Samson TROVIS SAFE 3730 Series, Operating Instructions Manual

Page 1: ...Operating Instructions EB 8389 1S EN Firmware version 1 1x Edition May 2015 Series 3730 TROVIS SAFE 3730 6 Electropneumatic Positioner EXPERTplus Valve Diagnostics...

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

Page 3: ...r 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 s...

Page 4: ...erence 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 statu...

Page 5: ...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 poin...

Page 6: ...ion 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 Configuration required for...

Page 7: ...IEW 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 configure various SAMSON de vi...

Page 8: ...ing valve signature Yes No Later recording of reference graphs Operating mode MAN Zero Valve signature D1 Valve signature D1 All reference values are overwritten Code 81 Code 81 Not successful Success...

Page 9: ...nstructions u EB 8384 6S EN The monitoring of friction supply pressure leakage actuator springs course of end po sition and zero point shift requires additional reference tests of the valve signature...

Page 10: ...ocess The positioner follows the set point to po sition the valve A classified status alarm or fault alarm is generated if the posi tioner detects an event 2 Dynamic tests Similar to the monitoring fu...

Page 11: ...ehaves differ ently in the automatic mode AUTO Control valve The positioner uses the set point to posi tion the valve The valve position current position ap pears in on the display On off valve Discre...

Page 12: ...riable range u 6 on page 41 Set point deviation histogram Manipulated variable range limitation Seat leakage Positioner valve linkage Average set point deviation u 7 on page 44 Cycle counter histogram...

Page 13: ...n the posi tioner itself or in one of its peripherals or an initialization has not yet been suc cessfully completed You can view these messages in TROVIS VIEW 4 in the Diagnostics folder Monitor ing a...

Page 14: ...iagnos tic data Code 48 h3 The setting 00 00 00 causes the resetting at regu lar intervals to be deactivated Reset start up parameters Code 36 Std Parameters are reset as described in uSection 17 4 Re...

Page 15: ...alues YES YES YES YES Short term monitoring Sampling time and measured values YES YES YES YES Set point deviation e histogram Measured values YES YES YES YES Short term monitoring Sampling time and me...

Page 16: ...pling time and Max test duration parameters Alarm settings NO See uSec 17 4 Status classification according to NAMUR 107 NO NO NO YES All logged messages see u Section 2 2 YES NO YES YES Operating hou...

Page 17: ...Note The condensed state is marked by until the positioner data have been up loaded The condensed state can be read in the posi tioner display in Code 48 d6 See u Table 3 Condensed state at the fault...

Page 18: ...d ditionally logged when the time entered in Min interval for new logging of inter nal solenoid valve has elapsed between the generation of two Internal solenoid valve forced venting supply pressure m...

Page 19: ...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...

Page 20: ...ition Trigger value Trigger band Trigger condition Trigger lead time Sampling time 100 measured val ues w x e pout Start 1 PROCESS Trigger event Logged by operating hours counter Measured values w x e...

Page 21: ...wing events occurs Failure of power supply of the posi tioner Failure of power supply of the exter nal solenoid valve 3 1 Permanent data logging The measured variables are logged at the rate defined i...

Page 22: ...values before the triggering event for the time se lected 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...

Page 23: ...e undercut Lower 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 falls below the limit Trigger value Trigger...

Page 24: ...nd 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 sig nal Trigger lead time 0 0 s to 100 x Sampling time 20 0 s Trigger condition Decreasing signal lo...

Page 25: ...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...

Page 26: ...ssification NE 107 Status classification NE 107 Zero Spring pre load ing Supply pressure Change in friction x0 ZPInit Zero limit x0 Zero limit Reduced spring pre loading Too low Not available Perm lim...

Page 27: ...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...

Page 28: ...each logging Defining parameters The reference graph is automatically plotted after initialization when Initialization includ ing valve signature Yes Start up Initialization including valve signature...

Page 29: ...n at pmin not reached venting 1 Even though the pressure was re duced in steps from the maximum amount of air for filling the actuator the valve was not able to reach the minimum position in closed lo...

Page 30: ...4 2 1 Analysis and monitoring If the monitoring line has a smaller gradient than the reference line this pinpoints to a re duced compression of the actuator springs Diagnostics Monitoring Actuator Def...

Page 31: ...nd Upper limit the corresponding limit must be acti vated first The limits are automatically deter mined while the valve signature is being plotted Alternatively user defined limits can be entered Def...

Page 32: ...pressure exceeds the Lower limit Permissible limit exceeded if the supply pressure exceeds 7 0 bar A fluctuating supply pressure is recognized by the positioner whenever the supply pres sure continuo...

Page 33: ...ady been plotted Data logging does not need to be activated Defining parameters 1 Record the reference graph See u Sec tion 4 1 2 Select classification for status messages See uSection 4 2 1 2 Device...

Page 34: ...reases to more than double of the reference friction the friction is regarded to be higher If the friction at a fixed point drops to less than half of the reference friction the friction is regarded t...

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Page 36: ...ng Final travel angle value not reached Final travel angle value increasing decreasing Define parameters for partial stroke test see u Section 12 On off diagnosis Discrete set point analysis PST First...

Page 37: ...point The valve moves back to the fail safe position 0 in the example if the set point then falls below Fail safe action limit Operating point Operating point limit Fail safe action limit Fail safe p...

Page 38: ...12 1 Start up Type of application Code 49 h0 On off valve 2 Device settings Positioner Transfer characteristic on off Operating point Code 49 h1 0 0 to 100 100 Fail safe action limit Code 49 h2 0 0 t...

Page 39: ...the amount entered in Travel time assess ment limit The current Transit time increasing dif fers from the reference value by the amount entered in Travel time assess ment limit The current Transit tim...

Page 40: ...ues are reset by selecting and executing Reset measured On off valve values The positioner saves the reference analysis and two further test analyses The analysis of the oldest test is deleted when an...

Page 41: ...l oc curred within a valve position class is shown in a bar graph Mean value Average class assignment of valve positions throughout Monitoring duration Number of measurement points Total number of val...

Page 42: ...toring period begins No analysis is performed for on off valves If the control valve mainly works during the monitoring duration near or in one of the end positions the positioner generates the Manipu...

Page 43: ...By selecting and executing the command Reset Short term valve position x histo gram the diagnostic parameters and mea sured data in the Short term monitoring folder are reset Diagnostics Service main...

Page 44: ...ation remained within a class is shown in a bar graph Mean value Average class assignment of set point deviation throughout Moni toring duration Number of measurement points Total number of values rec...

Page 45: ...reater than 1 follow ing in quick succession pinpoint to a limita tion of the upper operating range In this case the positioner generates the Manipu lated variable range limitation and Posi tioner val...

Page 46: ...viation e histogram By selecting and executing the Reset Set point deviation e histogram command all diagnostic parameters and measured data of the histogram and the short term monitor ing are reset B...

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Page 48: ...NE 107 External leakage possibly to be expected soon 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 st...

Page 49: ...e two changes in direction is the cycle span The positioner records the cycle height when the Stem seal setting is set to Bellows seal The cycle height is the travel performed be tween two changes in...

Page 50: ...ber of measured cycle spans ex ceeds 450000 when Live loaded is se lected as the stem seal The number of measured cycle spans ex ceeds 180000 when Adjustable is se lected as the stem seal The number o...

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Page 52: ...2 Successful Phase 1 Successful Reset Leakage sensor manufacturer reference Reset Leakage sensor process reference Alarm settings Response time preset alarm limits Status classification NE 107 Alarm l...

Page 53: ...eakage sensor 1 A leakage sensor is mounted to the valve Refer to the standard mounting and operating instructions of the posi tioner u EB 8384 6 EN 2 The leakage sensor option has been se lected 3 Th...

Page 54: ...ile the manufacturer reference test is run ning the parameters listed below are auto matically deactivated Activate CLOSED end position Activate ramp function Phase 1 The valve moves to eleven defined...

Page 55: ...the Sensitivity sound level is not reached after the valve has moved to all eleven newly defined points then the change in sound pressure level is too low In this case phase 3 starts Phase 2 not succe...

Page 56: ...points must continuously increase from Set point 1 to Set point 11 The valve moves to the set points in steps of 0 1 Set points must be rounded up to two decimal places User defined settings can be sa...

Page 57: ...ossible to perform the process ref erence test the user defined alarm limits can be entered See u Section 9 1 2 2 While the process reference test is running the parameters listed below are automatica...

Page 58: ...self is subdivided into eleven fixed points Each fixed point is located at a distance of 0 03 to the next point The valve moves to the new fixed points one after the other After reach ing a fixed poin...

Page 59: ...255 dB 10 dB Edit set points 0 00 to 100 00 1 0 00 2 0 10 3 0 20 4 0 03 5 0 04 6 0 05 7 0 06 8 0 07 9 0 08 10 0 09 11 1 00 3 Start process reference Note By selecting and executing Cancel ref erence...

Page 60: ...ser defined settings can be selected When user defined limits are entered the alarm limits must rise continuously from Alarm limit 1 to Alarm limit 3 During closed loop operation the mean sound levels...

Page 61: ...larm limit 2 exceeded Alarm limit 3 exceeded 1 On selecting the alarm limit User defined we recommend checking the correct setting of the alarm limits using an operating time of one to three months ba...

Page 62: ...our recorded sound levels If this value deviates from the previous mean value by Sensitivity sound level the new mean value is saved in the short term moni toring The last Mean value recorded in the s...

Page 63: ...d level trend over a long pe riod of time the long term monitoring con tains all the mean values saved in the short term monitoring since the last reset Mean value The average sound level calculated f...

Page 64: ...tion showing how often the sound level oc curred within a valve position class is shown in a bar graph Data are recorded in the background re gardless of the operating mode selected Da ta logging doe...

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Page 66: ...re complete u Section 4 1 NO YES First zero point Reference Subsequent zero calibration over Code 6 ZP Zero calibration Zero shifted monotonically increasing decreasing alternating Status classificati...

Page 67: ...stamp by the operat ing hours counter when the valve moves to the lower end position The new recorded valve position is compared to the last saved zero point If it differs by the Recording threshold...

Page 68: ...course of end position graph Note If the reference value has been reset by selecting and executing Reset Reference values for course of lower end position see u Section 2 1 1 the first zero point that...

Page 69: ...The step height is determined automatically from the number of measured values No until re versing and the defined test range The as cendent and descendent are plotted within the test range The respo...

Page 70: ...0 s No until reversing 1 to 50 3 Start test Note Cancel the test by right clicking Can cel test and selecting Execute or by pressing the rotary pushbutton at the positioner After the test has been can...

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Page 72: ...me The valve has not reached the Stop position before Perm time until step end has elapsed The valve position has fallen below the monitoring value The signal pressure change has exceeded or fallen be...

Page 73: ...een overcome it can be assumed that the valve is able to completely close Record ing the test results additionally allows an analysis of the dynamic control response The partial stroke test can be per...

Page 74: ...hange before performing a second step change in the opposite direction from Stop to the operating position The Sampling time defines the time interval be tween which the measured values are re corded...

Page 75: ...the change in signal pressure exceeds or falls below the reference val ue The reference value is made up of p out reference value and p out moni toring value This cancelation condition only becomes ef...

Page 76: ...is too low After recording 100 measured values per variable logging is stopped but the test continues until it is completed After the partial stroke test is canceled the PST status reading indicates N...

Page 77: ...0 3 Device settings Alarm settings Status classification PST FST x cancelation p out cancelation Tolerance band exceeded Max test duration exceeded Test canceled manually Measured data memory full Can...

Page 78: ...ing time The Recommended min sampling time is calculated from the Ex pected duration of test 12 1 Start triggered by the set point The partial stroke test of on off valves is trig gered when the set p...

Page 79: ...ith a time stamp in the PST measured data assessment folder A graph of the last partial stroke test is shown in the Partial stroke test PST folder Test completed successfully When a partial stroke tes...

Page 80: ...omplet ed successfully 12 4 Resetting single status mes sages The diagnostic parameters and measured data analysis of the partial stroke test are re set by selecting and executing the command Reset PS...

Page 81: ...Automatic Automatic 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...

Page 82: ...ime Perm time until CLOSED position Status classification PST FST Solenoid valve triggered forced venting active Control loop error Set point start difference too high Current too low Supply pressure...

Page 83: ...l can be performed either in steps or in a ramp function Fig 20 For the test in a ramp function additionally the times for the increasing and decreasing ramps need to be defined After being activated...

Page 84: ...reached Max breakaway time The test is can celed when the time entered in Settling time before starting test has elapsed and the valve has still not changed its posi tion This cancelation condition o...

Page 85: ...is canceled the FST status reading indicates Not successful The reason for cancelation is marked by the Failure message in the Measured data as sessment folder Current test Defining parameters 1 Switc...

Page 86: ...me exceeded Perm time until CLOSED position exceeded Canceled by supply pressure 4 Diagnostics Monitoring tests Dynamic tests Full stroke test FST Start test Note concerning setting the FST diagnostic...

Page 87: ...test is used as the new reference measurement Activate ramp function Ramp time increasing Ramp time decreasing Waiting time after step change Test not completed If the test was not completed the reas...

Page 88: ...the valve to move to its fail safe position Monitoring of the input signal The i p converter is switched off when the input signal of the positioner at terminals 11 12 falls below 3 8 mA or 4 4 mA de...

Page 89: ...rter 17 Actuation of solenoid valve 5 Microcontroller 18 Electrical insulation 6 i p converter 19 D A converter 7 Air capacity booster 20 Communication interface 8 Pressure regulator 21 HART connectio...

Page 90: ...t up Type of application Code 49 h0 Control valve 3 Diagnostics Service maintenance SIL operator test Start SIL operator test 14 1 Analysis and monitoring SIL operator test completed successfully OK a...

Page 91: ...e manual mode or fail safe position mode Switch 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 fai...

Page 92: ...ng contact 0 24 V Select function Transmit switching state Activate local write protection Start PST Move valve to safety set point Switch AUTO MAN Start data logger Reset diagnostics Binary input con...

Page 93: ...Secondary variable assignment Set point Direction of action set point Set point after transit time specification Valve position Set point deviation e Absolute total valve travel Binary input status I...

Page 94: ...forced venting status 0 De energized 1 Energized 2 Not installed Condensed state 0 No message 1 Maintenance required 2 Maintenance request 3 Failure 4 Out of specification 7 Function check Temperature...

Page 95: ...Read only The number of zero calibrations performed since last initialization d4 No of initializations Read only Number of initializations performed since last start with default values d5 Zero limit...

Page 96: ...acting ELSE Other Diagnostic parameters h h0 Initialization including valve signature No YES ESC Initialization with YES or without No plotting the valve signature The valve signature involves the sig...

Page 97: ...test range Lower range value Code 49 d2 to Upper range value Code 49 d3 and back again in a ramp or in steps Recorded variables time set point valve position set point devia tion control signal A1 Tim...

Page 98: ...value p_out reference value Code 49 A7 and the p_out monitoring value d Step parameters for the partial stroke test PST d0 d1 Unassigned d2 Lower range value 0 0 to 100 0 ESC Start value of the test...

Page 99: ...g time after step change 1 0 to 240 0 s 2 0 s ESC Waiting time between step change from Lower range value Code 49 d2 to Upper range value Code 49 d3 and vice ver sa d9 Sampling time 0 2 to 250 0 s 0 8...

Page 100: ...ring value Code 49 E1 F3 p_out cancelation The test was canceled The signal pressure change p_out exceeded or fell below the ref erence value F4 Tolerance band ex ceeded The valve position deviation e...

Page 101: ...move to the fail safe position h3 Lower limit to start test 25 0 of the set point If the set point is between Lower limit to start test 25 and Fail safe action limit Code 49 h2 the valve remains in it...

Page 102: ...Proportional action coefficient Kp level lower than 3 was detected dur ing initialization Activate volume restriction in positioner output x signal Code 62 Actuator s measured value re cording failed...

Page 103: ...nd pressure limit Re initialize positioner Attachment Code 52 Wrong lever mounted Supply pressure too low valve cannot be moved to desired po sition Nominal range could not be reached during nominal r...

Page 104: ...ng actuators For your information only No fur ther action required Valve signature canceled Code 81 Error while recording valve signature Refer to section Restart the valve signature record ing or sta...

Page 105: ...itation The working range is limited at upper or lower range value The valve is jammed Check that pneumatic installa tions and connections are tight Check supply pressure Check plug stem for external...

Page 106: ...Diagnostics Monitoring PST FST status Status Code 84 The partial stroke test or the full stroke test has not been completed successfully Read test status See section 12 13 On off valve Code 85 The bre...

Page 107: ...eference assessment Assessment Valve position x histogram Diagnostic parameters Measured data in histogram Set point deviation e histogram Diagnostic parameters Measured data in histogram Cycle counte...

Page 108: ...cle count is set to 1000000 Start up Fail safe action Air supply failure NO NO YES Power supply failure of positioner NO NO YES Power supply failure of external solenoid valve NO NO YES Emergency mode...

Page 109: ...NO YES Preset alarm limits NO NO YES Alarm limits 1 to 3 NO NO YES Set points NO NO YES Device settings Positioner Attachment NO NO YES Inductive limit switch Code 38 NO NO NO Device settings Position...

Page 110: ...is not displayed after resetting Parameters of the Transfer characteristic on off folder are reset to their default settings CLOSED end position Code 14 NO Activate OPEN end position Code 15 NO OPEN...

Page 111: ...NO NO YES Pressure balancing NO NO YES Facing leakage class NO NO YES Friction coefficient of facing NO NO YES Bellows seal NO NO YES Valve seat diameter NO NO YES Kvs NO NO YES Kvs unit NO NO YES Plu...

Page 112: ...edium NO NO YES Device settings Further accessories Filter regulator NO NO YES Reversing amplifier NO NO YES Booster NO NO YES Quick exhaust valve NO NO YES 3 2 way valve NO NO YES Choke valve NO NO Y...

Page 113: ...lity factor NO NO YES Viscosity NO NO YES Flow coefficient NO NO YES Outlet velocity NO NO YES Relative travel angle NO NO YES Differential pressure ratio NO NO YES Sound pressure level NO NO YES Devi...

Page 114: ...ressure NO NO YES Critical pressure NO NO YES Isentropic exponent NO NO YES Compressibility factor NO NO YES Viscosity NO NO YES Outlet velocity NO NO YES Flow coefficient NO NO YES Relative travel an...

Page 115: ...tivate upper limit NO YES YES Upper limit NO YES YES Device settings Alarm settings Status classification Positioner All classifications NO NO YES Device settings Alarm settings Status classification...

Page 116: ...le range limitation NO NO YES Course of end position NO NO YES Positioner valve linkage NO NO YES Manipulated variable range NO NO YES Change in manipulated variable range NO NO YES Partial stroke tes...

Page 117: ...term monitoring Sensitivity sound level YES NO YES Diagnostics Monitoring tests Dynamic tests Valve dead band Lower range value YES YES YES Stop YES YES YES Waiting time after step change YES YES YES...

Page 118: ...band monitoring Code 49 E5 NO YES YES PST tolerance band Code 49 E6 NO YES YES Diagnostics Monitoring tests Dynamic tests Full stroke test FST Tolerance limit NO YES YES Activate ramp function NO YES...

Page 119: ...8389 1S EN 119 Appendix Abbreviations 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 variab...

Page 120: ...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 8389 1S EN 2015 05 29 English...