Samson TROVIS 3731-3 Service manual

Electropneumatic Ex d Positioner
Type 3731-3
With HART®communication
Mounting and
Operating Instructions
EB 8387-3 EN
Firmware version 1.3x
Edition November 2005
Fig. 1 · Type 3731-3

Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . 6
1.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Attachment to the control valve – Mounting parts and accessories . . . 10
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 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 32
4.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 34
4.2.2 SAFE – Fail-safe position . . . . . . . . . . . . . . . . . . . . . . . 35
5 Start-up – Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Adapting the display . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Limiting the signal pressure . . . . . . . . . . . . . . . . . . . . . . 36
5.3 Checking the operating range of the positioner . . . . . . . . . . . . . 37
5.4 Determining the fail-safe position . . . . . . . . . . . . . . . . . . . 37
5.5 Positioner initialization . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5.1 Initialization modes . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.6 Fault/failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.7 Zero calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.8 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 49
5.9 Start-up via local interface (SSP) . . . . . . . . . . . . . . . . . . . . 50
5.10 Start-up over HART®communication. . . . . . . . . . . . . . . . . . 50
6 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 51
6.1 Standard EXPERT diagnostics . . . . . . . . . . . . . . . . . . . . . 51
2EB 8387-3 EN
Contents

6.2 Extended EXPERT+diagnostics . . . . . . . . . . . . . . . . . . . . . 51
6.3 Classification of the status alarms and the condensed status . . . . . . . 52
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 54
9 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Setting with TROVIS-VIEW software – Parameter list. . . . . . . . . . 72
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.2 Starting TROVIS-VIEW and performing basic settings . . . . . . . . . . 73
10.3 Setting the parameters. . . . . . . . . . . . . . . . . . . . . . . . . 76
11 Parameter list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
12 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
EB 8387-3 EN 3
Contents

4EB 8387-3 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 8.
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 the positioner/vent opening
facing upwards. The vent opening must not be sealed when the positioner is
installed on site.
4
Proper shipping and appropriate storage are assumed.
4
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 8387-3 EN 5
Article code
Article code Type 3731-3 XXXXXX00000XX
Explosion protection
II 2 G EEx d IIC T6/II 2 G EEx de IIC T6
acc. to ATEX
EEx d IIC T6 acc. to FM/CSA
2
2
1
3
Optional additional equipment:
Position transmitter 0 1
Forced venting 0 5
Binary output (NAMUR/PLC) 0 6
EXPERT diagnostics
EXPERT+diagnostics
1
2
Electrical threaded connection M20x1.5
½ NPT 1 2
Special applications
None
Device compatible with paint 0 1
Special versions None 000

1 Design and principle of
operation
The electropneumatic Ex d positioner is
mounted to pneumatic control valves and is
used to assign the valve position (controlled
variable x) to the control signal (reference
variable w). The DC control signal received
from a control unit is compared to the travel
or rotational angle of the control valve and
the corresponding signal pressure (output
variable y) is issued.
The positioner is designed depending on the
corresponding accessories for direct attach-
ment to Type 3277 Actuators or for attach-
ment 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 included in the accessories to
permit the powered operation in either di-
rection.
The positioner basically consists of a travel
sensor system that functions proportional to
resistance, an analog i/p module with
downstream booster as well as the electronic
unit with a microcontroller. All parts are en-
closed in an Ex d housing. The electrical
cables are connected over a separate termi-
nal compartment which also has Ex d pro-
tection.
The position of the valve is transmitted as
linear travel motion or angle of rotation to
the travel sensor (2) and to an analog PD
controller (3). Simultaneously, an A/D con-
verter (4) transmits the position of the valve
to the microcontroller (5). The PD controller
compares the actual value with the 4 to
20 mA DC control signal issued by the con-
trol unit.
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.
Serial interface
The positioner is equipped with an interface
to allow the SAMSON TROVIS-VIEW Con-
figuration and Operator Interface software
to transmit data and parameters over a se-
rial interface adapter from the RS-232 inter-
face of a computer to the positioner.
Options
Forced venting: If there is no operating volt-
age at the corresponding terminals, the i/p
module is not actuated. The positioner
cannot operate anymore and the control
valve moves to the fail-safe position deter-
mined by the actuator, independent of the
reference variable.
Binary contact: The positioner has three in-
ternal binary signals which can be analyzed
over the A/B/C terminals. Two of these sig-
nals are assigned to the valve end positions
6EB 8387-3 EN
Design and principle of operation

and one signal to a fault alarm contact (con-
densed status).
The assignment of these signals to the
A/B/C terminals is determined over
Code 25.
Position transmitter: The position transmitter
(13) is a two-wire transmitter and issues the
travel sensor signal as a 4 to 20 mA signal
processed by the microcontroller. Since this
signal is issued independent of the
positioner’s input signal (min. current
3.8 mA), the actual travel/angle of rotation
is controlled in real-time. Additionally, the
position transmitter provides the possibility
of signaling a positioner fault over a signal
current of 2.4 mA or 21.6 mA.
1.1 Communication
The positioner is equipped with an interface
for HART®protocol (Highway Addressable
Remote Transducer) for communication pur-
poses. Data are transmitted in a superim-
posed frequency (FSK = Frequency Shift
Keying) on the existing signal loop for the 4
to 20 mA reference variable.
Either a HART®capable handheld commu-
nicator or a PC with FSK modem can be
used to establish communication and oper-
ate the positioner.
EB 8387-3 EN 7
Design and principle of operation
Fig. 2 · Functional diagram
%
S
mm
%
mm
w
x
G
PD
Serial
Interface 16
22
20
13
23
2
4
21
17
FSK
519
3
6
7
81
w
9
x
y
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
13* Analog position transmitter
16 Display
17* Control of
forced venting
19 D/A converter
20 Interface (SSP)
21 HART®modulation
22 Rotary pushbutton
23* Binary output
* Optional
Ex d enclosure

1.2 Technical data
8EB 8387-3 EN
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/nominal angle, max. ratio 1 : 5
Reference variable w Signal range 4 to 20 mA, 2-wire unit, reverse polarity protection,
min. span 4 mA, static destruction limit 40 V, internal current limit 60 mA
Minimum current 3.6 mA for display, 3.8 mA for operation
Load impedance ≤9 V corresponding to 450 Ωat 20 mA
Supply air
Supply pressure from 1.4 to 6 bar (20 to 90 psi),
Air quality acc. to ISO 8573-1 (edition 2004): 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.
percentage/segmented ball valve linear/segmented ball valve eq.percentage
Deviation from terminal-based conformity ≤1 %
Hysteresis ≤0.3 %
Sensitivity ≤0.1 %
Transit time Separately adjustable up to 240 seconds for supply air and exhaust air
Direction of action Reversible
Air consumption, steady
state Independent from supply pressure approx. 110 ln/h
Air delivery
Actuator pressurized
Actuator vented At Δp = 6 bar: ≥8.5 mn3/h, at Δp = 1.4 bar: 3.0 mn3/h KVmax (20 °C) = 0.09
at Δp = 6 bar: ≤14.0 mn3/h, at Δp = 1.4 bar: 4.5 mn3/h KVmax (20 °C) = 0.15
Permissible ambient
temperature
–40 to +80 °C
The limits specified in the EC Type Examination Certificate additionally apply for
explosion-protected devices.
Influences Temperature: ≤0.2 %/10 K Supply air: None
Vibration: ≤0.25 % up to 2000 Hz and 4 g acc. to IEC 770
Degree of protection IP 66
Electromagnetic
compatability Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21
Explosion protection II 2 G EEx d IIC T6 / II 2 G EEx de IIC T6 acc. to ATEX
EEx d IIC T6 acc. to FM/CSA

EB 8387-3 EN 9
Design and principle of operation
Optional binary output Software limit switch, galvanically isolated, optionally NAMUR EN 60947-5-6 or PLC
or fault alarm output
Signal status
Terminals B-C
Switching output AC/DC (PLC) Terminals A-B
Conductive/remaining voltage < 1.7 V Non-conducting/ ≥2.1 mA
Non-conducting/high resist. I < 100 μA Conductive/ ≤1.2 mA
Operating voltage Switch. capacity: 40 V DC/28 V/AC 0.3 A
Static destr. limit: 45 V DC/32 V/AC 0.4 A Only for connection to signal converter acc. to EN 60 957-5-6
Optional forced venting, galvanically isolated
Input 0 to 40 V DC/ 0 to 28 V AC, static destruction limit 45 V DC/ 32 V AC,
input resistance ≥7 kΩ
Signal Fail-safe position when
input voltage ≤3 V Normal operation when input voltage > 5 V
Optional analog
position transmitter Two-wire transmitter
Supply voltage 11 to 35 V DC, reverse polarity protection, static destruction limit 45 V
Output signal 4 to 20 mA
Direction of action Reversible
Operating range –1.25 to 103 % of the travel range, corresponding to 3.8 to 20.5 mA, optionally also
for fault alarm over 2.4 or 21.6 mA acc. to NAMUR Recommendation NE 43
Characteristic Linear
Hysteresis and
HF influence Same as positioner
Other influences Same as positioner
Fault alarm Can be issued with current signal 2.4 mA or 21.6 mA
Materials
Housing: Die-cast aluminum EN AC-AL-Si10Mg(Fe) acc. to DIN EN 1706, chromated and plastic coated,
External parts: Stainless steel 1.4301/1.4305/1.4310
Weight Approx. 2.5 kg
Communication (local) SAMSON SSP interface and serial interface adapter
Software requirements TROVIS-VIEW with database module 3731-3
Communication (HART) HART®field communication protocol
Software requirements
(HART)
For handheld communicator: device description for 3731-3,
For PC: DTM file acc. to Specification 1.2, suitable for integrating the positioner in frame
applications that supports the FDT/DTM concept (e.g. PACTware);
other integration options (e.g. AMS, PDM) available.

2 Attachment to the control
valve – Mounting parts and
accessories
The positioner can be attached either di-
rectly to a SAMSON Type 3277 Actuator or
according to IEC 60534-6 (NAMUR) to con-
trol valves with cast yokes or rod-type yokes
as well as to rotary actuators according to
VDI/VDE 3845.
For attachment to the various actuators, cor-
responding mounting parts and accessories
are required. These are listed with their or-
der numbers in Tables 1 to 5.
On mounting the positioner, use the assign-
ment between the lever and pin position
specified in the travel tables opposite.
The travels show the maximum setting range
at the positioner. The actual travel at the
valve is additionally restricted by the
fail-safe position selected and the required
actuator spring compression.
The positioner is standard equipped with the
lever M(pin position 35).
Note!
If the standard mounted lever M (pin posi-
tion 35) is replaced, the newly mounted le-
ver must be moved once all the way as far
as it will go in both directions to adapt it to
the internal measuring lever.
Note!
A signal pressure restriction must be in-
serted into the positioner when actuators
with less than 240 cm² diaphragm area are
used (see Table 6 on page 13).
The positioner is fitted with pneumatic con-
nections with ¼ NPT threads. In case, G ¼
threaded connections are required, the con-
necting plate (6) included in the accessories
must be attached.
10 EB 8387-3 EN
Attachment to the control valve – Mounting parts and accessories