Samson TROVIS 3731-3 Service manual

Translation of original instructions
EB 8387-3 EN
Firmware version 1.61
Edition May 2017
Type3731-3 Electropneumatic Exd Positioner
with HART®communication
EB + CD

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.
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
Department (aftersalesser[email protected]).
The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.
Denition 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
2 EB 8387-3 EN

Contents
EB 8387-3 EN 3
1 Safety instructions and measures ...................................................................6
1.1 Notes on possible severe personal injury .........................................................8
1.2 Notes on possible personal injury ...................................................................9
1.3 Notes on possible property damage................................................................9
2 Markings on the device ...............................................................................11
2.1 Nameplate..................................................................................................11
2.2 Article code.................................................................................................12
2.3 Firmware versions........................................................................................14
3 Design and principle of operation ................................................................15
3.1 Additional equipment...................................................................................17
3.2 Communication ...........................................................................................18
3.2.1 CongurationusingtheTROVIS-VIEWsoftware .............................................18
3.3 Accessories .................................................................................................19
3.4 Travel tables ................................................................................................22
3.5 Technical data .............................................................................................23
3.6 Dimensions in mm........................................................................................28
3.7 FixinglevelsaccordingtoVDI/VDE3845(September2010) ..........................29
4 Measures for preparation............................................................................31
4.1 Unpacking ..................................................................................................31
4.2 Transporting ................................................................................................31
4.3 Storage.......................................................................................................31
5 Mounting and start-up.................................................................................32
5.1 Mounting position........................................................................................32
5.2 Lever and pin position..................................................................................32
5.3 Type 3277-5 Actuator..................................................................................34
5.4 Type 3277 Actuator .....................................................................................36
5.5 Attachment according to IEC 60534-6 (NAMUR) ...........................................38
5.6 AttachmenttoType3510Micro-owValve ....................................................40
5.7 Attachment to rotary actuators ......................................................................42
5.8 Reversingamplierfordouble-actingactuators ..............................................44
5.8.1 Reversingamplier(1079-1118or1079-1119) ............................................46
5.9 Pneumatic connections..................................................................................47
5.10 Connecting the supply air.............................................................................47
5.10.1 Signal pressure connection ...........................................................................48
5.10.2 Signal pressure gauges ................................................................................48
5.10.3 Supply pressure ...........................................................................................48
5.10.4 Signal pressure (output)................................................................................49

Contents
4 EB 8387-3 EN
5.11 Electrical connections ...................................................................................49
5.11.1 Connecting the electrical power ....................................................................51
5.11.2 Establishing communication..........................................................................51
6 Operating controls and readings..................................................................54
6.1 Rotary pushbutton........................................................................................54
6.2 Serial interface ............................................................................................54
6.3 Readings.....................................................................................................55
6.4 HART®communication .................................................................................57
6.4.1 Dynamic HART® variables.............................................................................57
7 Operating the positioner..............................................................................59
7.1 Adapting the display direction ......................................................................59
7.2 Limiting the signal pressure...........................................................................60
7.3 Checking the operating range of the positioner ..............................................61
7.4 Determining the fail-safe position ..................................................................62
7.5 Initializing the positioner ..............................................................................63
7.5.1 Initialization based on maximum range (MAX)...............................................65
7.5.2 Initialization based on nominal range (NOM)................................................66
7.5.3 Initialization based on a manually selected range (MAN)................................69
7.5.4 Substitute calibration (SUB)...........................................................................71
7.6 Zero calibration...........................................................................................76
7.7 Reset to default settings.................................................................................77
8 Operation...................................................................................................79
8.1 Enabling and selecting parameters................................................................79
8.2 Operating modes.........................................................................................80
8.2.1 Automatic (AUTO) and manual (MAN) modes ...............................................80
8.2.2 Fail-safe position (SAFE)...............................................................................82
8.3 Fault/malfunction.........................................................................................82
8.3.1 Conrmingerrormessages...........................................................................84
9 Servicing.....................................................................................................85
9.1 Preparation for return shipment.....................................................................85
10 Malfunctions ...............................................................................................86
10.1 Emergency action ........................................................................................86
11 Decommissioning and disassembly ..............................................................86
11.1 Decommissioning.........................................................................................86
11.2 Removing the positioner ...............................................................................87

Contents
EB 8387-3 EN 5
11.3 Disposal......................................................................................................87
12 Appendix....................................................................................................87
12.1 After-sales service........................................................................................87
12.2 Code list......................................................................................................88
12.3 Error codes..................................................................................................98
12.4 Selecting the characteristic..........................................................................105
The functions of the EXPERTplus Valve Diagnostics are described in the Operating
Instructions uEB8389. EB8389 is included on the enclosed CD-ROM and is available
on our website.
Note

6 EB 8387-3 EN
Safety instructions and measures
1 Safety instructions and measures
Intended use
SAMSON'sTROVIS3731-3Positionerismountedonpneumaticcontrolvalvesandis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3731-3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speciedbySAMSON
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 are to 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 spe-
cialized training, their knowledge and experience as well as their knowledge of the applica-
ble standards.
Theexplosion-protectedversionsoftheType3731-3Positioneraretobehandlesonlyby
personnel who has undergone special training or instructions or who is authorized to work
on explosion-protected devices in hazardous areas.

EB 8387-3 EN 7
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, 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. They must observe all hazard
statements, warning and caution notes in these mounting and operating instructions, espe-
cially 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 level, it must be restricted using a suitable supply pressure reducing station.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
Operators are obliged to provide these mounting and operating instructions to the operating
personnel and to instruct them in proper operation. Furthermore, the operator must ensure
that operating personnel or third persons 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.

8 EB 8387-3 EN
Safety instructions and measures
Servicing explosion-protected devices
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de-
viceamarkofconformity.Inspectionbyaqualiedinspectorisnotrequiredifthemanufac-
turer performs a routine test on the device before putting it back into operation. Document
the passing of the routine test by attaching a mark of conformity to the device.
Referenced standards and regulations
ThedevicewithaCEmarkingfulllstherequirementsoftheDirectives2014/30/EUand
2011/65/EUaswellas2014/34/EUdependingontheversion(Type3731-321).Thedec-
larations of conformity are included at the end of these instructions.
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−OperatinginstructionsofEXPERTplusValveDiagnosticsuEB8389
−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 cause 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 performed by per-
sonnel who has undergone special training or instructions or who is authorized to
work on explosion-protected devices in hazardous areas.

EB 8387-3 EN 9
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 actuator stem 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.
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.
Risk of malfunction due to incorrect sequence during start-up.
The positioner can only work properly if the mounting and start-up are performed in the
prescribed sequence.
ÎPerformmountingandstart-upasdescribedinsection5.

10 EB 8387-3 EN
Safety instructions and measures
An incorrect electric signal will damage the positioner.
A current source must be used to provide the electrical power for 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 according to the prescribed terminal assignment.
Malfunction due to initialization not yet completed.
The initialization causes the positioner to be adapted to the mounting situation. After ini-
tialization is completed, the positioner is ready to use.
ÎInitializethepositioneronthe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.