Samson 3731-5 Service manual

Series 3731
Type 3731-5
Electropneumatic Ex d Positioner
with FOUNDATION™fieldbus communication
Mounting and
Operating Instructions
EB 8387-5 EN
Firmware version R 1.4x
Edition March 2016
Fig. 1 · Type 3731-5
EB + CD

2EB 8387-5 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, informa-
tion and tips
Definitions of the signal words used in these instructions

Contents
1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 5
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 7
3.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . . 9
3.2.2 Configuration using the NI-BUS™ Configurator . . . . . . . . . . . . . . . . . 9
3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Attachment to the control valve – Mounting parts and accessories . . . 13
4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 20
4.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 22
4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 24
4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26
4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 26
4.6 Required mounting parts and accessories. . . . . . . . . . . . . . . . 28
5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 37
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 38
6.1 Rotary pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3 Readings on display. . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 40
7.3 Checking the operating range of the positioner . . . . . . . . . . . . . 41
7.4 Determining the fail-safe position. . . . . . . . . . . . . . . . . . . . 42
7.5 Positioner initialization. . . . . . . . . . . . . . . . . . . . . . . . . 43
7.5.1 Initialization based on MAX maximum range . . . . . . . . . . . . . 44
EB 8387-5 EN 3
Contents

7.5.2 Initialization based on NOM nominal range . . . . . . . . . . . . . . 45
7.5.3 Initialization based on MAN manually selected range . . . . . . . . . 47
7.5.4 SUB substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 48
7.6 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.7 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 53
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 54
8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.2.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 55
8.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 56
8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 57
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58
11 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 78
12.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 80
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
13.1 Selecting the valve characteristic . . . . . . . . . . . . . . . . . . . . 82
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4EB 8387-5 EN
Contents
Note concerning these Mounting and Operating Instructions
These instructions EB 8387-5 describe the mounting, start up and on-site operation of the
Type 3731-5 Positioner.
You can find additional information on the enclosed CD-ROM (CD 8387-5) or on the Internet
at http://www.samson.de.

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 experi-
enced personnel familiar with the product.
According to these Mounting and Operating Instructions, trained personnel is referred
to as 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.
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.
To avoid damage to any equipment, the following also applies:
4Proper shipping and appropriate storage are assumed.
4Do not operate the positioner with the back of the positioner/vent opening facing up-
wards.
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 and
2004/108/EC.
The Declaration of Conformity is included on the enclosed CD-ROM.
EB 8387-5 EN 5
Important safety instructions
Vent opening

2 Article code
Positioner Type 3731 - 5 xxxxxx000x1x000
With LCD, autotune, FOUNDATION™fieldbus
Explosion protection
ATEX:
II 2G Ex d IIC T6,T5,T4 Gb; II 2G Ex de IIC T6,T5,T4 Gb; II 2D Ex tb IIIC T80°C DB IP66
II 2G Ex d IIC T6 Gb; II 2G Ex de IIC T6 Gb; II 2D Ex tb IIIC IP65 T80°C
2 1
FM/CSA:
Class I, Div. 1+2, Groups B, C, D; Class I, Zone 1, Groups IIB+H2;
Class I, Div. 1+2 Groups E, F, G; Class III/
Class I, Zone 1, Group IIB+H2 T4...T6; Class I, Div. 1+2, Groups B, C, D T4...T6;
Class II, Div. 1, Groups E, F, G
2 3
JIS: Ex d IIC T6 2 7
Options (additional equipment)
Without 0 0
Binary input 0 3
Forced venting 0 5
Diagnostics
EXPERT 1
EXPERT+/PST 2
Electrical connections
2x M20 x 1.5 1
2x ½ NPT 2
Explosion-protection certificates
As specified in Explosion protection 0
IECEx: Ex d IIC T6, T5, T4 Gb; Ex d e IIC T6, T5, T4 Gb; Ex tb IIIC T80°C Db IP66 2 1 2
GOST: 1Ex d IIC T6/T5/T4 Gb X; 1Ex d e IIC T6/T5/T4 Gb X; Ex tb IIIC T 80°C Db X 2 1 3
Special applications
Without 0
Positioner compatible with paint (IP 41/NEMA 1) 1
Special version
Without 0 0 0
6EB 8387-5 EN
Article code

3 Design and principle of
operation
The electropneumatic Ex d positioner is at-
tached to pneumatic control valves. It is used
to assign the valve stem position (controlled
variable x) to the control signal (reference
variable w). The input signal received from
a control system is compared to the travel or
rotational angle of the control valve, and a
signal pressure (output variable y) is pro-
duced for the pneumatic actuator.
The positioner basically consists of an
electrical travel sensor system (2), an analog
i/p converter (6) with downstream air ca-
pacity booster (7) and the electronic unit
with a microcontroller (5).
In case of a system deviation, the actuator is
either vented or filled with more air. The sig-
nal pressure supplied to the actuator can be
limited to 1.4 bar, 2.4 bar or 3.7 bar by
software or on site at the positioner.
EB 8387-5 EN 7
Design and principle of operation
%
S
mm
%
mm
w
x
G
PD
Serial
Interface 16
22
20 23
2
4
17
519
3
6
7
81
9
x
y
Fig. 2 · Functional diagram
1 Control valve
2 Travel sensor
3 PD controller
4 IEC 61158-2
interface module
5 Microcontroller
6 i/p converter
7 Air capacity booster
8 Pressure regulator
9 Flow regulator
16 Display
17 Forced venting control
(optional)
19 D/A converter
20 Serial interface (SSP)
22 Rotary pushbutton
23 Binary input
(optional)
FOUNDATION™
fieldbus
IEC 61158-2

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 (7). The
i/p converter (6) is supplied with a constant
upstream pressure by the pressure regulator
(8) to make it independent of the supply
pressure.
All parts are enclosed in an Ex d housing.
The electrical cables are connected over a
separate terminal compartment which also
has Ex d protection.
The standard EXPERT diagnostics are inte-
grated into the positioner. It provides infor-
mation on the positioner and generates di-
agnostic and status messages, which allow
faults to be pinpointed quickly.
The positioner is suitable for the following
types of attachment using the corresponding
accessories:
4Direct attachment to SAMSON
Type 3277 Actuator: Section 4.1
4Attachment to actuators acc. to
IEC 60534-6 (NAMUR): Section 4.2
4Attachment to Type 3510 Micro-flow
Valve: Section 4.3
4Attachment to rotary actuators acc. to
VDI/VDE 3845: Section 4.4
3.1 Additional equipment
Binary input
The positioner has an optional binary input.
Connected at terminals A-B:
The binary input for DC voltage signals al-
lows process information to be exchanged
over the FOUNDATION™fieldbus network.
Connected at terminals B-C:
This input connects a floating contact which
is powered by the positioner. The switching
state of the binary input can be indicated
over the FOUNDATION™fieldbus network.
Forced venting
The i/p converter stops working if the oper-
ating voltage supply to the relevant terminals
is interrupted. The positioner can no longer
operate and the control valve moves to the
fail-safe position determined by the actua-
tor, independent of the reference variable.
Extended EXPERT+valve diagnostics
Refer to Table 5 on page 30 for order num-
bers.
EXPERT+is an optional diagnostic firmware
integrated in the positioner which allows the
predictive, status-oriented maintenance of
pneumatic control valves. It upgrades the
standard EXPERT diagnostics firmware in-
corporated in the positioner. The upgraded
version provides extended functions to pin-
point valve parameters that have worsened,
allowing the user to plan predictive mainte-
nance and service work before malfunctions
can affect the process, causing unscheduled
plant shutdowns.
The extended EXPERT+diagnostics can be
activated later at the positioner by purchas-
ing an activation code or using a USB
dongle in conjunction with TROVIS-VIEW
software when EXPERT+is not already acti-
vated on delivery of the positioner.
8EB 8387-5 EN
Design and principle of operation

3.2 Communication
The positioner is completely controlled over
the digital signal transmission implemented
according to FOUNDATION™ fieldbus spec-
ification.
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.
3.2.1 Configuration using
TROVIS-VIEW software
Refer to Table 5 on page 30 for order num-
bers.
The positioner can be configured using the
TROVIS-VIEW configuration and operator
interface.
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 or USB port of the
computer to the positioner.
The TROVIS-VIEW software enables the user
to easily set parameters in the positioner
and view process parameters online.
Note: Instructions on how to install and ope-
rate the TROVIS-VIEW software are inclu-
ded in the Configuration Manual
KH 8387-5 on the CD-ROM.
3.2.2 Configuration using the
NI-BUS™ Configurator
The NI-FBUS™ Configurator from National
Instruments can also be used to configure
the positioner. For this purpose, an interface
card must be installed in a computer to con-
nect it to the FOUNDATION™ fieldbus.
The integrated function blocks are linked us-
ing the NI-FBUS™ Configurator.
EB 8387-5 EN 9
Design and principle of operation

3.3 Technical data
10 EB 8387-5 EN
Design and principle of operation
Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)
Rated travel Adjustable Direct attachment to Type 3277: 3.6 to 30 mm
Attachment acc. to IEC 60534-6 (NAMUR): 3.6 to 200 mm
Attachment to rotary actuators (VDI/VDE 3845): 24° to 100°
Travel range Adjustable Adjustable within the initialized travel/angle of rotation;
travel can be restricted to 15at the maximum
Bus connection Fieldbus interface acc. to IEC 61158-2 bus-powered
Physical Layer Class: 113 (without ex. protection) und 111 (with ex. protection)
Field device acc. to FM 3610 Entity and FISCO
Communication
Fieldbus Data transmission as per FOUNDATION™ fieldbus specification,
Communication Profile Class: 31 PS, 32 L;
Interoperability tested according to Interoperability Test System (ITS) Revision 4.6
Execution time AO FB: 20 ms DI FB: 40 ms PID: 60 ms
Local communication SAMSON SSP interface and serial interface adapter
Software requirements (SSP): TROVIS-VIEW with database module 3731-5
Permissible operating
voltage
9 to 32 V DC · Powered over bus line
The limits in the test certificate additionally apply.
Max. operating current 15 mA
Additional current in case of fault 0 mA
Supply air Pressure Type 3731-521, Type 3731-527: 1.4 to 7 bar (20 to 105 psi),
Type 3731-523: 1.4 to 6 bar (20 to 90 psi)
Air quality Compliance with ISO 8573-1: 2004
Max. particle size and density: Class 4
Oil content: Class 3
Moisture and water: Class 3
Pressure dew point: At least 10 K beneath the lowest ambient temperature to be
expected
Signal pressure (output) 0 bar up to supply pressure
Characteristic Linear/equal percentage/reverse equal percentage
User-defined (over operating software and communication)
Butterfly valve/Rotary plug valve/Segmented ball valve: linear/equal percentage
Deviation from terminal-based conformity ≤1 %
Hysteresis ≤0.3 %
Sensitivity ≤0.1 %
Direction of action Reversible
Air consumption Independent from supply pressure 110 ln/h
Air output
capacity
to fill actuator
with air At ∆p = 6 bar: 8.5 mn³/h · At ∆p = 1.4 bar: 30 mn³/h · KVmax(20° C) = 0.09
to vent actuator At ∆p = 6 bar: 14.0 mn³/h · At ∆p = 1.4 bar: 4.5 mn³/h · KVmax(20° C) = 0.15