Samson 3730-6 Service manual

Series 3730
Electropneumatic Positioner
Type 3730-6
with HART®communication and pressure sensors
Mounting and
Operating Instructions
EB 8384-6 EN (1300-1623)
Firmware version 1.01
Edition February 2012
Fig. 1 · Type 3730-6

2EB 8384-6 EN
DANGER!
indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING!
indicates a hazardous situation which, if not
avoided, could result in death or serious
injury.
NOTICE
indicates a property damage message.
Note: Supplementary explanations, informa-
tion and tips
Definitions of the signal words used in these instructions

Contents Page
1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8
3.1 Safety function (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Valve diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Flow rate calculation. . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Type of application . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5.1 Configuration using TROVIS-VIEW 4 . . . . . . . . . . . . . . . . . . 12
3.6 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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 (NAMUR) . . . . . . . . . . . . 26
4.3 Attachment to Type 3510 Micro-flow Valve with Type 3271-5 Actuator . 28
4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 30
4.4.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 34
4.6 Attaching an external position sensor. . . . . . . . . . . . . . . . . . 34
4.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 34
4.6.2 Mounting the position sensor with attachment according to IEC 60534-6 36
4.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 37
4.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 38
4.7 Mounting the leakage sensor. . . . . . . . . . . . . . . . . . . . . . 39
4.8 Attaching positioners with stainless steel housings. . . . . . . . . . . . 40
4.9 Air purging function for single-acting actuators . . . . . . . . . . . . . 40
4.10 Required mounting parts and accessories. . . . . . . . . . . . . . . . 41
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 48
EB 8384-6 EN 3
Contents

5.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 49
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 52
6.1 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 HART®communication . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3 Dynamic HART®variables . . . . . . . . . . . . . . . . . . . . . . . 54
7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 56
7.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 57
7.3 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 57
7.5 Checking the operating range of the positioner . . . . . . . . . . . . . 58
7.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . . 60
7.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 61
7.6.3 MAN – Initialization based on a manually selected OPEN position . . . 62
7.6.4 MAN2 – Initialization based on manually selected end positions. . . . . 64
7.6.5 SUB – Substitute calibration . . . . . . . . . . . . . . . . . . . . . . 65
7.6.6 Tuning the KP input filter . . . . . . . . . . . . . . . . . . . . . . . . 68
7.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8 Settings for on/off valves . . . . . . . . . . . . . . . . . . . . . . . 69
7.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 71
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 74
8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.2.1 Automatic and manual modes . . . . . . . . . . . . . . . . . . . . . 75
8.2.2 Fail-safe position (SAFE) . . . . . . . . . . . . . . . . . . . . . . . . 76
8.3 Malfunction/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 77
9 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 78
9.1 Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 80
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 81
12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 81
13 Maintenance, calibration and work on equipment . . . . . . . . . . . 82
14 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4EB 8384-6 EN
Contents

15 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 109
15.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . 110
16 Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 111
Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
EB 8384-6 EN 5
Contents

1 Important safety instructions
For your own safety, follow these instructions concerning the mounting, start-up and opera-
tion of the positioner:
4The positioner is to be mounted, started up or operated only by trained and
experienced personnel familiar with the product.
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.
4Explosion-protected versions of this positioner may only be operated by personnel
who have undergone special training or instructions or who are authorized to work
on explosion-protected devices in hazardous areas. Refer to section 11.
4Any hazards that could be caused by the process medium, the operating pressure, the
signal pressure or by moving parts of the control valve are to be prevented by means
of the appropriate measures.
4If inadmissible motions or forces are produced in the actuator as a result of the supply
pressure, the supply pressure must be restricted by means of a suitable supply
pressure reducing station.
To avoid damage to any equipment, the following also applies:
4Do not operate the positioner with the back of the positioner/vent opening facing up-
wards.
The vent opening must not be sealed when the positioner is installed on site
4Proper shipping and appropriate storage are assumed.
4Do not ground electric welding equipment near to the positioner.
Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC
(ATEX) and 89/336/EEC (EMC).
The Declaration of Conformity is available on request.
6EB 8384-6 EN
Important safety instructions
Vent opening

2 Article code
Positioner Type 3730-6- xxxxxx x 0 x x 0 x 0 0
With HART®communication and pressure sensors
Explosion protection
ATEX: II 2G Ex ia IIC/IIB T6; II 2D Ex tb IIIC T6 IP 66 110
IECEx: Ex ia IIC/IIB T6; Ex d[ia] IIC/IIB T6; Ex tD A21 IP 66 T 80°C 111
GOST: 1Ex ia IIC T6 X, DIP A21 Ta80°C, IP 66 113
ATEX: II 3G Ex nA II T6; II 3G Ex ic IIC/IIB T6; II 3D Ex tc IIIC T 80°C IP 66 810
IECEx: Ex nA II T6; Ex nL IIC/IIB T6; Ex tD A22 IP 66 T 80°C 811
GOST: Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 66 813
Options (additional equipment)
Inductive limit switch Without
With SJ2-SN
With SJ2-S1N
0
1
2
0
Venting function Without
Solenoid valve 24 V DC
Forced venting 24 V DC
0
1
2
Additional equipment Without
Position transmitter
Leakage sensor
Binary input
0
1
2
3
0
External position sensor Without
Including 10 m connecting cable
Prepared for connection, without sensor
0
1
2
1
Emergency shutdown 3.8 mA
4.4 mA
0
1
Housing material
Standard aluminum 1
Stainless steel 1.4581 2
Special applications
None 0
Compatible with paint 1
Exhaust air connection with ¼–18 NPT thread, back of positioner housing sealed 2
Attachment according to VDI/VDE 3847 6
Article code
EB 8384-6 EN 7

3 Design and principle of
operation
The electropneumatic positioner is attached
to pneumatic control valves. It is used to as-
sign the valve stem position (controlled vari-
able x) to the control signal (reference vari-
able w). The input signal received from a
control system is compared to the travel or
rotational angle of the control valve, and a
pneumatic signal pressure (output variable
y) is produced.
The positioner basically consists of an elec-
trical travel sensor system (2), an analog i/p
converter (6) with downstream air capacity
booster (7) and the electronics unit with a
microcontroller (5).
The standard positioner is fitted with three
binary contacts: A fault alarm output indi-
cates a fault to a control station and two
configurable software limit switches are
used to indicate the end positions of the
valve.
The valve position (x) is transmitted as a lin-
ear travel motion or an angle of rotation by
the pick-up lever and travel sensor (2) to an
analog PD controller (3). Simultaneously, an
A/D converter (4) transmits the position of
the valve to the microcontroller (5). The PD
controller compares this valve position to the
4 to 20 mA DC control signal supplied by
the controller after it has been converted by
the A/D converter (4). In case of a system
deviation, the actuator (1) is either vented or
filled with more air by changes to the i/p
converter (6). This causes the valve plug to
adopt the position corresponding to the ref-
erence variable (w).
The supply air is supplied to the air capacity
booster (7) and the pressure regulator (8).
An intermediate flow regulator (9) with fixed
settings is used to purge the positioner and
also guarantees trouble-free operation of the
air capacity booster. The output signal pres-
sure supplied by the booster can be limited
over the software. Both pressure sensors (23
and 24) monitors the supply pressure psand
the signal pressure pout.
The volume restriction Q (10) is used to opti-
mize the positioner.
The positioner is suitable for the following
types of attachment using the corresponding
accessories:
4Direct attachment to SAMSON
Type 3277 Actuator: Section 4.1
4Attachment to actuators acc. to
IEC 60534-6 (NAMUR): Section 4.2
4Attachment to Type 3510 Micro-flow
Valve: Section 4.3
4Attachment to rotary actuators acc. to
VDI/VDE 3845: Section 4.4
8EB 8384-6 EN
Design and principle of operation

EB 8384-6 EN 9
Design and principle of operation
1 Control valve
2 Travel sensor
3 PD controller
4 A/D converter
5 Microcontroller
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
10 Volume restriction
11* Inductive limit switch
12* Solenoid valve
13* Analog position transmitter or binary input
14 Software limit switches A1/A2
15 Fault alarm output A3
16 LCD
17* Solenoid valve control
18* Galvanic isolation
19 D/A converter
20 Communication interface
21 HART®modulation
22* Binary input BE
23 Pressure sensor for supply pressure ps
24 Pressure sensor for signal pressure pout
25* Forced venting
* Option
%
S
mm
%
mm
PD
FSK
w
x
Q
GG
Serial
Interface 16
13
22
15
A2
A3
BE
A1
11
2
4
21
20
19
5
3
12 25
6
7
23
8
10
1
14
14
w
x
y
24 V DC
9
17 18
x
1)
>12 V
&
24
Fig. 2 · Functional diagram
x1) depending
on version
> 3.8 mA
> 4.4 mA

3.1 Safety function (SIL)
The safety function is based on the shutdown
of the i/p converter (6). This causes the
pneumatic actuator to be vented and the
valve to move to its fail-safe position.
Monitoring of the input signal
The i/p converter is switched off when the
input signal of the positioner at terminals
+11/–12 falls below 3.8 mA or 4.4 mA de-
pending on the positioner version (a signal
range of 4 to 20 mA is required). See
Fig. 18 on page 48.
Monitoring the voltage supply
(version with forced venting and solenoid
valve)
The i/p converter and the solenoid valve
(when installed) are shut down whenever the
voltage at terminals +81/–82 falls below
12 V (an input voltage of 24 V DC is re-
quired). See Fig. 18 on page 48.
When the i/p converter is switched off by
the monitoring of the input signal or the volt-
age supply, the fail-safe position
S is acti-
vated and is indicated on the positioner
display.
If required, the user can check the safety
function using the software.
For more details, refer to the Operating In-
structions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
3.2 Valve diagnostics
The EXPERTplus valve diagnostics are inte-
grated into the positioner. They provide in-
formation on the valve condition (see Ta-
ble 1) and generate status messages to
quickly pinpoint faults.
For more details, refer to the Operating In-
structions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
3.3 Flow rate calculation
Due to the differential pressure measurement
Dp out, EXPERTplus is able to calculate the
flow rate in a SAMSON Type 3241 or
Type 3251 Valve, provided all the parame-
ters regarding the medium and the process
have been defined in the positioner.
For more details, refer to the Operating In-
structions EB 8389-1 EN on EXPERTplus
Valve Diagnostics.
10 EB 8384-6 EN
Design and principle of operation