Samson 3430 User manual

Series 430

Pneumatic Indicating Controllers

Type 3430

Fig. 1 · Controller stations

Mounting and

Operating Instructions

EB 7030 EN

Edition October 2010

Type 3432 Controller Station

– with Type 3435 Transmitter Module for Pressure

– with Type 3436 Transmitter Module for Temperature

– with Type 3438 Transmitter Module for Temperature (Pt 100)

– for standardized signals

Version shown with lockable door and integrated

Type 3436 Transmitter Module for Temperature

Type 3431 Controller Station

– for standardized signals

Contents Page

1 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Settings at the controller modules . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Operating action . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.2 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1.3 Proportional-action coefficient Kp . . . . . . . . . . . . . . . . . . . . 6

2.1.4 Reset time Tn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1.5 Rate time Tv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1.6 Operating point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Setting the limit switches. . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Tuning the controller . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1.1 Setting the operating point in P and PD controllers . . . . . . . . . . . . 9

3.2 Smooth automatic/manual mode changeover . . . . . . . . . . . . . 10

3.3 Smooth changeover between the internal and external reference variable 10

3.4 Readjusting the controller’s zero point . . . . . . . . . . . . . . . . . 10

4 Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1 Transmitter modules . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.2 Controller station . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.3 Controller modules. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3.1 Type 3433 Controller Modules . . . . . . . . . . . . . . . . . . . . . 14

5.3.2 Type 3434 Controller Modules . . . . . . . . . . . . . . . . . . . . . 17

5.4 Additional modules . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.1 Type 6112 i/p Converter . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.2 wint/wext selector switch . . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.3 Supply pressure regulators . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.4 Inductive limit switches . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.1.1 Changing scales. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.2 Installing the temperature sensor . . . . . . . . . . . . . . . . . . . . 22

7 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.1.1 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.1.2 Adjusting the supply air for version with supply pressure regulator. . . . 25

7.2 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2EB 7030 EN

Contents

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1 Checking the air supply . . . . . . . . . . . . . . . . . . . . . . . . 27

9 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.1 Changing the controller function . . . . . . . . . . . . . . . . . . . . 28

9.2 Exchanging the transmitter module . . . . . . . . . . . . . . . . . . . 30

9.3 Checking the controller function . . . . . . . . . . . . . . . . . . . . 30

10 Use in hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . 31

10.1 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 31

11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

EB 7030 EN 3

Contents

General safety instructions

The device may only be assembled, started up or operated by trained and

experienced personnel familiar with the product.

According to these mounting and operating instructions, trained personnel is

referred to as 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 relevant

standards.

Explosion-protected versions may only be operated by personnel who have

undergone special training or instructions or who are authorized to work on

explosion-protected devices in hazardous areas.

Any hazards that could be caused by the signal pressure are to be

prevented by means of the appropriate measures.

Proper shipping and appropriate storage of the device are assumed.

1 Application

The Series 430 Pneumatic Indicating Con-

trollers are used for applications in process

automation and industrial plants.

The controllers directly measure the con-

trolled variables (pressure, temperature,

electric or pneumatic standardized signal)

and display the value. They compare the

measured variable with the set point and is-

sue a corresponding pneumatic control sig-

nal from 0.2 to 1 bar (3 to 15 psi).

A supply pressure of 1.4 bar ±0.1 bar

(20 psi ±1.5 psi) is required or an operat-

ing pressure of 2 to 12 bar (30 to 180 psi)

when a supply pressure regulator is in-

stalled.

2 Operation

2.1 Settings at the controller

modules

The controller module in the station can be

accessed after the lock (Fig. 2) has been re-

leased and the indicating unit (5) has been

opened out.

The settings for operating action (turnboard

A) and air supply (turnboard B) must be

performed prior to commissioning.

4Unscrew the mounting screw (6) on the

controller module. Pull it off its self-seal-

ing hose fittings and lift out of the con-

troller station.

2.1.1 Operating action

The operating action for the control loop is

set at the turnboard A(Fig. 2), where the

position of its arrow symbol according to the

arrow symbol on the controller module de-

termines the operation action of the control-

ler.

34Arrow tips facing opposite

directions:

Operating direction:

Increasing/decreasing =

As the controlled variable x increases,

the output signal pressure y

decreases.

44Arrow tips facing the same direction:

Operating direction:

Increasing/increasing

As the controlled variable x increases,

the output signal pressure y

increases.

4EB 7030 EN

Application

Fig. 2 · Turnboards and adjusters

1 Controller station (Type 3432)

1.1 Scale

1.3 Actual value pointer (red)

1.4 Set point adjuster

2 Transmitter module

or connecting base

3 Controller module

3.1 Comparator

3.2 Connecting plate

3.3 Hex screws

3.4 Screws (inside)

4 Lock

5 Indicating unit

6 Mounting screw

7 Restriction

8 Zero adjuster

9 Kp adjuster

10 Tn adjuster

11 Tv adjuster (only in

PD or PID controller)

12 Operating point adjuster

(only in P or PD controller)

Type 3432 Contr. Module

Side view without comparator

1.3

1.1

1.4

3.3

A3.2 3.4 8 9 3.1

63109

Oper. action

Type 3433-2 (PI) Controller Module Type 3434-2 (PI) Controller Module

Air supply Oper. action

Setting or modifying the operating direction:

Unfasten the screw in turnboard A(Fig. 2)

and lift it off together with the turnboard. If

necessary, lever the board at the side.

Do not lose the rubber seal.

4Turn the board by 90° so that the re-

quired arrow is aligned with the arrow

on the base plate.

4Insert board and tighten screw.

4Reassemble the controller module in the

controller station.

2.1.2 Air supply

(only with Type 3433 Controller Module)

The position of the turnboard B(Fig. 2) with

its arrow symbol determines the air supply

to the feedback bellows. It can be accessed

after the comparator (3.1) has been re-

moved.

4yA Normal air supply, approx. 1 mn³/h

per % of the system deviation

4RLarge air supply, approx. 3 mn³/h

per % of the system deviation

(not with P or PD controller modules)

EB 7030 EN 5

Operation

4Unfasten screws (3.3) and pull off the

connecting plate (3.2) together with nuts

and bolts from the controller module.

4Unscrew the hexagonal socket-head

screws (3.4) at the side and lift the com-

parator (3.1) out of the controller mod-

ule.

Setting or modifying the air supply:

4Unfasten screw in turnboard Band lift it

off together with the turnboard. If neces-

sary, lever the board at the side.

Do not lose the rubber seal.

4Turn the board so that the arrow is

aligned with the mark yA or Ron the

controller module. Insert board and

tighten screw.

4Reassemble the controller module in the

controller station.

2.1.3 Proportional-action

coefficient Kp

The setting of the KP(adjuster 9) determines

the controller gain and is related to the con-

trolled system that is being tuned (section

3.1).

2.1.4 Reset time Tn

Controller versions with integral-action com-

ponent require the reset time to be set at the

restriction (10). The setting depends on the

controlled system that is being tuned

(section 3.1).

2.1.5 Rate time Tv

For Type 3433 Controller versions with de-

rivative-action component, the rate time Tv

needs to be set at the restriction (11). The

setting depends on the controlled system that

is being tuned (section 3.1).

2.1.6 Operating point

Controller modules without integral-action

component such as P or PD controllers have

an operating point. In Type 3433 Controller

Module, it can be adjusted between 0 and

100 % which corresponds to 0.2 to 1 bar by

an operating point adjuster (12). The setting

depends on the manipulated variable y (sec-

tion 3.1.1).

In Type 3434 P Controller Module, the oper-

ating point is fixed at 0.6 bar.

6EB 7030 EN

Operation

2.2 Setting the limit switches

Only applies to controller stations with the

limit switch option:

To set the limit switches, first release the lock

(4, Fig. 2) and open out the indicating unit

(5). The contacts can be accessed at the

back.

Adjust proximity switches by placing a

screwdriver in the clamps between 0 and

100 % of the reference scale and move until

a contact is made over the connected switch-

ing amplifier.

EB 7030 EN 7

Operation

Fig. 3 · Limit switches

Clamps with proximity switch

3 Commissioning

Prior to commissioning the control loop,

check all devices to make sure they are con-

nected correctly, do not leak and function

properly.

Release lock (4) and open out the indicating

unit (5) to enable easy access to the operat-

ing controls at the controller.

Check the turnboard to make sure the cor-

rect operating action is set at the controller

(see section 2.1.1).

3.1 Tuning the controller

The controller needs to be tuned to the char-

acteristics of the controlled system using the

KPand Tnand/or Tvadjusters at the control-

ler module to ensure that the controller can

keep any system deviations for all set points

caused by the disturbance variables to zero

or at least to minimize them.

In case of controller stations which have a

manual/ automatic switch (1.6), the plant

must be started up manually.

We recommend to determine the settings by

using a tuning test (following the Ziegler and

Nichols method) which produces sufficient

results in most cases:

1. Apply supply air (1.4 ±0.1 bar).

2. Set the proportional-action coefficient KP

to a low value at the comparator.

3. Set Tnrestrictor to its maximum value

and Tvto its lowest value (applies only to

PI and PID controllers).

Setting in manual mode:

4. Set manual/automatic switch to Manual.

5. Operate manual adjuster (1.7) for the

control signal so that the controlled vari-

able (actual value pointer 1.3) slowly

settles on the adjusted set point (set point

pointer 1.4).

Should the differential pressure indicator

(1.8) move to zero, set the manual/auto-

matic switch (1.6) to Automatic.

Proceed as described in points 6 and 7.

Setting in automatic mode:

4. Set the set point to the required value at

the rotary knob (1.4) on the indicating

unit.

5. Set the Tnrestriction briefly to its lowest

value (completely open) to move the red

8EB 7030 EN

Commissioning

Fig. 4 · Front view

1.8

1.6

1.5

1.7

1.3

1.4

1.3 Actual value pointer (red)

1.4 Set point adjuster with green pointer

1.5 Signal pressure display

1.6 Manual/automatic switch

1.7 Adjuster for signal pressure (manual)

1.8 Differential pressure indicator

4 Lock

5 Indicating unit

actual value pointer to the green set

point pointer. Close the Tnrestriction

again.

6. Starting from a low value, increase the

proportional-action coefficient KPuntil

the actual value pointer displays an har-

monic oscillation pattern (uniform oscil-

lation amplitudes as shown in Fig. 5) of

the controlled variable.

If oscillations do not arise with a large

KPsetting, turn the rotary knob to

change the set point slightly and then re-

turn it to its former setting. It may be

necessary to increase the gain (KP)

slightly until an harmonic oscillation pat-

tern arises.

7. Write down the adjusted value of the KP

scale you have just adjusted as the criti-

cal proportional-action coefficient KPkrit.

Use a stopwatch to time the oscillation

time for one entire oscillation as Tkrit (PI

and PID controller only).

Multiply both values with the values in

the table (Fig. 5) and set as the favor-

able settings for KP, Tn, and Tvat the

controller.

Should oscillations still occur despite these

settings, slightly reduce KPand increase Tn.

Repeat these steps, if necessary, until the

control loop shows a satisfactory perfor-

mance. Leave enough time in between set-

ting to allow the controller to stabilize.

3.1.1 Setting the operating point in

P and PD controllers

(Type 3433 Controller Module only)

After setting the proportion-action coefficient

KPas described previously, set the operating

point for P and PD controllers instead of the

reset time Tn.

4Read off the controlled variable yA of the

controller at the display (1.5) when the

plant is in a steady-state condition and

set this value directly at the operating

point adjuster (12, Fig. 2). (Setting 0.2 to

1 bar = 0 to 100 %).

4Recorrect slightly until the system devia-

tion is zero. In case the signal pressure

display deviates, average the value.

Note!

On changing set point or reference variable,

the operating point must be set again as de-

scribed above.

If the reference variable is changed more of-

ten, set the operating point to 0.6 bar =

50 % (average value).

EB 7030 EN 9

Commissioning

Fig. 5 · Harmonic oscillation, settings

Cntr. KPTnTv

P 0.50 · KP,krit

PI 0.45 · KP,krit 0.85 · Tkrit

PID 0.59 · KP,krit 0.50 · Tkrit 0.12 · Tkrit

Controlled variable

(actual value)

Tkrit

–

Note!

The T

restriction must be completely opened

with a P/PI controller is switched over to P

action to allow the operating point adjuster

to work without delay.

Version with w-dependent operating point

This version does not need to be adjusted

since the operating point automatically fol-

lows the set point w.

3.2 Smooth automatic/manual

mode changeover

(only for controller station with manual/au-

tomatic changeover, Fig. 4)

The smooth switchover ensures that no pres-

sure surges can reach the valve when the

manual/automatic switch is activated as fol-

lows:

Changeover from automatic to manual

Use the manual adjuster (1.7) to adjust

signal pressure manual yH until the differen-

tial pressure indicator (1.8) is zero. Switch

over to manual at the switch.

Changeover from manual to automatic

If the plant is to be controlled manually to

the required value, the automatic signal

pressure yA must be matched to the manual

signal pressure yH by adjusting the set point

adjuster (1.4).

The switch (1.6) can only be set to automatic

after the differential pressure indicator (1.8)

is at zero.

Set the set point again to the required value.

3.3 Smooth changeover between

the internal and external re-

ference variable

When combining the fixed set point control

and follower control, the Type 3432 Con-

troller Station is equipped with a wint/wext

switch, a pressure adjuster and a differential

pressure indicator (Fig. 10).

The differential pressure indicator must first

be brought to zero by activating the pres-

sure adjuster in order to switch between the

reference variables.

3.4 Readjusting the controller’s

zero point

Should deviations arise between the actual

value and set point during operation, the

zero point adjustment can be readjusted by

turning the zero screw at the back of the dis-

play unit (5) until the actual value and set

point on the front display are the same

again.

Deviations between the actual value and set

point can also be corrected at the zero point

adjuster (8, Fig. 2) of the controller module.

10 EB 7030 EN

Commissioning

Differential pressure indicator

With Without deviation

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