Samson 3730-6 Service manual

Series 3730

Electropneumatic Positioner

Type 3730-6

with HART®communication and pressure sensors

Mounting and

Operating Instructions

EB 8384-6 EN (1300-1623)

Firmware version 1.01

Edition February 2012

Fig. 1 · Type 3730-6

2EB 8384-6 EN

DANGER!

indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING!

indicates a hazardous situation which, if not

avoided, could result in death or serious

injury.

NOTICE

indicates a property damage message.

Note: Supplementary explanations, informa-

tion and tips

Definitions of the signal words used in these instructions

Contents Page

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 6

2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 8

3.1 Safety function (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Valve diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Flow rate calculation. . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Type of application . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5.1 Configuration using TROVIS-VIEW 4 . . . . . . . . . . . . . . . . . . 12

3.6 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.7 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Attachment to the control valve – Mounting parts and accessories . . . 20

4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 26

4.3 Attachment to Type 3510 Micro-flow Valve with Type 3271-5 Actuator . 28

4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 30

4.4.1 Heavy-duty version . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 34

4.6 Attaching an external position sensor. . . . . . . . . . . . . . . . . . 34

4.6.1 Mounting the position sensor with direct attachment. . . . . . . . . . . 34

4.6.2 Mounting the position sensor with attachment according to IEC 60534-6 36

4.6.3 Mounting the position sensor to Type 3510 Micro-flow Valve . . . . . . 37

4.6.4 Mounting the position sensor to rotary actuators . . . . . . . . . . . . 38

4.7 Mounting the leakage sensor. . . . . . . . . . . . . . . . . . . . . . 39

4.8 Attaching positioners with stainless steel housings. . . . . . . . . . . . 40

4.9 Air purging function for single-acting actuators . . . . . . . . . . . . . 40

4.10 Required mounting parts and accessories. . . . . . . . . . . . . . . . 41

5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 45

5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 46

5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.2.1 Switching amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 48

EB 8384-6 EN 3

Contents

5.2.2 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 49

6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 52

6.1 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.2 HART®communication . . . . . . . . . . . . . . . . . . . . . . . . 54

6.3 Dynamic HART®variables . . . . . . . . . . . . . . . . . . . . . . . 54

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.1 Defining the valve closed position . . . . . . . . . . . . . . . . . . . 56

7.2 Setting the volume restriction Q . . . . . . . . . . . . . . . . . . . . 57

7.3 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.4 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 57

7.5 Checking the operating range of the positioner . . . . . . . . . . . . . 58

7.6 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.6.1 MAX – Initialization based on maximum range . . . . . . . . . . . . . 60

7.6.2 NOM – Initialization based on nominal range . . . . . . . . . . . . . 61

7.6.3 MAN – Initialization based on a manually selected OPEN position . . . 62

7.6.4 MAN2 – Initialization based on manually selected end positions. . . . . 64

7.6.5 SUB – Substitute calibration . . . . . . . . . . . . . . . . . . . . . . 65

7.6.6 Tuning the KP input filter . . . . . . . . . . . . . . . . . . . . . . . . 68

7.7 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.8 Settings for on/off valves . . . . . . . . . . . . . . . . . . . . . . . 69

7.9 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . . 71

8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 74

8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.2.1 Automatic and manual modes . . . . . . . . . . . . . . . . . . . . . 75

8.2.2 Fail-safe position (SAFE) . . . . . . . . . . . . . . . . . . . . . . . . 76

8.3 Malfunction/Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 77

9 Adjusting the limit switch . . . . . . . . . . . . . . . . . . . . . . . 78

9.1 Retrofitting an inductive limit switch. . . . . . . . . . . . . . . . . . . 80

10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

11 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 81

12 Firmware update (serial interface) . . . . . . . . . . . . . . . . . . . 81

13 Maintenance, calibration and work on equipment . . . . . . . . . . . 82

14 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4EB 8384-6 EN

Contents

15 Dimensions in mm . . . . . . . . . . . . . . . . . . . . . . . . . . 109

15.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . 110

16 Valve characteristic selection . . . . . . . . . . . . . . . . . . . . . 111

Certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

EB 8384-6 EN 5

Contents

1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start-up and opera-

tion of the positioner:

4The 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 dangers due to their specialized training, their knowledge and experience as

well as their knowledge of the applicable standards.

4Explosion-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.

4Any 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.

4If inadmissible motions or forces are produced in the actuator as a result of the supply

pressure, the supply pressure must be restricted by means of a suitable supply

pressure reducing station.

To avoid damage to any equipment, the following also applies:

4Do not operate the positioner with the back of the positioner/vent opening facing up-

wards.

The vent opening must not be sealed when the positioner is installed on site

4Proper shipping and appropriate storage are assumed.

4Do not ground electric welding equipment near to the positioner.

Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC

(ATEX) and 89/336/EEC (EMC).

The Declaration of Conformity is available on request.

6EB 8384-6 EN

Important safety instructions

Vent opening

2 Article code

Positioner Type 3730-6- xxxxxx x 0 x x 0 x 0 0

With HART®communication and pressure sensors

Explosion protection

ATEX: II 2G Ex ia IIC/IIB T6; II 2D Ex tb IIIC T6 IP 66 110

IECEx: Ex ia IIC/IIB T6; Ex d[ia] IIC/IIB T6; Ex tD A21 IP 66 T 80°C 111

GOST: 1Ex ia IIC T6 X, DIP A21 Ta80°C, IP 66 113

ATEX: II 3G Ex nA II T6; II 3G Ex ic IIC/IIB T6; II 3D Ex tc IIIC T 80°C IP 66 810

IECEx: Ex nA II T6; Ex nL IIC/IIB T6; Ex tD A22 IP 66 T 80°C 811

GOST: Ex nA II T6, Ex nL IIC T6, DIP A22 Ta80°C, IP 66 813

Options (additional equipment)

Inductive limit switch Without

With SJ2-SN

With SJ2-S1N

Venting function Without

Solenoid valve 24 V DC

Forced venting 24 V DC

Additional equipment Without

Position transmitter

Leakage sensor

Binary input

External position sensor Without

Including 10 m connecting cable

Prepared for connection, without sensor

Emergency shutdown 3.8 mA

4.4 mA

Housing material

Standard aluminum 1

Stainless steel 1.4581 2

Special applications

None 0

Compatible with paint 1

Exhaust air connection with ¼–18 NPT thread, back of positioner housing sealed 2

Attachment according to VDI/VDE 3847 6

Article code

EB 8384-6 EN 7

3 Design and principle of

operation

The electropneumatic positioner is attached

to pneumatic control valves. It is used to as-

sign the valve stem position (controlled vari-

able x) to the control signal (reference vari-

able w). The input signal received from a

control system is compared to the travel or

rotational angle of the control valve, and a

pneumatic signal pressure (output variable

y) is produced.

The positioner basically consists of an elec-

trical travel sensor system (2), an analog i/p

converter (6) with downstream air capacity

booster (7) and the electronics unit with a

microcontroller (5).

The standard positioner is fitted with three

binary contacts: A fault alarm output indi-

cates a fault to a control station and two

configurable software limit switches are

used to indicate the end positions of the

valve.

The valve position (x) is transmitted as a lin-

ear travel motion or an angle of rotation by

the pick-up lever and travel sensor (2) to an

analog PD controller (3). Simultaneously, an

A/D converter (4) transmits the position of

the valve to the microcontroller (5). The PD

controller compares this valve position to the

4 to 20 mA DC control signal supplied by

the controller after it has been converted by

the A/D converter (4). In case of a system

deviation, the actuator (1) is either vented or

filled with more air by changes to the i/p

converter (6). This causes the valve plug to

adopt the position corresponding to the ref-

erence variable (w).

The supply air is supplied to the air capacity

booster (7) and the pressure regulator (8).

An intermediate flow regulator (9) with fixed

settings is used to purge the positioner and

also guarantees trouble-free operation of the

air capacity booster. The output signal pres-

sure supplied by the booster can be limited

over the software. Both pressure sensors (23

and 24) monitors the supply pressure psand

the signal pressure pout.

The volume restriction Q (10) is used to opti-

mize the positioner.

The positioner is suitable for the following

types of attachment using the corresponding

accessories:

4Direct attachment to SAMSON

Type 3277 Actuator: Section 4.1

4Attachment to actuators acc. to

IEC 60534-6 (NAMUR): Section 4.2

4Attachment to Type 3510 Micro-flow

Valve: Section 4.3

4Attachment to rotary actuators acc. to

VDI/VDE 3845: Section 4.4

8EB 8384-6 EN

Design and principle of operation

EB 8384-6 EN 9

Design and principle of operation

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* Analog position transmitter or binary input

14 Software limit switches A1/A2

15 Fault alarm output A3

16 LCD

17* Solenoid valve control

18* Galvanic isolation

19 D/A converter

20 Communication interface

21 HART®modulation

22* Binary input BE

23 Pressure sensor for supply pressure ps

24 Pressure sensor for signal pressure pout

25* Forced venting

* Option

FSK

Serial

Interface 16

12 25

24 V DC

17 18

>12 V

Fig. 2 · Functional diagram

x1) depending

on version

> 3.8 mA

> 4.4 mA

3.1 Safety function (SIL)

The safety function is based on the shutdown

of the i/p converter (6). This causes the

pneumatic actuator to be vented and the

valve to move to its fail-safe position.

Monitoring of the input signal

The i/p converter is switched off when the

input signal of the positioner at terminals

+11/–12 falls below 3.8 mA or 4.4 mA de-

pending on the positioner version (a signal

range of 4 to 20 mA is required). See

Fig. 18 on page 48.

Monitoring the voltage supply

(version with forced venting and solenoid

valve)

The i/p converter and the solenoid valve

(when installed) are shut down whenever the

voltage at terminals +81/–82 falls below

12 V (an input voltage of 24 V DC is re-

quired). See Fig. 18 on page 48.

When the i/p converter is switched off by

the monitoring of the input signal or the volt-

age supply, the fail-safe position

is acti-

vated and is indicated on the positioner

display.

If required, the user can check the safety

function using the software.

For more details, refer to the Operating In-

structions EB 8389-1 EN on EXPERTplus

Valve Diagnostics.

3.2 Valve diagnostics

The EXPERTplus valve diagnostics are inte-

grated into the positioner. They provide in-

formation on the valve condition (see Ta-

ble 1) and generate status messages to

quickly pinpoint faults.

For more details, refer to the Operating In-

structions EB 8389-1 EN on EXPERTplus

Valve Diagnostics.

3.3 Flow rate calculation

Due to the differential pressure measurement

Dp out, EXPERTplus is able to calculate the

flow rate in a SAMSON Type 3241 or

Type 3251 Valve, provided all the parame-

ters regarding the medium and the process

have been defined in the positioner.

For more details, refer to the Operating In-

structions EB 8389-1 EN on EXPERTplus

Valve Diagnostics.

10 EB 8384-6 EN

Design and principle of operation

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