Samson TROVIS SAFE 3730-6 Service manual

Translation of original instructions
EB 8384-6S EN
Firmware version 1.12
Series3730
TROVIS SAFE3730-6 Electropneumatic Positioner
with HART®communication and pressure sensors
Edition December 2017

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 8384-6S EN

Contents
EB 8384-6S EN 3
1 Safety instructions and measures ...................................................................7
1.1 Notes on possible severe personal injury .......................................................10
1.2 Notes on possible personal injury .................................................................10
1.3 Notes on possible property damage..............................................................11
2 Markings on the device ...............................................................................13
2.1 Nameplate..................................................................................................13
2.2 Article code.................................................................................................14
2.3 Firmware versions........................................................................................15
3 Design and principle of operation ................................................................17
3.1 Safety function (SIL)......................................................................................18
3.2 Type of application.......................................................................................19
3.3 Mounting versions........................................................................................19
3.4 Additional equipment...................................................................................19
3.5 Communication ...........................................................................................21
3.6 CongurationusingtheTROVIS-VIEWsoftware .............................................21
3.7 Device overview and operating controls.........................................................21
3.8 Accessories .................................................................................................23
3.8.1 Travel tables ................................................................................................28
3.9 Technical data .............................................................................................29
3.10 Dimensions in mm........................................................................................35
3.10.1 FixinglevelsaccordingtoVDI/VDE3845(September2010) ..........................39
4 Measures for preparation............................................................................41
4.1 Unpacking ..................................................................................................41
4.2 Transporting ................................................................................................41
4.3 Storage.......................................................................................................41
5 Mounting and start-up.................................................................................43
5.1 Mounting position........................................................................................43
5.2 Lever and pin position..................................................................................43
5.3 Direct attachment.........................................................................................46
5.3.1 Type3277-5Actuator ..................................................................................46
5.3.2 Type3277Actuator .....................................................................................48
5.4 AttachmentaccordingtoIEC60534-6...........................................................50
5.5 AttachmentaccordingtoVDI/VDE3847-1....................................................52
5.6 AttachmentaccordingtoVDI/VDE3847-2....................................................56
5.6.1 Versionforsingle-actingactuator ..................................................................58
5.6.2 Versionfordouble-actingactuator.................................................................60
5.7 AttachmenttoType3510Micro-owValve ....................................................64

Contents
4 EB 8384-6S EN
5.8 Attachment to rotary actuators ......................................................................64
5.8.1 Heavy-duty version ......................................................................................66
5.9 Reversingamplierfordouble-actingactuators ..............................................70
5.9.1 Reversingamplier(1079-1118or1079-1119) ............................................70
5.10 Attachment of external position sensor...........................................................72
5.10.1 Mounting the position sensor with direct attachment........................................73
5.10.2 MountingthepositionsensorwithattachmentaccordingtoIEC60534-6 .........75
5.10.3 MountingthepositionsensortoType3510Micro-owValve...........................76
5.10.4 Mounting on rotary actuators........................................................................77
5.11 Mounting the leakage sensor ........................................................................78
5.12 Retrottinganinductivelimitswitch ...............................................................79
5.13 Attaching positioners with stainless steel housings...........................................80
5.14 Air purging function for single-acting actuators..............................................80
5.15 Pneumatic connections..................................................................................83
5.15.1 Connecting the supply air.............................................................................83
5.15.2 Output signal display ...................................................................................84
5.15.3 Supply pressure ...........................................................................................84
5.15.4 Signal pressure (output)................................................................................85
5.16 Electrical connections ...................................................................................85
5.16.1 Connecting the electrical power ....................................................................87
5.16.2 SwitchingamplieraccordingtoEN60947-5-6 ............................................88
5.16.3 Establishing communication..........................................................................88
6 Operation...................................................................................................91
6.1 Serial interface ............................................................................................93
6.2 HART®communication .................................................................................93
6.3 DynamicHART® variables.............................................................................94
7 Operating the positioner..............................................................................97
7.1 Determining the fail-safe position ..................................................................98
7.2 Adjusting the volume restriction Q.................................................................98
7.3 Adapting the display direction ......................................................................99
7.4 Limiting the signal pressure...........................................................................99
7.5 Checking the operating range of the positioner ............................................100
7.6 Initialize the positioner ...............................................................................101
7.6.1 MAX – Initialization based on maximum range............................................104
7.6.2 NOM – Initialization based on nominal range .............................................105
7.6.3 MAN – Initialization based on a manually selected OPEN position................106
7.6.4 MAN2 – Initialization based on manually selected end positions ...................108

Contents
EB 8384-6S EN 5
7.6.5 SUB – Substitute calibration ........................................................................109
7.6.6 TuningtheKPinputlter .............................................................................113
7.7 Zero calibration.........................................................................................114
7.8 On/offapplications ...................................................................................115
7.8.1 Selecting the type of application..................................................................118
7.9 Adjusting inductive limit switch....................................................................119
7.10 Resettodefaultsettings...............................................................................121
7.11 Enabling and selecting parameters..............................................................124
7.12 Operating modes.......................................................................................125
7.12.1 Automatic and manual modes ....................................................................125
7.12.2 Fail-safe position (SAFE).............................................................................126
8 Servicing...................................................................................................127
8.1 Firmware update........................................................................................127
8.2 Preparation for return shipment...................................................................128
9 Malfunctions .............................................................................................129
9.1 Conrmingerrormessages.........................................................................130
9.2 Emergency action ......................................................................................130
10 Decommissioning and removal ..................................................................131
10.1 Decommissioning.......................................................................................131
10.2 Removingthepositioner .............................................................................131
10.3 Disposal....................................................................................................131
11 Annex.......................................................................................................133
11.1 After-sales service......................................................................................133
11.2 Certicates ................................................................................................133
11.3 Code list....................................................................................................134
11.4 Error codes................................................................................................145
11.5 Selecting the characteristic..........................................................................153
 Certicates ................................................................................................155

6 EB 8384-6S EN
The functions of the EXPERTplus Valve Diagnostics are described in the Operating Instructions
uEB8389-1S. EB8389-1SEN is included on the enclosed CD-ROM and is available on
our website.
Note

EB 8384-6S EN 7
Safety instructions and measures
1 Safety instructions and measures
Intended use
SAMSON'sTROVISSAFE3730-6Positionerismountedonpneumaticcontrolvalvesand
used to assign the valve position to the control signal. The device is designed to operate un-
derexactlydenedconditions(e.g.operatingpressure,temperature).Therefore,operators
must ensure that the positioner is only used in applications where the operating conditions
correspond to the technical data. In case operators intend to use the positioner in other ap-
plications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SAFE3730-6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 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 hazards due to their specialized training, their knowledge and expe-
rience as well as their knowledge of the applicable standards.
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.

8 EB 8384-6S 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.Anyhazardsthatcouldbecausedin
the valve by the process medium, the signal pressure or by moving parts are to be prevented
by taking appropriate precautions. They 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.
Explosion protection
−Explosive dust atmospheres of zone21 or zone22
ThefollowingappliestotypeofprotectionExiincombustibledustatmospheres:
Ifintrinsicsafetyisimpairedbytheinuenceofdust,anenclosurecomplyingwith
Clause6.1.3ofEN60079-11withatleastindegreeofprotectionIP5Xmustbeused.
TherequirementsaccordingtoClause6.1.3applytothecableglandsaccordingly.The
degreeofingressprotectionisveriedbyatestaccordingtoIEC60529andEN60079-
0(e.g.performedbyVDE).
For use in the presence of combustible dust in compliance with type of protection
ExtbIIIC(protectionbyenclosure),observeClause5.6.3ofEN60079-14.

EB 8384-6S EN 9
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
according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 manufacturer performed a routine test on the device before putting it back into op-
eration. Document the passing of the routine test 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 used outside hazardous areas and are intended for fu-
ture use inside hazardous areas must comply with the safety requirements placed on ser-
viced devices. Before being operated inside hazardous areas, test the devices according
tothespecicationsforservicingexplosion-protecteddevices.
EN60079-17appliestoservicingexplosion-protecteddevices.
−Maintenance, calibration and work on equipment
Observethemaximumpermissiblevaluesspeciedinthecerticatesforintrinsicallysafe
circuits to ensure that components relevant to explosion protection are not damaged.
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.
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.Thedeclarationsofconfor-
mity are included at the end of these instructions.

10 EB 8384-6S EN
Safety instructions and measures
Referenced documentation
The following documents apply in addition to these mounting and operating instructions:
−Operating instructions for valve diagnostics: uEB8389-1S
−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.
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.