Samson 3730-4 Service manual

Translation of original instructions
EB 8384-4 EN (1300-1613)
Firmware version 1.53
EB + CD
Edition August 2019
Type3730-4 Electropneumatic Positioner
with PROFIBUS-PA communication
Old design
New design

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 8384-4 EN

Contents
EB 8384-4 EN 3
1 Safety instructions and measures ...................................................................7
1.1 Notes on possible severe personal injury .......................................................11
1.2 Notes on possible personal injury .................................................................11
1.3 Notes on possible property damage..............................................................12
2 Markings on the device ...............................................................................13
2.1 Nameplate..................................................................................................13
2.2 Article code.................................................................................................14
2.3 Firmware versions........................................................................................15
3 Design and principle of operation ................................................................17
3.1 Mounting versions........................................................................................18
3.2 Additional equipment...................................................................................18
3.3 Communication ...........................................................................................19
3.4 CongurationusingtheTROVIS-VIEWsoftware .............................................19
3.5 Device overview and operating controls.........................................................19
3.5 Accessories .................................................................................................21
3.5.1 Travel tables ................................................................................................26
3.7 Technical data .............................................................................................27
3.7 Dimensions in mm........................................................................................33
3.8 FixinglevelsaccordingtoVDI/VDE3845(September2010) ..........................37
4 Measures for preparation............................................................................39
4.1 Unpacking ..................................................................................................39
4.2 Transporting ................................................................................................39
4.3 Storage.......................................................................................................39
5 Mounting and start-up.................................................................................41
5.1 Mounting position........................................................................................41
5.2 Lever and pin position..................................................................................41
5.3 Direct attachment.........................................................................................44
5.3.1 Type3277-5Actuator ..................................................................................44
5.3.2 Type3277Actuator .....................................................................................46
5.4 AttachmentaccordingtoIEC60534-6...........................................................48
5.5 AttachmentaccordingtoVDI/VDE3847-1....................................................50
5.6 AttachmentaccordingtoVDI/VDE3847-2....................................................54
5.6.1 Versionforsingle-actingactuator ..................................................................56
5.6.2 Versionfordouble-actingactuator.................................................................58
5.7 AttachmenttoType3510Micro-owValve ....................................................62
5.8 Attachment to rotary actuators ......................................................................62
5.8.1 Heavy-duty version ......................................................................................64

Contents
4 EB 8384-4 EN
5.9 Reversingamplierfordouble-actingactuators ..............................................68
5.9.1 Reversingamplier(1079-1118or1079-1119) ............................................68
5.10 Attachment of external position sensor...........................................................70
5.10.1 Mounting the position sensor with direct attachment........................................71
5.10.2 MountingthepositionsensorwithattachmentaccordingtoIEC60534-6 .........73
5.10.3 MountingthepositionsensortoType3510Micro-owValve...........................74
5.10.4 Mounting on rotary actuators........................................................................75
5.11 Mounting the leakage sensor ........................................................................76
5.12 Retrottinganinductivelimitswitch ...............................................................77
5.13 Attaching positioners with stainless steel housings...........................................78
5.14 Air purging function for single-acting actuators..............................................78
5.15 Pneumatic connections..................................................................................81
5.15.1 Connecting the supply air.............................................................................81
5.15.2 Signal pressure gauges ................................................................................82
5.15.3 Supply pressure ...........................................................................................82
5.15.4 Signal pressure (output)................................................................................83
5.16 Electrical connections ...................................................................................83
5.16.1 Connecting the electrical power ....................................................................85
5.16.2 SwitchingamplieraccordingtoEN60947-5-6 ............................................86
5.16.3 Establishing communication..........................................................................87
6 Operation...................................................................................................89
7 Operating the positioner..............................................................................93
7.1 Determining the fail-safe position ..................................................................94
7.2 Adjusting the volume restriction Q.................................................................94
7.3 Adapting the display direction ......................................................................95
7.4 Limiting the signal pressure...........................................................................95
7.5 Checking the operating range of the positioner ..............................................96
7.6 Initialize the positioner .................................................................................97
7.6.1 MAX – Initialization based on maximum range............................................100
7.6.2 NOM – Initialization based on nominal range .............................................101
7.6.3 MAN – Initialization based on a manually selected range.............................103
7.6.4 SUb – Substitute calibration........................................................................104
7.7 Zero calibration.........................................................................................109
7.8 Adjusting inductive limit switch....................................................................110
7.9 Reset to default settings...............................................................................111
7.10 Start-up via local interface (SSP) .................................................................112
7.11 Setting the bus address...............................................................................112

Contents
EB 8384-4 EN 5
7.12 Enabling and selecting parameters..............................................................113
7.13 Operating modes.......................................................................................114
7.13.1 Automatic and manual modes ....................................................................114
7.13.2 Fail-safe position (SAFE).............................................................................116
8 Servicing...................................................................................................117
8.1 Firmware update........................................................................................117
8.2 Preparation for return shipment...................................................................118
9 Malfunctions .............................................................................................119
9.1 Conrmingerrormessages.........................................................................120
9.2 Emergency action ......................................................................................120
10 Decommissioning and removal ..................................................................121
10.1 Decommissioning.......................................................................................121
10.2 Removing the positioner .............................................................................121
10.3 Disposal....................................................................................................121
11 Appendix..................................................................................................123
11.1 After-sales service......................................................................................123
11.2 Certicates ................................................................................................123
11.3 Code list....................................................................................................124
11.4 Error codes................................................................................................131
11.5 Selecting the characteristic..........................................................................140
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 8384-4 EN

EB 8384-4 EN 7
Safety instructions and measures
1 Safety instructions and measures
Intended use
SAMSON'sType3730-4Positionerismountedonpneumaticcontrolvalvesandisusedtoas-
sign 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 con-
ditions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3730-4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 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 hazards due to their specialized training, their knowledge and expe-
rience as well as their knowledge of the applicable standards.
Explosion-protected versions of this device are to be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

8 EB 8384-4 EN
Safety instructions and measures
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.
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.Anyhazardsthatcouldbecausedin
the valve by the process medium, the signal pressure or by moving parts are to be prevented
by taking appropriate precautions. They must observe all hazard statements, warning and
caution notes in these mounting and operating instructions, especially 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.
Explosion protection
−Explosive dust atmospheres of zone21 or zone22
ThefollowingappliestotypeofprotectionExiincombustibledustatmospheres:
Ifintrinsicsafetyisimpairedbytheinuenceofdust,anenclosurecomplyingwith
Clause6.1.3ofEN60079-11withatleastindegreeofprotectionIP5Xmustbeused.
TherequirementsaccordingtoClause6.1.3applytothecableglandsaccordingly.The
degreeofingressprotectionisveriedbyatestaccordingtoIEC60529andEN60079-
0(e.g.performedbyVDE).
For use in the presence of combustible dust in compliance with type of protection
ExtbIIIC(protectionbyenclosure),observeClause5.6.3ofEN60079-14.

EB 8384-4 EN 9
Safety instructions and measures
−Servicing explosion-protected devices
If a part of the device on which the explosion protection is based needs to be serviced,
thedevicemustnotbeputbackintooperationuntilaqualiedinspectorhasassessedit
accordingtoexplosionprotectionrequirements,hasissuedaninspectioncerticate,or
giventhedeviceamarkofconformity.Inspectionbyaqualiedinspectorisnotrequired
if the manufacturer performed a routine test on the device before putting it back into op-
eration. Document the passing of the routine test by attaching a mark of conformity to the
device.
Replace explosion-protected components only with original, routine-tested components by
the manufacturer.
Devices that have already been used outside hazardous areas and are intended for fu-
ture use inside hazardous areas must comply with the safety requirements placed on ser-
viced devices. Before being operated inside hazardous areas, test the devices according
tothespecicationsforservicingexplosion-protecteddevices.
EN60079-17appliestoservicingexplosion-protecteddevices.
−Maintenance, calibration and work on equipment
To ensure that components relevant to explosion protection are not damaged, observe the
maximumpermissiblevaluesspeciedinthecerticatesforintrinsicallysafecircuits.
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.

10 EB 8384-4 EN
Safety instructions and measures
Referenced standards and regulations
ThedevicewithaCEmarkingfulllstherequirementsoftheDirectives2014/30/EUand
2011/65/EUaswellas2014/34/EUdependingontheversion.Thedeclarationsofconfor-
mity are included at the end of these instructions.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Operating instructions for valve diagnostics: uEB 8389
−The mounting and operating instructions of the components on which the positioner is
mounted (valve, actuator, valve accessories, etc.).

EB 8384-4 EN 11
Safety instructions and measures
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to the formation of an explosive atmosphere.
Incorrect installation, operation or maintenance of the positioner in potentially explosive
atmospheres may lead to ignition of the atmosphere and cause death.
ÎThefollowingregulationsapplytoinstallationinhazardousareas:EN60079-14
(VDE0165,Part1).
ÎInstallation, operation or maintenance of the positioner must only performed by per-
sonnel who has undergone special training or instructions or who is authorized to
work on explosion-protected devices in hazardous areas.
1.2 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inserthandsorngersintothevalveyokeanddonot
touch any moving valve parts.

12 EB 8384-4 EN
Safety instructions and measures
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the positioner due to incorrect mounting position.
ÎDo not mount the positioner with the back of the device facing upward.
ÎDo not seal or restrict the vent opening when the device is installed on site.
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5.
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.
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.
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 the mounting position.
Risk of positioner damage due to incorrect grounding of the electric welding
equipment.
ÎDo not ground electric welding equipment near to the positioner.

EB 8384-4 EN 13
Markings on the device
2 Markings on the device
2.1 Nameplate
1 Supply pressure
2 Type of protection for explosion-protected devices
3 Features: Yes/No
−Binaryinput5...30VDC
−Binary input, Floating contact
−Limit switch, inductive
−Limit switches, software
−Solenoid valve
4Firmwareversion(seesection2.3)
Explosion-protected version Version without explosion protection
SAMSON 3730 - 4
PROFIBUS Positioner
Supply
Diagnostics EXPERTplus
Firmware
Model 3730 - 4
Var. ID Serial no.
SAMSON AG D-60314 Frankfurt Made in Germany
* See technical data and explosion-protection
certificate for permissible ambient temperature
and maximum values for connection to
certified intrinsically safe circuits.
Media access according to EN 61158-2
PROFIBUS PA* (FISCO)
1
SAMSON AG D-60314 Frankfurt Made in Germany
Var.-ID Serial no.
Model 3730 - 4
Firmware
Diagnostics EXPERTplus
See technical data for ambient temperature
PROFIBUS PA
Media access according to EN 61158-2
Supply
PROFIBUS Positioner
SAMSON 3730 - 4
1
2
4
4
5
5
6
6
7
88
3
3
5 Model no.
6CongurationID
7 Serial number
8 Compliance
7

14 EB 8384-4 EN
Markings on the device
2.2 Article code
Positioner Type3730-4 xxx0x0xx1x00x0xx
WithLCDandautotune,PROFIBUS-PA
Explosion protection
Without 0
ATEX II 2G Ex ia IIC T6 Gb; II 2D Ex ia III T80°C Db 1
CSA Ex ia IIC T6, Class I, II, Div. 1, Groups A–G;
Ex nA II T6, Ex nL IIC T6;
Class I, Div. 2, Groups A–D; Class II, Div. 1, Groups E–G
3
FM 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
ATEX II 2D Ex tb IIIC T80°C Db 5
ATEX II 3G Ex nA IIC T6 Gc, II 3D Ex tc IIIC T80°C Dc 8
Additional equipment
Inductive limit switch Without 0
SJ2-SN (NC contact) 1 0
Solenoid valve Without 0
With,24VDC 4
External position sensor Without 0
With 0 1 0 0
Binary input Without 0
Floating contact 0 1
Diagnostics
EXPERTplus 4
Housing material
Aluminum (standard) 0
Stainless steel 0 1
Special applications
Without 0
Device compatible with paint 1
Exhaustairportwith¼-18NPTthread,backofpositionersealed 0 0 0 0 2
AttachmentaccordingtoVDI/VDE3847includinginterface 6
AttachmentaccordingtoVDI/VDE3847preparedforinterface 7

EB 8384-4 EN 15
Markings on the device
Special version
Without 000
NEPSI ExiaIICT6 1 0 0 9
NEPSI Ex nA II T6, Ex nL IIC T6 8 0 1 0
IECEx ExiaIICT6…T4Gb;ExiaIICT80°CDb 1 0 1 2
IECEx Ex tb IIIC T80°C Db 5 0 3 4
IECEx ExnAIICT6…T4Gc;ExtcIIICT80°CDc 8 0 1 5
EAC Ex 1ExiaIICT6;ExtbIIICT80°CDbX,IP66 1 0 1 4
EAC Ex 2ExnAicIICT6/T5/T4GcX;ExtcIIICT80°CDbX,IP66 8 0 2 0
2.3 Firmware versions
Firmware revisions (Control R)
ControlR1.43 R1.44 to 1.46
Internal revisions
R1.52
Diagnostics All EXPERTplus diagnostic functions are available without having to ac-
tivate them in the positioner (uEB8389onEXPERTplusValveDiagnos-
tics).
Code 48 extended The following subitems have been added to Code 48:
h0:Activation/deactivationreferencetest
h1:Referencetestcompleted(YES/No)
h3: Automatic reset of diagnosis after this time
h4: Remaining time until diagnosis reset
R1.53
Internal revisions
Revisions to the communication rmware are listed in the Conguration Manual
uKH8384-4.KH8384-4isincludedontheenclosedCD-ROMandisavailableonour
website.

16 EB 8384-4 EN

EB 8384-4 EN 17
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.1
The positioner is mounted on pneumatic con-
trol valves and is used to assign the valve
position (controlledvariablex)tothecontrol
signal (setpointw).Thepositionercompares
the control signal of a control system to the
travel or rotational angle of the control valve
and issues a signal pressure (output vari-
abley)forthepneumaticactuator.
The positioner mainly consists of an electric
travelsensorsystem,ananalogi/pconvert-
er with a downstream air capacity booster
and the electronics with the microcontroller.
Whenasystemdeviationoccurs,theactua-
toriseitherventedorlledwithair.Ifneces-
sary, the signal pressure change can be
slowed down by a volume restriction. The
signal pressure supplied to the actuator can
be limited by software or on site to 1.4, 2.4
or3.7bar.
Thexedowregulatorensuresaconstant
airowtotheatmosphere,whichisusedto
ushtheinsideofthepositionerhousingand
tooptimizetheaircapacitybooster.Thei/p
converter is supplied with a constant up-
stream pressure by the pressure regulator to
1 Control valve
2 Travel sensor
3 PD controller
4A/Dconverter
5 Microcontroller
6i/pconverter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
10 Volumerestriction
11* Inductive limit contact
12* Solenoid valve
13 IEC61158-2interface
module
14 Binary input BI1
(voltage input)
15* Binary input BI2
(foroatingcontact)
16 Display
17* Actuation of solenoid valve
18 Electrical insulation
19 D/Aconverter
20 Serial interface
* Option
w
x
Q
%
S
mm
GG
PD
Serial
Interface 16
15
BE2
BE1
11
2
4
13
20
17 18
19
24V DC
5
3
12
6
7
8
10
1
14
9
x
y
Fig.1: Block diagram

18 EB 8384-4 EN
Design and principle of operation
compensateforanyuctuationsinthesupply
pressure.
The positioner communicates and is powered
usingIEC61158-2transmissiontechnology
conformingtoPROFIBUS-PAspecications.
As a standard feature, the positioner comes
with a binary input for DC voltage signals to
signalize process information over the
PROFIBUS-PA network.
The extended EXPERTplus diagnostics are in-
tegrated into the positioner. They provide in-
formation on the positioner and generate di-
agnostic and status messages, which allow
faults to be pinpointed quickly.
3.1 Mounting versions
The positioner is suitable for the following
types of attachment using the corresponding
accessories(seesection3.5):
−Direct attachment to SAMSON
Type3277 Actuator
ÎSeesection5.3.
−Attachment to actuators according to
IEC60534-6:
ÎSeesection5.4.
−Attachment according to VDI/
VDE3847-1/-2:
ÎSeesection5.5andsection5.6.
−Attachment to Type3510 Micro-ow
Valve
ÎSeesection5.7.
−Attachment to rotary actuators accord-
ing to VDI/VDE3845:
ÎSeesection5.8.
3.2 Additional equipment
Solenoid valve
If the voltage supply for the solenoid valve
(12)fails,thesupplypressureforthei/p
converter is vented to the atmosphere. The
positioner can no longer operate and the
control valve moves to the fail-safe position
determined by the actuator, regardless of the
set point.
The manual set point is also reset to 0 % af-
ter the solenoid valve is activated.
A different manual set point must be entered
again (Code 1).
Inductive limit contact
In this version, the rotary shaft of the posi-
tioner carries an adjustable tag which actu-
ates the built-in proximity switch.
External position sensor
In this version, only the sensor is mounted to
the control valve. The positioner is located
separately from the valve. The connection of
x and y signals to the valve is established by
cable and piping for air (only without induc-
tive limit contact).
Binary input BI1
As a standard feature, the positioner comes
with a binary input for DC voltage signals to
signalize process information over the
PROFIBUS-PA network.
NOTICE
!

EB 8384-4 EN 19
Design and principle of operation
Binary input BI2
This binary input BI2 is optional. It is an ac-
tive input which is powered by the positioner
toconnectaoatingcontact.Theswitching
stateoftheoatingcontactcanbeindicated
over the PROFIBUS-PA network.
3.3 Communication
The positioner is controlled completely by
digital signal transmission according to
PROFIBUS-PAproleclassBaccordingto
DINEN50170andDIN19245-4.
Data are transmitted over the bus using digi-
tal, bit-synchronous Manchester coding at a
Baudrateof31.25kbit/sovertwisted-pair
wiresaccordingtoIEC61158-2.
Usually, the positioner settings are made on
a computer. One or more positioners can be
connected over a segment coupler to the
PROFIBUS segment of the computer.
Conguration and operation of the posi-
tioner over PROFIBUS-PA are described in
the Conguration Manual
u KH8384-4.
3.4 Conguration using the
TROVIS-VIEW software
Thepositionercanbeconguredwith
SAMSON'sTROVIS-VIEWSoftware.
The positioner has for this purpose a serial
interface to allow the RS-232 or USB port of
a computer to be connected to it using an
adapter cable.
TheTROVIS-VIEWsoftwareenablestheuser
toeasilycongurethepositioneraswellas
view process parameters online.
TROVIS-VIEW provides a uniform user inter-
face that allows users to congure and pa-
rameterize various SAMSON devices using
device-specic database modules. The de-
vice module 3730-4 can be downloaded
free of charge from our website at
uwww.samson.de > SERVICE & SUPPORT
> Downloads > TROVIS-VIEW.
Further information on TROVIS-VIEW (e.g.
system requirements) is available on our
website and in the Data Sheet uT6661.
3.5 Device overview and oper-
ating controls
ÎSeesection6.
Note

20 EB 8384-4 EN