Samson TROVIS SAFE 3731 Series Operating Instructions Manual Download Page 1

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Operating Instructions

EB 8389S EN

Firmware version 1.6x
Edition May 2015

Series 3731
TROVIS SAFE 3731-3 Electropneumatic

Positioner

EXPERTplus Valve Diagnostics

Summary of Contents for TROVIS SAFE 3731 Series

Page 1: ...Operating Instructions EB 8389S EN Firmware version 1 6x Edition May 2015 Series 3731 TROVIS SAFE 3731 3 Electropneumatic Positioner EXPERTplus Valve Diagnostics...

Page 2: ...h if not avoided will result in death or seri ous injury WARNING Hazardous situations which if not avoided could result in death or se rious injury NOTICE Property damage message or mal function Note...

Page 3: ...sis and monitoring 23 3 1 3 Resetting single status messages 23 3 2 Data logger 25 3 2 1 Permanent data logging 25 3 2 2 Triggered data logging 26 3 3 Travel histogram 30 3 3 1 Analysis and monitoring...

Page 4: ...atic characteristic 62 4 3 1 Resetting single status messages 63 4 4 Partial stroke test PST 65 4 4 1 Start triggered by the set point 70 4 4 2 Start triggered by the binary input 70 4 4 3 Analysis an...

Page 5: ...EB 8389S EN 5...

Page 6: ...ction 4 5 T No configuration required for monitoring Travel histogram u Section 3 3 S Set point deviation histogram u Section 3 4 S Cycle counter histogram u Section 3 5 S Trend of travel end position...

Page 7: ...plus allows the parameters to be viewed or changed using the TROVIS VIEW software version 3 or 4 or DD DTM eDD TROVIS VIEW 3 and 4 Operator inter face used to configure various SAMSON devices and defi...

Page 8: ...teady state d1 Reference of drive signal diagram hysteresis d2 Reference of drive signal diagram steady state d1 Reference of drive signal diagram hysteresis d2 All reference values are overwritten Co...

Page 9: ...ed in de tail in the mounting and operating in structions see u EB 8384 3S EN During positioner initialization the propor tional action coefficient Kp and deriva tive action time Tv levels are optimal...

Page 10: ...itten and the di agnostic data to be deleted If the reference data could not be recorded correctly or are incom plete Code 48 h1 is generated in the positioner If the Initializa tion with reference te...

Page 11: ...l signal falls below a certain level or when the solenoid valve is triggered or the forced venting func tion is activated 1 3 1 Application type Different diagnostic functions are available depending...

Page 12: ...0 Set point deviation histogram Limit working range Connection positioner valve Inner seat leakage Average set point deviation 3 4 page 33 Cycle counter histogram Stuffing box external leakage Dynamic...

Page 13: ...springs 4 1 page 55 Drive signal dia gram hysteresis Friction 4 2 page 59 Static character istic Dead band 4 3 page 62 Partial stroke test PST Overshooting Dead time T63 T89 Rise time Settling time 4...

Page 14: ...state and temperature Settings Positioner Error control In formation on total valve travel with con figurable limits Positioner Start up Initialization List of initialization errors which are also Re...

Page 15: ...messages in the Di agnosis folder Status messages as well as in the Diagnosis folder Status messag es Extended 2 1 1 Resetting status messages When a status message is generated you should first loca...

Page 16: ...vals enter the time in Required time Reset diagnosis The setting 00 00 00 or 0 causes the resetting at regular intervals to be deactivated Operation Reset Reset diagnosis Code 36 Diag Required time Re...

Page 17: ...x YES YES YES Short term monitoring YES YES YES Set point deviation histogram e YES YES YES Short term monitoring YES YES YES Cycle counter histogram YES YES YES Short term monitoring YES YES YES Driv...

Page 18: ...ut In positioners with a fault alarm output the condensed state can also be read out at the fault alarm output if one of the following conditions occurs 1 Condensed state Maintenance alarm is activate...

Page 19: ...osition x drive signal y and set point devi ation e even while the process is running to obtain information on the valve actuator and pneumatic air supply The data com piled while the process is runni...

Page 20: ...or partial stroke test see u Section 4 4 On off diagnosis Discrete set point analysis PST x w t s t 6 s 25 50 x w t s First analysis after defining parameters Reference PROCESS Breakaway time tran sit...

Page 21: ...ds Limit op erating point the valve moves to the Oper ating point The valve moves back to the fail safe position 0 in the example if the set point then falls below Limit fail safe posi tion Operating...

Page 22: ...afe position Code 49 h2 0 0 to 20 0 12 5 Limit operating point Code 49 h5 55 0 to 100 0 75 0 3 Diagnosis Tests Partial stroke test See u Section 4 4 3 1 1 On off diagnosis 3730 2 3730 3 3731 3 3730 4...

Page 23: ...amount entered in Limit value time analysis The current Valve end position rising differs from the reference value by the amount entered in Limit value travel analysis The current Valve end position f...

Page 24: ...FV w or SV FV BE Trigger value Trigger band Trigger edge Trigger value Trigger band Trigger edge 100 values w x e y Pre trigger time Scan rate Start PROCESS Trigger event Logged by operating hours co...

Page 25: ...p ply of the positioner Failure of power supply of the ex ternal solenoid valve 3 2 1 Permanent data logging The measured variables are logged at the rate defined in Scan rate and saved in a circular...

Page 26: ...time selected being included in the 100 measured values per measured variable The Pre trigger time may include the value 100 x Scan rate at the maximum Defining parameters 1 Select Trigger Selection 2...

Page 27: ...dge High signal rising edge top band exit Top band limit Trigger value trigger band Trigger value Trigger band w x y e The conditions for starting a trigger event are met when the value exceeds the li...

Page 28: ...Scan rate 0 2 to 3600 0 s 1 0 s 4 Start data logger 3 2 2 3 Triggered by internal sole noid valve forced venting Triggering by the internal solenoid valve forced venting is only active when an inter n...

Page 29: ...edge top band exit Band exit Band entry 3 Scan rate 0 2 to 3600 0 s 1 0 s 4 Start data logger 3 2 2 5 Triggered by binary input Positioners can be optionally fitted with a bi nary input Triggering by...

Page 30: ...every 24 hours in the positioner Short term monitoring In order to be able to recognize any short term changes in valve position the position er records the valve positions according to the adjusted...

Page 31: ...rates the Working range message with the selected status classification For analysis of the short term monitoring a complete set of data 100 measured values is required The positioner generates the Sh...

Page 32: ...nd Reset Travel histogram x This command resets all diagnostic parameters and measured data of the histogram and the short term monitor ing By selecting and executing the command Reset Travel histogra...

Page 33: ...oint devia tion indicates the largest set point devia tion measured during the observation period The measured data are saved every 24 hours in the positioner Short term monitoring In order to be able...

Page 34: ...follow ing in quick succession pinpoint to a limita tion of the lower working range or to seat leakage In this case the positioner gener ates the Limit working range and Inner leakage messages with t...

Page 35: ...g and executing the command Set point deviation histogram e short term By selecting and executing the Reset Set point deviation histogram e command all diagnostic parameters and measured data of the h...

Page 36: ...rhaps soon expected PROCESS Determining the cycle spans t s x 1 2 3 4 Determining the cycle height t s x 1 2 3 4 Dynamic stress factor Dynamic stress factor Dynamic stress factor 90 Dynamic stress fac...

Page 37: ...when the Stuffing box stem seal setting is set to Bellows seal The valve stroke between these two changes in direction is the cycle height The cycle spans or cycle heights are as signed to classes Th...

Page 38: ...s directly af ter the change to manual or automatic mode The load on the bellows and or packing can be read from the Dynamic stress factor pa rameter The value is determined from the cy cle spans or c...

Page 39: ...the Reset Cycle counter histogram command all diagnostic parameters and measured data of the histo gram and the short term monitoring as well as the Dynamic stress factor are reset By selecting and ex...

Page 40: ...r springs Leakage pneumatics Perhaps modified not enough Working at full capacity Perhaps too large existing PROCESS Working at full capacity Status classification NE 107 logged by operating hours cou...

Page 41: ...ly pressure pneumatics or actuator springs Data are recorded in the background re gardless of the operating mode selected Da ta logging does not need to be activated The positioner records the valve p...

Page 42: ...ed values The last ten recorded values of each variable are listed in the Drive signal y folder and the Valve position x folder Requirements 1 A single acting actuator is mounted on the valve 2 No boo...

Page 43: ...downwards with a smaller gradient than in the reference graph pinpointing to a reduced spring force in a fail close control valve The po sitioner generates the Actuator springs message with the select...

Page 44: ...diately User defined Min time distance from test Cancelation condition Tolerance band of hysteresis Status classification NE 107 Friction PROCESS Much higher lower over whole range Much higher lower o...

Page 45: ...friction forces Data are recorded after the hysteresis test is activated A single test can be performed im mediately or regular tests can be performed after the adjusted time interval has elapsed The...

Page 46: ...e working range the position er indicates Test at operating point not possible Test information Short term monitoring To provide a short term trend the last ten valve positions x and the associated ch...

Page 47: ...change in set point w it is reactivated after waiting 60 seconds using the new oper ating point The test is started again ten times at the maximum The time between tests is in creased by 30 seconds e...

Page 48: ...EN Statistical information short term the measured data in the Short term folder are reset Diagnosis Status messages Reset Reset Drive signal diagram hysteresis Reset Drive signal diagram hysteresis...

Page 49: ......

Page 50: ...eted u Section 1 2 1 NO YES First zero point Reference Subsequent zero calibration over Code 6 ZP Zero calibration ZP shift monotone down up average above below reference NP alternate above below refe...

Page 51: ...e drive signal y together with the time stamp by the operating hours counter when the valve moves to the lower end position The new recorded valve posi tion is compared to the last saved zero point If...

Page 52: ...Zero point shift monotone up average below reference Zero point alternate average below reference 3 8 1 Analysis and monitoring Analysis of the histogram starts directly af ter the change to manual or...

Page 53: ...formed Therefore it is im portant to check before starting a test whether the conditions in the plant or process allow the valve to move through its working range The tests provide a trend showing the...

Page 54: ...st Reference Start test Test analysis Air supply Perhaps modified Perhaps not enough Working at full capacity Actuator springs Perhaps spring stiffness reduced bias reduced Working at full capaci ty P...

Page 55: ...to various fixed valve positions distributed over the working range of the valve The drive signal y is measured for each valve position x and compared with the reference graph The recorded data of th...

Page 56: ...umatics Perhaps existing TEST Perhaps too large TEST Actuator springs Perhaps spring stiffness reduced TEST Perhaps bias reduced TEST Working at full capacity TEST 3 Start test Note Cancel the test by...

Page 57: ...for the valve to move through its entire working range The positioner generates the Air supply message with the selected status classification The drive signal shifts downwards with a smaller gradien...

Page 58: ...7 Friction MANUAL MODE TEST Start test Reference test complet ed See section 1 2 1 NO YES First test Refer ence Start test Test analysis Friction Much higher lower over whole range Much higher lower o...

Page 59: ...ing to each valve position a ramp movement changing the valve travel by less than 1 is performed The change in drive signal y is measured for each valve position x and compared with the reference data...

Page 60: ...ting Execute or by pressing the rotary pushbutton at the positioner After the test has been canceled the posi tioner remains in manual mode In TROVIS VIEW the test information and progress flag of the...

Page 61: ...oner generates a corre sponding status message Diagnosis Status messages Extended Friction 4 2 2 Resetting single status messages The diagnostic parameters and measured data analysis from the Drive si...

Page 62: ...dent and descendent are plotted within the test range The response of the valve position x to the change in set point w is plotted in a graph The dead band is analyzed in the positioner when a step he...

Page 63: ...1 to 25 0 s 1 0 s Number of measurement values until turn back 1 to 50 50 3 Start test Note Cancel the test by right clicking Stop test and selecting Execute or by pressing the rotary pushbutton at t...

Page 64: ...ax breakaway time The valve position exceeds x control value The drive signal exceeds the comparative value given by the delta y monitoring The valve position deviation exceeds the PST tolerance band...

Page 65: ...valve trim After the breakaway torque has been overcome it can be assumed that the valve is able to completely close Recording the test results additionally allows an analysis of the dynamic control r...

Page 66: ...the test does not start until the Settling time before test start has elapsed Starting from the Step start the valve moves to Step end The valve remains in this position for the time defined by the D...

Page 67: ...on as the drive signal y falls below or exceeds the reference value The reference value is made up of the diagnostic parameters delta y moni toring reference value and delta y mon itoring value The de...

Page 68: ...etersetting the PST di agnostic parameters on page 69 2 Define parameters for cancelation condi tions 3 Select classification for status message 4 Start the partial stroke test The Test information st...

Page 69: ...After the test has been canceled the positioner remains in selected mode The Status of partial stroke test reading indicates Not successful In TROVIS VIEW the test information and progress flag of the...

Page 70: ...hen Tar get PST testing mode PST Man The test and its cancelation are described in u Section 4 4 while the test assessment is described in uSection 4 4 3 It is important to make sure that the diag nos...

Page 71: ...d regardless of the status classification Diagnosis Status messages Extended PST FST Note The No test available status remains active until a partial stroke test is completed successfully 4 4 4 Resett...

Page 72: ...tic Control valve Automatic mode AUTO Not possible Not possible Not possible Manual mode MAN Possible Not possible Possible On off valve Automatic mode AUTO Possible Possible Possible Possible Manual...

Page 73: ...EB 8389S EN 73...

Page 74: ...s No 1 Yes Ramp time rising Ramp time falling Cancelation condition Max test duration Status classification PST FST Maximum test duration or allowed time to reach full closed position exceeded The val...

Page 75: ...n The change in travel can be performed ei ther in steps or in a ramp function Fig 15 For the test in a ramp function additionally the times for the rising and falling ramps need to be defined After b...

Page 76: ...st is canceled when the maximum permissible test du ration is reached Additionally the full stroke test is canceled when one of the following events arises Aborted by int solenoid valve forced venting...

Page 77: ...tivated as the condensed state 1 Operation Operating mode Target mode Code 0 Manual 2 Diagnosis Tests Full stroke test Tolerance limit of step response 0 1 to 10 0 2 0 Activation of the ramp function...

Page 78: ...erence measurement Note Changes in the diagnostic parame ters listed below affect the test The results of the next following full stroke test are used as the new reference measurement Activation of th...

Page 79: ...EB 8389S EN 79 Tests analysis of the penultimate test is deleted when another test is performed Diagnosis Status messages Reset Reset FST...

Page 80: ...sing a universal com mand Depending on the positioner the dynamic HART variables can be assigned by the DD or in TROVIS VIEW Settings Operation unit as shown in Ta ble 5 Settings Operating unit Assign...

Page 81: ...ion Valve position Set point deviation e Set point deviation e Absolute total valve travel Absolute total valve travel Binary input status 0 Not active 1 Active 255 Internal solenoid valve forced vent...

Page 82: ...Switch between AUTO MAN The positioner changes from the auto matic mode to the manual mode or vice versa This function is not performed if the positioner is in the fail safe position mode Start data l...

Page 83: ...EB 8389S EN 83 Binary input...

Page 84: ...number of zero calibrations performed since the last initial ization Read only d4 No of initializations The total number of initializations that have been performed since the last reset Read only d5 Z...

Page 85: ...set diAG 0 to 365 days After an adjustable time period the diagnosis data are reset auto matically according to the settings in Code 36 diAG Example A start up behavior of the plant which is untypical...

Page 86: ...pulses The difference between these control pulses creates the y value 1 s The y monitoring reference value applies to the adjusted step val ues Code 49 d2 and Code 49 d3 and for the selected ramp tim...

Page 87: ...ramp function Initialization provides a sensible value that is not to be undercut if possible d7 Settling time before starting test 1 0 to 240 0 s Waiting time before test is started to ensure that va...

Page 88: ...st available or test canceled manually F1 Test OK F2 x cancelation The test was canceled by x cancelation function F3 y cancelation The test was canceled by y cancelation function F4 Tolerance band ex...

Page 89: ...art test 25 0 of reference variable The valve remains in its last valid position between the fail safe posi tion limit and the lower test limit A partial stroke test is performed after six seconds whe...

Page 90: ...setting Description Note Codes with marked with an asterisk must be enabled with Code 3 prior to configuration 49 h9 Status classification for on off C Maintenance required OK No message CR Maintenan...

Page 91: ...rate zero We recommend to re initialize the posi tioner if zero deviates by more than 5 Autocorrection Code 59 Data section error in posi tioner Fatal error Code 60 Error detected in safe ty relevant...

Page 92: ...data memo ry The valve is moved to fail safe position Confirm error and select Automatic operating mode If not successful reset initialization and re initial ize the positioner Control calculation Co...

Page 93: ...ning is impossi ble Activate volume restric tion in positioner out put Re initialize positioner Pin position fail safe switch Code 56 Pin position not entered for nominal range NOM or substitute SUB i...

Page 94: ...ion parameters Return positioner to SAMSON for repair Diagnosis parameter Code 80 Error in parameters not criti cal to control operation Confirm error Perform new reference test if necessary Diagnosis...

Page 95: ...on The friction is much high er lower over the entire working range The friction is much high er lower over a section Check the valve s packing uSec 3 7 2 uSec 4 2 2 Actuator springs The spring stiffn...

Page 96: ...reference value by the amount entered in Limit value time analysis The valve end position dif fers from the reference value by the amount en tered in Limit value travel analysis The end position canno...

Page 97: ...term monitoring Scan rate short term histogram Set point deviation histogram e Measured values Short term monitoring Scan rate short term histogram Cycle counter histogram Measured values Short term m...

Page 98: ...n PST tolerance band con trol PST tolerance band delta y monitoring reference value course of step response analysis of measured data number of tests Full stroke test d6 Tolerance limit of step respon...

Page 99: ...time before test start 10 s Delay time after step 4 0 s Scan rate Min recommended scan rate 2 Adjust Scan time of the data logger to 0 2 s and start the data logger Selection Per manent See section 3...

Page 100: ...100 EB 8389S EN Appendix Fig 16 Full stroke test to determine the ramp times for the partial stroke test The valve position closely follows the set point in the example shown here...

Page 101: ...EB 8389S EN 101...

Page 102: ...102 EB 8389S EN...

Page 103: ...used e Set point deviation pout Signal pressure ps Supply pressure x Valve position x0 Valve position when the valve is tightly shut w Set point reference variable BE Binary input FV Forced venting SV...

Page 104: ...SAMSON AG MESS UND REGELTECHNIK Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samson de www samson de EB 8389S EN 2015 05 28 English...

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