Samson Series 420 User manual
Mounting and
Operating Instructions
EB 7500 EN
Edition July 2017
Series 420
Pneumatic Control System
Type3416 IndicatorType3421 Compact Controller with Type3422
Controller Station and Type3423 Controller
Module
Type3417 Pneumatic
Control Unit
Type3427 Manual Control
Station
Type3425 Pneumatic
Controller (control room
installation)
Type3425 Pneumatic
Controller (eld unit)
2 EB 7500 EN
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.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
(www.samson.de) > Product documentation. You can enter the document
number or type number in the [Find:] eld to look for a document.
Denition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
Damage to health relating to the REACH regulation.
If a SAMSON device contains a substance which is listed as being a substance of very high
concern on the candidate list of the REACH regulation, this circumstance is indicated on the
SAMSON delivery note. Information on safe use of the part affected,
see uhttp://www.samson.de/reach-en.html.
WARNING
!
EB 7500 EN 3
Contents
1 General safety instructions.............................................................................5
2 Application ...................................................................................................6
3 Operation.....................................................................................................6
3.1 Settings at the controller modules ....................................................................6
3.1.1 Direction of action ..........................................................................................6
3.1.2 Air delivery ...................................................................................................7
3.1.3 Proportional-action coefcient KP ....................................................................8
3.1.4 Reset time Tn .................................................................................................8
3.1.5 Derivative-action time Tv .................................................................................8
3.1.6 Operating point .............................................................................................8
3.2 Adjusting the limit contacts .............................................................................9
4 Start-up and settings ...................................................................................10
4.1 Tuning the controller .....................................................................................10
4.2 Bumpless automatic/manual mode changeover ..............................................12
4.3 Readjusting the controller zero point ..............................................................12
4.4 Additional modules ......................................................................................12
4.4.1 Type3424-4 Manual/automatic Transfer .......................................................12
4.4.2 Type3424-5 Control Mode Changeover ........................................................12
4.4.3 Type3424-6 Signal Limiter ...........................................................................13
5 Design and principle of operation ................................................................14
5.1 Type3421 Compact Controller .....................................................................14
5.2 Type3427 Manual Control Station ................................................................16
5.3 Type3425 Pneumatic Controller (wall-mounted and eld controller) .................16
5.4 Type3416 Indicator .....................................................................................17
5.5 Type3417 Pneumatic Control Unit ................................................................17
5.6 Type3423 Controller Modules ......................................................................18
5.7 Additional modules ......................................................................................21
5.7.1 Type3424-2x for i/p conversion...................................................................21
5.7.2 Type3424-4 for bumpless manual/automatic switchover ................................22
5.7.3 Type3424-5 for control mode changeover.....................................................22
5.7.4 Type3424-6 for signal limitation ..................................................................22
5.8 Optional electrical limit contacts ....................................................................23
4 EB 7500 EN
Contents
6 Installation..................................................................................................24
6.1 Changing scales ..........................................................................................25
7 Connections ................................................................................................26
7.1 Pneumatic connections..................................................................................26
7.2 Electrical connections ...................................................................................28
8 Maintenance ...............................................................................................30
8.1 Checking the air supply ................................................................................30
9 Conversion..................................................................................................30
9.1 Changing the controller function ....................................................................30
9.2 Operating mode changeover in Type3424-2 i/p Converter ............................33
9.3 Checking the controller function ....................................................................34
10 Technical data.............................................................................................35
EB 7500 EN 5
General safety instructions
1 General safety instructions
−The device must be mounted, started up, or serviced by fully trained and
qualied personnel only; the accepted industry codes and practices are to
be observed. Make sure employees or third persons are not exposed to any
danger.
−All safety instructions and warnings given in these mounting and operating
instructions, particularly those concerning installation, start-up, and mainte-
nance, must be strictly observed.
−Devices with a CE marking have an EC declaration of conformity, which in-
cludes information about the applied conformity assessment procedure. The
EC Declaration of Conformity is available on request.
−According to these mounting and operating instructions, trained personnel
refers to individuals who are able to judge the work they are assigned to
and recognize possible dangers due to their specialized training, their
knowledge and experience as well as their knowledge of the applicable
standards.
−To ensure appropriate use, only use the device in applications where the op-
erating pressure and temperatures do not exceed the specications used for
sizing the device at the ordering stage.
−The manufacturer does not assume any responsibility for damage caused by
external forces or any other external factors.
−Proper transport, storage, installation, operation, and maintenance are as-
sumed.
6 EB 7500 EN
Application
2 Application
The Series420 Control System is used in au-
tomation applications in process engineering
and industrial plants. It can be used for ap-
plications with P, PI, PID, and PD controls, for
control loops with control mode changeover
or signal limitation, for xed set point, ratio,
cascade, or slave control.
The output signals of a connected transmitter
or master controller are measured as pneu-
matic standardized signals between 0.2 and
1bar or, in case of i/p additional modules,
0/4 to 20mA signals.
The integrated controller modules compare
the measured variable with the set point and
issue a corresponding pneumatic control sig-
nal of 0.2 to 1bar (2 to 15psi).
The controller requires a supply pressure of
1.4bar (20psi).
3 Operation
3.1 Settings at the controller
modules
The settings for direction of action and air
delivery must be performed prior to start-up.
Release the lock (4 in Fig.1) on the front
panel of the compact controller and pull the
manual control station completely out of the
housing to access the controller module.
3.1.1 Direction of action
The direction of action for the control loop is
set at the turnboard A. Tshe position of its
arrow symbol according to the arrow symbol
on the controller module determines the
direction of action of the controller (Fig.1).
< > Arrow tips facing opposite directions:
Direction of action increasing/decreas-
ing
As the controlled variable x increases,
the output pressure y falls.
>> Arrow tips facing the same direction:
Direction of action increasing/increas-
ing
As the controlled variable x increases,
the output pressure y increases.
Setting or changing the direction of action:
Unscrew the screw in turnboard A and lift it
off together with the turnboard. If necessary,
lever the board at the side. Do not lose the
rubber seal.
NOTICE
!
EB 7500 EN 7
Operation
− Turn the board by 90° so that the re-
quired arrow is aligned with the arrow
on the base plate.
− Insert board and tighten the screw.
3.1.2 Air delivery
(only with Type3423 Controller Module)
The position of turnboard B with its arrow
symbol determines the air delivery to the
feedback bellows.
>yA Normal air delivery,
approx. 1 mn³/h per % of the system de-
viation (default setting)
>R High air delivery,
approx. 3mn³/h per % of the system de-
viation (not with P or PD controller mod-
ules)
Setting or changing the air delivery
If the control valve that is to be controlled is
more than 15 meters away, increase the air
delivery by turning the position of turnboard
B from yA (standard) to R.
Fig.1: Turnboards and adjusters
1 Compact controller
2 Control room housing
3 Controller module
3.1 Comparator
3.2 Connecting plate
3.3 Hex screws
3.4 Screws (inside)
4 Lock
6 Fastening screw
7 Restriction
8Zero adjuster
9Kp adjuster
10 Tn adjuster
11 Tv adjuster (only in PD or PID
controller)
12 Operating point adjuster
(only in P or PD controller)
Turnboard
ADirection of action
BAir delivery
43
123.2 3
View from the side without
comparator (3.1)
Type3423-2 Controller Module (PI)
B
10
11
12
83.43.2 3.1 96A3.3
7
8 EB 7500 EN
Operation
1. Unscrew the fastening screw (6) at the
controller module and pull the module off
its self-seal push-on ttings.
2. Unscrew screws (3.3) and pull off the
connecting plate (3.2) together with
square nuts and bolts from the controller
module.
3. Unscrew the hexagonal socket head
screws (3.4) at the side and lift the com-
parator (3.1) off the controller module.
4. Unscrew the screw in turnboard B and lift
it off together with the turnboard. If nec-
essary, lever the board at the side. Do
not lose the rubber seal.
5. Turn the board so that the arrow is
aligned with yA or R on the controller
module. Insert board and tighten the
screw.
6. Remount the controller module and fas-
ten it in the controller station.
3.1.3 Proportional-action co-
efcientKp
The setting of the Kp (adjuster 9) determines
the controller gain and depends on the con-
trolled system that is to be tuned (see sec-
tion4.1).
3.1.4 Reset time Tn
Controller versions with integral-action com-
ponent require the reset time to be set at the
adjuster (10). The setting depends on the
controlled system that is to be tuned (see sec-
tion4.1).
3.1.5 Derivative-action time Tv
Controller versions with derivative-action
component require the derivative-action time
Tv to be set at the adjuster (11). The setting
depends on the controlled system that is to
be tuned (see section4.1).
3.1.6 Operating point
Controller modules without integral-action
component (e.g. P or PD, controllers) have
an operating point.
This can be adjusted at the operating point
adjuster (12) between 0 and 100%, which
corresponds to 0.2 to 1bar.
The setting depends on the output pressure y
that is to be tuned (see section4.1).
The Type3423-9 Controller Module does not
have an operating point adjuster. The oper-
ating point is dependent on the set point.
EB 7500 EN 9
Operation
Fig.2: Indicator with limit contacts
Adjustment screw
Indicator with
proximity switch
Lock
Limit adjuster in
Type3416
3.2 Adjusting the limit contacts
The listed limit contacts are no longer avail-
able.
InductivecontactsinType3422Manual
ControlStationandType3427Manual
Control Unit
−Release lock on the front panel and pull
out the indicating unit.
The proximity switches with min. and
max. contacts can be accessed through
the opening on the left-hand side.
−Use a 2.5 mm hex screwdriver to slightly
loosen the two fastening screws.
−Move the corresponding proximity switch
until the indicator points to the required
value on the reference scale and a con-
tact is made over the connected switch-
ing amplier or the LED on the front
lights up when contact is made.
−Retighten screws and place the marker
on the main scale at the corresponding
place.
Inductive and pneumatic contacts in
Type3416PneumaticIndicator
−Release lock on the front panel and pull
out the indicating unit.
−Move adjuster at the side until contact is
made.
Note
10 EB 7500 EN
Start-up and settings
4 Start-up and settings
Before start-up of the control loop, check all
devices to make sure that they are connected
correctly, do not leak, and function properly.
Release lock (7) and pull out the plug-in unit
of the compact controller station for easier
access to the operating controls at the con-
troller.
Check the turnboard to make sure the correct
direction of action is set at the controller (see
section3.1.1). Set arrow symbol (6) for
valve position at 100% signal pressure ac-
cordingly:
Arrow symbol facing:
Upward: valve OPEN
Downward: valve CLOSED
4.1 Tuning the controller
The controller needs to be tuned to the char-
acteristics of the controlled system using the
Kp and Tn and/or Tv adjusters at the control-
ler module (Fig.1) to ensure that the control-
ler can keep any system deviations for all set
points caused by the disturbance variables to
zero or at least minimize them.
The tuning test following the Ziegler and
Nichols method is a simple way to tune the
controller. In this method, the controller runs
in closed-loop operation with P action to the
point where it is still stable. It can only be
applied to controlled systems in which the
controlled variable can be made to hunt.
1. Set manual/automatic switch (10) to
manual. Apply supply pressure
(1.4±0.1bar) to Z.
2. Set the proportional-action coefcient Kp
to a low value (0.2) at the comparator.
PI and PID controllers only: set Tn restric-
tor to its maximum value (50 min) and Tv
to its lowest value (0.01 min).
3. Adjust the set point at the top rotary
knob (11) until the green pointer (2)
points to the required value on the scale.
PI and PID controllers:
4. Adjust the manual output yH at the bot-
tom rotary knob (9) to start up the con-
trol loop until the controlled variable in-
dicated by the red pointer (3) slowly ap-
proaches the adjusted set point (green
pointer).
Fig.3: Front view
1 Front panel
2 Set point pointer
3 Controlled variable
pointer
4 Control signal yA
5 Control signal yH
6 Valve CLOSED/OPEN
7 Lock
8LED
9Manual adjuster for yH
10 Manual/automatic
switchover
11 Set point adjuster
12 Label
2
4
3
5
1
12
10
11
9
7
8
6
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