Samson TROVIS 3730-3 Service manual

Translation of original instructions
EB 8484-3 EN
Firmware version 2.00.13
TROVIS3730-3 Smart Positioner (HART®)
Edition August 2021

Definition of signal words
Hazardous situations which, if not avoided,
will result in death or serious injury
Hazardous situations which, if not avoided,
could result in death or serious injury
Property damage message or malfunction
Additional information
Recommended action
DANGER
!
WARNING
!
NOTICE
!
Note
Tip
EB 8484-3 EN
Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.
ÎFor the safe and proper use of these instructions, read them carefully and keep them for
later reference.
ÎIf you have any questions about these instructions, contact SAMSON‘s After-sales Service
([e-mail]).
Documents relating to the device, such as the mounting and operating
instructions, are available on our website at www.samsongroup.com >
Service & Support > Downloads > Documentation.

Contents
EB 8484-3 EN
1 Safety instructions and measures ................................................................1-1
1.1 Notes on possible severe personal injury ......................................................1-3
1.2 Notes on possible personal injury ................................................................1-4
1.3 Notes on possible property damage.............................................................1-4
1.4 Special instructions concerning explosion protection ......................................1-5
1.5 Warnings on the device..................................................................................6
2 Markings on the device ..............................................................................2-1
2.1 Nameplate .................................................................................................2-1
2.2 Options......................................................................................................2-1
2.3 Firmware versions.......................................................................................2-2
2.4 Article code................................................................................................2-2
3 Design and principle of operation ...............................................................3-1
3.1 Additional equipment..................................................................................3-1
3.1.1 Optional additional functions.......................................................................3-3
3.2 Mounting versions.......................................................................................3-4
3.3 CongurationusingtheTROVIS-VIEWsoftware ............................................3-5
3.4 Technical data ............................................................................................3-6
3.5 Dimensions in mm.....................................................................................3-12
3.6 FixinglevelsaccordingtoVDI/VDE3845(September2010) .......................3-16
4 Shipment and on-site transport ...................................................................4-1
4.1 Accepting the delivered goods .....................................................................4-1
4.2 Removingthepackagingfromthepositioner.................................................4-1
4.3 Transporting the positioner...........................................................................4-1
4.4 Storing the positioner ..................................................................................4-1
5 Installation.................................................................................................5-1
5.1 Installation conditions..................................................................................5-1
5.2 Preparation for installation...........................................................................5-2
5.3 Turning the positioner shaft..........................................................................5-2
5.4 Adjusting the lever and pin position..............................................................5-2
5.4.1 Travel tables ...............................................................................................5-4
5.5 Installing a volume restriction .......................................................................5-5
5.6 Positioner attachment ..................................................................................5-6
5.6.1 Direct attachment........................................................................................5-6
5.6.2 AttachmentaccordingtoIEC60534-6..........................................................5-8
5.6.3 AttachmenttoType3510Micro-owValve .................................................5-12
5.6.4 AttachmentaccordingtoVDI/VDE3847-1.................................................5-12
5.6.5 AttachmentaccordingtoVDI/VDE3847-2.................................................5-19

Contents
EB 8484-3 EN
5.6.6 AttachmentaccordingtoVDI/VDE3845 ....................................................5-26
5.6.7 Reversingamplierfordouble-actingactuators ...........................................5-30
5.6.8 Attachmentofexternalpositionsensor........................................................5-30
5.6.9 Attaching positioners with stainless steel housings........................................5-36
5.6.10 Air purging function for single-acting actuators ...........................................5-36
5.7 Establishingpneumaticconnections ............................................................5-37
5.7.1 Supplyair ................................................................................................5-38
5.7.2 Signalpressureconnection ........................................................................5-38
5.7.3 Signalpressurereading.............................................................................5-39
5.7.4 Supplypressure ........................................................................................5-39
5.8 Establishingelectricalconnections ..............................................................5-40
5.8.1 Cableentrywithcablegland .....................................................................5-41
5.8.2 Electricalpower ........................................................................................5-41
5.8.3 EstablishingHART®communication ............................................................5-46
5.8.4 SwitchingamplieraccordingtoEN60947-5-6 .........................................5-46
5.9 Accessories ..............................................................................................5-48
6 Operation..................................................................................................6-1
6.1 Rotarypushbutton.......................................................................................6-1
6.2 AIRTOOPEN/AIRTOCLOSEslideswitch....................................................6-2
6.3 Initialization key (INIT).................................................................................6-2
6.4 Display ......................................................................................................6-3
6.4.1 Display icons..............................................................................................6-4
7 Start-up and conguration..........................................................................7-1
7.1 Firststart-up ...............................................................................................7-2
7.2 Start-upsettings ..........................................................................................7-3
7.3 Enablingcongurationtochangeparameters................................................7-3
7.4 Start-upmenu.............................................................................................7-4
7.4.1 Settingtheactuatortype ..............................................................................7-4
7.4.2 Determiningthefail-safeposition .................................................................7-4
7.4.3 Specifyingthepinposition...........................................................................7-5
7.4.4 Settingthenominalrange............................................................................7-5
7.4.5 Selectingtheinitializationmode...................................................................7-6
7.4.6 Settingtheinitializationmode ......................................................................7-7
7.5 Initializingthepositioner .............................................................................7-9
7.6 Adjustingtheswitchingpoints....................................................................7-11
7.6.1 AdjustingtheCLOSEDposition .....................................................................12
7.6.2 AdjustingtheOPENposition.........................................................................12

Contents
EB 8484-3 EN
8 Operation..................................................................................................8-1
8.1 Changingthereadingdirectionofthedisplay ...............................................8-1
8.2 HART®communication ................................................................................8-2
8.2.1 DynamicHART® variables............................................................................8-3
8.3 Changingoperatingmode...........................................................................8-4
8.4 Performingzerocalibration .........................................................................8-4
8.5 Resettingthepositioner................................................................................8-5
9 Malfunctions ..............................................................................................9-1
9.1 Emergency action .......................................................................................9-6
10 Servicing..................................................................................................10-1
10.1 Cleaning the cover window........................................................................10-1
10.2 Firmware updates .....................................................................................10-2
10.3 Periodic inspection and testing of the positioner...........................................10-2
11 Decommissioning .....................................................................................11-1
12 Removal ..................................................................................................12-1
13 Repairs ....................................................................................................13-1
13.1 Servicing explosion-protected devices.........................................................13-1
13.2 ReturningdevicestoSAMSON ..................................................................13-1
14 Disposal...................................................................................................14-1
15 Certicates...............................................................................................15-1
16 Annex A (conguration instructions)..........................................................16-1
16.1 Code list...................................................................................................16-1
16.1.1 Structure of the main display......................................................................16-1
16.1.2 Menu structure and parameters (menu level) ...............................................16-1
16.2 Valvecharacteristicselection....................................................................16-21
17 Annex B...................................................................................................17-1
17.1 After-salesservice.....................................................................................17-1

EB 8484-3 EN 1-1
Safety instructions and measures
1 Safety instructions and measures
Intended use
TheSAMSONTROVIS3730-3Positionerismountedonpneumaticcontrolvalvesandused
to assign the valve position to the control signal. The device is designed to operate under ex-
actlydenedconditions(e.g.operatingpressure,temperature).Therefore,operatorsmusten-
sure that the positioner is only used in applications where the operating conditions corre-
spond to the technical data. In case operators intend to use the positioner in other applica-
tionsorconditionsthanspecied,contactSAMSON.
SAMSON does not assume any liability for damage resulting from the failure to use the de-
vice for its intended purpose or for damage caused by external forces or any other external
factors.
ÎRefertothetechnicaldataforlimitsandeldsofapplicationaswellaspossibleuses.
Reasonably foreseeable misuse
TheTROVIS3730-3Positionerisnot suitable for the following applications:
− Useoutsidethelimitsdenedduringsizingandbythetechnicaldata
Furthermore, the following activities do not comply with the intended use:
− Use of non-original spare parts
− Performing maintenance activities not described in these instructions
Qualications of operating personnel
Thepositionermustbemounted,startedupandservicedbyfullytrainedandqualiedper-
sonnel only; the accepted industry codes and practices must be observed. 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 hazards due to their specialized
training, their knowledge and experience as well as their knowledge of the applicable stan-
dards.
Explosion-protected versions of this device must be operated only by personnel who has un-
dergone special training or instructions or who is authorized to work on explosion-protected
devices in hazardous areas.

1-2 EB 8484-3 EN
Safety instructions and measures
Personal protective equipment
No personal protective equipment is required for the direct handling of the positioner. Work
on the control valve may be necessary when mounting or removing the device.
ÎObservetherequirementsforpersonalprotectiveequipmentspeciedinthevalvedocu-
mentation.
ÎCheck with the plant operator for details on further protective equipment.
Revisions and other modications
Revisions,conversionsorothermodicationsoftheproductarenotauthorizedbySAMSON.
They are performed at the user's own risk and may lead to safety hazards, for example. Fur-
thermore, the product may no longer meet the requirements for its intended use.
Safety features
Upon failure of the air supply or electric signal, the positioner vents the actuator, causing the
valve to move to the fail-safe position determined by the actuator.
Warning against residual hazards
Thepositionerhasdirectinuenceonthecontrolvalve.Toavoidpersonalinjuryorproperty
damage, plant operators and operating personnel must prevent hazards that could be
caused in the control valve by the process medium, the operating pressure, the signal pres-
sure or by moving parts by taking appropriate precautions. Plant operators and operating
personnel must observe all hazard statements, warning and caution notes in these mounting
and operating instructions, especially for installation, start-up and service work.
If inadmissible motions or forces are produced in the pneumatic actuator as a result of the
supply pressure, it must be restricted using a suitable supply pressure reducing station.
Responsibilities of the operator
Operators are responsible for proper use and compliance with the safety regulations. Opera-
tors are obliged to provide these mounting and operating instructions to the operating per-
sonnel and to instruct them in proper operation. Furthermore, operators must ensure that op-
erating personnel or third parties are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these mounting and operating instructions as
wellasthespeciedhazardstatements,warningandcautionnotes.Furthermore,theoperat-
ing personnel must be familiar with the applicable health, safety and accident prevention
regulations and comply with them.

EB 8484-3 EN 1-3
Safety instructions and measures
Referenced standards, directives and regulations
DeviceswithaCEmarkingfulllthefollowingrequirementsoftheDirectives:
− TROVIS3730-3:2011/65/EU,2014/30/EU
− TROVIS3730-3-110/-510/-810/-850:2011/65/EU,2014/30/EU,2014/34/EU
DeviceswithanEACmarkingfullltherequirementsofthefollowingRegulations:
− TROVIS3730-3:TRCU020/2011andTRCU012/2011withtheapplicableGOST
standards:
− ГОСТ31610.0-2014(IEC60079-0:2011
− ГОСТ31610.11-2014(IEC60079-11:2011)
− TROVIS3730-3-110/-510/-810/-850:TRCU020/2011
SeeAnnexfordeclarationsofconformityandEACcerticates.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
− Operating instructions for valve diagnostics: uEB8389-3
− The mounting and operating instructions of the components on which the positioner is
mounted (valve, actuator, valve accessories etc.).
1.1 Notes on possible severe personal injury
DANGER
!
Risk of fatal injury due to the formation of an explosive atmosphere.
Incorrect installation, operation or maintenance of the positioner in potentially explosive
atmospheres may lead to ignition of the atmosphere and ultimately to death.
ÎThefollowingregulationsapplytoinstallationinhazardousareas:EN60079-14
(VDE0165,Part1).
ÎInstallation, operation or maintenance of the positioner must only be performed by
personnel who has undergone special training or instructions or who is authorized
to work on explosion-protected devices in hazardous areas.

1-4 EB 8484-3 EN
Safety instructions and measures
1.2 Notes on possible personal injury
WARNING
!
Risk of personal injury due to moving parts on the valve.
During initialization of the positioner and during operation, the valve moves through its
entiretravelrange.Injurytohandsorngersispossibleiftheyareinsertedintothe
valve.
ÎDuringinitialization,donotinserthandsorngersintothevalveyokeanddonot
touch any moving valve parts.
Sudden loud noise when the pneumatic actuator vents.
The positioner mounted onto the control valve can cause the pneumatic actuator to vent.
A loud noise may occur during venting. This can cause hearing damage.
ÎWear hearing protection when working near the valve.
1.3 Notes on possible property damage
NOTICE
!
Risk of damage to the positioner due to incorrect mounting position.
ÎDo not mount the positioner with the back of the device facing upward.
ÎDo not seal or restrict the vent opening when the device is installed on site.
An incorrect electric signal will damage the positioner.
A current source must be used to power the positioner.
ÎOnly use a current source and never a voltage source.
Incorrect assignment of the terminals will damage the positioner and will lead to mal-
function.
For the positioner to function properly, the prescribed terminal assignment must be ob-
served.
ÎConnect the electrical wiring to the positioner according to the prescribed terminal
assignment.

EB 8484-3 EN 1-5
Safety instructions and measures
Malfunction due to initialization not yet completed.
The initialization causes the positioner to be calibrated to adapt it to the mounting situa-
tion. After initialization is completed, the positioner is ready for use.
ÎInitializethepositioneronrststart-up.
ÎRe-initializepositionerafterchangingthemountingposition.
Risk of positioner damage due to incorrect grounding of the electric welding
equipment.
ÎDo not ground electric welding equipment near to the positioner.
1.4 Special instructions concerning explosion protection
If a part of the device on which the explosion protection is based needs to be serviced, the
devicemustnotbeputbackintooperationuntilaqualiedinspectorhasassesseditaccord-
ingtoexplosionprotectionrequirements,hasissuedaninspectioncerticate,orgiventhe
deviceamarkofconformity.Inspectionbyaqualiedinspectorisnotrequiredifthemanu-
facturer performs a routine test on the device before putting it back into operation and the
passing of the routine test is documented by attaching a mark of conformity to the device.
Replaceexplosion-protectedcomponentsonlywithoriginal,routine-testedcomponentsbythe
manufacturer.
Devices that have already been operated outside hazardous areas and are intended for fu-
ture use inside hazardous areas must comply with the safety requirements placed on serviced
devices.Beforebeingoperatedinsidehazardousareas,testthedevicesaccordingtothe
specicationsforservicingexplosion-protecteddevices.
Maintenance, calibration and work on equipment
ÎOnlyuseintrinsicallysafecurrent/voltagecalibratorsandmeasuringinstrumentsforin-
terconnection with intrinsically safe circuits to check or calibrate the equipment inside or
outside hazardous areas.
ÎObservethemaximumpermissiblevaluesspeciedinthecerticatesforintrinsicallysafe
circuits.

6 EB 8484-3 EN
Safety instructions and measures
Equipment with type of protection ExnA
ÎInequipmentoperatedwithtypeofprotectionExnA(non-sparkingequipment),onlycon-
nect, isolate or switch circuits while energized during installation, maintenance or repair.
ÎUsecertiedcableglandsandblankingplugswithappropriatetypeofprotectionand
IPrating≥6Xandsuitableforthecertiedtemperaturerange.
ÎConnectthesignalcircuitusingscrewterminals(terminal11/12)forelectricalconductors
withawirecross-sectionfrom0.2to2.5mm².Thetighteningtorqueis0.5to0.6Nm.
Equipment with type of protection Ext
ÎInequipmentoperatedwithtypeofprotectionExt(protectionbyenclosure),onlycon-
nect, isolate or switch circuits while energized during installation, maintenance or repair.
ÎWhile working on the device during operation in potentially explosive dust atmospheres,
be aware that opening the housing cover may cause the explosion protection to become
ineffective.
ÎUsecertiedcableglandsandblankingplugswithappropriatetypeofprotectionand
IPrating≥6Xandsuitableforthecertiedtemperaturerange.
ÎToconnectthesignalcircuit,usescrewterminals(terminal11/12)forelectricalconduc-
torswithawirecross-sectionfrom0.2to2.5mm².Thetighteningtorqueis0.5to
0.6Nm.
1.5 Warnings on the device
Warning Meaning of the warning
Warning against sudden loud noise
The positioner mounted onto the control valve can cause the pneumatic actu-
ator to vent. A loud noise may occur during venting. This can cause hearing
damage.

EB 8484-3 EN 7

8 EB 8484-3 EN

EB 8484-3 EN 2-1
Markings on the device
2 Markings on the device
2.1 Nameplate
Explosion-protected version Version without explosion protection
See technical data for ambient temperature
SAMSON TROVIS 3730-3
Supply
Input
HART Positioner
R
SAMSON AG D-60314 Frankfurt Made in Germany
Hardware
Firmware
Model 3730-3
Var.-ID Serial no.
2
3 4
67
5
1
* See EU Type Exam. Certificate for further values
10
9
SAMSON TROVIS 3730-3
Supply
Input
HART Positioner
R
SAMSON AG D-60314 Frankfurt Made in Germany
Hardware
Firmware
Model 3730-3
Var.-ID Serial no.
2
3 4
67
5
1
8
1 Supply pressure
2 Signal range
3 Firmware version
4Hardwareversion
5 Model number
6CongurationID
7Serial number
8Conformity
9 Type of protection for explosion-protected devices
10 Temperaturelimitsinthetestcerticatesforexplosion-protecteddevices
11 Monthandyearofmanufacture(mm/YYYY)
1) Date, Data, Дата or 날짜
Date1)
11
2.2 Options
IfoptionmodulesareinstalledintheTROVIS3730-3Positioner,alabeltoidentifythemod-
uleisafxedtothedevice:
Serial no.
Model
SAMSON TROVIS 3730 Module
1
2
3
1 Option's function
2 Model number
3 Serial number

2-2 EB 8484-3 EN
Markings on the device
2.3 Firmware versions
Firmware revisions
Old New
2.00.11 2.00.13
Initialization optimized
2.4 Article code
Positioner TROVIS3730-3- x x x 0 x x x x x 0 x x 0 x x x x 0 0 x x x x x
WithLCD,autotune,HART® communication
Explosion protection
Without 0 0 0
ATEX
II2GExiaIICT6Gb/
II2DExiaIIICT85°CDbIP66 110
Exdb[ia](witheldbarrier) 390
II2DExtbIIICT85°CDb 510
II3GExnAIICT6Gc/
II3DExtbIIICT85°CGb 81 0
II3GExnAIICT6Gc 8 5 0
IECEx
ExiaIICT4/T6Gb/
ExiaIIICT85°CDb 111
ExtbIIICT85°CDb 511
ExtbIIICT85°CDb/
ExnAIICT4/T6Gc 81 1
ExnAIICT6Gc 8 5 1
EAC 1ExiaIICT6...T4GbX
ExiaIIICT85°CDbX 113
Option A
Without 0
Positiontransmitter4to20mA 1
Binaryinput24VDC 2
OptionB
Without 0
Binaryinput24VDC 2
Forced venting 3

EB 8484-3 EN 2-3
Markings on the device
Positioner TROVIS3730-3- x x x 0 x x x x x 0 x x 0 x x x x 0 0 x x x x x
Option C
Without 0
2xSoftwarelimitswitches+binaryoutput(PLC) 1
2xSoftwarelimitswitches+binaryoutput(NAMUR) 2
2xInductivelimitswitches+Binaryoutput(NAMUR);
–50to+85°C
4
Option D
Without 0
External travel sensor with M12x1 connector;
with10mconnectingcable 1
Prepared for external travel sensor with M12x1 connector 2
Field barrier
Without 0
PreparedforType3770FieldBarrier 3
Emergency shutdown
3.8mA 0
Electrical connection
Two M20x1.5 (one cable gland, one blanking plug) 1
Housingmaterial
AluminumENAC-44300DF(standard) 0
Stainlesssteel1.4408 1
Cover
With round window 1
Without window 2
Housingversion
Standard 0 0
WithadditionalventholeandVDI/VDE3847adapter;withouttravelpick-offparts 2 0
With additional vent hole 2 1
Permissible ambient temperature
Standard:–20to+85°C 0
–40to+85°Cmetalcablegland 1
–55to+85°C,low-temperatureversionwithmetalcablegland 2

2-4 EB 8484-3 EN
Markings on the device
Positioner TROVIS3730-3- x x x 0 x x x x x 0 x x 0 x x x x 0 0 x x x x x
Hardwareversion
1.00.00 9 9
Firmware version
2.00.13 9 8

EB 8484-3 EN 3-1
Design and principle of operation
3 Design and principle of oper-
ation
ÎSeeFig.3-1
TheTROVIS3730-3ElectropneumaticPosi-
tioner is mounted on pneumatic control
valves and used to assign the valve position
(controlled variable x) to the control signal
(set point w). The positioner compares the
electric control signal of a control system to
the travel or opening angle of the control
valve and issues a signal pressure for the
pneumatic actuator.
The positioner mainly consists of a non-
contact travel sensor system (2), pneumatics
and the electronics with the microcontroller
(4). The valve position is transmitted either as
an angle of rotation or a travel to the pick-
up lever, from there to the travel sensor (2)
and forwarded to the microcontroller (4).
The PID algorithm in the microcontroller
compares the valve position measured by the
travelsensor(2)tothe4to20mADC
control signal issued by the control system
afterithasbeenconvertedbytheA/D
converter (3).
In case of a set point deviation, the activa-
tionofthei/pmodule(7)ischangedsothat
the actuator of the control valve (1) is pres-
surized or vented accordingly over the
downstream booster (6). As a result, the clo-
sure member of the valve (e.g. plug) is
moved to the position determined by the set
point.
The positioner is operated by a rotary push-
button (10) for menu navigation on the
plain-text display (11).
TheextendedEXPERTplusdiagnosticsarein-
tegrated into the positioner. They provide in-
formation on the control valve and positioner
and generate diagnostic and status messag-
es, which allow faults to be pinpointed
quickly.
3.1 Additional equipment
Volume restriction
The volume restriction Q serves to adapt the
air output capacity to the size of the actua-
tor.
The volume restriction is a screw restriction
which is screwed into the signal pressure
output of the positioner (or output of the
pressure gauge bracket or connecting plate).
ÎWe recommend using a volume restric-
tion
− For linear actuators with a transit
time<1s(e.g.withanactuatorarea
smallerthan240cm²)
− For rotary actuators with a volume of
lessthan300cm³
ÎActuatorswithatransittime≥1sdonot
requiretheairowratetoberestricted.

3-2 EB 8484-3 EN
Design and principle of operation
E
E
E
µC
FSK
#
#B
C
A
#
Exhaust Supply 9 Output 38
w
y
x
Serial Interface
M
1
2
M.1
M.4
M.5
M.6
M.2
M.3
3
4
8
7
56
12
910
1 Control valve
2 Travel sensor
3A/Dconverter
4 Microcontroller
5 Pressure reducer
6 Air booster
7 i/pconverter
8 D/Aconverter
9 Communication interface
10 Rotarypushbutton
11 Display
12 HART®connection
A Option A
B OptionB
C Option C
M Available options
M.1 Forcedventing(SlotBonly)
M.2 Position transmitters
M.3 Binaryinput
M.4 Softwarelimitswitcheswithbinaryoutput(PLC)
M.5 Softwarelimitswitcheswithbinaryoutput(NAMUR)
M.6 Inductivelimitswitcheswithbinaryoutput(NAMUR)
11
Fig.3-1: Block diagram