Samson TROVIS SAFE 3730 Series, TROVIS SAFE 3730-6, 3730 Series, 3730-6 Operating Instructions Manual

Series 3730
TROVIS SAFE 3730-6 Electropneumatic

Positioner
EXPERTplus Valve Diagnostics

Operating Instructions

EB 8389-1S EN

Firmware version 1.1x
Edition May 2015

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 seri­ous injury

2 EB 8389-1S EN

NOTICE

Property damage message or mal­function

Note:

Additional information

Tip:

Recommended action

Contents

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

EB 8389-1S EN 3

Contents

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

4 EB 8389-1S EN

Contents

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

EB 8389-1S EN 5

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

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.

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

6 EB 8389-1S EN

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. Di­agnostic data are compiled, saved and ana-

lyzed in the positioner itself. Classied status

messages on the state of the valve are gener­ated from the analysis.

All the parameter settings that are changed
must also be downloaded onto the posi­tioner to allow them to become effective.

Local operation

Some parameters can be changed at the po­sitioner as well as over the operator interface.
T

he 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 TROVIS­VIEW4. The default settings of the position­er and TROVIS-VIEW4 are written in
square brackets [ ]. Settings highlighted in
gray refer to operation using TROVIS­VIEW4.

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

EB 8389-1S EN 7

DescriptionDescription

Initialization mode

â â â

MAX NOM MAN/MAN2

â

Initialization including valve

signature

ß à

Yes

START-UP

â â

Zero

Valve signature (D1)

Code 81 Code 81

ß Not successful

ß Successful

Automatic change to

AUTO operating mode

à

No

Throttling or on/off service

Later recording of

reference graphs

â

Operating mode = MAN

Valve signature (D1)

All reference values are overwritten!

ß Not successful

â

Operating mode = AUTO

ß

8 EB 8389-1S EN

Description



1.2 Start-up

The positioner must be initialized to use the
full scope of the valve diagnostics. During ini­tialization the positioner adapts itself optimal­ly to the friction conditions and the signal
pr

essure 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 mechani­cal 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 manu­ally

The type of application, pressure limit and
the start-up parameters required for the se­lected initialization must be entered to initial­ize the positioner.

Note:

Positioner start-up is described in detail
in the associated Mounting and Oper­ating Instructions (

uEB8384-6S EN

).

The monitoring of friction, supply pressure,
leakage, actuator springs, course of end po­sition 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 includ­ing 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-ac­tion coefcient (Kp level) and derivative-ac­tion time (Tv level) can be adapted accord­ingly. 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.

EB 8389-1S EN 9

Description

NOTICE

Kp level changes affect the set point
deviation.

After changing the proportional-action coef-

cient 'Kp level', we recommend to recali­brate 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 posi­tioner 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 posi­tioner 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 func­tion is activated.

10 EB 8389-1S EN

1.3.1 Type of application

Different diagnostic functions are available
depending on the type of application select­ed in EXPERTplus. The types of application
'Control valve' and 'On/off valve' are
available. Depending on the type of applica­tion selected, the positioner behaves differ­ently in the automatic mode (AUTO):

− Control valve

The positioner uses the set point to posi­tion the valve.
The valve position (current position) ap­pears 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 alter­nating sequence on the display. See

uSection 5.

Description

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.

EB 8389-1S EN 11

Description

Description

Table 1: Diagnostic functions and test analysis

Control

Diagnostic functions

valve

Monitoring

Data logger • • Depending on trigger status

Valve signature •

On/off valve – • − Breakaway time

Valve position
histogram

Set point deviation
histogram

Cycle counter
histogram

Leakage sensor • • − Seat leakage u 9 on page 53
Course of end

position

Dynamic tests

Valve dead band • • − Dead band u 11 on page 69
Partial stroke test

(PST)

Full stroke test (FST) • • − Overshooting

• Full scope of functions

U Function is performed, but not analyzed

– Function is not performed

On/off

valve Assessment See section

selected

U

− Change in friction

− Supply pressure

− Defective actuator springs

− Pneumatic leakage

− Transit time

− Valve end position

•

U

− Change in manipulated variable
range

− Manipulated variable range

• • − Manipulated variable range
limitation

− Seat leakage

− Positioner-valve linkage

− Average set point deviation

• • − Packing leakage

− Dynamic stress factor

• • − Course of end position

− Zero shift

• • − Overshooting

− Dead time

− T86

− Settling time

− Dead time

− T86

− Settling time

u 3 on page 21

u 4 on page 27

u 5 on page 37

u 6 on page 41

u 7 on page 44

u 8 on page 49

u 10 on page 67

u 12 on page 73

u

13 on page 83

12 EB 8389-1S EN

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 per­formed 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 posi­tioner itself or in one of its peripherals or

an initialization has not yet been suc­cessfully completed.

You can view these messages in TROVIS-

VIEW4 in the Diagnostics folder (> Monitor-
ing) and its subfolders. The 'Positioner sta­tus', '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 di­agnosis can be reset. Resetting is performed
in the Diagnostics folder (> Service/mainte­nance > 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.

EB 8389-1S EN 13

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 "De­sired time until ‘Reset measured diagnos­tic data" (Code 48 - h3). The setting
"00:00:00" causes the resetting at regu­lar 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.

14 EB 8389-1S EN

Monitoring

Monitoring

Table 2: Resetting the diagnosis

Resetting

single status

messages

Reference
graphs

Data logger Conguration and measured values NO YES YES YES

Valve signature Signal pressure(x) Measured values YES YES YES YES

On/off valve Conguration YES NO YES YES

Valve position x histogram Measured values YES YES YES YES

Set point deviation e histogram Measured values YES YES YES YES

Cycle counter histogram Measured values YES YES YES YES

Leakage sensor Short-term monitoring 'Sensitivity sound level'

Course of lower end position Measured values YES YES YES YES

Valve dead band Conguration and

Partial stroke test (PST) Conguration and

Valve signature NO NO YES YES

Leakage sensor Manufacturer reference YES NO YES YES

Process reference YES NO 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

Measured values YES YES YES YES

Short-term monitoring 'Sampling time' and

measured values

Short-term monitoring 'Sampling time' and

measured values

Short-term monitoring Measured values YES YES YES YES

and measured values

Long-term monitoring Measured values YES YES YES YES

Sound level(x) Measured values YES YES YES YES

Reference value YES NO YES YES

measured values

measured values

* Except for 'Sampling time' parameter

YES YES YES YES

YES YES YES YES

YES YES YES YES

YES YES YES YES

YES NO* YES YES

Code 36

Diag Std DS

EB 8389-1S EN 15

Monitoring

Resetting

single status

messages

Full stroke test (FST) Conguration and

measured values

* 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

YES NO* YES YES

Code 36

Diag Std DS

16 EB 8389-1S EN

Monitoring



2.1.2 Condensed state

To provide a better overview on the condi­tion 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 mes­sage 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 uSec­tion 3.2.1.

Note:

The condensed state is marked by
until the positioner data have been up­loaded.

The condensed state can be read in the posi­tioner 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 acti­vated and the fault alarm output is acti­vated.

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

Function check

Out of specication

Maintenance request/
maintenance required

No message, OK

EB 8389-1S EN 17

red

orange

yellow

blue

green

Text e.g. TESTING, TUNE or

TEST

blinking

Monitoring



Device settings > Alarm settings

− Fault alarm at condensed state 'Function

2.

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 TROVIS­VIEW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 ad­ditionally logged when the time entered

in 'Min. interval for new logging of inter­nal 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]

18 EB 8389-1S EN

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)

Monitoring

EB 8389-1S EN 19

Monitoring

Data logger

â â

Permanent Triggered

â â

Sampling time

â

Start

START-UP

â

100 measured val-

(w, x, e, p

Function

1)

â â â â â

Con-

densed

state

â â â

Trigger condition

ues

) â

out

Triggered by

, x, e

w
or p

out

Trigger value

Trigger band

Trigger condition

Trigger lead time

Sampling time

Start

Solenoid

BE

valve/
forced

venting

w or solenoid

valve/forced

venting

Trigger value

Trigger band

Trigger condition

â

1)

â

Trigger event

â

Logged by operating hours

counter

â â

PROCESS

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

20 EB 8389-1S EN

Data logger





3 Data logger

The data logger records the measured vari­ables (valve position x, set point w, set point
deviation e and signal pressure p
corded data are plotted against time in a
graph.

Note:

The data logger is interrupted and
must be reactivated when one of the
following events occurs:

−

Failure of power supply of the posi­tioner

−

Failure of power supply of the exter­nal solenoid valve

). The re-

out

3.1 Permanent data logging

The measured variables are logged at the

rate dened in 'Sampling time' and saved in

a circular buffer, which holds 100 data
points per measured variable at one time.

Note:

You can read the measured data

logged over the past 24 hours from

the 'Data logger' graph when the Di­agnostics folder (> Data logger) is left

open over this period.

Fig. 1: Diagnostics > Data logger

EB 8389-1S EN 21

Data logger







Dening parameters

1. Select 'Permanent' (Function).

2. Enter sampling time.

3. Start data logger.

The 'Test information' status indicates
'Test active'.

Diagnostics > Data logger

1.

− Function: [Permanent]

2. − Sampling time: 0.2 to 3600.0 s, [1.0 s]

3. − Start data logger

Note:

Right-click 'Cancel data logger' and
select 'Execute' to stop the data logger
('Test information' = 'Test not active').

3.2 Triggered data logging

Measured values are saved in a circular buf-

fer after the event dened in 'Triggered by'

has occurred (see u Section 3.2.1 to 3.2.5).
The event that has triggered data logging is
recorded. Data logging is terminated after
100 measured values per measured variable
have been saved in the circular buffer. The

'Sampling time' determines the time between
recordings. A 'Trigger lead time' greater

than 0 also leads to the measuring values
before the triggering event for the time se­lected being included in the 100 measured

values per measured variable. The 'Trigger
lead time' may include the value 100 x
'Sampling time' at the maximum.

Dening parameters

1. Select 'Triggered' (Function).

2. Select the triggering event.

3. Enter sampling time.

4. Start data logger.

The 'Test information' status indicates
'Test active'.

When the data logging is nished, the
Progress bar indicates 'Memory full, data
recording completed'.

Note:

Right-click 'Cancel data logger' and
select 'Execute' to stop the data logger
('Test information' = 'Test not active').

3.2.1 Triggered by condensed
state

The measured values are included in the trig­gered event when the condensed state de­ned in 'Triggered by condensed state' aris­es.

Note:

If 'Function check' is selected as the
condensed state ('Triggered by con­densed state'), data are logged when
a dynamic test starts. Data from each
test start are logged.

Diagnostics > Data logger

1.

− Function: Triggered.

2. − Sampling time: 0.2 to 3600.0 s, [1.0 s]

3. − Triggered by: Condensed state

22 EB 8389-1S EN

Data logger

rigger band

gg

w, x, y, e

ger band

w, x, y, e

rigger band

rigger band

w, x, y, e

− Trigger lead time:

0.0 s to 100 x 'Sampling time', [20.0 s]

− Triggered by condensed state: No message,
Function check [Maintenance required],
Maintenance demanded, Out of specica­tion, Failure

4. − Start data logger

3.2.2 Triggered by set point,
valve position, set point
deviation or signal pres­sure

The measured values are included in the trig­gered data logging when the conditions for
the selected measured variable (set point w,
valve position x, set point deviation e or sig­nal pressure p

'Trigger band' and 'Trigger condition' are

met.

'Trigger condition' = Decreasing signal/
lower band value undercut

) dened in 'Trigger value',

out

'Trigger condition' = Increasing signal/
upper band value exceeded

Upper band limit =
Trigger value
Trigger value

Trigger band

+ ½ Trig

The conditions for starting a trigger event
are met when the value falls below the limit

('Trigger value' – ½ 'Trigger band').

'Trigger condition' = Band exit

Upper band limit =
Trigger value + ½ T

Trigger value

Lower band limit =
Trigger value - ½ T

Trigger band

Trigger value
Lower band limit =
Trigger value – ½ T

er band

Tri

The conditions for starting a trigger event
are met when the value falls below the limit

('Trigger value' – ½ 'Trigger band') or ex­ceeds the limit ('Trigger value' + ½ 'Trigger
band').

The conditions for starting a trigger event
are met when the value falls below the limit

This function is only active when 'Trigger
band' ≠ 0.

('Trigger value' – ½ 'Trigger band').

EB 8389-1S EN 23

Data logger

ger band

w, x, y, e

'Trigger condition' = Band entry

Upper band limit =
Trigger value
Trigger value
Lower band limit =
Trigger value - ½ Trigger band
Trigger band

+ ½ Trig

The conditions for starting a trigger event
are met when the value exceeds the limit

('Trigger value' – ½ 'Trigger band') or falls
below the limit ('Trigger value' + ½ 'Trigger
band').

This function is only active when 'Trigger
band' ≠ 0.

Diagnostics > Data logger

1.

− Function: Triggered

2. − Triggered by: Valve position, set point devi-
ation, signal pressure or set point

− Trigger value:

0.0 to 100.0 %, [99.0 %] (set point, valve
position, set point deviation)

0.0 to 7000.0 mbar, [99.0 mbar] (signal
pressure)

− Trigger band:

0.0 to 100.0 %, [99.0 %] (set point, valve
position, set point deviation)

0.0 to 10000.0 1/s, [99.0 1/s] (drive sig­nal)

− Trigger lead time:

0.0 s to 100 x 'Sampling time', [20.0 s]

− Trigger condition: [Decreasing signal/lower
band value undercut], Increasing signal/up-

per band value exceeded, Band exit, Band

entry

3. − Sampling time: 0.2 to 3600.0 s, [1.0 s]

4. − Start data logger

3.2.3 Triggered by binary in­put

This setting is only active when a binary in­put is installed in the positioner. If this is not

the case, the Progress bar indicates 'Cannot
start data logger – trigger cannot be set'.

The measured values are included in the trig­gered data logging when the state of the bi­nary input changes.

Diagnostics > Data logger

1.

− Function: Triggered

2. − Triggered by: Binary input

− Trigger lead time:

0.0 s to 100 x 'Sampling time', [20.0 s]

3. − Sampling time: 0.2 to 3600.0 s, [1.0 s]

4. − Start data logger

24 EB 8389-1S EN

Data logger

3.2.4 Triggered by internal so­lenoid valve/forced
venting

This setting is only active when an internal
solenoid valve/forced venting is installed in
the positioner. See 'Internal solenoid valve/

forced venting' reading. If this is not the
case, the Progress bar indicates 'Cannot start
data logger – trigger cannot be set'.

The measured values are included in the trig­gered data logging when the solenoid valve
is triggered or the forced venting is activat­ed.

Diagnostics > Data logger

1.

− Function: Triggered

2. − Triggered by: Internal solenoid valve/

forced venting

− Trigger lead time:

0.0 s to 100 x 'Sampling time', [20.0 s]

3. − Sampling time: 0.2 to 3600.0 s, [1.0 s]

4. − Start data logger

tions dened in 'Triggered by internal sole­noid valve/forced venting“ or 'Triggered by
set point' are met.

Diagnostics > Data logger

1.

− Function: Triggered

− Triggered by: Set point or internal solenoid

valve/forced venting

− Trigger value: 0.0 to 100.0 %, [99.0%]

− Trigger band: 0.0 to 100.0 %, [99.0 %]

− Trigger lead time:

0.0 s to 100 x 'Sampling time', [1.0 s]

− Trigger condition: [Decreasing signal/lower
band value undercut], Increasing signal/up-

per band value exceeded, Band exit, Band

entry

3. − Sampling time: 0.2 to 3600.0 s, [20.0 s]

4. − Start data logger

3.2.5 Triggered by set point or
internal solenoid valve/
forced venting

This setting is only active when an internal
solenoid valve/forced venting is installed in

the positioner. See 'Internal solenoid valve/
forced venting' reading. If this is not the
case, the Progress bar indicates 'Cannot start
data logger – trigger cannot be set'.

The measured values are included in the trig­gered data logging when one of the condi-

EB 8389-1S EN 25

Data logger

Valve signature

Requirements:

– Actuator: Single-acting

– Type of application: Control valve

Only applies to rst start-up after reset with Code 36 –

DS or Std.

â

Initialization including valve signature

â à

Start initialization

â

Valve signature recording

â

START-UP

Valve signature, signal pressure(x) Course of supply pressure Valve signature, friction(x)

â â

Alarm settings Recording threshold

Alar

â

m settings

ATC ATO and ATC

Zero limit,

lag time

Lower limit Upper limit

Status classication (NE 107) Status classication (NE 107) Status classication (NE 107)

Zero

x0 >
(ZP

+ Zero limit)

Init

x0 < (– Zero limit)

Spring pre-load

-

ing

Reduced spring
pre-loading

essure Change in friction

Supply pr

Not

available

Too low

Perm.

Too high

limit
exceeded

â â â â â â

Analysis (NE 107)/logged by

operating hours counter

PROCESS

Zero

Defective actuator

springs

Analysis (NE 107)/logged by

operating hours counter

Analysis (NE 107)/logged by

operating hours counter

Supply pressure status Change in friction

Min. supply pressure

Max. supply pressure

Dwell time (supply pressure

< 1.0bar)

l time (supply pressure

Dwel

> 7.0bar)

Valve signature

canceled

Not successful

â

Lower in total range
Lower/higher in mid-

position
Lower/higher near

max. OPEN position

Lower/higher near
CLOSED position

â

R

eset 'Pressure sensor monitoring values'

26 EB 8389-1S EN

Valve signature



4 Valve signature

The valve signature plots the signal pressure
p

as a function of valve position x.

out

All diagnostic functions dependent on the
signal pressure are based on the valve sig­nature, e.g. to detect pneumatic leakage or
to reveal an excessively high or low supply
pressure.

Note:

Additionally, the pneumatics are mon­itored using the 'Leakage limit' param
eter, which is adjustable between 0
and 100% in the Device settings fold-
er (> Alarm settings). The positioner
generates the 'Pneumatic leakage'
message whenever the leakage ex

ceeds this limit value. 'No message' is

assigned by default.

Requirements

1. A single-acting actuator is mounted on
the valve.

2. The valve operates as a control valve.

Device settings > Actuator

1.

− Principle of operation (Code 48 - d11):

Single-acting

Start-up

2.

− Type of application (Code 49 - h0):

Control valve

-

To perform monitoring while the process is

running, the reference graph must rst be

plotted.

-

Fig. 2: Start-up > Reference graphs > Valve signature

EB 8389-1S EN 27

Valve signature



4.1 Reference graphs

During the plotting of the reference graph
(Fig. 2), the valve is moved very slowly from
the end position at which no pressure is ap­plied to the actuator to the position at which
the maximum air signal is applied to the ac­tuator. The valve is then moved back again
to its end position. During which, the posi­tioner switches to open-loop control (control
without feedback).

The sensitivity of reference graph plotting de-

nes at which speed the valve is moved. The

time span how long the reference graph is to
be plotted depends on the sensitivity select-

ed. Select 'High' for valves with small bench

ranges and/or high friction.
After the reference graph has been plotted,

the recorded data points for signal pressure
p

and valve position x are converted into

out

xed points.

Note:

The valve positions cannot be predict­ed in open-loop control (control with­out feedback). The reference graph
may differ for the same valve after
each logging.

Dening parameters

The reference graph is automatically plotted

after initialization when 'Initialization includ­ing valve signature' = Yes.

Start-up

− Initialization including valve signature
(Code 48 - h0): [Yes]

The reference graph can also be plotted sep­arately outside initialization.

1. Switch to manual mode.

2. Select 'Sensitivity' from the drop-down
list.

3. Start test.

The 'Test information' status indicates
'Test active'. 'D1' and 'TEST' are indicat-

ed in alternating sequence on the posi­tioner display.

'Function check'

is activated as the

condensed state.

Start-up

1.

− Enter operating mode (Code 0): Manual

2.Start-up > Reference graphs > Valve

signature

− Sensitivity: Low, [Medium], High

3. − Start test

4.1.1 Analysis and monitoring

The positioner records the data for lling and

venting the actuator. It then determines the
characteristic values listed below:

− 'Mean hysteresis': Average hysteresis

(average signal pressure change Δp

relation to the spring range)

− 'Min. hysteresis': Lowest possible hystere-
sis (minimum signal pressure change

Δp

in relation to the spring range)

out

− 'Max. hysteresis': Highest possible hys-
teresis (maximum signal pressure change

Δp

in relation to the spring range)

out

in

out

28 EB 8389-1S EN

Valve signature



− 'Detected lower spring range value': Sig-
nal pressure p

lled with the minimum amount of air

− 'Detected upper spring range value': Sig-
nal pressure p

lled with the maximum amount of air

The 'Valve signature canceled' message is

generated if the test is canceled.

Start-up > Initialization result

− Valve signature canceled (Code 81):
, , ,

The 'Test status' reading indicates the reason

why the test was canceled:

− No supply pressure: The supply pressure

was under 500mbar during the test.

− Valve moved too quickly. Recommended
action: Increase sensitivity

− Position at p
air):
(1) Even though the pressure was in-

creased in steps from 0bar to the maxi­mum amount of air for lling the actua-

tor, the valve was not able to reach the
maximum position in closed-loop opera­tion.
(2) The minimum valve position without
tight-closing is below 96%.
Recommended action: Increase supply
pressure.

− Position at p
(1) Even though the pressure was re­duced in steps from the maximum
amount of air for lling the actuator, the
valve was not able to reach the minimum

when the actuator is

out

when the actuator is

out

not reached (lling with

max

not reached (venting):

min

position in closed-loop operation. The
valve might be jammed.
(2) The minimum valve position without

tight-closing is above 4%.

− Time-out

− Double-acting actuator

− Internal error

− Current too low

− Internal solenoid valve/forced venting
triggered

− SUB initialization

4.2 Valve signature, signal
pressure(x)

The positioner records the data for lling and

venting the actuator during closed-loop op­eration. The recorded data can be directly
compared with the reference graph. Addi­tionally, the minimum, maximum and current
supply pressure are shown in the graph.

Data are recorded in the background re­gardless of the operating mode selected if a
reference graph has already been plotted.
Data logging does not need to be activated.

Note:

The positioner determines the mini­mum and maximum supply pressure
while plotting the reference graph. The
current supply pressure may fall below
the minimum supply pressure and ex­ceed the maximum supply pressure.

Dening parameters

1. Record reference graph. u Section 4.2.

EB 8389-1S EN 29

Valve signature

2. Set the limit for zero monitoring in con­trol valves with closed position ATC (air
to close).

3. Select classication for status messages.
See u Section 4.2.1.

Device settings > Alarm settings

2.

− Zero limit (Code 48 - d5):

0.0 to 100.0 %, [5.0 %]

− Lag time: 1 to 9999 s, [30 s]

3.Device settings > Alarm settings > Status

classication > Positioner

− Zero (Code 58):

Device settings > Alarm settings > Status
classication > Actuator

Defective actuator springs

− Reduced spring pre-loading:

, [ ], ,

[ ], , ,

4.2.1 Analysis and monitoring

If the monitoring line has a smaller gradient
than the reference line, this pinpoints to a re­duced compression of the actuator springs.

Diagnostics > Monitoring > Actuator

− Defective actuator springs:

Valves with ATC (air to close) closed posi­tion

In valves with ATC closed position, the posi­tioner generates a zero error when the valve
position in the tight-closing position is larger
than the sum of the initialization zero points

and 'Zero limit' or smaller than the negative
'Zero limit' after the adjusted 'Lag time' has

elapsed.

Diagnostics > Monitoring > Positioner

− Zero (Code 58):

, , ,

, , ,

Fig. 3: Diagnostics > Monitoring/tests > Valve signature > Valve signature, signal pressure(x)

30 EB 8389-1S EN