Samson 373 Series Bedienungsanleitung

Series 373x Positioners

EXPERT+Valve Diagnostics

Operating Instructions

EB 8388 EN

Firmware version 1.4x

Edition November 2006

Fig. 1 · Valve diagnostics with SAMSON TROVIS-VIEW Operator Interface, e.g. for Type 3730-3 Positioner

Contents Page

1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Diagnostic tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 Activating EXPERT+. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.4 Actuator and valve specification data . . . . . . . . . . . . . . . . . . 5

1.5 Start the reference test . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 SUb initialization mode, double-acting actuator and booster . . . . . . . 6

1.7 Activation, analysis and presentation of diagnostic data . . . . . . . . . 7

1.7.1 Printing the diagnostic/ESD log . . . . . . . . . . . . . . . . . . . . . 8

2 Statistical information AUTO . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Data logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Travel histogram . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Setpoint deviation histogram. . . . . . . . . . . . . . . . . . . . . . 12

2.4 Cycle counter histogram . . . . . . . . . . . . . . . . . . . . . . . . 13

2.5 Drive signal diagram . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.5.1 Steady-state drive signal. . . . . . . . . . . . . . . . . . . . . . . . 15

2.5.2 Hysteresis test (d5) . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.6 End position trend. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3 Tests MAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Drive signal diagram steady-state (d1) . . . . . . . . . . . . . . . . . 22

3.2 Drive signal diagram hysteresis (d2) . . . . . . . . . . . . . . . . . . 23

3.3 Static characteristic (d3) . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 Step response (d4) . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 Status and diagnostic alarms . . . . . . . . . . . . . . . . . . . . . 28

4.1 Standard EXPERT diagnostic alarms . . . . . . . . . . . . . . . . . . 28

4.2 Extended EXPERT+diagnostic alarms . . . . . . . . . . . . . . . . . . 28

4.3 Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Classification of the status alarms . . . . . . . . . . . . . . . . . . . 29

4.5 Condensed state . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.6 Status modification . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5 Resetting diagnostic parameters. . . . . . . . . . . . . . . . . . . . 31

6 Diagnostic parameters saved in non-volatile memory . . . . . . . . . 34

7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8 EXPERT+without TROVIS-VIEW . . . . . . . . . . . . . . . . . . . . 38

2EB 8388 EN

Contents

1 Description

1.1 General

These instructions EB 8388 EN supplement

the standard mounting and operating in-

structions of the positioners:

Type Standard EB

3730-2 EB 8384-2 EN

3730-3 EB 8384-3 EN

3730-4 EB 8384-4 EN

3730-5 EB 8384-5 EN

3731-3 EB 8387-3 EN

EXPERT+is an optional diagnostic firmware

integrated in the positioner which allows the

predictive, status-oriented maintenance of

pneumatic control valves. Refer to section

1.3 on how to activate this option.

EXPERT+upgrades the standard EXPERT di-

agnostics firmware incorporated in the

positioner. The upgraded version provides

extended functions to pinpoint valve param-

eters that have worsened, allowing the user

to plan predictive maintenance and service

work before malfunctions can affect the pro-

cess, causing unscheduled plant shutdowns.

EXPERT+records the valve faults in auto-

matic mode while the process is running

and issues alarms on the required mainte-

nance work. In addition, numerous tests can

be performed in manual mode to pinpoint

emerging faults.

Owing to the numerous diagnostic tests,

EXPERT+is able to generate classified status

alarms on the state of the control valve.

The EXPERT+diagnostics are completely in-

tegrated in the positioner. Data required for

diagnostics are compiled automatically and

the test data are analyzed in automatic or

manual mode in the positioner itself. The re-

sulting data are used to issue classified sta-

tus alarms.

The diagnostics data, results and status

alarms are available over the DD (Device

Description). All the necessary reference

graphs are automatically plotted after the

positioner has been initialized and are

available when required.

After performing the basic settings at the

positioner using the rotary pushbutton, the

TROVIS-VIEW3 or DTM software allow the

parameters to be viewed and set

conveniently.

Type Integration

3730-2 TROVIS-VIEW3

373x-3 TROVIS-VIEW3, DD, DTM

3730-4 TROVIS-VIEW3, DD, DTM

3730-5 TROVIS-VIEW3, DD

The following sections contain a description

on how to operate the diagnostics over the

TROVIS-VIEW3 software.

Note!

All the parameter settings that are changed

over the operator interface must also be

downloaded onto the positioner to allow

them to become effective.

EB 8388 EN 3

Description

Note!

The optional integrated solenoid valve is

implemented by a forced venting function in

Types 3731-x Positioners.

1.2 Diagnostic tests

There are two main groups of diagnostic

tests available.

Statistical information AUTO

These tests are performed while the process

is running (automatic mode) without disrupt-

ing the process.

Activated tests are automatically performed

when they are triggered by their start condi-

tion (e.g. data logger and drive signal dia-

gram hysteresis).

Other tests are already performed in the

background without being activated (e.g.

histograms, cycle counter, drive signal

steady-state and end position trending).

Tests MAN

These tests should not be performed while

the process is running (i.e. in manual mode

instead) as the positioner cannot follow the

reference variable at the same time.

The valve is moved to a certain position de-

fined by the test settings and the valve may

move through its full range.

1.3 Activating EXPERT+

The extended EXPERT+diagnostics can be

activated later at the positioner when

EXPERT+is not already activated on delivery

of the positioner.

The required activation code can be ordered

(order number 1400-9318). On ordering

this option, specify the serial number of the

positioner (see nameplate or in the soft-

ware).

To activate EXPERT+, proceed as follows:

Enable configuration at the positioner:

Turn →Code

, press ,

turn →

, press .

After enabling configuration:

Turn →Code

, press

Code

blinks.

Turn to select

, press ,

turn to select

d8, press .

blinks

Turn and set the activation code XXXX.

Press to confirm the entered code.

4EB 8388 EN

Description

After the activation has been successfully

completed,

YES

appears on the display.

Note!

On entering the wrong activation code, the

display returns to Code 0. The activation of

EXPERT

has been unsuccessful.

After an incorrect activation code has been

entered three times, Err appears on the

display after selecting Code 48 and d8. An

activation code can only be entered again

after the positioner has been reset to its

default settings (Code 36).

1.4 Actuator and valve

specification data

To correctly analyze the diagnostic data,

several actuator and valve specifications

need to be entered for the EXPERT+diagnos-

tics.

Enter the required data in the

Identification

folder (>

Positioner > Actuator

) as well as

Positioner > Valve

Download the data to the positioner.

The

Model

and

Booster

parameters in the

Actuator

folder and

Stuffing box

parameter

in the

Valve

folder need to be entered.

The default settings of these parameters are:

Model

> Single-acting

Booster

> Not present

Stuffing box

> Self-adjustable

These parameters do not need to be

changed if the control valve also has these

default settings.

1.5 Start the reference test

After EXPERT+has been activated properly,

the reference graphs for future diagnostic

purposes need to be plotted to allow the di-

agnostics to function in their full scope.

The reference graphs are plotted automati-

cally after the positioner has been initialized

when the EXPERT+has been activated (e.g.

already on delivery).

On activating EXPERT+at later time, the ref-

erence graphs are plotted after the

positioner is re-initialized.

If reference graph plotting is to be started sep-

arately in an initialized positioner or if graphs

are to be replotted, proceed as follows:

Set the positioner to manual mode:

Turn →Code

, press ,

Code

blinks.

Turn →

MAN

, press , the positioner

moves to manual mode.

Manual operating mode

You can activate the reference test either by

selecting the

Diagnosis

folder (>

Start refer-

EB 8388 EN 5

Description

ence test

) and right-click the parameter to

select

Execute

, or, alternatively, start the ref-

erence test at the positioner itself by select-

ing Code

as follows:

Enable configuration at the positioner:

Turn →Code

turn →

, press .

After enabling configuration:

Turn →Code

, press

Code

blinks.

Turn until

appears, press ,

turn to select

d7, press .

blinks.

Turn →

press to start the reference test.

Caution!

The control valve moves through its travel

range during the reference test.

The tests

(drive signal diagram

steady-state) and

(drive signal diagram

hysteresis) are performed during the diag-

nostic reference test.

During the reference test,

tESt

and

appear in alternating sequence on the

positioner display.

The measured data are used as reference

data and any existing reference graphs are

overwritten.

If the reference graphs could not be plotted

correctly or are incomplete, Code 81 is is-

sued and saved in a non-volatile memory.

The positioner can function properly after it

has been initialized successfully without the

reference data.

1.6 SUb initialization mode,

double-acting actuator and

booster

The following points need to be observed

when the positioner is initialized in

SUb

mode or when a double-acting actuator

and/or booster is used:

Positioner initialization in SUb mode:

4Analysis in automatic or manual mode is

deactivated.

4All tests for both statistical information

AUTO and tests MAN of drive signal di-

agrams steady-state and hysteresis are

inactive.

4The reference test is inactive.

4The automatic test to start all tests MAN

is inactive.

Double-acting actuator with reversing

amplifier:

4All tests for both statistical information

AUTO and tests MAN of drive signal

diagrams steady-state and hysteresis are

inactive.

4The reference test is inactive.

6EB 8388 EN

Description

Booster:

4The analysis of the tests for both statisti-

cal information AUTO and tests MAN of

drive signal diagrams is inactive.

1.7 Activation, analysis and

presentation of diagnostic

data

All diagnostic tests which do not compile

data automatically in the background (data

logger, drive signal diagram hysteresis)

must be activated to start them.

To start these tests, select the corresponding

test order (>

Start data logger

Start test

)

and right-click the parameter to select

Exe-

cute

to activate the test.

Note!

The tests in statistical information AUTO in

automatic mode can only be activated when

the positioner is in automatic operating

mode.

To activate the tests MAN in manual mode,

the positioner must first be set to manual

mode over Code 0.

Canceling diagnostic tests

There are two ways to cancel an active test:

4On the TROVIS-VIEW operator interface,

select the corresponding folder (>

Stop

test

) to cancel the test. The positioner

then moves to the previously set operat-

ing mode and to the travel value previ-

ously set (manual mode) or returns to the

reference variable (automatic mode).

4Press once to cancel the tests MAN

(drive signal diagram steady-state)

(drive signal diagram hysteresis)

(static characteristic)

(step response),

and the test in statistical information

AUTO

(drive signal diagram hysteresis)

as well as the reference test over

Code

On canceling a test (d1 to d4), the

positioner moves to the fail-safe position.

The positioner only goes into automatic

mode on canceling test

The reference graphs must be plotted before

the tests for drive signal diagrams

steady-state and hysteresis in manual mode

can be analyzed.

Note!

The analysis of raw data in automatic mode

is started after the positioner has been in

controlled operation for over one hour (after

initialization).

This does not apply to the end position trend

test and the dynamic stress factor in the

cycle counter histogram as their analysis

starts directly after controlled operation

begins.

Alarms generated from the tests MAN are

marked

TEST

If the electrical auxiliary power is too low,

the test being performed is ended and the

positioner moves to the fail-safe position.

Upon failure of the auxiliary power, tests in

tests MAN and statistical information AUTO

must be restarted due reasons of safety.

EB 8388 EN 7

Description

However, the test in statistical information

AUTO drive signal diagram hysteresis re-

mains activated.

In the event that the solenoid valve

(Type 3730-x) is triggered or the forced

venting function (Type 3731-x) is activated,

active tests are stopped and the positioner

moves to the fail-safe position.

However, the test in statistical information

AUTO drive signal diagram hysteresis re-

mains activated.

In the event that the solenoid valve

(Type 3730-x) is triggered or the forced

venting function (Type 3731-x) is activated,

active tests are stopped and the positioner

moves to the fail-safe position.

1.7.1 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.

8EB 8388 EN

Description

2 Statistical information AUTO

The signals x, w and y need to be analyzed

on a more precise basis to obtain advanced

diagnostic information also over the valve,

actuator and pneumatic air supply. The

positioner compiles raw data for this pur-

pose.

The signals are plotted, stored and analyzed

while the process is running. In addition, an

additional underlayed hysteresis test detects

any changes in friction.

The diagnostic tests do not have any affect

on the positioner’s control performance.

2.1 Data logger

The data logger allows the reference vari-

able w, controlled variable x in relation to

the working range, drive signal y and

setpoint deviation e to be plotted over time.

The measured data are saved in an FIFO

memory with a capacity to save 100 data

points in the positioner.

In addition to the permanent plotting of

data, the plotting can be automatically trig-

gered when a start condition is fulfilled. The

travel condition (setpoint) or the optional in-

tegrated solenoid valve (optional integrated

forced venting) can be used to trigger the

data logger.

The data logger is completely integrated into

the positioner.

The software is only necessary for activation

and to set the parameters.

In addition, the measured data can be

viewed as a graph or in a list by selecting

Upload from Device

in the

Device

menu or

by clicking on the device toolbar.

Note! Upon disconnection of the auxiliary

power or upon changing the operating

mode, the test is inactive and must be reacti-

vated.

Data logging

Select

Data logger

folder (>

Selection

) and

select

Permanent

Trigger

and set the

Scan

rate

parameter. Right-click the

Start data

EB 8388 EN 9

Statistical information AUTO

Fig. 2 · Statistical information AUTO

logger

parameter and select

Execute

to start

data logging.

Permanent data logging

The variables w, x, y, and e are logged ac-

cording to the adjusted scan rate and saved

in the FIFO memory which always stores the

last 100 measured data points of each vari-

able.

Triggered data logging

On selecting

Trigger

in the

Selection

param-

eter, the data logger records the measured

data permanently in the background. A trig-

gering event leads to the last 100 measured

data points being stored together with the

pretrigger time and leads to the data log-

ging of the triggering condition.

The following parameters can be changed

for this function:

4Trigger status:

Triggered by the travel condition

(setpoint) and/or solenoid valve condi-

tion (forced venting)

4Start value:

Limit indicating from which travel condi-

tion (setpoint) the data logger should be

triggered

4Logging limit:

Indicating whether data logging should

start when the travel condition (setpoint)

exceeds or falls below the start value.

Travel condition (setpoint)

Note!

The valve position is used as the travel

condition in positioners in ESD version.

Select

Trigger status

parameter and select

Start trigger via travel condition (setpoint)

Activate data logging by selecting

Start data

10 EB 8388 EN

Statistical information AUTO

Fig. 3 · Data logger

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