Samson 3730-0 Service manual

Series 3730
Electropneumatic Positioner
Type 3730-0
Mounting and
Operating Instructions
EB 8384-0 EN (1300-1609)
Edition November 2010
Fig. 1 · Type 3730-0

2EB 8384-0 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,
information and tips
Definitions of the signal words used in these instructions

Contents Page
1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 4
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 6
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Attachment to the control valve – Mounting parts and accessories . . . . 9
4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 16
4.3 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 18
4.3.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 18
4.4 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 20
4.5 Attaching positioners with stainless steel housings. . . . . . . . . . . . 22
4.6 Air purging function for single-acting actuators . . . . . . . . . . . . . 22
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Operator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Default switch positions . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3 Volume restriction Q. . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4 Presetting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.5 Direction of action . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.6 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 29
7.7 Reference variable. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.8 Connecting the positioner . . . . . . . . . . . . . . . . . . . . . . . 30
7.9 Setting zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.10 Gain factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.11 Adapting the travel . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.12 Activate the tight-closing function. . . . . . . . . . . . . . . . . . . . 30
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 31
10 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3EB 8384-0 EN
Contents

4EB 8384-0 EN
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 indi-
viduals who are able to judge the work they are assigned to and recognize possible dan-
gers 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 explo-
sion-protected devices in hazardous areas. Refer to section 9.
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:
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.
Safety instructions

2 Article code
EB 8384-0 EN 5
Article code
Article code Type 3730-0 x00000000x00x0xx
Explosion protection
Without 0
ATEX: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80 °C IP 66 1
FM/CSA:
Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A–G;
Class I, Div. 2, Groups A–D; Class II, Div. 2, Groups F, G/
Ex ia IIC T6; Class I, Zone 0; Class II, Groups E–G;
Ex nA II T6; Class I, Zone 2; Class II, Division 2, Groups E–G
3
JIS: Ex ia IIC T6 7
ATEX: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T80°C IP 66 8
Housing material
Aluminum 0
Stainless steel 1.4581 1
Special applications
Without 0
Compatible with paint 1
Exhaust air with ¼ NPT connection, back of housing sealed 2
Special versions
Without 00
GOST: 1 Ex ia IIC T6 X, DIP A21 Ta80°C, IP 65; Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 65 1 4

3 Design and principle of
operation
The electropneumatic positioner is mounted
to pneumatic control valves and is used to
assign the valve position (controlled vari-
able x) to the control signal (reference vari-
able w). The DC control signal received from
a control unit is compared to the travel of
the control valve and issues a signal pres-
sure (output variable y).
A supply pressure between 1.4 to 6 bar is
required. The electric input signal is a refer-
ence variable between 4 to 20 mA.
The positioner is designed depending on the
corresponding accessories for direct attach-
ment to Type 3277 Actuators or for attach-
ment to actuators according to IEC 60534-6
(NAMUR).
The positioner basically consists of a travel
sensor system which is proportional to resis-
tance, an analog i/p converter with down-
stream air capacity booster, and analog
controller electronics.
The position of the valve is transmitted as
linear travel motion via pick-up lever and
travel sensor (2) to an analog PD controller
(3). The PD controller compares this actual
position to the 4 to 20 mA DC control signal
received from a control unit. In case of a
system deviation, the operation of the i/p
converter (6) is changed so that the actuator
(1) is filled or vented via the downstream air
capacity booster (7). This causes the valve
plug to move to the position determined by
the reference variable.
The pneumatic air capacity booster (7) and
the pressure regulator (8) are provided with
supply air. An intermediate flow regulator
(9) with fixed settings is used to purge the
positioner and also guarantees trouble-free
operation of the pneumatic booster.
The output signal pressure supplied by the
booster can be limited over the DIP switch
S5.
The volume restriction Q (10) and the switch
S6 are used to optimize the positioner by
adapting it to the actuator size and chang-
ing the gain factor.
Tight-closing function:
After activating the tight-closing function (re-
fer to section 7.12), the pneumatic actuator
is completely filled with air or vented as
soon as the reference variable falls below or
exceeds the corresponding deactivating
point of 4.5 mA or 19.5 mA.
In the case of three-way valves, the function
allows the plug move to the end position
with full actuator force.
6EB 8384-0 EN
Design and principle of operation

3.1 Technical data
EB 8384-0 EN 7
Design and principle of operation
2
3
6
7
8
10
1
9
4
w
x
Qy
x
Fig. 2 · Functional diagram
1 Control valve
2 Travel sensor
3 PD controller
4 DIP switches
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
10 Volume restriction
Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Nominal travel,
adjustable
Direct attachment to Type 3277: 5.3 to 30 mm,
Attachment acc. to IEC 60534-6: 5.3 to 200 mm
Travel range Adjustable within the rated travel, max. ratio 1:5
Reference variable w
Signal range 4 to 20 mA, split-range range 4 to 12 mA/12 to 20 mA, selectable at
DIP switches. 2-wire device, reverse polarity protection, static destruction limit
100 mA.
Minimum current > 3.6 mA

8EB 8384-0 EN
Design and principle of operation
Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Load impedance Version without explosion protection: £6 V (corresponding to 300 Wat 20 mA),
explosion-protected version: £6 V
Supply air
Supply pressure
Air quality acc. to
ISO 8573-1
(edition 2001-02):
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 supply pressure, can be limited to approx. 2.4 bar over DIP switch
Characteristic Linear; Deviation from terminal-based conformity £1 %
Hysteresis £1 %
Sensitivity £0.1 %
Direction of action Selectable over DIP switch
Air consumption, st. state Independent of supply pressure approx. 120 ln/h
Air delivery
Actuator pressurized
Actuator vented
At Dp = 6 bar: 8.5 mn3/h, at Dp = 1.4 bar: 3.0 mn3/h KVmax(20 °C) = 0.09
at Dp = 6 bar: 14.0 mn3/h, at Dp = 1.4 bar: 4.5 mn3/h KVmax(20 °C) = 0.15
Permissible ambient
temperature
–20 to +80 °C, with metal cable gland –45 to +80 °C
The limits in the test certificate additionally apply for explosion-protected devices.
Influences Temperature: £0.15 %/10 K Supply air: None
Vibration: £0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Electromagnetic
compatibility
Complying with requirements specified in EN 61000-6-2, EN 61000-6-3,
EN 61326-1 and NAMUR Recommendation NE 21
Explosion protection ATEX
FM
CSA
JIS
GOST
Type 3730-01: II 2G Ex ia IIC T6, II 2D Ex tb IIIC T 80 °C IP 66
Type 3730-08: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D Ex tc IIIC T80°C IP 66
Type 3730-03: Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A–G;
Class I, Div. 2, Groups A–D; Class II, Div.2, Groups F, G
Type 3730-03: Ex ia IIC T6; Class I, Zone 0; Class II, Groups E–G;
Ex nA II T6; Class I, Zone 2; Class II, Division 2, Groups E–G
Type 3730-07: Ex ia IIC T6
Type 3730-x00000000x00x014: 1 Ex ia IIC T6 X, DIP A21 Ta80°C, IP 65;
Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 65
Use in safety-
instrumented systems
acc. to IEC 61508
Suitable for use in safety instrumented systems up to SIL 2 (single device) and SIL 3
(redundant configuration), safety shutdown at a reference variable 0 mA
Degree of protection IP 66
Materials
Die-cast aluminum EN AC-Al Si12(Fe) (EN AC-44300) acc. to DIN EN 1706,
chromated and plastic coated
External parts: Stainless steel 1.4571 and 1.4301
Weight Approx. 1 kg

4 Attachment to the control
valve – Mounting parts and
accessories
The positioner can be attached either di-
rectly to a SAMSON Type 3277 Actuator or
according to IEC 60534-6 (NAMUR) to con-
trol valves with cast yokes or rod-type yoke.
For attachment to the various actuators, cor-
responding mounting parts and accessories
are required. These are listed with their or-
der numbers in Tables 1 to 4.
On attaching the positioner, it is important
to observe the assignment between lever
and pin position according to the travels
listed in the travel tables.
The travel that can be achieved at the valve
is restricted by the pin position used and ad-
ditionally by the selected fail-safe action and
the actuator spring compression required.
The positioner is standard equipped with the
lever M(pin position 35).
Note:
If the standard mounted lever M (pin posi-
tion 35) is replaced, the newly mounted le-
ver must be moved once all the way as far
as it will go in both directions to adapt it to
the internal measuring lever.
EB 8384-0 EN 9
Attachment to the control valve – Mounting parts and accessories
Fig. 3 · Lever M with pin position 35

10 EB 8384-0 EN
Attachment to the control valve – Mounting parts and accessories
Travel table for direct attachment to Type 3277 Actuator
Type
3277-5
and
3277
Actuators
Actuator size
cm²
Rated travel
mm
Adjustment range at positioner
Min. Travel Max.
Required
lever
Assigned
pin position
120 7.5 5.0 25.0 M 25
120/240/350 15 7.0 35.0 M 35
355/700 30 10.0 50.0 M 50
Travel table for attachment according to IEC 60534-6 (NAMUR)
SAMSON valves Other valves/actuators Required
lever
Assigned
pin position
Type 3271
Actuator
cm² Rated travel mm Min. Travel Max.
60 and 120 with
Type 3510 Valve 7.5 3.6 18.0 S 17
120 7.5 5.0 25.0 M 25
120/240/350 15 7.0 35.0 M 35
700 7.5
700 15 and 30 10.0 50.0 M 50
1000/1400/2800 30 14.0 70.0 L 70
1000/1400/2800 60 20.0 100.0 L 100
1400/2800 120 40.0 200.0 XL 200
Table 1 Direct attachment to Type 3277-5 Actuator Order no.
Mounting parts For actuators with 120 cm² effective diaphragm area, see Fig. 4 1400-7452
Accessories
for the
actuator
Switchover plate old for Actuator Type 3277-5xxxxxx.00 (old) 1400-6819
Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6822
Connecting plate new for Actuator Type 3277-5xxxxxx.01 (new) 1):
G ¼ and ¼ NPT 1400-6823
Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): G ¼ 1400-6820
Connecting plate old for Actuator Type 3277-5xxxxxx.00 (old): ¼ NPT 1400-6821
Note: Only new switchover and connecting plates can be used with new actuators (Index 01).
Old and new plates are not interchangeable.
Accessories
for the
positioner
Connecting plate (6) G ¼: 1400-7461 ¼ NPT: 1400-7462
or pressure gauge bracket (7) G ¼: 1400-7458 ¼ NPT: 1400-7459
Pressure gauge mounting kit (8)
up to max. 6 bar (output and supply)
Stainless steel/Brass:
1400-6950
Stainless steel/St. steel:
1400-6951