Samson 3730-2 Service manual

Mounting and
Operating Instructions
EB 8384-2 EN (1300-1611)
Firmware version 1.56
Edition April 2016
Series 3730
Type3730-2 Electropneumatic Positioner
EB + CD

2 EB 8384-2 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 8384-2 EN 3
1 Important safety instructions ..........................................................................8
2 Article code...................................................................................................9
3 Design and principle of operation ................................................................10
3.1 Additional equipment...................................................................................11
3.2 Communication ...........................................................................................12
3.3 Technical data .............................................................................................13
4 Attachment to the control valve – Mounting parts and accessories .................20
4.1 Direct attachment.........................................................................................22
4.1.1 Type3277-5 Actuator ..................................................................................22
4.1.2 Type3277 Actuator .....................................................................................24
4.2 Attachment according to IEC60534-6...........................................................26
4.3 Attachment according to VDI/VDE3847 .......................................................28
4.4 Attachment to Type3510 Micro-ow Valve ....................................................34
4.5 Attachment to rotary actuators ......................................................................34
4.5.1 Heavy-duty version ......................................................................................36
4.6 Reversing amplier for double-acting actuators ..............................................38
4.6.1 Reversing amplier (1079-1118 or 1079-1119)............................................40
4.7 Attachment of external position sensor...........................................................42
4.7.1 Mounting the position sensor with direct attachment........................................43
4.7.2 Mounting the position sensor with attachment according to IEC60534-6 .........45
4.7.3 Mounting the position sensor to Type3510 Micro-ow Valve...........................46
4.7.4 Mounting on rotary actuators........................................................................47
4.8 Mounting the leakage sensor ........................................................................48
4.9 Attaching positioners with stainless steel housings...........................................49
4.10 Air purging function for single-acting actuators ..............................................49
4.11 Required mounting parts and accessories.......................................................50
5 Connections ................................................................................................55
5.1 Pneumatic connections..................................................................................55
5.1.1 Signal pressure gauges ................................................................................55
5.1.2 Supply pressure ...........................................................................................55
5.1.3 Signal pressure (output)................................................................................56
5.2 Electrical connections ...................................................................................56
5.2.1 Switching amplier ......................................................................................59

4 EB 8384-2 EN
Contents
6 Operating controls and readings..................................................................60
6.1 Serial interface ............................................................................................62
7 Start-up and settings ...................................................................................63
7.1 Dening the fail-safe position........................................................................63
7.2 Adjusting the volume restriction Q.................................................................64
7.3 Adapting the display direction ......................................................................64
7.4 Limiting the signal pressure...........................................................................65
7.5 Checking the operating range of the positioner ..............................................65
7.6 Initialization ................................................................................................66
7.6.1 MAX – Initialization based on maximum range ..............................................68
7.6.2 NOM – Initialization based on nominal range ...............................................69
7.6.3 MAN – Initialization based on a manually selected range...............................70
7.6.4 SUb – Substitute calibration ..........................................................................71
7.7 Zero calibration ...........................................................................................74
7.8 Reset to default settings.................................................................................75
8 Operation...................................................................................................76
8.1 Enabling and selecting parameters................................................................76
8.2 Operating modes.........................................................................................76
8.2.1 Automatic and manual modes ......................................................................76
8.2.2 Fail-safe position (SAFE)...............................................................................77
8.3 Fault/malfunction.........................................................................................78
8.3.1 Conrming error messages...........................................................................79
9 Adjusting the limit switch.............................................................................80
9.1 Retrotting an inductive limit switch ...............................................................81
10 Maintenance ...............................................................................................83
11 Servicing explosion-protected devices ..........................................................83
12 Firmware update (serial interface)................................................................83
13 Maintenance, calibration and work on equipment ........................................84
14 Code list .....................................................................................................85
15 Dimensions in mm.....................................................................................103
15.1 Fixing levels according to VDI/VDE3845 (September 2010) ........................106

EB 8384-2 EN 5
Contents
16 Valve characteristic selection......................................................................107
Index........................................................................................................126
The functions of the EXPERTplus Valve Diagnostics are described in the Operating Instructions
uEB8389.
EB8389 is included on the enclosed CD-ROM and is available on our website.
Note

6 EB 8384-2 EN
Firmware revisions
Old New
1.01 1.10
The positioner can be congured and operated over the TROVIS-VIEW software after
connecting it to the computer over the serial interface and the serial interface adapter.
The following status messages have been added:
• Code76 – No emergency mode
• Code77 – Program load error
Reading indicates the number of zero calibrations performed since the last initialization.
For initialization of "AIR TO CLOSE" actuators, the direction of action (Code7) is
automatically set to increasing/decreasing.
Code3, the activation period of the enabled conguration function has been extended to
120s.
1.10 1.20
Electronics changed, no new functions added.
1.20 1.30
New EXPERTplus diagnostics functions (Code 48) added.
Positioner in EXPERTplus version with extended diagnostics features.
An initialization procedure in progress can be canceled by pressing the rotary
pushbutton.
The position transmitter (Code 37) and solenoid valve (Code45) options are
automatically detected.
1.30 1.40
All EXPERTplus functions can be used in this rmware version and higher.
The fault alarm contact is triggered by the condensed state of the positioner.
It is always active with ‘Maintenance alarm’ condensed state.
• When Code 32 = YES: also active with ‘Function check‘ condensed state
• When Code 33 = YES: also active with ‘Maintenance required/Maintenance
demanded‘ condensed state
The ‘Function check‘ condensed state is additionally set for Test A1, A2, fault alarm output
and position transmitter.
The min./max. values of the temperature monitoring can be reset.
1.40 1.41
Internal revisions
1.41 1.42
Internal revisions

EB 8384-2 EN 7
Firmware revisions
Old New
1.42 1.51
All EXPERTplus diagnostic functions are available without having to activate them in the
positioner (u EB8389 on EXPERTplus Valve Diagnostics).
Optional binary input with following actions:
• Transmit switching state
• Activate local write protection
• Switch between automatic and manual modes
• Various diagnostic functions uEB8389 (EXPERTplus valve diagnostics)
The pressure limit (Code16) is no longer automatically set during initialization.
1.51 1.54
Internal revisions
1.54 1.55
Code4: the setting for 300mm has been added to the pin position
1.55 1.56
Internal revisions

8 EB 8384-2 EN
Important safety instructions
1 Important safety instructions
For your own safety, follow these instructions concerning the mounting, start-up, and opera-
tion of the device:
−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:
−Do not operate the positioner with the back of the positioner/vent opening facing up-
wards.
The vent opening must not be sealed or restricted when the positioner is installed on site.
Vent opening
−Proper shipping and storage are assumed.
−Do not ground electric welding equipment near to the positioner.
The device with a CE marking fullls the requirements of the Directive 2014/34/EU and the
Directive 2014/30/EU. The EU declarations of conformity are included on the enclosed CD-
ROM.
Note

EB 8384-2 EN 9
Article code
2 Article code
Positioner Type3730-2 xxxxxxxx0x00x0x x
With LCD and autotune
Explosion protection
Without 0
ATEX II 2G Ex ia IIC T6 Gb, II 2D Ex ia IIIC T80°C Db 1
CSA Exia IIC T6; Class I, II, Div.1, Groups A, B, C, D, E, F, G;
Ex nA II T6; Ex nL IIC T6; Class I, Div.2, Groups A, B, C, D;
Class II, Div.1, Groups E, F, G
3
FM
Class I, Zone 0 AExia IIC; Class I, II, III, Div.1, Groups A, B, C, D, E, F, G;
Class I, Div.2, Groups A, B, C, D; Class II, III, Div.2, Groups F, G
ATEX II 2D Ex tb IIIC T80°C Db 5
JIS Ex ia IIC T6 7
ATEX II 3G Ex nA IIC T6 Dc, II 3D Ex tc IIIC T80°C Dc 8
Additional equipment
Inductive limit switch Without 0
SJ2-SN (NC contact) 1 0
SJ2-S1N (NO contact) 0/32
Solenoid valve Without 0
With, 24 V DC 4
Analog position transmitter Without 0
With 1
External position sensor Without 0
With 0 1
Prepared connection 0 2
Leakage sensor Without 0
With 1
Binary input Without 0
With 0 2
Diagnostics
EXPERTplus 4
Housing material
Aluminum (standard) 0
Stainless steel 1.4581 0 1
Special application
Without 0
Free of substances that impair paint adhesion 1
Exhaust air port with ¼-18NPT thread, back of positioner sealed 2
Attachment according to VDI/VDE3847 including interface 6
Attachment according to VDI/VDE3847 prepared for interface 7
Special version
Without 0 0
IECEx Exia IIC T6 1 1 2
GOST 1Ex ia IIC T6; Ex tb IIIC T80°C Db X, IP66 1 1 4
GOST 2Ex nA ic IIC T6/T5/T4 Gc X; Ex tc IIIC T80°C Db X, IP66 8 2 0

10 EB 8384-2 EN
Design and principle of operation
3 Design and principle of oper-
ation
The electropneumatic positioner is mounted
on pneumatic control valves and is used to
assign the valve position (controlled vari-
ablex) to the control signal (set pointw). The
electric signal from a controlling system is
compared to the travel or the rotational an-
gle of the control valve and a signal pressure
(output variable y) is produced for the actua-
tor.
The positioner consists of a travel sensor sys-
tem (2) proportional to resistance, an analog
i/p converter with a downstream air capaci-
ty booster (7) and the electronics with micro-
controller (5).
The positioner is tted with three binary con-
tacts as standard: A fault alarm output indi-
cates a fault to the control room and two
congurable software limit switches are used
to indicate the end positions of the valve.
The valve position is transmitted as a either
an angle of rotation or travel to the pick-up
lever and to the travel sensor (2) and sup-
plied to an analog PD controller. An A/D
converter (4) transmits the position of the
valve to the microcontroller (5). The PD con-
1 Control valve
2 Travel sensor
3 PD controller
4 A/D converter
5 Microcontroller
6 i/p converter
7Air capacity booster
8Pressure regulator
9Flow regulator
10 Volume restriction
11* Inductive limit switch
12* Solenoid valve
13* Analog position transmitter
14 Software limit switch alarm
1/2
15 Fault alarm output, alarm 3
16 Display
17* Actuation of solenoid valve
18* Electrical insulation
19 D/A converter
20 Communication interface
22 Binary input BE*
* Options
w
x
%
S
mm
GG
PD
Serial
Interface
16
20
13
15
A2
A3
A1
11
2
419
5
3
12
6
7
81
14
14
w
Q
10
x
y
24V DC
9
17 18
22
BE
Fig.1: Functional diagram