of SAMSON AG and its subsidiaries

12.1 After-sales service
Contact SAMSON's After-sales Service forsupport concerning service or repair work or
when malfunctions or defects arise.

The addresses of SAMSON AG, its subsidiaries, representatives and service facilities
worldwide can be found on our website(www.samsongroup.com) or in all SAMSON
product catalogs.

E-mail address

Required specifications

You can reach our after-sales service ataftersalesservice@samsongroup.com.

Please submit the following details:− Order number and position number inthe order− Type, serial number, firmware version,
device version

12.2 Structure of the main display
Display/numbering
0-0Start screen: Valve position in %0-1

Valve position in degrees

0-2

Set point in %0-3

Set point deviation in %

0-4

1)

Description

Supply pressure in bar

0-5

1)

Status of pneumatic module in slot A

0-6

1)

Status of pneumatic module in slot B

0-7 1)

Status of option module in slot C

0-8

Status of option module in slot D

1)

0-9

Messages, news items

0-10

Press

to go to the menu level.

Reading only in the event of an error

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Annex12.3 Menu structure and parameters (menu level)
Note
The availability of executed menu items and parameters depends on the positioner's configuration and the option modules used.

12.3.1 Parameters for on-site operation
Menu

Adjustment range/values [default setting]/description

Main menu
Target operating mode

1

[AUTO]: Automatic mode
SAFE:

Fail-safe position

MAN:

Manual mode

Switchover from automatic to manual mode is bumpless.
Set point (open-loop con- 2
trol)–90.0 to 90.0° [–30.0°]

Manual set point (MAN)–25.0 to 125.0 % [0.0 %]3

The valve can be moved manually by a positioner in openloop control mode (positioner not yet initialized) by determining a set point. The reading in degrees is not absolute and only intended as a guide.
Adjust the manual set point with the rotary pushbutton. The
current travel/angle is displayed in % when the positioner is
initialized. If the positioner is not initialized, the position of thelever in relation to the longitudinal axis is indicated in degrees(°).

Reason for fail-safe posi- 4
tion

Reason for change to fail-safe position displayed. The parameter is only displayed in the event of a change to the fail-safe
position.

Change reading direction 5

Reading direction

Reading direction/

The reading direction of the display is turned by 180°.
User level6[On-site: read]/On-site: write
The option to change data is unlocked (revoked if no settingsare entered within five minutes).

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Menu

Adjustment range/values [default setting]/description

Start-up

7

Actuator

7.1[Linear actuator]
Rotary actuator
Linear actuator (expert)
Select type of actuator: linear actuator (expert) with separate
setting options for pin position and nominal range.

Pin position

Follower pin must be mounted in the proper position depending on the valve travel/opening angle (see section 3.6 on
page 29).

Pin position for linear ac- 7.2
tuator[None]/17/25/35/50/70/100/200/300 mm

Pin position for rotary ac- 7.3
tuator[90°]/No lever

Pin position for linear ac- 7.4
tuator (expert)[10] to 655 mm

Nominal range

The possible adjustment range depends on the selected pin
position. If no pin position has been entered, 'Nominal range'
is only available for the 'Linear actuator (expert)' actuator
type.

Nominal range for linear 7.5
actuator

3.6 to 300.0 mm

Nominal range for rotary 7.6
actuator

9.0 to 170.0°

Nominal range for linear 7.7
actuator (expert)

3.6 to 999.0 mm

Max. nom. range

7.8

Maximum possible nominal range displayed, depending onvalues entered for pin position.

Detected nominal range

7.9

Determined nominal range for rotary actuators displayed.

Initialization mode

7.10

[MAX]: Travel/angle of the closure member from the CLOSED
position to the opposite stop in the actuator.
NOM: Travel/angle of the closure member measured fromthe CLOSED position to the indicated OPEN position.

116

MAN:

Manually selected range

SUB:

Substitute calibration (without initialization)

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Fail-safe position

Adjustment range/values [default setting]/description
7.11[ATO]: AIR TO OPEN  The signal pressure opens the valve,e.g. for a fail-close valve.
ATC:

AIR TO CLOSE  The signal pressure closes thevalve, e.g. for a fail-open valve.

Define the fail-safe position of the valve (0 %) taking the valve
type and the actuator's direction of action into account:Set point (open-loop
control)

7.12–90.0 to 90.0° [–30.0°]

Adopt valve position 1

7.13

Manually adjusted first end position of the valve in MAN initialization mode
Confirm to adopt.

Valve position 1

7.14

Reading only (lever position in degrees)

Adopt valve position 2

7.15

Manually adjusted second end position of the valve in MAN
initialization mode
Confirm to adopt.

Valve position 2

7.16

Reading only (lever position in degrees)

Current valve position

7.17–25.0 to 125.0 % [0.0 %]Direction of rotation

7.18

Counterclockwise/[Clockwise]
Determine the lever's direction of rotation. For example:
The valve closes when the plug stem moves downward. Thisaction causes the positioner's lever to turn counterclockwise(when looking at the display).
Setting: Counterclockwise

Output P3799 (primary)

7.19[OUTPUT 138]/OUTPUT 238
The primary output on which the fail-safe position is based
must be assigned.

Mounted device

7.20

Software restriction[No device]
Quick exhaust valve
Fast air supply
The software restriction serves to adapt the air output capacity
to the size of the actuator.

Supply7.21

25/50/75/[100 %]Exhaust7.22

25/50/75/[100 %]Start initialization

7.23

Confirm to start.

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Adjustment range/values [default setting]/description

Start zero calibration

7.24

Configuration

8

Set point processing

8.1

Lower w-range value

8.1.1

Confirm to start.

[0.0] to 75.0 %The lower set point range value must be lower than upper
range value (w-end), 0 % = 4 mA.
The set point range is the difference between w-end andw-start and must be Δw ≥ 25 % = 4 mA.
When the set point range of 0 to 100 % = 4 to 20 mA, thevalve must move through its entire operating range from 0 to
100 % travel/angle of rotation.
In split-range operation, the valves operate with smaller set
points. The control signal of the control unit to control twovalves is divided such, for instance, that the valves movethrough their full travel/angle of rotation at only half the input
signal (first valve set to 0 to 50 % = 4 to 12 mA and second
valve set to 50 to 100 % =12 to 20 mA).

Upper w-range value

8.1.2

25.0 to [100.0 %]The upper range value of the set point range must be greaterthan lower range value (w-start).

Direction of action

8.1.3[Increasing/increasing] or Increasing/decreasing
The set point's effect on the valve position is determined as follows:− Increasing/increasing: a globe valve opens as the set point
increases.
− Increasing/decreasing: a globe valve closes as the set point
increases.

Lower switching threshold 8.1.4

12.5 % (predefined value)
If the set point drops below the lower switching threshold, thevalve closes (see Fig. 2 on page 20).

Upper switching threshold

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8.1.5

75 % (predefined value)
If the set point exceeds the upper switching threshold, the valve
fully opens (see Fig. 2 on page 20).

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Ramp time (rising)

Adjustment range/values [default setting]/description
8.1.6[0.0] to 10000.0 s
Time required to move through the operating range when thevalve opens.
For some applications it is recommendable to limit the transit
time of the actuator to prevent it from engaging too fast in therunning process.

Ramp time (falling)

8.1.7[0.0] to 10000.0 s
Time required to move through the operating range when thevalve closes.
1.0 to 100.0 % [10.0 %]Travel/sec. (rising)

8.1.8

Travel/sec. (falling)

8.1.9

Lower end position

8.1.10[Active]/Not active

End position w <= (setpoint cutoff decrease)

8.1.11

0.0 to 49.0 % [1.0 %]Upper end position

8.1.12

Active/[Not active]

End position w >= (setpoint cutoff increase)

8.1.1351.0 to 100.0 % [99.0 %]Required travel change in % per second
1.0 to 100.0 % [10.0 %]Required travel change in % per second

If the set point w reaches up to the entered percentage at the
final value that causes the valve to close, the actuator isimmediately completely vented (with AIR TO OPEN) or filledwith air (with AIR TO CLOSE). This action always lead tomaximum tight-closing of the valve.

If the set point w reaches up to the entered percentage at the
final value that causes the valve to open, the actuator isimmediately filled with air (with AIR TO OPEN) or completely
vented (with AIR TO CLOSE). This action always leads to thevalve being completely opened.
Example: set the cutoff to 99 % for three-way valves.

Identification

8.2

Firmware version

8.2.1

Read only
Indicates current firmware version.

Serial number

8.2.2

Read only
Indicates serial number.

Positioner

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Confirm to display production number

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Menu

Adjustment range/values [default setting]/description

HART® communication

8.3

Non-conducting

8.3.1

Yes/[No]

Fixed value (communication)

8.3.2

Active/[Not active]

Fixed value (communication)

8.3.3

1.0 to [100.0 %]Polling address

8.3.4[0] to 63

Loop current value

8.3.5

0/1

Tag no.

8.3.6

Entry of max. 8 characters

Tag no. (long)

8.3.7

Entry of max. 32 characters

Preambles

8.3.8[5] to 20

Find device flag

8.3.9

Yes/[No]

Control parameters

8.4

Dead band

8.4.1[0.1] to 100.0 %Activate integral-action
component

8.4.2[Active] (PID)/Not active (PD)The control mode can be changed from PD to PID controller
and vice versa.

Kp (supply)

8.4.3[3.5] to 100
Setting of the proportional gain for supply

Ki (supply)

8.4.4

0.1 to 3.0 [0.8]Setting of the integral gain for supply

Kd (supply)

8.4.5

0.5 to 100.0 [20.0]
Setting of the derivative gain for supply

Kp (exhaust)

8.4.6[3.5] to 100.0
Setting of the proportional gain for exhaust

Ki (exhaust)

8.4.7

0.1 to 3.0 [0.8]Setting of the integral gain for exhaust

Kd (exhaust)

8.4.8

0.5 to 100.0 [20.0]
Setting of the derivative gain for exhaust

Software restriction(supply)

8.4.9

25/50/75/[100 %]Setting of the supply flow rate restriction in % of the pneumatic
module (slot A)

Software restriction(exhaust)

8.4.1025/50/75/[100 %]Setting of the exhaust flow rate restriction in % of the pneumatic module (slot A)

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Menu

Adjustment range/values [default setting]/description[Active]/Not active

End position (optimized)

8.4.12

Slot options

8.5

Forced venting switch

8.5.1

Read only

Status Z3799 C

8.5.2

Read only

Identification

8.5.3

Read only

Slot C

8.5.4

Parameters for C.1/C.2/C.3 (see section 12.3.2)

Status Z3799 D

8.5.5

Read only

Identification

8.5.6

Read only

Slot D

8.5.7

Parameters for D.1/D.2/D.3 (see section 12.3.2)

Pneumatic modules

8.6

P3799 A: status

8.6.1

Read only

Identification

8.6.2

Read only

P3799 B: status

8.6.3

Read only

Identification

8.6.4

Read only

12.3.2 Parameters of option modules
Note
The availability of parameters depends on the option modules used.
Menu

Adjustment range/values [default setting]/description

Configuration

8

Slot options

8.5

Slot C

8.5.4

Slot C.1/C.2/C.3

8.5.4.2.../8.5.4.4.../8.5.4.6...

Slot D

8.5.7

Slot D.1/D.2/D.3

8.5.7.2.../8.5.7.4.../8.5.7.6...

Terminal designation... .1

Read only

Function... .2Binary input (24 V)

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Menu

Adjustment range/values [default setting]/description

Configuration... .3

Contact (switch)Contact (0 to 24 V)

Action upon active
binary input... .4

Switching state
Activate local write protection
Start PST
Start FST
Move valve to fixed value

Fixed value over binary
input... .5

0.0 to 100.0 %Edge control... .6

Active = Switch closed
Active = Switch open

Function... .7

Reading
Software limit switch
Fault alarm output

Mode... .8Below limit
Above limit

Edge control... .9Conducting/highLocking/low

Function... .10

Leakage sensor

Function... .11

Position transmitter

Position transmitter's direction of action... .12

Increasing/increasing
Increasing/decreasing

Error message at position ... .13
transmitter

None
low
high

Limit

... .14–20.0 to 120.0 %Current state... .15

Read only

Signal of analog output... .16

Read only

Current state... .17

Read only

Signal of analog output... .18

Read only

Start test... .19

Confirm to start.

Start test... .20

Confirm to start.

Test mode... .21

Read only

Test signal of analog
output... .22–10.0 to 110.0 %122

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Menu

Adjustment range/values [default setting]/description

Process data

9

Current operating mode

9.1

Indicates current operating mode

Reason for fail-safe
position

9.2

Reason for fail-safe position displayed

Set point

9.3

Reading in %Manual set point (MAN)

9.4

Reading of adjusted set point

Set point after filter

9.5

Reading of adjusted set point after set point processing (split
range, tight-closing function etc.)

Valve position

9.6

Reading in %Valve position

9.7

Reading in degrees

Set point deviation

9.8

Reading in %Supply pressure

9.9

Reading in bar

Temperature inside device 9.10

Reading in °C

Fixed value(communication)

9.11

Active/Not active

Fixed value(communication)

9.12

Reading in %Fixed value over binary
input

9.13

Active/Not active

Fixed value over binary
input

9.14

Reading in %T98 (supply)

9.15

Reading in ms: time required to fill with air to achieve a stepfrom 0 to 98 %. The value is determined during initialization.

T98 (exhaust)

9.16

Reading in ms: time required to vent to achieve a step from 0
to 98 %. The value is determined during initialization.

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Menu

Adjustment range/values [default setting]/description

Diagnosis/maintenance10

Device state

10.1

Status messages

10.1.1

Condensed state

10.1.1.1

Start-up

10.1.1.2

Configuration

10.1.1.25

Process data

10.1.1.38

Diagnostics

10.1.1.44

Pressure sensors exist

10.1.2

Yes/No reading

OUTPUT 138: pressure

10.1.3

Reading in bar

OUTPUT 238: pressure

10.1.4

Reading in bar

Supply pressure

10.1.5

Reading in bar

Total valve travel

10.1.6

Totaled full valve travel cycle

Total valve travel limit x
1000

10.1.7

Limit of total valve travel limit

Lag time for set point
deviation

10.1.8

Reading in s. The lag time can only be set using theoperator software.

Tolerance band for set
point deviation +/-10.1.9Used for error monitoring.

Max. temperature insidedevice 1)

10.1.10

Reading in °C

Min. temperature insidedevice 1)

10.1.11

Reading in °C

Operating hours counter10.1.12

Reading in d:hh:mm:ss

Number of initializations

10.1.13

Number since the last initialization

Number of zero
calibrations

10.1.14

Number since the last zero calibration

Tests

10.2

Step response test (PST)

10.2.1

Start test

10.2.1.1

Start test

Test status

10.2.1.3

Reading as progress bar

Canceled: x monitoring

10.2.1.4

Reading in %. Canceled when range is violated.

124

Messages which may be displayed:
see section 12.3.4

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1)

Adjustment range/values [default setting]/description

Step response test (FST)10.2.2Start test

10.2.2.1

Start test

Test status

10.2.2.3

Reading as progress bar

The displayed value is merely intended as information. No error message is displayed with the ambient temperature exceeds or falls below the permissible range (see section 3.7 on page 30).

12.3.4 Diagnosis: status messages
Menu

Adjustment range/values [default setting]/description

Diagnosis/maintenance10

Device state

10.1

Status messages

10.1.1

Condensed state

10.1.1.1

Status indicators

Start-up

10.1.1.2

Status indicators

Initialization error

10.1.1.3

Status indicators

Incorrect operating mode 10.1.1.4
Travel too small

The incorrect operating mode is set.

10.1.1.5

Confirm to clear message.

10.1.1.6

The determined travel is below the limit.

10.1.1.7

Confirm to clear message.

Rated travel not achieved 10.1.1.8

The detected rated travel is smaller than the value in thesetting.

10.1.1.9

Confirm to clear message.

10.1.1.10

Possible cause: valve blockage.

10.1.1.11

Confirm to clear message.

10.1.1.12

The adjusted lever M does not match the rated travel.

10.1.1.13

Confirm to clear message.

Canceled (control
accuracy)

10.1.1.14

Control criteria are not fulfilled.

10.1.1.15

Confirm to clear message.

Low control accuracy

10.1.1.16

Control criteria are not fulfilled. The positioner remains
ready for use.

10.1.1.17

Confirm to clear message.

10.1.1.18

The positioner needs to be initialized.

No movement
Pin position

Positioner not initialized

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Initialization canceled(external)

Adjustment range/values [default setting]/description
10.1.1.19

Initialization was canceled, e.g. due to forced venting or
IP shutdown.

10.1.1.20

Confirm to clear message.

10.1.1.21

The maximum permissible angle of rotation (±30°) has
been exceeded.

10.1.1.22

Confirm to clear message.

10.1.1.23

Initialization takes too long.
Possible cause: valve blockage.

10.1.1.24

Confirm to clear message.

Configuration

10.1.1.25

Status indicators

P3799: combination

10.1.1.26

Impermissible combination of pneumatic modules (seeTable 14 on page 69).

No pneumatic module

10.1.1.27

Message when no pneumatic module has been inserted(at least one pneumatic module must be inserted).

Pressure sensor failure

10.1.1.28

No more communication with pressure sensors. Defective
pressure sensors.

Angle limitation

Timeout

10.1.1.29

Confirm to clear message.

Combination Z3799

10.1.1.30

The identical option module has been inserted into slot C
and D.

Forced venting switch
incorrect

10.1.1.31

Forced venting switch is set as described in Table 18 on
page 86.

Slot C.1: binary input
active10.1.1.32

State is active.

Slot C.2: binary input
active10.1.1.33

State is active.

Slot C.3: binary input
active10.1.1.34

State is active.

Slot D.1: binary input
active10.1.1.35

State is active.

Slot D.2: binary input
active10.1.1.36

State is active.

Slot D.3: binary input
active10.1.1.37

State is active.

Process data

10.1.1.38

Status indicators

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Adjustment range/values [default setting]/description

Operating mode not
AUTO

10.1.1.39

Current operating mode is not AUTO.

Forced venting function

10.1.1.40

The forced venting is active.

Test in progress

10.1.1.41

A test is being performed.

Emergency mode active

10.1.1.42

Emergency mode is active. Possible cause: travel measurement does not function properly.

10.1.1.43

Confirm to clear message.

Diagnostics

10.1.1.44

Status indicators

No supply pressure

10.1.1.50

No supply pressure is available.

Low supply pressure

10.1.1.51

Supply pressure is too low.

Supply pressure > 10 bar 10.1.1.52

Supply pressure is too high.

PST

10.1.1.53

Status indicators

PST: cancellation criteria
met

10.1.1.54

PST is canceled.

PST: start criteria not met

10.1.1.55

PST did not start.

FST

10.1.1.56

Status indicators

FST: cancellation criteria
met

10.1.1.57

FST is canceled.

FST: start criteria not met

10.1.1.58

FST did not start.

Pneumatic module A(P3799 A)

10.1.1.59

Status indicators

P3799: failure

10.1.1.60

Error in pneumatic module. Replacement may be necessary.

10.1.1.61

Confirm to clear message.

P3799: movement
impaired

10.1.1.62

Possible cause: no supply pressure, internal error, defect.

10.1.1.63

Confirm to clear message.

P3799: maintenancerequired

10.1.1.64

Possible cause: the friction conditions have changed.

10.1.1.65

Confirm to clear message.

P3799: initialization
error

10.1.1.66

Conditions for initialization not fulfilled.

10.1.1.67

Confirm to clear message.

Pneumatic module B(P3799 B)

10.1.1.68

Status indicators

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P3799: failure

P3799: movement
impaired
P3799: maintenancerequired
P3799: initializationerror
AMR signal outside
range
Hardware fault

Adjustment range/values [default setting]/description
10.1.1.69

Error in pneumatic module. Replacement may be necessary.

10.1.1.70

Confirm to clear message.

10.1.1.71

Possible cause: no supply pressure, internal error, defect.

10.1.1.72

Confirm to clear message.

10.1.1.73

Possible cause: the friction conditions have changed.

10.1.1.74

Confirm to clear message.

10.1.1.75

Conditions for initialization not fulfilled.

10.1.1.76

Confirm to clear message.

10.1.1.77

Travel measurement is defective.

10.1.1.78

Confirm to clear message.

10.1.1.79

Internal device error. Initialization key (INIT) jammed.
Contact SAMSON's After-sales Service Department.

Limit for total valve travel 10.1.1.80
exceeded

Limit of total valve travel limit exceeded.

Lower end position
shifted10.1.1.81

Possible cause: mounting arrangement or travel linkageof positioner has slipped.

10.1.1.82

Confirm to clear message.

10.1.1.83

Possible cause: mounting arrangement or travel linkageof positioner has slipped.

Upper end position
shifted10.1.1.84

Confirm to clear message.

Dynamic stress factor
exceeded

10.1.1.85

The limit is exceeded. It may be necessary to change thevalve packing.

Set point deviation

10.1.1.86

Control loop error, the valve no longer follows the controlled variable within tolerable times.

Brownout

10.1.1.87

Brief power failure. The positioner remains ready for use.

10.1.1.88

Confirm to clear message.

Current too low

10.1.1.89

Set point <3.7 mA

IP shutdown

10.1.1.90

Set point <3.85 mA

Current too high10.1.1.91

Set point >22 mA. The positioner remains ready for use.

Angle limitation

10.1.1.92

The maximum permissible angle of rotation (±30°) has
been exceeded (only in open-loop control mode).

10.1.1.93

Confirm to clear message.

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Menu

Adjustment range/values [default setting]/description

Temperature inside device 10.1.1.94
below min. limit

Warning not affecting the positioner's functioning.

Temperature inside device 10.1.1.95
above max. limit

Warning not affecting the positioner's functioning.

Logging suspended

10.1.1.96

It was not possible to write all logging entries.

10.1.1.97

Confirm to clear message.

12.3.5 Reset functions
Menu

Adjustment range/values [default setting]/description

Reset functions

11

Reset diagnosis

11.1

Resets all diagnostic functions including graphs and histograms.

Reset (standard)

11.2

Resets the positioner to the state as upon delivery. Actuator and valve-specific settings remain unchanged.

Reset (advanced)

11.3

All parameters will be reset to their defaults adjusted upon delivery.

Restart11.4

The positioner is shut down and restarted.

Reset initialization

11.5

All parameters for the start-up settings are reset. The positioner needs to be re-initialized afterwards.

12.3.6 Wizard
Menu

Adjustment range/values [default setting]/description

Wizard12

Reading direction

12.1[Pneumatics (right)]/Pneumatics (left)
Mounting position with pneumatic modules on the rightor left of the display

Sprache/Language

12.2[English]/Deutsch/Français
Language

The setting preferences havenow been set.

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Exit wizard

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

2023-09-29 · English

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