Samson 3730-3 ESD Service manual

Series 3730
Electropneumatic Positioner
Type 3730-3
ESD Version
With HART®communication
Mounting and
Operating Instructions
EB 8388-1 EN
Firmware version 1.4x
Edition November 2006
Fig. 1 · ESD mode in SAMSON TROVIS-VIEW 3 software

Contents
1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 ESD functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Presetting the positioner. . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Converting TROVIS-VIEW 3. . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Unlocking the positioner . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.3 Printing the diagnostic/ESD log . . . . . . . . . . . . . . . . . . . . . 7
2 ESD functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Changing ESD parameters and starting the partial stroke test . . . . . . 12
2.1.1 On-site operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Analyzing measured data . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Condensed state/Fault alarm output . . . . . . . . . . . . . . . . . . 14
2.3 Measured data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Resetting ESD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 List of ESD parameters. . . . . . . . . . . . . . . . . . . . . . . . . 16
3 EXPERT+test functions . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Notes on applications. . . . . . . . . . . . . . . . . . . . . . . . . 20
2EB 8388-1 EN
Contents

1 Description
The Type 3730-3 Positioner in ESD version
is based on the Type 3730-3 Positioner with
HART®Communication.
These mounting and operating instructions,
EB 8388-1 EN, supplement EB 8384-3 EN
and focus on the ESD functions.
Technical data, attachment, electrical and
pneumatic connections as well as operation
and the standard EXPERT valve diagnostics
are dealt with in Mounting and Operating
Instructions EB 8384-3 EN.
Note!
The optional external position sensor cannot
be used with the Type 3730-3 Positioner in
ESD version.
Extended EXPERT+valve diagnostics are de-
scribed in EB 8388 EN. By default, all
positioners in ESD version include the
EXPERT+valve diagnostic functions.
Note!
Positioners delivered not mounted on an ac-
tuator are configured with the default set-
tings, which means that the ESD functions
are not activated.
After mounting the positioner on a safety
shut-off valve and starting it up, switch the
positioner to ESD mode to allow it to per-
form the safety functions (for required set-
tings and instructions, see section 2 and
EB 8384-3 EN).
1.1 General
Note!
When the ESD function is active, the
positioner keeps the attached valve to a set
position, e.g. open. The valve does not per-
form any control tasks anymore.
In AUTO operating mode, the positioner
can be used to control the attached valve.
ESD (Emergency ShutDown) is a positioner
function with extended firmware and partial
stroke testing for the predictive, status-ori-
ented detection of malfunctions in pneumatic
shut-off valves in safety instrumented systems
(SIS).
As a result, the probability of failure on de-
mand (PFD) can be reduced and mainte-
nance intervals can be extended.
All testing and diagnostic functions are com-
pletely integrated into the positioner. The
measured data and test results are collected
and stored in the positioner.
Partial stroke tests can be started and can-
celled either manually at any time (on site or
using an engineering tool) or automatically
according to a certain 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
causes of the fault are given. Apart from be-
ing indicated on the positioner’s display or
in the engineering tool used, the test status is
also issued at the fault alarm output.
EB 8388-1 EN 3
Description

Operation
The positioner can be operated on site using
the rotary pushbutton (see section 2.1.1
“On-site operation“). Alarms are indicated
on the LCD and issued over the fault alarm
output (condensed status).
The TROVIS-VIEW 3 software allows for
convenient operation when communicating
through the SAMSON SSP interface proto-
col. Thanks to DD and the FDT/DTM con-
cept, the ESD functions can easily be inte-
grated into the process control system or as-
set management system.
The instructions concerning operation in the
following sections refer to operation with
TROVIS-VIEW 3.
Note! All parameter settings entered in the
user interface need to be downloaded to the
positioner to become effective.
1.2 ESD functions
ESD mode
In ESD mode, the safety shut-off valve is
moved to a specific set point within its work-
ing range. The valve does not perform any
control tasks anymore. The valve is fully
closed in case of an emergency.
In its basic setting, the positioner behaves
similar to a solenoid valve, which keeps the
attached valve to a set position, e.g. open.
For test purposes, the partial stroke test can
either be started manually (ESD Man) or
triggered automatically according to sched-
ule (ESD Auto).
Partial stroke test
The partial stroke test integrated into the
positioner can prevent a normally open
valve or a valve in its end position from
seizing up or getting jammed.
As the course of the partial stroke test is
plotted, the dynamic control response can
also be analyzed.
During the test, the valve is moved out of the
end position or from a start value 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.
The partial stroke test is performed, for ex-
ample between 10 and 15 % of the rated
travel, starting from the end position while
the plant is running, yet without disrupting
plant operation. The start and stop values
for the partial stroke test can be configured
by the user.
The following test cancellation conditions
provide additional protection against the
valve slamming shut and moving past the fi-
nal value:
4
Valve position x
4
Drive signal y
4
Maximum test time is exceeded
4
Tolerance range exceeded
The course of the controlled variable x , ref-
erence variable w
, setpoint deviation e , and
drive signal y parameters is saved in the
positioner, assigned to the operating hours
counter.
The
dead time, T63 , T98 , overshooting , rise
time
, and response time parameters of a
step response test are analyzed separately
4EB 8388-1 EN
Description

for the increasing and decreasing character-
istic.
The analyses of the last three partial stroke
tests are saved in the positioner with the as-
sociated time stamp.
The EXPERT+test functions Data logger and
Hysteresis test to detect friction changes are
also available in ESD mode (see section 3
and EB 8388 EN).
Note!
The valve position is used as the valve travel
condition by the data logger of positioners
in ESD version.
1.3 Presetting the positioner
1.3.1 Converting TROVIS-VIEW 3
The TROVIS-VIEW 3 version must match the
software version of the positioner.
When establishing communication or ex-
changing data between the PC and the
positioner, the firmware version is checked
automatically and the appropriate
TROVIS-VIEW 3 module is loaded.
To adapt the TROVIS-VIEW 3 version before
transmitting data proceed as follows:
1. In the File menu, select Convert.
A window listing all available firmware
versions is opened.
2. Select “Version 1.xx-1.xx ESD
”.
3. Confirm selection with OK.
TROVIS-VIEW 3 switches to the user in-
terface for the positioner in ESD version.
EB 8388-1 EN 5
Description

1.3.2 Unlocking the positioner
To prevent unauthorized access, the
positioner settings cannot be changed unless
the valid ESD code has been entered.
The positioner needs to be unlocked sepa-
rately for on-site operation and operation
through TROVIS-VIEW depending on the
operating mode.
The ESD code can be found on page 21.
Remove the code or make it unreadable to
prevent unauthorized use.
Entering the code on the positioner
Default: OFF
Turn →Code 3
Press .
Turn →ON
Press . Display shows:
0
Turn →ESD code
Press . Display shows:
ON ,
Entering the code in TROVIS-VIEW 3
1. In the Device menu, select ESD enabling
code.
TROVIS-VIEW 3 establishes a connec-
tion with the positioner.
2. Enter the code in the Value field.
3. Confirm selection with OK.
6EB 8388-1 EN
Description

1.3.3 Printing the diagnostic/ESD
log
The Print command allows you to print out a
diagnostic log of individual tests or the en-
tire diagnosis.
The diagnostic log includes a title page and
a list of all the data points including all their
values and properties.
The title page contains all key information
for clear identification of the printed log (de-
vice type, file name, time and date of cre-
ation, time and date of the last change and
TROVIS-VIEW version).
Select Print in the File menu to add further
information.
1. In the File menu, select Print Options to
choose the scope of the diagnostic log.
After installing/updating the
TROVIS-VIEW software, customer data
(Customer data in 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.
2. Right-click the [Diagnosis] folder or the
required subfolder and select Print from
the context-sensitive menu to print the di-
agnostic log.
The printout contains the contents of the
folder and its subfolders.
EB 8388-1 EN 7
Description

2 ESD functions
TROVIS-VIEW 3: [Diagnosis > Emergency
Shut Down]
In TROVIS-VIEW 3, the functions of the
positioner in ESD mode are listed in the
[Diagnosis] folder under Emergency Shut
Down. They include:
4Activating/deactivating ESD mode and
starting the partial stroke test
4Setting the parameters for partial stroke
testing
4Defining the cancellation conditions for
partial stroke testing
Note!
Instructions on how to change parameters
and start the partial stroke test can be found
in section 2.1 “Changing ESD parameters
and starting the partial stroke test“.
ESD mode
ESD mode is active if the
Target mode pa-
rameter in the [Positioner] folder under Op-
erating mode is set to “Emergency Shut
Down“ and
Desired ESD mode parameter in
the [Diagnosis] folder under Emergency Shut
Down is set to “On“.
In ESD mode, the safety shut-off valve is
specifically moved to the set point of the
valve working range (parameter:
Required
manual reference variable w
).
The positioner behaves similar to a solenoid
valve, which keeps the attached valve to a
set position, e.g. open. The valve does not
perform any control tasks anymore.
The current valve position is indicated under
Manual reference variable w .
The
ESD operating mode parameter sets the
conditions for starting the partial stroke test:
Test started manually (ESD Man)
ESD operating mode parameter = ESD Man
Partial stroke testing begins when triggered
by the
Start step response parameter. Other-
wise, the valve remains in the position de-
fined by the
Required manual reference
variable w
parameter.
Changes to the parameters can only be
made in ESD Man mode.
8EB 8388-1 EN
ESD functions

Test started automatically according to
schedule (ESD Auto)
ESD operating mode parameter = “ESD
Auto“
Partial stroke tests are conducted at regular
intervals. The
Time until the next automatic
ESD test
parameter indicates when the next
test is scheduled (countdown).
Partial stroke test
The course of the partial stroke test depends
on the parameters listed under Settings in
TROVIS-VIEW 3. Depending on the param-
eter settings, the partial stroke test is con-
ducted either in steps or in a ramp function
of the valve position (see Fig. 2).
After being triggered, the test does not start
until the
Settling time before test start (t1) has
elapsed. This waiting period ensures that the
valve has reached the position defined by
the
Step start parameter (pos. 2, see Fig. 2)
before the test starts.
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 vari-
able w
, pos. 1)
The
Step tolerance limit (range: 0.1 to
10.0 %) sets the permissible tolerance limit
for the step’s start and end values.
The
Scan rate (range: 0.2 to 30.0 s) 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, ref-
erence variable w, setpoint deviation e,
drive signal y and the time when they were
recorded). After 100 measured values per
EB 8388-1 EN 9
ESD functions

measured variable have been stored, the
logging is stopped. However, the test is still
completed. The
Measured data storage out
of memor
y alarm is generated. The Recom-
mended sampling time,
which should not be
shorter, if at all possible, is calculated from
the
Duration of the test.
The Display section in TROVIS-VIEW 3
shows the
Progress flag in percent.
1. Step response function, Fig. 2 left
The step response function is activated when
the
Activation of the ramp function parame-
ter is set to "Off".
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. 2 right
The ramp function is active when the
Activa-
tion of the ramp function
parameter is set to
"On".
Note!
A step before the partial stroke test can be
prevented by allocating the value of the
manual reference variable w to the
Step
start
parameter.
The valve is moved to the Step end (pos. 3)
and
Step start (pos. 2) positions with fixed
velocities (v1and v2) set by the
Ramp time
(falling)
and Ramp time (rising) parameters.
10 EB 8388-1 EN
ESD functions
Pos. 1
Pos. 2
Pos. 3
t
1
t
2
t
2
[%]
[s]
Pos. 1
Pos. 2
Pos. 3
t
1
t
2
t
2
[%]
ww
[s]
tt
v
1
v
2
Fig. 2 · Courses of the partial stroke tests with step response (left) and ramp function (right)
Valve positions:
Pos. 1 = Required manual
reference variable w
Pos. 2 = Step start
Pos. 3 = Step end
Times:
t1= Settling time before test start
t2= Delay time after step
Velocities:
v1=100
Ramp time (falling)
%
s
v2=100
Ramp time (rising)
%
s
Step response Ramp function