SH 8384-6S EN
Translation of original instructions

TROVIS SAFE 3730-6 Electropneumatic Positioner
with pressure sensors, communication: HART®

Edition July 2020

Definition of signal words! DANGER
Hazardous situations which, if not avoided,
will result in death or serious injury! WARNING
Hazardous situations which, if not avoided,
could result in death or serious injury

2! NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action

SH 8384-6S EN

Purpose of this manual
The Safety Manual SH 8384-6S contains information relevant for the use of the TROVISSAFE 3730-6 Positioner in safety-instrumented systems according to IEC 61508 andIEC 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 positioner.
Î Refer to the Mounting and Operating Instructions EB 8384-6S on how to mount the positioner, perform the electric and pneumatic connections as well as start up the positioner.
Î Observe the warnings and safety instructions written in the Mounting and Operating Instructions EB 8384-6S.
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.
TROVIS SAFE 3730-6 Positioner with HART® Communicationu T 8384-6S:
Data sheet
u EB 8384-6S: Mounting and operating instructions
u KH 8384-3:
Configuration manual for HART® communicationu KA 8384-2:
Quick guide
EXPERTplus diagnostics
u T 8389-1S:
Data sheet
u EB 8389-1S: Operating instructions

Note
In addition to the positioner documentation, observe the documentation for the pneumatic
actuator, valve and other valve accessories.

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4

SH 8384-6S EN

Contents

1
1.1
1.2
1.3
1.4

Scope............................................................................................................6
General.........................................................................................................6
Use in safety-instrumented systems...................................................................6
Versions and ordering data.............................................................................7
Attachment.....................................................................................................7

2

Technical data (excerpt from EB 8384-6S)........................................................8

3
3.1
3.2

Safety-related functions................................................................................10
Fail-safe action.............................................................................................10
Protection against unauthorized changes to the configuration...........................12

4

Mounting, connection and start-up................................................................12

5
5.1
5.2
5.3
5.4

Required conditions......................................................................................13
Selection......................................................................................................13
Mechanical and pneumatic installation...........................................................13
Electrical installation......................................................................................14
Operation....................................................................................................14

6
6.1
6.2

Proof testing.................................................................................................15
Visual inspection to avoid systematic failure....................................................15
Function testing.............................................................................................16

7

Maintenance and repair...............................................................................19

8

Safety-related data and certificates...............................................................19

SH 8384-6S EN

5Scope1 Scope
1.1 General
The TROVIS SAFE 3730-6 Electropneumatic Positioner is a single-acting, venting positioner
with HART® communication for attachment to pneumatic rotary and linear actuators withspring-return mechanism.
The positioner is ready configured for 'On/off valve' type of application. In this type of application, it is used to shut off or open on/off valves on demand. The positioner is used toposition control valves when the 'Control valve' is selected as the type of application. The
type of application does not have any effect on the safety-instrumented function.

1.2 Use in safety-instrumented systems
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 of the positioner is possible on observing the requirements of IEC 61511 and the required hardware fault tolerance in safety-instrumented systems up to SIL 2 (single device/
HFT = 0) and SIL 3 (redundant configuration/HFT = 1).
The individual safety functions of the positioner are to be regarded as Type A elements in accordance with IEC 61508-2.

6

SH 8384-6S EN

Scope1.3 Versions and ordering data
All versions of the TROVIS SAFE 3730-6 Positioner are suitable for use in safety-instrumented
systems. However, the optional equipment affects the safety-related behavior of the positioner. These options are the inductive limit contact SJ2-SN, solenoid valve and forced venting.
Furthermore, the emergency shutdown affects the fail-safe action.
The article code written on the nameplate (see next page) provides details on the optional
equipment and the emergency shutdown of the positioner.
TROVIS SAFE 3730-6 Positioner

x x x x x x x 0 x x 0 x 0 0

Option (additional equipment)
Without inductive limit contact
With inductive limit contact SJ2-SN (NAMUR NC contact)
Without solenoid valve
With 24 V DC solenoid valve
Forced venting, 24 V DC

0
1
0
1
2

Emergency shutdown
3.8 mA
4.4 mA01

1.4 Attachment
The positioner is suitable for the following types of attachment in combination with various
mounting parts:− Direct attachment to SAMSON Type 3277 Linear 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

SH 8384-6S EN

7Technical data (excerpt from EB 8384-6S)

2 Technical data (excerpt from EB 8384-6S)
TROVIS SAFE 3730-6 Positioner (technical data in test certificate additionally apply to explosion-protected devices)Set pointw

Signal range

4 to 20 mA · Two-wire device, reverse polarity protection · Minimum span 4 mA

Static destruction
limit

30 V

Minimum current

3.6 mA for display · Emergency venting at <3.8 mA or <4.4 mA

Load impedance≤9.2 V (corresponding to 460 Ω at 20 mA)

SupplySupply air

1.4 to 7 bar (20 to 105 psi)

Air quality acc. toISO 8573-1 (edition 2001-02)

Maximum particle size and density: Class 4 · Oil content: Class 3
Pressure dew point: Class 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 between 1.4 and 7.0 bar by software

Hysteresis≤0.3 %

Sensitivity≤0.1 %

Transit time

Exhaust and supply adjustable separately up to 240 s by software

Air output
capacity

Actuator (supply)

At Δp = 6 bar: 8.5 mn³/h · At Δp = 1.4 bar: 3.0 mn³/h · KVmax(20 °C) = 0.09

Actuator (exhaust)

At Δp = 6 bar: 14.0 mn³/h · At Δp = 1.4 bar: 4.5 mn³/h · KVmax (20 °C) = 0.15

Permissible ambient temperature –20 to +80 °C for all versions–45 to +80 °C with metal cable gland
The limits in the type examination certificate additionally apply to explosion-protected versions.
Certified according toIEC 61508/SIL

Suitable for use in safety-instrumented systems up to SIL 2 (single device/HFT = 0)
and SIL 3 (redundant configuration/HFT = 1) according to IEC 61511.
− Triggered by the set point, emergency venting depending on positioner version at <3.8 mA or <4.4 mA− By the optional solenoid valve, emergency venting at 0 V− By the optional forced venting function, emergency venting at <12 V

Safety-relevant options
Electronic forced venting · Approval acc. to IEC 61508/SIL
Input

24 V DC · Electrical isolation and reverse polarity protection · Static destruction limit 40 V
Power draw: I =U – 5.7 V
3.84 kΩ(corresponding to 4.8 mA at 24 V/114 mW)

Signal '0' (no response)<12 V (emergency shutdown at 12 V)

Signal '1' (response)> 19 V

8

SH 8384-6S EN

Technical data (excerpt from EB 8384-6S)

Solenoid valve · Approval acc. to IEC 61508/SIL
Input

24 V DC · Reverse polarity protection · Static destruction limit 40 V
Power draw:I =U – 5.7 V
3.84 kΩ(corresponding to 4.8 mA at 24 V/114 mW)

Signal '0' (no response)<12 V (emergency shutdown at 0 V)

Signal '1' (response)> 19 V

Service life

> 5 x 106 switching cycles

Inductive limit contact
by Pepperl+Fuchs

For connection to switching amplifier acc. to EN 60947-5-6
Can be used in combination with a software limit contact

SJ2-SN proximity switch

Measuring plate not detected: ≥3 mA · Measuring plate detected: ≤1 mA

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9

Safety-related functions

3 Safety-related functions
Emergency venting over the i/p converter (Fig. 1 path)

In automatic mode, the PD controller (3) compares the valve position to the DC control signal
issued by 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 supplied with air. Fail-safe action istriggered when a signal smaller or equal to the shutdown signal (3.8 mA or 4.4 mA, seesection 1.3 on page 7) is applied to terminals 11/12 and, as a result, to the i/p converter.
Emergency venting over the optional solenoid valve (Fig. 1 path)

The solenoid valve (12) is energized by a 24 V DC voltage signal. Fail-safe action is triggered and the signal pressure for the air booster (7) is vented to the atmosphere when a 0 V
signal is applied to terminals 81/82. As a result, the actuator is vented and the valve moves
to its fail-safe position.
Emergency venting over forced venting (Fig. 1 path)

The forced venting (25) is energized by a 24 V DC voltage signal. If the voltage signal at terminals 81/82 falls below 12 V, the i/p converter (6) is not activated. The positioner vents theactuator, causing the valve to move to the fail-safe position determined by the actuator, independent of the reference variable.
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 position
in a safety-instrumented system at terminals 41/42. See u EB 8384-6S for adjusting the limit contacts.

3.1 Fail-safe action
Fail-safe action is triggered by the i/p converter, solenoid valve or forced venting and upon
supply air failure. 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 supply air fails, the optional solenoid valve or forced venting is triggered and after
reaching the shutdown signal (3.8 mA or 4.4 mA, see section 1.3 on page 7), all positioner functions, except open/closed loop control, remain active (including diagnostics,
HART® communication as well as position and status feedback).
10

SH 8384-6S EN

Safety-related functions

22
Serial20
Interface

16

S %

mm

A3

15
w

11
12

4

5

19

A1

14

83
84
51
52
41
42

&

>12 V

w

24 V DC

81
82

A2

14

x1)

31
32
31
32

13

mm

%

21 FSK

BE

17

x

18

12

PD

G

25

6

11

2

3
G

9
8
23

1
2
3
4
5
6
7
8
9
10
11*
12*
13*

10
7

Control valve
Travel sensor
PD controller
A/D converter
Microcontroller
i/p converter
Air booster
Pressure regulator
Flow regulator
Volume restriction
Inductive limit contact
Solenoid valve
Analog position transmitter or binary
input

Q

14
15
16
17*
18
19
20
21
22*
23
24
25*
*

24
y

1
x

Software limit contacts A1/A2
Fault alarm output A3
LCD
Actuation of solenoid valve
Galvanic isolation
D/A converter
Communication interface
HART® connection
Binary input BI
Pressure sensor for supply air ps
Pressure sensor for signal pressure pout
Forced venting
OptionsFig. 1: Functional diagram of the positioner

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Mounting, connection and start-up

Note
The pneumatic output of the positioner can also be vented to the atmosphere over the software, e.g. by entering a suitable set point. This procedure is not a safety-instrumented function.

3.2 Protection against unauthorized changes to the configuration
A change to the configuration cannot affect the safety function nor cause it to be deactivated.

4 Mounting, connection and start-up
Refer to Mounting and Operating Instructions u EB 8384-6S on how to mount, perform theelectric and pneumatic connections as well as start up the positioner.
Only use the specified original mounting parts and accessories.
A3

+81

-82

+11 -12

+83

-84

A2

A1

+51 -52+41 -42GG+31 -32+31 -32+31 -32

LeakagesensorBinary input

A

24 V DCmA control
Forced ventsignal
ing/solenoid
valve(optional)

Switching amplifier EN 60947-56
A3
Fault alarm

Limit contacts
A2
Software

A1
Softwareoptionallyinductive

Two-wiretransmitter
Supply unit
only foroptionaltransmitter

Fig. 2: Electrical connections

12

SH 8384-6S EN

Required conditions

5 Required conditions! WARNING
Risk of malfunction due to incorrect selection or wrong installation and operating conditions.
Î Only use control valves in safety-instrumented systems if the necessary conditions in theplant are fulfilled. The same applies to the mounted positioner.

5.1 Selection
Î The required transit times of the control valve are observed.
The transit times to be implemented are determined by the process engineering requirements.
Tip
The minimum OPEN and CLOSE transit times can be read in Codes 40 and 41 after the
positioner has been initialized.
Î The positioner is suitable for the prevailing ambient temperature.
Versions

Temperature rangeAll–20 to +80 °C

With metal cable gland–45 to +80 °C

The limits in the test certificates additionally apply to explosion-protected versions.

Î The temperature limits are observed.

5.2 Mechanical and pneumatic installation
Î The positioner is mounted properly as described in the mounting and operating instructions and connected to the air supply.
Tip
Error codes 50 to 58 indicate incorrect attachment. For safety-instrumented systems, werecommend assigning the 'Maintenance alarm' status to these errors to quickly recognize
them when they occur (indicated by on the display).
Î The maximum supply pressure does not exceed 7 bar.

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Required conditions

Î The pneumatic air supply meets the instrument air specifications.
Particle size and quantity

Oil content

Pressure dew point

Class 4

Class 3

Class 3≤ 5 µm and 1000/m³≤ 1 mg/m³–20 °C or at least 10 K below the lowest ambient temperature to be expectedTip
We recommend installing a supply pressure regulator/filter upstream of the device. For
example, the SAMSON Type 4708 Supply Pressure Regulator with 5 µm filter cartridge
can be used.
Î The supply air line has a minimum inside diameter of 4 mm.
Select the cross section and length of the line to ensure that the supply pressure at the positioner on supplying air to the actuator does not fall below the minimum limit.
Î The positioner is mounted as prescribed.
Î The vent opening at the back of the positioner remains open when the positioner is installed on site.

5.3 Electrical installation
Î The positioner is connected to the electric power supply properly as described in themounting and operating instructions.
Î Only cables whose outside diameters are suitable for the cable glands are used.
Î The electrical cables in Ex i circuits comply with the data that planning was based on.
Î The cable glands and cover screws are fastened tightly to ensure that the degree of protection is met.
Î The installation requirements for the applicable explosion protection measures are observed.
Î The special conditions specified in the explosion protection certificates are observed.

5.4 Operation
Î When the optional inductive limit contact is used, Code 38 is set to YES.
Î The inductive limit contact is adjusted mechanically to meet the specifications.

14

SH 8384-6S 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 checklist.
! WARNING
Risk of dangerous failure due to malfunction in the event of emergency (actuator is notvented or the valve does not move to the fail-safe position).
Î 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).

6.1 Visual inspection to avoid systematic failure
To avoid systematic failure, inspect the positioner regularly. The frequency and the scope of
the inspection lie within the operator's responsibility. Take application-specific influences into
account, such as:− Dirt blocking the pneumatic connections− Corrosion (destruction primarily of metals due to chemical and physical processes)− Material fatigue− Aging (damage caused to organic materials, e.g. plastics or elastomers, by exposure tolight and heat)− Chemical attack (organic materials, e.g. plastics or elastomer, which swell, leach out or
decompose due to exposure to chemicals)! NOTICE
Risk of malfunction due to the use of unauthorized parts.
Î Only use original parts to replace worn parts.

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Proof testing

6.2 Function testing
Regularly check the safety function according to the test plan drawn up by the operator.
Note
Record any positioner faults and e-mail (aftersalesservice@samsongroup.com) them to
SAMSON.
Emergency venting by applying a mA signal to terminals 11/12 (control signal):
1. Supply the positioner with air within the permissible supply pressure range (max. 7 bar)which allows the valve to move to the maximum travel/angle of rotation.
2. Connect an electric input signal >3.8 mA or >4.4 mA to the positioner (terminals
11/12), depending on the emergency shutdown.
3. Switch the positioner to automatic mode (if it has not already been done).
4. Set the input signal (terminals 11/12) over a local current source or over the control system in such a way that the valve moves to the operating position. Check whether thevalve moves to this position.
Tip
The travel in automatic mode can be read at the positioner in Code 0.
5. Set the electric input signal depending on emergency shutdown to lower than 3.8 mA or
4.4 mA.
This must cause the valve to move to its fail-safe position (terminals 11/12).
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.
Emergency venting over solenoid valve (0 V signal to terminals 81/82):
1. Supply the positioner with air within the permissible supply pressure range (max. 7 bar)which allows the valve to move to the maximum travel/angle of rotation.
2. Connect an electric input signal >3.8 mA or >4.4 mA to the positioner (terminals
11/12), depending on the emergency shutdown.
3. Supply the solenoid valve with a voltage >19 V DC (terminals 81/82).

16

SH 8384-6S EN

Proof testing

4. Set the input signal (terminals 11/12) over a local current source or over the control system in such a way that the valve moves to the operating position.
Tip
The travel in automatic mode can be read at the positioner in Code 0.
5. Set the voltage to 0 V DC (terminals 81/82).
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.
Emergency venting over forced venting (signal <12 V at terminals 81/82).
1. Supply the positioner with air within the permissible supply pressure range (max. 7 bar)which allows the valve to move to the maximum travel/angle of rotation.
2. Connect an electric input signal >3.8 mA or >4.4 mA to the positioner (terminals
11/12), depending on the emergency shutdown.
3. Supply the forced venting with a voltage >19 V DC (terminals 81/82).
4. Set the input signal (terminals 11/12) over a local current source or over the control system in such a way that the valve moves to the operating position.
Tip
The travel in automatic mode can be read at the positioner in Code 0.
5. Set the voltage to <12 V DC (terminals 81/82).
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.
Safety-related end position monitoring
1. Supply the positioner with air within the permissible supply pressure range (max. 7 bar)which allows the valve to move to the maximum travel/angle of rotation.
2. Connect an electric input signal >3.8 mA or >4.4 mA to the positioner (terminals
11/12), depending on the emergency shutdown.

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17

Proof testing

3. Switch the positioner to automatic mode (if it has not already been done).
4. Set the input signal (terminals 11/12) over a local current source or over the control system in such a way that the valve moves to the operating position.
5. Set the input signal (terminals 11/12) over a local current source or over the control system in such a way that the valve moves to the end position.
6. Check whether a signal is issued at terminals 41/42 when the valve has reached the end
position.
Proof test
A full stroke test must be performed as the proof test. The following value can be used for
Proof Test Coverage to calculate PFDavg:
PTC (Proof Test Coverage) = 92 % for a proof test18

SH 8384-6S EN

Maintenance and repair

7 Maintenance and repair
Only perform the work on the positioner described in uEB 8384-6S.
! NOTICE
Safety function impaired due to incorrect repair.
Î Only allow trained staff to perform service and repair work.
For devices operated in the low demand mode, a useful lifetime of 11 years (plus 1.5 years
storage time) is confirmed by TÜV Rheinland® from the date of manufacture while taking into
account the specific conditions of use specified in the Safety Manual and the Mounting andOperating Instructions.
The results of the proof test must be assessed and the maintenance scheduled based on it. In
particular, after changes (e.g. signs of aging in elastomers, changed switching times or leakage etc.), it is essential that the manufacturer performs maintenance or repair work on thedevice.
MTC (Maintenance Coverage) > 99 %8 Safety-related data and certificates
PSTC (Partial Stroke Test Coverage)

68 %PTC (Proof Test Coverage)

92 %MTC (Maintenance Coverage)>99 %Further safety-related data are listed in the following certificate.

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SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samsongroup.com · www.samsongroup.com

2020-08-20 · English

SH 8384-6S EN