Samson FOUNDATION 3730-5 Service manual

Series 3730
Electropneumatic Positioner
Type 3730-5
with FOUNDATION™ fieldbus communication
FF Device Rev 2
Mounting and
Operating Instructions
EB 8384-5 EN (1300-1619)
Firmware version 1.55
Edition July 2012
Fig. 1 · Type 3730-5

Contents Page
1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 8
2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Design and principle of operation . . . . . . . . . . . . . . . . . . . 11
3.1 Application type. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . 14
3.3.2 Configuration using the NI-FBUS™ Configurator . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 41
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 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 48
6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 50
7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2EB 8384-5 EN
Contents

7.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 52
7.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 53
7.3 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 54
7.5 Checking the operating range of the positioner . . . . . . . . . . . . . 54
7.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . . 57
7.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 58
7.6.3 MAN – Initialization based on a manually selected range . . . . . . . . 59
7.6.4 SUb substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 60
7.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.8 Selecting the application type . . . . . . . . . . . . . . . . . . . . . 64
7.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 64
8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 65
8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.2.1 Automatic and manual modes . . . . . . . . . . . . . . . . . . . . . 66
8.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 67
8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 67
8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 68
9 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 69
9.1 Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 71
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 72
12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 72
13 Maintenance, calibration and work on equipment . . . . . . . . . . . 73
14 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
14.1 Decimal values of the modes in the FOUNDATION™ fieldbus blocks
(Code 48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
14.2 Decimal values of the states in the FOUNDATION™ fieldbus blocks
(Code 48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
15 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
15.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . 100
16 Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 101
Test certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
EB 8384-5 EN 3
Contents

4EB 8384-5 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 inju-
ry.
NOTICE
indicates a property damage message.
Note: Supplementary explanations,
information and tips
Definitions of the signal words used in these instructions

Revisions of the positioner firmware compared to the previous version – Control R
Control R 1.43 R 1.44
Internal revisions
R 1.45
Internal revisions
R 1.46
Internal revisions
R 1.52
Application type The user determines in the positioner whether the valve is to oper-
ate as a control valve or an open/close (on/off valve) (see section
3.1)
Diagnosis All EXPERTplus diagnostic functions are available without having
to activate them in the positioner (see EB 8389 EN on
EXPERTplus Valve Diagnostics).
Additional function blocks – 2x DO (Discrete Output)
– 1x IS (Input Selector)
– 1x MAI (Multiple Analog Input)
– 1x MAO (Multiple Analog Output)
Refer to Configuration Manual KH 8384-5 EN
New functions In the DO Function Block (Discrete Output), the following new
functions are implemented:
– Discrete analysis of on/off valves
– Start partial stroke test (PST)
– Start and reset the data logger
– Reset diagnosis
– Stop diagnosis
– Move to fail-safe position
– Lock local operation
Refer to Configuration Manual KH 8384-5 EN
Action on fault detection If the AO Transducer Block is in Out of Service mode and the
condensed state changes to 'Maintenance alarm', the following
actions can be started:
– Hold last value
– Move valve to fail-safe position
– Move to a predefined fault state value
Refer to Configuration Manual KH 8384-5 EN
EB 8384-5 EN 5
Revisions of the positioner firmware

Revisions of the positioner firmware compared to the previous version – Control R
Codes 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 time
See section 14.
R 1.54 and R 1.55
Internal revisions
Revisions to the communication firmware are listed in the Configuration Manual
KH 8384-5 EN.
6EB 8384-5 EN
Revisions of the positioner firmware

Note concerning these Mounting and Operating Instructions
These instructions EB 8384-5 EN describe the mounting, start up and on-site operation of the
Type 3730-5 Positioner.
You can find additional information on the enclosed CD-ROM (CD 8384-5) or on the Internet
at http://www.samson.de.
The CD-ROM (CD 8384-5) contains further information on the Type 3730-5 Positioner:
4[Documentation]
–KH 8384-5 EN: Configuration Manual for Type 3730-5 Electropneumatic
Positioner, configuration and operation over FOUNDATION™fieldbus
–T 8384-5 EN: Data Sheet for Type 3730-5 Electropneumatic Positioner
–EB 8389 EN: Instructions for Series 373x Positioners; EXPERTplus Valve Diagnostics
–T 8389 EN: Data Sheet for EXPERT/EXPERT+Valve Diagnostics
–T 6661 EN: Data Sheet for TROVIS-VIEW software
4[Approvals]
– PTB/ATEX – NEPSI
– CSA – GOST
– FM – STCC
– IECEx – JIS
– CERTUSP/INMETRO – CCoE
4[Declarations of Conformity]
4[Integrations]
– Enhanced Electronic Device Description (DD)
– 375/475 Field Communicator
– Emerson AMS™/DeltaV™
– Yokogawa PRM – Device Viewer
4[TROVIS-VIEW (demo version)]
The HTML-based CD-ROM allows you to easily find any required information using a web
browser.
The PDF documents can be read using Acrobat Reader software.
EB 8384-5 EN 7
Note concerning these Mounting and Operating Instructions

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 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.
4Do not ground electric welding equipment near to the positioner.
8EB 8384-5 EN
Important safety instructions
Vent opening

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 included on the CD-ROM (CD 8384-5).
EB 8384-5 EN 9
Important safety instructions

2 Article code
Positioner Type 3730-5 xxx0x0xx0x00x0xx
With LCD and autotune, FOUNDATION™ fieldbus
Explosion protection
Without 0
ATEX: II 2G Ex ia IIC T6; II 2D Ex tb IIIC T 80°C IP 66 1
FM/CSA:
Class I, Zone 0 AEx ia IIC; Class I, II, III, Div.1, Groups A–G;
ClassI,Div.2,GroupsA–D; ClassII,Div.2,GroupsF,G/
Ex ia IIC T6; Class I , II, Div.1, Groups A–G;
Ex nA II T6; Ex nL IIC T6; Class I, II, Div.2, Groups A–G; Class II, Div.1, Groups E–D
3
ATEX: II 3G Ex nA II T6, II 3G Ex ic IIC T6, II 3D tc IIIC T 80°C IP 66 8
Additional equipment
Inductive limit switch Without
SJ2-SN
SJ2-S1N
0
1
2
Solenoid valve Without
With, 24 V DC
0
4
External position sensor Without
With 0
0
10 0
Binary input Without
Floating contact 0
0
1
Diagnostics
EXPERTplus 4
Housing material
Aluminum (standard) 0
Stainless steel 1.4581 0 1
Special applications
None 0
Positioner compatible with paint 1
Vent connection with ¼-18 NPT thread, back of housing sealed 0 0 0 0 2
Special version
None 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 1 0 1 2
GOST: 0Ex ia IIC T8 X 1 0 1 4
10 EB 8384-5 EN
Article code