Samson 3731-5 Service-Handbuch

Series 3731

Type 3731-5

Electropneumatic Ex d Positioner

with FOUNDATION™fieldbus communication

Mounting and

Operating Instructions

EB 8387-5 EN

Firmware version R 1.4x

Edition March 2016

Fig. 1 · Type 3731-5

EB + CD

2EB 8387-5 EN

DANGER!

indicates a hazardous situation which, if not

avoided, will result 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 explanations, informa-

tion and tips

Definitions of the signal words used in these instructions

Contents

1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . 5

2 Article code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Design and principle of operation. . . . . . . . . . . . . . . . . . . . 7

3.1 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2.1 Configuration using TROVIS-VIEW software . . . . . . . . . . . . . . . 9

3.2.2 Configuration using the NI-BUS™ Configurator . . . . . . . . . . . . . . . . . 9

3.3 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Attachment to the control valve – Mounting parts and accessories . . . 13

4.1 Direct attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.1 Type 3277-5 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.2 Type 3277 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Attachment according to IEC 60534-6 (NAMUR) . . . . . . . . . . . . 20

4.3 Attachment to Type 3510 Micro-flow Valve. . . . . . . . . . . . . . . 22

4.4 Attachment to rotary actuators . . . . . . . . . . . . . . . . . . . . . 24

4.5 Reversing amplifier for double-acting actuators . . . . . . . . . . . . . 26

4.5.1 Reversing amplifier (1079-1118 or 1079-1119) . . . . . . . . . . . . 26

4.6 Required mounting parts and accessories. . . . . . . . . . . . . . . . 28

5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Pneumatic connections . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.1 Signal pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.2 Supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.3 Signal pressure (output) . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2.1 Establishing communication . . . . . . . . . . . . . . . . . . . . . . 37

6 Operator controls and readings . . . . . . . . . . . . . . . . . . . . 38

6.1 Rotary pushbutton. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.2 Serial interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.3 Readings on display. . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 Start-up – Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1 Adapting the display. . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.2 Limiting the signal pressure. . . . . . . . . . . . . . . . . . . . . . . 40

7.3 Checking the operating range of the positioner . . . . . . . . . . . . . 41

7.4 Determining the fail-safe position. . . . . . . . . . . . . . . . . . . . 42

7.5 Positioner initialization. . . . . . . . . . . . . . . . . . . . . . . . . 43

7.5.1 Initialization based on MAX maximum range . . . . . . . . . . . . . 44

EB 8387-5 EN 3

Contents

7.5.2 Initialization based on NOM nominal range . . . . . . . . . . . . . . 45

7.5.3 Initialization based on MAN manually selected range . . . . . . . . . 47

7.5.4 SUB substitute calibration . . . . . . . . . . . . . . . . . . . . . . . 48

7.6 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.7 Reset to default values . . . . . . . . . . . . . . . . . . . . . . . . 53

8 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.1 Enabling and selecting parameters . . . . . . . . . . . . . . . . . . 54

8.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2.1 Automatic and manual operating modes . . . . . . . . . . . . . . . . 55

8.2.2 SAFE – Fail-safe position. . . . . . . . . . . . . . . . . . . . . . . . 56

8.3 Malfunction/maintenance alarm . . . . . . . . . . . . . . . . . . . . 56

8.3.1 Confirming error messages . . . . . . . . . . . . . . . . . . . . . . 57

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10 Servicing explosion-protected devices . . . . . . . . . . . . . . . . . 58

11 Code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

12 Dimensions in mm. . . . . . . . . . . . . . . . . . . . . . . . . . . 78

12.1 Fixing levels according to VDI/VDE 3845 (September 2010) . . . . . . 80

13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

13.1 Selecting the valve characteristic . . . . . . . . . . . . . . . . . . . . 82

Test certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4EB 8387-5 EN

Contents

Note concerning these Mounting and Operating Instructions

These instructions EB 8387-5 describe the mounting, start up and on-site operation of the

Type 3731-5 Positioner.

You can find additional information on the enclosed CD-ROM (CD 8387-5) or on the Internet

at http://www.samson.de.

1 Important safety instructions

For your own safety, follow these instructions concerning the mounting, start up and opera-

tion of the positioner:

4The positioner may only be mounted, started up or operated by trained and experi-

enced personnel familiar with the product.

According to these Mounting and Operating Instructions, trained personnel is referred

to as individuals who are able to judge the work they are assigned to and recognize

possible dangers due to their specialized training, their knowledge and experience as

well as their knowledge of the relevant standards.

4Explosion-protected versions of this positioner may only be operated by personnel

who have undergone special training or instructions or who are authorized to work

on explosion-protected devices in hazardous areas.

4Any 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 appropriate measures.

4If inadmissible motions or forces are produced in the actuator as a result of the supply

pressure level, it must be restricted by means of a suitable supply pressure reducing

station.

To avoid damage to any equipment, the following also applies:

4Proper shipping and appropriate storage are assumed.

4Do not operate the positioner with the back of the positioner/vent opening facing up-

wards.

4Do not ground electric welding equipment near to the positioner.

Note: The device with a CE marking fulfills the requirements of the Directives 94/9/EC and

2004/108/EC.

The Declaration of Conformity is included on the enclosed CD-ROM.

EB 8387-5 EN 5

Important safety instructions

Vent opening

2 Article code

Positioner Type 3731 - 5 xxxxxx000x1x000

With LCD, autotune, FOUNDATION™fieldbus

Explosion protection

ATEX:

II 2G Ex d IIC T6,T5,T4 Gb; II 2G Ex de IIC T6,T5,T4 Gb; II 2D Ex tb IIIC T80°C DB IP66

II 2G Ex d IIC T6 Gb; II 2G Ex de IIC T6 Gb; II 2D Ex tb IIIC IP65 T80°C

2 1

FM/CSA:

Class I, Div. 1+2, Groups B, C, D; Class I, Zone 1, Groups IIB+H2;

Class I, Div. 1+2 Groups E, F, G; Class III/

Class I, Zone 1, Group IIB+H2 T4...T6; Class I, Div. 1+2, Groups B, C, D T4...T6;

Class II, Div. 1, Groups E, F, G

2 3

JIS: Ex d IIC T6 2 7

Options (additional equipment)

Without 0 0

Binary input 0 3

Forced venting 0 5

Diagnostics

EXPERT 1

EXPERT+/PST 2

Electrical connections

2x M20 x 1.5 1

2x ½ NPT 2

Explosion-protection certificates

As specified in Explosion protection 0

IECEx: Ex d IIC T6, T5, T4 Gb; Ex d e IIC T6, T5, T4 Gb; Ex tb IIIC T80°C Db IP66 2 1 2

GOST: 1Ex d IIC T6/T5/T4 Gb X; 1Ex d e IIC T6/T5/T4 Gb X; Ex tb IIIC T 80°C Db X 2 1 3

Special applications

Without 0

Positioner compatible with paint (IP 41/NEMA 1) 1

Special version

Without 0 0 0

6EB 8387-5 EN

Article code

3 Design and principle of

operation

The electropneumatic Ex d positioner is at-

tached to pneumatic control valves. It is used

to assign the valve stem position (controlled

variable x) to the control signal (reference

variable w). The input signal received from

a control system is compared to the travel or

rotational angle of the control valve, and a

signal pressure (output variable y) is pro-

duced for the pneumatic actuator.

The positioner basically consists of an

electrical travel sensor system (2), an analog

i/p converter (6) with downstream air ca-

pacity booster (7) and the electronic unit

with a microcontroller (5).

In case of a system deviation, the actuator is

either vented or filled with more air. The sig-

nal pressure supplied to the actuator can be

limited to 1.4 bar, 2.4 bar or 3.7 bar by

software or on site at the positioner.

EB 8387-5 EN 7

Design and principle of operation

Serial

Interface 16

20 23

519

Fig. 2 · Functional diagram

1 Control valve

2 Travel sensor

3 PD controller

4 IEC 61158-2

interface module

5 Microcontroller

6 i/p converter

7 Air capacity booster

8 Pressure regulator

9 Flow regulator

16 Display

17 Forced venting control

(optional)

19 D/A converter

20 Serial interface (SSP)

22 Rotary pushbutton

23 Binary input

(optional)

FOUNDATION™

fieldbus

IEC 61158-2

A constant air stream to the atmosphere is

created by the flow regulator (9) with a

fixed set point. The air stream is used to

purge the inside of the housing as well as to

optimize the air capacity booster (7). The

i/p converter (6) is supplied with a constant

upstream pressure by the pressure regulator

(8) to make it independent of the supply

pressure.

All parts are enclosed in an Ex d housing.

The electrical cables are connected over a

separate terminal compartment which also

has Ex d protection.

The standard EXPERT diagnostics are inte-

grated into the positioner. It provides infor-

mation on the positioner and generates di-

agnostic and status messages, which allow

faults to be pinpointed quickly.

The positioner is suitable for the following

types of attachment using the corresponding

accessories:

4Direct attachment to SAMSON

Type 3277 Actuator: Section 4.1

4Attachment to actuators acc. to

IEC 60534-6 (NAMUR): Section 4.2

4Attachment to Type 3510 Micro-flow

Valve: Section 4.3

4Attachment to rotary actuators acc. to

VDI/VDE 3845: Section 4.4

3.1 Additional equipment

Binary input

The positioner has an optional binary input.

Connected at terminals A-B:

The binary input for DC voltage signals al-

lows process information to be exchanged

over the FOUNDATION™fieldbus network.

Connected at terminals B-C:

This input connects a floating contact which

is powered by the positioner. The switching

state of the binary input can be indicated

over the FOUNDATION™fieldbus network.

Forced venting

The i/p converter stops working if the oper-

ating voltage supply to the relevant terminals

is interrupted. The positioner can no longer

operate and the control valve moves to the

fail-safe position determined by the actua-

tor, independent of the reference variable.

Extended EXPERT+valve diagnostics

Refer to Table 5 on page 30 for order num-

bers.

EXPERT+is an optional diagnostic firmware

integrated in the positioner which allows the

predictive, status-oriented maintenance of

pneumatic control valves. It upgrades the

standard EXPERT diagnostics firmware in-

corporated in the positioner. The upgraded

version provides extended functions to pin-

point valve parameters that have worsened,

allowing the user to plan predictive mainte-

nance and service work before malfunctions

can affect the process, causing unscheduled

plant shutdowns.

The extended EXPERT+diagnostics can be

activated later at the positioner by purchas-

ing an activation code or using a USB

dongle in conjunction with TROVIS-VIEW

software when EXPERT+is not already acti-

vated on delivery of the positioner.

8EB 8387-5 EN

Design and principle of operation

3.2 Communication

The positioner is completely controlled over

the digital signal transmission implemented

according to FOUNDATION™ fieldbus spec-

ification.

Data are transmitted as bit-synchronous cur-

rent modulation at a rate of 31.25 kbit/s

over twisted-pair cables conforming to

IEC 61158-2.

3.2.1 Configuration using

TROVIS-VIEW software

Refer to Table 5 on page 30 for order num-

bers.

The positioner can be configured using the

TROVIS-VIEW configuration and operator

interface.

The positioner is equipped with an addi-

tional digital SERIAL INTERFACE to allow a

computer to be connected over an adapter

cable from the RS-232 or USB port of the

computer to the positioner.

The TROVIS-VIEW software enables the user

to easily set parameters in the positioner

and view process parameters online.

Note: Instructions on how to install and ope-

rate the TROVIS-VIEW software are inclu-

ded in the Configuration Manual

KH 8387-5 on the CD-ROM.

3.2.2 Configuration using the

NI-BUS™ Configurator

The NI-FBUS™ Configurator from National

Instruments can also be used to configure

the positioner. For this purpose, an interface

card must be installed in a computer to con-

nect it to the FOUNDATION™ fieldbus.

The integrated function blocks are linked us-

ing the NI-FBUS™ Configurator.

EB 8387-5 EN 9

Design and principle of operation

3.3 Technical data

10 EB 8387-5 EN

Design and principle of operation

Type 3731-5 Ex d Positioner (technical data in test certificates additionally apply for explosion-protected devices)

Rated travel Adjustable Direct attachment to Type 3277: 3.6 to 30 mm

Attachment acc. to IEC 60534-6 (NAMUR): 3.6 to 200 mm

Attachment to rotary actuators (VDI/VDE 3845): 24° to 100°

Travel range Adjustable Adjustable within the initialized travel/angle of rotation;

travel can be restricted to 15at the maximum

Bus connection Fieldbus interface acc. to IEC 61158-2 bus-powered

Physical Layer Class: 113 (without ex. protection) und 111 (with ex. protection)

Field device acc. to FM 3610 Entity and FISCO

Communication

Fieldbus Data transmission as per FOUNDATION™ fieldbus specification,

Communication Profile Class: 31 PS, 32 L;

Interoperability tested according to Interoperability Test System (ITS) Revision 4.6

Execution time AO FB: 20 ms DI FB: 40 ms PID: 60 ms

Local communication SAMSON SSP interface and serial interface adapter

Software requirements (SSP): TROVIS-VIEW with database module 3731-5

Permissible operating

voltage

9 to 32 V DC · Powered over bus line

The limits in the test certificate additionally apply.

Max. operating current 15 mA

Additional current in case of fault 0 mA

Supply air Pressure Type 3731-521, Type 3731-527: 1.4 to 7 bar (20 to 105 psi),

Type 3731-523: 1.4 to 6 bar (20 to 90 psi)

Air quality Compliance with ISO 8573-1: 2004

Max. particle size and density: Class 4

Oil content: Class 3

Moisture and water: Class 3

Pressure dew point: At least 10 K beneath the lowest ambient temperature to be

expected

Signal pressure (output) 0 bar up to supply pressure

Characteristic Linear/equal percentage/reverse equal percentage

User-defined (over operating software and communication)

Butterfly valve/Rotary plug valve/Segmented ball valve: linear/equal percentage

Deviation from terminal-based conformity ≤1 %

Hysteresis ≤0.3 %

Sensitivity ≤0.1 %

Direction of action Reversible

Air consumption Independent from supply pressure 110 ln/h

Air output

capacity

to fill actuator

with air At ∆p = 6 bar: 8.5 mn³/h · At ∆p = 1.4 bar: 30 mn³/h · KVmax(20° C) = 0.09

to vent actuator At ∆p = 6 bar: 14.0 mn³/h · At ∆p = 1.4 bar: 4.5 mn³/h · KVmax(20° C) = 0.15

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