Samson FOUNDATION 3730-5, Mounting And Operating Instructions

Page 1: ...ng and Operating Instructions EB 8384 5 EN 1300 1619 Firmware version 1 56 Edition April 2016 Series 3730 Type 3730 5 Electropneumatic Positioner With FOUNDATION fieldbus communication FF device rev 2...

Page 2: ...if not avoided will result in death or seri ous injury WARNING Hazardous situations which if not avoided could result in death or seri ous injury NOTICE Property damage message or mal function Note A...

Page 3: ...hment to rotary actuators 32 4 5 1 Heavy duty version 34 4 6 Reversing amplifier for double acting actuators 36 4 6 1 Reversing amplifier 1079 1118 or 1079 1119 38 4 7 Attachment of external position...

Page 4: ...6 3 MAN Initialization based on a manually selected range 69 7 6 4 SUb Substitute calibration 70 7 7 Zero calibration 73 7 8 Reset to default settings 74 8 Operation 75 8 1 Enabling and selecting par...

Page 5: ...stic selection 104 Test certificates 106 Note Configuration and operation over FOUNDATION fieldbus are described in the Con figuration Manual u KH 8384 5 KH 8384 5 is included on the enclosed CD ROM a...

Page 6: ...ion Block Discrete Output new functions are imple mented Configuration Manual u KH 8384 5 Action on fault detection If the AO Transducer Block is in O S mode and the condensed state changes to Mainten...

Page 7: ...e A masking allows to set whether a de energized internal solenoid valve generates an AO block error resulting in a block alarm SOLENOID_SELECT parameter The SOLENOID_SELECT parameter in firmware K 1...

Page 8: ...oke test PST Start and reset the data logger Resetting the diagnosis Stop diagnosis Move to fail safe position Lock on site operation Action on fault detection If the AO Transducer Block is in O S mod...

Page 9: ...uthorized to work on explo sion protected devices in hazardous areas Refer to section 11 Any hazards that could be caused in the valve by the process medium the signal pres sure or by moving parts are...

Page 10: ...t 0 SJ2 SN NC contact 1 SJ2 S1N NO contact 0 2 Solenoid valve Without 0 With 24 V DC 4 External position sensor Without 0 With 0 1 0 0 Leakage sensor Without 0 With 1 Binary input Without 0 Floating c...

Page 11: ...al pressure supplied to the actuator can be limited by software or on site to 1 4 2 4 or 3 7 bar The fixed flow regulator ensures a constant air flow to the atmosphere which is used to flush the insid...

Page 12: ...to the atmosphere The positioner can no longer operate and the control valve moves to the fail safe posi tion determined by the actuator regardless of the set point NOTICE The manual set point is also...

Page 13: ...W software The positioner can be configured with SAMSON s TROVIS VIEW Configuration and Operator Interface The positioner has for this purpose a serial interface to allow the RS 232 or USB port of a c...

Page 14: ...s IS FB 30 ms AO FB 30 ms DO FB 30 ms MAO FB 50 ms Local SAMSON SSP interface and serial interface adapter Software requirements TROVIS VIEW with database module 3730 5 Permissible operating voltage 9...

Page 15: ...ed connection additionally exists Screw terminals for 0 2 to 2 5 mm wire cross sections Degree of protection IP 66 NEMA 4X Use in safety instrumented systems SIL Emergency venting at 0 V or over the o...

Page 16: ...acc to EN 60947 5 6 SJ2 SN proximity switch Measuring plate not detected 3 mA Measuring plate detected 1 mA SJ2 S1N proximity switch Measuring plate not detected 1 mA Measuring plate detected 3 mA Ext...

Page 17: ...11 KB4BO 0225 Ex ia IIC T6 T5 T4 Date 2011 11 10 Valid until 2016 11 10 No GYJ111267 Ex ia IIC T6 Date 2011 01 24 Valid until 2016 01 23 3730 53 No 1675804 Ex ia IIC T6 Class I II Div 1 Groups A G Ex...

Page 18: ...or rect assignment of lever and pin posi tion Attach the positioner to the control valve only using the mounting parts and accessories as specified in Ta ble 1 to Table 6 Observe the type of attachmen...

Page 19: ...achment according to IEC 60534 6 NAMUR SAMSON valves with Type 3271 Actuator Adjustment range at positioner 1 Other control valves Required lever Assigned pin position Actuator size Rated travel Min t...

Page 20: ...crew is located in the groove of the actuator stem 4 Mount cover plate 10 with narrow side of the cut out Fig 3 on the left pointing towards the signal pressure connection Make sure that the gasket 14...

Page 21: ...tachment Cut out of cover plate NOTICE Only use the connecting plate 6 in cluded in the accessories to connect supply and output Never screw threaded parts directly into housing 1 Lever 1 1 Nut 1 2 Di...

Page 22: ...e groove of the positioner housing 5 Place positioner on the cover plate in such a manner that the follower pin 2 rests on the top of the follower clamp 3 Adjust the lever 1 correspondingly and open t...

Page 23: ...ver plate 10 Actuator stem extends Actuator stem retracts Connection block old with switch plate 13 Actuator stem 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp 10 Cover plate 11 Cove...

Page 24: ...to the em bossed scale so that the follower plate 3 is shifted by half the angle range to the NAMUR bracket the slot of the follower plate is centrally aligned with the NAMUR bracket at mid valve trav...

Page 25: ...1 1 14 1 3 3 1 16 15 14 1 1 2 1 1 2 9 1 9 6 1 6 7 8 Attachment to rod type yoke Rods with 20 to 35 mm diameter Attachment to NAMUR rib Additional bracket for actuators with 2800 cm and travel 60 mm X...

Page 26: ...positioner attachment The Y2 port can be used for air purging of the spring chamber 1 Place follower clamp 3 on the actuator stem align it and screw tight so that the mounting screw is located in the...

Page 27: ...1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp 4 Screw plug 5 Stopper 6 Adapter bracket 6 1 Screws 6 2 Formed seal 6 3 Screws 11 Cover 11 1 Vent plug 12 Connecting plate 12 1 Seal 13 Adapter b...

Page 28: ...vent plug 11 1 into the Exh connection 11 For fail safe action actuator stem ex tends seal the Y1 port with a blanking plug For fail safe action actuator stem re tracts connect the Y1 port to the sig...

Page 29: ...valves with rod type yokes using the formed plate 15 which is placed around the yoke screw the four studs into the NAMUR connection block 10 Place the NAMUR connection block on the rod and position th...

Page 30: ...sten the adapter block 13 to the NAMUR connection block using the screws 13 1 9 Insert the vent plug into the Exh connec tion 10 Place the positioner on the adapter block 13 in such a manner that the...

Page 31: ...pin 3 Follower plate 3 1 Follower plate 4 Blanking plug 5 Stopper 6 Adapter bracket 6 1 Screws 6 2 Formed seal 6 3 Screws 10 NAMUR con nection block 11 Screw with toothed lock washer 13 Adapter block...

Page 32: ...ng sure the two seals are seated properly 7 Unscrew the standard M lever 1 includ ing follower pin 2 from the positioner shaft 8 Take the S lever 1 and screw the follow er pin 2 in the hole for pin po...

Page 33: ...readed parts directly into housing 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower plate 6 Connecting plate 6 1 Seals 7 Pressure gauge bracket 8 Pressure gauge mounting kit 9 Stem connector...

Page 34: ...r pin 2 from the positioner s M lever 1 Use the metal follower pin 5 mm included in the mounting kit and screw tight into the hole for pin position 90 7 Place positioner on the top bracket 10 and fast...

Page 35: ...into housing Legend for Fig 10 and Fig 11 1 Lever 1 1 Nut 1 2 Disk spring 2 Follower pin 3 Follower clamp Fig 10 4 Coupling wheel 4 1 Screw 4 2 Disk spring 4 3 Scale plate 5 Actuator shaft Adapter for...

Page 36: ...for required G connecting thread or pressure gauge bracket 7 with pressure gauges on the positioner making sure the two seals 6 1 are seated properly Dou ble acting springless rotary actuators re qui...

Page 37: ...4 3 Adhesive label 5 Actuator shaft or adapter 5 1 Adapter 6 Connecting plate only for G 6 1 Seals 7 Pressure gauge bracket 8 Pressure gauge mounting kit 10 Adapter housing 10 1 Screws 11 Spacer SAMSO...

Page 38: ...the accessories in Table 5 to the positioner Make sure that both O rings 6 1 are seated correctly 2 Thread the special nuts 1 3 from the ac cessories of the reversing amplifier into the boreholes of...

Page 39: ...1 A2 Z A1 Output 38 Supply 9 Output 38 Supply 9 1 3 1 2 1 1 From the positioner Control signals to the actuator 1 Reversing amplifier 1 1 Special screws 1 2 Gasket 1 3 Special nuts 1 4 Rubber seal 1 5...

Page 40: ...ting plate 6 or a pressure gauge bracket 7 must be fixed to the housing depending on the accessory chosen Make sure the seals 6 1 are correctly inserted see Fig 5 bot tom right For the electrical conn...

Page 41: ...aligned with the marking Fig 15 below Make absolutely sure that the gasket for the connecting plate 9 is correctly insert ed The connecting plate has threaded holes with NPT and G threads Seal the th...

Page 42: ...ivered with the M lever in pin position 35 on the sensor If necessary remove the follower pin 2 from its pin position and move it to the hole for the recommended pin po sition and screw tight 4 Place...

Page 43: ...vels se lect the lever and pin position from the travel table on page 19 L and XL levers are in cluded in the mounting kit 3 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever i...

Page 44: ...acket 21 3 Select the S lever 1 from the accessories and screw the follower pin 2 into the hole for pin position 17 Place the lever 1 and disk spring 1 2 on the sensor shaft Place the lever in mid pos...

Page 45: ...te 21 3 Replace the follower pin 2 normally at tached to the lever 1 with the metal fol lower pin 5 mm from the accessories and screw it into the hole for pin position 90 4 Place the lever 1 and disk...

Page 46: ...unction due to incorrect fastening Fasten the leakage sensor using a torque of 20 5 Nm The M8 threaded connection on the NAMUR rib should preferably be used to mount the sensor Fig 19 Tip If the posit...

Page 47: ...0534 6 NAMUR rib or attachment to rod type yokes All mounting kits from Table 3 can be used Connecting plate in stainless steel Attachment to rotary actuators All mounting kits from Table 5 can be use...

Page 48: ...the ambient pressure and damage the positioner when the exhausting components respond suddenly 4 11 Required mounting parts and accessories Table 1 Direct attachment to Type 3277 5 Actuator Fig 3 Orde...

Page 49: ...NPT 3 8 NPT 1402 0978 240 cm Steel G G 3 8 1400 6444 NPT 3 8 NPT 1402 0911 St steel G G 3 8 1400 6445 NPT 3 8 NPT 1402 0912 350 cm Steel G G 3 8 1400 6446 NPT 3 8 NPT 1402 0913 St steel G G 3 8 1400...

Page 50: ...red depending on the travel See rows above 1400 6771 Valtek Type 25 50 1400 9554 Accessories Connecting plate 6 G 1400 7461 NPT 1400 7462 Pressure gauge bracket 7 G 1400 7458 NPT 1400 7459 Pressure ga...

Page 51: ...78 with 320 cm and to VETEC Type S320 heavy duty version 1400 5891 and 1400 9526 Attachment to Camflex II 1400 9120 Accessories Connecting plate 6 G 1400 7461 NPT 1400 7462 Pressure gauge bracket 7 G...

Page 52: ...60 cm See Fig 17 1400 7469 Attachment to rotary actuators VDI VDE 3845 September 2010 see section 15 1 for details Actuator surface corresponds to fixing level 1 Size AA1 to AA4 with follower clamp a...

Page 53: ...T or G thread Custom ary fittings for metal or copper tubing or plastic hoses can be used NOTICE Risk of malfunction due to failure to comply with required air quality Only use supply air that is dry...

Page 54: ...of the positioner can be restricted to 1 4 bar 2 4 bar or 3 7 bar in Code 16 The limitation is not activated No by de fault 5 2 Electrical connections DANGER Risk of electric shock and or the for mat...

Page 55: ...Equipment for use in zone 2 zone 22 In equipment operated according to type of protection Ex nA II non sparking equipment according to EN 60079 15 2003 circuits may be connected interrupted or switche...

Page 56: ...M20x1 5 to NPT Powder coated aluminum 0310 2149 Stainless steel 1400 7114 Bus line Route the two wire bus line to the screw ter minals marked IEC 1158 2 whereby no polarity needs to be observed To con...

Page 57: ...s control system Bus termination Supply unit FOUNDATION fieldbus FOUNDATION fieldbus IEC 61158 2 Power Conditioner 3730 51 3730 51 3730 51 3730 51 IEC 61158 2 Process control system Bus termination Ha...

Page 58: ...or automation system or between a PC or work station and the positioner s is implemented to conform with IEC 61158 2 Note The action of the positioner upon fail ure of the FOUNDATION fieldbus communic...

Page 59: ...ting rotary actuators connections ac cording to section 4 6 Volume restriction Q The volume restriction serves to adapt the air output capacity to the size of the actuator Depending on the air passage...

Page 60: ...hat de pends on the sign and the value One bar element appears per 1 set point devi ation If the positioner has not been initialized blinks on the display the bar graph indi cates the lever position i...

Page 61: ...AFE_POS parameter in the AO Transducer Block AO TRD u KH 8384 5 and together AO Transducer Block is in the MAN mode u KH 8384 5 and S both blinking The positioner is manual mode while the mechanical f...

Page 62: ...f injury due to the actuator stem extending or retracting Do not touch or block the actuator stem Note The positioner performs a test in the start up phase while following its au tomation task at the...

Page 63: ...MAX The position of volume restriction Q also de pends on how the signal pressure is routed at the actuator in SAMSON actuators The SIDE position applies for actuators with a loading pressure connect...

Page 64: ...ressure Note If no settings are entered within 120 seconds the enabled configuration function becomes invalid Enable configuration Default No Turn g Code 3 display No Press Code 3 blinks Turn YES Pres...

Page 65: ...absolutely essential that you check the lever and pin position as described in section 4 WARNING Risk of injury due to the actuator stem extending or retracting Before exchanging the lever or changin...

Page 66: ...gs If nec essary perform a reset see sec tion 7 8 Alternating readings Initialization in progress Icon depending on initializa tion mode selected Bar graph display indicating the progress of the initi...

Page 67: ...ation process An initialization procedure in progress can be canceled by pressing the rotary pushbut ton STOP appears for three seconds on the display and the positioner then changes to the fail safe...

Page 68: ...n nominal range The calibrated sensor allows the effective valve travel to be set very accurately During initialization the positioner checks whether the control valve can move through the indi cated...

Page 69: ...ode 7 and if necessary change it 7 6 3 MAN Initialization based on a manually selected range Before starting initialization move the con trol valve manually to the OPEN position Turn the rotary pushbu...

Page 70: ...es the valve to move through its entire travel range several times This initialization mode however is an emergency mode in which the control parameters are estimated and not deter mined by an initial...

Page 71: ...de 3 blinks Turn YES Press display Enter the pin position and nominal range mm Pin position Default No mm Nominal range locked when Code 4 No Turn Code 4 Press Code 4 blinks Turn Pin position on lever...

Page 72: ...Press to confirm the setting Enter closing direction and blocking position Closing direction direction of ro tation causing the valve to move to the CLOSED position view on to positioner display Defa...

Page 73: ...ic mode The current valve position is indicated in Note If the positioner shows a tendency to oscillate in automatic mode the pa rameters KP and TV must be slightly corrected Proceed as follows Set TV...

Page 74: ...rt up parameters as well as the diagnosis to the factory default settings see code list in section 14 Enable configuration Turn g Code 3 display No Press Code 3 blinks Turn YES Press display Reset sta...

Page 75: ...e setting in Code 3 Turn YES Press display Configuration is enabled You can now configure codes one after the other Turn to select the required code Press to activate the selected code The code number...

Page 76: ...oves to the required position Note 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 Turn Code 0 Press C...

Page 77: ...functional fault in the posi tioner itself or in one of its peripherals or an initialization has not yet been suc cessfully completed Maintenance required The positioner still performs its control tas...

Page 78: ...the possible source of error is displayed in Code 49 onwards In this case Err appears on the display S Example Error caused by pin position Refer to the code list section 14 for possible causes and th...

Page 79: ...section 5 2 1 must be connected to the output circuit When the tag 1 is located in the inductive field of the switch the switch assumes a high resistance When it moves outside the field the switch as...

Page 80: ...contact is closed Tag entering the field contact is opened For OPEN position 1 Initialize the positioner 2 Move the valve to 95 in the MAN mode see display 3 Adjust the tag 1 at the yellow adjust ment...

Page 81: ...positioner Insert the fixing screws 2 and screw tight Attach the clamping plate 8 onto the proximity switch 6 Attach the rotary switch 5 Make sure the flattened side of the positioner shaft is turned...

Page 82: ...ne tested components from the manufacturer Devices that have already been operated outside hazardous areas and are intended for future use inside hazardous areas must comply with the safety requiremen...

Page 83: ...ed add the current firmware to the nameplate this can be done using labels 13 Maintenance calibration and work on equipment Interconnection with intrinsically safe cir cuits to check or calibrate the...

Page 84: ...lever in relation to the longitudinal axis is indicated in degrees Note It can only be selected when Code 0 MAN 2 Reading direction 1234 1234 ESC The reading direction of the display is turned by 180...

Page 85: ...b Substitute calibration without initialization 7 w x Increasing increas ing Increasing decreas ing ESC Direction of action of the set point w in relation to the travel angle x Automatic adaptation AI...

Page 86: ...range See also ex ample in Code 11 11 Travel angle upper limit upper x limit 50 0 to 120 0 100 of the operating range No ESC Limits travel angle to the entered value upper limit The characteris tic i...

Page 87: ...sure limitation for double acting actuators with fail safe position AIR TO OPEN 17 Proportional action coeffi cient KP level 0 to 17 7 ESC Read or change KP Note concerning changing the KP and TV leve...

Page 88: ...e 21 and 22 For some applications it is recommendable to limit the transit time of the actuator to prevent it from engaging too fast in the running pro cess Code 21 has priority over Code 15 NOTICE Th...

Page 89: ...h SUb initialization mode 36 Reset Std diAG ESC Std Resets all parameters and diagnosis data to their default set tings After a reset the positioner must be re initialized diAG Resets diagnosis data o...

Page 90: ...d valve info YES HIGH LOW No Read only Indicates whether a solenoid valve is installed or not If a voltage supply is connected at the terminals of the installed sole noid valve YES and HIGH appear on...

Page 91: ...active When prompted Err appears When fault alarms exist they are displayed here 50 x permissible range Value of measuring signal too high or too low the lever operates near its me chanical stops Pin...

Page 92: ...The positioner returns to the previous operating mode No pressure in supply line or pneumatic leakage Supply air failure during initialization Status classification Maintenance required Recommended ac...

Page 93: ...llows the controlled variable within tolerable times tolerance band alarm Code 19 Actuator blocked Positioner attachment shifted subsequently Supply pressure no longer suffices Status classification M...

Page 94: ...is defective The device continues functioning in emergency mode but it must be replaced as quickly as possible The emergency mode on the display is indicated by a blinking closed loop op eration icon...

Page 95: ...to the fail safe position Status classification Maintenance alarm cannot be classified Recommended action Return positioner to SAMSON AG for repair 67 Check calculation Hardware controller monitored...

Page 96: ...evice error Status classification Maintenance required Recommended action Return positioner to SAMSON AG for repair 74 FF parameters Error in parameters not critical to control operation Status classi...

Page 97: ...ation Maintenance required Recommended action Return positioner to SAMSON AG for repair Diagnosis errors Error codes Recommended action Condensed state message active When prompted Err appears When fa...

Page 98: ...ock alarm 132 Good NC Active advisory alarm 136 Good NC Active critical alarm 140 Good NC Unack block alarm 144 Good NC Unack advisory alarm 148 Good NC Unack critical alarm 152 Uncertain Non specific...

Page 99: ...Not selected 208 Good C Local override 216 Good C Fault state active 220 Bad Non specific 0 Bad Configuration error 4 Bad Not connected 8 Bad Device failure 12 Bad Sensor failure 16 Bad No comm with l...

Page 100: ...14 80 164 Output 38 Supply 9 86 70 15 46 34 70 70 28 Schild 58 58 Pressure gauge bracket or connecting plate Attachment according to IEC 60534 6 Lever mm S 17 M 50 L 100 XL 200 External position sens...

Page 101: ...mensions in mm Attachment according to VDI VDE 3847 to Type 3277 Attachment according to VDI VDE 3847 to a NAMUR rib 62 164 3 8 200 164 164 13 62 24 Lever mm M 50 L 100 XL 200 Fig 28 Attachment accord...

Page 102: ...Output A2 Supply 9 50 80 58 130 49 59 79 76 50 150 Reversing amplifier optional Connecting plate G or NPT Reversing amplifier Type 3710 see drawing of heavy duty version for dimensions 1079 1118 1079...

Page 103: ...o VDI VDE 3845 September 2010 A M6 C B 25 Mmin d D Fixing level 2 bracket surface Fixing level 1 actuator surface Actuator Dimensions in mm Size A B C d Mmin D AA0 50 25 15 5 5 for M5 66 50 AA1 80 30...

Page 104: ...tage select characteristic 2 0 50 100 0 50 100 Travel angle of rotation Reference variable 0 50 100 0 50 100 Travel angle of rotation Reference variable 16 Valve characteristic selection The character...

Page 105: ...lve linear select characteristic 5 VETEC rotary plug valve equal percentage select characteristic 6 0 50 100 0 50 100 Travel angle of rotation Reference variable 0 50 100 0 50 100 Travel angle of rota...

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Page 132: ...SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 8384 5 EN 2016 04 20 English...