Home

Operating Instructions EB 8388-5 EN

1. 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 from statistical information AUTO and tests MAN Static characteristic and partial stroke test EXPERT End position trend EXPERT Additionally the status classification is reset If the same status classification is to be used in future you can upload the settings onto a computer over for example 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 Status messages gt Reset Resetting diagnosis parameters 8388 5 EN 47 Diagnostic parameters saved in non volatile memory 6 Diagnostic parameters saved in non volatile memory
2. Data logger amp Travel histogram x Setpoint deviation histogram e 5 Cycle counter histogram Diagnosis Statistical information AUTO Tren be ON amp s Fig 9 End position trend 24 8388 5 EN Note The valve end position is also logged when the valve moves to the fail safe posi tion 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 ta ble of the measured data valve position x drive signal y with time stamp Reset Data and the reference value can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset Statistical information AUTO EB 8388 5 EN 25 Tests in manual mode 3 Tests in manual mode Select the Start all tests parameter to auto matically start the tests one after the other refer to sections 3 1 and 3 2 3 1 Tests MAN d1 to d3 These tests are not performed in closed loop operation The positioner does not follow its reference variable CAUTION In the tests d1 drive signal diagram steady state d2 drive signal diagram hys teresis and d3 static characteristic the
3. 9 0 Binary input 1 011 TRD 8 3 Binary input 2 012 TRD Reset hardware errors _ Codesg Diagnosis Reset hardware Code 65 i er E 3 Status messages 1 Reset control calculation Code 67 amp C3 Alarm state Reset initialization errors Code 50 Code 51 Code 52 Code 53 Code 54 Code 55 amp 3 Block errors es 3 Logger 1 Reset attachment Extended Reset initialization time exceeded o Reset initialization int solenoid valv amp C3 Statistical information AUTO 1 Reset travel time too short E Tests MAN 1 Reset pin position Code 56 Reset data errors Reset control parameter oD DOccocO CoO OO O Code 68 Reset poti parameter Fig 15 Resetting diagnostic parameters Code 69 EB 8388 5 EN 45 Resetting diagnosis parameters On restarting a test MAN the existing data are updated by the repeated measurement data and stored in the positioner 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 Diagno sis folder gt Status messages gt Reset 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 exi
4. Data saved if a parameter change is detected Cyclic saving 24 h Data logger Data logging scan rate start value log ging limit trigger status Travel histogram Setpoint deviation histogram Scan rate of short term monitoring Cycle counter histogram Data for long term histogram Drive signal histogram steady state Data for short term and long term histograms Drive signal histogram hysteresis d5 Minimum time between tests start test Data for long term monitoring End position trend Measured values when end position changes Drive signal diagram steady state d1 Drive signal diagram hyster esis d2 Reference test reference time stamp Static characteristic d3 Partial stroke test d4 Delta y monitoring reference value Activa tion delta y monitoring Delta y monitoring value Step start Step end Activation of the ramp function Ramp time falling Ramp time rising Settling time before test start Delay time after step Scan rate Activation x control x control value Activation PST tolerance band control PST tolerance band Maximum test duration parameters for analysis Number of steps Step tolerance limit Actuator and valve data Yes Logging Save when a new alarm is issued Classification of status alarms Yes 48 8388 5 EN Troubleshooting 7 _ Troubleshooting Fault cat
5. Enter the required value at which data log ging should be triggered in Start value pa rameter 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 saved at the adjusted scan rate in the FIFO 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 Pretrigger time parameter and selecting Modify However the pretrigger time entered may not be higher than the maximum pretrigger time deter mined by the positioner This maximum Statistical information AUTO pretrigger time is shown in the Max pretrigger time parameter The data logging finishes automatically as soon as the maxi mum memory capacity of 100 measured data points for each variable including the pretrigger time is reached Internal solenoid valve forced venting Note This function can only be used if the positioner is fitted with a solenoid valve Type 3730 5 or the forced venting function Type 3731 5 Select Trigger status parameter and select Start trigger via int sol valve forced vent ing Activate data logging by selecting Start data logger and select Execute to start data logging as soon as the internal solenoid valve voltage drops Type 3730 5 or the forced venting
6. Classification of individual events alarms with a status Positioner AO TRD folder gt Start up gt Initialization List of initialization errors which can also be found in the Diagnosis folder gt Sta tus messages Diagnosis folder gt Status messages gt Logger Alarms recorded that have been sent by the positioner 8388 5 41 Diagnosis Status alarms 4 2 Extended EXPERT alarms Further status alarms are generated from the extensive information gained in the diagnos tic functions of EXPERT and the partial stroke test which provide the user with infor mation covering the whole control valve These status alarms can be viewed in the Di agnosis folder gt Status messages gt Extended An active alarm generated by EXPERT or by the partial stroke test appears on the positioner display over Code 79 A partial stroke test that has not been suc cessfully completed is also registered in Code 82 4 3 Logging The last thirty alarms EXPERT EXPERT are stored in the positioner with a time stamp logged by the operating hours counter The alarms stored can be viewed in the Sta tus message folder gt Logger Entries can be reset in the Reset folder 4 4 Condensed state To provide a better overview the state of the positioner is summarized in a condensed state which is made up from a summary of all classified alarms generated by the positioner Note If an event is classified
7. The scan rate has been selected too low EB 8388 5 EN 37 Tests in manual mode After 100 measured data per measured variable have been recorded the log ging stops However the test is contin ued Int sol valve forced venting The test was canceled because the internal sole noid valve has been triggered Type 3730 5 or the forced venting has been activated Type 3731 5 Supply pressure friction An insufficient supply pressure or excessive friction oc curred during the test When a partial stroke test has been com pleted successfully analyzed parameters are also displayed separately for the in creasing and the decreasing characteristic Parameters for a partial stroke test step re sponse Overshoot relative to the step height Dead time s T63 s T98 s Rise time s Settling time s Minimum value for y control y_Min 1 s Parameters for a partial stroke test ramp Overshoot relative to the step height Minimum value for y control y_Min 1 s If the test has not been completed success fully this is indicated under Code 82 The influence on the condensed state is deter mined in the Partial Stroke Test Status active parameter default Maintenance re quested 38 8388 5 EN Reset Using the Reset PST parameter the parame ters of the partial stroke test are reset to their default values Any recorded measured values and error messages are deleted Lo
8. age drive signal y for each valve position class being determined from all measured data points per valve position class The av erage drive signal y is plotted against the valve position x 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 VIEW3_3731_5_0_2008 Apr 23 tro SAMSON TROVIS VIEW Eile Edit View Device Options 2 Deux E ce ix Positioner type 3731 5 Name lt Value Unit Comment 0 Identification Diagnosis Statistical information AUTO Drive signal diagram Steady 0 Operation unit RES 0 Positioner AO TRD Short term _ 6 Process controller PID Binary input 1 DIL TRD amp 5 Binary input 2 012 TRD 3 Diagnosis 8 00 Status messages H Statistical information AUTO Diagram drive signal y steady Data logger 5 Travel histogram x amp Setpoint deviation histogram e Cycle counter histogram 6000 E Drive signal diagram a dy 4 Hysteresis Trend of travel end position 3 Tests MAN ses 1 7000 4 5000 4000 3000 2000 1000 Fig 7 Drive signal diagram steady state Long term Shortterm Reference EB 8388 5 EN 19 Statistical information
9. as its default setting On resetting the positioner parameters to their default settings Code 36 the status classification is also reset to the default set ting Diagnosis Status alarms Note If modifications that have already been made should be kept we recommend uploading them on a computer before per forming a reset and then downloading them onto the positioner again afterwards The following classifications are possible Maintenance alarm The positioner cannot perform its control task due fo a functional fault in the de vice or in one of its peripherals or an ini tialization has not yet been successfully completed Maintenance required requested The positioner still performs its control task with restrictions A maintenance requirement or above average wear has been determined The wear tolerance will soon be exhausted or is reducing at a faster rate than expected Maintenance is necessary in the medium term Function check Test or calibration procedures are being performed The positioner is temporarily unable to perform its control task until this procedure is completed Status classification of individual alarms TROVIS VIEW3 DTM Maintenance alarm eo red Maintenance required Maintenance requested e blue Function check Y orange No message eb white EB 8388 5 EN 43 Diagnosis Status alarms Status classification over FOUNDATION field
10. control valve moves through its full working range after the test starts As a result it is important to make sure be fore starting the test whether the conditions in the plant or process allow the valve to move In contrast to the tests in statistical informa tion AUTO the corresponding test MAN covers the full working 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 2 manual operating mode 26 8388 5 EN Select the operating mode over Code 0 on the positioner or in Positioner AO TRD folder gt Operating mode The following list of parameters are changed while the tests MAN d1 to d3 are being performed Lower x range value Code 8 0 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 Characteristic Code 20 Linear W ramp OPEN CLOSED Code 21 22 Variable Note The tests MAN can only be activated in the manual operating mode 3 1 1 Drive signal diagram steady state d1 Fig 10 As described in detail in section 2 5 on the drive signal diagr
11. 8 Starting partial stroke test manually 52 9 Code 49 in parameter list 53 Note These Operating Instructions EB 8388 5 EN are valid for Type 3730 5 Positioners with firmware version R 1 44 K 1 24 and higher Type 3731 5 Positioners with firmware version R 1 45 K 1 25 and higher EB 8388 5 EN 3 Description Note The screen shots in these instructions are used to illustrate the appearance of TROVIS VIEW Certain details on screen may differ Description 1 1 General The Type 373x 5 Positioner in the EXPERT version with partial stroke testing PST is based on the Type 373x 5 Positioner with FOUNDATION fieldbus communication These instructions EB 8388 5 EN supple ment the Mounting and Operating Instruc tions EB 8384 5 EN and EB 8387 5 EN Technical data installation electrical con nection as well as operation and standard valve diagnostics are described in the Mounting and Operating Instructions Type 3730 5 8384 5 EN Type 3731 5 EB 8387 5 EN Differences from standard positioner EXPERT provides predictive status oriented maintenance of pneumatic control valves If EXPERT is not activated refer to section 1 3 on how to activate it 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
12. 8388 5 EN 3 1 3 Static characteristic d3 Fig 12 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 An analysis of the control loop is performed using the analysis parameters Min dead band Max dead band and Average dead band To accomplish this the reference variable w is commanded in small steps and the re sponse of the valve position x is plotted after waiting a predetermined period of time This test d3 allows the full working range of the valve to be recorded in manual mode It is also possible to define a test range by selecting the Start and End parameters The ascendent and descendent are plotted within Tests in manual mode the test range 100 measured points are plotted at the maximum i e max 50 mea sured points are available for the ascendent and the descendent The step height and the number of measur ing points are determined automatically by the adjusted test range The dead band is analyzed by a step height smaller than 0 2 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 While the test is active d3 and tESt appear on the positioner display in alternating se quence 7 indicates manual operating mode Name lt gt Operat
13. AUTO The Drive signal y and Valve position x fold ers contain a table of the last ten measured data points 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 working 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 working 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 the drive signal y is propor tional to the actuator pressure 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 start up was performed in the SUB mode substitute calibration 20 8388 5 EN Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset Note The valve can be moved through its travel range in manval mode during plant shutdown or when the process allows it by selecting Drive signal diagram steady sta
14. Drive signal diagram hysteresis for both Statistical information and Tests cannot be started Activating the partial stroke testing with cancelation conditions is not recom mended Booster The Drive signal diagram steady state and Drive signal diagram hysteresis for Statistical information are not performed nor analyzed Depending on the hystersis of the booster the reference graph of Drive signal diagram hysteresis d2 Test can not be plotted During the partial stroke test larger overshoots can occur if a booster is used As a result the default settings of the x control value and PST tolerance band parameters must be changed corre spondingly Note Code 81 is set if the reference graphs could not be plotted or are incomplete 1 7 Activation analysis and presentation of diagnostic data All diagnostic functions which do not com pile data automatically in the background data logger drive signal diagram hyster esis tests MAN must be activated to start them Note To activate the tests MAN in manual mode the positioner must be first set over Code 0 to manual mode Description Canceling diagnostic functions There are two ways to cancel an active test In the TROVIS VIEW operator interface select Stop test in the corresponding folder 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 retu
15. OK F2 x cancelation Test canceled by the x cancelation function F3 y cancelation Test canceled by the y cancelation function FA Tolerance band exceeded The test has been canceled x values outside the tolerance band occurred F5 Max test time exceeded Test not completed within the maximum test duration and therefore canceled F Test manually canceled Test canceled by the user F7 Measured data storage out of memory Storage for measured values out of memory After 100 measured values per measured variable the logging is stopped However the test is still continued F8 Int solenoid valve forced venting Type 3730 5 Test canceled because the solenoid valve has been triggered Type 3731 5 Test canceled because the forced venting has been activated F9 Supply pressure friction Test canceled due to insufficient supply pressure or excessive friction 8388 5 EN 55 SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 Internet http www samson de EB 8388 5 EN S Z 2008 08
16. The cancelation condition is active when Activation dela y monitoring is set to Yes Monitoring the delta y only makes sense when the partial stroke test is performed as a ramp function The results of the first partial stroke test are used as reference values PST tolerance band The test is canceled as soon as the deviation of the valve po sition in relation to the step height ex ceeds the adjusted value The condition is only active when Activation PST toler ance band control is set to Yes 36 8388 5 EN Note Changes to the parameters listed be low cause the delta y monitoring to change as well as the Scan time and Max test dura tion parameters As a result new reference values need to be saved Step start Step end Activation of the ramp function Ramp time falling Ramp time rising Delay time after step Starting the partial stroke test The partial stroke test can be started manu ally or automatically according to a time schedule Manual start of the partial stroke test AO Transducer Block The test can be started and canceled us ing the ENHANCED_ DIAG_CMD pa rameter in the AO Transducer Block see page 40 The test is started in the PST Man testing mode The AO Transducer Block must be in the Local Override mode display of on site operation 7 or in the manual mode display 7 and Refer to section 8 on page 52 In the manual mode the reference vari able
17. as No mes sage this event does not have any affect on the condensed state of the positioner The condensed state is displayed in the en gineering tool TROVIS VIEW DTM as well as on the positioner display as in the table below Additionally the condensed state can be read from the CONDENSED_STATE param eter in the Resource Block and from the OUT_D parameter in the DI Function Blocks Note The condensed state and status alarms are marked with E in TROVIS VIEW3 until they have been read out Function check Condensed state TROVIS VIEW DTM Positioner display Maintenance alarm ed T Maintenance required Maintenance requested e blue 2 Text Y orange B No message 42 8388 5 EN 4 5 Classification of the status alarms A status is assigned to every event or alarm The following states listed in the table below are possible Select Positioner AO TRD folder gt Error control gt Classification report to modify the classification of standard alarms generated by EXPERT Select Positioner AO TRD folder gt Error control gt Classification report gt Extended to modify the classification of alarms generated by EXPERT All additional alarms generated by EXPERT have the status No message by default except for the status alarms for the partial stroke test PST The status alarm for the partial stroke test has the Maintenance required
18. being stored together with the pretrigger time as well as the logging of the triggering condition VIEW3_3731_5_0_2008 Apr 23 tro SAMSON TROVIS VIEW lit s x Positioner type 3731 5 Identification C5 Operation unit RES Pocitionor TRD 2 Process controller PID Test active lt 2 Binary input 1 011 TRD CD Binary input 2 O12 TRD 425 Diagnosis Status Start trigger via setpoint 10s 99 0 96 Statistical information AUTO a Start when falling below th Travel histogram x Setpoint deviation histogram e Cycle counter histogram Drive signal diagram 3 Trend of travel end position Tests MAN Fig Data logger 12 8388 5 EN The following conditions are available for triggering data logging Setpoint Internal solenoid valve forced venting Valve position Setpoint deviation Drive signal y Binary input Setpoint valve position setpoint deviation drive signal y Right click Trigger status parameter and se lect Modify from the context sensitive menu to select the required trigger condition Activate data logging by selecting Start data logger parameter and select Execute The triggering event starts data logging when the start value exceeds or falls below an entered value
19. esis test from statistical information AUTO and the partial stroke test PST remain acti vated In the event that the solenoid valve is trig gered Type 3730 5 or the forced venting is activated Type 3731 5 active tests are stopped and the positioner changes to the fail safe position 1 7 1 Printing the diagnostic 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 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 10 EB 8388 5 EN Printing Settings x Summary Cancel Parameters Comments Graphics Customer data in the Edit menu and summary table of contents are listed in the diagnostic log by default Check the check boxes for the Comments and Graphics options to add these op tions to the diagnostic log Right dick the Diagnosis folder or the re quired subfolder and select Print from the context sensitive menu to print the di agnostic log The
20. 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 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 Short term monitoring 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 FIFO memory The scan rate can be changed in the Scan rate short term histogram parameter 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 FIFO memory Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset Statistical information AUTO 2 3 Setpoint deviation histogram Fig 5 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 set
21. ing number of zero calibrations and initializations total valve travel tempera ture initialization diagnostics zero control loop errors etc In addition the standard EXPERT diagnostics generates messages and status alarms which allow faults to be pinpointed quickly when a fault occurs The messages and sta tus alarms generated by EXPERT appear on the positioner display and can also be viewed on the TROVIS VIEW interface in the Diagnosis folder gt Status messages Alarms and messages are classified in the following main groups Status Operation Hardware Initialization Data memory Temperature Further information on the positioner status e g tight closing function and the parame ters e g characteristics are displayed in the Positioner AO TRD folder Diagnosis Status alarms The following folders contain particularly in formative data for valve diagnostics Positioner AO TRD folder gt Process data Information on the current process vari ables condensed state state of the Transducer Block and 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 AO TRD folder gt Error con trol Information on total travel with a freely defined limit Positioner AO TRD folder gt Error con trol gt Classification report
22. is activated Type 3731 5 Similar to the travel condition the variables w x e and y are saved at the adjusted scan rate in the FIFO 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 Pretrigger time parameter and selecting Modify However the pretrigger time entered may not be higher than the maximum pretrigger time deter mined by the positioner The data logging finishes automatically as soon as the maxi mum memory capacity of 100 measured dota points for each variable including the pretrigger time is reached EB 8388 5 EN 13 Statistical information AUTO Setpoint or internal solenoid valve forced venting The triggering event starts as soon as one of the conditions Start trigger via setpoint or Start trigger via int sol valve forced vent ing is fulfilled Binary input 1 Note Triggering is started by the binary in put voltage input only Set Selection binary input 1 parameter in the Binary input 1 011 TRD folder to 5 30 V DC Select Trigger status parameter and select Start via binary input Activate data logging by selecting Start data logger parameter and select Execute The triggering event starts data logging as soon as the state of the binary input is changed On selecting Start when falling below the initial value in Logging lim
23. seat Reset lower end position trend 8388 5 EN 49 Troubleshooting End position trend continued Zero point shift upwards monotonic Average value above the ref erence line Zero point fluctuates Average value above the ref erence line Zero point shift downwards monotonic Average value below the ref erence line Zero point shift upwards monotonic Average value below the ref erence line Zero point fluctuates Average value below the ref erence 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 Full range of Mainly near to CLOSED valve position Reconsider whether the Mainly near to max OPEN working range is suit rn hi Mainly CLOSED position able Mainly OPEN Friction 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 Check packing Reset hysteresis long term and short term monitoring 50 8388 5 EN Troubleshooting Friction continued Much higher lower over the full range of valve Much higher lower over part of the range TEST Check packing Reset hysteresis measured dat
24. the positioner 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 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 x and Difference signal drive 22 8388 5 EN Graphs The Hysteresis folder contains a graph with two lines plotted The Measurement line shows the measured data recorded for long term monitoring and the Reference line shows the reference dota recorded after ini tialization The graph plotted using the reference data covers the full working 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 working range of the valve A straight line from the average reference data is shown in cases where no data could be compiled for valve working ranges which were not covered by the long term monitor ing The diagram allows changes in Ay with the corresponding valve positions to be recog nized Changes in friction are highlighted as Ay is proportional to the actuator pressure which in turn is a measurement for friction A change in friction leads to an alarm being issued Test requirements A successfully
25. Binary input 2 DI2 TRD 5 Diagnosis Status 9 Statistical information AUTO Tests MAN o Drive signal diagram hysteresis est di _ 01 45 52 d himin Test finished 00 i Static characteristic 2 Step response PST Drive signal diagram steady al Fig 10 Drive signal diagram steady state 8388 5 EN 27 Tests in manual mode Viewing the recorded parameters The Drive signal diagram steady state folder contains the reference and repeated mea surements in a table and in a graph plotting the drive signal versus the valve position 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 start up was per formed in the SUB mode substitute cali bration 28 8388 5 EN 3 1 2 Drive signal diagram hysteresis d2 Fig 11 Similar to the corresponding test in statistical information AUTO this test d2 is used to analyze the change in friction forces However unlike the test in statistical infor mation AUTO this test causes the valve to move to defined valve positions over the travel range and determines Ay for each valve position The valve is mad
26. ST Man No Yes Yes PST testing mode PST Auto No Yes and Auto test time only 2 and C PST Man Yes Yes Yes o ina PST testing mode mode PST Auto No Yes and Auto test time 52 EB 8388 5 EN onl 9 Code 49 in parameter list Code 49 in parameter list Supplement to code list in section 15 1 of EB 8384 5 EN or EB 8387 5 EN Code Parameters display Description no Values default settings P Note Code 49 must be enabled for configuration first over Code 3 Refer to EB 8384 5 EN or EB 8387 5 EN The PST parameters except for A2 and A3 can only be changed in the PST Man testing mode 49 PST parameters AO Start test Al Time until the next automatic PST test Display only Time remaining until the next partial stroke test is started only applies in manual mode A2 Activation of auto test time Auto Man Man Activates or deactivates the automatic partial stroke test ac cording to time A3 Auto test time 1 to 56280 h 1 h Required time for repeating a partial stroke test A4 Status classification of Partial Stroke Test Status active OK C CR b C The following status classification are possible for a partial stroke test that has not been completed successfully OK No message C Maintenance required CR Maintenance requested b Maintenance alarm A5 Recommended minimum scan The scan rate parameter d9 should be config
27. Series 373x Electropneumatic Positioner Type 373x 5 EXPERT with FOUNDATION fieldbus communication 3731 5_0_2008 Apr 23 tro SAMSON TROVIS VIEW E 18 Eile Edit View ie Options 2 BOA XDRSe elo LE i Qo NNNM C3 Status messages c3 Statistical information AUTO Data logger 3 Travel histogram x Setpoint deviation histogram Cycle counter histogram 1 Drive signal diagram 1 Trend of travel end position Ei 3 Tests MAN 3 Drive signal diagram steady 09 Drive signal diagram hysteresis Static characteristic 0 Step response PST Fig Valve diagnostics with TROVIS VIEW Operator Interface Operating Instructions EB 8388 5 EN Firmware version R 1 4x K 1 2x Edition August 2008 Contents Contents NO ma eR Aa Aa ea eS eS eS ee 2 00 N EB 8388 5 EN Page Description lt us koh E Swe CR RR Y 4 Generale ue ae eS oad oe i ee d ee DEP S Nara Oe 4 Diagnostic functions 5 Activating EXPERT 2 oe eA 5 Activation with activation 5 Activation with USBdongle ee 6 Actuator and valve specification data 7 Start the reference test 7 Range of functions 2222s 8 Activation analysis and presentation of diagnostic data 9 Pr
28. a Actuator springs Spring rigidness possible re duced spring failure TEST Compression possible re duced TEST Check springs in the ac tuator 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 atmosphere and short term monitoring Reset Maybe to be expected soon Check packing hysteresis measured data Reset z long term histogram Dynamic stress Percentage as information on factor packing load Reset Leakage to the atmosphere Check packing alarm active when greater than 90 z long term histogram Partial stroke test PST status set Check cancelation conditions p 35 and measured data analysis p 37 Check valve for malfunction e g blockage Restart test after correcting Generated by tests MAN This value is included in the Cycle counter histogram in statistical information AUTO 8388 5 EN 51 Starting partial stroke test manually 8 Starting partial stroke test manually Partial stroke test start manually Operating mode PST testing see page 36 PST configuration site displ ibl display mode AO Transducer Block DI2 Function Block pom PST Man Yes Yes Yes et PST festing mode PST Auto No Yes and Auto test time Override mode only G P
29. am 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 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 Tests in manual mode over the full working 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 the Reference 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 computer 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 43 Operation unit RES Value Unit Comment est di I 0 Positioner TRD 5 Process controller PID 0 Binary input 1 011 amp 5
30. apacity to save 100 data points in the positioner Data logger The data logger is completely integrated into the positioner The software is only neces sary for activation and to set the parame ters 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 failure of the auxiliary power the data logger is inactive and must be re activated 8388 5 EN 11 Statistical information AUTO Data logging Data can be permanently logged or the log ging can be automatically triggered when a start condition is fulfilled Right click Selection parameter in Data log ger folder to select Permanent or Trigger and set the Scan rate parameter Right click the Start data logger parameter and select Execute to start data logging Permanent data logging The w x y and e variables are saved ac cording to the adjusted scan rate in the FIFO memory which always stores the last 100 measured data points of each variable Note You can read the data recorded over the last 24 hours in a graph in TROVIS VIEW3 by leaving the Data logger folder open and keeping the positioner on line during this time Triggered data logging On selecting Trigger in the Selection param eter the data logger records the measured data constantly in the background A trig gering event leads to the last 100 measured data points
31. ation of EXPERT Enable configuration at the positioner Turn gt Code 3 press turn ON press 6B After enabling configuration Turn gt Code 48 press Code 48 blinks EB 8388 5EN 5 Description Turn to select d press amp turn amp to select 48 press 48 blinks G g8 m LI Turn and set the activation code Press to confirm the entered code des 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 ac tivation of EXPERT has been unsuccessful After an incorrect activation code has been entered three times Err appears on the dis play after selecting Code 48 and d8 An ac tivation code can only be entered again af ter the positioner has been reset to its de fault settings Code 36 6 8388 5 EN 1 3 2 Activation with USB dongle Fig 2 EXPERT USB dongle order no 1400 9555 The EXPERT USB dongle can be ordered for the required number of activations order no 1400 9555 To activate EXPERT the TROVIS VIEW3 software firmware 3 30 and higher is re quired for the positioner Type 3730 5 Order no 6661 1058 Type 3731 5 Order no 6661 1065 Activation of EXPERT 1 Switch on the computer 2 Insert the EXPERT USB
32. bus The CONDENSED_ STATE is created by summarizing all classified status alarms from the positioner and is available in the Resource Block In addition the CONDENSED_STATE is shown in the OUT_D parameter of the DI Function Blocks and appears on the positioner display The status of individual alarms can be assigned as required using the ERROR_OPTS param eter The following classifications of the states are possible Maintenance required Maintenance requested Maintenance alarm Function check No message In addition to the condensed state the mes sages of Block Error Resource and AO Transducer Block can also be assigned to the events No message Device needs maintenance soon Device needs maintenance now 44 EB 8388 5 EN 5 Resetting diagnosis 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 recommended action in the error code list refer to EB 8384 5 EN or EB 8387 5 EN Recommended action on EXPERT alarms are listed in the table in section 7 Standard EXPERT diagnostics Alarms generated by EXPERT which are in dicated on the positioner display by an er ror code can be confirmed by pressing the 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 engineer
33. can be determined by the FINAL VALUE parameter of the AO Transducer Block Manual start of the partial stroke test using DI2 Function Block To start the partial stroke test and evalu ate the condensed status the DI2 Func tion Block can be used It can be acti vated by selecting the Condensed status and PST option of the SELECT BINARY INPUT2 parameter in the Re source Block The partial stroke test is started when the simulation is locked by writing the discrete value 7 on the SIMULATION_ VALUE with a status greater than uncertain The condensed status is issued at the dis crete output OUT_D for analysis pur poses The DI2 Function Block allows the test to be started manually from any operating mode with either PST Man and PST Auto Refer to section 8 on page 52 Note On enabling the simulation the par tial stroke test of the DI2 Function Block is deactivated Automatic starting of the test according to a predetermined time schedule Auto test time An automatic test according to a time schedule is only performed when the Auto test time parameter is set to 0 The testing mode also needs to be switched over to PST Auto The first test is started when the interval has elapsed for the first time The Time until the next automatic PS Test takes place parameter indicates the time that remains until the next test is started tEst d4 appears on the positioner display during the test The following
34. d After the test is canceled for the tenth time due to Aw the time entered in Minimum time distance from test parameter is kept again The hysteresis test is deactivated by default We recommend activating the test after you have entered Minimum time distance from test by selecting Start test 5 Binary input 1 DI1 TRD 5 Binary input 2 DI2 TRD D Test information ee E E Status messages Statistical information AUTO Data logger Ir L Tolerance band of hysteresis 16 i VIEW3_3731_5_0_2008 Apr 23 tro SAMSON TROVIS VIEW la x Ele Edit View Device Options 2 Den iu e i amp Le MES Positioner type 3731 5 1 BU value Unit Comment a Identification Diagnosis Statistical information AUTO Drive signal diagram Hysteresis s Operation unit REC Start test LI I 4 2 Positioner AO TRD Psmpmst 5 55 8 uet 5 Process controller PID Min time distance from test Immediately h 5 0 96 Test finished 5 Travel histogram x 42 Setpoint deviation histogram e Cycle counter histogram 2 Drive signal diagram e ao s Trend of travel end position 9 Tests MAN Hysteresis Fig 8 Drive signal diagram hysteresis 8388 5 EN 21 Statistical information AUTO The Minimum time distance from test and the control parameters are stored in the non volatile memory of
35. d To accomplish this function the valve posi 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 a FIFO memory that always stores 30 mea sured data points plus reference data Mea sured data are first recorded in the FIFO memory when the valve position x deviates from the previously recorded value by the threshold value 0 25 To allow the test to run automatically in the background activate the tight closing func tion over Code 14 or in the Positioner AO TRD folder gt Reference variable gt Setpoint cutoff decrease and make sure the positioner is in the AUTO operating mode In cases where a reference test has not been performed the first zero point that the valve moved to in closed loop operation serves as the reference The reference value is stored in a non volatile memory independently from the FIFO memory 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 Binary input 1 DI1 TRD amp Binary input 2 DI2 TRD Diagnosis Status messages Statistical information AUTO 8
36. dongle into a free USB port of the computer 3 Connect the positioner to the computer over the serial interface adapter 4 Start TROVIS VIEW for Type 373x 3 Positioner 5 In offline mode select EXPERT activa tion from the Device menu and follow the prompts 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 Enter the required data in the Identification folder gt Positioner AO TRD gt Actuator as well as gt Positioner AO TRD 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 Single acting Booster Not present Stuffing box Self adjusting 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 its full scope The reference graphs are plotted automati cally after the positioner has been initialized when the EXPERT has been activated e g supplied with EXPERT already activated On activating EXPERT at later time the ref erence graphs are plotted after the positioner is r
37. e 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 this information is saved under Code 81 which can be as signed to a classification refer to section 4 5 in a non volatile memory On canceling the reference test which was started in manual mode the positioner re mains in the manual mode On canceling a reference test automatically performed directly after initialization the positioner changes to the automatic mode 8 8388 5 EN The positioner can also function properly af ter it has been initialized successfully without the reference data 1 6 Range of functions The following points need to be observed when the positioner is started up in the SUB mode substitute calibration or when a dou ble acting actuator and or booster is used Start up of the positioner in SUB mode substitute calibration without initialization A reference test cannot be started The start of all tests Tests MAN in one sweep is not possible The Drive signal diagram steady state and Drive signal diagram hysteresis for both Statistical information and Tests cannot be started Activating the partial stroke testing with cancelation conditions is not recom mended Double acting actuator with reversing am plifier A reference test cannot be started The Drive signal diagram steady state and
38. e 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 and or packing 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 Statistical information AUTO 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 AO TRD gt Valve The number of cycles to determine the dy namic stress factor is limited to 1 000 000 if the Others is selected 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 Long term monitoring The Cycle counter histogram folder contains long term data i e measured data points are updated cyclically over the entire SAMSON TROVIS VIEW 3731_5_0_2008 Ap
39. e 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 Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset 18 8388 5 EN 2 5 Drive signal diagram 2 5 1 Steady state drive signal Fig 7 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 In relation to the valve position this signal runs directly proportional to the signal pres sure 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 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 val
40. e initialized If the reference graph plotting is to be started separately in an initialized positioner or replotted proceed as follows Description Set the positioner to manual mode Turn gt Code 0 press Code 0 blinks G 2 MIELE IN I Turn gt MAN press the positioner moves to manual mode 2 ao 86 l SP DR Op LICL Manual operating mode 1593 You can activate the reference test either by selecting the Diagnosis folder Start refer 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 gt Code 3 turn gt ON press After enabling configuration Turn gt Code 48 press Code 48 blinks Turn until d appears press EB 8388 5 EN 7 Description turn amp to select 47 press d7 blinks 3 81 ES Turn gt yES press to start the reference test CAUTION The control valve moves through its travel range during the reference test The tests d7 drive signal diagram steady state and d2 drive signal diagram hysteresis are performed during the diag nostic reference test During the reference test fESt and d1 or d2 appear in alternating sequence on th
41. e is moved to the Step end pos 3 and Step start pos 2 positions with fixed velocities v1 and v2 set by the Ramp time falling and Ramp time rising parameters The ramp time specifies the time required by the valve to move through the travel range 100 to 0 falling and O to 100 rising Note Times for the Ramp time falling ris ing are determined during initialization of the positioner Do not set the times in these parameters below these limits for the partial stroke test with ramp function Cancelation conditions The positioner cancels the partial stroke test when one of the following activated cancel ation conditions is fulfilled This cancelation causes a classified status alarm to be gener ated EB 8388 5 EN 35 Tests in manual mode Definable cancelation conditions include Max test duration The test is canceled when the maximum permissible test du ration is exceeded x control value The test is canceled when the value falls below the adjusted valve position The condition is only active when Activa tion x control is set to Yes delta y monitoring value The test is can celed when the control signal y falls be low the predetermined comparison value This comparison value is made up from delta y monitoring reference value parameter and the set safety factor delta y monitoring value The delta y control value is set in and is based on the entire control signal range 10 000 1 5
42. e 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 con cerning changes in Ay for changes in direc tion to precisely check the results or any alarms issued in automatic mode Tests in manual mode If the valve cannot move to a certain valve position node or the setpoint leaves the Tol erance band of hysteresis during the test a message 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 the Refer ence time stamp in the non volatile memory of the positioner Any further measurement is stored as a repeated measurement Previously recorded repeated measurements stored in the positioner are overwritten However you can upload previous repeated measurements to a computer before you start a new test While the test is active d2 and tESt appear on the positioner display in alternating se ZVIEW3_3731_5_0_2008 Apr 23 tro SAMSON TROVIS VIEW Eile Edit View Device Options 2 Leu E Positioner type 3731 5 amp 3 Identification i Operation unit RES quence 7 indicates manual operating mode laj x Ee i x SS Ed Name Pium i re Value Unit Comment Diagnosis Test
43. egory Alarm Recommended action Resetting alarm Supply pressure Possibly changed TEST Check supply pressure Reset Possibly at full capacity TEST Possibly insufficient Refer to the section on supply pressure in EB 8384 5 EN or EB 8387 5 EN y x signature measured ata Reset over Code 57 Reset y x long term and short term monitoring Trend con cerning working range of valve Working range shift CLOSED position Working range shift max OPEN Check the valve working range Reset x long term and short term histograms Air leakage in the pneumatics Possibly exists TEST Possibly too much TEST Possibly too much Possibly exists Check pneumatic actua tor and connections for leakage Reset y x signature measured data Reset y x long term and short term monitoring Reset over Code 57 Restriction of full Downwards Check pneumatic acces range of valve Upwards sories and connections for leakage Check supply pressure Reset over Code 57 and increase it if neces sary Reset No change possible termi nals Refer to the section on supply pressure in EB 8384 5 EN or EB 8387 5 EN Check plug stem for problems caused by an external source e short term histogram Reset e long term histogram End position trend Zero point shift downwards monotonic Average value above the ref erence line Check plug and
44. gging messages are not changed Resetting the start up parameters over Code 36 also resets the PST parameters 3 2 1 Step reponse The dynamic performance of the control valve can be tested by plotting its step re sponse The step response of the valve is plotted with the PST function by sudden changes in the valve position To proceed the Activation of the ramp function parameter needs to be set to No see Fig 14 left In addition the following settings are recommended Deactivate all cancelation conditions of the partial stroke test see page 35 Start the partial stroke test manually PST Man After the test is completed the data are au tomatically analyzed in the positioner and the Overshoot Dead time T63 T98 Rise time Settling time and Minimum value for y control parameters are determined sepa rately for both step responses Viewing the recorded parameters The PST folder contains a graph plotted over time of the parameters required for an anal ysis of the step response such as the refer ence variable w valve position x setpoint deviation e and drive signal y Tests in manual mode 3 3 Data logger The data logger from the statistical informa tion AUTO can also be started in the man ual mode refer to section 2 1 and as a re sult is available in the PST Aufo and PST Man testing modes Changes can only be made when PST Man is set EB 8388 5 EN 39 Tests in manual mode Access
45. ible functions of ENHANCED_DIAG_CMD parameter ANA ED lt 450 000 0 CO l0 I F0 O No function Start data logger Abort data logger Start hysteresis online test Abort hysteresis online test Start partial stroke test step response Abort partial stroke test step response Start test in turn Abort test in turn Start drive signal diagram steady Abort drive signal diagram steady Start drive signal diagram hysteresis Abort drive signal diagram hysteresis Abort static characteristic Start reference test Abort reference test Reset event logger Reset X long term histogram Reset Cycle counter histogram long term Reset E long term setpoint deviation Reset Y X long term Reset Y X short term Reset Hysteresis long term Reset Lower end position Reset Lower end position ref values Reset X short term histogram Reset E short term setpoint deviation Reset Cycle counter histogram short term Reset Hysteresis short term Reset Step response partial stroke test Reset Y X measured values Reset Hysteresis measured values 40 EB 8388 5 EN 4 Diagnosis Status alarms 4 1 Standard EXPERT alarms The standard EXPERT diagnostics provides information about positioner states such as operating hours counter process monitor
46. ing tool for example TROVIS VIEW3 software see Fig 15 Resetting diagnosis parameters Extended EXPERT diagnostics Extended alarms generated by EXPERT are based upon the tests in statistical informa tion AUTO and tests MAN An active EXPERT alarm is indicated by Code 79 in the positioner A partial stroke test that has not been successfully completed is also reg istered in Code 82 Select Diagnosis folder gt Status messages gt Reset to reset data from statistical infor mation AUTO and tests MAN see Fig 15 Note that the corresponding short term his togram short term monitoring is also reset on resetting long term histogram long term monitoring The data of the partial stroke test are directly reset in the Diagnosis folder gt Tests MAN gt Step response Partial stroke test gt Reset PST 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 VIEW3_3731_5_0_2008 Apr 23 tro SAMSON TROVIS VIEW ile Edit View Device Options ontro omm 125 EXPERTHPST Positioner type 3731 5 Name Value Unit Comment 6 Identification Diagnosis Status messages Reset 9 02 Operation unit RES 1 Reset total valve travel 9 0 Positioner AO TRD Reset operating errors Process controller PID 1 Reset zero point Code 58 Reset autocorrection
47. inting the diagnostic 10 Exporting measured data a 11 Statistical information AUTO 2 2 2 2 none 11 Data 11 Travel histogram 14 Setpoint deviation 15 Cycle counter histogram 2 2 22 cn nennen 17 Drive 18 Steady state drive signal 18 Hysteresis testi d5 iu s creer Rm fio 21 End 24 Tests in manual mode 26 Tests 1 43 26 Drive signal diagram steady state d1 27 Drive signal diagram hysteresis 42 29 Static characteristic d3 2 2 22 ooo leen 31 Partial stroke test PST d4 2 222 oo oo nennen 33 Step reponse s oe ss s pop Anna 8 SOS 33 39 Data loggen u a momo Ex BA 39 Diagnosis Status alarms losses 41 Standard EXPERT alarms 2 4 coe p Re Y RO OS Bd DR 41 Extended EXPERT alarms 2 ee 42 loggihg i12 xo Gd gee SEER aH Pee Re E EU 42 Condensed state A2 Classification of the status alarms 2222222222 43 Resetting diagnosis parameters 45 Contents 6 Diagnostic parameters saved in non volatile memory 48 7 Troubleshooting us Ee 49
48. ion unit RES 1 Start test m Positioner TRD ee 1 3 Diagnosis Tests MAN Static characteristic laix 8 Process controller PID amp Binary input 1 DI TRD C5 Binary input 2 DIZ TRD t3 Diagnosis 3 Status messages Statistical information AUTO IPG EE Static characteristic stati characteristic Fig 12 Static characteristic 8388 5 EN 31 Tests in manual mode Viewing the recorded parameters The Static characteristic folder contains a ta ble and a graph of the measured points plotting the valve position x versus the refer ence variable w The Measured data subfolder gt Valve posi tion x and gt Reference variable w contain a table of the individual corresponding measured points Data can be reset the Diagnosis folder gt Status messages gt Reset 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 Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset 32 8388 5 EN 3 2 Partial stroke test PST d4 Fig 13 The partial stroke test d4 is particularly suitable for the status oriented detection of malfunctions in pneumatic shut off valves As a result the probability of failure on de mand PFD can be
49. it parameter the logging is started when the binary input is passive By selecting Start when exceeding the initial value the logging is started when the binary input is active After fulfilling the start condition the vari ables w x e and y are saved at the ad justed scan rate in the FIFO memory The pretrigger time allows the variables to be stored that were logged before the trig gered event Enter the required pretrigger time by right clicking the Pretrigger time pa rameter and selecting Modify However the pretrigger time entered may not be higher than the maximum pretrigger time deter mined by the positioner This maximum pretrigger time is shown in the Max pretrigger time parameter The data logging 14 Eb 8388 5 EN finishes automatically as soon as the maxi mum memory capacity of 100 measured dota points for each variable including the pretrigger time is reached 2 2 Travel histogram Fig 4 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 operating range The valve travel is recorded and assigned to valve travel classes The distribution showing how often the valve travel remains within a class is shown in per cent The result is pre sented as a bar graph Long term monitoring The Travel histogram
50. listed parameters are changed correspondingly during a partial stroke test Lower x range value Code 8 0 Upper x range value Code 9 100 Tests in manual mode w ramp OPEN CLOSED Codes 21 22 variable A successfully performed partial stroke test is logged The cancelation messages created by the partial stroke test are recorded in the logging Should the same fault occur again at a later point in time this message is relogged The results of the first partial stroke test are used as reference values Measured data analysis Analyses of the last three partial stroke tests completed are saved in the positioner with a time stamp and a statement about how the test was started manually or automatically If the test has not been completed success fully the reason why the test was canceled is indicated under Maintenance alarm Possible reasons for cancelation depending on the defined cancelation conditions are x cancelation The valve position fell be low the x control value y cancelation The drive signal fell below the predefined comparison value see description on page 36 Tolerance band exceeded The deviation of the valve position exceeded the PST tolerance band Max test time exceeded The test was not completed within the specified period of time Further error messages include No text available Test man canceled The test has been manually canceled Measured data storage out of memory
51. low this minimum value 15 s value d7 Settling time before test start Delay time before test is started to ensure that the valve can 1 to 240 s 10 s be moved to the step start position safely t Fig 14 d8 Delay time after step Delay time between the first and the second step change 2 0 to 240 s 2 0 s t2 Fig 14 d9 Scan rate Scan rate of step response measurement 0 2 to 250 s 0 2 s EO Activation x control Activates or deactivates x monitoring Yes No No El x control value The test is canceled when the valve position falls below this 10 0 to 110 0 0 0 25 value E2 Unassigned E3 Unassigned E4 Unassigned E5 Activation PST tolerance band Activates or deactivates PST tolerance band monitoring control Yes No Yes 54 8388 5 EN Code 49 in parameter list Code no Parameters display Values default settings Description 49 E6 PST tolerance band 0 1 to 100 0 5 0 The test is canceled when the deviation of the valve position exceeds this percentage 49 E7 Max test duration 30 0 to 25000 0 s 30 0 s Maximum test duration the test is canceled in any case when this period has elapsed E8 Unassigned E9 Reset PST All PST parameters are reset to their default values All measured data are deleted PST error codes display only FO No test available No test available or test canceled manually Fl Test
52. olerance limit sets the permissible tolerance limit for the step s start and end values The Scan rate defines the interval at which the measured values are recorded during the test The positioner stores a maximum of 100 measured values per measured variable valve position x reference variable w setpoint deviation e drive signal y and the time when they were recorded The Min recommended scan time which should not be shorter if at all possible is calculated from the Duration of the test After 100 measured values per measured variable have been stored the logging is stopped However the test is still completed The Measured data storage out of memory alarm is generated if the test is not ended with data logging The Display section in TROVIS VIEW3 shows the Progress flag in percent Tests in manual mode 1 Step response function Fig 14 left The step response function is activated when the Activation of the ramp function parame ter is set to No The valve is moved in steps to the Step end position pos 3 during the first half of the test and to the Step start position pos 2 during the second half of the test 2 Ramp function Fig 14 right The ramp function is active when the Activa tion of the ramp function parameter is set to Yes default A step before the partial stroke test can be prevented when the Step start parameter is consistent with the operating point of the positioner The valv
53. plotted reference graph is necessary to analyze the friction 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 start up was per formed in the SUB mode substitute cali bration Statistical information AUTO 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 to check the results or statements determined in automatic mode in the Diag nosis folder gt Status message gt Extended The following parameters are changed cor respondingly during hysteresis test d5 from statistical information AUTO Lower x range value Code 8 0 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 Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset EB 8388 5 EN 23 Statistical information AUTO 2 6 position trend Fig 9 The end position 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 issue
54. point deviation is recorded and as signed to predetermined level classes The percentages showing how often the setpoint deviation remains within a class is presented as a bar graph Ideally the setpoint devia tion should be as small as possible Long term monitoring Similar to the 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 SAMSON TROVIS VIEW 31_5_0_2008 Apr 23 tro Eile Edit View Device Options 2 512816 Identification Operation unit RES itioner TRD Diagnosis Statistical information AUTO Travel histogram NY uL Value Unit Comment _30 lt lt 35 3 Process controller PID C3 Binary input 1 DI1 TRD NNI 01 07 53 d h min Binary input 2 DI2 TRD 3 Diagnosis Status messages Statistical information AUTO Data Setpoint deviation histogram amp 42 Cycle counter histogram Drive signal diagram 42 Trend of travel end position 9 3 Tests MAN Havel histogram x 383883838 Fig 4 Travel histogram EB 8388 5 EN 15 Statistical information AUTO 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 te
55. printout contains the contents of the folder and its subfolders 1 8 Exporting measured data You can export the measured data compiled from tests and statistical information in a file csv xml or xls 1 Open the Tests or Statistical information folder you require 2 Click the right hand side to switch to a table of the measured data 3 Click button to export the data 4 Save the data in a file selecting the file type and name as required 21x Speichern in EXPERT_Diagnase Qr uu Arbeitsplatz a Dateiname 373 5 bung Dateityp CSV esv E Speichern Abbrechen 5 Click 24 button to return the graph of the measured data button located below the graph on Statistical information AUTO 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 underlying hysteresis test detects any changes in friction 2 1 Fig 3 The data logger allows the reference vari able w valve position x in relation to the operating range drive signal y and setpoint deviation e to be plotted over time The measured data are saved in a FIFO memory with a c
56. r 23 tro Elle Edit View Device Options 2 Positioner type 3731 5 Identification Operation unit RES Diagnosis Average values z long i Statistical information AUTO Cycle counter histogram L Number of cycles 16 Value Unit Comment 10 Cycle lt 20 96 57282 1 I t Diagnosis amp 0 Status messages 2 Statistical information AUTO 42 Data logger 4 5 Travel histogram x 2 Setpoint deviation histogram e 5 Drive signal diagram 2 Trend of travel end position 0 Tests MAN Cycle counter histogram a ERES i PI T Fig 6 counter histogram itioner AO TRD Process controller PID Dynamic stress factor 21 inary input 1 DI1 TRD ms inary input 2 DI2 TRD 3Short term EB 8388 5 EN 17 Statistical information AUTO 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 points previously recorded Short term monitoring In order to obtain a summary of recent cy cles the last 100 cycles measured are stored in a FIFO memory The Short term folder contains this addi tional cycl
57. reduced and mainte nance intervals may possibly be extended The partial stroke test can prevent a valve normally in its end position from seizing up or getting jammed Recording the test addi tionally allows an analysis of the dynamic control response During the partial stroke test the valve is moved from a defined start value e g the operating point end position either in steps or in a ramp function until it reaches a defined final value Then the valve is moved back again to its initial position Tests in manual mode The partial stroke test can be performed for example between 5 and 10 based on the start value while the plant is running yet without disrupting plant operation The start and final values for the partial stroke test can be configured by the user The various test cancelation conditions pro vide additional protection against the valve slamming shut and moving post the final value The increasing and decreasing char acteristic are analyzed separately Partial stroke tests can be started and can celed either manually at any time on site or using an engineering tool or automatically according to a certain time schedule A test status is determined at the end of a partial stroke test which allows operators to directly see whether the test has been com pleted successfully or not When the test has not been completed successfully possible reasons why the test was canceled are given The test stat
58. rm histogram are shown in Fig 5 The Min setpoint deviation and Max setpoint deviation are also indicated as drag indicators Short term monitoring In order to obtain a summary of recent setpoint deviations the last 100 setpoint de viations are saved at an adjustable scan rate default 1 s in a FIFO memory The scan rate can be changed in the Scan rate short term histogram parameter On changing the scan rate old data in the short term histogram are deleted 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 Reset Data can be reset to their default settings in the Diagnosis folder gt Status messages gt Reset Positioner type 3731 5 Identification c5 Operation unit RES 5 Positioner TRD FS Binary input 1 DI1 TRD 5 Binary input 2 DI2 TRD Diagnosis Status messages Statistical information AUTO 2 Data logger 5 Travel histogram x 423 Cycle counter histogram Drive signal diagram C5 Trend of travel end position Tests MAN Fig 5 Setpoint deviation histogram 16 8388 5 EN 2 4 Cycle counter histogram Fig 6 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 strok
59. rns to the reference variable automatic mode Press the rotary pushbutton once to can cel the tests MAN d1 drive signal diagram steady state d2 drive signal diagram hysteresis d3 static characteristic d4 partial stroke test and the test in statistical information AUTO d5 drive signal diagram hysteresis as well as the reference test in Code 48 On canceling a test d1 to d4 the positioner moves to the operating mode pre viously set The positioner goes into auto matic mode on canceling test d5 from statis tical information AUTO The reference graphs must be plotted before the tests for drive signal diagrams steady state and hysteresis in the manual mode can be analyzed Note The analysis of raw data in automatic mode is started after the positioner has been in closed loop operation for over one hour after initialization This does not apply to the end position trend test and the dynamic stress factor in the cy cle counter histogram as their analysis starts directly after closed loop operation begins EB 8388 5 EN 9 Description 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 operating mode previously set Upon failure of the auxiliary power tests in tests MAN and statistical information AUTO must be restarted due reasons of safety However the drive signal diagram hyster
60. s MAN Drive signal diagram hysteresis 1 Start test L test d2 1 Stop test test d2 9 Positioner TRD Process controller PID amp C3 Binary input 1 DI1 TRD amp C3 Binary input 2 DI2 TRD 7 Tolerance band of hysteresis 5 0 96 5 Reference time stamp Li 1 12 35 06 d h min 5 Test information Li Test finished Progress flag 57 100 96 3 Diagnosis Status messages amp i Statistical information AUTO Tests MAN Diagram drive signal y hysteresis 2 Drive signal diagram s o 2 Static characteristic 43 Step response PST Drive siqnal diagram hysteresis Fig 11 Drive signal diagram hysteresis EB 8388 5 EN 29 Tests in manual mode Viewing the recorded parameters The Drive signal diagram hysteresis folder contains a table or graph with reference measurements and the last repeated mea surement performed plotting the change in drive signal Ay versus the valve position x 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 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 start up was per formed in the SUB mode substitute cali bration 30
61. sting 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 existing 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 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 statistical information AUTO and tests MAN Drive signal diagram hysteresis statistical information AUTO and tests MAN 46 8388 5 EN Setpoint deviation histogram long term and short term End position trend Partial stroke test A reference measurement needs to be performed due to the new ramp times see note on page 35 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 EB 8384 5 EN or EB 8387 5 EN The following diagnostic functions of EXPERT EXPERT diagnostics are reset Settings and activated tests from statisti cal information AUTO and tests MAN in
62. te in Test MAN to check the results or state ments determined in automatic mode in the Diagnosis folder gt Status message gt Ex tended 2 5 2 Hysteresis test d5 Fig 8 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 distance from test parameter is met and the pressure conditions 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 closed loop operation during this test phase if the valve position leaves the entered Tolerance band of hyster esis or a change in the reference variable Statistical information AUTO occurs which is greater than the Tolerance band of hysteresis If the test was interrupted due to a change in the reference variable the test is started 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 w the test is started again after waiting 60 sec onds with the new 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 peate
63. the code list in EB 838x 5 EN listing Code 49 section 9 on page 53 Depending on the parameter settings the partial stroke test is conducted either in steps or in a ramp function of the valve position see Fig 14 After being activated the test does not start until the Settling time before test start t has elapsed This waiting period ensures that the valve has reached the position defined by the Step start parameter pos 2 before the test starts T 1 ES t2 s Valve positions Times Velocities Pos 1 Required manual t Settling time before test start 100 f iabl i rererence Varigbiew t Delay time after step 1 Ramp time falling s Pos 2 Step start Pos Step end Fig 14 Courses of the partial stroke tests with step response left and ramp function right ar Pos 1 Pos 2 Pos 34 n 100 WT Ramp time rising s 34 8388 5 EN Starting from the Step start position pos 2 the valve moves to the defined end position Step end parameter pos 3 The valve re mains in this position for the time defined by the Delay time after step t2 before perform ing a second step change in the opposite di rection from Step end pos 3 to Step start pos 2 After the Delay time after step t2 has elapsed the valve is moved back to its initial position Required manual reference variable w pos 1 The Step t
64. to plan predictive maintenance and service work before malfunctions can affect the pro cess and may cause unscheduled plant shut downs 8388 5 EN Basics of EXPERT 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 The EXPERT diagnostics are completely in tegrated in the positioner Data required for diagnostics are automatically compiled and saved in the positioner These data are ana lyzed by the positioner which generates classified status alarms providing informa tion on the condition of the valve The diagnostics data results and status alarms are available over DD Device De scription Apart from the basic settings at the positioner using the rotary pushbutton the TROVIS VIEW3 software allow the pa rameters to be viewed and set conveniently 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 1 2 Diagnostic functions There are two main groups of diagnostic functions available Statistical information AUTO in service monitoring Data logger Histograms Drive signal diagram Drive signal diagram steady state Drive signal diagram hysteresis End position trending These tests are performed while the process is r
65. unning 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 dia gram steady state and end position trending Tests MAN out of service diagnostics Drive signal diagram steady state Drive signal diagram hysteresis Static characteristic Partial stroke test PST Additionally the data logger from statis tical information AUTO can be started in the manual mode These MAN tests must not be performed in closed loop operation as the positioner can Description not follow the reference variable while per forming these tests The valve is moved to a certain position de fined by the test settings and the valve may move through its full working range 1 3 Activating EXPERT The extended EXPERT diagnostics can be activated later at the positioner when EXPERT is not already activated on delivery of the positioner The required activation code or an EXPERT USB dongle can be purchased to activate EXPERT 1 3 1 Activation with activation code The activation code can be ordered order number 1400 9318 from SAMSON On ordering this option specify the serial num ber of the positioner EXPERT is activated directly at the positioner Activ
66. ured to this rate value at least Display only A6 y Min Display of minimum y value from the last performed partial Display only stroke test 7 delta y monitoring reference Predetermined limit for y cancelation value Display only Automatically determined during the test A8 Activation of delta y monitor Yes No Yes Activates or deactivates the delta y monitoring A9 delta y monitoring value 0 0 to 100 10 Safety factor added to the reference value EB 8388 5 EN 53 Code Parameters display Dostriphon no Values default settings 49 dO Unassigned dl Unassigned d2 Step start Start value for step response test 0 0 to 100 0 100 0 d3 Step end End value for step response test 0 0 to 100 0 90 0 d4 Activation of the ramp function Activates or deactivates the ramp function Yes No Yes d5 Ramp time rising Ramp time for O to 100 rising of the ramp function A 0 to 9999 s value deter suitable value is determined during initialization if pos mined during initialization sible make sure the ramp time does not fall below this minimum value 15 s value d Ramp time falling Ramp time for 100 to O falling of the ramp function A 0 to 9999 s value deter suitable value is determined during initialization if pos mined during initialization sible make sure the ramp time does not fall be
67. us and the reason for the 5_0_2008 Apr 23 tro SAMSON TROVIS VIEW Operation unit RES 2 Positioner TRD 0 Process controller PID amp Binary input 1 011 TRD Binary input 2 012 TRD Diagnosis i Status messages Statistical information AUTO 5 0 Tests MAN 5 Drive signal diagram steady 45 Drive signal diagram hysteresis Static characteristic o Fig 13 Step response partial stroke test PST EB 8388 5 EN 33 Tests in manual mode cancelation are indicated on the positioner s display and in the engineering tool used Upon failure of the auxiliary power the au tomatic activation of the partial stroke test remains active The time counter in Auto test time is reset to again The hysteresis test d5 from statistical infor mation AUTO as well as the setpoint devia tion histogram and cycle counter histogram are also available in manual mode if the partial stroke test is automatically started PST Auto refer to section on starting the partial stroke test Changes to the parameters are possible re gardless of the operating mode when the PST Man is set in the PST testing mode pa rameter Note You can configure the partial stroke test either over the operator interface or di recily at the positioner by selecting Code 49 These instructions contain a supplement to
68. ve while the process is running does cause the drive signal y to drop but the gra dient 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 The 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 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 Statistical information AUTO assigned to a valve position class The aver age drive signal y is calculated for each class The stored data can be read The ref erence data required are plotted and stored after initialization Long term monitoring The long term monitoring involves the aver

Operating Instructions EB 8388-5 EN

Contents

Download Pdf Manuals

Related Search

Related Contents