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Samson 3730-2 Mounting And Operating Instructions

Electropneumatic positioner
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Electropneumatic Positioner
Type 3730-2
Fig. 1 · Type 3730-2
Mounting and
Operating Instructions
EB 8384-2 EN
Firmware version 1.2x
Edition December 2004

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Summary of Contents for Samson 3730-2

  • Page 1 Electropneumatic Positioner Type 3730-2 Fig. 1 · Type 3730-2 Mounting and Operating Instructions EB 8384-2 EN Firmware version 1.2x Edition December 2004...

  • Page 2: Table Of Contents

    Contents Contents Page Design and principle of operation ....8 Additional equipment ......9 Technical data .
  • Page 3 Contents Zero calibration ......53 Reset to default values ......54 Adjusting the limit switch .
  • Page 4 Proper shipping and appropriate storage are assumed. Note! The device with a CE marking fulfils the requirements of the Directives 94/9/EC (ATEX) and 89/336/EEC (EMC). The declaration of conformity can be viewed and downloaded on the Internet at http://www.samson.de. EB 8384-2 EN...
  • Page 5 Versions Type 3730-2 X X X X X 0 0 X 0 X 0 0 x 0 Article code Explosion protection Without II 2 G EEx ia IIC T6/II 2 D IP 65 T 80 °C acc. to ATEX Ex ia FM/CSA II 3 G EEx na II T6 /II 3 D IP 65 T 80 °C...
  • Page 6 Firmware modification Modifications of positioner firmware in comparison to previous versions Previous 1.01 1.10 Via the serial interface and the serial interface adapter, the positioner can be configured and operated using TROVIS-VIEW software. The following additional status indications were implemented: Code 76 - No emergency mode Code 77 - Program loading error Displays number of zero calibrations performed since the last initialization.
  • Page 7 Firmware modification EB 8384-2 EN...

  • Page 8: Design And Principle Of Operation

    The positioner basically consists of a travel The positioner is equipped with an interface sensor system that functions proportional to to allow the SAMSON TROVIS-VIEW Con- the resistance, an analog i/p module with figuration and Operator Interface software downstream booster as well as the electronic to transmit data and parameters over an unit with a microcontroller.

  • Page 9: Additional Equipment

    Design and principle of operation Additional equipment Positioner with position transmitter The position transmitter (13) is a two-wire As an option, the device can be additionally transmitter and issues the travel sensor sig- equipped with a solenoid valve for forced nal as a 4 to 20 mA signal processed by the venting, an analog position transmitter, an microcontroller.

  • Page 10: Technical Data

    Design and principle of operation Version with inductive limit switch The rotary shaft of the positioner carries an adjustable tag which actuates the installed proximity switch. The optional inductive limit switch (11) leads to A1 and the software limit switch, which remains in operation, leads to A2.
  • Page 11 II 3 G EEx nA II T6 / II 3 D IP 65 T 80 °C Degree of protection IP 65 Communication (local) SAMSON SSP interface and serial interface adapter Software requirements TROVIS-VIEW with database module 3730-2 1 fault alarm contact,...
  • Page 12 Design and principle of operation Analog position Two-wire transmitter transmitter Supply voltage 12 to 30 V DC, reverse polarity protection, static destruction limit 40 V Output signal 4 to 20 mA Direction of action Reversible Operating range 0 to 100 % of the travel range, optional also for fault indication over 2.4 or 21.6 mA Characteristic Linear Hysteresis and...

  • Page 13: Attachment To The Control Valve - Mounting Parts And Accessories

    The positioner can be attached either di- The positioner is standard equipped with the rectly to a SAMSON Type 3277 Actuator or lever M (pin position 35). according to IEC 60534-6 (NAMUR) to con- trol valves with cast yokes or rod-type yokes...
  • Page 14 Attachment to the control valve – mounting parts and accessories Direct attachment to Type 3277-5 Actuator Order no. Table 1 Mounting parts For actuators with 120 cm effective diaphragm area 1400-7452 Switchover plate (old) for Actuator Type 3277-5xxxxxx.00 (old) 1400-6819 Switchover plate new for Actuator Type 3277-5xxxxxx.01 (new) 1400-6822 Connecting plate for additional attachment of a solenoid valve G 1/8...
  • Page 15 Attachment to the control valve – mounting parts and accessories Attachment to rotary actuators (VDI/VDE 3845 for all sizes of fixing level 2) see Figs. 7 and 8 Table 4 VDI/VDE 3845 for all sizes of fixing level 2 1400-7448 Mounting With follower clamp for Type 3278 Actuator with 160/320 cm...

  • Page 16: Direct Attachment

    Attachment to the control valve – mounting parts and accessories left) pointing towards the signal pressure Direct attachment connection. Make sure that the bonded gasket (14) points towards the actuator 2.1.1 Type 3277-5 Actuator yoke. Refer to Table 1 on page 14 for the required 5.
  • Page 17 Attachment to the control valve – mounting parts and accessories Lever Symbols 1.1 Nut Switchover plate (9) 1.2 Disk spring Actuator stem Follower pin extends Follower clamp Vent plug Attachment left Attachment right Stopper Connecting plate Actuator stem 6.1 Seal rings retracts Pressure gauge bracket Press.

  • Page 18: Type 3277 Actuator

    Attachment to the control valve – mounting parts and accessories rests on the top of the follower clamp 2.1.2 Type 3277 Actuator (3). Adjust the lever (1) correspondingly Refer to Table 2 on page 14 or the required and open the positioner cover to hold mounting parts as well as the accessories the positioner shaft in position at the cap with their order numbers.
  • Page 19 Attachment to the control valve – mounting parts and accessories Lever 12.1 Screw 1.1 Nut 12.2 Stopper or connection for external piping 1.2 Disk spring Switch plate Follower pin Gasket 10 14 Follower clamp Formed seal 10 Cover plate Gasket 11 Cover 12 Connection block Lever M...

  • Page 20: Attachment According To Iec 60534-6

    Attachment to the control valve – mounting parts and accessories 3. Mount connecting plate (6) or pressure Attachment according to gauge bracket (7) with pressure gauges IEC 60534-6 (8) on the positioner, making sure both The positioner is attached to the control seal rings (6.1) are seated properly.
  • Page 21 Attachment to the control valve – mounting parts and accessories Attachment to rod-type yoke Rods with Ø max. 35 mm Attachment to NAMUR rib Additional bracket for actuators with 2800 cm Lever XL and L and travel ≥ 60 mm Lever Disk spring 14.1...

  • Page 22: Attachment To Type 3510 Micro-Flow Valve

    Attachment to the control valve – mounting parts and accessories Attachment to Type 3510 Micro-flow Valve The positioner is attached to the valve yoke using a bracket. Refer to Table 3 on page 14 for the required mounting parts as well as the accessories with their order numbers.
  • Page 23 Attachment to the control valve – mounting parts and accessories Lever Disk spring Follower pin Clamp Connecting clamp Seal rings Pressure gauge bracket Pressure gauge mounting kit Bracket Screw Important! Always use the connecting plate (6) included in the accessories to connect supply and output.

  • Page 24: Attachment To Rotary Actuators

    (Ø5) included in the Prior to the attachment of the positioner to mounting kit and screw tight into the the SAMSON Type 3278 Rotary Actuator, bore for pin position 90°. you have to mount the associated adapter 7.
  • Page 25 Attachment to the control valve – mounting parts and accessories (7, 8) 10.1 Important! Always use the connecting plate (6) included in the accessories to connect supply and output. Never screw threaded Control valve opens counterclockwise parts directly into the housing.

  • Page 26: Reversing Amplifier For Double-Acting Actuators

    Attachment to the control valve – mounting parts and accessories Reversing amplifier for Note! double-acting actuators The sealing plug (1.5) in the Type 3730 Positioner should not be unscrewed out of For the use with double-acting actuators, the the reversing amplifier. positioner must be fitted with a reversing The rubber seal (1.4) is not required and amplifier.
  • Page 27 Attachment to the control valve – mounting parts and accessories From the positioner Output 38 Supply 9 Control signals to the actuator Reversing amplifer Connecting ring 6.1 O-rings 1.1 Special screws 6.2 Screws 1.2 Gasket 1.3 Special nuts 1.4 Rubber seal 1.5 Sealing plug 1.6 Filter Fig.

  • Page 28: Attaching An External Position Sensor

    Attachment to the control valve – mounting parts and accessories Attaching an external position sensor Refer to Table 6 on page 33 for a list of the mounting parts as well as the accessories re- quired for mounting the position sensor. Accessories for the pneumatic connection to the positioner housing can be found in Ta- ble 7.
  • Page 29 Attachment to the control valve – mounting parts and accessories 2. Screw the position sensor (20) onto the Type 3277 Actuator with 240 to 700 cm mounting plate (21). The signal pressure is routed to the connec- 3. Depending on the actuator size and tion at the side of the actuator yoke for the rated travel of the valve, determine the version "Actuator stem extends".

  • Page 30: Mounting The Position Sensor With Attachment According To Iec 60534-6

    Attachment to the control valve – mounting parts and accessories Place the lever (1) in mid-position and 2.6.2 Mounting the position sensor hold it in place. Screw on the nut (1.1). with attachment according to 5. Place the follower clamp (3) on the actu- IEC 60534-6 ator stem, align and fasten it, making For the required mounting parts as well as...

  • Page 31: Mounting The Position Sensor To Type 3510 Micro-Flow Valve

    Attachment to the control valve – mounting parts and accessories For other actuator sizes or travels, select the Place the lever (1) in mid-position and lever and pin position from the travel table hold it in place. Screw on the nut (1.1). on page 13.

  • Page 32: Mounting The Position Sensor To Rotary Actuators

    Attachment to the control valve – mounting parts and accessories 4. Place the lever (1) and disk spring (1.2) 2.6.4 Mounting the position sensor on the sensor shaft. to rotary actuators Place the lever (1) in mid-position and For the required mounting parts as well as hold it in place.
  • Page 33 Attachment to the control valve – mounting parts and accessories Mounting parts for position sensor Order no. Table 6 Direct attachment Mounting parts for actuators with 120 cm see Fig. 11 left 1400-7472 G 1/8 1400-6820 Connecting plate (9, old) for Actuator Type 3277-5xxxxxx.00 1/8 NPT 1400-6821...

  • Page 34: Connections

    Connections Connections 3.1.1 Signal pressure gauges To monitor the supply air (Supply) and sig- Pneumatic connections nal pressure (Output), we recommend that pressure gauges be attached (see accesso- Caution! ries in Tables 1 to 5). The threads in the positioner housing are not designed for direct air connection! 3.1.2 Supply pressure The required supply air pressure depends...
  • Page 35 Connections d = Seat diameter [cm] ∆p = Differential pressure across the valve [bar] A = Actuator diaphragm area [cm = Upper bench range of the actuator [bar] If there are no specifications, calculate as follows: Required supply pressure = Upper bench range value + 1 bar Note! The signal pressure at the output (Out-...

  • Page 36: Electrical Connections

    Connections Electrical connections Caution! The terminal assignment specified in the certificate must be adhered to. Re- For electrical installation, you are re- versing the assignment of the electrical ter- quired to observe the relevant elec- minals may cause the explosion protection trotechnical regulations and the acci- to become ineffective! dent prevention regulations that ap-...

  • Page 37: Switching Amplifiers

    Connections The position transmitter is operated on a Shorten the connecting lead to the re- two-wire circuit. The usual supply voltage is quired length and strip the insulation off. 24 V DC. Considering the resistance of the Route the strands to the following con- supply leads, the voltage at the position tacts of the free connector: transmitter terminals can be between 12...

  • Page 38: Operation

    Operation Operation Volume restriction Q The volume restriction is used to adapt the air delivery to the actuator size. Two fixed Note! settings are possible depending on how the A summary about operating and start up air is routed at the actuator: can be found in section 7 on page 57.
  • Page 39 Operation Displays and their meaning Automatic mode Initialization in progress Maximum range AUtO TunE Clockwise Available Not available Counterclockwise Zero calibration Nominal travel Error Escape Increasing/increasing ää ix greater than 21.6 mA Increasing/decreasing Reset äæ ix smaller than 2.4 mA Start Blinking Controlled operation w too low...

  • Page 40: Enabling And Selecting Parameters

    Operation Enabling and selecting Note! parameters To cancel a value that you have just entered under a code, turn the button until ESC The codes which are marked with an aster- appears on the display and press to con- isk (*) in section 11 on page 62 onwards firm.

  • Page 41: Operating Modes

    Operation Operating modes Switching to manual operating mode Over Code 0 , press the button, AUtO 4.3.1 Automatic and manual appears in the display, Code 0 blinks. operating modes Turn button until MAN appears. Prior to initialization: If the positioner has not been initialized yet, the automatic operating AUtO cannot be se- lected.

  • Page 42: Safe - Fail-Safe Position

    Start-up and settings 4.3.2 SAFE – Fail-safe position Start-up and settings If you want to move the valve to fail-safe po- Note! sition, proceed as follows: A summary about start-up and operation can be found in section 7 on page 57. A leaflet including the same summary is also Select Code 0 , press the button, AUtO or...

  • Page 43: Setting The Volume Restriction Q

    Start-up and settings does not have any effect on the operation of Turn button until the display is ad- the positioner. justed to the desired direction, then con- firm reading direction by pressing the button. Setting the volume restriction Q For actuators smaller than 240 cm with Limiting the signal pressure...
  • Page 44 Start-up and settings 3. Turn the button until Code 1 appears, Note! confirm Code 1 by pressing button. If the selected pin position is smaller than in- The hand symbol and Code 1 blink. tended for the respective travel range, the 4.

  • Page 45: Initialization

    Start-up and settings Initialization Warning! During the initialization, the control During initialization the positioner adapts it- valve moves through its entire tra- self optimally to the friction conditions and vel/angle of rotation range. Therefo- the signal pressure demand of the control re, do not start initialization while a valve.

  • Page 46: Initialization Modes

    Start-up and settings A malfunctioning leads to the process being adopts this travel/angle of rotation as the interrupted. The fault symbol appears on operating range from 0 to 100 %. the display. See section 5.7 on page 53. For control valves, whose maximum range If the slide switch is set to AIR TO CLOSE, exceeds the effective travel/angle of rotation the positioner with firmware version 1.10 or...
  • Page 47 Start-up and settings During the initialization procedure, the Note! positioner checks whether the control valve For MAX initialization, the positioner cannot can move through the indicated nominal indicate nominal travel/angle of rotation in range (travel or angle) without collision. mm/°, Code 5 remains disabled. In case of a positive result, the indicated In addition, the lower (Code 8) and the up- nominal range is adopted with the limits of...
  • Page 48 Start-up and settings MAN – Initialization based on nominal range Default 15 (with default upper x-range value by means of manual adjustment). Initialization mode just as NOM , however, for starting up valves with unknown nominal Turn → Code 5 , press range.
  • Page 49 Start-up and settings Turn →Code 6 , press turn → MAN , press (substitute configuration, without initializa- tion) This initialization mode is an emergency mode. The positioner parameters are esti- Default MAX mated and not determined by an initializa- tion procedure, so that a high stationary ac- curacy cannot be expected.
  • Page 50 Start-up and settings known, it is recommended to accept its K and T values. Default 15 After setting the AIR TO OPEN/CLOSE switch for the fail-safe position, setting the volume restriction and pressing the INIT key, the positioner calculates its configuration Turn →...
  • Page 51 Start-up and settings CCL = counterclockwise and CL = clockwise. Direction of rotation which causes the valve Default OFF to move to the CLOSED position (view onto the rotary switch movement while positioner cover is open). Turn → Code 16 , Press Retain default value for pressure limit, change value only if necessary.

  • Page 52: Start-Up Via Local Interface (Ssp)

    Code 0 blinks. serial interface adapter (Order no. 1400-7700). Turn until AUtO appears on the display. Use the TROVIS-VIEW software with 3730-2 Press to confirm the operating mode. device module installed. All device parameters can be accessed via The positioner switches to automatic opera- the software.

  • Page 53: Faults

    Start-up and settings Faults Zero calibration In case of a fault, the fault symbol In case of discrepancies with the closing po- pears at the top of the display in the sition of the valve, e.g. with soft-sealed left-hand corner. plugs, it may become necessary to recalibrate the zero point.

  • Page 54: Reset To Default Values

    Adjusting the limit switch Reset to default values Adjusting the limit switch This function resets all parameters to the fac- The positioner version with inductive limit tory default values (see list of codes in sec- switch has one adjustable tag (1) mounted tion 11).
  • Page 55 5 % (see LC display). The device is set up accordingly when deliv- 3. Adjust the tag using the yellow adjust- ered ex works SAMSON. ment screw (2) until the tag enters or leaves the field and the switching ampli- Setting the switching point: fier responds.
  • Page 56 Adjusting the limit switch leaves the field of the proximity switch (3). You can measure the switching voltage as an indicator. Contact function: Tag leaving the field > Contact is made. Tag entering the field > Contact is opened. EB 8384-2 EN...

  • Page 57: Quick Start-Up Guide

    Mounting Make sure the lever can still move. Direct attachment Attachment to rotary actuators to SAMSON Type 3277 Actuator Lever M pin position 90° Travel mm Actuator cm Pin position Put the valve into the closed position, de- termine the opening direction.

  • Page 58: Start-Up

    Quick start-up guide Start-up Operation Selecting the parameters or values Connect pneumatic supply air (1.4 to Each parameter has a code number which 6 bar). is shown in the display. Use the button to Apply an electrical reference variable (4 to select.

  • Page 59: Initialization

    Quick start-up guide turn → Code 4, ↵ Initialization Select pin position, ↵ turn → Code 5 , ↵ Important! Perform a reset (Code 36) prior to each ini- Enter nominal travel/range, ↵ tialization turn → Code 6 , ↵ select NOM , ↵...

  • Page 60: Retrofitting An Inductive Limit Switch

    Retrofitting an inductive limit switch Retrofitting an inductive limit switch Required retrofit kit: Limit switch Order no. 1400-7460 1. Take off the rotary pushbutton (3) and cap (1), unthread the five fixing screws (2) and lift off the plastic cover (9). 2.

  • Page 61: Maintenance

    Maintenance Maintenance Servicing explosion-protected devices The positioner does not require any mainte- nance. If a part of the positioner on which the ex- plosion protection is based needs to be ser- There are filters with a 100 mm mesh size in viced, the positioner must not be put back the pneumatic connections for supply and into operation until an expert has inspected...

  • Page 62: Code List

    Code list Code list Parameter – Display, values Code Description [default setting] Important! Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration. AUtO = Automatic mode MAN = Manual mode Operating mode SAFE = Fail-safe position ESC = Escape [MAN]...
  • Page 63 Code list Select the initialization mode Init mode MAX: Maximum range of the control valve, the travel/angle of [MAX] the closure member from the CLOSED position to the opposite stop in the actuator. NOM: Nominal range of the control valve, the travel/angle of the closure member measured from the CLOSED position to the indicated OPEN position.
  • Page 64 Code list Pin position Standard Adjustment range Pin position table Code 4 Code 5 Code 5 Specified in mm or angle ° 3.6 to 17.7 for rotary actuators. 5.0 to 25.0 Note! 15.0 7.0 to 35.4 If the pin distance has been selected 30.0 10.0 to 50.0 too small with Code 4, the device...
  • Page 65 Code list Upper range value of the applicable reference variable range, w-end must be greater than w-start. 25.0 to 100.0 [100.0] % of the reference variable range 100 % = 20 mA If w reaches up to 1 % towards the final value that causes the Final position w <...
  • Page 66 7: Segmented ball valve linear 3: Butterfly valve linear 8: Segmented ball valve eq. p. 4: Butterfly valve eq. percentage 9: User-defined * * Definition over SAMSON TROVIS-VIEW software The time required to pass through the operating range when the w-ramp Open valve opens.
  • Page 67 Code list Switching mode of software limit switches alarm A1 and A2 in Alarm mode responding state (when positioner initialized). 0 to 3 [2] 1) Explosion-protected version according to EN 60947-5-6 0: A1 ≥ 2.1 mA A2 ≤ 1.2 mA 1: A1 ≤...
  • Page 68 Code list Operating direction of the position transmitter; indicates how the Position transmitter x/ix travel/angle position is assigned to the output signal i, based on [ää] the closed position. äæ The operating range (see Code 8) of the valve is represented by the 4 to 20 mA signal.
  • Page 69 Code list Resets all parameters to default (factory setting). Reset Note: After setting RUN, the positioner must be re-initialized. [OFF] Display only, Position transmitter indicates whether the position transmitter option is installed. Yes No Indicates whether the inductive limit switch option is installed or Inductive alarm not.
  • Page 70 Code list Fault alarm symbol active, when prompted, Err appears. Error codes – Remedy If any fault messages exist, they are displayed here. Initizialization error (indicated by the fault symbol on the display) The value supplied by the measuring signal is either too high or x <...
  • Page 71 Code list 1) A solenoid valve is installed (Code 45 = YES) and was Init – Solenoid valve not or not properly connected so that an actuator pressure could not be built up. The message appears when you attempt to initialize the positioner. 2) If you attempt to initialize the device from the fail-safe position (SAFE).
  • Page 72 Remedy Return the positioner to SAMSON AG for repair. The reference variable is much smaller than 4 mA (0 %); occurs if...
  • Page 73 Additional message at the fault Valve moves to the fail-safe position. alarm contact! Remedy Return the positioner to SAMSON AG for repair. The hardware positioner is monitored by means of a test calcula- Test calculation tion.
  • Page 74 Remedy Interrupt current and restart positioner. Otherwise, return the positioner to SAMSON AG for repair. Errors in options parameters, e.g. due to EMC disturbances. Options parameter Remedy Return the positioner to SAMSON AG for repair. EB 8384-2 EN...

  • Page 75: Dimensions In Mm

    Dimensions in mm Dimensions in mm or connecting plate Pressure gauge External bracket position sensor NAMUR attachment Lever mm S = 17 M = 50 L = 100 XL = 200 Direct attachment M20 x 1.5 Output (38) Supply (9) Attachment to rotary actuators VDI/VDE 3845 for all sizes of fixing level 2...

  • Page 76: Test Certificates

    EB 8384-2 EN...
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  • Page 88 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany Phone: + 49 69 4009-0 · Fax: +49 69 4009-1507 EB 8384-2 EN Internet: http://www.samson.de...

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