Samson FOUNDATION 3730-5 Service manual

FOUNDATIONTM FIELDBUS Positioner
Type 3730-5
Mounting and
Operating Instructions
EB 8384-5 EN
Firmware version K 1.1x/ R 1.4x
Edition August 2005
Fig. 1 · Type 3730-5

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 6
1.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Attachment to the control valve – Mounting parts and accessories . . . 11
2.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Type 3277-5 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Type 3277 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Attachment according to IEC 60534-6 . . . . . . . . . . . . . . . . . 18
2.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 20
2.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 22
2.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 24
3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 30
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1 Operator controls and display . . . . . . . . . . . . . . . . . . . . . 32
4.2 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 34
4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 35
4.3.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 36
5 Start-up and settings . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 36
5.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . . 37
5.3 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 37
5.5 Checking the operating range of the positioner . . . . . . . . . . . . . 37
5.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.7 Fault/failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.8 Zero calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 48
5.10 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 49
2EB 8384-5 EN
Contents

6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 49
6.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 49
6.2 Extended EXPERT+diagnostics . . . . . . . . . . . . . . . . . . . . . 50
6.3 Classification of the status alarms and the condensed status . . . . . . . 50
7 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 52
8 Quick start-up guide . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.3 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3.1 Simplest method (
MAX ) . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3.2 Precise method (
NOM ) . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3.3 Manual method (MAN) . . . . . . . . . . . . . . . . . . . . . . . . 56
9 Retrofitting an inductive limit switch . . . . . . . . . . . . . . . . . . 57
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58
12 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
13 Parameter description . . . . . . . . . . . . . . . . . . . . . . . . 76
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
13.2 Device description (DD) . . . . . . . . . . . . . . . . . . . . . . . . 76
13.3 Notes concerning the parameters . . . . . . . . . . . . . . . . . . . 76
13.3.1 Legend for the parameters . . . . . . . . . . . . . . . . . . . . . . . 77
13.4 FOUNDATIONTM Fieldbus block model . . . . . . . . . . . . . . . . 77
13.5 Resource Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
13.5.1 Resource Block parameters . . . . . . . . . . . . . . . . . . . . . . 78
13.5.2 Analog Output Transducer Block . . . . . . . . . . . . . . . . . . . 88
13.5.3 Discrete Input Transducer Blocks . . . . . . . . . . . . . . . . . . . 115
13.5.4 Analog Output Function Block . . . . . . . . . . . . . . . . . . . . 115
13.5.5 Discrete Input Function Block DI1 . . . . . . . . . . . . . . . . . . . 125
13.5.6 Discrete Input Function Block DI2 . . . . . . . . . . . . . . . . . . . 130
13.5.7 Proportional Integral Derivative Function Block (PID process controller) . 131
13.6 Other parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13.6.1 Stale Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
13.6.2 Link Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
13.6.3 LAS Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . 148
14 Resetting the device . . . . . . . . . . . . . . . . . . . . . . . . . 148
15 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . 149
Test certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
EB 8384-5 EN 3
Contents

4EB 8384-5 EN
Safety instructions
General safety instructions
4
The positioner may only be assembled, started up or operated by trained
and experienced 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.
4
Explosion-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.
4
Any 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.
4
If 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.
Do not operate the positioner with the back of it/exhaust air opening facing
upwards. Never seal the exhaust air opening when the positioner is
mounted on site.
4
Proper shipping and appropriate storage are assumed.
Note! The device with a CE marking fulfils the requirements of the Directives
94/9/EC (ATEX) and 89/336/EEC (EMC).
The declaration of conformity is available on request.

EB 8384-5 EN 5
Article code
Article code Type 3730-5 XXX000XX0X00X0XX
Explosion protection
Without
II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C
acc. to ATEX
CSA/FM applied for
II 3 G EEx nA/nL II T6/II 3 D IP 65 T 80°C
acc. to ATEX
0
1
3
8
Additional equipment
Inductive
limit switch
Without
With Type SJ 2-SN
0
1
Solenoid
valve SIL 4
Without
24 V DC
0
4
Binary input 1
Binary input 2
Standard
Add. floating contact
0
1
Diagnostics EXPERT
EXPERT+(extended)
1
2
Housing material Aluminum
Stainless steel 1.4581
0
1
Positioner for
special
applications
Without
Free of substances that
impair painted surfaces
Exhaust air with pneum.
connection ¼ NPT 00 0
0
1
2
Special versions Without 0 0 0

1 Design and principle of
operation
The digital positioner receives the reference
variable (reference variable w) transmitted
cyclically over FOUNDATIONTM Fieldbus
and compares it to the travel or rotational
angle of the control valve (controlled vari-
able x). The positioner issues a pneumatic
signal pressure (output variable y) to correct
the valve position.
The Type 3730-5 Positioner communicates
with field devices, logic solvers, and process
control system over FOUNDATIONTM
Fieldbus protocol.
An integrated PID function block permits the
required process variable to be controlled
directly in the field.
The positioner is designed depending on the
corresponding accessories for direct attach-
ment to SAMSON Type 3277 Actuators or
for attachment to actuators according to
IEC 60534-6 (NAMUR).
Additionally, a coupling wheel included in
the accessories is required to transfer the ro-
tary motion for rotary actuators according to
VDI/VDE 3845.
Springless rotary actuators require a revers-
ing amplifier to allow the positioner to oper-
ate in either direction.
The positioner basically consists of a travel
sensor system that functions proportional to
the resistance, an analog i/p module with
downstream booster as well as the electronic
unit with a microcontroller.
The position of the valve is transmitted as an
angle of rotation to the travel sensor (2) and
to an analog PD controller (3).
Simultaneously, an A/D converter (4) trans-
mits the position of the valve to the
microcontroller (5). The PD compares this
actual position to the FOUNDATIONTM
Fieldbus reference variable transmitted cycli-
cally by the control equipment.
In case of a system deviation, the operation
of the i/p converter (6) is changed so that
the actuator (1) is filled or vented via the
downstream air capacity booster (7). This
causes the closure member of the control
valve to move to the position determined by
the reference variable.
The pneumatic air capacity booster (7) and
the pressure regulator (8) are provided with
supply air. An intermediate flow regulator
(9) with fixed settings is used to purge the
positioner and also guarantees trouble-free
operation of the pneumatic booster. The out-
put signal pressure supplied by the booster
can be limited over the software.
The volume restriction Q (10) is used to opti-
mize the positioner.
1.1 Additional equipment
Version with solenoid valve
If the operating voltage for the solenoid
valve (12) fails, the supply pressure for the
i/p module is vented to the atmosphere. The
positioner can no longer operate and the
control valve moves to the fail-safe position
determined by the actuator, independent of
the reference variable.
6EB 8384-5 EN
Design and principle of operation

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 over FOUNDATIONTM Fieldbus
can be issued.
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 FOUNDATIONTM
Fieldbus.
1.2 Communication
The positioner is completely controlled over
the digital signal transmission implemented
by FOUNDATIONTM Fieldbus specification
as per the draft E EN 50170/A1.
Data transmission is implemented as bit-syn-
chronous current modulation at a rate of
31.25 kbit/s over twisted-pair cables con-
forming to EN 61158-2.
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
EB 8384-5 EN 7
Design and principle of operation
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* EN 61158-2
interface module
14 Binary input, passive
15* Binary input, active
16 Display
17* Solenoid valve control
18* Galvanic isolation
19 D/A converter
20 Communication interface
* Optional
FOUNDATIONTM
Fieldbus

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.
Configuration using the NI-FBUSTM
Configurator
The NI-FBUSTM 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 FOUNDATIONTM Fieldbus.
The planning of whole FOUNDATIONTM
Fieldbus network can be performed using
the NI-FBUSTM Configurator.
8EB 8384-5 EN
Design and principle of operation

1.3 Technical data
EB 8384-5 EN 9
Design and principle of operation
Positioner
Nominal travel,
adjustable
Direct attachment to Type 3277: 3.6 to 30 mm, attachment acc. to IEC 60534-6:
3.6 to 200 mm or 24° to 100° opening angle for rotary actuators
Travel range Adjustable within the nominal travel, max. ratio 1 : 5
Bus connection
Feldbus interface acc. to EN 61158-2 bus-powered
Physical Layer Class: 113 (without explosion protection) und 111 (with ex. protection)
Field device acc. to FM 3610 Entity and FISCO.
Perm. operating voltage 9 to 32 V DC, power supply over bus line
Maximum operating cur-
rent 15 mA
Additional current
in case of failure 0 mA
Supply air
Supply pressure from 1.4 to 6 bar (20 to 90 psi),
Air quality acc. to ISO 8573-1 Edition 2001: Max. particle size and density: Class 4
Oil content: Class 3, pressure dew point: Class 3 or at least 10 K beneath the lowest
ambient temperature to be expected
Signal pressure (output) 0 bar up to supply pressure, limitable to 1.4/2.4/3.7 ±0.2 bar via software
Characteristic,
user-defined adjustable
over operating software
Linear/equal percentage/reverse equal percentage/butterfly valve linear/
butterfly valve eq. percentage/rotary plug valve linear/rotary plug valve eq. percenta-
ge/segmented ball valve linear/segmented ball valve eq.percentage
Deviation from terminal-based conformity ≤1 %
Hysteresis ≤0.3 %
Sensitivity ≤0.1 %
Direction of action Reversible
Air consumption, steady
state Independent from supply pressure approx. 110 ln/h
Air delivery
Actuator pressurized
Actuator vented
At ∆p = 6 bar: ≥8.5 mn
3/h, at ∆p = 1.4 bar: 3.0 mn 3/h KVmax (20 °C) = 0.09
at ∆p = 6 bar: ≤14.0 mn
3/h, at ∆p = 1.4 bar: 4.5 mn 3/h KVmax (20 °C) = 0.15
Permissible ambient
temperature
–40 to +80 °C, with metal cable gland
The limits specified in the EC Type Examination Certificate additionally apply for
explosion-protected devices.
Influences Temperature: ≤0.15 %/10 K Supply air: None
Vibration: ≤0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Electromagn. compatability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21
Explosion protection II 2 G EEx ia IIC T6 / II 2 D IP 65 T 80 °C
II 3 G EEx nA/nL II T6 / II 3 D IP 65 T 80 °C
Degree of protection IP 65

10 EB 8384-5 EN
Design and principle of operation
Binary contact 1
Input 5 to 30 V DC reverse polarity protection, static destruction limit 40 V / 5.8 mA,
current consumption 3.5 mA at 24 V, galvanically isolated
Signal Signal “0” at Ue > 5 V Signal “1” at Ue < 3 V
Binary contact 2 for floating contact
Switching input R < 100 Ω, contact loadability 100 mA, static destruction limit 20 V / 5.8 mA,
galvanically isolated
Solenoid valve SIL 4 approval acc. to IEC 61508
Input 24 V DC, max. 40 V, reverse polarity protection, static destruction limit 40 V;
Signal Signal "0" no pick-up ≤15 V Signal "1" safe pick-up >19 V
Service life >2 x 105switching cycles
Implementation in safety-
relevant systems in compli-
ance with IEC 61508
Probability of failure on demand of safety functions PFD < 2.8 x 10-7 for a confidence
level of 95 %.
The safe failure fraction (SFF) according to Table A1 in IEC 61508-2 is greater or
equal to 0.99.
The valves are therefore suitable for implementation in safety-related systems with a
hardware fault tolerance of 1 or 2 up to and including SIL 4.
Inductive limit switch
Type SJ 2SN Proximity
Switch For connection to switching amplifier acc. to EN 60947-5-6
Communication
(Local)
Software requirements
(SSP)
Over SAMSON SSP interface and serial interface adapter
SAMSON TROVIS-VIEW with database module 3730-5
(Bus communication)
Data transmission as per FOUNDATIONTM Fieldbus specification Communication
Profile Class: 31 PS, 32; Interoperability
tested according Interoperability Test System (ITK) Revision 4.6.
Materials
Housing:
External parts:
Die-cast aluminum GD AlSi12 acc. to DIN 1725 (3.2582), chromated and plastic-
coated, special version CrNiMo (1.4581);
Stainless steel 1.4571 and 1.4301.
Cable gland M20x1.5, black polyamide
Weight Approx. 1.0 kg