Samson 373 Series, 3730-2, 3730-3, 3731-3, 3730-4 Operating Instructions Manual

...

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

2 EB 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 diagnostics firmware incorporated in the positioner. The upgraded version provides extended functions to pinpoint valve parameters 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 condition (e.g. data logger and drive signal diagram 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.

4 EB 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 reference graphs are plotted after the positioner is re-initialized. If reference graph plotting is to be started separately 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:

Analysis in automatic or manual mode is deactivated.

All tests for both statistical information AUTO and tests MAN of drive signal di

agrams steady-state and hysteresis are inactive.

The reference test is inactive.

The automatic test to start all tests MAN is inactive.

Double-acting actuator with reversing amplifier:

All tests for both statistical information AUTO and tests MAN of drive signal diagrams steady-state and hysteresis are inactive.

The reference test is inactive.

6 EB 8388 EN

Description

Booster:

The 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 loggerorStart 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:

On 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).

Press 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

1.7.1 Printing the diagnostic/ESD

log

The Print command allows you to print out a diagnostic log of individual tests or the entire 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 diagnostic log. The printout contains the contents of the folder and its subfolders.

8 EB 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 variable 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 reactivated.

Data logging

Select

Data logger

folder (>

Selection

) and

select

PermanentorTrigger

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 logging of the triggering condition. The following parameters can be changed for this function:

Trigger status: Triggered by the travel condition (setpoint) and/or solenoid valve condi

tion (forced venting)

Start value: Limit indicating from which travel condi

tion (setpoint) the data logger should be triggered

Logging 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

logger

parameter and select

Execute

. The triggering event starts data logging when the start value exceeds or falls below an entered value. Enter the required value at which data log

ging should be triggered in relation to the setpoint in the

Start value

parameter. Select whether data logging should start when the entered value exceeds or falls be

low the start value in the

Logging limit

rameter. After being triggered, the variables w, x, y and e are logged at the adjusted scan rate and saved in the FIFO memory. Additionally, there is a pretrigger time avail

able to allow the variables to be stored that were logged before the triggered event. Enter the required pretrigger time by right-clicking the parameter and selecting

Modify

. However, the pretrigger time entered may not be higher than the maximum pretrigger time determined by the positioner. This maximum pretrigger time is shown in the

Max. pretrigger time

parameter. The data logging finishes automatically as soon as the maximum memory capacity of 100 measured data points for each vari

able including the pretrigger time is reached.

Solenoid valve condition (forced venting)

Select

Trigger status

parameter and select

Start via solenoid valve condition (forced venting)

. Activate data logging by selecting

Start data logger

parameter and select

Exe

cute

to start data logging as soon as the in

tegrated solenoid valve is triggered or the forced venting function is activated. Similar to the travel condition (setpoint), the variables w, x, e and y are logged at the adjusted scan rate and saved in the FIFO

memory on triggering. Additionally, there is a pretrigger time avail

able to allow the variables to be stored that were logged before the triggered event. Enter the required pretrigger time by right-clicking the parameter and selecting

Modify

. However, the pretrigger time en

tered may not be higher than the maximum pretrigger time determined by the positioner. The data logging finishes auto

matically as soon as the maximum memory capacity of 100 measured data points for each variable including the pretrigger time is reached.

Travel (setpoint) or solenoid valve condition (forced venting)

Select

Trigger status

parameter and select

Start via travel (setpoint)/solenoid valve condition (forced venting)

. Activate data

logging by selecting

Start data logger

pa-

rameter and select

Execute

. The triggering event starts data logging when the valve travel (setpoint)/solenoid valve conditions (forced venting) are met. The measured data are plotted over time in graphs. In addition, the compiled measured data are stored in the

Measured values

folder (see Fig. 3).

2.2 Travel histogram

The valve travel histogram is a statistical analysis of the plotted valve travel. The histogram provides information, for ex

ample, about where the valve mainly works during its service life and whether it shows a recent trend concerning changes in its work

ing range. The valve travel is recorded and assigned to valve travel classes. The distribution showing

EB 8388 EN 11

Statistical information AUTO

how often the valve travel remains within a class is shown in per cent. The result is pre

sented as a bar graph.

The

Travel histogram

folder contains

long-term data, i.e. measured data are up

dated cyclically (scan rate 1 s) over the en

tire positioner service life and stored every 24 hours in the positioner’s non-volatile memory for long-term monitoring. The

Number of measurement values

param

eter shows the total amount of classified measured data points previously recorded. The

Average value x long

parameter con

tains the class in which the travel remained on average the most. In order to be able to recognize any short-term changes in valve travel properly, the last 100 measured data points are stored at a scan rate (default: 1 s) in a non-volatile memory. The scan rate can be changed in the

Scan rate short time

param-

eter. On changing the scan rate, old data in the short-term histogram are deleted.

The

Average values x short

parameter con

tains the average class assignment for the last 100 measured data points stored in the non-volatile memory. Data can be reset in the

Status messages

folder.

2.3 Setpoint deviation histogram

The setpoint deviation histogram contains a statistical analysis of any setpoint deviations recorded. This provides a summary of how often and to which level a setpoint deviation has occurred during the positioner service life and whether it shows a recent trend concerning the setpoint deviation. The setpoint deviation is recorded and assigned to predetermined level classes. The percentages showing how often the setpoint deviation remains within a class is presented

12 EB 8388 EN

Statistical information AUTO

Fig. 4 · Travel histogram

+ 28 hidden pages

Samson 373 Series, 3730-2, 3730-3, 3731-3, 3730-4 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual