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.