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.

EB 8394 EN 11
Safety instructions and measures
Malfunction due to initialization not yet completed.
The initialization causes the positioner to be adapted to the mounting situation. After ini-
tialization is completed, the positioner is ready to use.
ÎInitialize the positioner on the rst start-up.
ÎRe-initialize positioner after changing the mounting position.
Risk of positioner damage due to incorrect grounding of the electric welding
equipment.
ÎDo not ground electric welding equipment near to the positioner.

12 EB 8394 EN
Markings on the device
2 Markings on the device
2.1 Nameplate
SAMSON 3725
Supply max. 10 bar / 150 psi
Input 4 ... 20 mA DC
See technical data for ambient temperature
-40 °C £Ta* £+80 °C
Positioner
SAMSON AG D-60314 Frankfurt Made in Germany
Firmware
Model 3725 - 110
Var.-ID Serial no.
2
4
5
78
6
1
3
1 Max. supply pressure
2 Signal range
3 Type of protection for explosion-protected devices
4Temperature limits in the test certicates for the explosion-protected devices
5 Firmware version
6 Model no.
7Conguration ID
8 Serial number

EB 8394 EN 13
Markings on the device
2.2 Article code
Positioner Type3725- x x x 0 0 0 0 x 0 0
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
Ship building certicate
Without 0
Bureau Veritas certication 1
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 examina-
tion 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

14 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).
3.1 Mounting versions
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 (Se-
ries V2001 Valves)
−Attachment to rotary actuators according
to VDI/VDE3845
ÎRefer to section5.2 onwards for a de-
scription of the types of attachment.

EB 8394 EN 15
Design and principle of operation
%
S
mm
%
mm
Q
34
11
6
7
810
1
w
9
x
y
2
5
1Valve 7 Air capacity booster
2 Sensor 8 Pressure regulator
3 A/D converter 9 Fixed restriction
4 Microcontroller 10 Volume restriction
5 D/A converter 11 Display
6 i/p converter
Fig.1: Circuit diagram

16 EB 8394 EN
Design and principle of operation
3.2 Accessories and mounting parts
Table2: Direct attachment to Type3277-5 and Type2780-2 Actuators (see sec-
tion5.2) Order no.
Mounting parts
For actuators up to 120cm² 1402-0239
Accessories for actuator
Switchover plate for Type 3277-5xxxxxx.01 Actuator 1400-6822
Connecting plate for additional attachment of, e.g. a solenoid valve: G
1
/
8
1400-6823
Accessories for positioner
Connecting plate (6) G¼ 1402-0235
¼ NPT 1402-0236
Pressure gauge bracket (7) G¼ 1402-0237
¼ NPT 1402-0238
Pressure gauge bracket for combination with Type4708-55 Supply Pressure Regulator 1402-1515
Pressure gauge mounting kit (8) up to max. 6bar
(output/supply)
Stainless steel/brass 1400-6950
Stainless steel/
stainless steel 1400-6951
Table3: Direct attachment to Type 3277 (section5.2.2) Order no.
Mounting parts
Actuators 240, 350, 355, 700cm² 1402-0240
Accessories
Connection block with seals and screw G¼ 1402-0241
¼NPT 1402-0242
Pressure gauge mounting kit up to max. 6bar
(output/supply)
Stainless steel/brass 1400-6950
Stainless steel/
stainless steel 1400-6951

EB 8394 EN 17
Design and principle of operation
Table4: Pipe connections for Type3277 (direct attachment)
Pipe connection Actuator size Material Connection Order no.
Piping with screw ttings
– for fail-safe action "actuator stem retracts"
– with air purging of the top diaphragm chamber
175cm²
Steel G¼ / G
3
/
8
1402-0930
¼NPT/
3
/
8
NPT 1402-0958
Stainless
steel
G¼ / G
3
/
8
1402-0950
¼NPT/
3
/
8
NPT 1402-0964
240cm²
Steel G¼ / G
3
/
8
1402-0927
¼NPT/
3
/
8
NPT 1402-0959
Stainless
steel
G¼ / G
3
/
8
1402-0951
¼NPT/
3
/
8
NPT 1402-0965
350cm²
Steel G¼ / G
3
/
8
1402-0928
¼NPT/
3
/
8
NPT 1402-0960
Stainless
steel
G¼ / G
3
/
8
1402-0952
¼NPT/
3
/
8
NPT 1402-0966
355cm²
Steel G¼ / G
3
/
8
1402-0956
¼NPT/
3
/
8
NPT 1402-0961
Stainless
steel
G¼ / G
3
/
8
1402-0953
¼NPT/
3
/
8
NPT 1402-0967
700cm²
Steel G¼ / G
3
/
8
1402-0929
¼NPT/
3
/
8
NPT 1402-0962
Stainless
steel
G¼ / G
3
/
8
1402-0954
¼NPT/
3
/
8
NPT 1402-0968
750cm²
Steel G¼ / G
3
/
8
1402-0957
¼NPT/
3
/
8
NPT 1402-0963
Stainless
steel
G¼ / G
3
/
8
1402-0955
¼NPT/
3
/
8
NPT 1402-0969

18 EB 8394 EN
Design and principle of operation
Table5: Attachment to NAMUR rib or attachment to rod-type yokes according to
IEC60534-6 (section5.3)
Order no.
5 to 50mm travel, lever already on positioner
For actuators
1402-0330
Actuators from other manufacturers and Type3271 with 120 to 700 cm² effective
areas
Accessories
Connecting plate G¼ 1402-0235
¼ NPT 1402-0236
Pressure gauge bracket G¼ 1402-0237
¼ NPT 1402-0238
Pressure gauge mounting kit up to max. 6bar
(output/supply)
Stainless steel/brass 1400-6950
Stainless steel/st.steel 1400-6951
Table6: Attachment to rotary actuators (section 5.5) Order no.
Light version
VDI/VDE3845 (September 2010), level 1 1), AA1 size 1402-0243
VDI/VDE3845 (September 2010), level 2 1), AA2 size 1402-0244
VETEC TypeS160 Actuator or SAMSON Type 3278 Rotary Actuator (160cm²) 1402-0294
VETEC Type S320 1402-0295
Heavy-duty version
VDI/VDE3845 (September 2010), level 1 1), AA1 to AA4 size 1402-1097
VDI/VDE3845 (September 2010), level 2 1) 1402-1099
VETEC Type S160/R 1402-1098
Accessories
Connecting plate G¼ 1402-0235
¼ NPT 1402-0236
Pressure gauge bracket G¼ 1402-0237
¼ NPT 1402-0238
Pressure gauge mounting kit up to max. 6bar
(output/supply)
Stainless steel/brass 1400-6950
Stainless steel/st. steel 1400-6951
Connecting plate for Type3710 Reversing Amplier 1402-0512
1) See page24 for details.

EB 8394 EN 19
Design and principle of operation
Table7: General accessories Order no.
Cable gland M20x1.5
Black plastic 8808-1011
Blue plastic 8808-1012
Nickel-plated brass 1890-4875
Stainless steel 1.4305 8808-0160
Adapter M20x1.5 to ½ NPT
Powder-coated aluminum 0310-2149
Stainless steel 1400-7114
Brief instructions inside cover
German 0190-6173
English 0190-6174

20 EB 8394 EN
Design and principle of operation
3.3 Travel tables
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 16.0/25.01)mm M 25
120/240/350 15 7.0mm 22.0/35.01)mm M 35
700 7.5
700/355 15/30 10.0mm 32.0/50.01)mm M 50
1) When 'MAX' is selected as the nominal range (P4 code, see page68)
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°
Note