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- Samson
- Valve Positioners
- 3730-2
- Operating Instructions Manual
Samson 3730-2 Operating Instructions Manual
Summary of 3730-2
Page 1
Operating instructions eb 8389 en firmware version edition august 2017 series 3730 and 3731 types 3730-2, 3730-3, 3730-4 and 3730-5 as well as types 3731-3 and 3731-5 electropneumatic positioners expertplus valve diagnostics 1.5x and 1.6x.
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2 eb 8389 en note on these mounting and operating instructions these mounting and operating instructions assist you in mounting and operating the device safely. The instructions are binding for handling samson devices. Î for the safe and proper use of these instructions, read them carefully and keep...
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Contents eb 8389 en 3 1 safety instructions and measures ...................................................................7 1.1 notes on possible property damage ................................................................9 2 operation .............................................................
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4 eb 8389 en contents 4.6 drive signal diagram steady-state .................................................................49 4.6.1 analysis and monitoring ...............................................................................51 4.6.2 resetting single status messages ........................
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Eb 8389 en 5 contents 7.3.1 resetting single status messages ..................................................................104 7.4 sound level monitoring ...............................................................................105 7.4.1 resetting single status messages .......................
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6 eb 8389 en.
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Eb 8389 en 7 safety instructions and measures 1 safety instructions and measures intended use expertplus is a diagnostic firmware integrated into the positioner which allows the predic - tive, status-oriented maintenance of valves with pneumatic actuators. Expertplus records the valve condition whil...
Page 8
8 eb 8389 en safety instructions and measures warning against residual hazards the software in online mode has a direct influence on the connected device and, as a result, on the valve. To avoid personal injury or property damage, plant operators and operating personnel must prevent hazards that cou...
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Eb 8389 en 9 safety instructions and measures 1.1 notes on possible property damage notice ! Valve malfunction due to a configuration that does not meet the requirements of the application. Settings for the expertplus valve diagnostics can be made in the trovis-view software. In online mode of this ...
Page 10: Overview of Functions
Overview of functions throttling service on/off service no configuration required for monitoring valve position x histogram section 4.3 b set point devia- tion histogram section 4.4 b cycle counter histogram section 4.5 b drive signal di- agram, steady- state section 4.6 section 5.1 b t trend of tra...
Page 11: 2 Operation
Eb 8389 en 11 operation 2 operation operation using trovis-view/dd/dtm/ edd expertplus allows the parameters to be viewed or changed using the trovis-view software or dd/dtm/edd. − trovis-view · samson user interface used to configure various samson de - vices − dtm · device type manager to describe...
Page 12: 2.3
12 eb 8389 en operation 2.3 differences between firm - ware versions these mounting and operating instructions are valid for types 3730-2/-3/-4/-5 and types 3731-3/-5 positioners in the following firmware versions: positioner firmware 1.5x firmware 1.6x type 3730-2 • • type 3730-3 • • type 3730-4 • ...
Page 13
Eb 8389 en 13 st ar t-up initialization mode â â â max nom man â initialization with reference test yes ß à no subsequent initialization â operating mode = man â â zero point reference of drive signal diagram steady- state (d1) reference of drive signal diagram hysteresis (d2) reference of drive sig...
Page 14: 2.4.1 Reference Test
14 eb 8389 en operation the derivative-action time until the desired behavior is reached. When the maximum value of 4 is reached for the derivative-ac- tion time, the proportional-action coefficient can be reduced in steps. Changing the proportional-action coefficient influences the set point deviat...
Page 15: 2.5 Diagnostic Functions
Eb 8389 en 15 operation for 'drive signal diagram steady-state' or 'drive signal diagram hysteresis'. Diagnostics − start reference test (code 48 - d7) or start-up − initialization with reference test (code 48 - h0): yes , [no] 2.5 diagnostic functions there are two main groups of diagnostic functio...
Page 16: 2.5.2 Analysis
16 eb 8389 en operation nating sequence on the display. See sec- tion 4.1. 2.5.2 analysis table 1 shows the diagnostic functions and their statements on the condition of the valve depending on the application type..
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Eb 8389 en 17 operation table 1: diagnostic functions and test analysis diagnostic functions control valve open/ close (on/off) valve 1) analysis see section statistical information open/close 1) – • breakaway time transit time valve end position 4.1, page 27 data logger 3), 5) • • depending on trig...
Page 18
18 eb 8389 en operation diagnostic functions control valve open/ close (on/off) valve 1) analysis see section tests drive signal diagram, steady- state • • air supply leakage pneumatics actuator springs 5.1, page 63 drive signal diagram hysteresis • • friction 5.2, page 67 static characteristic • • ...
Page 19: 3 Monitoring
Eb 8389 en 19 monitoring 3 monitoring 3.1 status messages the valve diagnostics integrated into the po- sitioner generates classified status messages. There are two types of status messages: standard status messages and extended status messages. Standard status messages standard status messages cont...
Page 20: Sages
20 eb 8389 en monitoring the following classifications are possible: − no message if an event is classified as “no message”, this event does not have any affect on the condensed state. − function check (not type 3730-5) test or calibration procedures are per- formed in the positioner. The positioner...
Page 21: 3.2 Condensed State
Eb 8389 en 21 monitoring − the reference value of 'trend of travel end position' (statistical information) is deleted. − the reference values of tests ('drive sig- nal diagram steady-state' and 'drive sig- nal diagram hysteresis') remain saved. − status classification and data logs re - main saved. ...
Page 22: Fault Alarm Output
22 eb 8389 en monitoring the condensed state is marked by until the positioner data have been uploaded. Diagnostics > status messages − condensed state (code 48 - d6) the condensed state can be read in the posi- tioner display in code 48 - d6 (see table 3). 3.2.1 condensed state at the fault alarm o...
Page 23
Eb 8389 en 23 monitoring table 2: reset functions all adjusted parameters and recorded measured values of the specified diagnostic test are reset, if not listed separately. Function resetting single status messages code 36 - diag code 36 - std operating hours counter device switched on since (last) ...
Page 24
24 eb 8389 en monitoring function resetting single status messages code 36 - diag code 36 - std drive signal diagram hysteresis (d2) reference values no no yes measured values yes yes yes static characteristic (d3) no yes yes partial stroke test (pst) (d4) yes no yes full stroke test (fst) (d6) yes ...
Page 25: 4 Statistical Information
Eb 8389 en 25 statistical information 4 statistical information the positioner records the set point w , valve position x , drive signal y and set point devi - ation e even while the process is running to obtain information on the valve, actuator and pneumatic air supply. The data com- piled while t...
Page 26
26 eb 8389 en st ar t-up prerequisite: – application type: open/close (on/off) â operating point, limit fail-safe position, limit operating point â limit value travel analysis limit value time analysis status classification (ne 107) open/close status active define parameters for partial stroke test ...
Page 27
Eb 8389 en 27 statistical information 4.1 open/close (on/off) valve 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • the travel range of open/close (on/off) is defined by the fail-safe position and the op - erating point. As a result, the following pa- rameters to determine the working range and ...
Page 28: 4.1.1 On/off Diagnosis
28 eb 8389 en statistical information of the travel range and remains there for longer than six seconds (see section 5.4.1). The pst diagnostic parameter 'step start' must be within the defined range of the 'tolerance limit of step response' for the partial stroke test to start. After the partial st...
Page 29: Messages
Eb 8389 en 29 statistical information 4.1.2 analysis and monitoring valve end position (falling) valve end position (rising) breakaway time (rising) transit time (rising) breakaway time (falling) transit time (falling) x [%] w [%] t [s] fig. 1: analysis of diagnostics for on/off valve the analysis p...
Page 30
30 eb 8389 en st ar t-up selection â â â permanent triggered â â scan rate trigger status start trigger via â start (operator software) â â â â â â â con- densed state w, x, e, y sol. Valve/ forced vent- ing w or solenoid valve/forced venting bi 1) bi 2) (fb di) fb do 3) â â â trigger value trigger ...
Page 31: 4.2 Data Logger
Eb 8389 en 31 statistical information 4.2 data logger the data logger records the measured vari- ables (valve position x, set point w, set point deviation e and drive signal y). The recorded data are plotted against time in a graph. The data logger is interrupted and must be reactivated when one of ...
Page 32: State
32 eb 8389 en statistical information defining parameters 1. Select 'permanent' (selection). 2. Enter scan rate. 3. Start data logger. The 'test information' status indicates 'test active'. 1. Diagnosis > statistical information > data logger − selection: [permanent] 2. − scan rate: 0.2 to 3600.0 s,...
Page 33: 4.2.2.2
Eb 8389 en 33 statistical information − trigger via condensed state: no message, [maintenance required], maintenance de- manded, out of specification 1) , mainte- nance alarm 3. − scan rate: 0.2 to 3600.0 s, [1.0 s] 4. − start data logger 1) type 3730-5: cannot be selected 4.2.2.2 triggered by set p...
Page 34: Noid Valve/forced Venting
34 eb 8389 en statistical information this function is only active when 'trigger band' ≠ 0. 'trigger edge' = "band entry" top band limit = trigger value + ½ trigger band bottom band limit = trigger value – ½ trigger band trigger value trigger band w, x, y, e the conditions for starting a trigger eve...
Page 35: Internal Solenoid Valve/
Eb 8389 en 35 statistical information 2. − trigger status: start trigger via int. Sol. Valve/forced venting − pre-trigger time: 0.0 s to 100 x 'scan rate', [0.0 s] 3. − scan rate: 0.2 to 3600.0 s, [1.0 s] 4. − start data logger 4.2.2.4 triggered by set point or internal solenoid valve/ forced ventin...
Page 36: 1 Or 2
36 eb 8389 en statistical information 4.2.2.6 triggered by discrete input 1 or 2 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • 1) 1) function available in firmware 1.5x and lower positioners have an integrated binary input as standard (bi1) and can be optionally fit - ted with another binary input (bi...
Page 37: 4.3 Travel Histogram X
Eb 8389 en 37 statistical information 4.3 travel histogram x 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the valve position histogram is a statistical analysis of the plotted valve positions. It pro- vides information about the range in which valve mainly works during its service life and ...
Page 38
38 eb 8389 en statistical information − the 'average value x short' contains the average class assignment for the last 100 measured values. The positioner saves the valve positions in a circular buffer, which holds 100 measured values at one time. On changing scan rate in 'scan rate short- term hist...
Page 39: Messages
Eb 8389 en 39 statistical information 4.3.2 resetting single status messages the 'working range' and the 'shifting work- ing range' messages can be reset by select- ing and executing the command "reset 'travel histogram x'". This command resets all diagnostic parameters and measured da- ta of the hi...
Page 40: Gram
40 eb 8389 en statistical information 4.4 set point deviation histo- gram 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the set point deviation histogram contains a statistical analysis of any set point deviations recorded. It provides information on to which extent a set point deviation has...
Page 41
Eb 8389 en 41 statistical information short-term monitoring in order to be able to recognize any short- term changes in set point deviation, the posi- tioner records the set point deviation accord- ing to the adjusted 'scan rate short-term his- togram' and analyses the last 100 measured values. − th...
Page 42: Messages
42 eb 8389 en statistical information leakage' messages with the selected status classifications. If almost all set point deviations during the short-term monitoring are greater than 1 % or smaller than –1 %, this may indicated that the actuator or valve stem is jammed. In this case, the positioner ...
Page 44
44 eb 8389 en st ar t-up stem seal â â â â â self-adjusting adjustable other, -/- bellows seal â max. Cycle counter limit â â â â â status classification (ne 107) external leakage perhaps soon expected status classification (ne 107) external leakage perhaps soon expected process â â determining the ...
Page 45
Eb 8389 en 45 statistical information 4.5 cycle counter histogram 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the cycle counter histogram provides a sta- tistical analysis of the cycles. As a result, the cycle counter also provides information on the dynamic stress of a bellows seal and/or...
Page 46
46 eb 8389 en statistical information the positioner saves the cycles in a circular buffer, which holds 100 measured values at one time. − the 'average value e short' contains the average class assignment of cycle heights for the last 100 measured values. Defining parameters 1. Select the type of st...
Page 47: Messages
Eb 8389 en 47 statistical information 4.5.2 resetting single status messages the 'external leakage' message can be reset by selecting and executing the command "reset 'cycle counter histogram'". By selecting and executing the "reset 'cycle counter histogram'" command, all diagnostic parameters and m...
Page 48
48 eb 8389 en st ar t-up requirements: – model: single acting – booster: not present – application type: control valve reference test completed (see section 2.4.1) â status classification (ne 107) air supply actuator springs leakage pneumatics perhaps modified/ not enough working at full capacity pe...
Page 49: 4.6 Drive Signal Diagram
Eb 8389 en 49 statistical information 4.6 drive signal diagram steady-state 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the 'drive signal diagram steady-state' re- cords the drive signal y in relation to the valve position x. The drive signal y is based on the internal control signal of th...
Page 50
50 eb 8389 en statistical information − no measured values are recorded if 'enable set point cutoff decrease' (tight- closing function, code 14) is active and the valve moves to the value entered in 'set point cutoff decrease'. Short-term monitoring in order to be able to recognize any short- term c...
Page 51: Messages
Eb 8389 en 51 statistical information 4.6.1 analysis and monitoring analysis of the drive signal for control valves starts one hour after the observation period begins. No analysis is performed for on/off valves. The following effects can be read by com- paring the correlation between the drive sig-...
Page 52
52 eb 8389 en st ar t-up requirements – model: single acting – booster: not present – application type: control valve – reference test completed (see section 2.4.1) â enable time distance â â immediately user-defined â min. Time distance from test â cancellation condition tolerance band of hysteresi...
Page 53: Teresis
Eb 8389 en 53 statistical information 4.7 drive signal diagram hys- teresis 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the 'drive signal diagram hysteresis' records the change in drive signal ∆y in relation to the valve position x. The drive signal y is based on the internal control signa...
Page 54
54 eb 8389 en statistical information − required transit time open (code 21): variable − required transit time closed (code 22): variable based on the operating point, the test is per- formed with a change in travel of less than 1 % to find the change in drive signal (∆y). The changes in drive signa...
Page 55
Eb 8389 en 55 statistical information 1. Settings > positioner > error control > classification report > extended > ... Friction − much higher over whole range 1) : [ ], , , ( ), ( ) − much lower over whole range 1): [ ], , , ( ), ( ) − much higher over section 1) : [ ], , , ( ), ( ) − much lower ov...
Page 56: Messages
56 eb 8389 en statistical information the results from the statistical information test can be checked by performing a test from tests (out-of-service diagnostics) if the process allows it. See section 5.2. 4.7.2 resetting single status messages the messages 'friction' and 'external leak- age' are r...
Page 58
58 eb 8389 en st ar t-up prerequisite - enable set point cutoff decrease: on â threshold value for recording data, zero point limit â alarm settings (ne 107) observing end position x [%] t [s] 0 process reference test completed? Section 2.4.1 ß no yes â à first zero point = reference à subsequent ze...
Page 59
Eb 8389 en 59 statistical information 4.8 trend of travel end position 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the travel end position trend is used to detect an alternating zero point or a creeping zero point shift due to seat and plug wear or dirt between the seat and plug. Data are ...
Page 60
60 eb 8389 en statistical information defining parameters 1. Activate tight-closing function. 2. Set conditions for saving reference value and zero point (see section 4.8.1). 3. Select classification for status messages. 1. Settings > positioner > reference variable − enable set point cutoff decreas...
Page 61: Messages
Eb 8389 en 61 tests diagnosis > status messages > extended − observing end position 4.8.2 resetting single status messages the 'observing end position' message and the measured data of the end position trend are reset by the command "reset 'lower end position". If only the reference zero point is to...
Page 62
62 eb 8389 en st ar t-up requirements – model: single acting – booster: not present – target mode: manual â status classification (ne 107) air supply actuator springs leakage pneu- matics â manu al mode (tes t) start test reference test completed? See section 2.4.1 no à yes â first test = reference ...
Page 63: 5.1 Drive Signal Diagram
Eb 8389 en 63 tests 5.1 drive signal diagram steady-state 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the 'drive signal diagram steady-state' (tests) allows you to check the results of the drive signal diagram steady-state in statisti- cal information (in-service monitoring) more closely (...
Page 64
64 eb 8389 en tests 1. Settings > identification > positioner > actu - ator − model: single acting, [-/-] 2. − booster: not present, [-/-] defining parameters 1. Switch to manual mode. 2. Select classification for status messages. 3. Start test. The 'test information' status indicates 'running test'...
Page 65: Messages
Eb 8389 en 65 tests 5.1.1 analysis and monitoring the following effects can be read by com- paring the correlation between the drive sig- nal and valve position measured during the test and in the reference graph: − the drive signal runs below the reference as the gradient rises. − the drive signal ...
Page 66
66 eb 8389 en st ar t-up requirements – model: single acting – booster: not present – target mode: manual â cancellation condition tolerance band of hysteresis status classification (ne 107) friction â manu al mode (tes t) start test â reference test completed (see section 2.4.1)? No à yes â first t...
Page 67: 5.2 Drive Signal Diagram
Eb 8389 en 67 tests 5.2 drive signal diagram hysteresis 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the 'drive signal diagram hysteresis' (tests) allows you to check the results of the drive signal diagram hysteresis in statistical infor- mation (in-service monitoring) more closely (see se...
Page 68
68 eb 8389 en tests 1. Settings > identification > positioner > actuator − model: single acting, [-/-] 2. − booster: not present, [-/-] defining parameters 1. Switch to manual mode. 2. Select classification for status messages. 3. Set cancellation condition (see sec- tion 5.2.1). 4. Start test. The ...
Page 69: Messages
Eb 8389 en 69 tests waiting 30 seconds using the new oper- ating point. − if this test is also canceled by a change in set point (∆w) , it is reactivated after waiting 60 seconds using the new oper- ating point. − the test is started again ten times at the maximum. The time between tests is in- crea...
Page 70: 5.3 Static Characteristic
70 eb 8389 en tests 5.3 static characteristic 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the static performance of the control valve is affected by the friction hysteresis and the elastic processes in the valve stem packing. The test is started in the manual mode. The positioner specifies...
Page 71: Messages
Eb 8389 en 71 tests 2. Select test parameters. 3. Start test. The 'test information' status indicates 'test active'. 'd3' and 'test' are indicated in alternating sequence on the positioner display. 'function check' is activated as the condensed state. 1. Operation > operating mode 1) − target mode (...
Page 72
72 eb 8389 en st ar t-up step response settings: step start, step end, tolerance limit of step response, settling time before test start, delay time after step, scan rate, number of step responses * note! T he posit ioner is write-pr otected when tests ar e per for med ac cor ding to a schedule (on-...
Page 73
Eb 8389 en 73 start conditions pst with application type = 'open/close valve' operating mode â â â safe auto man w fail-safe position' 25 % 50 % w > 'limit fail-safe position' â pst mode pst mode â â â â â â pst man pst auto pst auto pst man pst man pst auto ∆ t > 6 s 25 50 x [%] w [%] t [s] â â pst...
Page 74
74 eb 8389 en start conditions pst with application type = 'control valve' operating mode â â â â safe auto man â pst mode â â pst man pst auto â â â â pst not possible pst not possible pst 1, 3) possible pst 1, 2, 3) possible â â â â fail-safe action of actuator (fail-safe position operating mode) ...
Page 75
Eb 8389 en 75 tests 5.4 partial stroke test (pst) the partial stroke test (pst) is particularly suitable for the status-oriented detection of malfunctions in pneumatic shut-off valves. As a result, the probability of failure on demand (pfd) can be reduced and it may be possible to extend maintenance...
Page 76
76 eb 8389 en tests − characteristic selection (code 20): linear − required transit time open (code 21): variable − required transit time closed (code 22): variable during the partial stroke test, the valve moves from its current start value to a de- fined end value and back to the initial posi - ti...
Page 77
Eb 8389 en 77 tests test cancellation conditions various cancellation conditions provide ad- ditional protection against the valve slam- ming shut or moving past the end position. The positioner cancels the partial stroke test when one of the following cancellation con- ditions is fulfilled: − 'max....
Page 78
78 eb 8389 en tests − 'supply pressure/friction': an insufficient supply pressure or excessive friction oc- curred during the test. − 'difference w - step start too high': the 'step start' is outside the range of oper- ating point ± 'tolerance limit of step re- sponse'. − 'reference variable was cha...
Page 79
Eb 8389 en 79 tests − x control value (code 49 - e1): –10.0 to 110.0 %, [0.0 %])/[85.0 %] − activation delta y-monitoring (code 49 - a8): [no]/[yes] − delta y-monitoring value (code 49 - a9): 0 to 100 %, [0 %]/[10 %] − activation pst tolerance band control (code 49 - e5): yes, [no] − pst tolerance b...
Page 80: Off Valve
80 eb 8389 en tests − the 'ramp time (rising)' must be greater than the corresponding value for 'mini- mum transit time close' (code 41) deter- mined during initialization. − the 'ramp time (falling)' must be greater than the corresponding value for 'mini- mum transit time open' (code 41) deter- min...
Page 81
Eb 8389 en 81 tests − edge control binary input: [on: open switch/off: closed switch], on: closed switch/off: open switch − fail-safe reference value: 0.0 to 100.0 %, [50.0 %] − configuration binary input: [active], passive further details on optional binary input can be found in section 8. 5.4.3 an...
Page 82: Messages
82 eb 8389 en tests 5.4.4 resetting single status messages the diagnostic parameters and measured data analysis of the partial stroke test are re- set by selecting and executing the command 'reset pst'. The positioner saves the measured data analysis of the last three partial stroke tests. The analy...
Page 83
Eb 8389 en 83.
Page 84
84 eb 8389 en st ar t-up prerequisite – operating mode: manual â tolerance limit of step response, settling time before test start, delay time after step, scan rate activation of ramp function â 100 0 x [%] t [s] â â 100 0 x [%] t [s] no 1) yes â ramp time (rising) ramp time (falling) â cancellation...
Page 85
Eb 8389 en 85 tests 5.5 full stroke test (fst) 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • • • • the dynamic valve performance can be eval- uated by performing the test. The full stroke test is started in the manual mode. The following listed parameters are activated while the full stroke test i...
Page 86
86 eb 8389 en tests the 'delay time after step' before performing a second step change in the opposite direc- tion from the fail-safe position to the start position of the first step. After the 'delay time after step' has elapsed, the valve moves back to its operating point. The 'tolerance limit of ...
Page 87
Eb 8389 en 87 tests this cancellation condition only becomes effective after it has been activated ("ac- tivation 'allowed time to reach full closed position'" = yes). Additionally, the full stroke test is canceled when one of the following events arises: − 'aborted by int. Solenoid valve/forced ven...
Page 88
88 eb 8389 en tests types 3730-2/-3/-4/-5 (1.5x) and type 3731-3: 4. Settings > positioner > error control > classification report > extended > pst/fst − pst/fst - status active: , [ ], , ( ), ( ) type 3730-5 (1.6x) and type 3731-5: 4. Settings > positioner > diagnosis configuration > classification...
Page 89: Messages
Eb 8389 en 89 tests changes in the diagnostic parameters listed below affect the test. The results of the next following full stroke test is used as the new reference measurement: − 'activate ramp function' − 'ramp time (rising)' − 'ramp time (falling)' − 'delay time after step' test not completed i...
Page 90: 6 Dynamic Hart
90 eb 8389 en dynamic hart® variables 6 dynamic hart ® variables 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • the hart ® specification defines four dynam - ic variables consisting of a value and an en- gineering unit. These variables can be as- signed to device parameters as required. The universal...
Page 91
Eb 8389 en 91 dynamic hart® variables table 4: dynamic hart ® variables assignment variable meaning unit reference variable reference variable % valve set point valve set point % target position target position % valve position process variable % set point deviation e set point deviation e % absolut...
Page 92
92 eb 8389 en st ar t-up prerequisites – positioner accessories identification: leakage sensor – enable set point cutoff decrease: on â reference test repetition test with process conditions user-defined á â settling time before level measuring activation level lower than â à measured points of acti...
Page 93: 7 Leakage Sensor
Eb 8389 en 93 leakage sensor 7 leakage sensor 3730-2 3730-3 3731-3 3730-4 3730-5 3731-5 • • • by upgrading the positioner with a leakage sensor, it is possible to detect seat leakage when the valve is in the closed position. To achieve this, the leakage sensor measures the sound pressure level (db) ...
Page 94: Sensor
94 eb 8389 en leakage sensor 7.1 start-up of the leakage sensor to be able to use the full scope of functions, the response of the leakage sensor to stan- dardized conditions and to the prevailing process conditions must be measured. Fur- thermore, the limit to activate the alarm must be entered. 7....
Page 95
Eb 8389 en 95 leakage sensor phase 2: a 0.30 % band is placed around the last point that the valve moved to. One third of this band lies in front of the point that the valve moved to and two thirds of the band lies behind it. The band itself is subdi- vided into eleven new measured points. Each meas...
Page 96: 7.1.1.1 Analysis
96 eb 8389 en leakage sensor 2. Diagnosis > leakage detection > reference test − settling time before level measuring: 1 to 255 s, [5 s] − activation level: 3 to 255 db, [10 db] − measured point change: 0.00 to 100.00 % [1: 0.00 %; 2: 0.10 %; 3: 0.20 %; 4: 0.30 %; 5: 0.40 %; 6: 0.50 %; 7: 0.60 %; 8:...
Page 97: 7.1.2 Repetition Test
Eb 8389 en 97 leakage sensor operation > reset − reset 'leakage detection – reference test' 7.1.2 repetition test the repetition test (fig. 17) measures the re - sponse of the leakage sensor to process con- ditions. Process medium, inlet and outlet pressures as well as the process environment can ha...
Page 98
98 eb 8389 en leakage sensor phase 1 successful: the sound pressure level ex- ceeded the adjusted 'activation level' (10 db) be - tween set points 4 and 5. Phase 2 starts. If the 'activation level' is not reached after the valve has moved to all eleven measured points, the test is canceled. The canc...
Page 99
Eb 8389 en 99 leakage sensor phase 3: the valve moves to the user-defined points valid for phase 1 one after the other. This is plotted in a sound level vs. Travel graph. The graph shows where the point of activation is and to which value the 'activa- tion level' must be reduced to allow the test to...
Page 100: 7.1.2.1 Analysis
100 eb 8389 en leakage sensor 7.1.2.1 analysis while the repetition test is running, the posi- tioner determines three alarm limits from which alarm limits 2 and 3 can be used for the alarm setting. The relation between valve position x [%] and sound level [db] is shown in trovis-view: − relation 1:...
Page 101
Eb 8389 en 101 leakage sensor compared to the alarm limits. Which mean sound level is to be used for comparison can be selected in 'alarm release': − average of current/last tight-closing: the mean value calculated from the cur- rent sound level and from the last four sound levels measured while the...
Page 102: 7.1.2.3 Monitoring
102 eb 8389 en leakage sensor 7.1.2.3 monitoring if the determined mean sound level exceeds the 'alarm limit 2', the positioner generates a 'inner leakage' message with status classi- fication selected for 'alarm limit 2 exceed - ed'. If the determined mean sound level exceeds the 'alarm limit 3', t...
Page 103: 7.2 Short-Term Monitoring
Eb 8389 en 103 leakage sensor 7.2 short-term monitoring short-term monitoring provides an insight in- to short-term changes in the sound level while the valve is tightly shut. Data are recorded in the background re- gardless of the operating mode selected. Da- ta logging does not need to be activate...
Page 104: Messages
104 eb 8389 en leakage sensor 7.2.1 resetting single status messages the short-term monitoring (diagnostic pa- rameters, measured data and analysis) can be reset by selecting and executing the com- mand "reset 'short-term leakage sensor monitoring'". The data in the analysis of measured data folder ...
Page 105: Messages
Eb 8389 en 105 leakage sensor 7.4 sound level monitoring the sound level monitoring is shown in a his- togram. The distribution of recorded sound levels within fixed classes of valve position x is revealed. The leakage sensor records the sound level every second and assigns the data into pre- define...
Page 106: 8 Binary Input
106 eb 8389 en binary input 8 binary input 8.1 types 3730-2/-3 and type 3731-3 the following description only applies to po- sitioners fitted with an optional binary input. The optional binary input can be used to ac- tivate various functions: − [transfer switching state] the switching state of the ...
Page 107: 8.2
Eb 8389 en 107 binary input 8.2 type 3730-4 the optional binary input bi2 can be config - ured over the profibus pa network in the config_binary_input_2 parameter of the physical block. See u kh 8384-4. 8.3 types 3730-5 and 3731-5 binary input bi1 the following functions can be activated by the stan...
Page 108
108 eb 8389 en binary input issued in the binary_input2 parameter of the ao transducer block. − internal solenoid valve in this setting, the current switching state of the optional internal solenoid valve is analyzed and issued over out_d. '0' in- dicates a de-energized solenoid valve (u - noid valv...
Page 109: 9 Appendix
Eb 8389 en 109 appendix 9 appendix 9.1 code list code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 48* d0 current temperature –55.0 to 125.0 current operating temperature [°c] inside the posi...
Page 110
110 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. D8 expertplus activation firmware version 1.5x and higher without function 48* diagnostic parameters h h0 initializat...
Page 111
Eb 8389 en 111 appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 49* a4 status classification of pst status c maintenance required ok no message cr maintenance demanded b maintenance...
Page 112
112 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 49* d3 step stop 0.0 to 100.0 %, [90.0 %] 1), 2), 3) [95 %] 4), 5) stop value for step response d4 activation of ramp...
Page 113
Eb 8389 en 113 appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. E cancellation conditions of the partial stroke test (pst) e0 activation x control [no] 1), 2), 3) [yes] 4), 5) activ...
Page 114
114 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. F5 max. Test duration exceeded the test was not completed within the max. Test time and was auto- matically canceled....
Page 115: 9.1.1
Eb 8389 en 115 appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 49* h5 operating point limit 55.0 to 100.0 % of reference variable, [75.0 %] types 3730-2/-3 and type 3731-3 only val...
Page 116
116 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 48* f3 device start up counter f4 reset communication controller f5 reset closed-loop controller counter f6 reset bus...
Page 117
Eb 8389 en 117 appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 48* t2 final_position_value. Value current valve position in relation to the working range and its status t3 final_po...
Page 118: 9.1.2 F
118 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. 48* l1 actual mode di2 current operating mode 1) l2 di2 trd pv_d.Value discrete input variable and its status l3 di2 ...
Page 119
Eb 8389 en 119 appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. F3 simulate activation of simulation mode 48* ao function block a0 target mode target operating mode a1 actual mode c...
Page 120
120 eb 8389 en appendix code no. Parameter – readings/ values [default setting] description codes with marked with an asterisk (*) must be enabled with code 3 prior to configuration. T4 target mode di1 trd target operating mode 48* t5 actual mode di1 trd current operating mode t6 block error di1 trd...
Page 121
Eb 8389 en 121 appendix 9.2 error messages and recommended corrective action message possible reasons recommended action status classifica - tion single reset diagnostics > status messages control loop (code 57) − actuator is blocked. − positioner attachment has shifted subsequently. − insufficient ...
Page 122
122 eb 8389 en appendix message possible reasons recommended action status classifica - tion single reset x signal (code 62) − actuator's measured value recording failed. − conductive plastic element defective. Return positioner to samson for repair. • [ ] – i/p converter (code 64) current circuit o...
Page 123
Eb 8389 en 123 appendix message possible reasons recommended action status classifica - tion single reset initialization time exceeded (code 53) − initialization cycle takes too long (> 90 s). The positioner returns to its previous operating mode. − supply pressure too low. Actuator too slow. − posi...
Page 124
124 eb 8389 en appendix message possible reasons recommended action status classifica - tion single reset hart parameter (code 74); types 3730-3/3731-3 only error in hart ® parameters not critical to control operation. Confirm error and change parameter, if necessary. • [ ] • options parameter (code...
Page 125
Eb 8389 en 125 appendix message possible reasons recommended action status classifica - tion single reset working range − the working range is mainly close to the closed/max. Open position. − the working range is mainly in the closed/ max. Open position. Rethink the working range. • [ ] • section 4....
Page 126
126 eb 8389 en appendix message possible reasons recommended action status classifica - tion single reset open/close − the breakaway time or transit time differs from the reference value by the amount entered in 'limit value travel analysis'. − the valve end position differs from the reference value...
Page 127
Eb 8389 en 127 appendix data saved in a non-volatile memory: saved directly after they change saved cyclically every 24 h short-term monitoring lower end position measured values tests drive signal diagram steady-state (d1) values of the reference test 'reference time stamp' drive signal diagram hys...
Page 128
128 eb 8389 en appendix 9.4 determining the ramp times in partial stroke tests suitable ramp times for the partial stroke test can be determined by performing a full stroke test. To perform a full stroke test, observe section 5.5. The recording of the partial stroke test in the data logger is descri...
Page 129
Eb 8389 en 129 appendix fig. 21: full stroke test to determine the ramp times in the partial stroke test the valve position follows the set point closely in the example..
Page 130
130 eb 8389 en.
Page 131
Abbreviations used e set point deviation p out signal pressure ps supply pressure x valve position x 0 valve position when the valve is tightly shut w set point, reference variable atc air to close ato air to open bi binary input bsz operating hours counter fst full stroke test init initialization n...
Page 132: Eb 8389 En
Samson ag · mess- und regeltechnik weismüllerstraße 3 · 60314 frankfurt am main, germany phone: +49 69 4009-0 · fax: +49 69 4009-1507 samson@samson.De · www.Samson.De eb 8389 en 2018-01-08 · engl ish.