Professional Documents
Culture Documents
Type 3730-2
Electropneumatic Positioner
Safety Manual
SH 8384-2 EN
Edition December 2016
The mounting and operating instructions for all supplied devices are
included in the delivery. The latest versions of the documents are available
on our website at www.samson.de > Product documentation. You can
enter the document number or type number in the [Find:] field to look for
a document.
! DANGER ! NOTICE
Hazardous situations which, if not avoided, Property damage message or malfunction
will result in death or serious injury
Note
! WARNING Additional information
Hazardous situations which, if not avoided,
could result in death or serious injury
Tip
Recommended action
2 SH 8384-2 EN
Purpose of this manual
The Safety Manual SH 8384-2 contains information relevant for the use of the Type 3730-2
Positioner in safety-instrumented systems according to IEC 61508 and IEC 61511. The safety
manual is intended for planners, constructors, and operators of safety-instrumented systems.
! NOTICE
Risk of malfunction due to incorrect mounting, connection or start-up of the device.
Refer to the Mounting and Operating Instructions EB 8384-2 on how to mount the positioner,
perform the electric and pneumatic connections as well as start up the positioner.
Observe the warnings and safety instructions written in the Mounting and Operating
Instructions EB 8384-.
Further documentation
The documents listed below contain descriptions of the start-up, functioning, and operation of
the positioner. You can download these documents from the SAMSON website. The docu-
ments marked with an asterisk (*) are supplied with the positioner either in printed or elec-
tronic form.
Note
In addition to the positioner documentation, observe the documentation for the pneumatic
actuator, valve, and other valve accessories.
SH 8384-2 EN 3
Contents
1 Scope............................................................................................................5
2 Technical data (excerpt from EB 8384-2).........................................................6
3 Safety-related functions..................................................................................8
4 Mounting, connection, and start-up...............................................................10
5 Required conditions......................................................................................11
6 Proof testing.................................................................................................13
7 Repairs........................................................................................................15
4 SH 8384-2 EN
Scope
1 Scope
General
The Type 3730-2 Electropneumatic Positioner is a single-acting, venting positioner for attach-
ment to pneumatic rotary and linear actuators with spring-return mechanism. The positioner
is used to position control valves.
Note
The architecture and the interval between proof tests must be changed accordingly for a
higher safety integrity level.
SH 8384-2 EN 5
Technical data (excerpt from EB 8384-2)
Attachment
The positioner is suitable for the following types of attachment in combination with various
mounting parts:
−− Direct attachment to SAMSON Type 3277 Actuators
−− Attachment to linear actuators according to IEC 60534-6 (NAMUR)
−− Attachment to linear actuators according to VDI/VDE 3847
−− Attachment to SAMSON Type 3510 Micro-flow Valve
−− Attachment to rotary actuators according to VDI/VDE 3845, fixing levels 1 and 2
Reference Signal range 4 to 20 mA · Two-wire device, reverse polarity protection · Minimum span 4 mA
variable Static 100 mA
w destruction limit
Minimum current 3.6 mA for display · 3.8 mA for operation
Load impedance Without explosion protection: ≤6 V (corresponding to 300 Ω at 20 mA) · Explosion
protection: ≤7 V (corresponding to 350 Ω at 20 mA)
Supply air 1.4 to 7 bar (20 to 105 psi)
Supply air Air quality acc. Max. particle size and density: Class 4 · Oil content: Class 3 · Pressure dew point: Class
to ISO 8573-1 3 or at least 10 K below the lowest ambient temperature to be expected
Signal pressure (output) 0 bar up to the supply pressure · Can be limited to 1.4 bar/2.4 bar/3.7 bar ± 0.2 bar
by software
Hysteresis ≤0.3 %
Sensitivity ≤0.1 %
6 SH 8384-2 EN
Technical data (excerpt from EB 8384-2)
Type 3730-2 Positioner: the technical data for the explosion-protected devices may be restricted by the limits speci-
fied in the test certificates.
Transit time Venting or filling with air adjustable separately up to 240 s by software
To fill actuator At Δp = 6 bar: 8.5 mn³/h · At Δp = 1.4 bar: 3.0 mn³/h · KVmax (20 °C) = 0.09
Air output with air
capacity
To vent actuator At Δp = 6 bar: 14.0 mn³/h · At Δp = 1.4 bar: 4.5 mn³/h · KVmax (20 °C) = 0.15
–20 to +80 °C (all versions)
Permissible ambient tem- –45 to +80 °C with metal cable gland
perature The temperature limits for the explosion-protected devices may be further restricted
by the limits specified in the test certificates.
Observing the requirements of IEC 61508, the systematic capability of the pilot valve
for emergency venting as a component in safety-instrumented systems is given.
Use in safety-instrumented
systems (SIL) Use is possible on observing the requirements of IEC 61511 and the required hard-
ware fault tolerance in safety-instrumented systems up to SIL 2 (single device/HFT = 0)
and SIL 3 (redundant configuration/HFT = 1).
Safety-relevant options
Solenoid valve · Approval according to IEC 61508/SIL · Emergency venting function
24 V DC · Galvanically isolated and reverse polarity protection · Static destruction
limit 40 V
Input
Current consumption I = U – 5.7 V (corresponding to 4.8 mA at 24 V/114 mW)
3840 Ω
SH 8384-2 EN 7
Safety-related functions
3 Safety-related functions
1. Emergency venting over the i/p converter (Fig. 1 path )
In automatic operation, the PD controller (3) compares the actual value to the DC control
signal from 4 to 20 mA coming from the microcontroller. In case of a system deviation,
the activation of the i/p converter is changed so that the actuator (1) is either vented or
filled with air. Fail-safe action is triggered when no signal (0 mA) is applied to terminals
11/12 and, as a result, to the i/p converter.
3. Safety-related end position monitoring over the optional inductive limit contact
(Fig. 1 path )
The inductive limit contact SJ2-SN (NAMUR NC contact) indicates the adjusted end posi-
tion in a safety-instrumented system at terminals 41/42. See u EB 8384-2 for adjusting
the limit contacts.
Fail-safe action
Fail-safe action is triggered by the i/p converter or solenoid valve and upon supply air fail-
ure. The positioner fully discharges its pneumatic output to the atmosphere, causing the
mounted actuator to be vented. As a result, the valve moves to the fail-safe position. The fail-
safe position depends on how the springs are arranged in the pneumatic actuator (air-to-
close or air-to-open).
When the air supply fails and the optional solenoid valve is de-energized, all positioner
functions, except open/closed loop control, remain active (including diagnostics, position
and, status feedback).
Note
The pneumatic output of the positioner can also be vented to the atmosphere over the soft-
ware, e.g. by entering a suitable set point. This procedure is not a safety-instrumented func-
tion.
8 SH 8384-2 EN
Safety-related functions
22 BE 31
32
Serial
20 16
Interface 31
13
m
mm
32
% A3 83
15
84
4 5 A2
11 w 19 51
14
12 52
A1 41
14
w 42
81 24 V DC
PD
82 2 11
x
17 18 3
12 6 G G
8 1
y
Q 10 x
7
SH 8384-2 EN 9
Mounting, connection, and start-up
A3 A2 A1 G
+81 -82 +11 -12 +83 -84 +51 -52 +41 -42 +31 -32 +31 -32
10 SH 8384-2 EN
Required conditions
5 Required conditions
! WARNING
Risk of malfunction due to incorrect selection or wrong installation and operating conditions.
Only use control valves in safety-instrumented systems after the necessary conditions in the
plant have been fulfilled. The same applies to the mounted positioner.
Selection
ÎÎ The required transit times of the control valve are kept.
The transit times to be implemented are determined by the process engineering require-
ments.
Tip
The minimum OPEN and CLOSE transit times can be read in Codes 40 and 41 after the
positioner has been initialized.
Tip
Error codes 50 to 58 indicate incorrect attachment. For safety-instrumented systems, we
recommend assigning the 'Maintenance alarm' status to these errors to quickly recognize
them when they occur (indicated by on the display).
SH 8384-2 EN 11
Required conditions
Tip
We recommend installing a supply pressure regulator/filter upstream of the positioner.
For example, the SAMSON Type 4708 Supply Pressure Regulator with 5 µm filter car-
tridge can be used.
Electrical installation
ÎÎ The positioner is connected to the electric power supply properly as described in the
mounting and operating instructions.
ÎÎ Only cables whose outside diameters are suitable for the cable glands are used.
ÎÎ The electrical cables in Ex i circuits comply with the data that planning was based on.
ÎÎ The cable glands and cover screws are fastened tightly to ensure that the degree of pro-
tection is met.
ÎÎ The installation requirements for the applicable explosion protection measures are ob-
served.
ÎÎ The special conditions specified in the explosion protection certificates are observed.
Operation
ÎÎ When the optional inductive limit contact is used, Code 38 is set to YES.
ÎÎ The inductive limit contact is adjusted mechanically to meet the specifications.
12 SH 8384-2 EN
Proof testing
6 Proof testing
The proof test interval and the extent of testing lie within the operator's responsibility. The
operator must draw up a test plan, in which the proof tests and the interval between them
are specified. We recommend summarizing the requirements of the proof test in a check-
list.
! WARNING
Risk of dangerous failure due to malfunction in the event of emergency (actuator is not vented
or the valve does not move to the fail-safe position).
Only use devices in safety-instrumented systems that have passed the proof test according to
the test plan drawn up by the operator.
Regularly check the safety-instrumented function of the entire SIS loop. The test intervals are
determined, for example on calculating each single SIS loop in a plant (PFDavg).
Function testing
Regularly check the safety function according to the test plan drawn up by the operator.
Note
Record any faults in the positioner and inform SAMSON of them in writing.
Tip
The travel in automatic mode can be read at the positioner in Code 0.
SH 8384-2 EN 13
Proof testing
6. Check whether the actuator is fully vented within the demanded time.
Tip
Connect a pressure gauge to check that the actuator has completely vented.
Tip
The travel in automatic mode can be read at the positioner in Code 0.
Tip
Connect a pressure gauge to check that the actuator has completely vented.
14 SH 8384-2 EN
Repairs
! NOTICE
Risk of malfunction due to the use of unauthorized parts.
Only use original parts to replace worn parts.
7 Repairs
Only perform the work on the positioner described in u EB 8384-2.
! NOTICE
Fail-safe action impaired due to incorrect repair.
Service and repair work must only be performed by trained staff.
SH 8384-2 EN 15
Herstellererklärung Manufacturer's Declaration
Für folgende Produkte For the following products
Hiermit wird bestätigt, dass das Steuerventil in We hereby certify that the pilot valve installed
den o. g. Stellungsreglern gemäß IEC 61508 in the positioners mentioned above is suitable
für den Einsatz in sicherheitsgerichteten Krei- for use in safety-instrumented systems accord-
sen geeignet ist. ing to IEC 61508.
Die Stellungsregler haben eine HFT von 0 und The positioners have an HFT of 0 and can be
können nach IEC 61511 bis SIL 2 (einzelnes used up to SIL 2 (single device, HFT = 0) and
Gerät, HFT = 0) und SIL 3 (redundante Ver- SIL 3 (redundant configuration, HFT = 1) ac-
schaltung, HFT = 1) eingesetzt werden. cording to IEC 61511.
Die Geräte sind nach Typ A eingestuft. The devices are classified as type A.
Die Konformität des Entwicklungsprozesses, The conformity of the development process
der durchgeführten FMEDA und der Aussa- and the performed FMEDA as well as the
gen dieser Herstellererklärung sind von der statements in this Manufacturer’s Declaration
TÜV Rheinland Industrie Service durch das are certified by TÜV Rheinland Industrie Ser-
Zertifikat V60 2012 C8 vom Dezember 2012 vice GmbH in the Certificate V60 2012 C8 of
zertifiziert. December 2012.
Sicherheitstechnische Annahmen Safety-related assumptions
Unter Verwendung des i/p-Wandlers und/oder When the i/p converter and/or the optional so-
des optionalen Magnetventils schaltet der ein- lenoid valve are used, the single-acting posi-
fachwirkende Stellungsregler seinen pneuma- tioner discharges its pneumatic output to the
tischen Ausgang gegen Atmosphäre durch atmosphere, causing the mounted actuator to
und entlüftet dadurch den angeschlossenen be vented.
Ventilantrieb.
Sicherheitstechnische Kenndaten Safety-related data
λsafe, undetected 9 FIT λsafe, undetected 9 FIT
λsafe, detected 0 FIT λsafe, detected 0 FIT
λdangerous, undetected 1 FIT λdangerous, undetected 1 FIT
λdangerous, detected 0 FIT λdangerous, detected 0 FIT
PFDavg. bei jährlicher Prüfung 4,2 · 10-6 PFDavg. with annual test 4.2 · 10-6
HFT 0 HFT 0
Gerätetyp A Device type A
SFF (Safe Failure Fraction) 90 % Safe failure fraction (SFF) 90 %
MTBFgesamt 11940 Jahre MTBFtotal 11940 years
MTBFdangerous, undetected 119530 Jahre MTBFdangerous, undetected 119530 years
9 9
1 FIT = 1 Ausfall pro 10 Stunden 1 FIT = 1 failure per 10 hours
– Der elektrische Eingang des optionalen – The electrical input of the optional solenoid
Magnetventils wird energielos gesetzt. valve is de-energized.
o Typen 3730-2/-3/-4/-5: Spannungspegel o Types 3730-2/-3/-4/-5: 0 V DC voltage
0 V DC an den Klemmen: 81/82 level at terminals 81/82
Hinweis! Note!
Die Stellungsregler der Typen 3730-2/-3/-4/-5 The Types 3730-2/-3/-4/-5 Positioners come
sind mit umfangreichen Mitteln zur Diagnose with extensive diagnostic functions. They as-
ausgestattet. Diese Diagnose bewertet den sess the condition of the positioner as well as
Zustand des Stellungsreglers und der ange- of the control valve it is mounted on. The safe-
bauten Armatur. Die sicherheitstechnischen ty-related data can be improved by using the
Kennwerte können sich durch Einsatz der Di- diagnostics. Diagnostics also serve to reveal
agnose verbessern. Die Diagnose dient auch undetected systematic failures (refer to
der Aufdeckung unerkannter systematischer VDI 2180, sheet 5).
Fehler (siehe VDI 2180 Blatt 5).
Voraussetzungen Requirements
Die Reparaturzeit ist klein gegenüber der mitt- Short mean time to repair compared to the av-
leren Anforderungsrate. Durchschnittliche Be- erage rate of demand. Normal exposure to in-
anspruchung in industrieller Umgebung durch dustrial environment and fluids is assumed.
Medien und Umgebungsbedingungen wird vo- The user is responsible for ensuring that the
rausgesetzt. Der Anwender ist für den be- device is used as intended.
stimmungsgemäßen Gebrauch verantwortlich.