Samson 3724 Service manual

Translation of original instructions
EB 8395 EN
Firmware version 1.01
Edition October 2018
Type3724 Electropneumatic Positioner
Type3724 Positioner (cover removed)

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
at www.samson.de > Service & Support > Downloads > Documentation.
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
2 EB 8395 EN

Contents
EB 8395 EN 3
1 Safety instructions and measures ...................................................................5
1.1 Notes on possible personal injury ...................................................................7
1.2 Notes on possible property damage................................................................7
2 Markings on the device .................................................................................9
2.1 Nameplate ....................................................................................................9
2.2 Article code...................................................................................................9
3 Design and principle of operation ................................................................10
3.1 Technical data .............................................................................................12
3.2 Dimensions in mm........................................................................................14
4 Measures for preparation............................................................................15
4.1 Unpacking ..................................................................................................15
4.2 Transporting ................................................................................................15
4.3 Storage.......................................................................................................15
5 Mounting and start-up.................................................................................16
5.1 Pneumatic connections..................................................................................16
5.1.1 Supply pressure ...........................................................................................16
5.2 Electrical connections ...................................................................................18
5.2.1 Accessories .................................................................................................18
5.2.2 Selecting cables and wires............................................................................19
5.2.3 Cable entry .................................................................................................19
6 Operation...................................................................................................20
6.1 Operating controls .......................................................................................20
7 Operating the positioner..............................................................................22
7.1 Adapting the display....................................................................................23
7.2 Enabling conguration to change parameters.................................................23
7.3 Adjusting the volume restriction Q.................................................................24
7.4 Entering the opening direction/direction of action ..........................................25
7.5 Entering the direction of action......................................................................25
7.6 Limiting the signal pressure...........................................................................25
7.7 Adjusting the limit contacts ...........................................................................26
7.8 Setting other parameters...............................................................................26
7.9 Initialization ................................................................................................27
7.10 Zero calibration ...........................................................................................28
7.11 Manual mode..............................................................................................29
7.12 Reset...........................................................................................................30

Contents
4 EB 8395 EN
8 Servicing.....................................................................................................31
8.1 Preparation for return shipment.....................................................................31
8.2 Firmware update..........................................................................................31
9 Malfunction.................................................................................................32
9.1 Error codes..................................................................................................33
9.2 Emergency action ........................................................................................34
10 Decommissioning and removal ....................................................................35
10.1 Decommissioning.........................................................................................35
10.2 Removing the positioner ...............................................................................35
10.3 Disposal......................................................................................................35
11 Appendix....................................................................................................36
11.1 After-sales service........................................................................................36
11.2 Code list......................................................................................................37

EB 8395 EN 5
Safety instructions and measures
1 Safety instructions and measures
Intended use
The Type3724 Positioner is delivered as a ready-mounted unit on Type3379 Pneumatic
Piston Actuators. It is used to assign the valve position to the control signal. The device is
designed to operate under exactly dened conditions (e.g. operating pressure, temperature).
Therefore, operators must ensure that the positioner is only used in applications where the
operating conditions correspond to the technical data. In case operators intend to use the
positioner in other applications 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3724 Positioner is not suitable for the following applications:
−Use outside the limits dened during sizing and by 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
personnel 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
specialized training, their knowledge and experience as well as their knowledge of the
applicable standards.
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 device.
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.

6 EB 8395 EN
Safety instructions and measures
Revisions and other modications
Revisions, conversions or other modications of 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 the
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.
Referenced standards and regulations
The device with a CE marking fullls the requirements of the Directive 2014/30/EU and the
Directive 2014/35/EU. The Declaration of Conformity is available on request.
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 8395 EN 7
Safety instructions and measures
1.1 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 touch any moving valve parts.
1.2 Notes on possible property damage
NOTICE
!
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16 in page5.
Unauthorized manual adjustments to the positioner will damage it!
ÎDo not move the pick-up rod manually.
Dirty supply air will cause the positioner to malfunction!
ÎOnly use supply air that is dry and free of oil and dust.
ÎBlow through all air pipes and hoses thoroughly before connecting them.
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.

8 EB 8395 EN
Safety instructions and measures
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.
A reference variable above or below the static destruction limit will damage the posi-
tioner.
ÎKeep the reference variable within the static destruction limit of ±32V.
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 any parameters.
The process is disturbed by the movement of the actuator stem.
ÎDo not perform the initialization while the process is running. First isolate the plant by
closing the shut-off valves.
Risk of positioner damage due to incorrect grounding of the electric welding equip-
ment.
ÎDo not ground electric welding equipment near to the positioner.

EB 8395 EN 9
Markings on the device
2 Markings on the device
2.1 Nameplate
12
3
4
5
1Conguration ID
2 Firmware version
3Serial number
4 Reference variable
5 Supply
2.2 Article code
Positioner Type3724- 000000x00000
Housing material
Housing: 1.4409 · Cover: 1.4404 0
Surface nish
Micro-bead blasted 1
Polished (Ra ≤0.6µm) 2
Permissible ambient temperature
–20 to +80°C 0
Degree of protection
IP 65 1) (only applies in combination with Type3379 Pneumatic Actuator) 0
1) Pending

10 EB 8395 EN
Design and principle of operation
3 Design and principle of oper-
ation
The Type3724 Positioner is delivered as a
ready-mounted unit on Type3379 Pneumatic
Piston Actuators.
The positioner is used to assign the valve po-
sition (controlled variable x) to the control
signal (reference variable w). The positioner
compares the electric control signal of a con-
trol system to the travel of the control valve
(1) and issues a signal pressure (output vari-
able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)
−Software limit contacts (12)
The travel is measured by an internal pick-up
rod, which is connected to a magnet, as well
as a non-contact magnetoresistive sensor
and the downstream electronics.
The motion of the pick-up rod causes the di-
rection of the magnetic eld to change. This
change is sensed by the sensor (2). The elec-
tronics unit determines the current valve posi-
tion from this information.
The position of the valve is transmitted to the
microcontroller (4) over its A/D converter
(3). The microcontroller contains a modied
PID controller which compares the actual
valve position with the 4 to 20mA control
signal. The resulting output value is passed
on to the D/A converter. In case of a system
deviation, the activation of the i/p module
(6) is changed so that the actuator (1) is
pressurized or vented accordingly over the
downstream air capacity booster (7). The
supply air is supplied to the booster (7) and
the pressure regulator (8).
Unauthorized manual adjustments to the po-
sitioner will damage it!
Do not move the pick-up rod manually.
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 set point cutoff in P10 and P11 parame-
ter codes).
NOTICE
!

EB 8395 EN 11
Design and principle of operation
Q
34
11
6
7
810
1
w
9
x
y
2
5
A2
A1
12
1Control valve
2 Sensor
3 A/D converter
4Microcontroller
5D/A converter
6i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
10 Volume restriction
11 Display
12 Limit contacts
Fig.1: Circuit diagram

12 EB 8395 EN
Design and principle of operation
3.1 Technical data
Table1: General technical data
Positioner
Attachment Type3379 piston Ø: 63mm · Effective area: 31cm²
Type3379 piston Ø: 90mm · Effective area: 63cm²
Travel 4 to 16mm, adjustable in steps of 0.5mm
Reference variable w
(reverse polarity protection)
4 to 20mA signal range · Two-wire device
Split-range operation 4 to 11.9mA and 12.1 to 20mA
Static destruction limit ±32V
Minimum current 3.8mA
Load impedance Max. 6.3V
Supply air
Air quality acc. to
ISO8573-1
Supply air: 1.4 to 7bar (20 to 105psi)
Max. particle size and density: Class 4 · Oil content: Class 3 · Pressure
dew point: Class 3 or at least 10K below the lowest ambient
temperature to be expected
Signal pressure (output) 0 bar up to the supply pressure minus 0.4bar
Can be limited to approx. 2.3bar by software
Characteristic Three selectable characteristics:
Linear · Equal percentage · Reverse equal percentage
Transit time Only for actuators with initialization time > 0.4s 1)
Direction of action w/x reversible
Perm. ambient temperature –20 to +80°C
Electromagnetic
compatibility
Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR
Recommendation NE21
Degree of protection IP 65 2) (only applies in combination with Type3379 Pneumatic
Actuator)
Compliance
Materials
Housing 1.4409
Cover 1.4404
Dome (visual indicator) Polycarbonate
Weight (without actuator) Approx. 1.2kg
1) For faster actuators, a volume restriction must be used. Otherwise, the initialization cannot be
performed successfully.
2) Pending

EB 8395 EN 13
Design and principle of operation
Table2: Limit contacts
Binary contacts Two software limit contacts (min., max.)
Version Reverse polarity protection, galvanic isolation
Adjustment range 0 to 100% (see section7.7 on page 26)
Step size 0.5%
Static destruction limit ± 32V
Signal
state
No response Non-conducting (highly resistive), I < 100µA
Response Conducting (R = 330Ω)
For connection to −Binary input of a PLC acc. to IEC 61131-2,
Pmax = 400mW

14 EB 8395 EN
Design and principle of operation
3.2 Dimensions in mm
Actuator Piston Ø Ød
Type3379 63mm 69mm
90mm 94mm
Ø108
285
135
Ød
130
Fig.2: Dimensional drawings of Type3724 Positioner with Type3379 Pneumatic Piston Actuator

EB 8395 EN 15
Measures for preparation
4 Measures for preparation
After receiving the shipment, proceed as fol-
lows:
1. Check the scope of delivery. Compare
the shipment received with the delivery
note.
2. Check the shipment for transportation
damage. Report any transportation dam-
age.
4.1 Unpacking
Risk of positioner damage due to foreign
particles entering it.
Do not remove the packaging and protective
lm/protective caps until immediately before
mounting and start-up.
1. Remove the packaging from the position-
er.
2. Dispose of the packaging in accordance
with the valid regulations.
4.2 Transporting
−Protect the positioner against external in-
uences (e.g. impact).
−Protect the positioner against moisture
and dirt.
−Observe transport temperature depend-
ing on the permissible ambient tempera-
ture (see technical data in section3.1).
4.3 Storage
Risk of positioner damage due to improper
storage.
−Observe storage instructions.
−Avoid long storage times.
−Contact SAMSON in case of different stor-
age conditions or long storage periods.
Storage instructions
−Protect the positioner against external in-
uences (e.g. impact, shocks, vibration).
−Do not damage the corrosion protection
(coating).
−Protect the positioner against moisture
and dirt. In damp spaces, prevent con-
densation. If necessary, use a drying
agent or heating.
−Observe storage temperature depending
on the permissible ambient temperature
(see technical data in section3.1).
−Store positioner with closed cover.
−Seal pneumatic and electrical connec-
tions.
NOTICE
!
NOTICE
!

16 EB 8395 EN
Mounting and start-up
5 Mounting and start-up
Risk of malfunction due to incorrect sequence
of mounting, installation and start-up.
Observe the prescribed sequence.
The unit consisting of the Type3724 Posi-
tioner, Type3379 Actuator and valve is
ready assembled on delivery.
In special cases, the valve and actuator are
delivered separately and must be assembled
on site. In this case, read the associated
valve documentation.
ÎSequence to be kept on installing and
starting up the positioner:
1. Remove the protective caps from the
pneumatic connections.
2. Perform pneumatic installation.
ÎSection5.1 onwards
3. Perform electrical installation.
ÎSection5.2 onwards
4. Perform settings.
ÎSection7 onward
NOTICE
!
Note
5.1 Pneumatic connections
The Type3724 Positioner is delivered ready
mounted on the Type3379 Pneumatic Piston
Actuator. The pneumatic connections of the
positioner are connected internally to the
connections of the actuator.
The pneumatic connections of the actuator
are used (see Mounting and Operating In-
structions of the Type3379 Pneumatic Piston
Actuator uEB8315) for start-up (see sec-
tion7 on page22).
Dirty supply air will cause the positioner to
malfunction!
Only use supply air that is dry and free of oil
and dust.
Blow through all air pipes and hoses thor-
oughly before connecting them.
5.1.1 Supply pressure
The required supply air pressure depends on
the bench range and the actuator's operat-
ing direction (fail-safe action). The bench
range is written on the nameplate either as
the bench range or signal pressure range.
The operating direction is marked FA or FE
or by a symbol.
NOTICE
!

EB 8395 EN 17
Mounting and start-up
FA: actuator stem extends (air to open/
ATO)
Fail-close (for globe and angle valves):
Required supply pressure = Upper bench
range value + 0.4bar, minimum 1.4bar.
FE: actuator stem retracts (Air to close/ATC)
Fail-open (for globe and angle valves):
For tight-closing valves, the maximum signal
pressure pstmax is roughly estimated as fol-
lows:
pstmax =F + d² · π · ∆p [bar]
4 · A
d=Seat diameter [cm]
∆p = Differential pressure across the
valve [bar]
A= Actuator area [cm²]
F= Upper bench range value [bar]
If there are no specications, calculate as
follows:
Recommended supply pressure =
Upper bench range value + 1bar
The signal pressure at the output (38) of the
positioner can be restricted to approx.
2.3bar by setting P9 parameter code to
ON.
Note

18 EB 8395 EN
Mounting and start-up
5.2 Electrical connections
An incorrect electric signal will damage the
positioner.
Only use a current source and never a volt-
age source.
ÎConnect the wiring as shown in Fig.3.
ÎSelect cables and wires as described in
section5.2.2.
ÎInsert cables as described in sec-
tion5.2.3.
Incorrect assignment of the terminals will
damage the positioner and will lead to mal-
function.
Connect the electrical wiring to the position-
er according to the prescribed terminal as-
signment.
5.2.1 Accessories
Description Order no.
Cable gland:
Black plastic, M16x1.5 8808-1010
NOTICE
!
NOTICE
!
+11 –12 +41 –42 +51 –52
+11/–12: mA control signal
+41/–42: Limit contact 1 (min.)
+51/–52: Limit contact 2 (max.)
Plastic part
Fig.3: Electrical connections Fig.4: Cage clamp terminals

EB 8395 EN 19
Mounting and start-up
5.2.2 Selecting cables and
wires
The minimum radial thickness of the conduc-
tor insulation must be suitable for the con-
ductor diameter and type of insulation. It
must be at least 0.2mm.
The diameter of an individual wire in a
ne-stranded conductor must not be smaller
than 0.1mm.
Protect the conductor ends against splicing,
e.g. by using wire-end ferrules.
5.2.3 Cable entry
The M16x1.5 cable gland is designed for a
clamping range of 6 to 12mm.
The cage clamp terminals hold wire
cross-sections of 0.2 to 1.5mm².
ÎUnscrew the cover and remove it.
ÎTo unlock the cage clamp terminals:
place a slotted screwdriver on the plastic
part (Fig.4) and lightly push it into the
terminal block.
ÎInsert or remove the wire without force.
ÎGuide wires for the reference variable to
the terminals +11 and –12 located on
the housing.
A reference variable above or below the
static destruction limit will damage the posi-
tioner.
Keep the reference variable within the static
destruction limit of ±32V.
Mounting the cover
ÎMount the cover, briey turn it counter-
clockwise to center it. Turn it clockwise to
rmly close it.
NOTICE
!

20 EB 8395 EN
Operation
6 Operation
The positioner is operated by three pushbut-
tons for menu navigation on the display (see
Fig.5):
: Up
: Conrm
: Down
ÎTo adapt the air capacity, adjust the vol-
ume restriction (see section 7.3).
6.1 Operating controls
Press or button to select a parameter
code (P0 to P20). Then press button to
conrm the selected code.
To save changes to parameters in a non-vol-
atile memory, proceed as follows:
ÎAfter changing parameters, press or
button to change to Code P0 or
Îwait three minutes until the display re-
turns automatically to P0.
−The icon on the display indicates that
the changed parameter settings have not
yet been saved in the non-volatile memory.
−The selected parameter code remains ac-
tive until you change the setting or exit the
parameter code.
−After changing settings in P2, P4 and P8
parameter codes, the positioner must be
re-initialized.
Note
Settings not yet
saved in a non-
volatile memory
Unit/sign
Bar graph/
system deviation
Fault
Manual mode Closed-loop control
Parameter/error code
Fail-safe position
active
Limit contact 2 (max.)
Limit contact 1 (min.)
Operation
locked
Fig.5: Display with all readings