Samson 3725 Mounting And Operating Instructions
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Samson 3725 Mounting And Operating Instructions

Electropneumatic positioner
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Series 3725
Type 3725 Electropneumatic Positioner
Mounting and
Operating Instructions
EB 8394 EN
Firmware version 1.1x
Edition June 2014

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Summary of Contents for Samson 3725

  • Page 1 Series 3725 Type 3725 Electropneumatic Positioner Mounting and Operating Instructions EB 8394 EN Firmware version 1.1x Edition June 2014...
  • Page 2 Î For the safe and proper use of these instructions, read them carefully and keep them for later reference. Î If you have any questions about these instructions, contact SAMSON‘s After-sales Service Department (aftersalesservice@samson.de). The mounting and operating instructions for the devices are included in the scope of delivery.

  • Page 3: Table Of Contents

    Contents Safety instructions and measures ..............6 Notes on possible severe personal injury ............9 Notes on possible personal injury ..............10 Notes on possible property damage ..............10 Markings on the device ................12 Nameplate ....................12 Article code ....................13 Design and principle of operation ..............14 Mounting versions ..................14 Accessories and mounting parts ..............16 Travel tables ....................20...
  • Page 4 Contents Operation ....................48 Operating controls ..................48 6.1.1 Capacitive keys ....................48 6.1.2 Volume restriction Q ..................48 6.1.3 Display .......................49 Operating the positioner ................50 Adapting the display ..................51 Enabling configuration to change parameters..........51 Adjusting the volume restriction Q ..............52 Entering the air action ..................53 Entering the direction of action ..............53 Limiting the signal pressure ................54 Setting other parameters ................55...
  • Page 5 These Mounting and Operating Instructions EB 8394 EN are valid for positioners with firm- ware versions 1.10 to 1.19. The latest edition of these instructions, detailing the firmware version and modifications compared to the previous version, is available on our website u www.samson.de. EB 8394 EN...

  • Page 6: Safety Instructions And Measures

    In case operators intend to use the positioner in other applica- tions or conditions 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 7 Î Check with the plant operator for details on further protective equipment. Revisions and other modifications Revisions, conversions or other modifications to 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.
  • Page 8 Safety instructions and measures Servicing explosion-protected devices If a part of the device on which the explosion protection is based needs to be serviced, the device must not be put back into operation until a qualified inspector has assessed it accord- ing to explosion protection requirements, has issued an inspection certificate, or given the device a mark of conformity.

  • Page 9: Notes On Possible Severe Personal Injury

    Safety instructions and measures 1.1 Notes on possible severe personal injury DANGER Risk of the formation of an explosive atmosphere. Incorrect installation, operation, or maintenance of the positioner in potentially explosive atmospheres may lead to ignition of the atmosphere and cause death. Î...

  • Page 10: Notes On Possible Personal Injury

    Safety instructions and measures 1.2 Notes on possible personal injury WARNING Risk of personal injury due to moving parts on the valve. During initialization of the positioner and during operation, the actuator stem moves through its entire travel range. Injury to hands or fingers is possible if they are inserted into the valve.
  • Page 11 Safety instructions and measures Malfunction due to initialization not yet completed. The initialization causes the positioner to be adapted to the mounting situation. After ini- tialization is completed, the positioner is ready to use. Î Initialize the positioner on the first start-up. Î...

  • Page 12: Markings On The Device

    Supply max. 10 bar / 150 psi Input 4 ... 20 mA DC See technical data for ambient temperature -40 °C £ Ta* £+80 °C Firmware Model 3725 - 110 Var.-ID Serial no. SAMSON AG D-60314 Frankfurt Made in Germany Max.

  • Page 13: Article Code

    Markings on the device 2.2 Article code Positioner Type 3725- With LCD and autotune, 4 to 20 mA reference variable Explosion protection Without Intrinsic safety: ATEX Intrinsic safety: STCC Intrinsic safety: CSA Intrinsic safety: GOST Ship building certificate Without Bureau Veritas certification See Table 1 for details on explosion protection certificates.

  • Page 14: Design And Principle Of Operation

    3.1 Mounting versions the pick-up lever, non-contact magnetoresis- tive sensor and downstream electronics. The Type 3725 Positioner is suitable for the The pick-up lever is connected to a magnet following types of attachment: inside the device. The motion of the pick-up −...
  • Page 15 Design and principle of operation Valve Air capacity booster Sensor Pressure regulator A/D converter Fixed restriction Microcontroller Volume restriction D/A converter Display i/p converter Fig. 1: Circuit diagram EB 8394 EN...

  • Page 16: Accessories And Mounting Parts

    Design and principle of operation 3.2 Accessories and mounting parts Table 2: Direct attachment to Type 3277-5 and Type 2780-2 Actuators (see sec- Order no. tion 5.2) Mounting parts For actuators up to 120 cm² 1402-0239 Accessories for actuator Switchover plate for Type 3277-5xxxxxx.01 Actuator 1400-6822 Connecting plate for additional attachment of, e.g.
  • Page 17 Design and principle of operation Table 4: Pipe connections for Type 3277 (direct attachment) Pipe connection Actuator size Material Connection Order no. G ¼ / G  1402-0930 Steel ¼ NPT/  NPT 1402-0958 175 cm² G ¼ / G  1402-0950 Stainless steel ¼ NPT/  NPT 1402-0964 G ¼ / G  1402-0927 Steel ¼ NPT/...
  • Page 18 VDI/VDE 3845 (September 2010), level 1 , AA1 size 1402-0243 VDI/VDE 3845 (September 2010), level 2 AA2 size 1402-0244 VETEC Type S160 Actuator or SAMSON Type 3278 Rotary Actuator (160 cm²) 1402-0294 VETEC Type S320 1402-0295 Heavy-duty version VDI/VDE 3845 (September 2010), level 1 , AA1 to AA4 size 1402-1097 VDI/VDE 3845 (September 2010), level 2...
  • Page 19 Design and principle of operation Order no. Table 7: General accessories Cable gland M20x1.5 Black plastic 8808-1011 Blue plastic 8808-1012 Nickel-plated brass 1890-4875 Stainless steel 1.4305 8808-0160 Adapter M20x1.5 to ½ NPT Powder-coated aluminum 0310-2149 Stainless steel 1400-7114 Brief instructions inside cover German 0190-6173 English...

  • Page 20: Travel Tables

    [cm²] [mm] Min. Travel Max. 6/12 5.0 mm 16.0 mm 7.0 mm 22.0 mm Attachment according to IEC 60534-6 (NAMUR) SAMSON Type 3271 Actuator Travel of other valves Required Assigned lever pin position Rated travel Size [cm²] Min. Max. [mm] 5.0 mm 16.0/25.0  mm 120/240/350 7.0 mm...

  • Page 21: Technical Data

    Design and principle of operation 3.4 Technical data Type 3725 Positioner Travel (adjustable) Direct attachment to Type 3277: 5 to 30 mm Direct attachment to Type 2780-2: 6/12/15 mm Attachment to Type 3372 Actuator: 15/30 mm Attachment according to IEC 60534-6 (NAMUR): 5 to 50 mm Attachment to rotary actuators: 24 to 100°...
  • Page 22 Design and principle of operation Safety Influences Temperature: ≤ 0.15 %/10 K Effect of vibration: ≤ 0.25 % up to 2000 Hz and 4 g according to IEC 770 Supply air: None Electromagnetic Complying with EN 61000-6-2, EN 61000-6-3 and NAMUR Recommendation NE 21 compatibility Intrinsic safety: ATEX, STCC, CSA, GOST Explosion protection...

  • Page 23: Dimensions In Mm

    Design and principle of operation 3.5 Dimensions in mm M20 x 1.5 62.50 Fig. 2: Dimensional drawings for Type 3725 Positioner EB 8394 EN...
  • Page 24 Design and principle of operation Fixing levels according to VDI/VDE 3845 (September 2010) Fixing level 2 (bracket surface) Fixing level 1 (actuator surface) Actuator Dimensions in mm Size Ød ØD 5.5 for M5 5.5 for M5 5.5 for M5 ØD 5.5 for M5 5.5 for M5 6.5 for M6 Flange type F05 acc.

  • Page 25: Measures For Preparation

    − Observe storage instructions. 4.1 Unpacking − Avoid long storage times. − Contact SAMSON in case of different stor- age conditions or long storage periods. NOTICE Risk of positioner damage due to foreign Storage instructions particles entering it.

  • Page 26: Mounting And Start-Up

    Mounting and start-up 5 Mounting and start-up 5.1 Lever and pin position The positioner is adapted to the actuator and NOTICE to the rated travel by the lever on the back of Risk of malfunction due to incorrect sequence the positioner and the pin inserted into the of mounting, installation, and start-up.
  • Page 27 Mounting and start-up Fig. 3: M lever with pin position 35 Top stop Vent opening Bottom stop Fig. 4: Mechanical stops and vent opening EB 8394 EN...

  • Page 28: Direct Attachment

    Mounting and start-up 5.2 Direct attachment 4. 15 mm travel: Keep the follower pin (2) on the M lever (1) on the back of the po- 5.2.1 Type 3277-5 and sitioner in the pin position 35 (delivered state). 7.5 mm travel: Remove the fol- Type 2780-2 Actuators lower pin (2) from the pin position 35, Î...
  • Page 29 Mounting and start-up Lever 1.1 Nut Symbols Switchover plate (9) 1.2 Disk spring Follower pin Actuator stem Follower clamp extends Screw plug Stopper Left attachment Right attachment Connecting plate 6.1 Seals Pressure gauge Actuator stem bracket retracts Pressure gauge Signal pressure mounting kit input for left Switchover plate...
  • Page 30 Mounting and start-up 8. Mount cover (11) on the other side. Additional solenoid valve Make sure that the vent plug is located at If a solenoid valve is additionally mounted the bottom when the control valve is in- onto the actuator, the signal pressure port at stalled to allow any condensed water the back of the positioner must be sealed that collects to drain off (Fig. 7).
  • Page 31 Mounting and start-up Screw plug (4) (signal pressure port) Park position Fastening screw Fig. 8: Signal pressure port and park position for screw plug EB 8394 EN...

  • Page 32: Type 3277 Actuator

    Mounting and start-up 5.2.2 Type 3277 Actuator The lever (1) must rest on the follower clamp with spring force. Î Required mounting parts and accesso- Fasten the positioner on the actuator us- ries: Table 3 on page 16. ing the two fixing screws. Î...
  • Page 33 Mounting and start-up Type 3372 Actuator with Type 3725 10 15 1 2 3 Positioner (direct attachment) Ansicht A SUPPLY 12.1 12.2 M lever Disk spring Follower pin Follower clamp Cover Connection block View A 12.1 Screw 12.2 Stopper or connection for...

  • Page 34: Attachment According To Iec 60534-6

    Mounting and start-up 5.3 Attachment according to the slot of the follower plate (3). Adjust the lever (1) correspondingly. IEC 60534-6 Fasten the positioner to the NAMUR The positioner is attached to the control valve bracket using its two mounting screws. using a NAMUR bracket (10).
  • Page 35 Mounting and start-up Attachment to rod-type yoke 20 to 35 mm rod diameter Lever 14.1 Disk spring Follower pin Follower plate Connecting plate Seals Pressure gauge brack- Pressure gauge Stem connector Bracket NAMUR bracket Screw Bolt 14.1 Screws Travel indicator scale U-bolt Fig. 10: Attachment according to IEC 60534-6 EB 8394 EN...

  • Page 36: Attachment To Type 3372 Actuator (V2001)

    Mounting and start-up 5.4 Attachment to Type 3372 Actuator (V2001) The Type 3725 Positioner is already included in the scope of delivery for Series V2001 Valves (Fig. 11). The attachment is briefly described below to allow conversion work to be performed. Actuator with 120/350 cm², stem extends...
  • Page 37 Mounting and start-up Type 3372 Actuator, version with 120 cm² Type 3372 Actuator, version with 350 cm² Fig. 11: Mounting on Type 3372 Actuator EB 8394 EN...

  • Page 38: Attachment To Rotary Actuators

    Î Before attaching the positioner onto the is at half its angle of rotation. SAMSON Type 3278 Rotary Actuator 8. Stick the scale plate on the coupling (160 cm²) or VETEC Type S160 Actuator, wheel (4) so that the arrow tip indicates...
  • Page 39 Coupling wheel Mounting bracket Screw 10.1 Screws Disk spring Adapter Actuator shaft 10.1 10.1 10.1 Attachment to SAMSON Type 3278 Attachment according to VDI/ Rotary Actuator (160 cm²) or VETEC VDE 3845, level 1 Type S160 Actuator Fig. 13: Attachment to rotary actuators EB 8394 EN...

  • Page 40: Heavy-Duty Version

    (11) underneath, if neces- pressure gauge bracket or connecting plate). sary. 2. For SAMSON Type 3278 and VETEC 8. Fasten the positioner onto the adapter S160 Rotary Actuators, screw the adapt- plate (12). er (5) onto the free end of the shaft or 9.
  • Page 41 Distance piece Actuator shaft or Adapter plate adapter 10.1 10.1 SAMSON Type 3278 Attachment according to VDI/VDE 3845 VETEC S160, VETEC R (Sept. 2010) Fixing level 1, AA1 to AA4 size (see page 24) Fig. 15: Attachment to rotary actuators (heavy-duty version) EB 8394 EN...

  • Page 42: Mounting The Type 3710 Reversing Amplifier

    Mounting and start-up 5.5.2 Mounting the Type 3710 Reversing Amplifier When a Type 3710 Reversing Amplifier is used, a connecting plate is placed between the positioner and reversing amplifier. The reversing amplifier is fastened together with the connecting plate to the positioner using screws (Fig. 16).

  • Page 43: Pneumatic Connections

    Mounting and start-up 5.6 Pneumatic connections NOTICE Risk of malfunction due to failure to comply WARNING with required air quality. Risk of injury by possible movement of the Only use supply air that is dry and free of oil actuator stem after connecting the signal and dust.

  • Page 44: Supply Pressure

    Mounting and start-up Attachment according to IEC 60534-6 Supply pressure for fail-close valves (for (NAMUR) globe and angle valves): Î For attachment according to IEC 60534- Î Required supply pressure = Upper bench 6 (NAMUR), the signal pressure can be range value + 0.2 bar, minimum 1.4 bar. routed to either the top or bottom dia- Supply pressure for fail-open valves (for phragm chamber of the actuator, de-...

  • Page 45: Electrical Connections

    Mounting and start-up 5.8 Electrical connections DANGER Risk of the formation of an explosive atmosphere. For installation in hazardous areas, observe the relevant standards that apply in the country of use. Standard applicable in Germany: EN 60079-14: 2008 (VDE 0165, Part 1) Explosive Atmo- spheres –...

  • Page 46: Electric Power Supply

    Mounting and start-up 5.8.2 Cable entry Equipment for use in zone 2/zone 22 In equipment operated according to type of The M20x1.5 cable gland is designed for a protection Ex nA II (non-sparking equipment) clamping range of 6 to 12 mm. according to EN 60079-15: 2003: The cage clamp terminals hold wire Î...
  • Page 47 Mounting and start-up Plastic part Terminal assignment for mA control signal: Fig. 17: Electrical connections EB 8394 EN...

  • Page 48: Operation

    Operation 6 Operation 6.1 Operating controls Three capacitive keys are used to operate the positioner and allow the user to navigate with- in the menu on the display (Fig. 18). Additionally, the volume restriction allows the air output capacity to be adapted to the size of the actuator. 6.1.1 Capacitive keys : Up...

  • Page 49: Display

    Operation 6.1.3 Display Icons which are assigned to certain codes and functions are indicated on the display (Fig. 18). The bar elements indicate the system deviation that depends on the sign (+/–) and the value. One bar element appears per 1 % system deviation. If the positioner has not yet been initialized, the lever position in degrees in relation to the mid-axis is indicated.

  • Page 50: Operating The Positioner

    Operating the positioner 7 Operating the positioner Before start-up, mount the positioner following the sequence described in section 5. Apply the electric reference variable to start up the positioner. Refer to section 5.8.3. Note − LOW on the display indicates that the reference variable is lower than 3.8 mA. −...

  • Page 51: Adapting The Display

    Operating the positioner 7.1 Adapting the display The display reading direction can be rotated by 180°. If the displayed data appear upside down, proceed as follows: 1. Touch until Code P1 appears. 2. Press to confirm the selected code. P1 blinks. 3.

  • Page 52: Adjusting The Volume Restriction Q

    Operating the positioner 7.3 Adjusting the volume restriction Q The volume restriction Q (see Fig. 19) serves to adapt the air output capacity to the size of the actuator: Actuators with a transit time < 1 s, e.g. linear actuators with an effective area smaller than 240 cm², require a restricted air flow rate.

  • Page 53: Entering The Air Action

    Operating the positioner 7.4 Entering the air action − ATO (air to open) applies to a valve opening as the signal pressure increases. − ATC (air to close) applies to a valve closing as the signal pressure increases. The signal pressure is the pneumatic pressure at the output of the positioner applied to the actuator.

  • Page 54: Limiting The Signal Pressure

    Operating the positioner The following correlation applies: Valve CLOSED OPEN Display 100 % Direction of action increasing/increasing (>>) 4 mA 20 mA Direction of action increasing/decreasing (<>) 20 mA 4 mA 7.6 Limiting the signal pressure If the maximum actuator force is too high for the valve used, the signal pressure limit can be activated in Code P9.

  • Page 55: Setting Other Parameters

    Operating the positioner 7.7 Setting other parameters The following table lists all the parameter codes and their default settings. Proceed as de- scribed previously to change parameters. More details concerning the parameter codes can be found in section 11.2. Parameter codes [default settings] Status indication End position w >...

  • Page 56: Canceling Initialization

    Operating the positioner The type and extent of self-adaptation depends on the preset parameters. MAX applies as the default setting for the nominal range (Code P4). During the initialization process, the po- sitioner determines the total travel range or rotational range of the valve (from the CLOSED position to the opposite end position).

  • Page 57: Zero Calibration

    Operating the positioner Initial state 1: The positioner is not initialized. The positioner goes to the fail-safe position after the initialization process has been canceled. Initial state 2: The positioner is initialized. On canceling a new initialization process, the positioner returns to closed-loop operation. The settings of the previous initialization are used.

  • Page 58: Canceling Zero Calibration

    Operating the positioner 7.9.1 Canceling zero calibration Zero calibration can be canceled: : ESC blinks on the display. 1. During zero calibration touch 2. Press to confirm: Zero calibration is canceled. Note This code must be confirmed by pressing . Otherwise, the code remains active. The positioner changes to closed-loop operation without performing a zero calibration.

  • Page 59: Reset

    Operating the positioner Positioner that has not been initialized Touch for a long time to move the valve manually. The valve is only moved in one direction uncontrolled. The bar elements on the display indi- cate the change in direction. Touch to deactivate manual mode.

  • Page 60: Servicing

    SAMSON, which comply with the original u www.samson.de > Contact. specifications. The Type 3725 Positioner requires no main- tenance. There are filters with a 100 µm mesh size in the pneumatic connections for supply and output which can be removed and cleaned, if required.

  • Page 61: Malfunctions

    Malfunctions 9 Malfunctions In case of a fault, the fault indication icon is displayed. Switch past Code P0 or P20 to dis- play the respective error code E0 to E15 together with ERR appear on the display. Refer to the error code list in section 9.2 for the cause of the errors and the recommended action. Example: If, for instance, a travel has been entered in Code P4 (nominal range) which is larger than the maximum valve travel possible, the initialization process would be interrupted (E2 error...

  • Page 62: Resetting Error Codes

    Malfunctions 9.1 Resetting error codes The E0 and E8 error codes can be reset as follows: 1. Touch to select the error code. to confirm the error code. ESC is displayed and the er- 2. Touch ror code blinks. 3. Touch until RST appears.
  • Page 63 Malfunctions EB 8394 EN...

  • Page 64: Error Codes

    The errors listed in the following table are assigned to error classes: Error class 1: No operation possible Error class 2: Manual operation only possible Error class 3: Manual operation and closed-loop control possible Contact SAMSON's After-sales Service department for malfunctions not listed in the table (see section 11.1). Code Description...

  • Page 65: Emergency Action

    Reset error code (see section 9.1). Check positioner mounting and re-initialize the positioner. Device error (internal) Return positioner to SAMSON AG for repair. 9.3 Emergency action Upon failure of the air supply or electric signal, the positioner vents the actuator, causing valve to move to the fail-safe position determined by the actuator.

  • Page 66: Decommissioning And Disassembly

    Decommissioning and disassembly 10 Decommissioning and disas- 10.2 Removing the positioner sembly 1. Disconnect the wires for the control sig- nal from the positioner. DANGER 2. Disconnect the lines for supply air and Risk of fatal injury due to ineffective explo- signal pressure (not required for direct sion protection.

  • Page 67: Annex

    You can reach the After-sales Service De- partment at aftersalesservice@samson. 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 the SAMSON website, in all SAMSON product catalogs or on the back of these Mounting and Operat- ing Instructions.

  • Page 68: Code List

    Annex 11.2 Code list 11.2.1 Parameter codes Code Display, values Description [default setting] Note: Codes marked by an asterisk (*) indicate that the positioner needs to be re-initialized after- wards Status reading with The reading indicates the valve position or angle of rotation in % basic information when the positioner is initialized.
  • Page 69 0, 1, 2 for globe valves, 0 to 8 with rotary actuators (P3 = 90°) Linear 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...
  • Page 70 Annex Press button to cancel the initialization process. As a result, the Start initialization valve moves to the fail-safe position. After a power supply failure during initialization, the positioner starts with the values of the last initialization (if available). The zero calibration process can be interrupted by touching Start zero calibration The control valve returns to closed-loop operation.
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  • Page 80 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 EB 8394 EN samson@samson.de · www.samson.de...

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