Table of Contents
Related Manuals for Samson 373 Series
Summary of Contents for Samson 373 Series
- Page 1 Series 373x Positioners EXPERT Valve Diagnostics Fig. 1 · Valve diagnostics with SAMSON TROVIS-VIEW Operator Interface, e.g. for Type 3730-3 Positioner Operating Instructions EB 8388 EN Firmware version 1.4x Edition November 2006...
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Page 2: Table Of Contents
Contents Contents Page Description....... 3 General ....... . 3 Diagnostic tests . -
Page 3: Description
Description The EXPERT diagnostics are completely in- Description tegrated in the positioner. Data required for diagnostics are compiled automatically and General the test data are analyzed in automatic or manual mode in the positioner itself. The re- These instructions EB 8388 EN supplement sulting data are used to issue classified sta- the standard mounting and operating in- tus alarms. -
Page 4: Diagnostic Tests
Description The required activation code can be ordered Note! (order number 1400-9318). On ordering The optional integrated solenoid valve is this option, specify the serial number of the implemented by a forced venting function in positioner (see nameplate or in the soft- Types 3731-x Positioners. -
Page 5: Actuator And Valve Specification Data
Description These parameters do not need to be changed if the control valve also has these default settings. Start the reference test After the activation has been successfully After EXPERT has been activated properly, completed, YES appears on the display. the reference graphs for future diagnostic purposes need to be plotted to allow the di- agnostics to function in their full scope. -
Page 6: Sub Initialization Mode, Double-Acting Actuator And Booster
Description ence test ) and right-click the parameter to nostic reference test. select Execute , or, alternatively, start the ref- During the reference test, tESt and d1 or erence test at the positioner itself by select- d2 appear in alternating sequence on the ing Code 48 as follows: positioner display. -
Page 7: Activation, Analysis And Presentation Of Diagnostic Data
Description Press once to cancel the tests MAN Booster: d1 (drive signal diagram steady-state) The analysis of the tests for both statisti- d2 (drive signal diagram hysteresis) cal information AUTO and tests MAN of d3 (static characteristic) drive signal diagrams is inactive. d4 (step response), and the test in statistical information Activation, analysis and... -
Page 8: Printing The Diagnostic/Esd Log
Description However, the test in statistical information summary (table of contents) are listed in AUTO drive signal diagram hysteresis re- the diagnostic log by default. 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. -
Page 9: Statistical Information Auto
Statistical information AUTO data, the plotting can be automatically trig- Statistical information AUTO gered when a start condition is fulfilled. The The signals x, w and y need to be analyzed travel condition (setpoint) or the optional in- on a more precise basis to obtain advanced tegrated solenoid valve (optional integrated diagnostic information also over the valve, forced venting) can be used to trigger the... - Page 10 Statistical information AUTO logger parameter and select Execute to start Trigger status: data logging. Triggered by the travel condition (setpoint) and/or solenoid valve condi- tion (forced venting) Permanent data logging Start value: The variables w, x, y, and e are logged ac- Limit indicating from which travel condi- cording to the adjusted scan rate and saved tion (setpoint) the data logger should be...
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Page 11: Travel Histogram
Statistical information AUTO logger parameter and select Execute . memory on triggering. The triggering event starts data logging Additionally, there is a pretrigger time avail- when the start value exceeds or falls below able to allow the variables to be stored that an entered value. -
Page 12: Setpoint Deviation Histogram
Statistical information AUTO how often the valve travel remains within a eter. On changing the scan rate, old data in class is shown in per cent. The result is pre- the short-term histogram are deleted. sented as a bar graph. The Average values x short parameter con- The Travel histogram folder contains tains the average class assignment for the... -
Page 13: Cycle Counter Histogram
Statistical information AUTO as a bar graph. Ideally, the setpoint devia- The Average values e short parameter indi- tion should be as small as possible. cates the class in which the last 100 mea- sured setpoint deviations were stored on av- Similar to the valve travel histogram, the erage in the FIFO memory. - Page 14 Statistical information AUTO The Dynamic stress factor parameter is spec- positioner service life and stored every 24 ified as a percentage reflecting the stress of hours in the positioner’s non-volatile mem- the packing. An alarm is issued if the dy- ory for long-term monitoring.
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Page 15: Drive Signal Diagram
Statistical information AUTO pinpoints to one of these events having oc- Drive signal diagram curred. A reduced spring force or a control valve 2.5.1 Steady-state drive signal with the fail-safe position ”Fail-to-close” leads to the drive signal y shifting down- The signature diagram plotting drive signal wards with an ever smaller gradient. - Page 16 Statistical information AUTO leaks in the pneumatics before they have an Graphs impact on the process. The Steady-state folder contains a common The measured data allows the following graph for long-term, short-term and refer- problems to be detected and the associated ence data.
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Page 17: Hysteresis Test (D5)
Statistical information AUTO again after waiting 30 seconds using the 2.5.2 Hysteresis test (d5) new operating point. The hysteresis test allows changes in friction If the test is canceled again at this point due to a change in the reference variable ∆w, to be analyzed and an alarm is issued when a significant change in friction is detected. - Page 18 Statistical information AUTO change in friction leads to an alarm being Long-term monitoring issued. The measured results ∆y are classified ac- cording to the valve position x in the valve Test requirements: position classes. The average value ∆y per The test is possible in relation to the travel valve position class is determined from all range between 2 and 98 %.
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Page 19: End Position Trend
Statistical information AUTO The following parameters are changed dur- tion x and the drive signal y are automati- ing hysteresis test/d5 correspondingly: cally logged and time-stamped by the oper- ating hours counter in automatic mode Lower x-range value (Code 8): 0 % when the valve moves to the lower end posi- Upper x-range value (Code 9): 100 % tion. - Page 20 Statistical information AUTO An alarm is generated after a change in zero point or when a zero point shift outside of the zero point limit is detected. Enter the zero point limit in the Positioner folder (> Error control > Zero point limit ) or over Code 48 in the positioner, selecting d5 (default setting 5 %).
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Page 21: Tests Man
Tests MAN Select the operating mode over Code 0 on Tests MAN the positioner or in Positioner folder (> Op- erating mode ). These tests are performed when the process in not running (i.e. manual operation). The Select the Start all tests parameter to start all positioner does not follow its reference vari- tests automatically in sequence. -
Page 22: Drive Signal Diagram Steady-State (D1)
Tests MAN The drive signal y is measured for each Drive signal diagram valve position x and stored in the positioner steady-state (d1) memory. The necessary data set for the ref- erence graph is automatically plotted and As described in detail in section 2.5 on the stored directly after initialization. -
Page 23: Drive Signal Diagram Hysteresis (D2)
Tests MAN Viewing the recorded parameters: Drive signal diagram hysteresis (d2) The Drive signal diagram steady-state folder contains the reference and repeated mea- Similar to the corresponding test in auto- surements plotted in a graph. matic mode, this test ( tESt d2 ) is used to an- The individual measured points are saved in alyze the change in friction forces. - Page 24 Tests MAN While the test is active, d2 and tESt appear Test requirements: on the positioner display in alternating se- A successfully plotted reference graph quence. indicates manual operating and repeated measurements are neces- mode. sary in order to analyze the data. If a reference graph still has not been Viewing the recorded parameters: plotted on starting the test, this test is...
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Page 25: Static Characteristic (D3)
Tests MAN It is also possible to define a test range by Static characteristic (d3) selecting the Start and End parameters. The The static performance of the control valve is ascendent and descendent are plotted within affected by the friction hysteresis and the the test range. -
Page 26: Step Response (D4)
Tests MAN Fig. 13 lists the settings and information pa- Step response (d4) rameters. The dynamic valve performance can be ex- While the test is active, d3 and tESt appear amined by recording the step responses. on the positioner display in alternating se- Usually, two steps in reference variable are quence. - Page 27 Tests MAN Viewing the recorded parameters: The parameters required to analyze the step response test such as reference variable w, valve position x, setpoint deviation e and drive signal y are plotted in graphs over time in the Step response folder. The Measured values subfolder contains all measured and analyzed parameters such as valve position, setpoint, drive signal,...
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Page 28: Status And Diagnostic Alarms
Status and diagnostic alarms The following folders contain particularly in- Status and diagnostic alarms formative data for valve diagnostics: Standard EXPERT diagnostic Positioner folder (process data) alarms Information on the current process vari- ables, condensed status, operating The standard EXPERT diagnostics provides mode, limit switch, temperature. -
Page 29: Logging
Status and diagnostic alarms Logging Condensed state The last thirty alarms (EXPERT/ EXPERT ) are To provide a better overview, the state of the stored in the positioner with a time-stamp positioner is summarized in a condensed (logged by the operating hours counter). status which is made up from a summary of However, it is important to note that the all classified positioner alarms. -
Page 30: Status Modification
Status and diagnostic alarms Status modification The classification of the status alarms can be changed as required. The following assign- ment of the states are: Maintenance alarm Maintenance required/Maintenance demanded No message possible Select Positioner folder (> Error control > Status classification ) to modify the classifica- tion of standard alarms issued by EXPERT. -
Page 31: Resetting Diagnostic Parameters
Resetting diagnostic parameters rotary pushbutton after selecting the corre- Resetting diagnostic sponding error code. parameters Resetting error codes as well as resetting op- tions such as logging or the total valve travel When an alarm is issued, the source of the can be performed using an engineering error should be first located and the error tool, for example, TROVIS-VIEW3 software. - Page 32 Resetting diagnostic parameters Note that the corresponding short-term his- ence data are overwritten. The new refer- togram/short-term monitoring is also reset ence data and the optimized control param- on resetting long-term histogram/long-term eters cause the following statistical informa- monitoring. tion AUTO and MAN tests to be reset: On performing the tests MAN, the measur- Drive signal diagram steady-state ing data of the last measurement as well as...
- Page 33 Resetting diagnostic parameters If the same status classification is to be used in future, you can upload the settings onto a PC over, for example, the TROVIS-VIEW software. Mounting the positioner onto another con- trol valve As the EXPERT extended diagnostics pro- vides statements about the entire control valve, the data from statistical information AUTO and tests MAN need to be reset...
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Page 34: Diagnostic Parameters Saved In Non-Volatile Memory
Diagnostic parameters saved in non-volatile memory Diagnostic parameters saved in non-volatile memory The following parameters are saved in a non-volatile memory to prevent their loss: Which data are saved if a Cyclic saving (24 h) parameter change is detected Statistical information AUTO Data logging, scan rate, start value, logging limit, trigger Data logger... -
Page 35: Troubleshooting
Troubleshooting Troubleshooting Fault category Alarm Remedy Resetting alarm Supply pressure Possibly changed (test) Reset y-x signature measured Possibly at full capacity (test) data Check supply pressure. Refer to the section on Reset over Code 57. supply pressure in the EB Possibly insufficient Reset y-x long-term and of the positioner. - Page 36 Troubleshooting End position Zero point shift downwards trend monotonic Average value above the reference line Zero point shift upwards monotonic Average value above the reference line Zero point fluctuates Average value above the reference line Reset Check plug and seat lower end position trend Zero point shift downwards monotonic...
- Page 37 Troubleshooting Friction Much higher over the full range of valve Much lower over the full Reset range of valve hysteresis long-term and Much higher over part of the short-term monitoring range Check packing Much lower over part of the range Much higher/lower over the full range of valve (test) Reset...
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Page 38: Expert + Without Trovis-View
EXPERT without TROVIS-VIEW EXPERT without TROVIS-VIEW The EXPERT valve diagnostics are displayed in different ways depending on the type of communication and the connected engineering tool. The TROVIS-VIEW software with communication over the SSP interface provides full access to EXPERT diagnostic functions: Numerical display of parameters Display of parameters in the form of graphs... - Page 39 EXPERT without TROVIS-VIEW Communication HART – DD HART-DTM HART-EDD FF – DD Profibus-EDD Engineering tool e.g. PACTWare e.g. Siemens PDM Various Siemens PDM Steady-state drive No graphical – • – • display signal · short-term No numerical display Hysteresis test · No graphical •...
- Page 40 SAMSON AG · MESS- UND REGELTECHNIK Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany Phone: +49 69 4009-0 · Fax: + 49 69 4009-1507 EB 8388 EN Internet: http://www.samson.de...