Samson 3725 series Service manual

Mounting and
Operating Instructions
EB 8394 EN
Firmware version 1.12
Edition June 2014
Series 3725
Type3725 Electropneumatic Positioner

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 8394 EN

Contents
EB 8394 EN 3
1 General safety instructions.............................................................................6
2 Article code...................................................................................................7
3 Design and principle of operation ..................................................................8
3.1 Technical data .............................................................................................10
4 Mounting the positioner...............................................................................12
4.1 Mounting sequence......................................................................................12
4.2 Lever and pin position ..................................................................................12
4.3 Direct attachment.........................................................................................14
4.3.1 Type3277-5andType2780-2Actuators ......................................................14
4.3.2 Type3277Actuator .....................................................................................18
4.4 AttachmentaccordingtoIEC60534-6...........................................................20
4.5 AttachmenttoType3372Actuator(V2001)...................................................22
4.6 Attachmenttorotaryactuators ......................................................................24
4.6.1 Heavy-dutyversion ......................................................................................26
4.6.1 MountingtheType3710ReversingAmplier .................................................28
4.7 Accessoriesandmountingparts....................................................................29
5 Connections ................................................................................................33
5.1 Pneumatic connections..................................................................................33
5.1.1 Supply pressure ...........................................................................................33
5.2 Electricalconnections ...................................................................................34
5.2.1 Electricpowersupply ...................................................................................35
5.2.2 Selecting cables and wires............................................................................35
5.2.3 Equipmentforuseinzone2 .........................................................................35
5.2.4 Cableentry .................................................................................................35
6 Operation...................................................................................................36
6.1 Operatingcontrols .......................................................................................36
6.1.1 Capacitivekeys............................................................................................36
6.1.2 VolumerestrictionQ.....................................................................................36
6.1.3 Display .......................................................................................................37
7 Start-up ......................................................................................................38

4 EB 8394 EN
Contents
8 Settings.......................................................................................................39
8.1 Adaptingthedisplay....................................................................................39
8.2 Enablingcongurationtochangeparameters.................................................39
8.3 AdjustingthevolumerestrictionQ.................................................................40
8.4 Enteringthedirectionofaction......................................................................41
8.5 Enteringthedirectionofaction......................................................................41
8.6 Limitingthesignalpressure...........................................................................42
8.7 Settingotherparameters...............................................................................42
8.8 Initialization ................................................................................................43
8.8.1 Cancelinginitialization.................................................................................44
8.9 Zerocalibration ...........................................................................................44
8.9.1 Cancelingzerocalibration............................................................................45
8.10 Manualmode..............................................................................................45
8.11 R eset...........................................................................................................47
8.12 Fault ...........................................................................................................47
8.12.1 Resettingerrorcodes....................................................................................48
9 Code list .....................................................................................................49
9.1 Parameter codes ..........................................................................................49
9.2 Errorcodes..................................................................................................52
10 Maintenance ...............................................................................................54
11 Servicing explosion-protected devices ..........................................................54
12 Dimensions in mm.......................................................................................55
12.1 FixinglevelsaccordingtoVDI/VDE3845(September2010) ..........................56

EB 8394 EN 5
Contents
Firmware revisions
1.02(old) 1.03(new)
Internalrevisions
1.03(old) 1.10(new)
Settingofthetravelinstepsof0.5mm(P4parametercode)
Monitoringoftheendstopsonlyduringinitializationandinman-
ual mode
Tosuppresscommon-modeinterferenceonthesignallines,theD
componentofthepositionerisswitchedoffwhentheactuatoris
at a standstill.
1.10(old) 1.11(new)
Internalrevisions
1.11(old) 1.12(currentversion)
Internalrevisions

6 EB 8394 EN
General safety instructions
1 General safety instructions
Foryourownsafety,followtheseinstructionsconcerningthemounting,startupandopera-
tionofthepositioner:
−Thedeviceistobemounted,starteduporoperatedonlybytrainedandexperienced
personnelfamiliarwiththeproduct.Accordingtothesemountingandoperatinginstruc-
tions,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applicablestandards.
−Explosion-protectedversionsofthisdevicearetobeoperatedonlybypersonnelwhohas
undergonespecialtrainingorinstructionsorwhoisauthorizedtoworkonexplosion-pro-
tecteddevicesinhazardousareas.
−Anyhazardsthatcouldbecausedinthevalvebytheprocessmedium,thesignalpres-
sureorbymovingpartsaretobepreventedbytakingappropriateprecautions.
−Ifinadmissiblemotionsorforcesareproducedinthepneumaticactuatorasaresultof
thesupplypressurelevel,itmustberestrictedusingasuitablesupplypressurereducing
station.
To avoid damage to any equipment, the following also applies:
−Proper shipping and storage are assumed.
Note:
Devices with a CE marking fulll the requirements of the Directives 2014/34/EU and
2014/30/EU. The declaration of conformity is included in the Appendix of these in-
structions.


EB 8394 EN 7
Article code
2 Article code
Positioner Type3725- x x x 00000009999
WithLCDandautotune,4to20mAreference
variable
Explosionprotection1)
Without 0 0 0
Intrinsicsafety:ATEX 1100
Intrinsicsafety:STCC 1100
Intrinsicsafety:CSA 1300
Intrinsicsafety:GOST 1130
1) SeeTable1fordetailsonexplosionprotectioncerticates.
Table1: Summary of explosion protection certicates
Type Certication Type of protection
3725-1100
STCC Number No.2860 0ExiaIICT4X
Validuntil 2017-10-08
Number PTB11ATEX2020X
II2GExiaIICT4
Date 2011-08-25
ECtype
examination
certicate
3725-113
Number RUC-DE.GB08.B.00697
1ExiaIICT4GbXDate 2014-12-15
Validuntil 2019-12-14
3725-130 ®
C US
Number 2703735X ExiaIICT4;
ClassI,Zone0,AExiaIICT4;
ClassI,Div.1,GroupsA,B,C,D
Date 2014-06-03

8 EB 8394 EN
Design and principle of operation
3 Design and principle of oper-
ation
TheType3725ElectropneumaticPositioneris
mounted on pneumatic control valves and is
usedtoassignthevalveposition(controlled
variablex)tothecontrolsignal(reference
variablew).Thepositionercomparesthe
electriccontrolsignalofacontrolsystemto
thetraveloropeningangleofthecontrol
valveandissuesasignalpressure(output
variabley)forthepneumaticactuator.
Thepositionermainlyconsistsofthefollow-
ingcomponents(seeFig.1):
−Magnetoresistivesensor(2)
−Analogi/pconverter(6)withadown-
streamaircapacitybooster(7)
−Electronicsunitwithmicrocontroller(4)
The travel or opening angle is measured by
thepick-uplever,non-contactmagnetoresis-
tive sensor and downstream electronics.
Thepick-upleverisconnectedtoamagnet
insidethedevice.Themotionofthepick-up
levercausesthedirectionofthemagnetic
eldtochange.Thischangeissensedbythe
sensor. The electronics unit determines the
currentpositionoftheactuatorstemoropen-
inganglefromthisinformation.
Thepositionoftheactuatorstemoropening
angleistransmittedtothemicrocontroller(3)
overtheA/Dconverter(4).ThePDcontrol
algorithm in the microprocessor compares
thisactualpositiontothe4to20mAcontrol
signalafterithasbeenconvertedbythe
A/Dconverter(3).Incaseofasystemdevi-
ation,theactivationofthei/pmodule(6)is
changedsothattheactuatorofthevalve(1)
ispressurizedorventedaccordinglyoverthe
downstreambooster(7).Thesupplyairis
supplied to the booster and the pressure reg-
ulator(8).
The output signal pressure supplied by the
boostercanbelimitedto2.3barbysoft-
ware.
ThevolumerestrictionQ(10)isusedtoopti-
mizethepositionerbyadaptingittotheac-
tuator.
Tight-closing function
Thepneumaticactuatoriscompletelylled
withairorventedassoonasthereference
variablefallsbelow1%orexceeds99%
(seeendpositionssetinP10andP11pa-
rametercodes).

EB 8394 EN 9
Design and principle of operation
%
S
mm
%
mm
Q
34
11
6
7
810
1
w
9
x
y
2
5
1Valve 7Aircapacitybooster
2 Sensor 8Pressure regulators
3A/Dconverter 9 Fixed restriction
4 Microcontroller 10 Volumerestriction
5D/Aconverter 11 Display
6 i/pconverter
Fig.1: Circuit diagram

10 EB 8394 EN
Design and principle of operation
3.1 Technical data
Type3725 Positioner
Travel(adjustable) DirectattachmenttoType3277: 5 to 30 mm
DirectattachmenttoType2780-2: 6/12/15mm
AttachmenttoType3372Actuator: 15/30mm
AttachmentaccordingtoIEC60534-6(NAMUR): 5 to 50 mm
Attachmenttorotaryactuators: 24 to 100°
Referencevariablew
(reversepolarityprotec-
tion)
Static destruction limit
4to20mAsignalrange·Two-wiredevice
Split-rangeoperation4to11.9mAand12.1to20mA
±33V
Minimum current 3.8mA
Load impedance Max.6.3V
Supply air
Airqualityacc.to
ISO8573-1
Supplyair:1.4to7bar(20to105psi)
Max.particlesizeanddensity:Class4·Oilcontent:Class3·Pressuredewpoint:Class
3oratleast10Kbelowthelowestambienttemperaturetobeexpected
Signalpressure(output) 0baruptothesupplypressure·Canbelimitedtoapprox.2.3barbysoftware
Characteristic 3characteristicsforglobevalves·9characteristicsforrotaryvalves
Hysteresis ≤0.3%
Sensitivity ≤0.1%
Transit time Onlyforactuatorswithinitializationtime>0.5s1)
Directionofaction w/xreversible
Airconsumption ≤100ln/hwithasupplypressureupto6barandasignalpressureof0.6bar
Airoutputcapacity
Tollactuatorwith
air AtΔp6bar:8.5mn³/h AtΔp=1.4bar:3.0mn³/h, KVmax(20°C)=0.09
To vent actuator AtΔp6bar:14.0mn³/h AtΔp=1.4bar:4.5mn³/h, KVmax(20°C)=0.15
Permissible ambient
temperature
–20to+80°C
–25to+80°Cwithmetalcablegland
Thelimitsinthetestcerticatesadditionallyapplyforexplosion-protectedversions
1) Forfasteractuators,avolumerestrictionmustbeused.Otherwise,theinitializationcannotbeperformed
successfully.

EB 8394 EN 11
Design and principle of operation
Safety
Inuences Temperature: ≤0.15%/10K
Effectofvibration: ≤0.25%upto2000Hzand4gaccordingtoIEC770
Supplyair: None
Electromagnetic
compatibility
ComplyingwithEN61000-6-2,EN61000-6-3andNAMURRecommendationNE21
Explosionprotection1) Intrinsicsafety:ATEX, STCC, CSA, GOST
Degreeofprotection IP66
Compliance ·
Materials
Housing Polyphthalamide(PPA)
Cover Polycarbonate(PC)
Externalparts Stainless steel 1.4571 and 1.4301
Cablegland M20x1.5,blackpolyamide(PA)
Ventplugs High-densitypolyethylene(PE-HD)
Weight Approx. 0.5kg
1) SeeTable1onpage7fordetailsonexplosionprotectioncerticates.

12 EB 8394 EN
Mounting the positioner
4 Mounting the positioner
TheType3725Positionerissuitableforthe
followingtypesofattachment:
−DirectattachmenttoSAMSON
Type3277andType2780-2Actuators
−Attachmenttoactuatorsaccordingto
IEC60534-6(NAMUR)
−AttachmenttoType3372Actuator
(SeriesV2001Valves)
−Attachmenttorotaryactuatorsaccording
toVDI/VDE3845
Applies to all types of attachment:
ÎDo not mount the positioner with the
vent opening (Fig.2) facing upward.
ÎDo not seal the vent opening.
4.1 Mounting sequence
Mountthepositioner,keepingthefollowing
sequence:
1. Usecorrectleverandpinposition.Refer
tosection4.2.
2. Mount the positioner on the control
valve.Refertosection4.3ff.
3. Connectthesupplyair.Refertosec-
tion5.1.
4. Connecttheelectricreferencevariable.
Refertosection5.2.
5. Performstart-up.Refertosection7.
4.2 Lever and pin position
The positioner is adapted to the actuator and
totheratedtravelbytheleveronthebackof
the positioner and the pin inserted into the
lever.
Thetraveltablesonpage13showtheas-
signment between the required lever and pin
position.
The positioner is equipped with the Mlever
(pinposition35)asstandard.
Removing the lever and changing the pin
position:
NOTICE
Incorrect removal of the lever will
damage the positioner.
Only remove the lever when it is po-
sitioned at the bottom mechanical
stop.
1. Holdtheleverinplace.Undothenutus-
ingawrench(widthacrossatsSW10).
2. Removetheleverfromtheshaft.
3. Insertpininpositionaslistedinthetrav-
el table.
4. Fasten the lever.
Top stop
Bottom
stop
Ventopening
Fig.2: Mechanical stops and vent opening

EB 8394 EN 13
Mounting the positioner
Travel tables
Note:
The M lever is included in the scope of delivery.
Direct attachment to Type3277-5 and Type3277 Actuators
Actuator size Rated travel Adjustment range at positioner Required
lever
Assigned
pin position
[cm²] [mm] Min. Travel Max.
120 7.5 5.0mm to 16.0mm M 25
120/240/350 15 7.0mm to 22.0mm M 35
355/700 30 10.0mm to 32.0mm M 50
Direct attachment to Type2780-2 Actuator
Actuator size Rated travel Adjustment range at positioner Required
lever
Assigned
pin position
[cm²] [mm] Min. Travel Max.
120 6/12 5.0mm to 16.0mm M 25
120 15 7.0mm to 22.0mm M 35
Attachment according to IEC60534-6 (NAMUR)
SAMSON Type3271 Actuator Travel of other valves Required
lever
Assigned
pin position
Size [cm²] Rated travel
[mm] Min. Max.
120 7.5 5.0mm 16.0/25.01)mm M 25
120/240/350 15 7.0mm 22.0/35.01)mm M 35
700 7.5
700/355 15/30 10.0mm 32.0/50.01)mm M 50
1) WithMAXsetasthenominalrange(CodeP4,seepage51)
Attachment to rotary actuators according to VDI/VDE3845
Rotary actuators Required
lever
Assigned
pin position
Min. Openingangle Max.
24° to 100° M 90°


14 EB 8394 EN
Mounting the positioner
4.3 Direct attachment
4.3.1 Type 3277-5 and
Type2780-2 Actuators
ÎRequiredmountingpartsandaccesso-
ries:Table2onpage29.
ÎObservetraveltablesonpage13.
Actuator with 120cm² diaphragm area
Dependingonthetypeofpositionerattach-
ment,thesignalpressureisroutedeitherleft
orrightoftheyokethroughaholetotheac-
tuator diaphragm.
ÎDependingonthefail-safeactionofthe
actuator "actuator stem extends" or "ac-
tuatorstemretracts",rstattachtheswi-
tchoverplate(9)totheactuatoryoke
(whilealigningitwiththecorresponding
symbolforleftorrightattachmentac-
cordingtothemarking,seeFig.4).
1. Mountconnectingplate(6)orpressure
gaugebracket(7)withpressuregauges
onthepositioner,makingsurethetwo
seals(6.1)areseatedproperly.
2. Screwthescrewplug(4)onthebackof
thepositionerintotheholebelowit(park
position)(seeFig.6)andsealthesignal
pressure output on the connecting plate
(6)oronthepressuregaugebracket(7)
withthestopper(5)includedintheac-
cessories.
3. Placefollowerclamp(3)ontheactuator
stem,alignitandscrewtightsothatthe
mounting screw is located in the groove
oftheactuatorstem.
4. 15 mm travel:Keepthefollowerpin(2)
ontheMlever(1)onthebackofthepo-
sitionerinthepinposition35(delivered
state).7.5 mm travel:Removethefol-
lowerpin(2)fromthepinposition35,
repositionitintheholeforpinposition
25 and screw tight.
5. Insertformedseal(15)intothegrooveof
the positioner housing.
6. Place positioner on the actuator in such a
mannerthatthefollowerpin(2)restson
topofthefollowerclamp(3).Whiledo-
ingthis,pressontheribbedareashown
inFig.3tolockthepick-upleverinthe
topposition.Thelever(1)mustreston
thefollowerclampwithspringforce.
Fig.3: Locking the pick-up lever in position
7. Mount the positioner on the actuator us-
ingthetwoxingscrews.
8. Mountcover(11)ontheotherside.
Makesurethattheventplugislocatedat
the bottom when the control valve is in-
stalled to allow any condensed water
thatcollectstodrainoff(Fig.4).

EB 8394 EN 15
Mounting the positioner
911
Supply 9 Output 38
5
6
7
3
2
1
15
6.1
1.1
1.2
8
4
16
1 Lever
1.1 Nut
1.2 Diskspring
2 Follower pin
3 Follower clamp
4 Screw plug
5 Sealing plug
6 Connectingplate
6.1 Seals
7 Pressure gauge
bracket
8Pressure gauge
mountingkit
9 Switchover plate
(actuator)
11 Cover
15 Formed seal
16 Ventplug
Symbols
Actuatorstem
extends
Switchoverplate(9)
Marking
Actuatorstem
retracts
Signal pressure
inputforright
attachment
Signal pressure
inputforleft
attachment
Leftattachment Rightattachment
Fig.4: Direct attachment – Signal pressure connection for Type3277-5 Actuator (120cm²)

16 EB 8394 EN
Mounting the positioner
Additional solenoid valve
Ifasolenoidvalveisadditionallymounted
ontotheactuator,thesignalpressureportat
thebackofthepositionermustbesealed
(seeFig.6).Todothis,unscrewthescrew
pluglocatedinthemiddlehole(screwplug
inparkposition)andscrewitintothesignal
pressure port to seal it.
Inthiscase,routethesignalpressurefrom
the signal pressure output to the actuator
overtheconnectingplate(6)orpressure
gaugebracket(7).Theconnectingplate(ac-
cessoriesfortheactuator)replacestheswi-
tchoverplate(9).
Note:
The switchover plate and connecting
plate are accessories for the actuator
(120 cm²).They are listed in sec-
tion4.7 on page29.

Cover Ventplug
Fig.5: Cover with vent plug when the valve is
installed

EB 8394 EN 17
Mounting the positioner
Screwplug(4)
(signalpressureport)
Parkposition
Fastening
screw
Fig.6: Signal pressure port and park position for screw plug

18 EB 8394 EN
Mounting the positioner
4.3.2 Type3277 Actuator
ÎRequiredmountingpartsandaccesso-
ries:Table3onpage29.
ÎObservetraveltablesonpage13.
Actuators with 240 to 700cm² effective ar-
eas
The positioner can be mounted either on the
leftorrightsideoftheyoke.Thesignalpres-
sure is routed to the actuator over the con-
nectionblock(12),foractuatorswithfail-
safeaction"actuatorstemextends"internal-
lythroughaholeinthevalveyokeandfor
"actuator stem retracts" through an external
pipe.
Placefollowerclamp(3)ontheactuator
stem,alignitandscrewtightsothatthe
mountingscrewislocatedinthegrooveof
the actuator stem.
1. Foractuators240and350cm²with
15mmtravel,keepthepin(2)inpinpo-
sition 35.
Foractuatorswith355or700cm²,re-
movethepin(2)onMlever(1)onthe
backofthepositionerfrompinposition
35,repositionitintheholeforpinposi-
tion50andfastentight.
2. Insertformedseal(15)inthegrooveof
the positioner housing.
3. Place positioner on the actuator in such a
mannerthatthepin(2)restsontopof
thefollowerclamp(3).
4. Whiledoingthis,pressontheribbedar-
eatolocktheleverinthetopposition
(seeFig.3).
Thelever(1)mustrestonthefollower
clampwithspringforce.
Fasten the positioner on the actuator us-
ingthetwoxingscrews.
5. Makesurethatthetipofthegasket(16)
projectingfromthesideoftheconnec-
tionblockispositionedtomatchtheac-
tuatorsymbolfortheactuator'sfail-safe
action "actuator stem extends" or "actua-
torstemretracts".Ifthisisnotthecase,
unscrewthethreefasteningscrewsand
liftoffthecover.Turnthegasket(16)by
180°andre-insertit.
6. Placetheconnectionblock(12)withthe
associated seals against the positioner
andtheactuatoryokeandfastenusing
thescrew(12.1).
7. Foractuatorswithfail-safeaction"Actu-
atorstemretracts",additionallyremove
thestopper(12.2)andmounttheexter-
nal signal pressure pipe.
8. Mountcover(11)ontheotherside.
Makesurethattheventplugislocatedat
the bottom when the control valve is in-
stalled to allow any condensed water
thatcollectstodrainoff(seeFig.5on
page16).

EB 8394 EN 19
Mounting the positioner
2
10 15 12
31
1
1.1
1.2
12.11216
16
12.2
SUPPLY
A
Ansicht A
1
2
10 15 12311
1.1
1.2
12.11216
16
12.2
SUPPLY
A
Ansicht A
1
1 M lever
1.1 Nut
1.2 Diskspring
2 Follower pin
3 Follower clamp
11 Cover
12 Connectionblock
12.1 Screw
12.2 Stopperorconnectionfor
external piping
15 Formed seal
16 Gasket
Type3372ActuatorwithType3725
Positioner(directattachment)
Fig.7: Direct attachment · Signal pressure connection for Type3277 Actuator with 240 to 700cm²

20 EB 8394 EN
Mounting the positioner
4.4 Attachment according to
IEC60534-6
The positioner is attached to the control valve
usingaNAMURbracket(10).
ÎRequiredmountingpartsandaccesso-
ries:Table5onpage31.
ÎObservetraveltablesonpage13.
1. Screwthetwobolts(14)tothebracket
(9.1)ofthestemconnector(9),placethe
followerplate(3)ontopandusethe
screws(14.1)forfastening.
2. FastentheNAMURbracket(10)tothe
control valve.
−ForvalvewithNAMURrib:Fastenthe
NAMURbracket(10)usingtheM8
screw(11)andtoothedlockwasherdi-
rectlytotheyokehole.
−Forvalveswithrod-typeyoke:Placethe
twoU-bolts(16)aroundthestem.Posi-
tiontheNAMURbracket(10)andfasten
itusingthenuts,washersandtoothed
lockwashers.
3. AligntheNAMURbracket(10)sothatits
mounting holes are approximately in line
tothemiddleofthetravelscaleindicator
(15)(theslotofthefollowerplatemust
becentrallyalignedwiththeNAMUR
bracketatmidvalvetravel).
4. Mountconnectingplate(6)orpressure
gaugebracket(7)withpressuregauges
(8)onthepositioner,makingsurethe
twoseals(6.1)areseatedproperly.
5. PlacepositionerontheNAMURbracket
insuchamannerthatthepin(2)restsin
theslotofthefollowerplate(3).Adjust
thelever(1)correspondingly.
FastenthepositionertotheNAMUR
bracketusingitstwomountingscrews.