Samson 3730 Series Service manual

Series 3730
Electropneumatic Positioner
Type 3730-3
with HART®communication
Mounting and
Operating Instructions
EB 8384-3 EN
Firmware version 1.52
Edition September 2008
Fig. 1 · Type 3730-3

2EB 8384-3 EN
DANGER!
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING!
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
NOTICE
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 . . . . . . . . . . . . . . . . . . . . . . 9
2 Article code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Design and principle of operation . . . . . . . . . . . . . . . . . . . 11
3.1 Application type . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 14
3.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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
4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 30
4.5.1 Pressure gauge attachment . . . . . . . . . . . . . . . . . . . . . . 30
4.6 Attaching an external position sensor . . . . . . . . . . . . . . . . . 32
4.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 32
4.6.2 Mounting the position sensor with attachment according to IEC 60534-6 34
4.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 35
4.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 36
4.7 Attaching positioners with stainless steel housings. . . . . . . . . . . . 37
4.8 Air purging function for single-acting actuators . . . . . . . . . . . . . 37
4.9 Required mounting parts and accessories. . . . . . . . . . . . . . . . 38
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2.1 Switching amplifiers. . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 46
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 48
6.1 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.2 HART®communication . . . . . . . . . . . . . . . . . . . . . . . . 50
EB 8384-3 EN 3
Contents

7 Start-up – Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 51
7.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 52
7.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 53
7.5 Checking the operating range of the positioner . . . . . . . . . . . . . 53
7.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . 56
7.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 57
7.6.3 MAN – Initialization based on a manually selected range . . . . . . . 58
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 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
13 Settings in TROVIS-VIEW software. . . . . . . . . . . . . . . . . . . 99
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.2 Installing TROVIS-VIEW software . . . . . . . . . . . . . . . . . . . 100
13.3 Starting TROVIS-VIEW and performing basic settings . . . . . . . . . 101
13.4 Data transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 103
13.4.1 Offline operation (indirect data transmission) . . . . . . . . . . . . . 104
13.4.2 Online operation (direct data transmission) . . . . . . . . . . . . . . 104
13.4.3 Setting parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.5 Initializing the positioner . . . . . . . . . . . . . . . . . . . . . . . 107
13.6 Status classification . . . . . . . . . . . . . . . . . . . . . . . . . 109
4EB 8384-3 EN
Contents

14 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . 111
15 Valve characteristic selection. . . . . . . . . . . . . . . . . . . . . 112
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
EB 8384-3 EN 5
Contents

6EB 8384-3 EN
Modifications of positioner firmware
Modifications of positioner firmware in comparison to previous versions
Previous New
1.00 1.10
The HART protocol as per HART®specification Revision 5 is supported by default set-
ting.
The setting can be changed to HART®Revision 6 over TROVIS-VIEW. HART®tools as
well as AMS or handheld communicators are currently not supported by the Revision 6
version.
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 EXPERT+diagnostics functions (Code 48) added
Positioner in EXPERT+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 EXPERT+functions can be used over HART®communication 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.

EB 8384-3 EN 7
Modifications of positioner firmware
Modifications of positioner firmware in comparison to previous versions
Previous New
1.40 1.41
Internal modifications
1.41 1.42
Internal modifications
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 EXPERT+diagnostic functions are available in the positioner without having to
activate them first (refer to EB 8389 EN on EXPERT+valve diagnostics)
Optional binary input with following actions (refer to EB 8389 EN on EXPERT+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
– External solenoid valve connected
– Leakage sensor
The pressure limit (Code 16) is no longer automatically set during initialization.
1.51 1.52
Internal modifications

8EB 8384-3 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 may only be mounted, started up or operated 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 relevant 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.
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:
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.
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.
EB 8384-3 EN 9
Important safety instructions
Vent opening

2 Article code
10 EB 8384-3 EN
Article code
Article code Type 3730-3 xxxxx0xx0x00x0xx
With LC display, autotune, HART®communication
Explosion protection
Without
II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C acc. to ATEX
CSA/FM intrinsically safe/non incendive
II 3 G EEx na II T6 /II 3 D IP 65 T 80 °C acc. to ATEX
0
1
3
8
Options (additional equipment)
Inductive limit switch Without
With Type SJ 2-SN
0
10
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
EXPERT plus 4
Housing material
Aluminum
Stainless steel 1.4581 0
0
1
Special applications
None
Free of paint-impairing substances
Exhaust air connection with ¼ NPT thread
0
1
2
Special versions
None
IECEx 1
0
1
0
2