Samson 3725 series Service manual

Mounting and
Operating Instructions
EB 8394 EN
Firmware version 1.1x
Translation of original instructions
Edition June 2014
Series 3725
Type3725 Electropneumatic Positioner

2 EB 8394 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.
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

Contents
EB 8394 EN 3
1 Safety instructions and measures ...................................................................6
1.1 Notes on possible severe personal injury .........................................................9
1.2 Notes on possible personal injury .................................................................10
1.3 Notes on possible property damage..............................................................10
2 Markings on the device ...............................................................................12
2.1 Nameplate..................................................................................................12
2.2 Article code.................................................................................................13
3 Design and principle of operation ................................................................14
3.1 Mounting versions........................................................................................14
3.2 Accessories and mounting parts....................................................................16
3.3 Travel tables ................................................................................................20
3.4 Technical data .............................................................................................21
3.5 Dimensions in mm........................................................................................23
4 Measures for preparation............................................................................25
4.1 Unpacking ..................................................................................................25
4.2 Transporting and lifting ................................................................................25
4.2.1 Transporting ................................................................................................25
4.2.2 Lifting..........................................................................................................25
4.3 Storage.......................................................................................................25
5 Mounting and start-up.................................................................................26
5.1 Lever and pin position..................................................................................26
5.2 Direct attachment.........................................................................................28
5.2.1 Type 3277-5 and Type2780-2 Actuators ......................................................28
5.2.2 Type3277 Actuator .....................................................................................32
5.3 Attachment according to IEC60534-6...........................................................34
5.4 Attachment to Type3372 Actuator (V2001)...................................................36
5.5 Attachment to rotary actuators......................................................................38
5.5.1 Heavy-duty version ......................................................................................40
5.5.2 Mounting the Type3710 Reversing Amplier .................................................42
5.6 Pneumatic connections..................................................................................43
5.7 Connecting the supply air.............................................................................43
5.7.1 Signal pressure connection ...........................................................................43
5.7.2 Supply pressure ...........................................................................................44
5.8 Electrical connections ...................................................................................45
5.8.1 Electric power supply ...................................................................................46
5.8.2 Cable entry .................................................................................................46
5.8.3 Connecting the electrical power ....................................................................46

4 EB 8394 EN
Contents
6 Operation...................................................................................................48
6.1 Operating controls.......................................................................................48
6.1.1 Capacitive keys............................................................................................48
6.1.2 Volume restriction Q.....................................................................................48
6.1.3 Display .......................................................................................................49
7 Operating the positioner..............................................................................50
7.1 Adapting the display....................................................................................51
7.2 Enabling conguration to change parameters.................................................51
7.3 Adjusting the volume restriction Q.................................................................52
7.4 Entering the air action..................................................................................53
7.5 Entering the direction of action......................................................................53
7.6 Limiting the signal pressure...........................................................................54
7.7 Setting other parameters...............................................................................55
7.8 Initialization ................................................................................................55
7.8.1 Canceling initialization.................................................................................56
7.9 Zero calibration...........................................................................................57
7.9.1 Canceling zero calibration............................................................................58
7.10 Manual mode..............................................................................................58
7.11 R eset...........................................................................................................59
8 Servicing.....................................................................................................60
8.1 Preparation for return shipment.....................................................................60
9 Malfunctions ...............................................................................................61
9.1 Resetting error codes....................................................................................62
9.2 Error codes..................................................................................................64
9.3 Emergency action ........................................................................................65
10 Decommissioning and disassembly ..............................................................66
10.1 Decommissioning.........................................................................................66
10.2 Removing the positioner ...............................................................................66
10.3 Disposal......................................................................................................66
11 Annex.........................................................................................................67
11.1 After-sales service........................................................................................67
11.2 Code list......................................................................................................68
11.2.1 Parameter codes ..........................................................................................68

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
manual 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
These Mounting and Operating Instructions EB8394EN are valid for positioners with rm-
ware versions 1.10 to 1.19. The latest edition of these instructions, detailing the rmware
version and modications compared to the previous version, is available on our website
uwww.samson.de.
Note

6 EB 8394 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
The SAMSON Type3725 Positioner is mounted on pneumatic control valves and is used to
assign the valve position to the control signal. The device is designed to operate under exact-
ly dened conditions (e.g. operating pressure, temperature). Therefore, operators must en-
sure that the positioner is only used in applications where the operating conditions corre-
spond to the technical data. In case operators intend to use the positioner in other applica-
tions or conditions than specied, contact SAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefer to the technical data for limits and elds of application as well as possible uses.
Reasonably foreseeable misuse
The Type3725 Positioner is not suitable for the following applications:
−Use outside the limits dened during sizing and in the technical data
Furthermore, the following activities do not comply with the intended use:
−Use of non-original spare parts
−Performing maintenance activities not specied by SAMSON
Qualications of operating personnel
The positioner must be mounted, started up, and serviced by fully trained and qualied per-
sonnel only; the accepted industry codes and practices are to be observed. 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 hazards due to their spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.
Explosion-protected versions of this device are to be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

EB 8394 EN 7
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the positioner. Work
on the control valve may be necessary when mounting or removing the positioner.
ÎObserve the requirements for personal protective equipment specied in the valve docu-
mentation.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions, conversions or other modications to the product are not authorized by SAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety features
Upon failure of the air supply or electric signal, the positioner vents the actuator, causing
valve to move to the fail-safe position determined by the actuator.
Warning against residual hazards
The positioner has direct inuence on the control valve. To avoid personal injury or property
damage, plant operators and operating personnel must prevent hazards that could be
caused in the control valve by the process medium, the operating pressure, the signal pres-
sure or by moving parts by taking appropriate precautions. They must observe all hazard
statements, warning and caution notes in these mounting and operating instructions, espe-
cially 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 level, it must be restricted using a suitable supply pressure reducing station.
Responsibilities of the operator
The operator is responsible for proper operation 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, the operator must ensure
that operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
well as the specied hazard statements, warning and caution notes. Furthermore, the operat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

8 EB 8394 EN
Safety instructions and measures
Servicing explosion-protected devices
If a part of the device on which the explosion protection is based needs to be serviced, the
device must not be put back into operation until a qualied inspector has assessed it accord-
ing to explosion protection requirements, has issued an inspection certicate, or given the
device a mark of conformity. Inspection by a qualied inspector is not required if the manu-
facturer performs a routine test on the device before putting it back into operation. Document
the passing of the routine test by attaching a mark of conformity to the device. Replace ex-
plosion-protected components only with original, routine-tested components by the manufac-
turer.
Devices that have already been operated outside hazardous areas and are intended for fu-
ture 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 the
specications for servicing explosion-protected devices.
Maintenance, calibration, and work on equipment
ÎOnly use intrinsically safe current/voltage calibrators and measuring instruments for in-
terconnection with intrinsically safe circuits to check or calibrate the equipment inside or
outside hazardous areas.
ÎObserve the maximum permissible values specied in the certicates for intrinsically safe
circuits.
Referenced standards and regulations
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 at the end of these instructions.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−The mounting and operating instructions of the components on which the positioner is
mounted (valve, actuator, valve accessories, etc.).

EB 8394 EN 9
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of 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 cause death.
ÎThe following regulations apply to installation in hazardous areas: EN60079-14
(VDE0165, Part1).
ÎInstallation, operation, or maintenance of the positioner must only performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.

10 EB 8394 EN
Safety instructions and measures
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 actuator stem moves
through its entire travel range. Injury to hands or ngers is possible if they are inserted
into the valve.
ÎDuring initialization, do not insert hands or ngers into the valve yoke and do not
touch any moving valve parts.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the positioner due to incorrect mounting position.
ÎDo not mount the positioner with the back of the device/vent opening facing upward.
ÎDo not seal 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 the
prescribed sequence.
ÎPerform mounting and start-up as described in section5 in page26.
An incorrect electric signal will damage the positioner.
A current source must be used to provide the electrical power for the positioner.
ÎOnly use a current source and never a voltage source.
Incorrect assignment of the terminals will damage the positioner and will lead to mal-
function.
For the positioner to function properly, the prescribed terminal assignment must be ob-
served.
ÎConnect the electrical wiring to the positioner according to the prescribed terminal
assignment.