Samson TROVIS SAFE 3731 Series User manual

Operating Instructions
EB 8389S EN
Firmware version 1.6x
Edition May 2015
Series 3731
TROVIS SAFE 3731-3 Electropneumatic
Positioner
EXPERTplus Valve Diagnostics

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or seri-
ous injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or se-
rious injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 8389S EN

Contents
EB 8389S EN 3
1 Description....................................................................................................7
1.1 General ........................................................................................................7
1.2 Start-up .........................................................................................................9
1.3 Diagnostic functions .....................................................................................10
1.2.1 Reference tests .............................................................................................10
1.3.1 Application type ..........................................................................................11
1.3.2 Analysis ......................................................................................................11
2 Monitoring..................................................................................................14
2.1 Status messages ...........................................................................................14
2.1.1 Resetting status messages .............................................................................15
2.2 Condensed state ..........................................................................................18
2.2.1 Condensed at the fault alarm output ..............................................................18
2.3 Logging .......................................................................................................18
3 Statistical information..................................................................................19
3.1 Open/close (on/off) valve ............................................................................21
3.1.1 On/off diagnosis .........................................................................................22
3.1.2 Analysis and monitoring ............................................................................... 23
3.1.3 Resetting single status messages ....................................................................23
3.2 Data logger .................................................................................................25
3.2.1 Permanent data logging ...............................................................................25
3.2.2 Triggered data logging ................................................................................. 26
3.3 Travel histogram ..........................................................................................30
3.3.1 Analysis and monitoring ............................................................................... 31
3.3.2 Resetting single status messages ....................................................................32
3.4 Set point deviation histogram ........................................................................33
3.4.1 Analysis and monitoring ............................................................................... 34
3.4.2 Resetting single status messages ....................................................................35
3.5 Cycle counter histogram ...............................................................................37
3.5.1 Analysis and monitoring ............................................................................... 38
3.5.2 Resetting single status messages ....................................................................39
3.6 Drive signal diagram steady-state .................................................................41
3.6.1 Analysis and monitoring ............................................................................... 42
3.6.2 Resetting single status messages ....................................................................43
3.7 Drive signal diagram hysteresis .....................................................................45

4 EB 8389S EN
Contents
3.7.1 Analysis and monitoring ............................................................................... 47
3.7.2 Resetting single status messages ....................................................................47
3.8 Trend of travel end position ........................................................................... 51
3.8.1 Analysis and monitoring ............................................................................... 52
3.8.2 Resetting single status messages ....................................................................53
4 Tests ...........................................................................................................53
4.1 Drive signal diagram steady-state .................................................................55
4.1.1 Analysis and monitoring ............................................................................... 56
4.1.2 Resetting single status messages ....................................................................57
4.2 Drive signal diagram hysteresis .....................................................................59
4.2.1 Analysis and monitoring ............................................................................... 60
4.2.2 Resetting single status messages ....................................................................61
4.3 Static characteristic ......................................................................................62
4.3.1 Resetting single status messages ....................................................................63
4.4 Partial stroke test (PST) ..................................................................................65
4.4.1 Start triggered by the set point ......................................................................70
4.4.2 Start triggered by the binary input.................................................................70
4.4.3 Analysis and monitoring ............................................................................... 70
4.4.4 Resetting single status messages ....................................................................71
4.4.5 Step response ..............................................................................................71
4.5 Full stroke test (FST) ......................................................................................75
4.5.1 Analysis and monitoring ............................................................................... 78
4.5.2 Resetting single status messages ....................................................................78
5 Dynamic HART® variables............................................................................80
6 Binary input................................................................................................82
7 Appendix....................................................................................................84
7.1 Code list ...................................................................................................... 84
7.2 Error messages and recommended corrective action .......................................91
7.3 Diagnostic parameters and measured data saved in a non-volatile memory .....97
7.4 Determining the ramp times of the partial stroke test .......................................99

EB 8389S EN 5

Overview
Throttling service On/off service
No conguration
required for
monitoring
Travel histogram
u Section 3.3
S
Set point
deviation
histogram
u Section 3.4
S
Cycle counter
histogram
u Section 3.5
S
Drive signal
diagram,
steady-state
u Section 3.6
u Section 4.1
S
T
Trend of travel
end position
u Section 3.8
S
Conguration
required for
diagnosis
Data logger
u Section 3.2
S
Stufng box
u Section 3.5
S
Drive signal
diagram,
steady-state
u Section 4.1
T
Drive signal dia-
gram hysteresis
u Section 3.7
u Section 4.2
S
T
Static
characteristic
u Section 4.3
T
Full stroke test
u Section 4.5
T
No conguration
required for
monitoring
Travel
histogram
u Section 3.3
S
Set point
deviation
histogram
u Section 3.4
S
Cycle counter
histogram
u Section 3.5
S
Trend of travel
end position
u Section 3.8
S
Conguration
required for
diagnosis
On/off diagnosis
u Section 3.1
S
Data logger
u Section 3.2
S
Stufng box
u Section 3.5
S
Static
characteristic
u Section 4.3
T
Partial stroke
test
u Section 4.4
S
T
Full stroke test
u Section 4.5
T
Note:
−S = Statistical information (in-service monitoring) , T = Tests (out-of-service diagnostics)
−Tests highlighted in red border require an initialization with reference test
−Tests highlighted in gray can optimize the proper functioning of safety equipment according to IEC61508 and
IEC61511, provided these tests are performed regularly.

EB 8389S EN 7
Description
1 Description
1.1 General
These instructions EB8389EN supplement
the standard mounting and operating in-
structions for TROVIS SAFE 3731-3 Position-
er (uEB8384-3SEN)
EXPERTplus is a diagnostic rmware inte-
grated into the positioner which allows the
predictive, status-oriented maintenance of
valves with pneumatic actuators.
EXPERTplus records the valve condition while
the process is running (in automatic mode)
and generates messages on the required
maintenance work. In addition, numerous
tests can be performed in manual mode to
pinpoint emerging faults.
The diagnostic functions of EXPERTplus are
completely integrated into the positioner. Di-
agnostic data are compiled, saved and ana-
lyzed in the positioner itself. Classied status
messages on the state of the valve are gener-
ated from the analysis.
Operation using TROVIS-VIEW/DD/DTM/
eDD
EXPERTplus allows the parameters to be
viewed or changed using the TROVIS-VIEW
software (version 3 or 4) or DD/DTM/eDD.
−TROVIS-VIEW 3 and 4 · Operator inter-
face used to congure various SAMSON
devices and dene parameters (current
version is TROVIS-VIEW 4)
−DTM · Device type manager to describe
the device and communication properties
−DD/eDD · Device description/enhanced
device description
All parameter settings that are changed
over the operator interface must also be
downloaded onto the positioner to allow
them to become effective.
Local operation
Some parameters can be changed at the po-
sitioner as well as over the operator inter-
face. The positioner code of these parame-
ters are written in parentheses. Refer to the
mounting and operating instructions of the
positioner for a list of all parameters that can
be changed at the positioner.
The operation described in the following
sections illustrates operation using
TROVIS-VIEW. The default settings of the
positioner and TROVIS-VIEW are written in
square brackets [ ].
Settings highlighted in gray refer to opera-
tion using TROVIS-VIEW.

8 EB 8389S EN
START-UP
Initialization mode
âââ
MAX NOM MAN
â
Initialization with reference test
Yes ß à No Subsequent
initialization
â
Operating mode =
MAN
â â
Zero
Reference of drive signal diagram
steady-state (d1)
Reference of drive signal diagram
hysteresis (d2)
Reference of drive signal diagram
steady-state (d1)
Reference of drive signal diagram
hysteresis (d2)
All reference values are overwritten!
Code 48-h1
andCode 81 Code 48 - h1
ß Not successful
ß Successful
ß Not successful
â
Operating mode =
AUTO
Automatic change to
AUTO operating
mode
àThrottling or on/off service ß
Description – Start-up

EB 8389S EN 9
Description
1.2 Start-up
The positioner must be initialized to use the
full scope of the valve diagnostics. During
initialization the positioner adapts itself opti-
mally to the friction conditions and the signal
pressure required by the control valve.
The positioner can be initialized using one of
the following initialization modes: maximum
range (MAX), nominal range (NOM) and
manual adjustment (MAN).
−Maximum range (MAX)
Initialization mode for simple start-up of
valves with two clearly dened mechani-
cal end positions, e.g. three-way valves
−Nominal range (NOM)
Initialization mode for all globe valves
−Manually selected range (MAN)
Initialization mode for globe valves re-
quiring OPEN position to be entered
manually
The application type, pressure limit and the
start-up parameters required for the selected
initialization must be entered to initialize the
positioner.
Note:
Positioner start-up is described in de-
tail in the mounting and operating in-
structions (see uEB8384-3SEN).
During positioner initialization, the propor-
tional-action coefcient Kp and deriva-
tive-action time Tv levels are optimally set. If
the positioner tends to overshoot impermissi-
bly due to other disturbances, the propor-
tional-action coefcient and derivative-action
time can be adapted accordingly. Increment
the derivative-action time until the desired
behavior is reached. When the maximum
value of 4 is reached for the derivative-ac-
tion time, the proportional-action coefcient
can be reduced in steps.
NOTICE
Changing the proportional-action co-
efcient inuences the set point de-
viation!
Start-up
−Application type (Code 49 - h0):
[Control valve], Open/Close valve
−Initialization mode (Code 6):
[Maximum range(MAX)], Nominal range
(NOM) or Manual adjustment (MAN)
−Pin position (Code 4): [Off], 17, 25, 35, 50,
70, 100, 200, 300 mm, 90°
−Pressure limit (Code 16):
[Off], 3.7, 2.4, 1.4bar
Settings > Positioner > Performance
characteristics
−Required proportional-action coefcient Kp
(level) (Code 17): 0 to 17, [7]
−Required derivative-action time Tv (level)
(Code 18): Off, 1 to 4, [2]


10 EB 8389S EN
Description
1.2.1 Reference tests
The monitoring of friction, supply pressure,
leakage (pneumatics and to the atmosphere),
zero point and actuator springs requires ad-
ditional reference tests for 'Drive signal dia-
gram steady-state' (test d1) and 'Drive signal
diagram hysteresis' (test d2). See u Section
4.1 and section 4.2.
NOTICE
−The valve moves through its work-
ing range during the reference test.
−The reference test cannot be per-
formed if the positioner has been
initialized in the substitute calibra-
tion (SUB) mode.
Right-click 'Start reference test' in the Diag-
nosis folder and select ‘Execute’ to start the
recording of reference data. tESt and d1 or
d2 appear in alternating sequence on the
positioner display.
Note:
−Right-click 'Stop reference test'
and select ‘Execute’ to can-
cel the reference test.
−The positioner records the ref-
erence data automatically af-
ter initialization if 'Initialization
with reference test' is set to Yes.
−A new reference test causes the
results of existing reference tests
to be overwritten and the di-
agnostic data to be deleted.
−If the reference data could not be
recorded correctly or are incom-
plete, Code 48 - h1 is generated

−in the positioner. If the 'Initializa-
tion with reference test' parameter
is activated, an incorrect reference
test is also indicated in Code 81.
−The positioner can still perform
its control task properly even if
the reference test was not record-
ed correctly or is incomplete.
−Data from the rst reference test
are used as the reference if no ref-
erence data are saved in the posi-
tioner on starting the tests for 'Drive
signal diagram steady-state' or
'Drive signal diagram hysteresis'
Diagnostics
−Start reference test (Code 48 - d7)
or
Start-up
−Initialization with reference test (Code 48 - h0):
Yes, [No]
1.3 Diagnostic functions
There are two main groups of diagnostic
functions available: Statistical information
(in-service monitoring) and Tests (out-of-ser-
vice diagnostics).
1. Statistical information (in-service moni-
toring)
Data are compiled, saved and analyzed
by the positioner while the process is
running without disrupting the process.
The positioner follows the set point to po-
sition the valve. A classied status alarm
or fault alarm is generated if the posi-
tioner detects an event.