Samson 3738-20 Service manual

Mounting and
Operating Instructions
EB 8390 EN
Firmware version 1.20
Edition June 2015
Type3738-20 Electronic Limit Switch
with optional integrated solenoid valve
for on/off valves

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 8390 EN

Contents
EB 8390 EN 3
1 Important safety instructions ..........................................................................7
2 Article code...................................................................................................8
3 Design and principle of operation ..................................................................9
3.1 Versions......................................................................................................12
3.2 Communication ...........................................................................................13
3.3 Safety-related information ............................................................................13
4 Technical data .............................................................................................15
4.1 Electronic limit switch ...................................................................................15
4.2 Solenoid valve.............................................................................................19
5 Attachment .................................................................................................20
5.1 Attachment to linear actuators.......................................................................21
5.1.1 Preparations................................................................................................21
5.1.2 Attachment..................................................................................................22
5.2 Attachment to rotary actuators ......................................................................24
5.2.1 Preparations................................................................................................26
5.2.2 Attachment..................................................................................................26
5.3 Accessories .................................................................................................30
6 Connections ................................................................................................31
6.1 Pneumatic connections..................................................................................31
6.2 Supply pressure ...........................................................................................32
6.3 Electrical connection.....................................................................................32
7 Operating controls and readings..................................................................36
7.1 Rotary pushbutton........................................................................................36
7.2 SAMSON SSP interface................................................................................36
7.3 Operating structure......................................................................................37
8 Start-up ......................................................................................................41
8.1 Adapting the display direction ......................................................................41
8.2 Verifying readings on display........................................................................42
8.3 Determining the actuator type .......................................................................43
8.4 Determining the direction of action................................................................43
8.5 Determining the switching function of contacts................................................43

4 EB 8390 EN
Contents
8.6 Adjusting the limit switches ...........................................................................44
8.7 Initialization ................................................................................................44
8.7.1 Start automatic initialization .........................................................................45
8.7.2 Start manual initialization.............................................................................46
8.8 Replacing an electronic limit switch................................................................47
8.9 Zero/end position calibration .......................................................................48
8.10 Reset to default settings.................................................................................48
9 Operation...................................................................................................49
9.1 Lock operation.............................................................................................49
9.2 Partial stroke test (PST)..................................................................................49
9.2.1 DeningthePSTtargetrange........................................................................51
9.2.2 Starting the partial stroke test........................................................................52
9.2.3 Example: PTO direction of action...................................................................53
9.3 Testing the contacts.......................................................................................55
9.4 Testing the solenoid valve..............................................................................56
9.5 Faults..........................................................................................................57
9.5.1 Status messages...........................................................................................57
9.5.2 Error messages............................................................................................57
9.5.3 Conrmingstatusanderrormessages ...........................................................58
10 Maintenance, calibration and work on equipment ........................................58
10.1 Maintenance ...............................................................................................58
11 Servicing explosion-protected devices ..........................................................58
12 Firmware update (serial interface)................................................................59
13 Parameter list..............................................................................................60
13.1 Status messages...........................................................................................64
13.2 Error messages............................................................................................67
14 Dimensions in mm.......................................................................................69
14.1 FixinglevelsaccordingtoVDI/VDE3845(September2010) ..........................70
Assignment based on the direction of action.................................................83

EB 8390 EN 5
Firmware revisions
Firmware Revisions
1.12 Changes to parameters and error messages (see section13)
• Parameters renumbered due to parameters being added or removed.
Removed parameters:
– 'PST initialization' (the partial stroke test no longer needs to be initialized).
– Info: Rotary motions
New parameters:
–'Actuatortype'(rotaryorlinearactuator).Seesection8.3.
–'Switchingfunctionofcontacts'(NOorNCcontact).Seesection8.5.
• Error messages renumbered due to error messages being removed.
Removed error messages:
– 'PST target range not reached'
– 'PST target range exceeded'
• The new parameter 'Actuator type' as well as the 'Actuator's direction of action' pa-
rameter are locked after the electronic limit switch has been initialized. See sec-
tions8.3and8.4.
• The actuator transit time monitoring (F4) depends on the value adjusted in 'Status
readoutforactuatortransittime(P13).Thisisadjustablebetween0(OFF)and1800s.
• The dead time is already included in the information parameters 'Actuator transit time
when the solenoid valve is de-energized' and 'Actuator transit time when the solenoid
valve is energized'.
• Themonitoringoftherotarymotioncountercanbedeactivatedbyconguring'Maxi-
mum rotary motions' (P26) = OFF.
Changes to the partial stroke test (PST) (see section9.2)
• The minimum pulse length at contact C is three seconds during partial stroke testing.
• The PST target range is made up of 'PST step end (P14) ± ½ 'PST tolerance band'
(P15).
• Once a partial stroke test has been completed, the assessment of the transit times when
the solenoid valve is de-energized and energized ('PST transit time when the solenoid
valve is de-energized' and 'PST transit time when the solenoid valve is energized').
Only the duration of the entire test is shown in version 1.01.
• In the TROVIS-VIEW software, a diagram plotting the valve position against time while
the solenoid valve is de-energized and energized is shown (256 measuring points).
The data can be read out by connecting the device at the SSP interface to a computer.

6 EB 8390 EN
Firmware revisions
Firmware Revisions
1.20 Changes to parameter readings on the display
• P3VerifyLCDsegments:TSTDreading(seesection8.2)
• P9Automaticinitialization:INIAreading(seesection8.7)
• P10Manualinitialization:INIMreading(seesection8.7)
• P11Endpositioncalibration:REFreading(seesection8.9)
• P17StartmanualPST:PSTreading(seesection9.2)
• P19Testingcontacts:TSTCreading(seesection9.3)
• P20Testingsolenoidvalve:TSTSreading(seesection9.4)
• P21Reset:RSTreading(seesection8.10)
New status message F15
ThisstatusmessageisgeneratedwhenthecongurationmodeSETisactivated.
Changes to the partial stroke test (PST) (see section9.2)
A canceled partial stroke test (PST) is logged with a time stamp in TROVIS-VIEW.

EB 8390 EN 7
Important safety instructions
1 Important safety instructions
For your own safety, follow these instructions concerning the mounting, start up and opera-
tion of the electronic limit switch:
−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 by moving parts are to be prevented by taking appro-
priate precautions.
−Forusewithinhazardousareas,theSpecialConditionsmentionedintheECtypeexam-
inationcerticateanditsaddendamustbeobserved.
−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.
−Do not ground electric welding equipment near to the electronic limit switch.
Note:
The device with a CE marking fullls the requirements of the Directive 2004/108/EC.


8 EB 8390 EN
Article code
2 Article code
Electronic Limit Switch Type 3738-20- x x x 1 x 0 0 x x x x 0 x
With LCD
Explosion protection
Without 0 0 0
ATEX:II2GExiaIICT6;II2DExIIICT80°CIP66 110
ATEX:II2GExeb[ia]IICT4;II2DExtbIIICT80°CIP66 3 1 0 0
GOST:1ExiaIICT6/T5/T4GaX;ExtbIIICT80°CDbX 113
GOST:1Exe[ia]IICT4GbX;ExtbIIICT80°CDbX 313
Solenoid valve
External 0
Integrated 4
Company version
SAMSON 0
AIR TORQUE 1
Housing
Standard aluminum, black structured, RAL 9005 1
Cover
Gray beige 0
Black 1
Silver gray 3
Safetyapproval(seesection3.3)
TÜV/IEC61508 2
Special applications
Without 0

EB 8390 EN 9
Design and principle of operation
3 Design and principle of oper-
ation
The Type 3738-20 Electronic Limit Switch
can replace conventional solenoid valves
and limit switches used for the automation of
on/off valves without the need to change the
wiring or signal level. Major features of the
electronic limit switch include:
−Unicationofthefunctionsfeaturedinlim-
it switches and a solenoid valve in one
housing
−Power supplied in a two-wire system from
the connection of contact A, without the
need for an additional power supply
−Non-contact sensing of the rotation angle
by a magnetoresistive sensor system
−Integrated diagnostics with partial stroke
testing (PST)
−Suitable for use in safety-instrumented sys-
tems up to SIL 2 (single device) and SIL 3
(redundantconguration).Seesection3.3.
Fig.1: Valve assembly with electronic limit
switch (version with integrated solenoid
valve)
Fig.2 and Fig.3
The electronic limit switch is designed for at-
tachment to linear and rotary actuators. The
travel is measured without contact using a
magnet (on a screw) positioned centrically
on the actuator shaft. The screw with magnet
does not need to be adjusted. The AMR
(anisotropic magnetoresistive) sensor located
in the device together with the measuring
electronics (1) can detect the directional
changeoftheappliedmagneticeldand,as
a result, sense the movement of the actuator.
The actuator is operated by a solenoid valve
(7) which converts the binary signal issued
issued by the electric control equipment (6)
into a binary pressure signal.
The electronic limit switch has four NAMUR
contacts: the limit switch for fail-safe position
(contact A, 13) and the limit switch for oper-
ating position (contact B, 14) issue a limit
signal when the valve reaches the corre-
sponding end position. Contact C (15) indi-
cates when a third limit is reached or the PST
target range of the partial stroke test has
been reached. The switching response of the
contacts can be adjusted within the travel
range. The fault alarm contact St (16) indi-
cates the generation of any status and error
messages.
An electronic limit switch version for an ex-
ternalsolenoidvalve(Fig.2)isavailablefor
higher air capacities required by large actu-
ators. The principle of operation is the same.

10 EB 8390 EN
Article code
SSP
interface
10 9
3
12
B
A
13
C
15
St
2
4
6
11 7
81
51
6
14
Signal for solenoid
v
alve: V1 or V3
Power
Supply
Electronic limit switch
Actuator
1 AMR sensor with electronics
2 A/D converter
3 Microcontroller
4 Galvanic isolation
5 Galvanic isolation
6 Actuation of solenoid valve
7 Solenoid valve
8 Air capacity booster
9 Display
10 Rotary pushbutton (local operation)
11 LED for solenoid valve
12 Internal supply
13 NAMUR contact A (limit switch for fail-safe position)
14 NAMUR contact B (limit switch for operating position)
15 NAMUR contact C (signal on reaching target range during
partial stroke test)
16 NAMUR contact St (fault alarm contact)
Fig.2: Schematic diagram – Type 3738-20-xxx1400xxx000 Electronic Limit Switch with integrated
solenoid valve