Samson 3730 Series 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 June 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 . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Changing the graph settings in TROVIS-VIEW 3 . . . . . . . . . . . . . 6
2 ESD functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Changing ESD parameters and starting the partial stroke test . . . . . . 11
2.1.1 On-site operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Analyzing measured data . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Condensed state . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Measured data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Resetting ESD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 List of ESD parameters. . . . . . . . . . . . . . . . . . . . . . . . . 14
3 EXPERT+test functions . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Notes on applications. . . . . . . . . . . . . . . . . . . . . . . . . 18
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 valve diagnostics EXPERT
are dealt with in Mounting and Operating
Instructions EB 8384-3 EN.
EXPERT+extended 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 without being mounted
on an actuator are configured with the de-
fault settings, which means that the ESD
functions are not activated.
After mounting the positioner on a safety
shut-off and starting it up, switch the
positioner to ESD mode, allowing it to per-
form the safety functions (for required set-
tings and instructions, see section 2 and
EB 8384-3 EN).
1.1 General
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 values and test results are col-
lected and made available in the positioner.
Partial stroke tests can be launched and
cancelled either manually at any time (on
site or using an engineering tool) or auto-
matically 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.
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.
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 control system or asset man-
agement system.
EB 8388-1 EN 3
Description

The operating instructions given in the fol-
lowing 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 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 open.
For test purposes, the partial stroke test can
either be started manually (ESD Man) or
triggered automatically according to sched-
ule (ESD Auto).
Note!
Normal positioner operation is possible in
addition to ESD mode (Auto or Man).
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
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 value. Then, the valve is moved
back again to its initial position.
The step response 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
, set point 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 are an-
alyzed separately for the increasing and
decreasing characteristic.
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
EB 8388 EN).
4EB 8388-1 EN
Description

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.
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 19.
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 ,
EB 8388-1 EN 5
Description

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.
1.3.3 Changing the graph settings
in TROVIS-VIEW 3
The parameters for setting the axis gradua-
tion in the function diagrams can be
changed in the [Diagnosis] folder under
[Graph settings > Data logger, Hysteresis,
and Emergency Shut Down].
Note!
The function diagrams of the tests can be
printed by clicking on the displayed dia-
gram with the right mouse button.
6EB 8388-1 EN
Description

2 ESD functions
TROVIS-VIEW 3: [Diagnosis > ESD]
In TROVIS-VIEW 3, the functions of the
positioner in ESD version 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
Desired ESD mode
parameter 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 open.
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.
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).
EB 8388-1 EN 7
ESD functions

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. If the adjusted
Scan rate matches the Recommended sam-
pling time
, the entire step response is avail-
able as a diagram.
Otherwise, only the last 100 measured val-
ues can be analyzed. In this case, the
Mea-
sured data storage out of memory
parame-
ter is set to “Maintenance alarm“, but the
test is not cancelled.
8EB 8388-1 EN
ESD functions

When the test is active, the test duration de-
termined by the positioner is indicated by
the
Duration of the test parameter. The Dis-
play section in TROVIS-VIEW 3 shows the
Progress flag in percent.
1. Step change 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".
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.
The ramp time specifies the time required by
the valve to move through the travel range
100 to 0 % (falling) and 0 to 100 % (rising).
Note!
Times for the
Ramp time (falling/rising) are
determined during initialization of the
positioner. These times are not to be ex-
ceeded when setting the parameters for the
partial stroke test with ramp function.
EB 8388-1 EN 9
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 change (left) and ramp function (right)
Step change function Ramp function
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

Cancellation conditions
To ensure that the running process is not dis-
rupted and that the shut-off valve does not
slam shut unintentionally, it is advisable to
define conditions that cause the positioner to
cancel an active partial stroke test. The
positioner issues an alarm when a test has
been cancelled (see section 2.2).
Possible cancellation conditions are:
4
Max. test duration : The test is cancelled
when the maximum permissible test du-
ration (range: 30.0 to 3000.0 s) is ex-
ceeded.
4
x control value : The test is cancelled
when the adjusted valve position (range:
–10 to 110 %) is exceeded.
The condition is only active when
Activa-
tion x control
is set to “On“.
4
y control value : The test is cancelled
when the adjusted drive signal (range: 0
to 9999 1/s) is exceeded. The
Minimum
value y control
(in TROVIS-VIEW 3 un-
der Display) can be used a guide value
for monitoring. The smallest drive signal
value determined during the last partial
stroke test is given under this parameter.
The condition is only active when
Activa-
tion y control
is set to "On".
Monitoring the drive signal y only makes
sense when the partial stroke test is per-
formed as a ramp function because the
y cancellation condition is always met
with the step change function.
4
ESD tolerance band : The test is cancelled
when the deviation of the valve position
exceeds the adjusted value (range: 0.1
to 100.0 %).
The condition is only active when
Activa-
tion tolerance band control
is set to
"On".
During the course of the test, the following
parameters are changed as specified:
4Lower x-range value (code 8): 0 %
4Upper x-range value (code 9): 100 %
4Lower/upper x-limit (codes 14/15): OFF
4Pressure limit (code 16): active pressure
limit increased by one stage
4Characteristic (code 20): linear
4w-ramp OPEN/CLOSED (codes 21/22):
variable
The data can be reset in the [Status mes-
sages] folder under Reset.
10 EB 8388-1 EN
ESD functions