Samson 3730-4 Service manual

Series 3730
Type 3730-4 Electropneumatic Positioner
with PROFIBUS-PA communication
Mounting and
Operating Instructions
EB 8384-4 EN (1300-1613)
Firmware version K 1.17/R 1.46
Edition July 2017
Fig. 1 · Type 3730-4
New design
Old design

2EB 8384-4 EN

Contents Page
1 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 9
1.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Attachment to the control valve – Mounting parts and accessories . . . 14
2.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 24
2.3 Attachment according to VDI/VDE 3847 . . . . . . . . . . . . . . . . 26
2.4 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 32
2.5 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 34
2.5.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 38
2.6.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 38
2.7 Attaching an external position sensor. . . . . . . . . . . . . . . . . . 40
2.7.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 40
2.7.2 Mounting the position sensor with attachment according to IEC 60534-6 42
2.7.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 43
2.7.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 44
2.8 Attaching positioners with stainless steel housings. . . . . . . . . . . . 46
2.9 Air purging function for single-acting actuators . . . . . . . . . . . . . 46
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 52
4 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 54
4.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 56
4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 57
4.3.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 58
5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 59
5.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . . 59
EB 8384-4 EN 3
Contents

5.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Checking the operating range of the positioner . . . . . . . . . . . . . 60
5.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7 Fault/failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.8 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.10 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 72
5.11 Setting the bus address . . . . . . . . . . . . . . . . . . . . . . . . 72
6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 74
6.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 74
6.2 Extended EXPERT+diagnostics . . . . . . . . . . . . . . . . . . . . . 74
6.3 Classification of the status alarms and the condensed status . . . . . . . 75
7 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 78
8 Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.3 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.1 Simplest method (MAX) . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.2 Precise method (NOM) . . . . . . . . . . . . . . . . . . . . . . . . 81
8.3.3 Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . 82
9 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 82
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11 Servicing explosion- protected devices. . . . . . . . . . . . . . . . . 84
12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 84
13 Maintenance, calibration and work on equipment . . . . . . . . . . . 85
14 PROFIBUS-PA communication . . . . . . . . . . . . . . . . . . . . . 86
14.1 Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
14.2 Cyclic data exchange . . . . . . . . . . . . . . . . . . . . . . . . . 86
14.2.1 GSD files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.2.2 Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
14.2.3 Integration for PCS7 control system. . . . . . . . . . . . . . . . . . . 94
14.2.4 General instructions to start up the positioner . . . . . . . . . . . . . . 94
14.3 CHECKBACK – Device status. . . . . . . . . . . . . . . . . . . . . . 94
14.4 Status coding of measured values . . . . . . . . . . . . . . . . . . . 96
14.4.1 Status alarm according to Profile 3.01 . . . . . . . . . . . . . . . . . 96
4EB 8384-4 EN
Contents

14.4.2 Status alarms according to Profile 3.01 Condensed Status . . . . . . . 100
14.5 Diagnostics with PROFIBUS-DP protocol . . . . . . . . . . . . . . . . 104
14.6 Acyclic data exchange . . . . . . . . . . . . . . . . . . . . . . . . 110
15 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
15.1 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
15.2 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
16 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 184
16.1 Fixing levels according to VDI/VDE 3848 (September 2010) . . . . . 187
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
EB 8384-4 EN 5
Contents

Modifications to positioner firmware compared to the previous version
Communication
Firmware Modification
K 1.01 Internal modifications
K 1.10 The FEATURE_SELECT parameter allows you to set whether an active diagnostic func-
tion is to be reported by a GOOD_FUNCTION_CHECK or a BAD_FUNCTION_
CHECK (see page 144)
K 1.11 –More trigger conditions in the data logger (see page 142)
–More additional functions (FEATURE_SELECT) (see page 144)
–The limits of the discrete valve position (POS_D_LIMIT_LOW, POS_D_LIMIT_UP) can
now be defined as required (see page 86)
K 1.12 Resetting the identification parameters resets all the parameters saved in the controller.
The parameters saved in the controller are, however, not reset when just the start-up
parameters are reset (see page 134).
K 1.13 Internal modifications
K 1.15 Feature of ID number adaptation acc. to PROFIBUS PA Profile 3.02 added. It allows a
Type 3785 Positioner (Profile 2.0 and Profile 3.0) to be directly replaced with a
Type 3730-4 Positioner in the compatability mode (see page 87).
K 1.16 The function to suppress extended diagnostic messages allows messages for the
PROFIBUS diagnosis protocol to be suppressed. The messages are still included in the
condensed state according to their classification. The parameter to suppress the
diagnositic messages exists in the following integrations:
DD: 2.2.007
TROVIS-VIEW: 3.60.005 (device module) and higher
DTM: 1.3.0.1
K 1.17 The versions K1.12 to K1.16 do not save a reference variable received in acyclic data
exchange as the valid value for the fail-safe action 'Last valid setpoint is used'. In the
affected modules for data exchange, the polling for a valid reference variable has
been changed to GOOD_NON_SPECIFIC.
Communication
Firmware Modification
R 1.43 to
R 1.46
Internal modifications
6EB 8384-4 EN
Modifications to positioner firmware compared to the previous version

EB 8384-4 EN 7
Safety instructions
General safety instructions
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 on Servicing explosion-protected versions.
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 level, it must be restricted by means of a suitable supply
pressure reducing station.
4Do not operate the positioner with the back of the positioner/vent opening
facing upwards. The vent opening must not be sealed or restricted 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 Directive
2014/30/EU and, depending on the version, the requirements of the Directive
2014/34/EU. The EU declarations of conformity can be found at the back of
these instructions.
Vent opening

8EB 8384-4 EN
Article code
Positioner Type 3730-4 x x x 0 x 0 x x 1 x 0 0 x 0 x x
With LCD and autotune, PROFIBUS-PA
Explosion protection
None 0
ATEX: II 2G Exia IIC T6 Gb; II 2D Ex ia IIIC T80°C Db 1
CSA/FM:
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/
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
3
ATEX: II 2D Ex tb IIIC T80°C Db 5
ATEX: II 3G Ex nA II T6; II 3G Exic IIC T6; II 3D Ex tc IIIC T80°C IP66 8
Additional equipment
Inductive
limit switch
Without
SJ2-SN (NC contact)
0
1
Solenoid valve Without
With, 24 V DC
0
4
External position sensor Without
With 0
0
1 0 0
Binary input Without
Floating contact 0
0
1
Diagnostics
EXPERT (standard) 1
EXPERT+(extended diagnostics) 2
Housing material
Aluminum (standard) 0
Stainless steel 1.4581 0 1
Special application
None 0
Postioner compatible with paint 1
Exhaust connection with ¼-18 NPT thread, back of positioner housing sealed 0 0 0 0 2
Special version
None 0 0 0
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 1 0 1 2
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

1 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 vari-
able y) is produced.
The positioner consists of a travel sensor sys-
tem proportional to resistance, an analog
i/p converter with a downstream booster
and the electronics unit with microcontroller.
When a deviation occurs, the actuator is
pressurized or vented. If required, the
changes in the signal pressure can be
slowed down by a connectable Q 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.
A constant air stream to the atmosphere is
created by the flow regulator (9) with a
fixed set point. The air stream is used to
purge the inside of the housing as well as to
optimize the air capacity booster. The i/p
module (6) is supplied with a constant up-
stream pressure by the pressure regulator
(8) to make it independent of the supply air
pressure.
EB 8384-4 EN 9
Design and principle of operation
Fig. 2 · Functional diagram
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
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 IEC 61158-2
interface module
14 Binary input 1
(voltage input)
15 Binary input 2 (for
floating contact)
16 Display
17* Solenoid valve control
18 Galvanic isolation
19 D/A converter
20 Serial interface (SSP)
* Optional
PROFIBUS-PA
IEC 61158-2

The positioner communicates and is pow-
ered using IEC 61158-2 transmission tech-
nology conforming to PROFIBUS-PA specifi-
cation.
As a standard feature, the positioner comes
with a binary input for DC voltage signals to
signalize process information over the
PROFIBUS-PA.
1.1 Additional equipment
Version with solenoid valve
If the operating voltage for the solenoid
valve (12) fails, the supply pressure for the
booster is vented to the atmosphere. As a
result, the actuator is vented and the valve
moves to the fail-safe position.
NOTICE
In manual mode (MAN), the manual set
point is also reset to 0 %. A different manual
set point must be entered again (Code 1).
Version with inductive limit switch
The rotary shaft of the positioner carries an
adjustable tag which actuates the installed
proximity switch.
Version with binary contact
All positioners are fitted with a binary input
for DC voltage signals over which process
information can be issued over the
PROFIBUS-PA network.
Another optional binary input is an active
input powered by the positioner to connect a
floating contact. Its switching condition can
also be issued over the PROFIBUS-PA net-
work.
Version with 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 via cable and piping for
air (only without inductive limit switch).
1.2 Communication
The positioner is completely controlled over
the digital signal transmission implemented
complying with PROFIBUS-PA Profile B as
per DIN EN 50170 and DIN 19245 Part 4.
Data are transmitted as bit-synchronous cur-
rent modulation at a rate of 31.25 kbit/s
over twisted-pair cables conforming to
IEC 61158-2.
Usually, the positioner settings are made on
a computer which is connected to one or
more positioners linked over a segment cou-
pler to the PROFIBUS segment of the com-
puter.
Configuration using TROVIS-VIEW software
The positioner can be configured using
TROVIS-VIEW Configuration and Operator
Interface software.
The positioner is equipped with an addi-
tional digital SERIAL INTERFACE to allow a
computer to be connected over an adapter
cable from the RS-232 interface of the com-
puter to the positioner.
The TROVIS-VIEW software enables the user
to easily set parameters in the positioner
and view process parameters online.
10 EB 8384-4 EN
Design and principle of operation