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

Set point

deviation

histogram

u Section 3.4

Cycle counter

histogram

u Section 3.5

Drive signal

diagram,

steady-state

u Section 3.6

u Section 4.1

Trend of travel

end position

u Section 3.8

Conguration

required for

diagnosis

Data logger

u Section 3.2

Stufng box

u Section 3.5

Drive signal

diagram,

steady-state

u Section 4.1

Drive signal dia-

gram hysteresis

u Section 3.7

u Section 4.2

Static

characteristic

u Section 4.3

Full stroke test

u Section 4.5

No conguration

required for

monitoring

Travel

histogram

u Section 3.3

Set point

deviation

histogram

u Section 3.4

Cycle counter

histogram

u Section 3.5

Trend of travel

end position

u Section 3.8

Conguration

required for

diagnosis

On/off diagnosis

u Section 3.1

Data logger

u Section 3.2

Stufng box

u Section 3.5

Static

characteristic

u Section 4.3

Partial stroke

test

u Section 4.4

Full stroke test

u Section 4.5

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

Initialization with reference test

Yes ß à No Subsequent

initialization

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

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)

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.

EB 8389S EN 11

Description

2. Tests (out-of-service diagnostics)

Similar to the statistical information func-

tion, data are compiled, saved and ana-

lyzed by the positioner. However, in this

case, the valve position is not determined

by the set point, but by the active test.

NOTICE

The tests can only be started when

the conditions in the plant allow it

(e.g. plant shutdown or service work

in the workshop). For reasons of

safety, these tests, except for partial

stroke testing, can only be performed

in the manual mode.

An active test is stopped and the posi-

tioner changes to the fail-safe position

when the electrical signal falls below a

certain level or when the solenoid valve

is triggered or the forced venting func-

tion is activated.

1.3.1 Application type

Different diagnostic functions are available

depending on the application type selected

in EXPERTplus.

Depending on the application type selected,

the positioner behaves differently in the au-

tomatic mode:

−Control valve

The positioner uses the set point to posi-

tion the valve.

The valve position (current position) ap-

pears in % on the display.

−Open/close (on/off) valve

Discrete analysis of the set point

The valve position (current position) in %

and O/C (Open/Close) appear in alter-

nating sequence on the display. See u

Section 3.1.

1.3.2 Analysis

Table 2 shows the diagnostic functions and

their statements on the condition of the valve

depending on the application type.

12 EB 8389S EN

Description

Table1: Diagnostic functions and test analysis

Diagnostic functions

Control

valve

Open/Close

(on/off)

valve 1) Analysis See section

Statistical information

Open/Close – •

Breakaway time

Transit time

Valve end position

3.1, page 21

Data logger • • Depending on trigger status

selected 3.2, page 25

Travel histogram •¡Shifting working range

Working range 3.3, page 30

Set point

deviation

histogram

• •

Limit working range

Connection positioner-valve

Inner (seat) leakage

Average set point deviation

3.4, page 33

Cycle counter

histogram • • Stufng box/external leakage

Dynamic stress factor 3.5, page 37

Drive signal

diagram

steady-state

•¡

Air supply

Leakage pneumatics

Actuator springs

3.6, page 41

Drive signal

diagram

hysteresis

•¡

Friction

External leakage perhaps

soon expected

3.7, page 45

Trend of travel

end position • • Observing end position

Zero shift 3.8, page 51

• Full scope of functions

¡ Function is performed, but not analyzed

– Function is not performed

EB 8389S EN 13

Description

Diagnostic functions

Control

valve

Open/Close

(on/off)

valve 1) Analysis See section

Tests

Drive signal

diagram steady-

state

• •

Air supply

Leakage pneumatics

Actuator springs

4.1, page 55

Drive signal dia-

gram hysteresis • • Friction 4.2, page 59

Static character-

istic • • Dead band 4.3, page 62

Partial stroke test

(PST) • •

Overshooting

Dead time

T63

T89

Rise time

Settling time

4.4, page 65

Full stroke test

(FST) • •

Overshooting

Dead time

T63

T89

Rise time

Settling time

4.5, page 75

• Full scope of functions

¡ Function is performed, but not analyzed

– Function is not performed

14 EB 8389S EN

Monitoring

2 Monitoring

2.1 Status messages

The valve diagnostics integrated into the po-

sitioner generate classied status messages.

There are two types of status messages: stan-

dard status messages and extended status

messages.

Standard status messages

Standard status messages contain informa-

tion on start-up as well as on operation and

the condition of the positioner.

Messages are divided into the following

main groups:

−Status

−Operation

−Hardware

−Initialization

−Data memory

−Temperature

Standard status messages are indicated in

the positioner by the codes listed in the stan-

dard positioner instructions.

Additional informative data are listed in the

subfolders of the Positioner folder:

−Operation > Process data: Information

on current process variables, condensed

state and temperature

−Settings > Positioner > Error control: In-

formation on total valve travel with con-

gurable limits

−Positioner > Start-up > Initialization: List

of initialization errors, which are also Re-

setting the diagnosis contained in the Di-

agnosis folder (> Status messages)

Extended status messages

The extended status messages are generated

from the results gained from Statistical infor-

mation (in-service monitoring) and Tests (out-

of-service diagnostics).

The messages provide information on the fol-

lowing topics to allow users to plan predic-

tive maintenance and service work:

−Air supply

−Shifting working range

−Leakage pneumatics

−Limit working range

−Observing end position

−Connection positioner-valve

−Working range

−Friction

−Actuator springs

−Inner (seat) leakage

−External leakage

−PST/FST

−Open/Close

Any active diagnostic message is indicated

in the positioner by Code 79.

Extended status messages can be classied

according to the possible causes. See u Sec-

tion 3.3 to section 4.5.

EB 8389S EN 15

Monitoring

The following classications are possible:

−No message

If an event is classied as “No message”,

this event does not have any affect on the

condensed state.

−Function check

Test or calibration procedures are per-

formed in the positioner. The positioner is

temporarily unable to perform its control

task as long as the procedure is taking

place.

−Maintenance required/Maintenance de-

manded

The positioner still performs its control

task (with restrictions). A maintenance

demand 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.

−Out of specication/invalid process

state

The positioner is running outside the

specied operating conditions.

−Maintenance alarm

The positioner cannot perform its control

task due to a functional fault in the posi-

tioner itself or in one of its peripherals or

an initialization has not yet been success-

fully completed.

You can view the status messages in the Di-

agnosis folder (> Status messages)as well

as in the Diagnosis folder (> Status messag-

es > Extended).

2.1.1 Resetting status

messages

When a status message is generated, you

should rst locate the source of the fault and

take action to remedy it.

For recommended action concerning the sta-

tus messages u Section 7.2.

Status messages can be reset individually or

using the reset function. u Table2 contains

an overview on how the diagnosis can be

reset. The status messages can be reset in the

Diagnosis folder (> Reset) and/or the Oper-

ation folder (> Reset).

If you want to keep measured data and the

analysis after resetting the positioner, it is

possible to upload them onto a computer.

Resetting single status messages

−Status messages represented by a code

in the positioner can be conrmed at the

positioner itself. Select the error code

and conrm it by pushing the rotary

pushbutton. See the standard instructions

of the positioner (uEB8384-3SEN).

−On resetting histograms and diagrams,

the data for short-term monitoring are al-

so reset.

−Resetting measured data does not cause

the diagnostic parameters and reference

value to be reset as well.

−The positioner does not need to be re-ini-

tialized after resetting.

16 EB 8389S EN

Monitoring

Resetting the diagnosis

Code 36 - Diag

−Data from Statistical information and

Tests are reset according to u Table 3.

−The reference value of ‘Trend of travel

end position’ (Statistical Information) is

deleted.

−The reference values of Tests (‘Drive sig-

nal diagram steady-state’ and ‘Drive sig-

nal diagram hysteresis’) remain saved.

−Status classication and data logs re-

main saved.

−The positioner does not need to be re-ini-

tialized after resetting.

If the diagnosis is to be reset at regular inter-

vals, enter the time in “Required time ‘Reset

diagnosis”. The setting “00:00:00” or “0”

causes the resetting at regular intervals to be

deactivated.

Operation > Reset

−Reset diagnosis (Code 36 - Diag)

−Required time ‘Reset diagnosis’ (Code48 - h3):

congurable as required,

[0.00:00:00 d.h:min:s]

Start with default values

Code 36 - Std

−Data from Statistical information and

Tests are reset according to u Table 3.

−Reference values are deleted.

−Status classication and data logs are

deleted.

−The positioner must be re-initialized after

resetting.

NOTICE

Before mounting the positioner on a

new control valve, perform a reset by

activating Code 36 - Std and re-ini-

tialize the positioner.

Operation > Reset

−Start with default values (Code 36 - Std)

EB 8389S EN 17

Monitoring

Table2: Reset functions

All adjusted parameters and recorded measured values of the specied diagnostic test are

reset, if not listed separately.

Function

Resetting

single status

messages

Code

36 - Diag

Code

36 - Std

Operating hours counter

Device switched on since (last) initialization NO YES YES

Device in closed loop since initialization NO YES YES

Status classication NO NO YES

Logging YES NO YES

Statistical information

Open/Close 1) Parameters YES NO YES

Measured values YES YES YES

Data logger NO YES YES

Travel histogram x YES YES YES