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Operating Instructions EB 8388 EN

1. Travel histogram Setpoint deviation histogram Cycle counter histogram H Drive signal diagram s Tests MAN c Graphic adjustment End position trend Fig 9 End position trend with zero point shift at measuring point 1 EB 38388 EN 19 Statistical information AUTO An alarm is generated after a change in zero point or when a zero point shift outside of the zero point limit is detected Enter the zero point limit in the Positioner folder gt Error control gt Zero point limit or over Code 48 in the positioner selecting d5 default setting 5 Note The valve end position is also logged when the valve moves to the fail safe position over the forced venting option and with an actuator with AIR TO OPEN Graph versions Select Trend of valve end position folder to view a graph of the recorded end positions The reference value is represented by a straight line in the graph The graph highlights a trend and a change in the end position The Lower end position folder contains a table of the measured data valve position x drive signal y with time stamp Data and the reference value can be reset in the Status messages gt Reset folder 20 EB 8388 EN 3 Tests MAN These tests are performed when the process in not running i e manual operation The positioner does not follow its reference vari able In all the following tests the control valve moves through the f
2. Value Unit Comment Diagnosis Tests MAN test d1 d2 d3 d4 H Positioner Stop all tests Static characteristic l Drive signal diagram steady H Drive signal diagram hysteresis _ Step response H Static characteristic H Step response H Graphic adjustment Fig 10 Tests MAN test d1 d2 d3 d4 Diagnosis 5 Automatical test status H Status messages HC Statistical information AUTO _ Drive signal diagram steady Tests MAN Drive signal diagram hysteresis EB 8388 EN 21 Tests MAN 3 1 Drive signal diagram steady state d1 As described in detail in section 2 5 on the drive signal diagram the drive signal y plot ted versus valve position x allows the follow ing changes at the control valve to be recog nized and an alarm issued Air leakage in the pneumatics Spring force reduced Changes in the supply pressure This test fESt d1 causes the valve to move through the travel range to allow the results and alarms issued in automatic mode to be accurately checked After starting the test the valve is moved to various fixed valve positions x distributed over the full range of the valve The drive signal y is measured for each valve position x and stored in the positioner memory The necessary data set for the ref erence graph is automatically plotted and stored directly after initialization The start time for the reference graph is stored with a reference
3. 2 2 222mm 12 Cycle counter histogram 222 2 2 2m nn 13 Drive signal diagram 22 2 2 oo onen 15 Steady state drive signal 2 aa a 15 Hysteresis test d5 2222 aa a 17 End P siiontrend s gt lt asiru 42 eon ee eb dee dew es 19 Tess MAN 2 oo non 2 Drive signal diagram steady state d1 2 222222 222 27 Drive signal diagram hysteresis d2 2 2 22 222222 23 Static characteristic d3 aaa a a 25 Step response d4 ole 26 Status and diagnosticalarms 0 28 Standard EXPERT diagnostic alarms 04 28 Extended EXPERT diagnostic alarms 2222222220 28 Tess NOE ee RPA ee a ee 29 Classification of the status alarms 2 2222 2222 29 Condensed state o oo a a leen 29 Status m dilicalion a s ss s an a sansi arto oe we de Sox d 30 Resetting diagnostic parameters 2 222 aa aaa a 3 Diagnostic parameters saved in non volatile memory 34 Troubleshooting a 35 EXPERT without TROVIS VIEW 38 Description 1 1 General These instructions EB 8388 EN supplement the standard mounting and operating in structions of the positioners Type Standard EB 3730 2 EB 8384 2 EN 3730 3 EB 8384 3 EN 3730 4 EB 8384 4 EN 3730 5 EB 8384 5 EN 3731 3 EB 8387 3 EN EXPERT is an optional diagnostic firmware integrated in the positioner which allows the predictive status oriented mainte
4. Diagnosis j Test information Li Test not active g La Ii Measurement E Reference EB 8388 EN 17 Statistical information AUTO Long term monitoring The measured results Ay are classified ac cording to the valve position x in the valve position classes The average value Ay per valve position class is determined from all the measured data The Long term folder contains a table of the results Short term monitoring To provide a short term trend the last ten valve positions x and the associated Ay val ues are saved in the Short term folder gt Valve position and Difference signal drive Graphs The Hysteresis folder contains a graph with two curves plotted The Measurement curve shows the measured data recorded for long term monitoring and the Reference curve shows the reference data recorded af ter initialization The graph plotted using the reference data covers the full range of the valve The data for long term monitoring are re corded online while the process is running and therefore the graphs do not necessarily cover the full range of the valve Reference values are used in cases where no data could be compiled for valve classes If the test has not yet been activated the graph for the reference data is represented by a straight line The diagram allows changes in Ay with the corresponding valve positions to be recognized Changes in friction are highlighted as Ay is proporti
5. EB 38388 EN 9 Statistical information AUTO logger parameter and select Execute to start data logging Permanent data logging The variables w x y and e are logged ac cording to the adjusted scan rate and saved in the FIFO memory which always stores the last 100 measured data points of each vari able Triggered data logging On selecting Trigger in the Selection param eter the data logger records the measured data permanently in the background A trig gering event leads to the last 100 measured data points being stored together with the pretrigger time and leads to the data log ging of the triggering condition The following parameters can be changed for this function Trigger status Triggered by the travel condition setpoint and or solenoid valve condi tion forced venting Start value Limit indicating from which travel condi tion setpoint the data logger should be triggered Logging limit Indicating whether data logging should start when the travel condition setpoint exceeds or falls below the start value Travel condition setpoint Note The valve position is used as the travel condition in positioners in ESD version Select Trigger status parameter and select Start trigger via travel condition setpoint Activate data logging by selecting Start data e Positioner type 3730 3 Name UU tei Value Unit j Comment H H Identification Diagnosis Statis
6. The reference data required are plotted and stored after initialization Long term monitoring The long term monitoring involves the aver age drive signal y for each valve position class being determined from all measured data points per valve position class The Long term folder contains a table of the valve position classes with the associated average drive signal y Short term monitoring The short term monitoring involves the aver age drive signal y determined from the last measured data points per valve position class This allows short term changes in ac tuator pressure to be pinpointed at various valve positions The Differential drive signal and Valve posi tions folders contain a table of the last ten measured data points 16 EB 8388 EN Graphs The Steady state folder contains a common graph for long term short term and refer ence data The graph plotted using the ref erence data covers the full range of the valve The data for long term and short term moni toring are recorded online while the process is running and therefore the graphs do not necessarily cover the full range of the valve Reference values are used in cases where no data could be compiled for valve positions x as the valve did not move to those positions or a steady state could not be reached The diagram allows changes in drive signal y at the corresponding valve positions to be easily recognized Changes in pressure are also evident as
7. sponse of the controlled variable x is plotted after waiting a predetermined period of time This test tESt d3 allows the full range of the valve to be recorded in manual mode Tests MAN It is also possible to define a test range by selecting the Start and End parameters The ascendent and descendent are plotted within the test range 100 measured points are plotted at the maximum i e max 50 measured points are available for the ascendent and the descen dent The step height and the number of measur ing points are determined automatically by the adjusted test range The dead zone is analyzed by a step height smaller than 0 2 76 The setpoint difference that causes a mini mal change in the valve position x is termed dead band It is recorded and analyzed in the positioner for each step 5 Reference variable w c b Positioner type 3730 X Name 3 Value Unit Comment H Identification Diagnosis Tests MAN Static characteristic ete Operation unit Starttest test d3 H Positioner Stop test test d3 EC Diagnosis gt Testinformation _ ji j ftestd3 H Status messages E Start E l 46 0 9 5 Statistical information AUTO End E 54 0 o Tests MAN Step height E2 0 160 5 0 Drive signal diagram steady Delay time after step E ifs amp amp Drive signal diagram hysteresis Number of measurement values until L3 5D 2 2 Static characteristic
8. Reset logger Reset x long time histogram JL m EN il Reset x shorttime histogram p Reset e long time setpoint deviation Reset e short time setpoint deviation Reset cycle counter histogram long Reset cycle counter histogram sho Reset y xlong time Reset y x shorttime Reset hvsteresis Innn time Fig 15 Resetting diagnostic parameters EB 8388 EN 31 Resetting diagnostic parameters Note that the corresponding short term his togram short term monitoring is also reset on resetting long term histogram long term monitoring On performing the tests MAN the measur ing data of the last measurement as well as the reference measurements for d1 and d2 are stored in the positioner On restarting a test MAN the existing data are updated by the repeated measurement data In addition the repeated measurements of the tests MAN such as drive signal diagram steady state and drive signal diagram hys teresis can be reset by selecting the Status messages folder gt Reset Note Resetting the measured data does not cause the reference graphs to be reset Drive signal diagram steady state Drive signal diagram hysteresis Reference value for the end position trend However the existing data set is replaced by the new reference data when the refer ence graphs for steady state and hysteresis graphs see section 1 5 are replotted The data sets from already ex
9. the positioner The data logging finishes auto matically as soon as the maximum memory capacity of 100 measured data points for each variable including the pretrigger time is reached Travel setpoint or solenoid valve condition forced venting Select Trigger status parameter and select Start via travel setpoint solenoid valve condition forced venting Activate data logging by selecting Start data logger pa rameter and select Execute The triggering event starts data logging when the valve travel setpoint solenoid valve conditions forced venting are met The measured data are plotted over time in graphs In addition the compiled measured data are stored in the Measured values folder see Fig 3 2 2 Travel histogram The valve travel histogram is a statistical analysis of the plotted valve travel The histogram provides information for ex ample about where the valve mainly works during its service life and whether it shows a recent trend concerning changes in its work ing range The valve travel is recorded and assigned to valve travel classes The distribution showing EB8388 EN 11 Statistical information AUTO how often the valve travel remains within a class is shown in per cent The result is pre sented as a bar graph The Travel histogram folder contains long term data i e measured data are up dated cyclically scan rate 1 s over the en tire positioner service life and stored every 24 hours
10. the drive signal y is propor tional to the actuator pressure Data can be reset in the Status messages folder Test requirements A successfully plotted reference graph is necessary to record and analyze the data Refer to section 1 6 in case a double acting actuator with reversing amplifier or a booster is used or SUb initialization mode is set Note The valve can be moved through its travel range in manual mode during plant shut down or when the process allows it by se lecting Drive signal diagram steady in Test MAN to check the results or statements de termined in automatic mode in the Status message folder gt Extended 2 5 2 Hysteresis test d5 The hysteresis test allows changes in friction to be analyzed and an alarm is issued when a significant change in friction is detected If the diagnostic test d5 is activated and the condition for the Minimum time between tests parameter is met and the pressure con ditions have settled the test is performed with a change in travel lt 1 to find Ay tESt and d5 appear on the positioner dis play in alternating sequence and 7 for manual mode appears while the test is run ning The test is immediately canceled and the positioner returns to automatic mode if the valve travel leaves the tolerance band or a change in the reference variable occurs which is greater than the tolerance band set If the test was interrupted due to a change in the reference variable the
11. trig gered when a start condition is fulfilled The travel condition setpoint or the optional in tegrated solenoid valve optional integrated forced venting can be used to trigger the data logger The data logger is completely integrated into the positioner The software is only necessary for activation and to set the parameters In addition the measured data can be viewed as a graph or in a list by selecting Upload from Device in the Device menu or by clicking on the device toolbar Note Upon disconnection of the auxiliary power or upon changing the operating mode the test is inactive and must be reacti vated Data logging Select Data logger folder gt Selection and select Permanent or Trigger and set the Scan rate parameter Right click the Start data t 9 Value Unit Comment Diagnosis Statistical information AUTO a Positioner type 3730 X Name H Identification Operation unit cj Data logger H Positioner Cj Travel histogram a Diagnosis Lj Setpoint deviatio n histogram H Status messages 3 Cycle counter his togram gt Statistical information AUTO c Drive signal diag ram O Trend of travel end position Data logger C3 Travel histogram G Setpoint deviation histogram Cycle counter histogram Drive signal diagram C3 Trend of travel end position Tests MAN Graphic adjustment E Fig 2 Statistical information AUTO
12. 2 Min gead barc 3 E E A gt M dwel 2 Average dead ban BJ EE GET ees Te 5 Max dead band Bi 0 26 c Valve position x gt Progress flag L3 0 Step response 3 Graphic adjustment c3 Data logger B Steady 3 Hysteresis O Trend oftravel end position down O Static characteristic Step response c Static characteristic 3 Measured values Fig 13 Static characteristic E Static characteristic EB 8388 EN 25 Tests MAN Fig 13 lists the settings and information pa rameters While the test is active d3 and fESt appear on the positioner display in alternating se quence 7 indicates manual operating mode Viewing the recorded parameters The Static characteristic folder contains a graph of the measured points plotting the valve position x versus the reference vari able The Measured values subfolder gt Valve po sition x and gt Reference variable w con tain a table of the individual corresponding measured points Data can be reset in the Status messages folder Test requirements The starting point must be smaller than the final point The dead band is analyzed if the step height is smaller than 0 2 26 EB 8388 EN 3 4 Step response d4 The dynamic valve performance can be ex amined by recording the step responses Usually two steps in reference variable are performed and the course of the valve posi tion x and the drive sign
13. Cycle counter histogram Data for long term histogram Drive signal histogram steady state Drive signal histogram hysteresis d5 Minimum time between tests start test Data for short term and long term histograms Data for long term monitoring End position trend Measured values when end position changes Tests MAN Drive signal diagram steady state d1 Drive signal diagram hysteresis d2 Reference test reference time stamp Static characteristic d3 Step response d5 Scan rate step start step end delay time after step number of step responses analysis parameters General Details on actuator and valve data Yes Logging Save when a new alarm is issued Classification of status alarms Yes 34 EB 8388 EN 7 Troubleshooting Troubleshooting the pneumatics Possibly too much test Possibly too much Possibly exists Check pneumatic actuator and connections for leakage y x signature measured data Fault category Alarm Remedy Resetting alarm Supply pressure Possibly changed test Reset x signat d Possibly at full capacity test nn Check supply pressure 29 Refer to the section on Reset over Code 57 Possibly insufficient supply pressure in the EB Reset y x long term and of the positioner short term monitoring Trend Working range shift Reset concerning
14. O memory Additionally there is a pretrigger time avail able to allow the variables to be stored that were logged before the triggered event Enter the required pretrigger time by right clicking the parameter and selecting Modify However the pretrigger time en tered may not be higher than the maximum pretrigger time determined by the positioner This maximum pretrigger time is shown in the Max pretrigger time parame ter The data logging finishes automatically as soon as the maximum memory capacity of 100 measured data points for each vari able including the pretrigger time is reached Solenoid valve condition forced venting Select Trigger status parameter and select Start via solenoid valve condition forced venting Activate data logging by selecting Start data logger parameter and select Exe cute to start data logging as soon as the in tegrated solenoid valve is triggered or the forced venting function is activated Similar to the travel condition setpoint the variables w x e and y are logged at the adjusted scan rate and saved in the FIFO Statistical information AUTO memory on triggering Additionally there is a pretrigger time avail able to allow the variables to be stored that were logged before the triggered event Enter the required pretrigger time by right clicking the parameter and selecting Modify However the pretrigger time en tered may not be higher than the maximum pretrigger time determined by
15. Series 373x Positioners EXPERT Valve Diagnostics Y VIEW 3730 3 0 2005 Aug 09 tro SAMSON TROVIS VIEW File Edit View Device Options J ROVIS iD e MESRA C W Positioner type 3730 3 Version 14x EXPERT Comment Value Unit Name Positioner type 3730 3 Identification C Operation unit Positioner Diagnosis 0 Identification Operation unit Positioner 4 Diagnosis j Diagnosis Fig 1 Valve diagnostics with SAMSON TROVIS VIEW Operator Interface e g for Type 3730 3 Positioner Operating Instructions EB 8388 EN Firmware version 1 4x Edition November 2006 Contents Contents OR tl 37 171 2 1 2 2 2 3 2 4 29 2 9 1 2 5 2 2 6 3 1 3 2 33 3 4 4 4 2 4 3 4 4 4 5 4 6 CON OO 2 EB 8388 EN Page Description na eae EP RR Eee Re GS 3 Ee E E 3 Diagnostic tests 2 22 ss oro 4 Activating EXPERT ud OG eo eee ee RO wee S UE OR E Us 4 Actuator and valve specification data 22222 2222 5 Start the reference test oo Como 5 SUb initialization mode double acting actuator and booster 6 Activation analysis and presentation of diagnostic data 7 Printing the diagnostic ESDlog 2 22 2 nn nn 8 Statistical information AUTO 2 2 2 onen 9 Data logger u ma are ac OG ee drip do xe ee OS 9 Travel SOS 4 es a u ea we a EH OD eS 1 Setpoint deviation histogram
16. T diagnostic alarms Further status alarms are generated from the extensive information gained in the diagnos tic tests of EXPERT which provide the user with information covering the whole control valve see table below These status alarms can be viewed in the Di agnosis folder gt Extended An active diagnostic alarm issued by EXPERT appears on the positioner display over Code 79 4 3 Logging The last thirty alarms EXPERT EXPERT are stored in the positioner with a time stamp logged by the operating hours counter However it is important to note that the same alarm is only logged once when it first occurs The alarms stored can be viewed in the Log ger folder Entries can be reset in the Reset folder 4 4 Classification of the status alarms Any event or alarm is assigned a status The following states listed in the table below are possible Engineering tool TROVIS VIEW DTM C status ok ico ra status_on ico Individual status alarm Inactive Active No message classification Active Maintenance Status and diagnostic alarms 4 5 Condensed state To provide a better overview the state of the positioner is summarized in a condensed status which is made up from a summary of all classified positioner alarms Note If an event is classified as No message this event does not have any affect on the condensed status of the positioner The condensed status is display
17. al y are plotted until a steady state is reached This test is stored and analyzed in the positioner The reference variable w the setpoint devia tion e and time t are also stored and ana lyzed The default setting is two steps with the first step usually starting at a defined start value and ending at a defined end value After a certain delay the second step is per formed starting at the end value of the first step and ending at the defined start value of the first step The data are automatically analyzed in the positioner after the test is completed Param eters such as overshoot dead time T63 T98 rise time and settling time are deter mined separately for each step Refer to Fig 14 for the setting and informa tion parameters The following analysis parameters are deter mined separately for each step gt Overshoot relative to the step height in gt Dead time gt 163 gt 198 gt Rise time gt Settling time While the test is active dd and tESt appear on the positioner display in alternating se quence 7 indicates manual operating mode Viewing the recorded parameters The parameters required to analyze the step response test such as reference variable w valve position x setpoint deviation e and drive signal y are plotted in graphs over time in the Step response folder The Measured values subfolder contains all measured and analyzed parameters such as valve position setpoint drive s
18. cancel an active test On the TROVIS VIEW operator interface select the corresponding folder gt Stop test to cancel the test The positioner then moves to the previously set operat ing mode and to the travel value previ ously set manual mode or returns to the reference variable automatic mode Description Press once to cancel the tests MAN d1 drive signal diagram steady state d2 drive signal diagram hysteresis d3 static characteristic d4 step response and the test in statistical information AUTO d5 drive signal diagram hysteresis as well as the reference test over Code 48 On canceling a test d1 to d4 the positioner moves to the fail safe position The positioner only goes into automatic mode on canceling test d5 The reference graphs must be plotted before the tests for drive signal diagrams steady state and hysteresis in manual mode can be analyzed Note The analysis of raw data in automatic mode is started after the positioner has been in controlled operation for over one hour after initialization This does not apply to the end position trend test and the dynamic stress factor in the cycle counter histogram as their analysis starts directly after controlled operation begins Alarms generated from the tests MAN are marked TEST If the electrical auxiliary power is too low the test being performed is ended and the positioner moves to the fail safe position Upon failure of the aux
19. ed in the en gineering tool as well as on the positioner display as in the table below Furthermore the condensed state is issued at the fault alarm output Refer to the mount ing and operating instructions of the positioner for further details ea au ung tool Device TROVIS VIEW DTM display Maintenance ff Bu alarm status crific ico Maintenance required required Maintenance demanded classification P status main ico Active Function check classification N status funct ico Active Maintenance alarm classification amp status critic ico Maintenance demanded Pa status main ico Function check A status funct ico Text No message e status ok ico EB 8388 EN 29 Status and diagnostic alarms 4 6 Status modification The classification of the status alarms can be changed as required The following assign ment of the states are Maintenance alarm Maintenance required Maintenance demanded No message possible Select Positioner folder gt Error control gt Status classification to modify the classifica tion of standard alarms issued by EXPERT Select Positioner folder gt Error control gt Status classification gt Extended to modify the classification of alarms issued by EXPERT Note All additional alarms generated by EXPERT have the status No message by default On rese
20. er On changing the scan rate old data in the short term histo gram are deleted Statistical information AUTO The Average values e short parameter indi cates the class in which the last 100 mea sured setpoint deviations were stored on av erage in the FIFO memory Data can be reset in the Status messages folder 2 4 Cycle counter histogram The histogram shows the span of cycles the valve has moved through and the frequency of the cycles A valve cycle starts at the point where the valve stroke changes direction until the point where it changes direction again The valve stroke between these two changes in direc tion is the cycle span The cycle counter histogram provides a sta tistical analysis of the cycles As a result the cycle counter also provides information on the dynamic stress of a bellows seal or packing Positioner type 3730 X Name i Value Unit Commerr H Identification Diagnosis Statistical information AUTO Setpoint deviation histogram c Operation unit 3 Average values e Long L 01 e 02 H Positioner Diagnosis FO Status messages Counter of all measured values L3 6962 5 Min setpoint deviation ol oo mme 5 Max setpoint deviation L3 1 0 EMC Statistical information AUTO amp Data logger H Travel histogram Setpoint deviation histogram Shor time H Cycle counter histogram H Drive signa
21. full CLOSED position Check the valve working x long term and short term range of valve Weine neh cae histograms max OPEN Air leakage in Possibly exists test Reset Reset y x long term and short term monitoring Reset over Code 57 Restriction of full range of valve Downwards Upwards No change possible terminals Check pneumatic accessories and connections for leakage Check supply pressure and increase it if necessary Refer to the section on supply pressure in the EB of the positioner Check plug stem for problems caused by an external source Reset over Code 57 Reset e short term histogram Reset e long term histogram EB 8388 EN 35 Troubleshooting End position trend Zero point shift downwards monotonic Average value above the reference line Zero point shift upwards monotonic Average value above the reference line Zero point fluctuates Average value above the reference line Zero point shift downwards monotonic Average value below the reference line Zero point shift upwards monotonic Average value below the reference line Zero point fluctuates Average value below the reference line Check plug and seat Reset lower end position trend Mechanical connection linking positioner control valve Possible restriction of the full range of valve Check attachment Reset e short term histogram Fu
22. g EXPERT The extended EXPERT diagnostics can be activated later at the positioner when EXPERT is not already activated on delivery of the positioner 4 EB 8388 EN The required activation code can be ordered order number 1400 9318 On ordering this option specify the serial number of the positioner see nameplate or in the soft ware To activate EXPERT proceed as follows Enable configuration at the positioner Goa Turn 9 Code 3 press D turn 9 ON press amp After enabling configuration Turn 9 Code 48 press Code 48 blinks G B Turn amp to select d press turn to select d8 press 9 d8 blinks Turn and set the activation code XXXX Press amp to confirm the entered code After the activation has been successfully completed YES appears on the display Note On entering the wrong activation code the display returns to Code 0 The activation of EXPERT has been unsuccessful After an incorrect activation code has been entered three times Err appears on the display after selecting Code 48 and d8 An activation code can only be entered again after the positioner has been reset to its default settings Code 36 1 4 Actuator and valve specification data To correctly analyze the diagnostic data several actuator and valve specifications need to be entered for the EXPERT diagnos tics E
23. he Edit menu and 8 EB 8388 EN summary table of contents are listed in the diagnostic log by default Printing Settings I Customer data OF Cancel W Summary Parameters Comments Graphics Check the check boxes for the Comments and Graphics options to add these op tions to the diagnostic log Right click the Diagnosis folder or the required subfolder and select Print from the context sensitive menu to print the di agnostic log The printout contains the contents of the folder and its subfolders 2 Statistical information AUTO The signals x w and y need to be analyzed on a more precise basis to obtain advanced diagnostic information also over the valve actuator and pneumatic air supply The positioner compiles raw data for this pur pose The signals are plotted stored and analyzed while the process is running In addition an additional underlayed hysteresis test detects any changes in friction The diagnostic tests do not have any affect on the positioner s control performance 2 1 Data logger The data logger allows the reference vari able w controlled variable x in relation to the working range drive signal y and setpoint deviation e to be plotted over time The measured data are saved in an FIFO memory with a capacity to save 100 data points in the positioner In addition to the permanent plotting of Statistical information AUTO data the plotting can be automatically
24. he steady state drive signal diagram con tains recent data to allow recent changes to be recognized Furthermore long term data are also analyzed to be able to detect prob lems due to supply pressure changes or air a Positioner type 3730 X Name H Identification c3 Operation unit cjLong time Positioner Short time a Diagnosis H Status messages J Statistical information AUTO HC Data logger HC Travel histogram H Setpoint deviation histogram v 1 5 fC Cycle counter histogram EMC Drive signal diagram ao H Hysteresis H Trend of travel end position Tests MAN H Graphic adjustment C Steady ma Fig 7 Steady state drive signal diagram Diagnosis Statistical information AUTO Drive signal diagram Steady Value Unit Comment M Long time B Shorttime Bi Reference EB 8388 EN 15 Statistical information AUTO leaks in the pneumatics before they have an impact on the process The measured data allows the following problems to be detected and the associated alarms to be issued Air leakage in the pneumatics Spring force reduced Changes in supply pressure The valve position and its associated drive signal y are measured after the pressure conditions have settled steady state Each pair of measured data points recorded is assigned to a valve position class The average drive signal y is calculated for each class The stored data can be read
25. iewed and set conveniently Type Integration 3730 2 TROVIS VIEW3 373 3 TROVIS VIEW3 DD DTM 3730 4 TROVIS VIEW3 DD DTM 3730 5 TROVIS VIEW3 DD The following sections contain a description on how to operate the diagnostics over the TROVIS VIEW3 software Note All the parameter settings that are changed over the operator interface must also be downloaded onto the positioner to allow them to become effective EB8388EN 3 Description Note The optional integrated solenoid valve is implemented by a forced venting function in Types 3731 x Positioners 1 2 Diagnostic tests There are two main groups of diagnostic tests available Statistical information AUTO These tests are performed while the process is running automatic mode without disrupt ing the process Activated tests are automatically performed when they are triggered by their start condi tion e g data logger and drive signal dia gram hysteresis Other tests are already performed in the background without being activated e g histograms cycle counter drive signal steady state and end position trending Tests MAN These tests should not be performed while the process is running i e in manual mode instead as the positioner cannot follow the reference variable at the same time The valve is moved to a certain position de fined by the test settings and the valve may move through its full range 1 3 Activatin
26. ignal setpoint deviation and the points in time at which they were recorded Data can be reset in the Status messages folder Tests MAN E Positioner type 3730 3 Name i Value Unit Comment H Identification Diagnosis Tests MAN Step response C Operation unit Start step response L3 test d4 E C eo Stop step response test d4 E nn messages nn gt 10 0 S c Statistical information AUTO E Step end z 20 0 Eu 5 5 Tests MAN E Delay time after step L 22 s 10 Drive signal diagram steady Scan rate c 0 2 BE 40 Drive signal diagram hysteresis J Duration of the test Li 945 45 Statistic characteristic E Number of step responses Li 2 c Step response Progress flag L 0 Graphic adjustment i 3 Overshoot rising L3 0 9 95 Dead time rising O 04s T63 rising L3 1 4 5 T98 rising Li 22 Rise time rising L ZZ t C Graphic adjustment E Valve position x E Reference variable w E Setpoint deviation e F Drive signal y Fig 14 Step response test EB 8388 EN 27 Status and diagnostic alarms 4 Status and diagnostic alarms 4 1 Standard EXPERT diagnostic alarms The standard EXPERT diagnostics provides information about positioner states such as operating hours counter process monitor ing number of zero calibrations and initializa
27. iliary power tests in tests MAN and statistical information AUTO must be restarted due reasons of safety EB 8388 EN 7 Description However the test in statistical information AUTO drive signal diagram hysteresis re mains activated In the event that the solenoid valve Type 3730 x is triggered or the forced venting function Type 3731 x is activated active tests are stopped and the positioner moves to the fail safe position However the test in statistical information AUTO drive signal diagram hysteresis re mains activated In the event that the solenoid valve Type 3730 x is triggered or the forced venting function Type 3731 x is activated active tests are stopped and the positioner moves to the fail safe position 1 7 1 Printing the diagnostic ESD log The Print command allows you to print out a diagnostic log of individual tests or the en tire diagnosis The diagnostic log includes a title page and a list of all the data points including all their values and properties The title page contains all key information for clear identification of the printed log de vice type file name time and date of cre ation time and date of the last change and TROVIS VIEW version Select Print in the File menu to add further information 1 In the File menu select Print Options to choose the scope of the diagnostic log After installing updating the TROVIS VIEW software customer data Customer data in t
28. in the positioner s non volatile memory for long term monitoring The Number of measurement values param eter shows the total amount of classified measured data points previously recorded The Average value x long parameter con tains the class in which the travel remained on average the most In order to be able to recognize any short term changes in valve travel properly the last 100 measured data points are stored at a scan rate default 1 s in a non volatile memory The scan rate can be changed in the Scan rate short time param eter On changing the scan rate old data in the short term histogram are deleted The Average values x short parameter con tains the average class assignment for the last 100 measured data points stored in the non volatile memory Data can be reset in the Status messages folder 2 3 Setpoint deviation histogram The setpoint deviation histogram contains a statistical analysis of any setpoint deviations recorded This provides a summary of how often and to which level a setpoint deviation has occurred during the positioner service life and whether it shows a recent trend con cerning the setpoint deviation The setpoint deviation is recorded and as signed to predetermined level classes The percentages showing how often the setpoint deviation remains within a class is presented Positioner type 3730 X Name t Value Unit Comment H Identification O
29. inear in relation to the valve position similar to the signal pressure in the pneumatic actuator This graph is plotted after initialization and is stored as a reference in the positioner A pressure drop across the valve while the process is running causes the signal pres sure in the actuator to change by the same amount as the valve travel because the flow forces have an affect on the equilibrium of forces at the valve stem A similar effect arises when the actuator springs loose their compression due to one or more springs failing As a result a change in the correlation between the inter nal drive signal y and the valve travel also Statistical information AUTO pinpoints to one of these events having oc curred A reduced spring force or a control valve with the fail safe position Fail to close leads to the drive signal y shifting down wards with an ever smaller gradient In contrast the pressure drop across the valve while the process is running does cause the drive signal y to drop but the gradient rises irrelevant of the valve travel If significant leakage in the pneumatics arises due to screw fittings that are not tight ened properly or due to a tear in the dia phragm the drive signal even starts to rise steadily at a certain valve opening com pared to the reference graph The drive signal y starts to rise almost un steadily at the restricted valve position if the positioner supply pressure is insufficient T
30. isting mea surements of steady state and hysteresis graphs recorded in both statistical informa tion AUTO and tests MAN are reset when both reference graphs are updated Initialization After an initialization has been successfully completed new reference measurements are automatically plotted and the existing refer 32 EB 8388 EN ence data are overwritten The new refer ence data and the optimized control param eters cause the following statistical informa tion AUTO and MAN tests to be reset Drive signal diagram steady state AUTO and MAN tests Drive signal diagram hysteresis AUTO and MAN tests Setpoint deviation histogram long term and short term End position trend Resetting over Code 36 EXPERT EXPERT Activate Code 36 or select Operation unit folder gt Start with default settings to reset the positioner parameters to their default settings see code list in the mounting and operating instructions of the positioner The following diagnostic functions of EXPERT EXPERT diagnostics are reset Settings and activated statistical informa tion AUTO and tests MAN in EXPERT Status classification settings EXPERT EXPERT Operating hours counter gt Device switched on since initialization and gt Device since initialization in control loop EXPERT Total valve travel EXPERT All short term histograms EXPERT Drive signal diagram steady state and diagram hysteresis Statistical informati
31. itioner is initialized in SUb mode or when a double acting actuator and or booster is used Positioner initialization in SUb mode Analysis in automatic or manual mode is deactivated All tests for both statistical information AUTO and tests MAN of drive signal di agrams steady state and hysteresis are inactive The reference test is inactive The automatic test to start all tests MAN is inactive Double acting actuator with reversing amplifier All tests for both statistical information AUTO and tests MAN of drive signal diagrams steady state and hysteresis are inactive The reference test is inactive Booster The analysis of the tests for both statisti cal information AUTO and tests MAN of drive signal diagrams is inactive 1 7 Activation analysis and presentation of diagnostic data All diagnostic tests which do not compile data automatically in the background data logger drive signal diagram hysteresis must be activated to start them To start these tests select the corresponding test order gt Start data logger or Start test and right click the parameter to select Exe cute to activate the test Note The tests in statistical information AUTO in automatic mode can only be activated when the positioner is in G automatic operating mode To activate the tests MAN in manual mode the positioner must first be set to 2 manual mode over Code 0 Canceling diagnostic tests There are two ways to
32. ividual measured points are saved in the corresponding subfolders gt Reference valve position gt Reference drive signal gt Repetition value of valve position gt Repetition value of drive signal Test requirements A successfully plotted reference graph and repetition lines are necessary in or der to analyze the data If a reference graph still has not been plotted on starting the test this test is adopted as the reference Refer to section 1 6 in case a double act ing actuator with reversing amplifier or a booster is used or SUb initialization mode is set Tests MAN 3 2 Drive signal diagram hysteresis d2 Similar to the corresponding test in auto matic mode this test HESt d2 is used to an alyze the change in friction forces However unlike the test in automatic mode this test causes the valve to move to defined valve positions over the full range of the valve and determines Ay for each valve po sition The valve is made to move to fixed nodes of the valve position x and the valve position is ramped up lt 1 correspondingly The drive signal y and the change in valve opening are analyzed during this test phase concerning changes in Ay for changes in di rection to precisely check the results or alarms issued in automatic mode To enable a test the tolerance band Code 19 or in Positioner folder gt Error control must be greater than 1 default 5 If the valve cannot move to a cer
33. l diagram Trend of travel end position H Tests MAN H Graphic adjustment C Setpoint deviation histogram Fig 5 Setpoint deviation histogram EB 8388 EN 13 Statistical information AUTO The Dynamic stress factor parameter is spec ified as a percentage reflecting the stress of the packing An alarm is issued if the dy namic stress factor exceeds 90 The Dynamic stress factor is determined from the cycle span and how often the cycle spans occurred frequency depending on which packing has been selected see section 1 4 self adjusting adjustable or bellows seal To ensure this factor is correctly determined make sure the correct packing is selected in the Stuffing box parameter in the Identifica tion folder gt Positioner gt Valve The cycle counter records the number of cy cles and the cycle spans which are assigned to cycle classes The calculated percentages on how often a cycle occurs within a class are shown as a bar graph The Cycle counter histogram folder contains long term data i e measured data points are updated cyclically over the entire positioner service life and stored every 24 hours in the positioner s non volatile mem ory for long term monitoring The Average value z long parameter con tains the cycle class in which the average cycle spans were found The Counter of all measured values parame ter contains the total of classified measured data point
34. lay No graphical display No graphical display Steady state drive signal long term 38 Eb 8388 EN No graphical display Communication HART DD HART DTM EXPERT without TROVIS VIEW HART EDD FF DD Profibus EDD Engineering tool Steady state drive signal short term Hysteresis test long term No graphical display No graphical display e g PACTWare e g Siemens PDM Various No numerical display No graphical display Siemens PDM End position trend N Tests MAN refer to sect No graphical display ion 3 for descr iption Drive signal diagram steady state d1 No graphical display No numerical display No graphical display Drive signal diagram hysteresis d2 No graphical display No numerical display No graphical display Static characteristic d3 Restricted numerical display 2 No graphical display Restricted numerical display 2 No graphical display Step response d4 Restricted numerical display 2 No graphical display Diagnostics Status alarms refer to section 4 for desc ription Restricted numerical display 2 No graphs displayed Extended EXPERT status alarms Logging Classification of status alarms Resetting diagnostic parameters refer to
35. ll range of valve Mainly near to CLOSED position Mainly near to max OPEN Mainly CLOSED position Mainly max OPEN Reconsider whether the working range is suitable Reset x long term histogram 36 EB 8388 EN Friction Actuator springs Much higher over the full range of valve Much lower over the full range of valve Much higher over part of the range Much lower over part of the range Much higher lower over the full range of valve test Much higher lower over part of the range test Spring rigidness possible reduced spring failure test Compression possible reduced test Check packing Check springs in the actuator Troubleshooting Reset hysteresis long term and short term monitoring Reset hysteresis measured data Reset y x signature measured data Seat leakage Possibly different Check plug and seat Reset y x signature measured data Reset e short term histogram Leakage to the Reset hysteresis long term alarm active when greater than 90 atmosphere and short term monitoring WM Reset Maybe to be expected soon Check packing livstenssis measured data Reset z long term histogram Dynamic stress Percentage as information on factor packing load Leakage to the atmosphere Ghedi Reset z long term histogram This value is included in the Cycle counter histogram in statistical informati
36. nance of pneumatic control valves Refer to section 1 3 on how to activate this option EXPERT upgrades the standard EXPERT di agnostics firmware incorporated in the positioner The upgraded version provides extended functions to pinpoint valve param eters that have worsened allowing the user to plan predictive maintenance and service work before malfunctions can affect the pro cess causing unscheduled plant shutdowns EXPERT records the valve faults in auto matic mode while the process is running and issues alarms on the required mainte nance work In addition numerous tests can be performed in manual mode to pinpoint emerging faults Owing to the numerous diagnostic tests EXPERT is able to generate classified status alarms on the state of the control valve Description The EXPERT diagnostics are completely in tegrated in the positioner Data required for diagnostics are compiled automatically and the test data are analyzed in automatic or manual mode in the positioner itself The re sulting data are used to issue classified sta tus alarms The diagnostics data results and status alarms are available over the DD Device Description All the necessary reference graphs are automatically plotted after the positioner has been initialized and are available when required After performing the basic settings at the positioner using the rotary pushbutton the TROVIS VIEW3 or DTM software allow the parameters to be v
37. nter the required data in the Identification folder gt Positioner gt Actuator as well as gt Positioner gt Valve Download the data to the positioner The Model and Booster parameters in the Actuator folder and Stuffing box parameter in the Valve folder need to be entered The default settings of these parameters are Model gt Single acting Booster gt Not present Stuffing box gt Self adjustable Description These parameters do not need to be changed if the control valve also has these default settings 1 5 Start the reference test After EXPERT has been activated properly the reference graphs for future diagnostic purposes need to be plotted to allow the di agnostics to function in their full scope The reference graphs are plotted automati cally after the positioner has been initialized when the EXPERT has been activated e g already on delivery On activating EXPERT at later time the ref erence graphs are plotted after the positioner is re initialized If reference graph plotting is to be started sep arately in an initialized positioner or if graphs are to be replotted proceed as follows Set the positioner to 7 manual mode Turn 9 Code 0 press e Code 0 blinks G NIL IN ae je l o Turn 9 MAN press B the positioner moves to manual mode Lor ae Nc ok NI o lt oa ea Manual operating mode _ d You can ac
38. on AUTO EB 8388 EN 37 EXPERT without TROVIS VIEW 8 EXPERT without TROVIS VIEW The EXPERT valve diagnostics are displayed in different ways depending on the type of communication and the connected engineering tool The TROVIS VIEW software with communication over the SSP interface provides full access to EXPERT diagnostic functions Numerical display of parameters Display of parameters in the form of graphs Parameterization where applicable The representation may differ in other engineering tools The table below illustrates the differ ences Communication Engineering tool Start reference test section 1 5 HART DD HART DTM e g PACTWare HART EDD e g Siemens PDM Statistical information AUTO refer to section 2 for description FF DD Various Profibus EDD Siemens PDM Data logger No numerical display No graphical display No numerical display No graphical display No numerical display No graphical display Travel histogram long term i Travel histogram short term No graphical display No graphical display No parame terization No graphical display Setpoint deviation histogram long term H No graphical display Setpoint deviation histogram short term No graphical display No parame terization Cycle counter histogram long term Cycle counter histogram short term No graphical disp
39. on AUTO and tests MAN EXPERT Static characteristic and step response EXPERT End position trend EXPERT If the same status classification is to be used in future you can upload the settings onto a PC over for example the TROVIS VIEW software Mounting the positioner onto another con trol valve As the EXPERT extended diagnostics pro vides statements about the entire control valve the data from statistical information AUTO and tests MAN need to be reset when the positioner is attached to a different control valve After mounting the positioner on the new control valve perform a reset over Code 36 and re initialize the positioner This leads to the most of the diagnostic functions being reset We recommend additionally to manually re set the long term travel histogram and the long term cycle counter histogram as well as the logging by selecting the Diagnosis folder gt Reset Resetting diagnostic parameters EB 8388 EN 33 Diagnostic parameters saved in non volatile memory 6 Diagnostic parameters saved in non volatile memory The following parameters are saved in a non volatile memory to prevent their loss Statistical information AUTO Data logger Which data are saved if a parameter change is detected Data logging scan rate start value logging limit trigger status Cyclic saving 24 h Travel histogram Setpoint deviation histogram Scan rate of short term monitoring
40. onal to the actuator pressure which in turn is a measurement for friction A 18 Eb 8388 EN change in friction leads to an alarm being issued Test requirements The test is possible in relation to the travel range between 2 and 98 A successfully plotted reference graph is necessary in order to analyze the fric tion The test can only be started when the tol erance band Code 19 or Positioner folder gt Error control gt Tolerance band is greater than 1 The characteristic type Code 20 must be set to Linear in order to record the data Refer to section 1 6 in case a double act ing actuator with reversing amplifier or a booster is used or the SUb initialization mode is set Note The valve can be moved through its travel range in manual mode during plant shutdown or when the process allows it by selecting Drive signal diagram hysteresis in Test MAN fo check the results or statements determined in automatic mode in the Status message folder Extended The following parameters are changed dur ing hysteresis test d5 correspondingly Lower x range value Code 8 O Upper x range value Code 9 100 Lower upper x limit Code 10 11 OFF Setpoint cutoff w decrease increase Code 14 15 OFF Pressure limit Code 16 Active pressure limit is raised one stage higher W ramp OPEN CLOSED Code 21 22 Variable Data can be reset in the Status messages folder 2 6 End position trend The end p
41. osition trend is used to detect a creeping zero point shift due to seat and plug wear or dirt between the seat and plug A fluctuating zero point also causes an alarm to be issued To accomplish this function the valve posi Statistical information AUTO tion x and the drive signal y are automati cally logged and time stamped by the oper ating hours counter in automatic mode when the valve moves to the lower end posi tion The measured data are stored in an FIFO memory that always stores 30 mea sured data points The measured data are first stored in a ring buffer if the valve position x differs by 0 25 from the measured value previ ously recorded To allow the test to run automatically in the background activate the tight closing func tion over Code 14 or in the Positioner folder gt Reference variable gt Setpoint cut off decrease and make sure the positioner is in AUTO operating mode When the valve moves to the zero point for the first time in controlled operation this measured value serves as a reference The reference value is stored in a non volatile memory independent from the ring buffer Name E Positionertype 3730 X H Identification c Operation unit Value Unit Commen Diagnosis Statistical information AUTO Hysteresis Trend of travel end position cj Lower end position Positioner 34 Diagnosis H Status messages El Statistical information AUTO Data logger
42. peration unit Diagnosis Statistical information AUTO Travel histogram J Average values x Long j O 45 lt x lt 50 H Positioner Number of measurement values La 7721 Ec Diagnosis H Status messages O Shor time 2 0 Statistical information AUTO c3 Data logger Travel histogram C Setpoint deviation histogram Cycle counter histogram Drive signal diagram Trend of travel end position C Tests MAN Graphic adjustment Fe Eh HE C Graphic adjustment Fig 4 Travel histogram 0 x 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95100 gt 96 12 Eb 8388 EN as a bar graph Ideally the setpoint devia tion should be as small as possible Similar to the valve travel histogram the Setpoint deviation histogram folder contains long term data i e measured data are up dated cyclically scan rate 1 s over the en tire positioner service life and stored every 24 hours in the positioner s non volatile memory for long term monitoring Additional information determined from this long term histogram are shown in Fig 5 The minimum and maximum setpoint devia tions are also indicated In order to obtain a summary of recent setpoint deviations the last 100 setpoint de viations are logged at an adjustable scan rate default 1 s and saved in an FIFO memory The scan rate can be changed in the Scan rate short time paramet
43. s previously recorded In order to obtain a summary of recent cy cles the last 100 cycles measured are stored in an FIFO memory The Short folder contains this additional cy cle counter histogram The Average value z short parameter con tains the average cycle class for the last 100 measured data points stored in the FIFO memory Data can be reset in the Status messages folder a Positioner type 3730 X i Value Unit Commen Identification Diagnosis Statistical information AUTO Cycle counter histogram c3 Operation unit B Positioner 3 Average values z long Counter of all measured values BE 76 ie 2 lt Qycle lt 5 c3 Diagnosis j Dynamic stress factor IC o H Status messages 2 5 Statistical information AUTO O Shor time c3 Data logger Travel histogram B Setpoint deviation histogram D Cycle counter histogram ic Short time EMC Drive signal diagram Hp Steady BC Hysteresis H Trend oftravel end position FO Tests MAN Graphic adjustment C Cycle counter histogram Fig 6 Cycle counter histogram Cycle 96 gt 14 EB 8388 EN 2 5 Drive signal diagram 2 5 1 Steady state drive signal The signature diagram plotting drive signal versus valve position is based upon the drive signal y being the internal control signal of the i p converter This signal runs l
44. section 5 for description Resetting diagnostic parameters e Full scope of functions all functions that are available with TROVIS VIEW 1 EXPERT functions cannot be parameterized 2 Only analyzed data are shown the measured data are not shown 3 With Siemens PDM full functionality with numerical and graphical display EB 8388 EN 39 SAMSON AG MESS UND REGELTECHNIK Weism llerstraBe 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 8388 EN S Z 2007 10
45. tain valve position node or the setpoint leaves the tol erance band during the test an alarm is generated in Test information and the test is canceled The necessary data set for the reference graph is automatically plotted and stored di rectly after initialization The start time for the reference graph is stored with a refer ence time stamp in the non volatile memory of the positioner Any further measurement is stored as a re peated measurement Previously recorded repeated measurements stored in the positioner are overwritten However you can upload previous repeated measure ments to a PC before you start a new test EB 8388 EN 23 Tests MAN While the test is active d2 and tESt appear on the positioner display in alternating se quence 2 indicates manual operating mode Viewing the recorded parameters The Drive signal diagram hysteresis folder contains a graph with reference measurements and the last measurement performed plotting the change in drive sig nal Ay versus the valve position x The Refer ence valve position subfolder contains a list of the valve positions that the valve moved to The recorded Ay are saved in the corre sponding subfolders gt Reference hysteresis gt Repetition value of hysteresis Test requirements A successfully plotted reference graph and repeated measurements are neces sary in order to analyze the data If a reference graph still has not been plotted on starting
46. test is started Statistical information AUTO again after waiting 30 seconds using the new operating point If the test is canceled again at this point due to a change in the reference variable Aw the test is started again after waiting 60 sec onds with the operating point This can happen ten times during which the time between tests is increased by 30 sec onds each time 30 s x Number of tests re peated After the test is canceled for the tenth time due to Aw the time entered in Minimum time between tests parameter is kept again The hysteresis test is deactivated by default We recommend activating the test after en tering Minimum time between fests by select ing Start now The Minimum time between tests and the control parameters are stored in the non volatile memory of the positioner Positioner type 3730 X 3 3 Identification Name Status messages Statistical information AUTO Data logger Travel histogram Setpoint deviation histogram jLong time Shor time Cycle counter histogram Drive signal diagram Steady Trend of travel end position 9 0 Tests MAN Graphic adjustment L Hysteresis Fig 8 Hysteresis test diagram i Value Unit Commen Diagnosis Statistical information AUTO Drive signal diagram Hysteresis Operation unit Starttest o Test active test d5 Positioner Min time distance from test imi 10 h
47. tests MAN An active EXPERT alarm is indicated by Code 79 at the positioner Select Diagnosis folder gt Status messages gt Reset to reset data from statistical infor mation AUTO and tests MAN see Fig 15 Reset initialization time exceeded Reset of the corresponding error message ae Identification c3 Operation unit H Positioner Elf Diagnosis C Status messages C3 Logger O Extended H Statistical information AUTO Tests MAN H Graphic adjustment Name i Value Unit Comment Diagnosis Status messages Reset Reset total valve travel Reset default values flag Reset configuration changed flag Reset operating errors Reset zero point Code 58 Reset autocorrection Code 59 Reset hardware errors Reset hardware Code 65 Reset control calculation Code 6 Reset initialization errors Reset x gt range Code 50 Reset deltax lt range Code 51 Reset attachment Code 52 Reset initialization time exceeded Code 53 Reset initialization solenoid valve Cade 54 Reset travel time too short Code 55 Reset pin position Code 56 Reset data errors Reset control parameter Code 58 Reset poti parameter Code 69 Reset general parameter Code 1 Reset HART Parameter Code 74 Reset options parameter Code 78 Reset diagnosis parameter Code 80 Reset statistical information
48. the test this test is adopted as the reference Refer to section 1 6 in case a double act ing actuator with reversing amplifier or a booster is used or the SUb initialization mode is set Ec Tests MAN 9 0 Drive signal diagram steady pim H Static characteristic H Step response CO Graphic adjustment O Data logger delta y 1 5 500 400 Stead y 300 C3 Hysteresis C3 Trend of travel end position down O Static characteristic 200 Step response 100 Fig 12 Drive signal diagram hysteresis Positioner type 3730 X Name Value Unit Commen amp 4 Identification Diagnosis Tests MAN Drive signal diagram hysteresis Operation unit Starttest Li test d2 H Positioner Stop test test d2 2 4 Diagnosis 3 Reference time stamp L 00 46 57 d h min 9 0 Status messages 3 Test information L3 Test finished H Statistical information AUTO 2 Progress flag O 0 E Reference Repetition 24 EB 8388 EN 3 3 Static characteristic d3 The static performance of the control valve is affected by the friction hysteresis and the elastic processes in the valve stem packing The static characteristic is plotted to check the static performance The analysis of minimum maximum and average dead band parameters allows the control loop to be evaluated To accomplish this the reference variable w is commanded in small steps and the re
49. tical information AUTO Data logger HE Operator unit Start data logger O Ec Diagnosis El Selection L Permanent 2 on AUTO B Trigger status L3 Start trigger via travel condition a Data logger E Scan rate i L3 0 5 5 H A Batchconfiguration H Travel histogram H Setpoint deviation histogram B Start value Li 99 0 I H E Cycle counter histogram E Logging limit L3 Start at exceeding the initial value E H Drive signal diagram Pretrigger time L 0 s C Trend of travel end position J Max pretrigger time La 6 6 5 Tests MAN Solenoid valve L Implemented Code 45 73 Graphic adjustment 1 EN E valve position x E Reference variable w E Setpoint deviation e 100 0 4 j Graphic adjustment 150 0 t 0 0 t 10 0 Fig 3 Data logger t 20 0 t 30 0 t 40 0 t F Drive signal y T2000 50 0 t21 05 42 31 d h min sec 10 Eb 8388 EN logger parameter and select Execute The triggering event starts data logging when the start value exceeds or falls below an entered value Enter the required value at which data log ging should be triggered in relation to the setpoint in the Start value parameter Select whether data logging should start when the entered value exceeds or falls be low the start value in the Logging limit pa rameter After being triggered the variables w x y and e are logged at the adjusted scan rate and saved in the FIF
50. time stamp in the positioner s non volatile memory Any further measurement is stored as a re peated measurement Previously recorded repeated measurements stored in the positioner are overwritten However note that you can upload previous repeated mea surements to a PC before starting a new test While the test is active d1 and tESt appear on the positioner display in alternating se quence and 7 indicates manual operating mode H Static characteristic Repetition value of val H Step response Graphic adjustment v 1 5 Diagnosis Tests MAN Drive signal diagram steady Fig 11 Drive signal diagram steady state cQ Positioner type 3730 X Name 1 Value Unit Commen H Identification Diagnosis Tests MAN Drive signal diagram steady Operation unit Starttest O test d1 iC Positioner 1 Stop test test d1 Ec Diagnosis 5 Reference time stamp Lj 00 46 57 d h min Status messages 3 Test information O Testfinished Statistical information AUTO 2 Progress flag O o 3 Tests MAN 9 8 Reference valve posit 4 Drive signal diagram hysteresis Reference drive signal Repetition value of drive signal ion ve position B Reference iUi Repetition 22 EB 8388 EN Viewing the recorded parameters The Drive signal diagram steady state folder contains the reference and repeated mea surements plotted in a graph The ind
51. tions total valve travel tempera ture initialization diagnostics zero control loop errors etc In addition the standard EXPERT diagnostics generates diagnostic and status alarms which allow faults to be pinpointed quickly when a fault occurs The diagnostic and status alarms issued by EXPERT appear on the positioner display and can also be viewed in TROVIS VIEW software in the Diagnosis folder gt Status messages Alarms are classified in the following main groups Status Operation Hardware Initialization Data memory Temperature Further information on the positioner status e g limit switches tight closing function and the parameters e g characteristics are displayed in the Positioner folder 28 EB 8388 EN The following folders contain particularly in formative data for valve diagnostics Positioner folder process data Information on the current process vari ables condensed status operating mode limit switch temperature The Trend Viewer function activate Trend Viewer in the View menu allows process variables to be shown in one or more graphs To proceed drag and drop the required process variable into the graph Positioner folder gt Error control Information on total travel with a freely defined limit Positioner folder gt Start up gt Initializa tion List of initialization errors which can also be found in the Diagnosis folder gt Sta tus messages 4 2 Extended EXPER
52. tivate the reference test either by selecting the Diagnosis folder gt Start refer EB 8388 EN 5 Description ence test and right click the parameter to select Execute or alternatively start the ref erence test at the positioner itself by select ing Code 48 as follows Enable configuration at the positioner Turn 9 Code 3 turn Y ON press GB After enabling configuration Turn amp Code 48 press Code 48 blinks Turn until d appears press turn to select d7 press d7 blinks Z di N I iM o Turn amp gt ON press to start the reference test Caution The control valve moves through its travel range during the reference test The tests d drive signal diagram steady state and d2 drive signal diagram hysteresis are performed during the diag 6 Eb 8388 EN nostic reference test During the reference test fESt and d1 or d2 appear in alternating sequence on the positioner display The measured data are used as reference data and any existing reference graphs are overwritten If the reference graphs could not be plotted correctly or are incomplete Code 81 is is sued and saved in a non volatile memory The positioner can function properly after it has been initialized successfully without the reference data 1 6 SUb initialization mode double acting actuator and booster The following points need to be observed when the pos
53. tting the positioner parameters to their default settings Code 36 the status classification is also reset to the default set ting If modifications that have already been made should be kept we recommend uploading them on a PC before performing a reset and then downloading them onto the positioner again afterwards Note In the Type 3730 5 Positioner Foundation Fieldbus block error alarms as well as the condensed states can be assigned to events Refer to EB 8384 5 EN for further instructions 30 EB 8388 EN 5 Resetting diagnostic parameters When an alarm is issued the source of the error should be first located and the error remedied In the case of an EXPERT alarm we recom mend reading the corresponding remedy notes listed in the error code list refer to the Operating Instructions of the positioner Remedy notes on EXPERT alarms are listed in the table in section 7 EXPERT Alarms generated by EXPERT which are indicated on the positioner display by an er ror code can be confirmed by pressing the a Positioner type 3730 X Resetting diagnostic parameters rotary pushbutton after selecting the corre sponding error code Resetting error codes as well as resetting op tions such as logging or the total valve travel can be performed using an engineering tool for example TROVIS VIEW3 software EXPERT Extended alarms generated by EXPERT are based upon the statistical information AUTO and
54. ull range of the valve af ter the test is started Therefore before start ing the test it is absolutely important to make sure whether the process and plant conditions allow it In contrast to the tests in statistical informa tion AUTO the corresponding test MAN covers the full range of the valve and also serves to detect errors within the travel range The tests MAN provide a trend showing the current control valve state any possible ex isting malfunctions and help to pinpoint faults and to schedule predictive mainte nance work For reasons of safety the tests MAN can only be started when the positioner is in manual operating mode Tests MAN Select the operating mode over Code 0 on the positioner or in Positioner folder gt Op erating mode Select the Start all tests parameter to start all tests automatically in sequence During the test the following parameters are changed for all tests MAN d1 to d4 Lower x range value Code 8 0 Upper x range value Code 9 100 Lower upper x limit Code 10 11 OFF not in a step response test Setpoint cutoff w decrease increase Code 14 15 OFF Pressure limit Code 16 Active pressure limit is raised one stage higher Characteristic Code 20 Linear W ramp OPEN CLOSED Code 21 22 Variable Note The tests MAN can only be activated in manual operating mode a Positioner type 3730 X Name fC Identification Operation unit Start all tests

Operating Instructions EB 8388 EN

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