Samson 3730 Series Service manual

Series 3730
Electropneumatic Positioner
Type 3730-2
Mounting and
Operating Instructions
EB 8384-2 EN (1300-1611)
Firmware version 1.54
Edition February 2012
Fig. 1 · Type 3730-2

2EB 8384-2 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 in-
jury.
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 . . . . . . . . . . . . . . . . . . . . . . 8
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Design and principle of operation . . . . . . . . . . . . . . . . . . . 10
3.1 Application type . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 13
3.4 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Attachment to the control valve – Mounting parts and accessories . . . 18
4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 24
4.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 26
4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 28
4.4.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 32
4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 32
4.6 Attaching an external position sensor. . . . . . . . . . . . . . . . . . 34
4.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 34
4.6.2 Mounting the position sensor with attachment according to IEC 60534-6 36
4.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 37
4.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 38
4.7 Attaching positioners with stainless steel housings. . . . . . . . . . . . 39
4.8 Air purging function for single-acting actuators . . . . . . . . . . . . . 39
4.9 Mounting parts and accessories . . . . . . . . . . . . . . . . . . . . 40
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 48
6.1 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
EB 8384-2 EN 3
Contents

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 51
7.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 51
7.3 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 52
7.5 Checking the operating range of the positioner . . . . . . . . . . . . . 53
7.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . 55
7.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 56
7.6.3 MAN – Initialization based on a manually selected range . . . . . . . 57
7.6.4 SUb substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 59
7.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.8 Performing settings for open/close valves. . . . . . . . . . . . . . . . 63
7.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 65
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 66
8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.2.1 Automatic and manual modes . . . . . . . . . . . . . . . . . . . . . 67
8.2.2 Fail-safe position (SAFE) . . . . . . . . . . . . . . . . . . . . . . . . 68
8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 68
8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 69
9 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 70
9.1 Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 72
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 73
12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 73
13 Maintenance, calibration and work on equipment . . . . . . . . . . . 74
14 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15 Settings in TROVIS-VIEW software . . . . . . . . . . . . . . . . . . 100
15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
15.1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . 100
15.2 Installing TROVIS-VIEW software . . . . . . . . . . . . . . . . . . . 101
15.3 Starting TROVIS-VIEW and performing basic settings . . . . . . . . . 102
15.4 Data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 104
15.4.1 Offline operation (indirect data transmission) . . . . . . . . . . . . . 105
4EB 8384-2 EN
Contents

15.4.2 Online operation (direct data transmission) . . . . . . . . . . . . . . 105
15.4.3 Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 106
15.5 Initializing the positioner . . . . . . . . . . . . . . . . . . . . . . . 108
15.6 Status classification. . . . . . . . . . . . . . . . . . . . . . . . . . 110
16 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 112
16.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . 114
17 Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 115
Test certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
EB 8384-2 EN 5
Contents
Note:
The functions of EXPERTplus valve diagnostics are described in the Mounting and Operating
Instructions EB 8389 EN

6EB 8384-2 EN
Modifications of positioner firmware
Modifications of positioner firmware in comparison to previous versions
Previous New
1.00 1.10
The serial interface and serial interface adapter allow the positioner to be operated
and configured using TROVIS-VIEW software
The following additional status messages were implemented:
Code 76 - No emergency mode
Code 77 - Program loading error
Displays number of zero calibrations performed since the last initialization.
For initialization of "AIR TO CLOSE" actuators, the direction of action (Code 7) is auto-
matically set to increasing/decreasing.
Code 3, the activation period of the enabled configuration function was
extended to 120 s.
1.10 1.20
Electronics changed, no new functions added.
1.20 1.30
New EXPERTplus diagnostics functions (Code 48) added
Positioner in EXPERTplus version with extended diagnostics features.
A running initialization can be canceled by pressing the rotary pushbutton.
The position transmitter (Code 37) and solenoid valve (Code 45) options are automati-
cally recognized.
1.30 1.40
All EXPERTplus functions can be used in this firmware version and higher.
The fault alarm contact is triggered by the condensed state of the positioner. It is al-
ways active when condensed state = “Maintenance alarm”.
If Code 32 is set to
Yes : Also active with “Function check” condensed state
If Code 33 is set to
Yes : Also active with “Maintenance required/Maintenance de-
manded” condensed state
The “Function check” condensed state is additionally set for Test A1, A2, fault alarm
output and position transmitter.
The min./max. values of the temperature monitoring can be reset.
1.40 1.41
Internal modifications
1.41 1.42
Internal modifications

EB 8384-2 EN 7
Modifications of positioner firmware
Modifications of positioner firmware in comparison to previous versions
Previous New
1.42 1.51
Setting can be performed at the positioner to determine whether the valve is to operate
as a control valve or an on/off (open/close) valve (see section 3.1)
All EXPERTplus diagnostic functions are available in the positioner without having to
activate them first (refer to EB 8389 EN on EXPERTplus valve diagnostics)
Optional binary input with following actions (refer to EB 8389 EN on EXPERTplus valve
diagnostics):
– Set local operation write protection
– Start Partial Stroke Test (PST)
– Go to fail-safe reference variable
– Switch between AUTO/MAN
– Start data logger
– Reset diagnosis
The pressure limit (Code 16) is no longer automatically set during initialization.
1.51 1.54
Internal modifications

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
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 are to be operated only 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.
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 pneumatic 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:
4Do not operate the positioner with the back of the positioner/vent opening facing
upwards.
The vent opening must not be sealed 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 Directives 94/9/EC
(ATEX) and 89/336/EEC (EMC).
The Declaration of Conformity is available on request.
8EB 8384-2 EN
Important safety instructions
Vent opening

2 Article code
EB 8384-2 EN 9
Article code
Article code Type 3730-2 xxxxx0xx0x00x0xx
With LC display, autotune
Explosion protection
Without 0
ATEX: II 2G Ex ia IIC T6, II 2D Ex tD A21 IP65 T80 °C 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 I, II, Groups A–G;
Class I, Zone 2; Class I, II, Div. 2, Groups A–G
3
JIS: Ex ia IIC T6 7
ATEX: II 3G Ex nA II T6, II 3D Ex nL IIC T6, II 3D Ex tD A21 IP65 T80°C 8
Options (additional equipment)
Inductive limit switch Without
With SJ2-SN
With SJ2-S1N
0
1
2
0
Solenoid valve SIL 4 Without
24 V DC
0
4
Analog position transmitter Without
With
0
1
External position sensor Without
With 0
0
1
Binary input Without
With 0
0
2
Diagnostics
EXPERTplus 4
Housing material
Aluminum 0
Stainless steel 1.4581 0 1
Special applications
Without 0
Compatible with paint 1
Exhaust air with ¼ NPT connection, back of housing sealed 2
Special versions
Without 00
IECEx: Ex ia IIC T4/T5/T6;IP 54 and IP 65 T 80°C 1 1 2
GOST: 0Ex ia IIC T6 X 1 1 4

3 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 variable
y) is produced.
The positioner basically consists of an elec-
trical travel sensor system (2), an analog i/p
converter (6) with downstream air capacity
booster (7) and the electronic unit with a
microcontroller (5).
The standard positioner is fitted with three
binary contacts: A fault alarm output indi-
cates a fault to a control station and two
configurable software limit switches are
used to indicate the end positions of the
valve.
The position of the valve is transmitted as
linear travel motion or angle of rotation via
pick-up lever and travel sensor (2) to an an-
alog PD controller (3). Simultaneously, an
A/D converter (4) transmits the position of
the valve to the microcontroller (5). The PD
controller compares this actual position to
10 EB 8384-2 EN
Design and principle of operation
w
x
Q
%
S
mm
GG
PD
Serial
Interface
16
20
13
15
A2
A3
A1
11
2
419
5
3
12
6
7
8
10
1
14
14
w
x
y
24V DC
9
17 18
22 BE
Fig. 2 · Functional diagram
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* Analog position transmitter
14 Software limit switches
Alarm 1/2
15 Fault alarm output
Alarm 3
16 Display
17* Solenoid valve control
18* Galvanic isolation
19 D/A converter
20 Communication interface
21 Binary input BE*
* Optional