Samson 430 Series Service manual

Translation of original instructions

EB 7030 EN

Type3430 Pneumatic Indicating Controllers

Series430

Edition May 2018

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

The version with lockable door and installed Type3436

Transmitter Module for temperature is shown.

Type3431 Controller Station

- for standardized signals

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

(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.

Denition 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

2 EB 7030 EN

WARNING!

Damage to health relating to the REACH regulation.

If a SAMSON device contains a substance which is listed as being a substance of

very 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 uwww.samsongroup.com/en/about-

samson/material-compliance/reach-regulation.html.

Contents

EB 7030 EN 3

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 output capacity ........................................................................................7

3.1.3 Proportional-action coefcient 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 Adjusting the operating point in P and PD controllers ......................................11

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

4.4 Bumpless changeover between internal or external set point ............................12

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

5 Design and principle of operation ................................................................13

5.1 Transmitter modules ......................................................................................14

5.2 Controller station .........................................................................................16

5.3 Controller modules .......................................................................................16

5.3.1 Type3433 Controller Modules ......................................................................16

5.3.2 Type3434 Controller Module .......................................................................20

5.4 Diaphragm seal ...........................................................................................21

5.4.1 Mounting with diaphragm seal......................................................................21

5.4.2 Diaphragm seal for general use ....................................................................22

5.4.3 Diaphragm seals for use with oxygen ............................................................22

5.4.4 Diaphragm seals for use with ammable gases ..............................................22

5.5 Additional units ...........................................................................................25

5.5.1 Type6112 i/p Converter ..............................................................................25

5.5.2 wint/wext selector switch................................................................................25

5.5.3 Supply pressure regulator .............................................................................25

5.5.4 Inductive limit contacts ..................................................................................26

6 Installation..................................................................................................26

6.1 Mounting ....................................................................................................26

6.1.1 Changing scales ..........................................................................................33

6.2 Installing the temperature sensor ...................................................................33

Contents

4 EB 7030 EN

7 Connections ................................................................................................36

7.1 Pneumatic connections..................................................................................36

7.1.1 Connection examples ...................................................................................36

7.1.2 Adjusting the supply air in supply pressure regulators .....................................37

7.2 Electrical connections ...................................................................................38

8 Maintenance ...............................................................................................40

8.1 Checking the air supply ................................................................................40

9 Conversion..................................................................................................41

9.1 Changing the controller function ....................................................................41

9.2 Exchanging the transmitter module ................................................................44

9.3 Checking the controller function ....................................................................44

10 Use in hazardous areas...............................................................................45

10.1 Servicing explosion-protected devices ............................................................46

11 Technical data .............................................................................................47

12 Certicates..................................................................................................51

EB 7030 EN 5

General safety instructions

1 General safety instructions

−The device must be mounted, started up or serviced by fully trained and

qualied 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 EU declaration of conformity, which

includes information about the applied conformity assessment procedure.

The EU 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 specications 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 7030 EN

Application

2 Application

The Series430 Pneumatic Controllers are

used for the automation of process and in-

dustrial plants.

The controllers measure directly the

controlled variable (pressure, temperature,

electric or pneumatic standardized signal),

compare the measured value with the set

point and issue a pneumatic control signal of

0.2 to 1bar (3 to 15psi).

A supply pressure of 1.4bar ±0.1bar

(20psi ±1.5psi) or an operating air pres-

sure of 2 to 12bar (30 to 180psi) with an

installed supply pressure regulator is re-

quired.

3 Operation

3.1 Settings at the controller

modules

The controller module in the station can be

accessed after releasing the lock (4, Fig.1)

and opening the indicating unit (5).

The settings for direction of action (turnboard

A) and air delivery (turnboard B) must be

performed prior to start-up.

Unscrew the fastening screw (6) at the con-

troller module, pull the module off its self-

seal push-on ttings and lift it out of the con-

troller station.

3.1.1 Direction of action

The direction of action for the control loop is

set at the turnboard A, where the 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/

decreasing

As the controlled variable x

increases, the output pressure y falls.

 Arrow tips facing the same direction:

Direction of action: increasing/

increasing

As the controlled variable x

increases, the output pressure y

increases.

Setting or changing the direction of action:

Undo the screw in turnboard A (Fig.1) and

lift it off together with the turnboard. If nec-

essary, lever the board at the side. Do not

lose the rubber seal.

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

quired arrow is aligned with the arrow

on the base plate.

ÎInsert board and tighten the screw.

ÎRemount the controller module and

fasten it in the controller station.

EB 7030 EN 7

Operation

3.1.2 Air output capacity

(Type3433 Controller Module only)

The position of turnboard B (Fig.1) with its

arrow symbol determines the air delivery to

the feedback bellows. It can only be ac-

cessed after removing the comparator (3.1).

yA Normal air delivery

Approx. 1mn³/h per % of the system

deviation

RHigh air delivery

approx. 3mn³/h per % of the system

deviation (not with P or PD controller

modules)

Direction of

action

1.1

1.4

1.3

83.4

3.2 A

3.3

1 Controller station (Type3432)

1.1 Dial plate

1.3 Controlled variable pointer

1.4 Set point adjuster

2Transmitter module or 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 Fastening screw

7Restriction with lter

8 Zero adjuster

9Kp adjuster

10 Tn adjuster

11 Tv adjuster (PD or PID

controller only)

12 Operating point adjuster (P

or PD controller only)

Turnboard

ADirection of action

BAir output capacity

91036

Type3433-3 Controller Module (PID)Type3433 Controller Module

View from the side without

comparator

Type3434-2 Controller Module (PI)

Fig.1: Turnboards and adjusters

8 EB 7030 EN

Operation

ÎUndo screws (3.3) and pull off the

connecting plate (3.2) together with

square nuts and bolts from the controller

module.

ÎUnscrew the hexagonal socket head

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

parator (3.1) off the controller module.

Setting or changing the air delivery

ÎUndo the screw in turnboard B and lift it

off together with the turnboard. If neces-

sary, lever the board at the side. Do not

lose the rubber seal.

ÎTurn the board so that the arrow is

aligned with yAor R on the controller

module. Insert board and tighten the

screw.

ÎRemount the controller module and fas-

ten it in the controller station.

3.1.3 Proportional-action coef-

cient Kp

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-

tion4.1).

3.1.4 Reset time Tn

Controller versions with integral-action

component require the reset time to be set at

the adjuster (10). The setting depends on the

controlled system that is to be tuned (see

section4.1).

3.1.5 Derivative-action time Tv

Controller versions with derivative-action

component require the derivative-action time

Tv to be set at the adjuster (11). The setting

depends on the controlled system that is to

be tuned (see section4.1).

3.1.6 Operating point

Controller modules without integral-action

component, such as 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 1bar in Types3433-

1/-4/-5/-6 Controller Modules.

The setting depends on the output pressure y

(see section4.1).

The operating point of the Type3434-1

Controller Module is xed at 0.6bar.

EB 7030 EN 9

Operation

3.2 Adjusting the limit contacts

Only with controller station that have the op-

tional inductive limit contacts.

Before adjustment, release the lock (4,

Fig.1) and open the indicating unit (5). The

contacts can be accessed on the back of the

device.

Use a screwdriver to move the proximity

switches in the holders between 0 and

100% on the scale until contact is made with

the aid of a connected switching amplier.

Fig.2: Limit contacts

Holder with proximity switch

10 EB 7030 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 the lock (4) and open the indicating

unit (5) to access the operating controls on

the controller.

Check the turnboard to make sure the correct

direction of action is set at the controller (see

section3.1.1).

4.1 Tuning the controller

The controller needs to be tuned to the

characteristics of the controlled system using

the Kp and Tn and/or Tv adjusters at the

controller module (Fig.1). This ensures that

the controller can maintain any system

deviations for all set points caused by the

disturbance variables to zero or at least

minimize them.

The system must be started up manually

when a controller station is tted with a

manual/automatic switch (1.6).

In most cases, a tuning test following the

Ziegler and Nichols method is sufcient to

tune the controller:

1. Apply supply air (1.4±0.1bar).

2. Set the proportional-action coefcient Kp

to a low value at the comparator.

3. Set the Tn restrictor to its maximum value

and Tv to its lowest value (PI and PID

controllers only).

1.6

1.7

1.5

1.8

1.4

1.3

Fig.3: Front view

Setting for manual mode:

4. Set manual/automatic switch to manual.

5. Move the adjuster (1.7) for the control

signal until the controlled variable (con-

trolled variable pointer, 1.3) slowly starts

to settle to the adjusted set point (set

point adjuster, 1.4).

After the differential pressure indicator

(1.8) reads zero, set the switch (1.6) to

automatic.

Proceed as described in steps 6 to 7.

Setting for automatic mode:

4. Turn the adjuster (1.4) on the indicating

unit to set the set point to the required

value.

1.3 Controlled variable pointer (red)

1.4 Set point adjuster (green)

1.5 Output pressure display

1.6 Manual/automatic switch

1.7 Manual output pressure adjuster

1.8 Differential pressure indicator

4 Lock

5 Indicating unit

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