Samson TROVIS SAFE 3730 Series User manual

Operating Instructions
EB 8389-1S EN
Firmware version 1.1x
Edition May 2015
Series 3730
TROVIS SAFE 3730-6 Electropneumatic
Positioner
EXPERTplus Valve Diagnostics

Denition of signal words
DANGER!
Hazardous situations which, if not
avoided, will result in death or serious
injury
WARNING!
Hazardous situations which, if not
avoided, could result in death or seri-
ous injury
NOTICE
Property damage message or mal-
function
Note:
Additional information
Tip:
Recommended action

2 EB 8389-1S EN

Contents
EB 8389-1S EN 3
1 Description....................................................................................................7
1.1 General ........................................................................................................7
1.2 Start-up .........................................................................................................9
1.3 Diagnostic functions .....................................................................................10
1.3.1 Type of application.......................................................................................11
1.3.2 Assessment .................................................................................................. 11
2 Monitoring..................................................................................................13
2.1 Status messages ...........................................................................................13
2.1.1 Resetting status messages .............................................................................13
2.1.2 Condensed state ..........................................................................................17
2.2 Logging .......................................................................................................18
3 Data logger ................................................................................................21
3.1 Permanent data logging ...............................................................................21
3.2 Triggered data logging ................................................................................. 22
3.2.1 Triggered by condensed state ........................................................................ 22
3.2.2 Triggered by set point, valve position, set point deviation or signal pressure ...... 23
3.2.3 Triggered by binary input .............................................................................24
3.2.4 Triggered by internal solenoid valve/forced venting ........................................25
3.2.5 Triggered by set point or internal solenoid valve/forced venting ....................... 25
4 Valve signature ...........................................................................................27
4.1 Reference graphs .........................................................................................28
4.1.1 Analysis and monitoring ............................................................................... 28
4.2 Valve signature, signal pressure(x) .................................................................29
4.2.1 Analysis and monitoring ............................................................................... 30
4.3 Course of supply pressure .............................................................................31
4.3.1 Analysis and monitoring ............................................................................... 32
4.4 Valve signature, friction(x) ............................................................................33
4.4.1 Analysis and monitoring ............................................................................... 34
4.5 Resetting single status messages ....................................................................34
5 On/off valve...............................................................................................37
5.1 Diagnostics for on/off valve .......................................................................... 38
5.2 Analysis and monitoring ............................................................................... 39
5.3 Resetting single status messages ....................................................................40

4 EB 8389-1S EN
6 Valve position x histogram ..........................................................................41
6.1 Analysis and monitoring ............................................................................... 42
6.2 Resetting single status messages ....................................................................42
7 Set point deviation e histogram....................................................................44
7.1 Analysis and monitoring ............................................................................... 45
7.2 Resetting single status messages ....................................................................46
8 Cycle counter histogram ..............................................................................49
8.1 Analysis and monitoring ............................................................................... 50
8.2 Resetting single status messages ....................................................................50
9 Leakage sensor ...........................................................................................53
9.1 Start-up of the leakage sensor ....................................................................... 54
9.1.1 Manufacturer reference ................................................................................54
9.1.2 Process reference .........................................................................................57
9.2 Short-term monitoring ..................................................................................62
9.2.3 Resetting single status messages ....................................................................63
9.3 Long-term monitoring ...................................................................................63
9.3.1 Resetting single status messages ....................................................................63
9.4 Sound level(x) ..............................................................................................64
9.4.2 Resetting single status messages ....................................................................64
10 Course of end position.................................................................................67
10.1 Analysis and monitoring ............................................................................... 68
10.2 Resetting single status messages ....................................................................68
11 Valve dead band.........................................................................................69
11.1 Resetting single status messages ....................................................................70
12 Partial stroke test (PST) ................................................................................73
12.1 Start triggered by the set point ......................................................................78
12.2 Start triggered by the binary input.................................................................78
12.3 Analysis and monitoring ............................................................................... 79
12.4 Resetting single status messages ....................................................................80
13 Full stroke test (FST) .....................................................................................83
13.1 Analysis and monitoring ............................................................................... 87
Contents

EB 8389-1S EN 5
13.2 Resetting single status messages ....................................................................87
14 SIL operator test ..........................................................................................88
14.1 Analysis and monitoring ............................................................................... 90
15 Binary input................................................................................................91
16 Dynamic HART® variables............................................................................93
17 Appendix....................................................................................................95
17.1 Code list ...................................................................................................... 95
17.2 Error messages and recommended corrective action .....................................102
17.3 Diagnostic data points saved in a non-volatile memory .................................107
17.4 Resetting parameters ..................................................................................108
Contents

6 EB 8389-1S EN
Overview
Throttling service On/off service
No conguration
required for
monitoring
Travel histogram
u Section 6
Set point deviation
histogram e
u Section 7
Cycle counter
histogram
u Section 8
Course of end
position
u Section 10
Conguration
required for
diagnosis
Data logger
u Section 3
Valve signature
u Section 4
Packing
u Section 8
Leakage sensor
u Section 9
Valve dead band
u Section 11
Full stroke test (FST)
u Section 13
No conguration
required for
monitoring
Travel histogram
u Section 6
Set point deviation
histogram e
u Section 7
Cycle counter
histogram
u Section 8
Course of end
position
u Section 10
Conguration
required for
diagnosis
Data logger
u Section 3
On/off diagnosis
u Section 5
Packing
u Section 8
Leakage sensor
u Section 9
Valve dead band
u Section 11
Partial stroke test
(PST)
u Section 12
Full stroke test (FST)
u Section 13
Note:
−Tests highlighted in red border require an initialization with valve signature
−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 8389-1S EN 7
Description
1 Description
1.1 General
These instructions supplement the standard
Mounting and Operating Instructions for the
TROVIS SAFE3730-6 Positioner
(uEB8384-6S 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 4/DD/DTM/
eDD
EXPERTplus allows the parameters to be
viewed or changed using the TROVIS-
VIEW4 software or DD/DTM/eDD.
TROVIS-VIEW4 · SAMSON operator inter-
face used to congure various SAMSON de-
vices
−DTM · Device type manager to describe
the device and communication properties
−DD/eDD · Device description/enhanced
device description
All the parameter settings that are changed
must also be downloaded onto the posi-
tioner to allow them to become effective.
Local operation
Some parameters can be changed at the po-
sitioner as well as over the operator interface.
The positioner code of these parameters are
written in parentheses. Refer to the Mounting
and Operating Instructions of the TROVIS
SAFE3730-6 Positioner (EB8384-6SEN) 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4. The default settings of the position-
er and TROVIS-VIEW4 are written in
square brackets [ ]. Settings highlighted in
gray refer to operation using TROVIS-
VIEW4.

8 EB 8389-1S EN
DescriptionDescription
START-UP
Initialization mode
âââ
MAX NOM MAN/MAN2
â
Initialization including valve
signature
Yes ß à No Later recording of
reference graphs
â
Operating mode = MAN
â â
Zero
Valve signature (D1)
Valve signature (D1)
All reference values are overwritten!
Code 81 Code 81
ß Not successful
ß Successful
ß Not successful
â
Operating mode = AUTO
Automatic change to
AUTO operating mode
àThrottling or on/off service ß

EB 8389-1S EN 9
Description
1.2 Start-up
The positioner must be initialized to use the
full scope of the valve diagnostics. During ini-
tialization the positioner adapts itself optimal-
ly 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), manual
setting 1 (MAN) and manual setting 2
(MAN2).
−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
−Manual setting 1 (MAN)
Initialization mode for globe valves re-
quiring OPEN position to be entered
manually
−Manual setting 2 (MAN2)
Initialization mode for globe valves re-
quiring the end positions (OPEN and
CLOSED positions) to be entered manu-
ally
The type of application, pressure limit and
the start-up parameters required for the se-
lected initialization must be entered to initial-
ize the positioner.
Note:
Positioner start-up is described in detail
in the associated Mounting and Oper-
ating Instructions ( uEB8384-6S EN ).
The monitoring of friction, supply pressure,
leakage, actuator springs, course of end po-
sition and zero point shift requires additional
reference tests of the valve signature to be
performed. Refer to Section 4. The reference
tests required for the diagnostic functions
cannot be performed if the positioner has
been initialized in the substitute calibration
(SUB) mode. By setting 'Initialization includ-
ing valve signature' = Yes, the positioner re-
cords the reference data automatically after
initialization.
Start-up
−Type of application (Code 49 - h0): Control
valve, [On/off valve]
−Initialization mode (Code 6): [Maximum
range(MAX)], Nominal range (NOM), Manual
setting 1 (MAN) or Manual setting 2 (MAN2)
−Initialization including valve signature
(Code 48 - h0): [Yes]
−Pin position (Code 4): [Off], 17, 25, 35, 50,
70, 100, 200 mm, 90°
−Pressure limit (Code 16): 1.4 to [7.0] bar
During positioner initialization, the 'Kp level'
and 'Tv level' are optimally set. If the posi-
tioner tends to overshoot impermissibly due
to other disturbances, the proportional-ac-
tion coefcient (Kp level) and derivative-ac-
tion time (Tv level) can be adapted accord-
ingly. Increment the derivative-action time
until the desired behavior is reached. When
the maximum value of 4 is reached for the
derivative-action time, the proportional-ac-
tion coefcient can be reduced in steps.


10 EB 8389-1S EN
Description
NOTICE
Kp level changes affect the set point
deviation.
After changing the proportional-action coef-
cient 'Kp level', we recommend to recali-
brate the ne lter in the positioner. Use the
'Fine-tuning after Kp change' function for
this.
Start-up > Control parameters
−Proportional-action coefcient Kp level
(Code 17): 0 to 17, [7]
−Derivative-action time Tv level (Code 18): Off, 1
to 4, [2]
−Fine-tuning after Kp change
1.3 Diagnostic functions
There are two different types of diagnostic
functions:
1. Monitoring functions
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.
2. Dynamic tests
Similar to the monitoring function, data
are compiled, saved and analyzed by
the positioner. However, in this case, the
valve position is not determined by the
set point, but by the settings of the test.
The dynamic 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, the
dynamic tests, except for partial stroke
testing, can only be performed in the
MAN operating mode.
A dynamic 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.

EB 8389-1S EN 11
Description
1.3.1 Type of application
Different diagnostic functions are available
depending on the type of application select-
ed in EXPERTplus. The types of application
'Control valve' and 'On/off valve' are
available. Depending on the type of applica-
tion selected, the positioner behaves differ-
ently in the automatic mode (AUTO):
−Control valve
The positioner uses the set point to posi-
tion the valve.
The valve position (current position) ap-
pears in % on the display.
−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 5.
1.3.2 Assessment
Table 1 shows the diagnostic functions and
their statements on the condition of the valve
depending on the type of application.

12 EB 8389-1S EN
Description
Table 1: Diagnostic functions and test analysis
Diagnostic functions
Control
valve
On/off
valve Assessment See section
Monitoring
Data logger • • Depending on trigger status
selected
u 3 on page 21
Valve signature •U −Change in friction
−Supply pressure
−Defective actuator springs
−Pneumatic leakage
u 4 on page 27
On/off valve – • −Breakaway time
−Transit time
−Valve end position
u 5 on page 37
Valve position
histogram
•U −Change in manipulated variable
range
−Manipulated variable range
u 6 on page 41
Set point deviation
histogram
• • −Manipulated variable range
limitation
−Seat leakage
−Positioner-valve linkage
−Average set point deviation
u 7 on page 44
Cycle counter
histogram
• • −Packing leakage
−Dynamic stress factor
u 8 on page 49
Leakage sensor • • −Seat leakage u 9 on page 53
Course of end
position
• • −Course of end position
−Zero shift
u 10 on page 67
Dynamic tests
Valve dead band • • −Dead band u 11 on page 69
Partial stroke test
(PST)
• • −Overshooting
−Dead time
−T86
−Settling time
u 12 on page 73
Full stroke test (FST) • • −Overshooting
−Dead time
−T86
−Settling time
u
13 on page 83
• Full scope of functions
U Function is performed, but not analyzed
– Function is not performed
Description

EB 8389-1S EN 13
Monitoring
2 Monitoring
2.1 Status messages
The valve diagnostics integrated into the po-
sitioner generates classied status messages.
Messages generated from the analysis of the
diagnosis can be classied according to the
possible causes. See u Section 4 to 13.
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 request/maintenance re-
quired
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
The positioner is running outside the
specied operating conditions.
−Failure
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 suc-
cessfully completed.
You can view these messages in TROVIS-
VIEW4 in the Diagnostics folder (> Monitor-
ing) and its subfolders. The 'Positioner sta-
tus', 'Valve status', 'Actuator status' and
'Valve position status' messages provide a
condensed state of the status messages of
each subfolder.
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 see u Section 17.2.
Status messages can be reset individually or
using the reset function. Table 2 on page
15 contains an overview on how the di-
agnosis can be reset. Resetting is performed
in the Diagnostics folder (> Service/mainte-
nance > 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 8384-6S EN.
−On resetting histograms and diagrams,
the data for short-term monitoring are
also reset.

14 EB 8389-1S EN
Monitoring
−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.
Reset measured diagnostic data
Code 36 - Diag
−Parameters are reset as described in u
Section 17.4.
−Resets diagnostics assessment.
−Reference values remain unchanged.
−Status classication and data logs re-
main saved.
−The positioner does not need to be re-ini-
tialized after resetting.
−If the diagnostic data are to be reset at
regular intervals, enter the time in "De-
sired time until ‘Reset measured diagnos-
tic data" (Code 48 - h3). The setting
"00:00:00" causes the resetting at regu-
lar intervals to be deactivated.
Reset start-up parameters
Code 36 - Std
−Parameters are reset as described in
u Section 17.4.
−Resets diagnostics assessment.
−Reference values are deleted.
−Status classication remains unchanged.
−Data logs are reset.
−The positioner must be re-initialized after
resetting.
Reset to default settings
Code 36 - DS
−Parameters are reset as described in
u Section 17.4.
−Resets diagnostics assessment.
−Reference values are deleted.
−Status classication and data logs are
deleted.
−The positioner must be re-initialized after
resetting.
Note:
Before mounting the positioner on a
new control valve, perform a reset by
selecting the command 'Reset to de-
fault settings' (Code 36 - DS) and re-
initialize the positioner.


EB 8389-1S EN 15
Monitoring
Table 2: Resetting the diagnosis
Resetting
single status
messages
Code 36
Diag Std DS
Reference
graphs
Valve signature NO NO YES YES
Leakage sensor Manufacturer reference YES NO YES YES
Process reference YES NO YES YES
Data logger Conguration and measured values NO YES YES YES
Valve signature Signal pressure(x) Measured values YES YES YES YES
Course of supply pressure Conguration NO NO YES YES
Measured values YES YES YES YES
Friction(x) Measured values YES YES YES YES
On/off valve Conguration YES NO YES YES
Measured values YES YES YES YES
Valve position x histogram Measured values YES YES YES YES
Short-term monitoring 'Sampling time' and
measured values
YES YES YES YES
Set point deviation e histogram Measured values YES YES YES YES
Short-term monitoring 'Sampling time' and
measured values
YES YES YES YES
Cycle counter histogram Measured values YES YES YES YES
Short-term monitoring Measured values YES YES YES YES
Leakage sensor Short-term monitoring 'Sensitivity sound level'
and measured values
YES YES YES YES
Long-term monitoring Measured values YES YES YES YES
Sound level(x) Measured values YES YES YES YES
Course of lower end position Measured values YES YES YES YES
Reference value YES NO YES YES
Valve dead band Conguration and
measured values YES YES YES YES
Partial stroke test (PST) Conguration and
measured values YES NO* YES YES
* Except for 'Sampling time' parameter
Monitoring

16 EB 8389-1S EN
Monitoring
Resetting
single status
messages
Code 36
Diag Std DS
Full stroke test (FST) Conguration and
measured values YES NO* YES YES
* Except for 'Sampling time' and 'Max. test duration' parameters
Alarm settings NO See uSec.17.4
Status classication according to NAMUR107 NO NO NO YES
All logged messages, see u Section 2.2 YES NO YES YES
Operating hours counter NO NO NO NO
Device in operation NO NO YES YES
Device switched on since initialization NO NO YES YES
Device in operation since initialization NO NO YES YES

EB 8389-1S EN 17
Monitoring
2.1.2 Condensed state
To provide a better overview on the condi-
tion of the positioner, all status messages are
summarized in a condensed state which is
made up from a summary of all classied
messages in the positioner. The status mes-
sage with the highest priority determines
which condensed state is set.
The condensed state appears in TROVIS-
VIEW4 on the right-hand side of the info
bar and in the Measured process values
folder. See u Table 3 for a description of the
icons and their meaning.
Additionally, the condensed state can be
used to trigger the data logger. See uSec-
tion 3.2.1.
Note:
The condensed state is marked by
until the positioner data have been up-
loaded.

The condensed state can be read in the posi-
tioner display in Code 48 - d6. See u Table
3.
Condensed state at the fault alarm output
The condensed state also be read out at the
fault alarm output if one of the following
conditions occurs:
1. Condensed state 'Failure' is activated.
2. Condensed state 'Function check' is acti-
vated and the fault alarm output is acti-
vated.
3. Condensed state 'Maintenance required'
or 'Out of specication' is activated and
the fault alarm output is activated.
Table 3: Condensed state reading
Status message TROVIS-VIEW 4/DTM Positioner Priority
Failure red
Function check orange Text e.g. TESTING, TUNE or
TEST
Out of specication yellow blinking
Maintenance request/
maintenance required blue
No message, OK green

18 EB 8389-1S EN
Monitoring
2.
Device settings > Alarm settings
−Fault alarm at condensed state 'Function
check' (Code 32): Yes
3. −Error message in case of 'Maintenance re-
quired' and 'Out of specication' con-
densed states (Code 33): Yes
2.2 Logging
The last 30 generated messages are saved in
the positioner with a time-stamp (logged by
the operating hours counter) and with details
on how long the message exists.
You can view these messages in TROVIS-
VIEW4 in the Diagnostics folder (> Monitor-
ing > Logging).
Logging starts automatically 15 minutes after
initialization. It does not need to be activated
by the user.
Messages are logged when:
−Their status classication is not 'No mes-
sage'.
−Their recording in the logging is activat-
ed.
−The 'Internal solenoid valve/forced vent-
ing/supply pressure' message is only ad-
ditionally logged when the time entered
in 'Min. interval for new logging of inter-
nal solenoid valve' has elapsed between
the generation of two 'Internal solenoid
valve/forced venting/supply pressure'
messages.
Note:
Logging can only be deactivated when
the associated status classication is
set to 'No message'.
Device settings > Alarm settings > Status
classication > Logging
−Supply pressure: [Yes], No
−Change in friction: [Yes], No
−Seat leakage: [Yes], No
−Packing leakage: [Yes], No
−Pneumatic leakage: [Yes], No
−Defective actuator springs: [Yes], No
−Manipulated variable range limitation: [Yes],
No
−Course of end position: [Yes], No
−Positioner-valve linkage: [Yes], No
−Manipulated variable range: [Yes], No
−Change in manipulated variable range: [Yes],
No
−Partial stroke test (PST) [Yes], No
−Full stroke test (FST): [Yes], No
−On/off valve: [Yes], No
−Code 50-58, 61, 63, 76, 81: [Yes], No
−Binary input: [Yes], No
−Data logger: [Yes], No
−Internal solenoid valve/forced venting/supply
pressure: [Yes], No
−Min. interval for new logging of internal
solenoid valve: 0 to 5000 s, [300 s]


EB 8389-1S EN 19
Monitoring
The following messages are not logged if
they are generated due to a hardware error:
−Packing leakage
−Pneumatic leakage
−Manipulated variable range limitation
−Course of end position
−Positioner-valve linkage
−Manipulated variable range
−Change in manipulated variable range
In this case, only the original hardware error
is logged:
−x > range (Code 50)
−Internal solenoid valve/forced venting/
supply pressure (Code 54)
−Transit time not reached (Code55)
−Inconsistent data memory (Code 59)
−Internal device error (Code 60)
−x signal (Code 62)
−i/p converter (Code 64)
−Hardware (Code 65)

20 EB 8389-1S EN
Monitoring
START-UP
Function
â â
Permanent Triggered
â â
Sampling time Triggered by
â
Start
1)
â â â â â
Con-
densed
state
w, x, e
or p
out
BE
Solenoid
valve/
forced
venting
w or solenoid
valve/forced
venting
â â â
Trigger condition
Trigger value
Trigger band
Trigger condition
Trigger value
Trigger band
Trigger condition
â
â
Trigger lead time
Sampling time
100 measured val-
ues
(w, x, e, p
out
)â
Start
1)
PROCESS
â
Trigger event
â
Logged by operating hours
counter
â â
Measured values (w, x, e, pout) before trigger
event
(Number = Trigger lead/Sampling time)
+Measured values (w, x, e, pout) after trigger event
(Number = 100 – Trigger lead/Sampling time)
â
Total 100 measured values (w, x, e, pout)
1)
The data logger is started by the software, e.g. TROVIS-VIEW 4
Data logger