Samson 3730-6, Mounting And Operating Instructions

Page 1: ...30 Electropneumatic Positioner Type 3730 6 with HART communication and pressure sensors Mounting and Operating Instructions EB 8384 6 EN 1300 1623 Firmware version 1 01 Edition February 2012 Fig 1 Typ...

Page 2: ...t in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury NOTICE indicates a property damage message Note Supplementary explanat...

Page 3: ...actuators 30 4 4 1 Heavy duty version 32 4 5 Reversing amplifier for double acting actuators 34 4 6 Attaching an external position sensor 34 4 6 1 Mounting the position sensor with direct attachment 3...

Page 4: ...ly selected OPEN position 62 7 6 4 MAN2 Initialization based on manually selected end positions 64 7 6 5 SUB Substitute calibration 65 7 6 6 Tuning the KP input filter 68 7 7 Zero calibration 68 7 8 S...

Page 5: ...15 Dimensions in mm 109 15 1 Fixing levels according to VDI VDE 3845 September 2010 110 16 Valve characteristic selection 111 Certificates 113 Index 121 EB 8384 6 EN 5 Contents...

Page 6: ...Refer to section 11 4 Any hazards that could be caused by the process medium the operating pressure the signal pressure or by moving parts of the control valve are to be prevented by means of the appr...

Page 7: ...a80 C IP 66 813 Options additional equipment Inductive limit switch Without With SJ2 SN With SJ2 S1N 0 1 2 0 Venting function Without Solenoid valve 24 V DC Forced venting 24 V DC 0 1 2 Additional equ...

Page 8: ...r 5 The PD controller compares this valve position to the 4 to 20 mA DC control signal supplied by the controller after it has been converted by the A D converter 4 In case of a system deviation the a...

Page 9: ...put 14 Software limit switches A1 A2 15 Fault alarm output A3 16 LCD 17 Solenoid valve control 18 Galvanic isolation 19 D A converter 20 Communication interface 21 HART modulation 22 Binary input BE 2...

Page 10: ...volt age supply the fail safe position S is acti vated and is indicated on the positioner display If required the user can check the safety function using the software For more details refer to the O...

Page 11: ...ated variable range limitation Seat leakage Positioner valve linkage Max set point deviation Cycle counter histo gram Packing leakage Dynamic load factor Leakage sensor Seat leakage Course of end posi...

Page 12: ...on for ATC See section 7 1 for valve closed position 3 5 Communication The positioner is equipped with an interface for HART protocol Highway Addressable Remote Transducer for communication pur poses...

Page 13: ...issued in dependent of the positioner s input signal the momentary travel angle of rotation is controlled in real time Additionally the po sition transmitter allows positioner faults to be indicated...

Page 14: ...data is reset once Additionally the external solenoid valve function can be selected if a non floating contact is configured 4 External solenoid valve The voltage for an external solenoid valve is con...

Page 15: ...to the capacity of supply pressure Limitable between 1 4 and 7 0 bar by soft ware Character istic Adjustable Linear equal percentage reverse equal percentage user defined by software Butterfly rotary...

Page 16: ...eld communicator device description for Type 3730 6 Software requirements PC DTM file acc to Specification 1 2 suitable for integrating the positioner in frame applications that supports the FDT DTM c...

Page 17: ...the forced venting must both be operated in a safety related system Forced venting Approval acc to IEC 61508 SIL Input 24 V DC reverse polarity protection static destruction limit 40 V Current consum...

Page 18: ...fault Passive switching behavior Connection For externally applied DC voltage reverse polarity protection Electrical data 3 to 30 V Destruction limit 40 V Current draw at 24 V 3 7 mA Voltage 6 V Switc...

Page 19: ...EB 8384 6 EN 19...

Page 20: ...to 43 to mount the positioner Observe the type of attachment Observe the assignment between lever and pin position see travel tables on page 21 Lever and pin position The positioner is adapted to the...

Page 21: ...ording to IEC 60534 6 NAMUR SAMSON valves Type 3271 Actuator Other valves actuators Required lever Assigned pin position Actuator size Rated travel cm mm min Travel max 60 and 120 with Type 3510 Valve...

Page 22: ...mm travel Remove the follower pin 2 from the pin position 35 reposition it in the bore for pin position 25 and screw tight 6 Insert formed seal 15 in the groove of the positioner housing 7 Place posit...

Page 23: ...m 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp 5 Stopper 6 Connecting plate 6 1 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 9 Connecting plate for actuator 10...

Page 24: ...follower pin 2 rests on the top of the follower clamp 3 Adjust the lever 1 correspond ingly and open the positioner cover to hold the positioner shaft in position at the cap or the switch Fig 21 on pa...

Page 25: ...connection for Type 3277 Actuator with 240 350 355 and 700 cm 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp 10 Cover plate 11 Cover 11 1 Vent plug 12 Connection block 12 1 Screw 12...

Page 26: ...lly aligned with the NAMUR bracket at mid valve travel 3 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges 8 on the positioner making sure both seal rings 6 1 are seated proper...

Page 27: ...et for actuators with 2800 cm 2 and travel 60 mm Lever L or XL 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower plate 3 1 Follower plate 6 Connecting plate 6 1 Seal rings 7 Pressure gauge bra...

Page 28: ...d properly NOTICE The lever must be held stationary in the mid position while undoing or fastening the nut to ensure that the lever does not move to one of the end stops 4 Unscrew the standard install...

Page 29: ...0 Micro flow Valve 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Clamp 6 Connecting clamp 6 1 Seal rings 7 Pressure gauge bracket 8 Pressure gauge mounting kit 10 Bracket 11 Screw Note Always use t...

Page 30: ...r size to the actuator case Position top pair of brackets 10 and screw tight 5 Mount connecting plate 6 or pressure gauge bracket 7 with pressure gauges to the positioner making sure both O rings are...

Page 31: ...ply and output Never screw threaded parts directly into the housing Control valve opens clockwise Control valve opens counterclockwise Legends Figs 8 9 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3...

Page 32: ...valve is OPEN Adhesive labels with explana tory symbols are enclosed and can be stuck on the housing if required 4 Screw tight coupling wheel 4 onto the slotted actuator shaft or adapter 3 us ing scre...

Page 33: ...Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Adapter 4 Coupling wheel 4 1 Screw 4 2 Disk spring 4 3 Adhesive label 5 Actuator shaft or adapter 5 1 Adapter 6 Connecting plate only for G 6 1 Seal rin...

Page 34: ...5 1 and 5 2 apply for the pneumatic and electrical connection Operation and setting are described in sections 7 and 8 Since 2009 the back of the position sen sor 20 is fitted with two pins acting as m...

Page 35: ...on the actuator size and rated valve travel determine the re quired lever and position of the fol lower pin 2 from the travel table on page 21 The positioner is delivered with lever M in pin position...

Page 36: ...t collects to drain off 4 6 2 Mounting the position sen sor with attachment accord ing to IEC 60534 6 For the required mounting parts and acces sories refer to Table 7 on page 44 1 Place the lever 1 o...

Page 37: ...rews onto the valve 4 6 3 Mounting the position sen sor to Type 3510 Mi cro flow Valve For the required mounting parts and acces sories refer to Table 7 on page 44 1 Place the lever 1 in mid position...

Page 38: ...sk spring 1 2 from the sensor shaft 2 Screw the position sensor 20 onto the mounting plate 21 3 Replace the follower pin 2 normally attached to the lever 1 with the metal follower pin 5 from the acces...

Page 39: ...on the NAMUR rib should preferably be used to mount the sen sor Fig 17 Note If the positioner was mounted directly onto the actuator integral attachment the NAMUR interfaces on either side of the val...

Page 40: ...4 9 Air purging function for single acting actuators The exhaust air from the positioner is di verted to the actuator spring chamber to provide corrosion protection inside the actu ator The following...

Page 41: ...ies EB 8384 6 EN 41 Attachment to the control valve Mounting parts and accessories Table 2 Direct attachment to Type 3277 5 Actuator Fig 4 Order no Mounting parts Mounting parts for actuators 120 cm o...

Page 42: ...er no Travel in mm Lever For actuators 7 5 S Type 3271 5 Actuator with 60 120 cm on Type 3510 Valve Fig 7 1400 7457 5 to 50 M 1 Actuators from other manufacturers and Type 3271with 120 to 700 cm 1400...

Page 43: ...T 1400 7459 Pressure gauge mounting kit up to max 6 bar output supply St steel brass 1400 6950 St steel st steel 1400 6951 Table 6 General accessories Order no Accessories Pneumatic reversing amplifie...

Page 44: ...ollower clamp and coupling wheel version with CrNiMo steel bracket see Fig 16 Size AA1 to AA4 heavy duty version Size AA5 heavy duty version e g Air Torque 10 000 1400 7473 1400 9384 1400 9992 Bracket...

Page 45: ...up stream pressure reducing stations must be observed If the positioner is attached directly to the Type 3277 Actuator the connection of the positioner s output pressure to the actuator is fixed For a...

Page 46: ...allation observe the rel evant electrotechnical regulations and the accident prevention regulations that apply in the country of use NOTICE Adhere to the terminal assignment Switching the assignment o...

Page 47: ...range There is a second M20 x 1 5 threaded bore in the housing that can be used for addi tional connection when required The screw terminals are designed for wire cross sections of 0 2 to 2 5 mm Tigh...

Page 48: ...r the amplifiers should com ply with the limit values of the output circuits conforming to EN 60947 5 6 If the positioner is to be installed in hazard ous areas the relevant regulations must be observ...

Page 49: ...ans of the HART protocol all control room and field devices connected in the loop are individually accessible through their address via point to point or standard bus multidrop Point to point The bus...

Page 50: ...ge of 330 mV is relea sed 16 5 W at 20 mA Alternatively a 250 W resistor can be con nected in series and a 22 mF capacitor can be connected in parallel to the analog out put Note The load for the cont...

Page 51: ...EB 8384 6 EN 51...

Page 52: ...connection Readings on display Icons appear on the display that are as signed to parameters codes and functions Operating mode Manual mode see section 8 2 1 Automatic mode see section 8 2 1 S SAFE see...

Page 53: ...sing Increasing decreasing blinks Emergency mode see Code 62 blinks Not initialized S Valve in mechanical fail safe position Failure Maintenance required demanded blinks Out of specification blinks Wr...

Page 54: ...on locally at the positioner The write access is enabled by default The on site operation including the INIT key can be locked over HART communication The word HART then blinks on the display when Cod...

Page 55: ...vel Absolute total valve travel Binary input status 0 Not active 1 Active 255 Internal solenoid valve forced venting status 0 De energized 1 Energized 2 Not installed Condensed state 0 No message 1 Ma...

Page 56: ...NOTICE Perform the start up settings in the same se quence as listed section 7 1 to section 7 6 Note The positioner performs a test in the start up phase while following its automa tion task at the s...

Page 57: ...position of the restriction has been changed 7 3 Adapting the display The data representation on the positioner display can be turned by 180 to adapt it to how the positioner is mounted Reading direct...

Page 58: ...ode Operating mode Default MAN Turn Code 0 Press Code 0 blinks Turn MAN Press The positioner changes to the manual operating mode Checking the operating range Manual set point current angle of rotatio...

Page 59: ...t values Refer to section 7 9 Note When the write protection is acti vated the initialization cannot be started During initialization the positioner adapts it self optimally to the friction conditions...

Page 60: ...sed position AIR TO CLOSE If the slide switch is set to AIR TO CLOSE the positioner automatically switches to the direction of action increasing decreasing on successful completion of initializa tion...

Page 61: ...Press to confirm MAX as the initialization mode Start initialization 4 Press INIT key to start initialization After initialization the maximum travel an gle of rotation Code 5 which was detected durin...

Page 62: ...n mode Default MAX Turn Code 6 Press Code 6 blinks Turn NOM Press to confirm the NOM as the initial ization mode Start initialization 4 Press INIT key to start initialization Note If the nominal range...

Page 63: ...ant section on attachment Press Turn Skip nominal range Code 5 and go to Code 6 Select the initialization mode Initialization mode Default MAX Turn Code 6 Press Code 6 blinks Turn MAN Press to confirm...

Page 64: ...tarted when the valve position differs in the end positions and the positioner has not yet been initialized Enable configuration Note If no settings are entered within 120 seconds the enabled configur...

Page 65: ...several times This initialization mode however is an emergency mode in which the control parameters are estimated and not deter mined by an initialization procedure As a result a high level of accura...

Page 66: ...de 6 Press Turn SUB Press to confirm SUB as the initialization mode Enter the direction of action Direction of action Default Turn Code 7 Press Code 7 blinks Turn Direction of action Press Deactivate...

Page 67: ...fine the valve closed position 4 Set switch for valve closed position AIR TO OPEN or AIR TO CLOSE as de scribed in section 7 1 on page 56 4 Set volume restriction as described in section 7 2 on page 5...

Page 68: ...During the tuning the valve moves through its whole range and the input filter is recalibrated 7 7 Zero calibration In case of discrepancies with the closing po sition of the valve e g with soft seale...

Page 69: ...Set point lower range value Code 12 Set point upper range value Code 13 Discrete analysis If the reference variable w is below Operating point limit Code 49 h5 at the start of automatic operation the...

Page 70: ...e low the Fail safe action limit The valve moves back to fail safe position Enable configuration Turn Code 3 display No Press Code 3 blinks Turn YES Press display Select on off valve as type of applic...

Page 71: ...in another posi tion or when the positioner is to be mounted to another valve Performing a reset does not necessarily mean the positioner must be re initialized Enable configuration Turn Code 3 displ...

Page 72: ...minal range NO YES YES 6 Initialization mode NO YES YES 7 Direction of action NO YES YES 8 Lower travel angle range value NO YES YES 9 Upper travel angle range value NO YES YES 10 Lower travel angle r...

Page 73: ...troke test PST A2 Test start NO NO NO A3 Enter test interval NO YES YES A8 Activate Dp out monitoring NO YES YES A9 Dp out monitoring value NO YES YES d2 Lower range value NO YES YES d3 Upper range va...

Page 74: ...figuration enabled Turn Code 3 display No Press Code 3 blinks Change the setting of Code 3 Turn YES Press display Configuration is enabled You can now configure codes one after the other Turn and sele...

Page 75: ...set point last used during automatic mode The current position is displayed in Adjust the manual set point Turn Code 1 Press Code 1 blinks Turn until sufficient pressure has been built up in the posi...

Page 76: ...OVIS VIEW 4 For more details refer to the Operating Instructions EB 8389 1 EN on EXPERTplus Valve Diagnostics To provide a better overview the classified messages are summarized in a condensed state T...

Page 77: ...is case ERR appears on the display Example Error caused by pin position The cause and recommended action are listed in the code list section 14 Fault alarm output The Failure as the condensed state ca...

Page 78: ...n both end posi tions of the valve The switch however can also be adjusted to indicate intermediate valve positions Note The inductive limit switch replaces the software limit switch A1 with terminal...

Page 79: ...the tag enters or leaves the field and the switching am plifier responds You can measure the switching voltage as an indicator Contact function 4 Tag leaving the field contact is made 4 Tag entering...

Page 80: ...e socket X7 of the top board and insert the cable connector 11 5 Guide the cable in such a manner that the plastic cover can be placed back onto the positioner Insert the fixing screws 2 and screw tig...

Page 81: ...opera tion outside hazardous areas and are in tended for future use inside hazardous ar eas must comply with the safety require ments placed on serviced devices Before being used inside hazardous area...

Page 82: ...ration and work on equipment The interconnection with intrinsically safe circuits to check or calibrate the apparatus must only be performed with intrinsically safe current voltage calibrators and mea...

Page 83: ...rotary pushbutton the current travel angle is displayed in when the positioner is ini tialized otherwise the position of the lever in relation to the cen tral axis is indicated in degrees Note Can on...

Page 84: ...0 0 200 120 0 40 0 to 200 0 90 90 0 24 0 to 100 0 300 200 0 60 0 to 300 0 5 Nominal range 15 0 mm or angle ESC For initialization using NOM nominal range or SUB substitute calibration the nominal rang...

Page 85: ...Increasing decreasing a globe valve closes as the set point increases The direction of action is adapted to the change in closed direc tion as follows ATO AIR TO OPEN After initialization the directio...

Page 86: ...wer limit and 100 to the adjusted upper limit 10 Lower travel angle limit lower x limit No 0 0 to 49 9 of the operating range ESC Lower limitation of the travel angle of rotation to the entered value...

Page 87: ...e valid set point range This value must be greater than the lower range value w start 14 CLOSED end position end position w No 0 0 to 49 9 of the span set over Code 12 13 ESC 1 0 Limit of the set poin...

Page 88: ...se behavior is reached or when the maximum value of 4 is reached the KP level can be decreased in incre ments 18 Derivative action time Tv level No 1 to 4 ESC 2 See Code 19 A change of the TV level ha...

Page 89: ...ntered in this code does not apply when the safety function is triggered the solenoid valve forced venting is acti vated or when the auxiliary power fails The time required to pass through the operati...

Page 90: ...itialized the software limit switches always register the signal as in the state of no response If there is no mA signal at the terminals 11 12 the software limit switches both switch to 1 2 mA signal...

Page 91: ...Code 32 YES the position transmitter issues the value as set in Code 30 during initialization or zero calibration When Code 32 No 4 mA is issued during a running self ad aptation 30 Fault alarm ix 3 N...

Page 92: ...h motion when the positioner cover is open Note Only needs to be entered when the SUB initialization mode Code 6 is selected 35 Blocking position 0 mm ESC Distance up to CLOSED position Note Only need...

Page 93: ...ve contact option is installed 39 Set point deviation e Read only Shows the set point deviation e w x 40 Min transit time OPEN Read only Minimum opening time determined during initialization 41 Min tr...

Page 94: ...tandard multidrop bus A maximum of 15 field devices can be connected in parallel to a single pair of wires The HART master drive tells them apart by their addresses in the range from 1 to 15 47 HART w...

Page 95: ...g TROVIS VIEW 4 d6 Condensed state Read only Summary of all the classified status messages according to the NAMUR Recommendation NE 107 OK No message C Maintenance required CR Maintenance demanded S O...

Page 96: ...ed Note The valve signature is required to perform diagnostic func tions For more details refer to the Operating Instructions EB 8389 1 EN on EXPERTplus Valve Diagnostics h1 Unassigned h2 Unassigned h...

Page 97: ...e Code 49 d2 and upper range value Code 49 d3 with a certain signal pressure The Dp_out reference value bar is calculated from the two signal pressures Note The reference value only applies to the adj...

Page 98: ...iod in which the valve moves through the operating range from the open to the closed position The time to move from Upper range value Code 49 d3 to Lower range value Code 49 d2 is calculated Lower ran...

Page 99: ...available F1 Unassigned F2 x cancelation The test was canceled The valve position fell below the x monitoring value Code 49 E1 F3 Dp_out cancelation The test was canceled The change in signal pressure...

Page 100: ...position h3 Lower limit to start test 25 0 set point If the set point is between Lower limit to start test 25 and Fail safe action limit Code 49 h2 the valve remains in its last valid position If the...

Page 101: ...f specification blinking Failure alarm If No message is assigned to the error code as the status classification the error is not in cluded in the condensed state A status classification is assigned to...

Page 102: ...pan of the sensor is too low Pin positioned incorrectly Incorrect lever installed Pressure limit selected too low A rotational angle smaller than 16 at the positioner shaft creates just an alarm An an...

Page 103: ...ctly connected 2 If you attempt to initialize the device from the fail safe position SAFE Status classification Maintenance required Recommended action Re 1 Check connection and supply voltage of the...

Page 104: ...Error codes Recommended action Condensed state alarm active when prompted ERR appears When fault alarms exist they are displayed here 104 EB 8384 6 EN...

Page 105: ...o its reference variable signal so that the process remains in a safe state Status classification Maintenance required Recommended action Return the positioner to SAMSON AG for repair 63 SIL shutdown...

Page 106: ...d by means of a test calcula tion Status classification Failure Recommended action Confirm error If this is not possible return the positioner to SAMSON AG for repair Data errors Error codes Recommend...

Page 107: ...re Error messages are saved in a non volatile memory They cannot be reset Status classification Maintenance required Recommended action Restart plotting of the valve signature or start initialization...

Page 108: ...they are displayed here 86 SIL tests The SIL operator test has failed Refer to Operating Instructions EB 8389 1 EN on EXPERTplus Valve Diagnostics Status classification Failure status classification c...

Page 109: ...210 28 14 80 164 Output 38 Supply 9 86 70 15 46 34 70 70 28 Schild 58 58 Fig 23a NAMUR and direct attachment Direct attachment Attachment acc to IEC 60534 6 External position sensor Lever mm S 17 M 5...

Page 110: ...VDE 3845 Sept 2010 level 1 size AA1 to AA4 Type 3710 Reversing Amplifier A M6 C B 25 Mmin d D Level 2 bracket surface Level 1 actuator surface Actuator Dimensions in mm Size A B C d Mmin D AA0 50 25 1...

Page 111: ...ing the operator software e g TROVIS VIEW 4 Linear select characteristic 0 Equal percentage select characteristic 1 Rev equal percentage select characteristic 2 EB 8384 6 EN 111 Valve characteristic s...

Page 112: ...ear select characteristic 7 Segmented ball valve equal percentage select characteristic 8 0 50 100 0 50 100 Travel angle of rotation Reference variable 0 50 100 0 50 100 Travel angle of rotation Refer...

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Page 121: ...ions 109 110 Display 52 53 turning by 180 57 E Electrical connection 46 50 Error messages confirming 77 data errors 106 diagnostic errors 107 error appendix 106 hardware errors 105 initialization erro...

Page 122: ...controls 52 55 Output signal pressure 46 P Parameters enabling 74 Pneumatic connections 46 Position transmitter 13 technical data 17 Principle of operation positioner 8 18 R Reset 72 Reversing amplifi...

Page 123: ...EB 8384 6 EN 123 diagnostic functions 11 Z Zero calibration 68 Index...

Page 124: ...SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 8384 6 EN 2012 08...