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Samson 3730 Series Mounting And Operating Instructions

Electropneumatic positioner with pressure sensors, communication: hart
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EB 8384-6 EN
Translation of original instructions
Old design
New design
Series 3730
Type 3730-6 Electropneumatic Positioner
with pressure sensors, communication: HART
®
Firmware version 1.12
Edition October 2020

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Summary of Contents for Samson 3730 Series

  • Page 1 EB 8384-6 EN Translation of original instructions Old design New design Series 3730 Type 3730-6 Electropneumatic Positioner with pressure sensors, communication: HART ® Firmware version 1.12 Edition October 2020...
  • Page 2 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.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ..............1-1 Notes on possible severe personal injury ............1-4 Notes on possible personal injury ..............1-4 Notes on possible property damage .............1-5 Special instructions concerning explosion protection ........1-6 Markings on the device ................2-1 Nameplate ....................2-1 Article code ....................2-2 Firmware versions ..................2-4 Design and principle of operation ...............3-1 Additional equipment ..................3-2...
  • Page 4 Contents 5.5.1 Mounting the position sensor with direct attachment ........5-31 5.5.2 Mounting the position sensor with attachment according to IEC 60534-6 ..5-32 5.5.3 Mounting the position sensor to Type 3510 Micro-flow Valve ......5-34 5.5.4 Mounting on rotary actuators ..............5-35 Mounting the leakage sensor ..............5-36 5.7 Retrofitting inductive limit switch ..............5-37 5.8 Mounting positioners with stainless steel housings ........5-38 Air purging function for single-acting actuators ...........5-38 5.10 Connecting the air supply ................5-40 5.10.1...
  • Page 5 10.5 Periodic inspection and testing of the positioner ...........10-2 Decommissioning ..................11-1 Removal ....................12-1 Repairs ....................13-1 13.1 Servicing explosion-protected devices ............13-1 Returning devices to SAMSON ...................13-1 Disposal ....................14-1 Certificates ....................15-1 Annex A (configuration instructions) ............16-1 16.1 Parameters and functions ................16-1 16.1.1 Error codes .....................16-12...
  • Page 6 EB 8384-6 EN...

  • Page 7: Safety Instructions And Measures

    In case operators intend to use the positioner in other applications or con- ditions than specified, 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.
  • Page 8 Î Observe the requirements for personal protective equipment specified in the valve docu- mentation. Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications 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.
  • Page 9 Safety instructions and measures Referenced standards, directives and regulations Devices with a CE marking fulfill the following requirements of the Directives: − Type 3730-6: 2014/30/EU, 2011/65/EU − Type 3730-6-110, -210, -510, -810: 2014/30/EU, 2014/34/EU, 2011/65/EU Devices with an EAC marking fulfill the following requirements of the Regulations: − Type 3730-6: TR CU 020/2011 − Type 3730-6-113, -213, -813: TR CU 012/2011 with the applicable GOST standards: – ГОСТ 31610.11-2014 (IEC 60079-11:2011) – ГОСТ 31610.15-2012/МЭК 60079-15:2005 – ГОСТ 31610.0-2014 (IEC 60079-0:2011) – ГОСТ IEC 60079-1-2011 – ГОСТ IEC 60079-31-2010 See the 'Certificates' section for the declarations of conformity and EAC certificates. Referenced documentation The following documents apply in addition to these mounting and operating instructions: −...

  • Page 10: Notes On Possible Severe Personal Injury

    Safety instructions and measures 1.1 Notes on possible severe personal injury DANGER Risk of fatal injury due to the ignition 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. Î...

  • Page 11: Notes On Possible Property Damage

    Safety instructions and measures 1.3 Notes on possible property damage NOTICE Risk of damage to the positioner due to incorrect mounting position. Î Do not mount the positioner with the back of the device facing upward. Î Do not seal or restrict the vent opening when the device is installed on site. An incorrect electric signal will damage the positioner.

  • Page 12: Special Instructions Concerning Explosion Protection

    Safety instructions and measures Incorrect cleaning will damage the window. The window is made of Makrolon and will be damaged when cleaned with abrasive ® cleaning agents or agents containing solvents. Î Do not rub the window dry. Î Do not use any cleaning agents containing chlorine or alcohol or abrasive cleaning agents.
  • Page 13 They must be subjected to testing according to the specifications in EN 60079-19. – EN 60079-19 applies to servicing explosion-protected devices. – Use the protective cable designed by SAMSON when interconnecting non-intrin- sically safe set point calibrators with intrinsically safe equipment for repair, cali- bration etc. to ensure that components relevant to explosion protection are not damaged. EB 8384-6 EN...
  • Page 14 EB 8384-6 EN...

  • Page 15: Markings On The Device

    Markings on the device 2 Markings on the device 2.1 Nameplate Version without explosion Explosion-protected version protection SAMSON 3730 - 6 SAMSON 3730 - 6 Date  1) Digital HART Positioner ® Digital HART Positioner ® Supply Supply 1 Supply pressure...

  • Page 16: Article Code

    Markings on the device 2.2 Article code Positioner Type 3730-6- x x x x x x x 0 x x 0 x 0 0 With display and autotune, HART communication, 4 to 20 mA set point, ® two software limit contacts, one fault alarm contact Explosion protection Without 0 0 0 ATEX II 2 G Ex ia IIC T6 Gb; II 2 D Ex ia IIIC T80 °C Db 1 1 0...
  • Page 17 Markings on the device Positioner Type 3730-6- x x x x x x x 0 x x 0 x 0 0 Additional equipment Without Position transmitter Leakage sensor (including cable and fixing screw) Binary input External position sensor Without With, including 10 m connecting cable Prepared for connection, without sensor Function Standard (control valves) Emergency shutdown 3.8 mA 4.4 mA...

  • Page 18: Firmware Versions

    Markings on the device 2.3 Firmware versions Firmware revisions 1.0x 1.10 A positioner that has not yet been initialized has 'Out of specification' NAMUR status (previ- ously 'Failure'). Default settings of diagnostic parameters revised u EB 8389-1. 1.10 1.11 A positioner that has not yet been initialized assumes the 'Out of specification' NAMUR sta- tus ('Failure' in version 1.10 and lower). Default values of the dynamic test adapted to the positioner series. Other production-related revisions.

  • Page 19: Design And Principle Of Operation

    Design and principle of operation 3 Design and principle of opening angle of the control valve and issues a signal pressure (output variable y) for the operation pneumatic actuator. Î See Fig. 3-1 The positioner consists of a travel sensor sys- The electropneumatic positioner is mounted tem (2) proportional to resistance, an analog on pneumatic control valves and used to as- i/p converter (6) with a downstream air sign the valve position (controlled variable x)

  • Page 20: Additional Equipment

    Design and principle of operation 3.1 Additional equipment cates a fault to the control room and two configurable software limit contacts are used to indicate the end positions of the valve. Inductive limit contact The valve position (x) is transmitted as a In this version, the rotary shaft of the posi- either an angle of rotation or travel to the tioner carries an adjustable tag which actu- pick-up lever and to the travel sensor (2) and...
  • Page 21 The positioner changes from the auto- accessories: matic mode (AUTO) to the manual − Direct attachment to SAMSON mode (MAN) or vice versa. Type 3277 Actuator This function is not performed if the posi- − Attachment to actuators according to tioner is in the fail-safe position mode IEC 60534-6...

  • Page 22: Communication

    SUPPORT > Downloads > TROVIS-VIEW. supported by the Type 3730-6 Positioner Further information on TROVIS-VIEW (e.g. can be found on the SAMSON website system requirements) is available on our (u www.samsongroup.com > SERVICE & website and in the Data Sheet u T 6661.

  • Page 23: Technical Data

    Design and principle of operation 3.5 Technical data Table 3-1: Type 3730-6 Electropneumatic Positioner Type 3730-6 Positioner The listed technical data for the explosion-protected devices may be further restricted by the limits specified in the test certificates. Travel Adjustable Direct attachment to Type 3277 Actuator: 3.6 to 30 mm Attachment according to IEC 60534-6-1: 3.6 to 300 mm...
  • Page 24 • Triggered by the set point, emergency venting depending on positioner version at ≤3.8 mA or ≤4.4 mA • By the optional solenoid valve, emergency venting at 0 V • By the optional forced venting function, emergency venting at <12 V Communication (local) SAMSON SSP interface and serial interface adapter, software requirements (SSP): TROVIS-VIEW with database module 3730-6 Communication (HART HART field communications protocol · Impedance in HART frequency range: ® ® ® Receiving 350 to 450 Ω · Sending approx. 115 Ω...
  • Page 25 Design and principle of operation Type 3730-6 Positioner Cable gland M20x1.5, black polyamide Weight Approx. 1.0 kg · Stainless steel version: 2.2 kg Conformity · Table 3-2: Optional additional functions Electronic forced venting · Approval acc. to IEC 61508/SIL Input 24 V DC · Electrical isolation and reverse polarity protection · Static destruction limit 40 V U – 5.7 V Power draw: I = (corresponding to 4.8 mA at 24 V/114 mW) 3.84 kΩ Signal '0' (no response) <12 V (emergency venting at 12 V) Signal '1' (response) >19 V Solenoid valve · Approval acc. to IEC 61508/SIL...
  • Page 26 Design and principle of operation Inductive limit contact by For connection to switching amplifier acc. to EN 60947-5-6 Pepperl+Fuchs Can be used in combination with a software limit contact SJ2-SN proximity switch Measuring plate not detected: ≥3 mA · Measuring plate detected: ≤1 mA External position sensor Travel Same as positioner Cable 10 m · Flexible and durable · With M12x1 connector · Flame-retardant according to VDE 0472 · Resistant to oils, lubricants and coolants as well as other aggressive media Permissible ambient –40 to +90 °C with a fixed connection between positioner and position sensor · The temperature limits in the test certificate additionally apply for explosion-protected versions.
  • Page 27 Design and principle of operation Table 3-3: Summary of explosion protection approvals Type 3730-6 Certification Type of protection Number PTB 10 ATEX 2007 II 2 G Ex ia IIC T6 Gb -110 II 2 D Ex ia IIIC T80 °C Db Date 2020-01-20 Number PTB 10 ATEX 2007 II 2 G Ex d[ia] IIC T6 Gb -210 II 2 D Ex tb IIIC T80 °C Db Date 2020-01-20 ATEX Number PTB 10 ATEX 2007 II 2 D Ex tb IIIC T80 °C Db -510 Date 2020-01-20 Number PTB 10 ATEX 2008X II 3 G Ex nA ic IIC T6 Gc -810...
  • Page 28 Design and principle of operation Type 3730-6 Certification Type of protection Number IECEx PTB 10.0057 Ex ia IIC/IIB T6 -111 Ex tD A21 IP66 T80°C Date 2011-01-10 Number IECEx PTB 10.0057 Ex d[ia] IIC/IIB T6 -211 IECEx Ex tD A21 IP66 T80°C Date 2011-01-10 Number IECEx PTB 10.0058X Ex nA IIC T6 -811 Ex nL IIC T6 Date 2010-12-10 Ex tD A22 IP 66 T80 °C Number GYJ17.1406X Ex ia IIC T4~T6 Ga Ex iaD 20 T80 -112 Date...

  • Page 29: Dimensions In Mm

    Design and principle of operation 3.6 Dimensions in mm Attachment according to IEC 60534-6 Connecting plate Pressure gauge bracket External position sensor Direct attachment EB 8384-6 EN 3-11...
  • Page 30 Design and principle of operation Attachment according to VDI/ VDE 3847-1 onto Type 3277 Actuator Lever Attachment according to VDI/ VDE 3847-1 to a NAMUR rib 3-12 EB 8384-6 EN...
  • Page 31 Design and principle of operation Attachment according to VDI/VDE 3847-2 with single-acting actuator Attachment according to VDI/VDE 3847-2 with double-acting actuator EB 8384-6 EN 3-13...
  • Page 32 Design and principle of operation Attachment to rotary actuators according to VDI/VDE 3845 Heavy-duty version Type 3710 Reversing Amplifier Ø101 Light version Type 3710 Reversing Amplifier 3-14 EB 8384-6 EN...

  • Page 33: Fixing Levels According To Vdi/Vde 3845 (September 2010)

    Design and principle of operation Lever Lever 17 mm 25 mm 33 mm 25 mm 50 mm 66 mm 70 mm 100 mm 116 mm 100 mm 200 mm 216 mm 200 mm 300 mm 316 mm 3.6.1 Fixing levels according to VDI/VDE 3845 (September 2010) Fixing level 2 (bracket surface) Fixing level 1 (actuator surface) Actuator Dimensions in mm Size...

  • Page 34: Shipment And On-Site Transport

    (refer to delivery note). Î Observe the storage instructions. Î Avoid long storage times. 4.2 Removing the packaging Î Contact SAMSON in case of different from the positioner storage conditions. Observe the following sequence: Note Î Do not remove the packaging and the...
  • Page 35 Shipment and on-site transport Storage instructions − Protect the positioner against external in- fluences (e.g. impact, shocks, vibration). − Do not damage the corrosion protection (coating). − Protect the positioner against moisture and dirt. In damp spaces, prevent con- densation. If necessary, use a drying agent or heating.

  • Page 36: Installation

    Installation 5 Installation NOTICE The work described in this section is only to Risk of malfunction due to incorrect mount- be performed by personnel appropriately ing parts/accessories. qualified to carry out such tasks. Î Only use the mounting parts and acces- sories listed in these mounting and oper- ating instructions to mount and install the DANGER positioner.

  • Page 37: Preparation For Installation

    Installation 5.2 Preparation for installation the positioner and the pin inserted into the lever. Before mounting, make sure the following The travel tables on page 5-4 show the conditions are met: maximum adjustment range at the position- − The positioner is not damaged. er. The travel that can be implemented at the −...
  • Page 38 Installation Vent opening Fig. 5-1: Vent opening (back of the positioner) Fig. 5-2: Permissible mounting positions Fig. 5-3: M lever with pin position 35 Lever Disk spring Follower pin Fig. 5-4: Mounting the lever and follower pin EB 8384-6 EN...

  • Page 39: Travel Tables

    [mm] Travel [mm] 5.0 to 25.0 120/175/240/350 7.0 to 35.0 355/700/750 10.0 to 50.0 The min./max. adjustment range is based on the NOM (nominal range) initialization mode Table 5-2: Attachment according to IEC 60534-6 (NAMUR) SAMSON valves with Type 3271 Adjustment range at positioner Actuator Other control valves  1) Actuator size Rated travel Min. travel Max. travel...
  • Page 40 EB 8384-6 EN...

  • Page 41: Direct Attachment

    Installation 5.4 Positioner attachment mounting screw is located in the groove of the actuator stem. 6. Mount cover plate (10) with narrow side 5.4.1 Direct attachment of the cut-out (Fig. 5-5, on the left) point- ing towards the signal pressure connec- a) Type 3277-5 Actuator tion. Make sure that the gasket (14) points towards the actuator yoke.
  • Page 42 Installation Lever 1.1 Nut 1.2 Disk spring Follower pin Signal pressure Follower clamp Actuator stem Stopper Symbol extends retracts Connecting plate 6.1 Seals Pressure gauge bracket Pressure gauge Marking mounting kit Switchover plate (actuator) Cover plate 10.1 Seal Cover Gasket Molded seal Cut-out of cover plate...
  • Page 43 Installation b) Type 3277 Actuator just the lever (1) correspondingly and open the positioner cover to hold the po- Î Required mounting parts and accesso- sitioner shaft in position at the cap or ro- tary pushbutton. The lever (1) must rest ries: Table 5-6 on the follower clamp with spring force.
  • Page 44 Installation Lever Connection block 1.1 Nut 12.1 Screw 1.2 Disk spring 12.2 Stopper or connection for external piping Follower pin Switch plate 10 14 Follower clamp Gasket Cover plate Molded seal Cover 11 11.1 Gasket 11.1 Vent plug M lever Cut-out of cover plate (10) View C Ansicht C...

  • Page 45: Attachment According To Iec 60534-6

    Installation 5.4.2 Attachment according to aligned with the NAMUR bracket at mid valve travel). IEC 60534-6 3. Mount connecting plate (6) or pressure Î See Fig. 5-7 gauge bracket (7) with pressure gauges Î Required mounting parts and accesso- on the positioner, making sure the two seals (6.1) are seated properly. ries: Table 5-7 Î Observe the travel table on page 5-4. 4.
  • Page 46 Installation Attachment to rod-type yoke Rods with 20 to 35 mm diameter Attachment to NAMUR rib Additional bracket for actuators with 2800 cm² and travel ≥ 60 mm XL and L lever Lever 1.1 Nut 14.1 1.2 Disk spring Follower pin Follower plate 3.1 Follower plate Connecting plate 6.1 Seals Pressure gauge bracket Pressure gauge mounting kit Stem connector 9.1 Bracket NAMUR bracket...

  • Page 47: Attachment According To Vdi/Vde 3847-1

    Installation 5.4.3 Attachment according to mounting screw is located in the groove of the actuator stem. VDI/VDE 3847-1 2. Place the adapter bracket (6) on the po- The Type 3730-6-xxx0xxxx0x0060xx and sitioner and mount using the screws Type 3730-6-xxx0xxxx0x007000 Position- (6.1). Make sure that the seals are cor- ers with air purging of the actuator's spring rectly seated.
  • Page 48 Installation 13.1 17.2 18 17.1 18.1 11.1 12.1 Exh. 6.2 6.1 Lever Disk spring Follower pin Follower clamp 12.1 Seal Screw plug Adapter block Stopper 13.1 Screws Adapter bracket Turnboard Screws 17.1 Molded seal Molded seal 17.2 Screws Screws Blank plate Cover 18.1 Screws 11.1 Vent plug...
  • Page 49 Installation 7. Insert the screws (13.1) through the mid- Place positioner on the adapter block dle holes of the adapter block (13). (13) in such a way that the follower pin (2) rests on the top of the follower clamp 8. Place the connecting plate (12) together (3).
  • Page 50 Installation Attachment to NAMUR rib (see Fig. 5-10) For attachment to valves with rod-type yokes using the formed plate (15), which − Required mounting parts and accesso- is placed around the yoke: screw the four ries: see Table 5-8 studs into the NAMUR connection block − Observe the travel table on page 5-4. (10). Place the NAMUR connection block 1. Series 240 Valves, actuator size up to on the rod and position the formed plate 1400-60 cm²: Screw the two bolts (14) (15) on the opposite side. Use the nuts...

  • Page 51: Attachment According To Vdi/Vde 3847-2

    Installation 7. Mount the blank plate (18) to the turn- For double-acting actuators and actua- board using the screws (18.1). Make tors with air purging, connect the Y2 sure that the seals are correctly seated. port of the adapter block to the signal pressure connection of the second actua- tor chamber or spring chamber of the Note actuator.
  • Page 52 Installation 13.1 17.1 17.2 18.1 Exh. 14.1 Lever Disk spring Follower pin Follower plate Follower plate 13.1 Screws Screw plug Bolt 6.2 6.1 Stopper 14.1 Screws Adapter bracket Formed plate Screws Bracket Molded seal Turnboard Screws 17.1 Molded seal NAMUR connection 17.2 Screws block Blank plate...
  • Page 53 Installation a) Version for single-acting actuator Mounting onto a PFEIFFER Type 31a (edi- tion 2020+) SRP Rotary Actuator Î See Fig. 5-13 1. Fasten the adapter block (1) to the actua- 1 Retaining tor's NAMUR interface using the four screw fastening screws (2). 2 Air blocker Î Make sure that the seals are correctly seated.
  • Page 54 Installation 1 Adapter block 2 Fastening screws 3 Follower wheel 4 Adapter bracket 5 Fastening screws 6 Fastening screws Fig. 5-13: Mounting on a single-acting actuator EB 8384-6 EN 5-19...
  • Page 55 Installation b) Version for double-acting 7. Mount the Type 3710 Reversing Amplifi- er (7) together with the two guide bush- actuator ings (8) and terminal plate (9) onto the adapter bracket using the associated fas- A reversing amplifier must be additionally tening screws (10). mounted for applications with double-acting Î Make sure that the seals are correctly (DAP) actuators or applications with sin- seated. gle-acting (SAP) actuators that include par- tial stroke testing.
  • Page 56 Installation 1 Adapter block 2 Fastening screws 3 Follower wheel 4 Adapter bracket 5 Fastening screws 6 Fastening screws 7 Reversing amplifier 8 Guide bushings 9 Terminal plate 10 Fastening screws Fig. 5-15: Mounting on a double-acting actuator or single-acting actuator with partial stroke testing EB 8384-6 EN 5-21...
  • Page 57 Installation Intermediate plate for AA4 interface Mounting a solenoid valve Î Refer to Fig. 5-16 Î Refer to Fig. 5-17 An intermediate plate (1) must be mounted A solenoid valve (13) can also be mounted between the adapter block and adapter in place of the blank plate (12). The orienta- bracket for PFEIFFER SRP and DAP rotary ac- tion of the turnboard (14) determines the tuators in sizes 900 and 1200 with AA4 in-...
  • Page 58 Installation 12 Blank plate 13 Solenoid valve 14 Turnboard Fig. 5-17: Mounting a solenoid valve EB 8384-6 EN 5-23...

  • Page 59: Attachment To Type 3510 Micro-Flow Valve

    (12.1), ensuring that the Prior to attaching the positioner to the scale is aligned with the stem connector. SAMSON Type 3278 Rotary Actuator, 4. Fasten the hex bar (11) onto the outer mount the associated adapter (5) to the free side of yoke by screwing the M8 screws end of the rotary actuator shaft.
  • Page 60 Installation 12.1 11.1 10.1 S lever Lever Connecting plate Stem connector 10.1 Screw 1.1 Nut 6.1 Seals 9.1 Bracket Hex bar 1.2 Disk spring Pressure gauge bracket 11.1 Screws 9.2 Bolt Follower pin Pressure gauge 12.1 Screws 9.3 Screws mounting kit Follower plate Bracket Fig. 5-18: Attachment to Type 3510 Micro-flow Valve...
  • Page 61 Installation 2. Place coupling wheel (4) with flat side side of the positioner housing (see sec- facing the actuator on the follower clamp tion 5.4.7). (3). Refer to Fig. 5-20 to align slot so that 6. Unscrew the standard follower pin (2) it matches the direction of rotation when from the positioner's M lever (1). Use the the valve is in its closed position. metal follower pin (Ø 5 mm) included in 3. Fasten the coupling wheel (4) and follow- the mounting kit and screw tight into the er clamp (3) tightly onto the actuator shaft hole for pin position 90°.
  • Page 62 Installation (7, 8) 10.1 80 mm 130 mm Slot Legend for Fig. 5-19 and Fig. 5-20 Lever Disk spring Follower pin Follower clamp (Fig. 5-19) Control valve opens counterclockwise Coupling wheel Screw Control valve opens clockwise Disk spring Scale plate Actuator shaft Adapter for Type 3278 Connecting plate Seals Pressure gauge bracket Pressure gauge mounting kit...
  • Page 63 M lever (1). Attach place spacers (11) underneath, if neces- the follower pin (Ø5 mm) included in the sary. mounting kit to pin position 90°. Proceed 2. For SAMSON Type 3278 and VETEC as described in section 5.3. S160 Rotary Actuators, fasten the 6. Mount connecting plate (6) for required adapter (5) onto the free end of the shaft G ¼ connecting thread or pressure...
  • Page 64 Connecting plate (only for G ¼) 10.1 10.1 Attachment according to VDI/VDE 3845 SAMSON Type 3278 (September 2010), fixing level 1, AA1 to VETEC S160, VETEC R AA4 size (see the 'Design and principle of operation') Fig. 5-22: Attachment to rotary actuators (heavy-duty version)

  • Page 65: Reversing Amplifier For Double-Acting Actuators

    Reversing amplifier for 5.5 Mounting the external double-acting actuators position sensor For the use with double-acting actuators, the positioner must be fitted with a reversing am- plifier, e.g. the SAMSON Type 3710 Revers- ing Amplifier (see Mounting and Operating In- structions u EB 8392). The following applies to all reversing am- plifiers: The signal pressure of the positioner is sup- plied at the output 1 of the reversing amplifi- Positioner unit with sensor mounted on a micro- er.

  • Page 66: Mounting The Position Sensor With Direct Attachment

    Installation Operation and setting are described in the Type 3277 Actuator with 175 to 750 cm²: 'Start-up and configuration' section. The signal pressure is routed to the connec- − Since 2009, the back of the position sen- tion at the side of the actuator yoke for the sor (20) is fitted with two pins acting as version with fail-safe action "actuator stem mechanical stops for the lever (1).

  • Page 67: Mounting The Position Sensor With Attachment According To Iec 60534-6

    Installation 5.5.2 Mounting the position 6. Place the mounting plate together with the sensor onto the actuator yoke so that sensor with attachment the follower pin (2) rests on the top of the according to follower clamp (3). It must rest on it with IEC 60534-6 (NAMUR) spring force.
  • Page 68 Installation 2. Screw the position sensor (20) onto the 4. Screw the two bolts (14) to the bracket bracket (21). (9.1) of the stem connector (9), place the follower plate (3) on top and use the The standard attached M lever with the fol- screws (14.1) for fastening.

  • Page 69: Mounting The Position Sensor To Type 3510 Micro-Flow Valve

    Installation 5.5.3 Mounting the position 3. Select the S lever (1) from the accessories and screw the follower pin (2) into the sensor on a Type 3510 hole for pin position 17. Place the lever Micro-flow Valve (1) and disk spring (1.2) on the sensor shaft. Place the lever in mid-position and Î...

  • Page 70: Mounting On Rotary Actuators

    Installation 5.5.4 Mounting on rotary ac- 3. Replace the follower pin (2) normally at- tached to the lever (1) with the metal fol- tuators lower pin (Ø 5 mm) from the accessories Î See Fig. 5-26 and screw it into the hole for pin position 90°. Î Required mounting parts and accesso- ries: Table 5-11 4.

  • Page 71: Mounting The Leakage Sensor

    Installation 5.6 Mounting the leakage The M8 threaded connection on the NAMUR rib should preferably be used to mount the sensor sensor (Fig. 5-27). Î See Fig. 5-27 Normally, the control valve is delivered with positioner and leakage sensor already If the positioner was mounted directly onto mounted. the actuator (integral attachment), the If the leakage sensor is mounted after the NAMUR interfaces on either side of the valve valve has been installed or it is mounted on...

  • Page 72: Retrofitting Inductive Limit Switch

    Installation 5.7 Retrofitting inductive limit 6. Attach the rotary switch (5). Make sure the flattened side of the positioner shaft is contact (limit switch) turned so that the rotary switch (5) can be Required retrofit kit: attached with the metal tag next to the proximity switch. Limit switch Order no. 1402-1770 7. On start-up of the positioner, set the op- tion inductive alarm under Code 38 from...

  • Page 73: Mounting Positioners With Stainless Steel Housings

    Installation 5.8 Mounting positioners with Attachment to rotary actuators stainless steel housings All mounting kits from Table 5-10 can be used except for the heavy-duty version. Con- Positioners with stainless steel housings re- necting plate in stainless steel. quire mounting parts that are completely 5.9 Air purging function for made of stainless steel or free of aluminum.
  • Page 74 Installation Attachment according to IEC 60534-6 (NAMUR rib or attachment to rod-type yokes) and to rotary actuators The positioner requires an additional port for the exhaust air that can be connected over piping. An adapter available as an accesso- ry is used for this purpose: Threaded bushing G ¼...

  • Page 75: Connecting The Air Supply

    Installation 5.10 Pneumatic connection WARNING Risk of injury by possible movement of exposed parts (positioner, actuator or valve) after connecting the signal pressure. Î Do not touch or block exposed moving Output 38 Supply 9 parts. Output 38 Supply 9 NOTICE Incorrect connection of the supply air will damage the positioner and will lead to malfunction.

  • Page 76: Signal Pressure Connection

    Installation 5.10.1 Signal pressure connec- The bench range is written on the nameplate either as the bench range or signal pressure tion range depending on the actuator. The direc- The signal pressure connection depends on tion of action is marked FA or FE or by a sym- how the positioner is mounted onto the actu- bol.

  • Page 77: Signal Pressure (Output)

    Installation 5.10.4 Signal pressure (output) The following additionally applies: For positioners in type of protection Ex tb The signal pressure at the output (38) of the (Type 3730-65) and type of protection positioner can be restricted to 1.4 bar, Ex nA (Type 3730-68), the cable glands and 2.4 bar or 3.7 bar in Code 16. blanking plugs must be certified according to The limitation is not activated by default EN 60079-7 (Ex e). [7.0 bar]. Selecting cables and wires 5.11 Electrical connection Î Observe Clause 12 of EN 60079-14 for installation of the intrinsically safe cir- For electrical installation, observe the rele- cuits.
  • Page 78 Installation The special conditions of use mentioned in There is a second M20x1.5 threaded hole in the statement of conformity must be ob- the housing that can be used for additional served for the rated values and the installa- connection, when required. The screw termi- tion of the series-connected fuse for intercon- nals are designed for wire cross-sections of nection of Ex nA circuits.

  • Page 79: Connecting The Electrical Power Supply

    Installation Refer to Fig. 5-30 or to the label on the ter- Viator FSK modem minal block. − RS-232 Not ex Order no. 8812-0130 − PCMCIA Not ex Order no. 8812-0131 Connecting the electrical power − USB Not ex Order no. 8812-0132 Before performing the pneumatic connection, make sure the following conditions are met: If the load impedance of the controller or −...
  • Page 80 Installation +51 -52 +11 -12 +41 -42 +31 -32 +31 -32 +31 -32 Switching amplifier EN 60947-5-6 24 V DC mA control Leakage Binary Two-wire trans- signal mitter sensor input Forced vent- Supply unit only ing/solenoid Limit contacts Fault alarm for optional valve (optional) transmitter Software Software optionally inductive...

  • Page 81: Mounting Accessories

    Installation Note Communication errors may occur when the process controller/control station output is not HART -compatible. ® Alternatively, a 250 Ω resistor can be con- nected in series and a 22 µF capacitor can be connected in parallel to the analog out- put.
  • Page 82 0510-0522 0510-0510 Lever 0510-0511 0510-0512 0510-0525 Retrofit kit for inductive limit contact 1 x SJ2-SN 1402-1770 Isolated USB interface adapter (SSP interface to USB port on a computer) including TROVIS-VIEW CD- 1400-9740 Serial interface adapter (SAMSON SSP interface to RS-232 port on a computer) 1400-7700 TROVIS-VIEW 6661 (u www.samsongroup.com > SERVICE & SUPPORT > Downloads > TROVIS-VIEW) Table 5-5: Direct attachment to Type 3277-5 Actuator Designation Order no. Standard version for actuators 120 cm² or smaller 1400-7452 Mounting parts Version compatible with paint for actuators 120 cm² or smaller 1402-0940 Old switchover plate for Type 3277-5xxxxxx.00 Actuator (old)
  • Page 83 Installation Table 5-6: Direct attachment to Type 3277 Actuator Mounting parts/accessories Order no. Standard version for actuators 175, 240, 350, 355, 700, 750 cm² 1400-7453 Version compatible with paint for actuators 175, 240, 350, 355, 700, 750 cm² 1402-0941 G ¼ 1400-8819 Connection block with seals and screw ¼ NPT 1402-0901 Stainless steel/brass 1402-0938 Pressure gauge mounting kit up to max. 6 bar (output/supply) Stainless steel/stainless steel 1402-0939 Piping with screw fittings Order no.  1) G ¼/G  1402-0970 Actuator (175 cm²), steel ¼ NPT/  NPT...
  • Page 84 Mounting parts Order no. VDI/VDE 3847 interface adapter 1402-0257 ISO 228/1-G ¼ 1402-0268 Aluminum ¼–18 NPT 1402-0269 Connecting plate, including connection for air purging of actuator spring chamber ISO 228/1-G ¼ 1402-0270 Stainless steel ¼–18 NPT 1402-0271 Mounting kit for attachment to SAMSON Type 3277 Actuator with 175 to 750 cm² 1402-0868 Mounting kit for attachment to SAMSON Type 3271 Actuator or third-party actuators 1402-0869 Travel pick-off for valve travel up to 100 mm 1402-0177 Travel pick-off for 100 to 200 mm valve travel (SAMSON Type 3271 Actuator only) 1402-0178 EB 8384-6 EN 5-49...
  • Page 85 Table 5-10: Attachment to rotary actuators Mounting parts/accessories Order no. Attachment according to VDI/VDE 3845 (September 2010), actuator surface corresponds to fixing level 1 Size AA1 to AA4, version with CrNiMo steel bracket 1400-7448 Size AA1 to AA4, heavy-duty version 1400-9244 Size AA5, heavy-duty version (e.g. Air Torque 10 000) 1400-9542 Bracket surface corresponds to fixing level 2, heavy-duty version 1400-9526 1400-8815 Attachment for rotary actuators with max. 180° opening angle, fixing level 2 1400-9837 Attachment to SAMSON Type 3278 with 160/320 cm², CrNiMo steel bracket 1400-7614 Attachment to SAMSON Type 3278 with 160 cm² and to VETEC Type S160, Type R and Type M, 1400-9245 heavy-duty version 1400-5891 Attachment to SAMSON Type 3278 with 320 cm² and to VETEC Type S320, heavy-duty version 1400-9526 Attachment to Camflex II 1400-9120 G ¼ 1400-7461 Connecting plate ¼ NPT 1400-7462 G ¼...
  • Page 86 VDI/VDE 3845 (September 2010), see the 'Design and principle of operation' section for details. Actuator surface corresponds to fixing level 1 Size AA1 to AA4 with follower clamp and coupling wheel, version with CrNiMo steel bracket 1400-7473 Size AA1 to AA4, heavy-duty version 1400-9384 Attachment to Size AA5, heavy-duty version (e.g. Air Torque 10 000) 1400-9992 rotary actuators Bracket surface corresponds to fixing level 2, heavy-duty version 1400-9974 SAMSON Type 3278 with 160 cm² and VETEC Type S160 and Type R, heavy- 1400-9385 duty version 1400-5891 SAMSON Type 3278 with 320 cm² and VETEC Type S320, heavy-duty version 1400-9974 1400-7461 G  ¼ Connecting plate (6)  NPT 1400-7462 ¼ G  1400-7458 ¼...
  • Page 87 5-52 EB 8384-6 EN...

  • Page 88: Operation

    Operation 6 Operation Volume restriction Q The volume restriction serves to adapt the air Rotary pushbutton output capacity to the size of the actuator. The rotary pushbutton is located underneath Depending on the air passage at the actua- the front protective cover. The positioner is tor, two fixed settings are available. operated on site using the rotary pushbutton: −...

  • Page 89: Serial Interface

    Operation Operating modes Status messages (manual mode) − Failure − The positioner follows the manual set − Maintenance demanded/Mainte- point (Code 1) instead of the mA signal. nance required − blinks: Out of specification blinks: The positioner is not initialized. Operation only possible over manual set These icons indicate that an error has oc- point (Code 1). curred.
  • Page 90 Operation Closed-loop Failure/malfunction Code Manual mode control Bar graph for set point Designation deviation or lever Position position Parameters Units Limit contact alarm 1 Limit contact alarm 2 Fail-safe position active Configuration enabled Maintenance demanded/ Maintenance required blinks: Out of specification AUTO Automatic blinking Emergency mode (see error code 62) Clockwise blinking Positioner not initialized Counterclockwise...

  • Page 91: Hart ® Communication

    Operation 6.2 HART communication Locking on-site operation ® The on-site operation including the INIT key The positioner must be supplied with at least can be locked over HART communication. ® 3.6 mA. The FSK modem must be connected The word 'HART' then blinks on the display in parallel to the current loop. when Code 3 is selected. This locking func- A DTM file (Device Type Manager) conform- tion can only be disabled over HART...
  • Page 92 Operation Table 6-1: Dynamic HART variables assignment ® Variable Meaning Unit Set point Set point Direction of action set point Direction of action set point Set point after transit time Set point after transit time specification specification Valve position Valve position Set point deviation e Set point deviation e Absolute total valve travel Absolute total valve travel –...
  • Page 93 EB 8384-6 EN...

  • Page 94: Start-Up And Configuration

    Start-up and configuration 7 Start-up and configuration The work described in this section is only to be performed by personnel appropriately quali- fied to carry out such tasks. DANGER Risk of fatal injury due to the ignition of an explosive atmosphere. Î Observe EN 60079-14 (VDE 0165, Part 1) for work on the positioner in potentially explosive atmospheres.

  • Page 95: Determining The Fail-Safe Position

    Start-up and configuration Sequence for start-up: Action Section 1. Determine the fail-safe position. 2. Adjust the volume restriction Q. 3. Limit the signal pressure. 4. Check the operating range of the positioner. 5. Initialize the positioner. 6. Configure the positioner by setting further parameters. 7. Positioners with inductive limit contacts: Adjust the inductive limit contact. 7.1 Determining the fail-safe position Define the fail-safe position of the valve (0 %) taking the valve type and the actuator's direction of action into account. Position the AIR TO OPEN/AIR TO CLOSE slide switch...

  • Page 96: Adjusting The Volume Restriction Q

    Start-up and configuration 7.2 Adjusting the volume restriction Q The volume restriction Q serves to adapt the air output capacity to the size of the actuator: MIN SIDE − MAX BACK setting for actuators with a transit time <1 s, e.g. linear actuators with an effective area smaller than 240 cm², re- MAX SIDE quire a restricted air flow rate. Fig. 7-3: Volume restriction Q − MAX SIDE setting for actuators with a tran- MIN SIDE setting sit time ≥1 s (the air flow rate does not need to be restricted.)

  • Page 97: Checking The Operating Range Of The Positioner

    Start-up and configuration Limit the signal pressure: 1. Turn until Code 16 appears. Pressure limit Default: No 2. Press , the code number 16 blinks. 3. Turn until the required pressure limit (1.4/2.4/3.7 bar) appears. 4. Press to confirm. 7.4 Checking the operating range of the positioner To check the mechanical attachment and the proper functioning, the valve should be moved through the operating range of the positioner in the manual mode with the manual set...

  • Page 98: Initializing The Positioner

    Start-up and configuration To ensure the positioner is working properly, the outer bar elements must not blink while the valve is moving through the operating range. Exit Code 1 by pressing the rotary pushbutton ( The permissible range has been exceeded when the displayed angle is more than 30° and the outer right or left bar element blinks. The positioner goes to the fail-safe position (SAFE). After canceling the fail-safe position (SAFE) (see the 'Operation' section) it is absolutely es- sential that you check the lever and pin position as described in the 'Installation' section.
  • Page 99 Start-up and configuration During initialization the positioner adapts itself optimally to the friction conditions and the signal pressure required by the control valve. The type and extent of auto tuning depends on the initialization mode selected: − Maximum range (MAX) (standard range) Initialization mode for simple start-up of valves with two clearly defined mechanical end positions, e.g. three-way valves (see section 7.5.1) − Nominal range (NOM) Initialization mode for all globe valves (see section 7.5.2) − Manually selected OPEN position (MAN) Initialization mode for globe valves requiring OPEN position to be entered manually (see section 7.5.3) −...
  • Page 100 Start-up and configuration The time required for the initialization proce- Alternating readings dure depends on the actuator transit time, Initialization in progress which means that initialization can take a few Icon depending on ini- tialization mode select- minutes. After a successful initialization, the positioner runs in closed-loop operation indicated by the closed-loop operation icon. Bar graph display indi- cating the progress of A malfunction leads to the process being can- the initialization celed. The initialization error is displayed ac- cording to how it has been classified by the...

  • Page 101: Max - Initialization Based On Maximum Range

    Start-up and configuration 7.5.1 MAX – Initialization based on maximum range The positioner determines travel/angle of rotation of the closing member from the CLOSED position to the opposite travel stop and adopts this travel/angle of rotation as the operating range from 0 to 100 %. Enable configuration: Configuration is locked again if no settings are entered within 120 s. 1. Turn until Code 3 appears (reading: Enable configuration Default: No No). 2. Press , the code number 3 blinks. 3. Turn until YES appears. 4. Press to confirm (reading: ). Enter the pin position: Pin position 1.

  • Page 102: Nom - Initialization Based On Nominal Range

    Start-up and configuration 7.5.2 NOM – Initialization based on nominal range The calibrated sensor allows the exact valve travel to be measured very accurately. During initialization, the positioner checks whether the control valve can move through the indicated nominal range (travel or angle) without collision. If this is the case, the indicated nominal range is adopted with the limits of travel/angle range start (Code 8) and travel/angle range end (Code 9) as the operating range.

  • Page 103: Man - Initialization Based On A Manually Selected Open Position

    Start-up and configuration Select the initialization mode: Init mode 1. Turn until Code 6 appears. Default: MAX 2. Press , the code number 6 blinks. 3. Turn until NOM appears. 4. Press to confirm the NOM initialization mode. Start initialization: Î Press INIT key. Î After the initialization has been successfully completed: Check the direction of action (Code 7) and, if necessary, change it. 7.5.3 MAN –...
  • Page 104 Start-up and configuration Enter the pin position: Pin position 1. Turn until Code 4 appears. Default: No 2. Press , the code number 4 blinks. 3. Turn to select pin position on lever (see relevant section on attachment). 4. Press to confirm. Select the initialization mode: Init mode 1.

  • Page 105: Man2 - Initialization Based On Manually Selected End Positions

    Start-up and configuration 7.5.4 MAN2 – Initialization based on manually selected end po- sitions Before starting initialization, move the control valve manually to the end positions. The posi- tioner calculates the travel/angle difference from the positions that the valve moved to and adopts it as the operating range with limits of lower travel/angle range value (Code 8) and upper travel/angle range value (Code 9). Note This initialization mode can only be started when the valve position differs in the end posi- tions and the positioner has not yet been initialized. Enable configuration: Configuration is locked again if no settings are entered within 120 s.

  • Page 106: Sub - Substitute Calibration

    Start-up and configuration POS1 (end position 1) 4. Press to confirm the MAN2 as the ini- tialization mode. POS1 and the current an- gle position of the lever are indicated on the display in alternating sequence. 5. Turn clockwise in small steps until the POS2 (end position 2) required valve position is reached.
  • Page 107 Start-up and configuration by means of a pressure signal which is routed to the actuator externally. The blocking posi- tion ensures that the plant continues to operate with this valve position. The blocking position can also be the fail-safe position when this condition is beneficial for the temporary phase. Î Perform a reset before re-initializing the positioner if the substitute positioner has already been initialized (see the 'Operation' section). Enable configuration: Configuration is locked again if no settings are entered within 120 s.
  • Page 108 Start-up and configuration Select the initialization mode: Init mode 1. Turn until Code 6 appears. Default: MAX 2. Press , the code number 6 blinks. 3. Turn until SUB appears. 4. Press to confirm the SUB initialization mode. Enter the direction of action: Direction of action 1. Turn until Code 7 appears.
  • Page 109 Start-up and configuration Pressure limit 1. Turn until the required Code 16/17/18 Default: No appears. 2. Press , the code number 16/17/18 blinks. 3. Turn to set the control parameter select- level Default: 7 4. Press to confirm. level Default: 2 Enter closing direction and blocking position: Closing direction (di- 1.

  • Page 110: Tuning The Kp Input Filter

    Start-up and configuration Start initialization: Î Press INIT key. The operating mode is changed to automatic mode Since initialization has not been completed, the error code 76 (no emergency mode) and possibly also error code 57 (control loop) may appear on the display. These alarms do not influence the positioner’s readiness for operation. Î If the positioner shows a tendency to oscillate in automatic mode, the parameters K must be slightly corrected. Proceed as follows: – Set T (Code 18) to 4. – If the positioner still oscillates, the gain K (Code 17) must be decreased until the posi- tioner shows a stable behavior. Zero point calibration Î...

  • Page 111: Setting Other Parameters

    Start-up and configuration Tune the input filter: Tuning the input filter 1. Turn until Code 6 appears. Default: MAX 2. Press , the code number 6 blinks. 3. Turn until KP appears. Î Press INIT key. During the tuning, the valve moves through its whole range and the input filter is recali- brated. 7.6 Setting other parameters All codes and their meaning and default settings are listed in the code list in Annex A.
  • Page 112 Start-up and configuration Cancel the setting: To cancel a value before it is confirmed (by pressing ) proceed as follows: Canceling the reading Turn until ESC appears. Press to confirm. The entered value is not adopted. 7.7 Adjusting inductive limit contact The positioner version with an inductive limit contact has an adjustable tag (1) mounted on the axis of rotation, which operates the proximity switch (3).
  • Page 113 Start-up and configuration Adjust the switching point Note During adjustment or testing, the switching point must always be approached from mid- position (50 %). To guarantee the switching under all ambient conditions, adjust the switching point approx. 5 % before the mechanical stop (OPEN – CLOSED). For CLOSED position: 1.
  • Page 114 Start-up and configuration Adjustment screw (2) Metal tag (1) Proximity switch (3) Fig. 7-4: Adjusting the limit contact EB 8384-6 EN 7-21...
  • Page 115 7-22 EB 8384-6 EN...

  • Page 116: Operation

    Operation 8 Operation The work described in this section is only to be performed by personnel appropriately quali- fied to carry out such tasks. DANGER Risk of fatal injury due to the ignition of an explosive atmosphere. Î Installation, operation or maintenance of the positioner must only be performed by per- sonnel who has undergone special training or instructions or who is authorized to work on explosion-protected devices in hazardous areas.

  • Page 117: Closed-Loop Operation (Automatic Mode)

    Operation 8.2 Changing the operating modes 8.2.1 Closed-loop operation (automatic mode) After initialization has been completed suc- Automatic mode cessfully, the positioner is in automatic mode (AUTO). 8.2.2 Manual mode Switching to manual mode (MAN): Automatic mode 1. Turn until Code 0 appears. 2. Press , reading: AUTO, the code number 0 blinks.

  • Page 118: Fail-Safe Position (Safe)

    Operation The positioner automatically returns to Code 0 if no settings are made within 120 seconds, but remains in the manual mode. Switch to automatic mode 1. Turn until Code 0 appears. 2. Press , the code number 0 blinks. 3. Turn until AUTO appears. 4. Press . The positioner switches to automatic mode. 8.2.3 Fail-safe position (SAFE) If you want to move the valve to the fail-safe position determined during start-up (see the 'Start-up and configuration' section), proceed as follows: 1.

  • Page 119: Performing Zero Calibration

    Operation 8.3 Performing zero calibration In case of inconsistencies in the closed position of the valve, e.g. with soft-seated plugs, it might be necessary to recalibrate zero. WARNING Risk of injury due to the actuator stem extending or retracting. Î Do not touch or block the actuator stem. NOTICE The process is disturbed by the movement of the actuator stem.

  • Page 120: Resetting The Positioner

    Operation Perform zero calibration: Init mode 1. Turn until Code 6 appears. Default: MAX 2. Press , the code number 6 blinks. 3. Turn until ZP appears. Î Press INIT key. Zero calibration starts. The positioner moves the valve to the CLOSED position and recalibrates the internal electrical zero point. 8.4 Resetting the positioner A reset allows the positioner to be reset to the default settings. To reset the positioner, the op- tions DIAG, STD and DS are available in Code 36. Table 8-2 lists the reset functions.
  • Page 121 Operation Reset start-up parameters: 1. Turn until Code 36 appears (reading: ••–••–). 2. Press , the code number 36 blinks. Reset 3. Turn until DIAG/STD/DS appears. Default: No 4. Press to confirm. The parameters are reset depending on the setting made (see Table 8-2). Table 8-2: Reset functions Reset Code 36 DIAG Initialization Fail-safe action...
  • Page 122 Operation Reset Code 36 DIAG Lower travel/angle range value Upper travel/angle range value Set point, lower range value Set point, upper range value CLOSED end position OPEN end position Pressure limit Proportional-action coefficient Kp level Derivative-action time Tv level Tolerance band Valve characteristic selection Enter transit time OPEN Enter transit time CLOSED Total valve travel limit Alarm mode Limit A1 Limit A2...
  • Page 123 EB 8384-6 EN...

  • Page 124: Malfunction

    Malfunction 9 Malfunction been determined. The wear tolerance will soon be exhausted or is reducing at a Malfunctions are indicated on the display faster rate than expected. Maintenance is by error codes. Annex A lists possible error necessary in the medium term. messages and recommended action.

  • Page 125: Troubleshooting

    Code 49 on- wards. In this case, ERR is displayed. Note Contact SAMSON's After-sales Service for malfunctions that cannot be remedied as de- scribed in Table 9-2 and the code list in An- nex A.
  • Page 126 Malfunction Table 9-2: Further troubleshooting Description of fault Measures No reading on the display Î Check electrical connection and electrical power. Î Check the ambient temperature (the display's operat- ing range is from –30 to +65 °C). Actuator moves too slowly Î Check the supply pressure. Î Deactivate software restriction. Î...

  • Page 127: Emergency Action

    Malfunction 9.2 Emergency action Fail-safe action is triggered by the i/p con- verter or solenoid valve and upon supply air failure. The positioner fully discharges its pneumatic output to the atmosphere, causing the pneumatic actuator to be vented. As a result, the valve moves to the fail-safe posi- tion.

  • Page 128: Servicing

    Servicing 10 Servicing The positioner was checked by SAMSON before it left the factory. The work described in this section is only to − The product warranty becomes void if be performed by personnel appropriately service or repair work not described in qualified to carry out such tasks.

  • Page 129: Maintenance Of The Supply Air Pressure Reducing Stations

    Servicing 10.3 Maintenance of the supply Î The individual approved by SAMSON confirms the update by attaching the as- air pressure reducing signed test mark (stamp). stations 10.5 Periodic inspection and The maintenance instructions of any up- testing of the positioner stream supply air pressure reducing stations must be observed.
  • Page 130 Servicing Table 10-1: Recommended inspection and testing Inspection and testing Action to be taken in the event of a negative result Check the markings, labels and nameplates on Immediately renew damaged, missing or incor- the positioner for their readability and complete- rect nameplates or labels.
  • Page 131 10-4 EB 8384-6 EN...

  • Page 132: Decommissioning

    Decommissioning 11 Decommissioning The work described in this section is only to be performed by personnel appropriately qualified to carry out such tasks. DANGER Risk of fatal injury due to ineffective explo- sion protection. The explosion protection becomes ineffective when the positioner cover is opened. Î...
  • Page 133 11-2 EB 8384-6 EN...

  • Page 134: Removal

    Removal 12 Removal The work described in this section is only to be performed by personnel appropriately qualified to carry out such tasks. DANGER Risk of fatal injury due to the ignition of an explosive atmosphere. Î The following regulations apply to instal- lation in hazardous areas: EN 60079-14 (VDE 0165, Part 1).
  • Page 135 12-2 EB 8384-6 EN...

  • Page 136: Repairs

    Î Do not perform any repair work on your EN 60079-19 applies to servicing explo- own. sion-protected devices. Î Contact SAMSON's After-sales Service for repair work. 13.2 Returning devices to SAMSON 13.1 Servicing explosion- Defective devices can be returned to protected devices SAMSON for repair.
  • Page 137 13-2 EB 8384-6 EN...

  • Page 138: Disposal

    Disposal 14 Disposal We are registered with the German national register for waste electric equipment (stiftung ear) as a producer of electrical and electronic equipment, WEEE reg. no.: DE 62194439 Î Observe local, national and internation- al refuse regulations. Î Do not dispose of components, lubricants and hazardous substances together with your other household waste. On request, we can appoint a service pro- vider to dismantle and recycle the product.
  • Page 139 14-2 EB 8384-6 EN...

  • Page 140: Certificates

    Certificates 15 Certificates The following certificate is shown on the next page: − EU declaration of conformity for Type 3730-6 − EU declaration of conformity for Type 3730-6-110 and -210 − EU declaration of conformity for Type 3730-6-810 − EAC certificate for Type 3730-6 − EAC certificate for Type 3730-6-113, -213 and -813 − ATEX: statement of conformity − ATEX: EU type examination certificate − IECEx: IECEx certificate of conformity for Type 3730-6-111 and -211 − IECEx: IECEx certificate of conformity for Type 3730-6-811 − CSA certificate − FM certificate The certificates shown were up to date at the time of publishing. The latest certificates can be found on our website: u www.samsongroup.com > Products &...
  • Page 141 EMC 2014/30/EU +A1:2011, EN 61326-1:2013 RoHS 2011/65/EU EN 50581:2012 Hersteller / Manufacturer / Fabricant: SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 D-60314 Frankfurt am Main Deutschland/Germany/Allemagne Frankfurt / Francfort, 2017-07-29 Im Namen des Herstellers/ On behalf of the Manufacturer/ Au nom du fabricant.
  • Page 142 Explosion Protection 2014/34/EU (ab/from 2016-04-20) EN 60079-31:2009 RoHS 2011/65/EU EN 50581:2012 Hersteller / Manufacturer / Fabricant: SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 D-60314 Frankfurt am Main Deutschland/Germany/Allemagne Frankfurt / Francfort, 2017-07-29 Im Namen des Herstellers/ On behalf of the Manufacturer/ Au nom du fabricant.
  • Page 143 Explosion Protection 2014/34/EU (ab/from 2016-04-20) EN 60079-15:2010, EN 60079-31:2009 RoHS 2011/65/EU EN 50581:2012 Hersteller / Manufacturer / Fabricant: SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 D-60314 Frankfurt am Main Deutschland/Germany/Allemagne Frankfurt / Francfort, 2017-07-29 Im Namen des Herstellers/ On behalf of the Manufacturer/ Au nom du fabricant.
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  • Page 177 Installation Manual for apparatus certified by CSA / FM for use in hazardous locations. Intrinsically safe if installed as specified in manufacturer’s installation manual. CSA- certified for hazardous locations FM- approved for hazardous locations Ex ia IIC T6: Class I, Zone 0 AEx ia IIC T6: Class I, Zone 0 Class I, Div.
  • Page 178 Notes general for CSA Certification: The apparatus may be installed in intrinsically safe circuits only when used in conjunction with CSA / FM certified apparatus. For maximum values of U or V or I or P and L of the various apparatus see Table 1, 2 and 3 on page 1 and 3 For barrier selection see Table 2 on page 3.
  • Page 179 Circuit Serial interface BU External position sensor (R ≥ 10KΩ passive) Terminal Connector Analog pcb. pin p9, p10, p11/ External Connector 7.88V 7.88V or V or V or V 60 mA 69.2 mA 13.2 mA or I [mA] or I or I or P or P...
  • Page 180 CSA- certified for hazardous locations FM- approved for hazardous locations Ex nA II T6 / Ex nL IIC T6 Class I, Zone 2 AEx nA II T6; Ex nL IIC T6 Class I, Zone 2. Class I, Div. 2, Groups A, B, C, D, Class I, Div.
  • Page 181 The installation must be in accordance with the Canadian Electrical Code, Part 1 For the maximum values for the individual energy limited circuits see Table 4. Cable entry only rigid metal conduit according to drawing No. 1050-0539 T and 1050-0540 T The positioners rated voltage is 32 V DC and thus below the limit of 75 V DC specified in IEC 60079-15:2001, Clause 12 b.
  • Page 182 Installation manual for equipment certified by FM for use in hazardous areas Intrinsically safe if installed as specified in manufacturer’s installation manual FM approved for hazardous areas Class I, II, III, Div. 1, Groups A, B, C, D, E, F, G Class I, Zone 0, AEx ia IIC Field enclosures NEMA 4X HAZARDOUS...
  • Page 183 Notes on FM installation: Installation must be in accordance with ANSI/NFPA 70 and ANSI/RP 12.06.01. For FM installation, safety barriers must be FM approved and installed in accordance with ANSI/NFPA 70 and ANSI/RP 12.06.01. Each pair of intrinsically safe wires must be protected by a shield that is grounded at the intrinsically safe ground.
  • Page 184 Table 2: CSA/FM-certified barrier parameters of circuit 1, 2 and 6 Supply barrier Evaluation barrier Barrier min. max. min. Circuit 1 ,2, 6 ≤ 28 V ≥ 245 Ω ≤ 115 mA ≤ 1 W ≤ 28 V 0 mA In grounded signal circuits with only one barrier, the return line must be grounded or included in the equipotential bonding system of the system.
  • Page 185 FM approved for hazardous areas Class I, Div. 2 Groups A, B, C, D Class II, III, Div. 2 Groups E, F, G (non-incendive field wiring) Field enclosures NEMA 4X HAZARDOUS SAFE AREA LOCATION Type 3730-6-130 Positioner Control signal Circuit 1 HART connection Position transmitter...
  • Page 186 Note! 1.) For the maximum values of the individual energy limited circuits see Table 4. 2.) Cable entry: only rigid metal conduit according to drawing no. 1050-0540 T Table 4: Electrical rating of energy-limited circuits (non-incendive) parameters Fault Limit contacts HART Binary Leakage...
  • Page 187 Installation drawing: control relay KHA5-OTI/Ex2, KHA6-OTI/Ex1 or KHA6-OTI/Ex2 with Type SJ-b-N proximity switch SAFE HAZARDOUS LOCATION AREA To intrinsically safe output Intrinsically safe output to sensor or contact Channel 1 Proximity switch Software limit contact Intrinsically safe output Proximity switch to sensor or contact Software limit contact Channel 2...
  • Page 188 EB 8384-6 EN 15-49...
  • Page 189 15-50 EB 8384-6 EN...

  • Page 190: Annex A (Configuration Instructions)

    Annex A (configuration instructions) 16 Annex A (configuration instructions) 16.1 Parameters and functions Code Parameter – Readings/ Description values [default setting] Note: Codes marked with an asterisk (*) must be enabled with Code 3 prior to configuration. Operating mode Switchover from automatic to manual mode is bumpless. [MAN] Manual mode Automatic mode only possible if positioner has been initialized.
  • Page 191 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] Pin position Pin position Standard Adjustment range Code 4 Code 5 Code 5 (continued) 3.6 to 17.7 If you select a pin position in 5.0 to 25.0 Code 4 that is too small, the positioner switches to SAFE 15.0 7.0 to 35.4 mode for reasons of safety.
  • Page 192 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] Initialization mode Fine tuning of the input filter · The valve moves through its (init mode) entire valve range. (continued) Zero calibration · The zero point is recalibrated. Note: Valve will temporarily be moved from its operating point to CLOSED position. Set point's effect on the valve position Direction of action (w/x) Increasing/increasing: a globe valve opens as the set [ää], äæ, ESC ää:...
  • Page 193 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] Travel/angle range end Upper range value for the travel/angle of rotation in the operating (upper x-range value) range. 20.0 to [100.0 %] of the Nominal range and characteristic are automatically adapted. nominal range, ESC Example: The operating range is modified, for example to limit the Specified in mm or angle ° range of a control valve which has been sized too large. For this provided Code 4 is activat- function, the entire resolution range of the set point is converted to the new limits.
  • Page 194 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] 13* Set point end (w-end) Upper range value (100 % = 20 mA) of valid set point range 25.0 to [100.0] %, ESC This value must be greater than the lower range value. 14* CLOSED end position/set Limit of the set point w point cutoff decrease (end Actuators with ATO fail-safe action are completely vented and position w <) actuators with ATC fail-safe action are completely filled with air 0.0 to 49.9 %, [1.0 %] of the...
  • Page 195 Note: The lag time can only be set using the operator software. 20* Select characteristic Characteristic selection (see section 16.2) Linear [0] to 9, ESC Equal percentage Reverse equal percentage SAMSON butterfly valve, linear SAMSON butterfly valve, equal percentage VETEC rotary plug valve, linear VETEC rotary plug valve, equal percentage Segmented ball valve, linear Segmented ball valve, equal percentage User-defined (defined over operator software) 21* Transit time OPEN...
  • Page 196 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] 23* Absolute total valve travel Totaled full valve travel cycle [0] to 99 · 10 , YES, ESC Can be reset to 0 in Code 36 – STD and Code 36 – DS. Exponential reading from Note: The total valve travel is saved in a non-volatile memory ev- 9999 travel cycles onwards ery 24 hours.
  • Page 197 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] 27* Limit A2 (alarm limit 2) The valve position limit relating to the operating range. 0.0 to 100.0 [98.0] % of the Alarm A2 responds when the value falls below the limit. operating range, No, ESC 28* Alarm test Testing the software limit switch alarm A1 and A2 as well as the fault alarm contact A3.
  • Page 198 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] 32* Error message in case of YES: 'Failure' and 'Function check' condensed state cause an 'Function check' condensed error message to be generated. state 'Failure' condensed state causes an error message to be generated.
  • Page 199 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] Options Indicates which option (terminals 31 and 32, Fig 17) is installed. No: No option installed Read only POS: Analog position transmitter dI: Binary input LS: Leakage sensor XI: 4 to 20 mA x input When the binary input is used, DI and HIGH or LOW status are displayed in alternating sequence. When the leakage sensor is used, LS and the detected sound level in dB are displayed in alternating sequence. 38* Inductive limit contact Indicates whether the inductive limit contact option is installed or not.
  • Page 200 Annex A (configuration instructions) Code Parameter – Readings/ Description values [default setting] Internal solenoid valve/ Indicates whether a solenoid valve/forced venting is installed or forced venting not. Read only If a voltage supply is connected at the terminals +81/–82, YES and HIGH appear on the display in alternating sequence. If a volt- age supply is not connected (actuator vented, fail-safe position in- dicated on the display by the S icon), YES and LOW appear on the display in alternating sequence.

  • Page 201: Error Codes

    Annex A (configuration instructions) 16.1.1 Error codes Initialization errors Error codes – Recommended Condensed state message active, when prompted, ERR appears. action When fault alarms exist, they are displayed here. 50 x > range Value of measuring signal too high or too low; the lever operates near its mechanical stops. • Pin not mounted properly • NAMUR attachment: bracket slipped or follower pin not properly seated on the follower plate's slot. •...
  • Page 202 Recommended action • Activate volume restriction in positioner output. • Re-initialize positioner. 56 Pin/switch position Pin position not entered for nominal range (NOM) or substitute (SUB) initialization. ATO/ATC switch defective. Status classification [Maintenance required] Recommended action Enter pin position and nominal range. Re-initialize positioner. Return positioner to SAMSON for repair. EB 8384-6 EN 16-13...
  • Page 203 The positioner goes to the fail-safe position (SAFE). Additional indication at the fault alarm contact Status classification Failure (cannot be classified) Recommended action Return positioner to SAMSON for repair. 61 KP too low Proportional-action coefficient Kp level lower than 3 was detected during initialization. Note: A Kp level < 3 does not cause the initialization process to be canceled.
  • Page 204 However, the positioner continues operation according to its set point so that the process remains in a safe state. Status classification [Maintenance demanded] Recommended action Return positioner to SAMSON for repair. 63 SIL shutdown/w too low Emergency shutdown of the i/p block is implemented by 3.8 mA or 4.4 mA (depending on the positioner version)´. The set point w is lower than 3.7 mA. This state is indicated on the positioner display by LOW blinking.
  • Page 205 Additional indication at the safe position (SAFE). fault alarm contact As long as the error exists, no EXPERTplus diagnostic messages are logged. Status classification [Failure] Recommended action Confirm error and return to automatic mode or perform a reset and re-initialize the positioner. In the problem still persists, return device to SAMSON for repair. Unassigned Check calculation Hardware controller monitored by test calculation. Additional indication at the fault alarm contact Status classification [Failure] Recommended action Confirm error. If this is not possible, return the device to SAMSON for repair.
  • Page 206 Annex A (configuration instructions) Data errors Error codes – Recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. 68 to Unassigned No emergency mode The travel measuring system of the positioner has a self-monitoring func- tion (see Code 62). An emergency mode (open-loop control) is not available for certain ac- tuators, such as double-acting actuators.
  • Page 207 Annex A (configuration instructions) Error codes – Recommended Condensed state message active, when prompted, Err appears. action When fault alarms exist, they are displayed here. PST/FST A partial stroke test or full stroke test cannot be started or has been can- celed. Status classification [No message] Recommended action Read out test status (only in the operator software) On/off valve The transit time and breakaway time or the final travel/angle value of the on/off valve has changed.

  • Page 208: Selecting The Characteristic

    Annex A (configuration instructions) 16.2 Selecting the characteristic The characteristics that can be selected in Code 20 are shown in the following in graph form. Note A characteristic can only be defined (user-defined characteristic) using a workstation/operat- ing software (e.g. TROVIS-VIEW). Linear (select characteristic: 0) Travel/angle [%] Set point [%]...
  • Page 209 SAMSON butterfly valve linear (select charac- SAMSON butterfly valve equal percentage (se- teristic: 3) lect characteristic: 4) Travel/angle [%] Travel/angle [%] Set point [%] Set point [%] VETEC rotary plug valve linear (select char- VETEC rotary plug valve equal percentage (se- acteristic: 5) lect characteristic: 6)

  • Page 210: Annex B

    0510-0522 0510-0510 Lever 0510-0511 0510-0512 0510-0525 Retrofit kit for inductive limit contact 1 x SJ2-SN 1402-1770 Isolated USB interface adapter (SSP interface to USB port on a computer) inc. TROVIS-VIEW CD-ROM 1400-9740 Serial interface adapter (SAMSON SSP interface to RS-232 port on a computer) 1400-7700 TROVIS-VIEW 6661 (u www.samsongroup.com > SERVICE & SUPPORT > Downloads > TROVIS-VIEW) Table 17-3: Direct attachment to Type 3277-5 Actuator Designation Order no. Standard version for actuators 120 cm² or smaller 1400-7452 Mounting parts Version compatible with paint for actuators 120 cm² or smaller 1402-0940 Old switchover plate for Type 3277-5xxxxxx.00 Actuator (old)
  • Page 211 Annex B Designation Order no. G  1400-7461 ¼ Connecting plate (6)  NPT 1400-7462 ¼ G  1400-7458 ¼ Accessories for Pressure gauge bracket (7) positioner  NPT 1400-7459 ¼ Stainless steel/brass 1402-0938 Pressure gauge mounting kit (8) up to max. 6 bar (output/supply) Stainless steel/stainless steel 1402-0939 Only new switchover and connecting plates can be used with new actuators (Index 01). Old and new plates are not interchangeable.
  • Page 212 Annex B Mounting parts/accessories Order no. G ¼/G  1402-0974 Actuator (750 cm²), steel ¼ NPT/  NPT 1402-0981 G ¼/G  1402-0975 Actuator (750 cm²), stainless steel ¼ NPT/  NPT 1402-0982 For "actuator stem retracts" fail-safe action with air purging of the top diaphragm chamber Table 17-5: Attachment to NAMUR rib or attachment to rod-type yokes according to IEC 60534-6 Travel in...
  • Page 213 ISO 228/1-G ¼ 1402-0268 Aluminum ¼–18 NPT 1402-0269 Connecting plate, including connection for air purging of actuator spring chamber ISO 228/1-G ¼ 1402-0270 Stainless steel ¼–18 NPT 1402-0271 Mounting kit for attachment to SAMSON Type 3277 Actuator with 175 to 750 cm² 1402-0868 Mounting kit for attachment to SAMSON Type 3271 Actuator or third-party actuators 1402-0869 Travel pick-off for valve travel up to 100 mm 1402-0177 Travel pick-off for 100 to 200 mm valve travel (SAMSON Type 3271 Actuator only) 1402-0178 Table 17-7: Attachment according to VDI/VDE 3847-2 Designation Order no. Mounting block for PFEIFFER Type 31a (edition 2020+) Rotary Actuators with...
  • Page 214 Annex B Mounting parts/accessories Order no. 1400-5891 Attachment to SAMSON Type 3278 with 320 cm² and to VETEC Type S320, heavy-duty version 1400-9526 Attachment to Camflex II 1400-9120 G ¼ 1400-7461 Connecting plate ¼ NPT 1400-7462 G ¼ 1400-7458 Accessories Pressure gauge bracket ¼ NPT 1400-7459 Stainless steel/brass 1402-0938 Pressure gauge mounting kit up to max. 6 bar (output/ supply) Stainless steel/stainless steel 1402-0939 Table 17-9: Attachment of external position sensor Mounting parts/accessories Order no.
  • Page 215 Annex B Mounting parts/accessories Order no. G  1400-7461 ¼ Connecting plate (6)  NPT 1400-7462 ¼ G  1400-7458 ¼ Pressure gauge bracket (7) Accessories for  NPT 1400-7459 ¼ positioner Stainless steel/brass 1402-0938 Pressure gauge mounting kit up to max. 6 bar (output/supply) Stainless steel/stainless steel 1402-0939 Bracket to mount the positioner on a wall (Note: The other fastening parts are to 0309-0184 be provided at the site of installation as wall foundations vary from site to site).

  • Page 216: After-Sales Service

    E-mail contact You can reach our after-sales service at af- tersalesservice@samsongroup.com. Addresses of SAMSON AG and its subsid- iaries The addresses of SAMSON AG, its subsid- iaries, representatives and service facilities worldwide can be found on our website (www.samsongroup.com) or in all SAMSON...
  • Page 220 EB 8384-6 EN SAMSON AKTIENGESELLSCHAFT Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 samson@samsongroup.com · www.samsongroup.com...

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