EB 8389S EN
Translation of original instructions

EXPERTplus Valve Diagnostics
TROVIS SAFE 3731-3 Electropneumatic Positioner

Firmware version 1.6x
Edition May 2015

The mounting and operating instructions for the devices are included in
the scope of delivery. The latest documentation is available on our website
at www.samson.de > Service & Support > Downloads > Documentation.

Definition 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! NOTICE
Property damage message or malfunction
Note
Additional information
Tip
Recommended action

EB 8389S EN

Contents

1

Description.....................................................................................................7

1.1

General.........................................................................................................7

1.2

Start-up..........................................................................................................9

1.3
1.2.1
1.3.1
1.3.2

Diagnostic functions......................................................................................10
Reference tests..............................................................................................10
Application type...........................................................................................11
Analysis.......................................................................................................112

Monitoring...................................................................................................14

2.1
2.1.1

Status messages............................................................................................14
Resetting status messages..............................................................................15

2.2
2.2.1

Condensed state...........................................................................................18
Condensed at the fault alarm output...............................................................18

2.3

Logging........................................................................................................18

3

Statistical information...................................................................................19

3.1
3.1.1
3.1.2
3.1.3

Open/close (on/off) valve.............................................................................21
On/off diagnosis..........................................................................................22
Analysis and monitoring................................................................................23
Resetting single status messages.....................................................................23

3.2
3.2.1
3.2.2

Data logger..................................................................................................25
Permanent data logging................................................................................25
Triggered data logging..................................................................................26

3.3
3.3.1
3.3.2

Travel histogram...........................................................................................30
Analysis and monitoring................................................................................31
Resetting single status messages.....................................................................32

3.4
3.4.1
3.4.2

Set point deviation histogram.........................................................................33
Analysis and monitoring................................................................................34
Resetting single status messages.....................................................................35

3.5
3.5.1
3.5.2

Cycle counter histogram................................................................................37
Analysis and monitoring................................................................................38
Resetting single status messages.....................................................................39

3.6
3.6.1
3.6.2

Drive signal diagram steady-state..................................................................41
Analysis and monitoring................................................................................42
Resetting single status messages.....................................................................43

3.7

Drive signal diagram hysteresis......................................................................45

EB 8389S EN

3

Contents

3.7.1
3.7.2

Analysis and monitoring................................................................................47
Resetting single status messages.....................................................................47

3.8
3.8.1
3.8.2

Trend of travel end position............................................................................51
Analysis and monitoring................................................................................52
Resetting single status messages.....................................................................53

4

Tests............................................................................................................53

4.1
4.1.1
4.1.2

Drive signal diagram steady-state..................................................................55
Analysis and monitoring................................................................................56
Resetting single status messages.....................................................................57

4.2
4.2.1
4.2.2

Drive signal diagram hysteresis......................................................................59
Analysis and monitoring................................................................................60
Resetting single status messages.....................................................................61

4.3
4.3.1

Static characteristic.......................................................................................62
Resetting single status messages.....................................................................63

4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5

Partial stroke test (PST)...................................................................................65
Start triggered by the set point.......................................................................70
Start triggered by the binary input.................................................................70
Analysis and monitoring................................................................................70
Resetting single status messages.....................................................................71
Step response...............................................................................................71

4.5
4.5.1
4.5.2

Full stroke test (FST).......................................................................................75
Analysis and monitoring................................................................................78
Resetting single status messages.....................................................................78

5

Dynamic HART® variables.............................................................................80

6Binary input.................................................................................................82

7

Appendix.....................................................................................................84

7.1

Code list.......................................................................................................84

7.2

Error messages and recommended corrective action........................................91

7.3

Diagnostic parameters and measured data saved in a non-volatile memory......97

7.4

Determining the ramp times of the partial stroke test........................................99

4

EB 8389S EN

EB 8389S EN

5Overview
On/off service

Throttling service

No configuration
required formonitoring

Configuration
required for
diagnosis

Travel histogram S

Data logger

u Section 3.3

u Section 3.2

Set point
deviation
histogramS

S

u Section 3.5
Drive signal
diagram,steady-stateS
Tu Section 4.1

u Section 3.8

Drive signal
diagram,steady-stateS

TravelhistogramST

Set point
deviation
histogram

Cycle counter
histogram

Drive signal dia- S
gram hysteresisTu Section 3.5

u Section 3.7

Trend of travelend positionu Section 3.8

T

On/off diagnosis S
u Section 3.1

S

Data logger

S

u Section 3.2
Stuffing box

S

u Section 3.5
S

StaticcharacteristicTu Section 4.3
SPartial stroke
test

S
T

u Section 4.4
Full stroke testu Section 4.3
Full stroke testS

u Section 3.4

u Section 4.1

Staticcharacteristic

Configuration
required for
diagnosis

u Section 3.3

u Section 4.2

u Section 3.6

Trend of travelend positionS

u Section 3.5

u Section 3.4
Cycle counter
histogram

Stuffing box

No configuration
required formonitoringu Section 4.5
T

u Section 4.5

Note:−− S = Statistical information (in-service monitoring) , T = Tests (out-of-service diagnostics)−− Tests highlighted in red border require an initialization with reference test−− Tests highlighted in gray can optimize the proper functioning of safety equipment according to IEC 61508 andIEC 61511, provided these tests are performed regularly.

TDescription

1 Description−− DD/eDD · Device description/enhanced
device description

1.1 General

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

These instructions EB 8389 EN supplement
the standard mounting and operating instructions for TROVIS SAFE 3731-3 Positioner (u EB 8384-3S)
EXPERTplus is a diagnostic firmware integrated into the positioner which allows thepredictive, status-oriented maintenance ofvalves 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 topinpoint emerging faults.
The diagnostic functions of EXPERTplus arecompletely integrated into the positioner.
Diagnostic data are compiled, saved andanalyzed in the positioner itself. Classified
status messages on the state of the valve are
generated from the analysis.

Local operation
Some parameters can be changed at thepositioner as well as over the operator
interface. The positioner code of theseparameters are written in parentheses. Referto the mounting and operating instructions of
the positioner for a list of all parameters thatcan be changed at the positioner.
The operation described in the following
sections illustrates operation using
TROVIS-VIEW. The default settings of thepositioner and TROVIS-VIEW are written insquare brackets [ ].
Settings highlighted in gray refer to operation using TROVIS-VIEW.

Operation using TROVIS-VIEW/DD/DTM/
eDD
EXPERTplus allows the parameters to beviewed or changed using the TROVIS-VIEW
software (version 3 or 4) or DD/DTM/eDD.
−− TROVIS-VIEW 3 and 4 · Operator interface used to configure various SAMSON
devices and define parameters (current
version is TROVIS-VIEW 4)−− DTM · Device type manager to describe
the device and communication properties

EB 8389S EN

7Description – Start-up

Initialization mode
â

â

â

MAX

NOM

MAN

â
Initialization with reference test

Yes

ß

à

Subsequent
initialization

No

START-UPâ
Operating mode =
MAN
â

â

Zero
Reference of drive signal diagram
steady-state (d1)Reference of drive signal diagramhysteresis (d2)Code 48 - h1
and Code 81

Reference of drive signal diagram
steady-state (d1)Reference of drive signal diagramhysteresis (d2)
All reference values are overwritten!

Code 48 - h1

ß Not successful

ß Not successfulâß Successful

Operating mode =AUTO

Automatic change to
AUTO operating
mode
à

8

Throttling or on/off serviceßEB 8389S EN

Description

1.2 Start-up
The positioner must be initialized to use thefull scope of the valve diagnostics. Duringinitialization the positioner adapts itself optimally to the friction conditions and the signal
pressure required by the control valve.
The positioner can be initialized using one of
the following initialization modes: maximum
range (MAX), nominal range (NOM) andmanual adjustment (MAN).
−− Maximum range (MAX)
Initialization mode for simple start-up ofvalves with two clearly defined mechanical end positions, e.g. three-way valves−− Nominal range (NOM)
Initialization mode for all globe valves−− Manually selected range (MAN)
Initialization mode for globe valves requiring OPEN position to be enteredmanually
The application type, pressure limit and thestart-up parameters required for the selected
initialization must be entered to initialize thepositioner.

time 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-action coefficient
can be reduced in steps.
! NOTICE
Changing the proportional-action coefficient
influences the set point deviation!
Start-up−−Application type (Code 49 - h0):[Control valve], Open/Close valve−−Initialization mode (Code 6):[Maximum range (MAX)], Nominal range(NOM) or Manual adjustment (MAN)−−Pin position (Code 4): [Off], 17, 25, 35, 50,
70, 100, 200, 300 mm, 90°−−Pressure limit (Code 16): [Off], 3.7, 2.4, 1.4 bar
Settings > Positioner > Performance
characteristics−−Required proportional-action coefficient Kp(level) (Code 17): 0 to 17, [7]−−Required derivative-action time Tv (level)(Code 18): Off, 1 to 4, [2]NotePositioner start-up is described in detail inthe mounting and operating instructions (seeu EB 8384-3S).
During positioner initialization, the proportional-action coefficient Kp and derivative-action time Tv levels are optimally set. If
the positioner tends to overshoot impermissibly due to other disturbances, the proportional-action coefficient and derivative-action

EB 8389S EN

9Description

1.2.1

Reference tests

The monitoring of friction, supply pressure,leakage (pneumatics and to the atmosphere),zero point and actuator springs requires additional reference tests for 'Drive signal diagram steady-state' (test d1) and 'Drive signal
diagram hysteresis' (test d2). See u Section
4.1 and section 4.2.
! NOTICE−−The valve moves through its working range
during the reference test.
−−The reference test cannot be performed if
the positioner has been initialized in thesubstitute calibration (SUB) mode.
Right-click 'Start reference test' in the Diagnosis folder and select ‘Execute’ to start therecording of reference data. tESt and d1 or
d2 appear in alternating sequence on thepositioner display.
Note−−Right-click 'Stop reference test' and select‘Execute’ to cancel the reference test.
−−The positioner records the reference data
automatically after initialization if 'Initialization with reference test' is set to Yes.
−−A new reference test causes the results ofexisting reference tests to be overwritten
and the diagnostic data to be deleted.
−−If the reference data could not be recorded
correctly or are incomplete, Code 48 - h1
is generated in the positioner. If the ‘Initialization with reference test’ parameter is activated, an incorrect reference test is also
indicated in Code 81.

10−−The positioner can still perform its control
task properly even if the reference test was
not recorded correctly or is incomplete.
−−Data from the first reference test are usedas the reference if no reference data are
saved in the positioner on starting the tests
for 'Drive signal diagram steady-state' or'Drive signal diagram hysteresis'
Diagnostics−−Start reference test (Code 48 - d7)orStart-up−−Initialization with reference test (Code 48 - h0):
Yes, [No]1.3 Diagnostic functions
There are two main groups of diagnostic
functions available: Statistical information(in-service monitoring) and Tests (out-of-service diagnostics).
1. Statistical information (in-service monitoring)
Data are compiled, saved and analyzed
by the positioner while the process isrunning without disrupting the process.
The positioner follows the set point to position the valve. A classified status alarmor fault alarm is generated if the positioner detects an event.

EB 8389S EN

Description

2. Tests (out-of-service diagnostics)
Similar to the statistical information function, data are compiled, saved and analyzed by the positioner. However, in thiscase, the valve position is not determinedby the set point, but by the active test.
! NOTICE
The 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, these tests, except for partial stroke testing, can only be performed in
the manual mode.
An active test is stopped and the positioner changes to the fail-safe position
when the electrical signal falls below acertain level or when the solenoid valve
is triggered or the forced venting function is activated.

1.3.1

Application type

Different diagnostic functions are available
depending on the application type selectedin EXPERTplus.
Depending on the application type selected,
the positioner behaves differently in the automatic mode:−− Control valve
The positioner uses the set point to position the valve.
The valve position (current position) appears in % on the display.
−− Open/close (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 3.1.

1.3.2

AnalysisTable 2 shows the diagnostic functions andtheir statements on the condition of the valve
depending on the application type.

EB 8389S EN

11Description

Table 1: Diagnostic functions and test analysis

Diagnostic functions

Control
valve

Open/Close(on/off)
valve 1)–•Analysis

See section

Statistical information
Breakaway time
Open/Close

Transit time

3.1, page 21

Valve end position
Data logger••

Travel histogram•¡

Depending on trigger status
selected
Shifting working range
Working range

3.2, page 25
3.3, page 30

Limit working range

Set point
deviation
histogram•

Cycle counter
histogram••

Drive signal
diagramsteady-state•¡

Drive signal
diagramhysteresis•¡

Trend of travelend position

•

•

•

Connection positioner-valve
Inner (seat) leakage

3.4, page 33

Average set point deviation
Stuffing box/external leakage
Dynamic stress factor

3.5, page 37

Air supply
Leakage pneumatics

3.6, page 41

Actuator springs
Friction
External leakage perhaps
soon expected
Observing end position
Zero shift

3.7, page 45

3.8, page 51• Full scope of functions¡ Function is performed, but not analyzed– Function is not performed

12

EB 8389S EN

Description

Diagnostic functions

Control
valve

Open/Close(on/off)
valve 1)Analysis

See section

Tests
Air supply

Drive signal
diagram steadystate•

Drive signal diagram hysteresis••

Friction

4.2, page 59

Static characteristic••

Dead band

4.3, page 62•

Leakage pneumatics

4.1, page 55

Actuator springs

Overshooting
Dead time
Partial stroke test
(PST)

•

•

T63
T89

4.4, page 65

Rise time
Settling timeOvershooting
Dead time
Full stroke test
(FST)

•

•

T63
T89

4.5, page 75

Rise time
Settling time
• Full scope of functions¡ Function is performed, but not analyzed– Function is not performed

EB 8389S EN

13

Monitoring

2 Monitoring
2.1 Status messages
The valve diagnostics integrated into the positioner generate classified status messages.
There are two types of status messages: standard status messages and extended status
messages.
Standard status messages
Standard status messages contain information on start-up as well as on operation andthe condition of the positioner.
Messages are divided into the following
main groups:−− Status−− Operation−− Hardware−− Initialization−− Data memory−− TemperatureStandard status messages are indicated in
the positioner by the codes listed in the standard positioner instructions.
Additional informative data are listed in the
subfolders of the Positioner folder:−− Operation > Process data: Information
on current process variables, condensed
state and temperature

setting the diagnosis contained in the Diagnosis folder (> Status messages)
Extended status messages
The extended status messages are generated
from the results gained from Statistical information (in-service monitoring) and Tests (outof-service diagnostics).
The messages provide information on the following topics to allow users to plan predictive maintenance and service work:−− Air supply−− Shifting working range−− Leakage pneumatics−− Limit working range−− Observing end position−− Connection positioner-valve−− Working range−− Friction−− Actuator springs−− Inner (seat) leakage−− External leakage−− PST/FST−− Open/Close
Any active diagnostic message is indicatedin the positioner by Code 79.
Extended status messages can be classified
according to the possible causes. See u Section 3.3 to section 4.5.

−− Settings > Positioner > Error control: Information on total valve travel with configurable limits−− Positioner > Start-up > Initialization: Listof initialization errors, which are also Re-

14

EB 8389S 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 thecondensed 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 required/Maintenance demanded
The positioner still performs its control
task (with restrictions). A maintenancedemand or above average wear has
been determined. The wear tolerance willsoon be exhausted or is reducing at afaster rate than expected. Maintenance isnecessary in the medium term.
−− Out of specification/invalid processstate
The positioner is running outside thespecified operating conditions.
−− Maintenance alarm
The positioner cannot perform its control
task due to a functional fault in the positioner itself or in one of its peripherals oran initialization has not yet been successfully completed.
You can view the status messages in the Diagnosis folder (> Status messages) as wellas in the Diagnosis folder (> Status messages > Extended).

EB 8389S EN

2.1.1

Resetting status
messages

When a status message is generated, you
should first locate the source of the fault andtake action to remedy it.
For recommended action concerning the status messages u Section 7.2.
Status messages can be reset individually or
using the reset function. u Table 2 contains
an overview on how the diagnosis can bereset. The status messages can be reset in the
Diagnosis folder (> Reset) and/or the Operation folder (> Reset).
If you want to keep measured data and theanalysis after resetting the positioner, it ispossible to upload them onto a computer.
Resetting single status messages−− Status messages represented by a codein the positioner can be confirmed at thepositioner itself. Select the error codeand confirm it by pushing the rotary
pushbutton. See the standard instructionsof the positioner (u EB 8384-3S).
−− On resetting histograms and diagrams,
the data for short-term monitoring are also reset.
−− 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-initialized after resetting.

15

Monitoring

Resetting the diagnosis
Code 36 - Diag−− Data from Statistical information andTests are reset according to u Table 3.
−− The reference value of ‘Trend of travelend position’ (Statistical Information) is
deleted.
−− The reference values of Tests (‘Drive signal diagram steady-state’ and ‘Drive signal diagram hysteresis’) remain saved.

! NOTICE
Before mounting the positioner on a newcontrol valve, perform a reset by activating
Code 36 - Std and re-initialize the positioner.
Operation > Reset−−Start with default values (Code 36 - Std)−− Status classification and data logs remain saved.
−− The positioner does not need to be re-initialized after resetting.
If the diagnosis is to be reset at regular intervals, enter the time in “Required time ‘Resetdiagnosis”. The setting “00:00:00” or “0”causes the resetting at regular intervals to bedeactivated.
Operation > Reset−−Reset diagnosis (Code 36 - Diag)−− Required time ‘Reset diagnosis’ (Code 48 - h3):
configurable as required,[0.00:00:00 d.h:min:s]Start with default values
Code 36 - Std−− Data from Statistical information andTests are reset according to u Table 3.
−− Reference values are deleted.
−− Status classification and data logs aredeleted.
−− The positioner must be re-initialized after
resetting.

16

EB 8389S EN

Monitoring

Table 2: Reset functions
All adjusted parameters and recorded measured values of the specified diagnostic test are
reset, if not listed separately.
Resettingsingle status
messages

FunctionCode
36 - DiagCode
36 - Std

Operating hours counter
Device switched on since (last) initialization

NO

YES

YES

Device in closed loop since initialization

NO

YES

YES

Status classification

NO

NO

YES

Logging

YES

NO

YES

Statistical information
Parameters

YES

NO

YES

Measured values

YES

YES

YES

Data logger

NO

YES

YES

Travel histogram x

YES

YES

YES

Open/Close 1)

Short-term monitoring

YES

YES

YES

Set point deviation histogram e

YES

YES

YES

Short-term monitoring

YES

YES

YES

YES

YES

YES

YES

YES

YES

Cycle counter histogram
Short-term monitoring
Drive signal diagram steady-state

YES

YES

YES

Short-term monitoring

YES

YES

YES

Drive signal diagram hysteresis (d5)

YES

YES

YES

YES

YES

YES

Reference value

YES

YES

YES

Parameters, measured
values

YES

YES

YES

Short-term monitoring
Trend of travel end
position
Tests
Drive signal diagram
steady-state (d1)Reference values

NO

NO

YES

Measured values

YES

YES

YES

Drive signal diagramhysteresis (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

NO

YES

EB 8389S EN

17

Monitoring

2.2 Condensed state
To provide a better overview on the condition of the valve assembly, all status messages are summarized in a condensed state
which is made up from a summary of allclassified messages in the positioner. The status message with the highest priority determines which condensed state is set.
The condensed state appears in TROVIS-VIEW on the right-hand side of the info
bar and in the Diagnosis folder (> Status
messages). See u Table 3 for a descriptionof the icons and their meaning.
Additionally, the condensed state can beused to trigger the data logger. See u Section 3.2.2.
Note
The condensed state is marked byuntil
the positioner data have been uploaded.
Diagnosis > Status messages−−Condensed state (Code 48 - d6)

The condensed state can be read in the positioner display in Code 48 - d6. See u Table 3.

2.2.1

Condensed at the fault
alarm output

In positioners with a fault alarm output, thecondensed state can also be read out at thefault alarm output if one of the following
conditions occurs:18

1. Condensed state 'Maintenance alarm' isactivated.
2. Condensed state 'Function check' is activated and the fault alarm output is activated.
3. Condensed state 'Maintenance required'is activated and the fault alarm output isactivated.
Settings > Positioner > Error control
2. −−Fault alarm at condensed state 'Function
check' (Code 32): [Yes]3. −−Fault alarm at condensed state 'Maintenance required' (Code 33) : [Yes]

2.3 Logging
The last 30 generated messages are saved in
the positioner with a time-stamp (logged by
the operating hours counter).
You can view these messages in TROVISVIEW in the Diagnosis folder (> Status
messages > Logger).
Note−−If the positioner is fitted with a solenoid
valve, a triggering of the solenoid valve
can only be logged when 'Logging of int.
solenoid valve' is activated.
−−In the event the solenoid valve is triggered
again, this is only logged when the 'Min.
clearance new logging int. solenoid valve'
has elapsed since the last triggering.

EB 8389S EN

Statistical information

3 Statistical information

Settings > Positioner > Error control−−Logging of int. solenoid valve: [Yes], No−−Min. clearance new logging int. solenoid valve:
0 to 5000 s, [300 s]

The positioner records the set point w, valve
position x, drive signal y and set point deviation e even while the process is running toobtain information on the valve, actuatorand pneumatic air supply. The data compiled while the process is running are saved
and analyzed by the monitoring functions in
Statistical information. In addition, a background hysteresis test can detect any changes in friction.
The monitoring functions in Statistical information do not have any affect on the running process.
The measured data are analyzed after the
positioner has been in automatic mode or inmanual mode for an hour. However, theanalysis for the 'Cycle counter histogram'and 'Trend of travel end position' start directly after the positioner changes to automatic
mode or manual mode.

Table 3: Condensed state reading
Status message

TROVIS-VIEW 4/DTM

Maintenance alarm

redFunction check 1)orangeOut of specification/invalid
process stateyellow

Maintenance demanded/
maintenance requiredblue

No message, OK

green

EB 8389S EN

Positioner

Priority

Text e.g. tESting, tunE or
tESt
blinking

19

Statistical information – Open/Close diagnosis

Prerequisite:– Application type: Open/Closeâ
Operating point, Limit fail-safe position, Limit operating pointâ

START-UP

Limit value time analysis
Limit value travel analysis
Status classification (NE 107)
On/off status activatedDefine parameters for partial
stroke test, see u Section 4.4ââ

On/off diagnosis

Discrete set point analysis PST

x [%]
w [%]

x [%]
w [%]

50
25

t [s]

∆t > 6 st [s]âFirst analysis after defining parameters= ­Reference

PROCESS

Breakaway time, transit time, valve end position (rising/falling)ââ

Analysis (NE 107)/
logged by operating hours counter

Analysis, see u Section 4.4

Open/Close status activatedâ
Reset measured data 'Open/Close'

Reset all parameters 'Open/Close'20

EB 8389S EN

Statistical information

3.1 Open/close (on/off) valve
The travel range of open/close (on/off) isdefined by the fail-safe position and the operating point. As a result, the following parameters to determine the working range
and set point range are not analyzed andcannot be changed.
−− Travel/angle range start/end (Code8/9)−− Travel/angle range lower/upper limit(Code 10/11)−− Reference variable range start/end(Code 12/13)
The discrete analysis of the set point is performed in automatic mode.
x [%]
w [%]

x [%]
w [%]
Operating point

Limit operating point

50
25
Limit fail-safe position
Fail-safe position

t<6s

t [s]

If the set point ( ) is above 'Limit operating
point' when the automatic mode starts, thevalve ( ) moves to the operating point. The
valve moves back to the fail-safe position(0 % in the example) if the set point then falls
below 'Limit fail-safe position'.
Starting the partial stroke test (PST)

Operating point

x [%]
w [%]

Limit operating point

Start PST

Stop PST

Operating point = Start (PST)
End (PST)

50

Limit operating point

25

50

Limit fail-safe position
Fail-safe position∆t > 6 st [s]25Limit fail-safe position

If the set point ( ) is below 'Limit operating
point' when the automatic mode starts, thevalve ( ) moves to the fail-safe position. If
the set point increases and exceeds 'Limit operating point', the valve moves to the 'Operating point'. The valve moves back to thefail-safe position (0 % in the example) if theset point then falls below 'Limit fail-safe position'.

EB 8389S EN

Fail-safe position

t>6s

t [s]

A partial stroke test is started when the set
point ( ) moves in the range between 25
and 50 % of the travel and remains there forlonger than six seconds. See u Section
4.4.1.
The PST diagnostic parameter 'Step start'
must be within the defined range of the21Statistical information'Tolerance limit of step response' for thepartial stroke test to start.
After the partial stroke test is completed, thevalve moves back to its last position (fail-safe
position or operating point).
Canceling the partial stroke test (PST)The partial stroke test is canceled whenever
the set point ( ) leaves the range between'Limit fail-safe position' and 'Limit operating
point'.
After the partial stroke test is canceled, thevalve moves back to its last position (fail-safe
position or operating point).
Defining parameters
1. Select 'Open/Close valve' as the application type.
2. Set parameters for on/off valve.
3. Set parameters for partial stroke test
(PST).
Start-up

3.1.1

On/off diagnosis

3730-23730-33731-3•••3730-43730-5•The diagnosis for on/off valves provides
statements on the valve end position, transit
times (rising/falling) and the breakaway
times (rising/falling). Data are constantly recorded in automatic mode. This monitoring
function does not need to be activated.
The positioner compares the current breakaway time, transit time and valve position
with the values recorded during the reference
measurement (first analysis) while the plant isrunning.
Defining parameters
1. Enter limits for monitoring. See u Section 3.1.2.
2. Select classification for status message.
Diagnosis > Statistical information > Open/Close

1. −−Application type (Code 49 - h0): Open/Close valve

1. −−Limit value time analysis (Code 49 - h7):
0.6 to 30.0 s, [0.6 s]

Settings > Positioner > Reference variable−− Limit value travel analysis (Code 49 - h8):
0.3 to 100.0 %, [0.3 %]2. −−Operating point (Code 49 - h1):
0.0 to 100 %, [100 %]−−Limit fail-safe position (Code 49 - h2):
0.0 to 20.0 %, [12.5 %]−−Limit operating point (Code 49 - h5):55.0 to 100.0 %, [75.0 %]Settings > Positioner > Error control >Classification report > Extended > Open/Close
2. −−Open/Close status active (Code 49- h9):[ ], , ,Diagnosis > Tests > Partial stroke test
3. See u Section 4.4

22

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Statistical information

3.1.2

Analysis and monitoring
x [%]
w [%]

amount entered in 'Limit value travel
analysis'.
−− The current 'Valve end position (falling)'
differs from the reference value by theamount entered in 'Limit value travel
analysis'.

Valve end position(rising)

If one of these conditions is met, the positioner generates an 'Open/Close' message according the selected status classification.
Diagnosis > Status messages > Extended

Valve end position(falling)
Breakaway time(rising)
Transit time(rising)

Breakaway time
(falling)

t [s]Transit time
(falling)

Fig. 1: Analysis of the on/off diagnosis

The analysis pinpoints a fault when at least
one of the following conditions is met whilethe valve is moving:−− The current 'Breakaway time (rising)' differs from the reference value by theamount entered in 'Limit value time analysis'.
−− The current 'Breakaway time (falling)'
differs from the reference value by theamount entered in 'Limit value time analysis'.
−− The current 'Transit time (rising)' differsfrom the reference value by the amountentered in 'Limit value time analysis'.

−−Open/Close:

3.1.3

,

,

,

Resetting single status
messages

The message and analysis are reset byright-clicking "Reset measured data 'Open/Close" and selecting ‘Execute’.
The parameters for the on/off valve and thelimit values are reset by right-clicking "Resetall parameters 'Open/Close" and selecting‘Execute’.
The positioner saves the reference analysis
and two further test analyses. The analysis of
the oldest test is deleted when another test is
performed.
Diagnosis > Status messages > Reset−−Reset measured data 'Open/Close'−−Reset all parameters 'Open/Close'−− The current 'Transit time (falling)' differsfrom the reference value by the amountentered in 'Limit value time analysis'.
−− The current 'Valve end position (rising)'
differs from the reference value by the

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23

Statistical information – Data logger

SelectionâââPermanent

TriggeredââScan rate

Trigger status
Start trigger via

â
Start

START-UP(software)

â

â

â

â

â

Condensed
state

w, x, e, y

SV/
FV

w or
SV/FV

BE

â

â

â

Trigger value

Trigger value

Trigger band

Trigger band

Trigger edge

Trigger edgeââ

100 values(w, x, e, y)

Pre-trigger time
Scan rateâ
Startâ
Trigger event

PROCESSâ
Logged by operating hours counterââ

Values (w, x, e, y)before trigger event

Values (w, x, e, y) after trigger event+âTotal 100 values (w, x, e, y)

24

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Statistical information

3.2 Data logger

3.2.1

Permanent data logging

The data logger records the measured variables (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 measured variables are logged at therate defined in 'Scan rate' and saved in acircular buffer, which holds 100 data points
per measured variable at one time.

Note
The data logger is interrupted and must bereactivated when one of the following eventsoccurs.
−−Change of the operating mode−−Air supply failure−−Failure of power supply of the positioner−−Failure of power supply of the external solenoid valve

Note
You can read the measured data logged
over the past 24 hours from the 'Data logger' graph when the Diagnosis folder (> Statistical information > Data logger) is left
open over this period.
Defining parameters
1. Select 'Permanent' (Selection).
2. Enter scan rate.
3. Start data logger.

Fig. 2: Diagnosis > Statistical information > Data logger

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25

Statistical information

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

Defining parameters

Diagnosis > Statistical information > Datalogger

2. Select the triggering event.

1. −−Selection: [Permanent]
2. −−Scan rate: 0.2 to 3600.0 s, [1.0 s]
3. −−Start data logger

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

3.2.2

Triggered data logging

Measured values are saved in a circular buffer after the event defined in 'Start trigger
via' has occurred (see u Section 3.2.2.1 tosection 3.2.2.5). The event that has triggereddata logging is recorded. Data logging isterminated after 100 measured values per
measured variable have been saved in thecircular buffer. The 'Scan rate' determines
the time between recordings. A 'Pre-trigger
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'Pre-trigger time' may include the value 100
x 'Scan rate' at the maximum.

1. Select 'Trigger' (Selection).
3. Enter scan rate.
4. Start data logger.
The 'Test information' status indicates'Test active'. At the end of data logging,
the progress flag reads 'Memory full,ending measuring'.
Note
Right-click 'Stop data logger' and select ‘Execute’ to stop the data logger ('Test information' = 'Test not active').

3.2.2.1 Triggered by condensed
state
The measured values are included in the triggered data logging when the condensed
state defined in 'Start trigger via condensed
state' arises.
Diagnosis > Statistical information > Datalogger1. −−Selection: Trigger
2. −−Trigger status:
Start trigger via condensed state−−Pre-trigger time:
0.0 s to 100 x 'Scan rate', [0.0 s]−−Trigger via condensed state: No message,[Maintenance required], Maintenance demanded, Out of specification, Maintenancealarm
3. −−Scan rate: 0.2 to 3600.0 s, [1.0 s]
4. −−Start data logger

26

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Statistical information

3.2.2.2 Triggered by set point,valve position, drive signal
or set point deviation
The measured values are included in the triggered data logging when the conditions forthe selected measured variable (set point w,
valve position x, set point deviation e ordrive signal y) defined in 'Trigger value','Trigger band' and 'Trigger edge' are met.
'Trigger edge' = Low signal/falling edge/
bottom band exit
w, x, y, e

Trigger value
Bottom band limit =Trigger value – ½ trigger band
Trigger band

The conditions for starting a trigger event
are met when the value falls below the limit('Trigger value' – ½ 'Trigger band').

The conditions for starting a trigger event
are met when the value exceeds the limit('Trigger value' + ½ 'Trigger band').
'Trigger edge' = Band exit
w, x, y, e

Top band limit
Trigger value + ½ trigger band
Trigger value
Bottom band limit=
Trigger value – ½ trigger band
Trigger band

The conditions for starting a trigger event
are met when the value falls below the lower
limit ('Trigger value' – ½ 'Trigger band') or
exceeds the upper limit ('Trigger value' + ½'Trigger band').
This function is only active when 'Trigger
band' ≠ 0.
'Trigger edge' = Band entry
w, x, y, e

'Trigger edge' = High signal/rising edge/
top band exit
w, x, y, e

Top band limit =Trigger value + ½ trigger band
Trigger value
Trigger bandEB 8389S EN

Top band limit =Trigger value + ½ trigger band
Trigger value
Bottom band limit =Trigger value – ½ trigger band
Trigger band

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

27

Statistical information

limit ('Trigger value' – ½ 'Trigger band') or
falls below the upper limit ('Trigger value' +½ 'Trigger band').
This function is only active when 'Trigger
band' ≠ 0.
Note
The bottom band limit assumes the value 0.0% or 0.0 1/s at the lowest. The top band limit
assumes the value 100.0 % or 100.0 1/s atthe most.
Diagnosis > Statistical information > Datalogger1. −−Selection: Trigger
2. −−Trigger status: Start trigger via set point,valve position, drive signal or set point deviation−−Trigger value:
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 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)−−Pre-trigger time:
0.0 s to 100 x 'Scan rate', [0.0 s]−−Trigger edge: [Low signal/falling edge/bottom band exit], High signal/rising edge/top
band exit, Band exit, Band entry
3. −−Scan rate: 0.2 to 3600.0 s, [1.0 s]
4. −−Start data logger

28

3.2.2.3 Triggered by internal solenoid valve/forced venting
Triggering by the internal solenoid valve/
forced venting is only active when an internal solenoid valve/forced venting is installedin the positioner. See 'Internal solenoid
valve/forced venting' reading (Code 45).
The measured values are included in the triggered data logging when the solenoid valve
is triggered or the forced venting is activated.
Diagnosis > Data logger
1. −−Selection: Trigger
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

3.2.2.4 Triggered by set point orinternal solenoid valve/
forced venting
Triggering by the internal solenoid valve/
forced venting is only active when an internal solenoid valve/forced venting is installedin the positioner. See 'Internal solenoid
valve/forced venting' reading (Code 45).
The measured values are included in the triggered data logging when one of the conditions defined in 'Start trigger via internal so-

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Statistical information

lenoid valve/forced venting' or 'Start trigger
via set point' are met.
Diagnosis > Data logger
1. −−Selection: Trigger
2. −−Trigger status:
Start trigger via set point/int. sol. valve/
forced venting−−Trigger value:
0.0 to 100.0 %, [99.0 %]Diagnosis > Statistical information > Datalogger1. −−Selection: Trigger
2. −−Trigger status:
Start trigger via binary input−−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−−Trigger band: 0.0 to 100.0 %, [99.0 %]−−Pre-trigger time:
0.0 s to 100 x 'Scan rate', [0.0 s]−−Trigger edge: [Low signal/falling edge/bottom band exit], High signal/rising edge/top
band exit, Band exit, Band entry
3. −−Scan rate: 0.2 to 3600.0 s, [1.0 s]
4. −−Start data logger

3.2.2.5 Triggered by binary input
Positioners can be optionally fitted with a binary input. Triggering by the binary input isonly active when the positioner is fitted witha binary input.
The measured values are included in the triggered data logging when the state of the binary input changes.

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29

Statistical information

3.3 Travel histogram
The valve travel histogram is a statisticalanalysis of the plotted valve positions. It provides information about the range in which
valve mainly works during its service life andwhether the working range is possibly shifting.
Data are recorded in the background regardless of the operating mode selected.
Data logging does not need to be activated.
The positioner records the valve position every second and assigns the data into predefined valve position classes. The distribution showing how often the valve remained
within a valve position class is shown in abar graph.
−− The 'Average value x long' indicates theaverage class assignment of the valve
position over the 'Observation period.'−− The 'Number of measurement values'
shows the total number of values were recorded during the 'Observation period'.
−− 'Observation period'
The measured data are saved every 24
hours in the positioner.
Short-term monitoring
In order to be able to recognize any shortterm changes in valve position, the positioner records the valve positions according to
the adjusted 'Scan rate short-term histogram'and analyses the last 100 measured values.
−− The 'Average value x short' contains theaverage class assignment for the last
100 measured values.

30

The positioner saves the valve positions in acircular buffer, which holds 100 measured
values at one time.
Note
On changing scan rate in 'Scan rate shortterm histogram', all existing measured values
are deleted from the circular buffer.
Defining parameters
1. Set 'Scan rate short-term histogram'.
2. Select classification for status messages.
Diagnosis > Statistical information > Travel
histogram x > Short-term
1. −−Scan rate short-term histogram:1 to 3600 s, [1 s] 1)
Settings > Positioner > Error control >Classification report > Extended > ...
2. Shifting working range−−Shifting working range to closing position:[ ], , ,−−Shifting working range to max. opening
position:[ ], , ,Working range−−Mostly near closing position:[ ], , ,−−Mostly near max. opening:[ ], , ,−−Mostly closing position:[ ], , ,−−Mostly max. opening:[ ], , ,EB 8389S EN

Statistical information

3.3.1

Analysis and monitoring

Analysis of the histogram for control valves
starts one hour after the observation period
begins. No analysis is performed for on/off
valves.

Diagnosis > Status messages > Extended−−Shifting working range:,−−Working range:

,

,

,

,

,

If the control valve mainly works during theobservation duration near or in one of theend positions, the positioner generates the'Working range' message with the selected
status classification.
For analysis of the short-term monitoring, acomplete set of data (100 measured values)
is required.
The positioner generates the 'Shifting working range' message with the selected statusclassification whenever a trend showing achange in the working range is found fromthe analysis of the histogram and the shortterm monitoring.

Fig. 3: Diagnosis > Statistical information > Travel histogram x

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31

Statistical information

3.3.2

Resetting single status
messages

The 'Working range' and the 'Shifting working range' messages can be reset by selecting and executing the command "Reset'Travel histogram x". This command resets all
diagnostic parameters and measured dataof the histogram and the short-term monitoring.
By selecting and executing the command"Reset 'Travel histogram x - short-term", thediagnostic parameters and measured data in
the Short-term folder are reset.
Diagnosis > Status messages > Reset−−Reset 'Travel histogram x'−−Reset 'Travel histogram x – short-term'

32

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Statistical information

3.4 Set point deviation histogram
The set point deviation histogram contains astatistical analysis of any set point deviations
recorded. It provides information on to which
extent a set point deviation has occurred
during the valve service life and whether
faults may occur due to a restricted working
range or due to seat leakage.
Data are recorded in the background regardless of the operating mode selected. Data logging does not need to be activated.
The positioner records the set point deviation
every second and assigns the data into predefined classes. The distribution showing
how often the set point deviation remained
within a class is shown in a bar graph.
−− The 'Average value e long' indicates theaverage class assignment of the set point
deviation over the 'Observation period.'−− The 'Number of measurement values'
shows the total number of values wererecorded during the 'Observation period'.
−− 'Observation period'−− 'Absolute value of max. set point deviation' indicates the largest set point deviation measured during the observation
period.
The measured data are saved every 24
hours in the positioner.
Short-term monitoring
In order to be able to recognize any shortterm changes in set point deviation, the posi-

EB 8389S EN

tioner records the set point deviation according to the adjusted 'Scan rate short-term histogram' and analyses the last 100 measured
values.
−− The 'Average value e short' contains theaverage class assignment for the last
100 measured values.
The positioner saves the set point deviations
in a circular buffer, which holds 100 measured values at one time.
Note
On changing scan rate in 'Scan rate shortterm histogram', all existing measured values
are deleted from the circular buffer.
Defining parameters
1. Set 'Scan rate short-term histogram'.
2. Select classification for status messages.
Diagnosis > Statistical information > Set
point deviation histogram e > Short-term
1. −−Scan rate short-term histogram:1 to 3600 s, [1 s] 1)
Settings > Positioner > Error control >Classification report > Extended > ...
2. Limit working range−−Down: [−−Up: [

],

],

,
,

,

−−Modification impossible (jammed):[ ], , ,Connection positioner-valve−−No optimum travel transmission (TEST)[ ], , ,−− Perhaps loose/(TEST): [

],

,

,

33

Statistical information−−Perhaps range limit:[ ], , ,Inner (seat) leakage−−Perhaps existing:[ ], , ,3.4.1

Analysis and monitoring

Analysis of the histogram starts one hour
after the observation period begins.
Ideally, the set point deviation should benearly 0 %.
Set point deviations greater than 1 % following in quick succession pinpoint to a limitation of the upper working range. In this case,the positioner generates the 'Limit working
range' message with the selected status classification.

ates the 'Limit working range' and 'Inner
leakage' messages with the selected statusclassifications.
If almost all set point deviations during theshort-term monitoring are greater than 1 %or smaller than –1 %, this may indicated thatthe actuator or valve stem is jammed. In thiscase, the positioner generates the 'Limit
working range' and 'Connection positioner valve' messages with the selected status classifications.
Diagnosis > Status messages > Extended,,−−Connection positioner-valve:,−−Inner (seat) leakage:,−−Limit working range:

,
,

,

,

,

Set point deviations smaller than 1 % following in quick succession pinpoint to a limitation of the lower working range or to seatleakage. In this case, the positioner gener-

Fig. 4: Diagnosis > Statistical information > Set point deviation histogram e

34

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Statistical information

3.4.2

Resetting single status
messages

The 'Inner leakage' and 'Limit working
range' messages can be reset by selecting
and executing the command "Reset 'Set
point deviation histogram e" or "Reset 'Set
point deviation histogram e - short-term".
The 'Connection positioner-valve' message
can be reset by selecting and executing thecommand 'Set point deviation histogram e short-term".
By selecting and executing the "Reset 'Set
point deviation histogram e" command, alldiagnostic parameters and measured dataof the histogram and the short-term monitoring are reset.
By selecting and executing the command"Reset 'Set point deviation histogram e Short-term", the diagnostic parameters andmeasured data in the Short-term folder are
reset.
Diagnosis > Status messages > Reset−−Reset 'Set point deviation histogram e'−−Reset 'Set point deviation histogram e – shortterm'

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35

Statistical information – Cycle counter histogram

Stem sealâââ

Self-adjustingâ

Adjustableâ

Other, -/-Bellows seal

START-UPâMax. 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
expectedââ
Determining the cycle height

Determining the cycle spans

x [%]

x [%]
1

3

2

1

2

4
3

4

t [s]

t [s]

PROCESSââ

Dynamic stress factor

Dynamic stress factor

Dynamic stress factor >Dynamic stress factor >â 90 %

â 90 %

Analysis (NE 107)/
logged by operating hours counter

Analysis (NE 107)/
logged by operating hours counter

External leakage

External leakage

âReset 'Cycle counter histogram'36

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Statistical information

3.5 Cycle counter histogram
The cycle counter histogram provides a statistical analysis of the cycles. As a result, thecycle counter also provides information on
the dynamic stress of a bellows seal and/or
packing.
Data are recorded in the background regardless of the operating mode selected. Data logging does not need to be activated.
The positioner records the number of cycle
spans when the 'Stuffing box' (stem seal) setting is set to 'Self-adjusting', 'Adjustablepacking', 'Other' or '-/-'. A cycle span starts
at the point where the valve stroke changes
direction until the point where it changes direction again.
The positioner records the cycle height whenthe 'Stuffing box' (stem seal) setting is set to'Bellows seal'. The valve stroke between
these two changes in direction is the cycle
height.

The cycle spans or cycle heights are assigned to classes. The distribution showing
how often the cycle span or height occurred
within a class is shown in a bar graph.
−− The 'Average value z long' indicates theaverage class assignment of the cycle
height over the 'Number of measurement
values'.
−− The 'Number of measurement values'
shows the total number of values recorded.
The measured data are saved every 24
hours in the positioner.
Short-term monitoring
To recognize short-term changes in the cycle
spans or cycle height, the positioner analyzes the last 100 cycle heights or cycle
spans.
The positioner saves the cycles in a circularbuffer, which holds 100 measured values at
one time.

Fig. 5: Diagnosis > Statistical information > Cycle counter histogramEB 8389S EN

37

Statistical information−− The 'Average value e short' contains theaverage class assignment of cycle
heights for the last 100 measured values.
Defining parameters
1. Select the type of stem seal.
When 'Other' is selected for 'Stuffingbox', the additional parameter 'Max. cycle counter limit' must also be set.
2. Select classification for status messages.
Settings > Identification > Positioner >
Valve
1.

−−Stuffing box:[-/-], Self-adjusting, Adjustable packing,
Bellows seal, Other−−Max. cycle counter limit 1):
1 to 1000000000, [1000000]
Settings > Positioner > Error control >Classification report > Extended > ...

2.

External leakage−−Perhaps soon expected:[ ], , ,1)

Setting only with 'Stuffing box' = Other

3.5.1

Analysis and monitoring

Analysis of the histogram starts directly after the change to manual or automaticmode.
The load on the bellows and/or packing canbe read from the 'Dynamic stress factor' parameter. The value is determined from the cycle spans or cycle heights and takes into account the type of packing used in the valve.
An 'External leakage' message is generated
with the selected status classification whenever:−− The number of measured cycle spans exceeds 450000 when 'Self-adjusting' isselected as the stem seal.
−− The number of measured cycle spans exceeds 180000 when 'Adjustable packing' is selected as the stem seal.
−− The number of measured cycle spans exceeds 90 % of the 'Max. cycle counter
limit' when 'Other' is selected as the stemseal.
−− The number of measured cycle heights
exceeds 180000 when 'Bellows seal' isselected as the stem seal.
Diagnosis > Statistical information > Cycle
counter histogram−−Dynamic stress factor
Diagnosis > Status messages > Extended−−External leakage:

38

,

,

,

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Statistical information

3.5.2

Resetting single status
messages

The 'External leakage' message can be resetby selecting and executing the command"Reset 'Cycle counter histogram".
By selecting and executing the "Reset 'Cycle
counter histogram" command, all diagnostic
parameters and measured data of the histogram and the short-term monitoring as wellas the 'Dynamic stress factor' are reset.
By selecting and executing the command"Reset 'Cycle counter histogram - shortterm", the measured data in the Short-termfolder are reset.
Diagnosis > Status messages > Reset−−Reset 'Cycle counter histogram'−−Reset 'Cycle counter histogram – short-term'

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39

START-UP

Statistical information – Drive signal diagram steady-state

Requirements:– Model: Single acting– Booster: Not present– Application type: Control valve– Reference test completed. See u Section 1.2.1

âStatus classification (NE 107)
Air supply

Actuator
springs

Working at full
capacity

Perhaps modified/
not enough

Leakagepneumatics

Perhaps too large/
existing

Working at full capacity

PROCESSâââ

Status classification (NE 107)/
logged by operating hours counter
Air supply

Actuator
springsââLeakagepneumatics
â

Reset 'Drive signal diagram – steady-state'
Reset 'Drive signal diagram steady-state - short-term'

40

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Statistical information

3.6 Drive signal diagram
steady-state
The 'Drive signal diagram steady-state' records the drive signal y in relation to thevalve position x.
The drive signal y is based on the internal
control signal of the i/p converter. This signal runs directly proportional to the signal
pressure pout in the pneumatic actuator, in relation to the valve position.
This test helps pinpoint faults in the supply
pressure, pneumatics or actuator springs.

Data are recorded in the background regardless of the operating mode selected. Data logging does not need to be activated.
The positioner records the valve position x
and its associated drive signal y in closedloop operation after the pressure conditions
have settled (steady-state). Each pair of measured values recorded is assigned to a valve
position class. The average drive signal iscalculated for each class. The stored data
can be read out. The drive signal y is plottedin a graph against the valve position x.

Fig. 6: Diagnosis > Statistical information > Drive signal diagram > Steady-state

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41

Statistical information

Note−−Reference values are used in cases where
no data could be compiled for valve positions x as the valve did not move to thosepositions or a steady state could not bereached.
−−No measured values are recorded if 'Enable set point cutoff decrease' (tight-closing function, Code 14) is active and thevalve moves to the value entered in 'Set
point cutoff decrease'.
Short-term monitoring
In order to be able to recognize any shortterm changes in the actuator pressure at various valve positions, the average drive signal
y is calculated from the last measured values
for each valve position class.
The positioner saves the drive signal y andthe valve position x in a circular buffer witha memory depth of ten measured values. The
last ten recorded values of each variable arelisted in the Drive signal y folder and the
Valve position x folder.
Requirements
1. A single-acting actuator is mounted on
the valve.
2. No booster is mounted on the control
valve.
3. The valve operates as a control valve.
4. A reference test has been performed.
See u Section 1.2.1.

42

Settings > Identification > Positioner >Actuator
1. −−Model: Single acting, [-/-]−−Booster: Not present, [-/-]Start-up
3. −−Application type (Code 49 - h0): Control
valve

Defining parameters
1. Select classification for status messages.
Settings > Positioner > Error control >Classification report > Extended > ...
1. Air supply−−Perhaps modified 1):[ ], , ,−−Perhaps not enough:[ ], , ,−−Working at full capacity:[ ], , ,Leakage pneumatics−−Perhaps too large:[ ], , ,−−Perhaps existing:[ ], , ,Actuator springs−−Working at full capacity:[ ], , ,3.6.1

Analysis and monitoring

Analysis of the drive signal for control
valves starts one hour after the observation
period begins. No analysis is performed foron/off valves.

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Statistical information

The following effects can be read by comparing the correlation between the drive signal and valve position measured during operation and in the reference graph:−− The drive signal runs below the reference
as the gradient rises.
−− The drive signal starts to rise steadily at a
certain valve opening compared to thereference graph. This pinpoints to significant leakage in the pneumatics arising
due to screw fittings that are not tightened properly or due to a tear in the diaphragm. The positioner generates the'Leakage pneumatics' message with theselected status classification.
−− The drive signal initially follows thecourse plotted in the reference graph andthen starts to rise almost steadily. This
pinpoints to a supply pressure that is insufficient for the valve to move throughits entire working range. The positioner
generates the 'Air supply' message withthe selected status classification.
−− The drive signal shifts downwards with asmaller gradient than in the referencegraph, pinpointing to a reduced springforce in a fail-close control valve. The positioner generates the 'Actuator springs'
message with the selected status classification.

Note
The results from the Statistical information
test can be checked by performing a testfrom Tests (out-of-service diagnostics) if theprocess allows it. See u Section 4.1.

3.6.2

Resetting single status
messages

The messages 'Air supply', 'Leakage pneumatics' and 'Actuator springs' are reset by
selecting and executing the command "Reset'Drive signal diagram steady-state" or "Reset'Drive signal diagram steady-state - shortterm".
By selecting and executing the command"Reset 'Drive signal diagram steady-state",
all the measured data of the diagram, including the short-term monitoring, are reset.
By selecting and executing the command"Reset 'Drive signal diagram steady-state short-term", the measured data in the Shortterm folder are reset.
Diagnosis > Status messages > Reset−−Reset 'Drive signal diagram steady-state'−−Reset 'Drive signal diagram steady-state short-term'

Diagnosis > Status messages > Extended−−Air supply:

,

,

,

−−Leakage pneumatics:,,−−Actuator springs:,,

EB 8389S EN

,

,

43

Statistical information – Drive signal diagram hysteresis

Requirements– Model: Single acting– Booster: Not present– Application type: Control valve– Reference test completed. See u Section 1.2.1
â

START-UP

Enable time distanceââ

Immediately

User-definedâMin. time distance fromtestâCancelation condition
Tolerance band of hysteresis
Status classification (NE 107)
Friction

Much higher/lower over whole
range

PROCESS

Much higher/lower over sectionâ
Status classification (NE 107)/logged by operating
hours counter
Frictionâ
Reset 'Drive signal diagram hysteresis'

44

EB 8389S EN

Statistical information

3.7 Drive signal diagram hysteresis
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 signal of the i/p converter. This signal runs directly proportional to the signal
pressure pout in the pneumatic actuator, in relation to the valve position.
The statistical information 'Drive signal diagram - Hysteresis' allows an analysis in thechange of the friction forces.
Data are recorded after the hysteresis test is
activated. A single test can be performed immediately or regular tests can be performed
after the adjusted time interval has elapsed.

The following listed parameters are activatedwhile the hysteresis test is being performed:−− Travel/angle range start (Code 8): 0 %−− Travel/angle range end (Code 9): 100 %−− Enable travel/angle lower limit(Code 10): Off−− Enable travel/angle upper limit(Code 11): Off−− Enable set point cutoff decrease(Code 14): Off−− Enable set point cutoff increase(Code 15): Off−− Required transit time OPEN (Code 21):
Variable−− Required transit time CLOSED (Code 22):
VariableFig. 7: Diagnosis > Statistical information > Drive signal diagram > Hysteresis

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45

Statistical information

Based on the operating point, the test is performed with a change in travel of less than
1 % to find the change in drive signal (∆y).
The changes in drive signal ∆y are classified
according to the valve position x in the valve
position classes. The average value ∆y pervalve position class is calculated from all thevalues and plotted in a graph (Measurement).
Note−−If the test is started in manual mode using
the setting 'Enable time distance' = 'User
defined' and another test is active at thetime selected, the hysteresis test starts 30
seconds after the active test ends.
−−A straight line from the average reference
data is shown in cases where no data
could be compiled for valve working ranges which were not covered by the longterm monitoring.
−−If the hysteresis test could not be completed
because the valve position is at the top or
bottom limit of the working range, the positioner indicates ‘Test at operating point
not possible’ (Test information).
Short-term monitoring
To provide a short-term trend, the last ten
valve positions x and the associated changes
in drive signal (∆y) values are saved in the
Short-term folder.
Requirements
1. A single-acting actuator is mounted on
the valve.

46

2. No booster is mounted on the control
valve.
3. The valve operates as a control valve.
4. A reference test has been performed.
See u Section 1.2.1.
Settings > Identification > Positioner >Actuator
1. −−Model: Single acting, [-/-]
2. −−Booster: Not present, [-/-]Start-up
3. −−Application type (Code 49 - h0): Control
valve

Defining parameters
1. Select classification for status messages.
2. Set cancelation condition. See u Section
3.7.1.
3. Define start conditions.
4. Start hysteresis test.
The 'Test information' status indicates'Running test'. 'd5' and 'tEST' are indicated in alternating sequence on the positioner display. 'Function check'isactivated as the condensed state.
Settings > Positioner > Error control >Classification report > Extended > ...
1. Friction−−Much higher over whole range:[ ], , ,−− Much lower over whole range: [

],

,

,

−−Much higher over section:[ ], , ,EB 8389S EN

Statistical information−−Much lower over section:[ ], , ,Diagnosis > Statistical information > Drive
signal diagram > Hysteresis
2. −− Tolerance band of hysteresis: 1 to 5 %, [5 %]3. −−Enable time distance:[User-defined], Immediately−−Min. time distance from test: 1 to 24 h, [1 h]4. −−Start test.

The test is started again ten times at the
maximum. The time between tests is increased by 30 seconds each time (30 s x
Number of tests repeated). After the test
is canceled for the tenth time, the timeentered in 'Min. time distance from test'
is kept again.
If the analysis of the hysteresis pinpoints'Friction' or 'External leakage', the positioner
generates a corresponding status message.
Diagnosis > Status messages > Extended

Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner.

3.7.1

Analysis and monitoring

The test is monitored by the 'Tolerance bandof hysteresis' parameter:−− If the valve position x leaves the 'Tolerance band of hysteresis' during the test,
the test is immediately canceled and thepositioner returns to closed-loop operation.
−− If a change in set point (∆w) occurs
which is greater than the 'Tolerance bandof hysteresis', the test is immediately canceled and the test is started again after
waiting 30 seconds using the new operating point.
If this test is also canceled by a change
in set point (∆w), it is reactivated after
waiting 60 seconds using the new operating point.

EB 8389S EN−−Friction:

,

,

,

Note
The results from the Statistical information
test can be checked by performing a testfrom Tests (out-of-service diagnostics) if theprocess allows it. See u Section 4.2.

3.7.2

Resetting single status
messages

The messages 'Friction' and 'External leakage' are reset by the command "Reset 'Drive
signal diagram hysteresis" or "Reset 'Drive
signal diagram hysteresis - short-term".
By selecting and executing the command"Reset 'Drive signal diagram hysteresis", all
the measured data of the diagram, including
the short-term monitoring, are reset.
By selecting and executing the command"Reset 'Drive signal diagram hysteresis short-term", the measured data in the Shortterm folder are reset.

47

Statistical information

Diagnosis > Status messages > Reset−−Reset 'Drive signal diagram hysteresis'−−Reset 'Drive signal diagram hysteresis - shortterm'48

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Statistical information – Trend of travel end position

Prerequisite- Enable set point cutoff decrease: On

START-UPâ
Threshold value for recording data, zero point
limit
â
Alarm settings (NE 107)
Observing end position

x [%]

0

t [s]

Reference test completed?
u Section 1.2.1

PROCESSß NO YESâàFirst zero point =ReferenceàZerocalibrationà

Subsequent zero calibration
over Code 6 - ZPß

ZP shift monotone down/up
average above/below reference
NP alternate - above/below referenceâ
Status classification (NE 107)/logged by operating
hours counter
Course of end positionâá

50

Reset 'Lower end position - ref.
values'â
Reset 'Lower end position'

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Statistical information

3.8 Trend of travel end position
The travel end position trend is used to detectan alternating zero point or a creeping zero
point shift due to seat and plug wear or dirt
between the seat and plug.
Data are recorded in the background regardless of the operating mode selected if
the tight-closing function (Code 14) is active.
Data logging does not need to be activated.
The course of end position records the valve
position x and the drive signal y together
with the time stamp by the operating 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 'Threshold value for record-ing data' from the last value, the data of the
new zero point are saved.
A graph of the recorded valve positions at
the lower end position is plotted over thenumber of measurements.
The positioner saves the valve positions in acircular buffer, which holds 30 measured
values at one time. The recorded measured
data are listed in the Lower end position
folder.

Fig. 8: Diagnosis > Statistical information > Trend of travel end position

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51

Statistical information

Defining parameters
1. Activate tight-closing function.
2. Set conditions for saving reference value
and zero point. See u Section 3.8.1.
3. Select classification for status messages.
Settings > Positioner > Reference variable
1. −−Enable set point cutoff decrease (Code 14):[On]−−Set point cutoff decrease (Code 14):0.0 to 49.9 %, [1.0 %]Diagnosis > Statistical information > Trendof travel end position
2. −−Threshold value for data recording:
0.10 to 5.00 %, [0.25 %]Settings > Positioner > Error control−−Zero point limit (Code 48 - d5):
0.0 to 100.0 %, [5.0 %]Settings > Positioner > Error control >Classification report > Extended > ...
3. Observing end position−−Zero point - shift monotone down; average
above reference: [ ], , ,−−Zero point - shift monotone up; average
above reference: [ ], , ,−−Zero point - alternate; average abovereference:[ ], , ,−−Zero point - shift monotone down; average
below reference: [ ], , ,3.8.1

Analysis and monitoring

Analysis of the histogram starts directly after the change to manual or automaticmode.
A reference zero point must be recorded toanalyze the end position trend. This is recorded during the reference test (see u Section 1.2.1). In case a reference test has notbeen performed, the first zero point that thevalve moved to serves as the reference value.
The reference value is represented by astraight line in the end position graph.
Note
If the reference value has been reset by selecting and executing "Reset 'Lower end position - ref. values" (see u Section 2.2.1),
the first zero point that the valve moves to after the reset serves as the new reference value, provided it does not exceed the 'Zeropoint limit'.
If the analysis of end position trend pinpoints
a fault, the positioner generates the 'Observing end position' message with the selected
status classification.
Diagnosis > Status messages > Extended−−Observing end position:

,

,

,

−−Zero point - shift monotone up; average
below reference: [ ], , ,−−Zero point - alternate; average below
reference: [ ], , ,52

EB 8389S EN

Tests3.8.2

Resetting single status
messages

The 'Observing end position' message andthe measured data of the end position trend
are reset by the command "Reset 'Lower end
position".
If only the reference zero point is to be reset,
select and execute "Reset 'Lower end position - Ref. values".
Diagnosis > Status messages > Reset−−Reset 'Lower end position'−−Reset 'Lower end position - ref. values'−− Travel/angle range start (Code 8): 0 %−− Travel/angle range end (Code 9): 100 %−− Enable travel/angle lower limit(Code 10): Off−− Enable travel/angle upper limit(Code 11): Off−− Enable set point cutoff decrease(Code 14): Off−− Enable set point cutoff increase(Code 15): Off−− Characteristic selection (Code 20): Linear−− Required transit time OPEN (Code 21):
Variable−− Required transit time CLOSED (Code 22):
Variable

4 Tests
For reasons of safety, these tests can only be
started when the positioner is in the manualmode.
! NOTICE
The control valve moves through its defined
working range while a test is being performed. Therefore, it is important to checkbefore starting a test whether the conditions(in the plant or process) allow the valve to
move through its working range.
The tests provide a trend showing the current
control valve state, any possible existing
malfunctions and help to pinpoint faults andto schedule predictive maintenance work.
The following parameters are briefly
changed while the tests are running:

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53

START-UP

Tests – Drive signal diagram steady-state

Requirements– Model: Single acting– Booster: Not present– Target mode: Manualâ
Status classification (NE 107)
Air supply

Actuator
springs

Leakagepneumatics

âStart test
Reference test completed?
u Section 1.2.1

NO à

YES
â

First test = Reference
Start test

MANUAL MODE (TEST)â
Test analysis

Air supply:

Actuator springs:

Pneumatic leakage:

Perhaps modified Perhaps spring stiffness Perhaps too large
Perhaps not enough
reduced/Perhaps existing
Working at full capacity
bias reduced
Working at full capacityâââ

Status classification (NE 107)/
logged by operating hours counter
Air supply

Actuator
springsââLeakagepneumatics
â

Reset 'Drive signal diagram steady-state measured data'54

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Tests

4.1 Drive signal diagram
steady-state
The 'Drive signal diagram steady-state'(Tests) allows you to check the results of thedrive signal diagram steady-state in Statistical information (in-service monitoring) moreclosely (see u Section 3.6). Besides pinpointing problems in supply pressure, it canalso detect defective actuator springs.
The test is started in the manual mode.
During the test the valve moves to various
fixed valve positions distributed over theworking range of the valve. The drive signal
y is measured for each valve position x andcompared with the reference graph.

The recorded data of the drive signal y areplotted versus the valve position x in a graph(Repetition).
Requirements
1. A single-acting actuator is mounted on
the valve.
2. No booster is mounted on the control
valve.
3. A reference test has been performed.
See u Section 1.2.1.
If a reference test has not be stored in thepositioner, the data of the first test performed are used as the reference.

Fig. 9: Diagnosis > Tests > Drive signal diagram steady-state

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55

TestsSettings > Identification > Positioner >Actuator
1. −−Model: Single acting, [-/-]
2. −−Booster: Not present, [-/-]

Defining parameters−−Perhaps bias reduced (TEST):[ ], , ,−−Working at full capacity (TEST):[ ], , ,3. Start test

1. Switch to manual mode.
2. Select classification for status messages.
3. Start test.
The 'Test information' status indicates'Running test'. 'd1' and 'tEST' are indicated in alternating sequence on the positioner display.
'Function check'is activated as thecondensed state.
Operation > Operating mode 1)
1. Target mode (Code 0): Manual
Settings > Positioner > Error control >Classification report > Extended > ...
2. Air supply−−Perhaps modified (TEST):[ ], , ,−−Perhaps not enough (TEST):[ ], , ,−−Working at full capacity (TEST):[ ], , ,Leakage pneumatics−−Perhaps existing (TEST):[ ], , ,Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner.
After the test has been canceled, the positioner remains in manual mode.
In TROVIS-VIEW the test information andprogress flag of the test are displayed. The'Test information' status indicates 'Test finished' after the test is finished.
Note
Every time the test is performed, old measured data are overwritten (Repetition).

4.1.1

Analysis and monitoring

The following effects can be read by comparing the correlation between the drive signal and valve position measured during thetest and in the reference graph:−−Perhaps too large (TEST):[ ], , ,Actuator springs−−Perhaps spring stiffness reduced (TEST)[ ], , ,56

EB 8389S EN

Tests−− The drive signal runs below the reference
as the gradient rises.
−− The drive signal starts to rise steadily at a
certain valve opening compared to thereference graph. This pinpoints to significant leakage in the pneumatics arising
due to screw fittings that are not tightened properly or due to a tear in the diaphragm. The positioner generates the'Leakage pneumatics' message with theselected status classification.
−− The drive signal initially follows thecourse plotted in the reference graph andthen starts to rise almost steadily. This
pinpoints to a supply pressure that is insufficient for the valve to move throughits entire working range. The positioner
generates the 'Air supply' message withthe selected status classification.

4.1.2

Resetting single status
messages

The diagnostic parameters and measured
data analysis from the 'Drive signal diaphragm steady-state' test are reset by selecting and executing the command "Reset'Drive signal diagram steady-state measured
data".
Diagnosis > Status messages > Reset−−Reset 'Drive signal diagram steady-state measured data'−− The drive signal shifts downwards with asmaller gradient than in the referencegraph, pinpointing to a reduced springforce in a fail-close control valve. The positioner generates the 'Actuator springs'
message with the selected status classification.
Diagnosis > Status messages > Extended−−Air supply:

,

,

,

−−Leakage pneumatics:,,−−Actuator springs:,,

EB 8389S EN

,

,

57

Tests > Drive signal diagram hysteresis

Requirements– Model: Single acting

START-UP– Booster: Not present– Target mode: ManualâCancelation condition
Tolerance band of hysteresis
Status classification (NE 107)
FrictionâStart testâ
Reference test complet- NO à
ed? See section 1.2.1.

MANUAL MODE (TEST)YESâFirst test = Reference
Start test

â
Test analysis

Friction:
Much higher/lower over whole range
Much higher/lower over sectionâ
Status classification (NE 107)/
logged by operating hours counter
Frictionâ
Reset 'Drive signal diagram hysteresis measured data'58

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Tests

4.2 Drive signal diagram hysteresis
The 'Drive signal diagram hysteresis' (Tests)
allows you to check the results of the drive
signal diagram hysteresis in Statistical information (in-service monitoring) more closely(u Section 3.7). Changes in friction can bedetected.
The test is started in the manual mode.
During the test the valve moves to various
fixed valve positions distributed over theworking range of the valve. After moving toeach valve position, a ramp movementchanging the valve travel by less than 1 % is
performed. The change in drive signal (∆y)
is measured for each valve position x andcompared with the reference data. The re-corded data of the change in drive signal(∆y) are plotted versus the valve position x ina graph.
Requirements
1. A single-acting actuator is mounted on
the valve.
2. No booster is mounted on the control
valve.
3. A reference test has been performed.
See u Section 1.2.1.
If a reference test has not be stored in thepositioner, the data of the first test performed are used as the reference.

Fig. 10: Diagnosis > Tests > Drive signal diagram hysteresis

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59

TestsSettings > Identification > Positioner >Actuator
1. −−Model: Single acting, [-/-]
2. −−Booster: Not present, [-/-]

Defining parameters
1. Switch to manual mode.
2. Select classification for status messages.
3. Set cancelation condition. See u Section
4.2.1.
4. Start test.
The 'Test information' status indicates'Running test'. 'd2' and 'tEST' are indicated in alternating sequence on the positioner display.
'Function check'is activated as thecondensed state.
Operation > Operating mode
1. −−Target mode (Code 0): Manual
Settings > Positioner > Error control >Classification report > Extended > ...
2. Friction−−Much higher/lower over whole range (TEST)
2): [ ], , ,−−Much higher/lower over section (TEST) 2): [], , ,
Diagnosis > Statistical information > Drive
signal diagram > Hysteresis
3. −−Tolerance band of hysteresis: 1.0 to 5 %, [5%]Diagnosis > Tests > Drive signal diagramhysteresis
4. −−Start test

60

Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner.
After the test has been canceled, the positioner remains in manual mode.
In TROVIS-VIEW the test information andprogress flag of the test are displayed. The'Test information' status indicates 'Test finished' after the test is finished.

4.2.1

Analysis and monitoring

The test is canceled if the valve cannot moveto a certain position or a value leaves the'Tolerance band of hysteresis'.
−− If the valve position x leaves the 'Tolerance band of hysteresis' during the test,
the test is immediately canceled and thepositioner returns to closed-loop operation.
−− If a change in set point (∆w) occurs
which is greater than the 'Tolerance bandof hysteresis', the test is immediately canceled and the test is started again after
waiting 30 seconds using the new operating point.
−− If this test is also canceled by a change
in set point (∆w), it is reactivated after
waiting 60 seconds using the new operating point.
−− The test is started again ten times at the
maximum. The time between tests is increased by 30 seconds each time (30 s x
Number of tests repeated). After the

EB 8389S EN

Teststenth time that the test is canceled, thetime entered in 'Min. time distance fromtest' is kept again.
If the analysis of the hysteresis pinpoints'Friction', the positioner generates a corresponding status message.
Diagnosis > Status messages > Extended−−Friction:

,

,

,

4.2.2

Resetting single status
messages

The diagnostic parameters and measured
data analysis from the 'Drive signal diaphragm hysteresis' test are reset by selecting
and executing the command "Reset 'Drive
signal diagram hysteresis measured data".
Diagnosis > Status messages > Reset−−Reset 'Drive signal diagram hysteresis measured data'

EB 8389S EN

61

Tests

4.3 Static characteristic
The static performance of the control valve isaffected by the friction hysteresis and theelastic processes in the valve stem packing.
The test is started in the manual mode.
The positioner specifies the set point w in adefined test range ('Start' and 'End') in small
steps and records the response of the valve
position x after waiting a 'Delay time after
step'. The step height is determined automatically from the 'Number of measurement values until turn back' and the defined test
range. The ascendent and descendent areplotted within the test range. The response of
the valve position x to the change in set point(∆w) is plotted in a graph.
The dead band is analyzed in the positioner
when a step height is smaller than 0.2 %.

−− 'Min. dead band': Minimum change inset point that causes a minimal change
in the valve position.
−− 'Average dead band': Average change
in set point that causes a minimal change
in the valve position.
−− 'Max. dead band': Maximum change inset point that causes a minimal change
in the valve position.
The difference in set point w that causes aminimal change in the valve position x is
termed ‘dead band’.
Defining parameters
1. Switch to manual mode.
2. Select test parameters.
3. Start test.

Fig. 11: Diagnosis > Tests > Static characteristic

62

EB 8389S EN

TestsThe 'Test information' status indicates'Test active'. 'd3' and 'tEST' are indicatedin alternating sequence on the positioner
display. 'Function check'is activatedas the condensed state.
Operation > Operating mode
1. −−Target mode (Code 0): Manual
Diagnosis > Tests > Static characteristic
2. −−Start: 0.0 to 100.0 %, [50.0 %]−−End: 0.0 to 100.0 % [52.0 %]−−Delay time after step:
0.1 to 25.0 s, [1.0 s]−−Number of measurement values until turnback: 1 to 50, [50]3. −−Start test

Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner.
After the test has been canceled, the positioner remains in manual mode.
In TROVIS-VIEW the test information andprogress flag of the test are displayed. The'Test information' status indicates 'Test not
active' after the test is finished.

4.3.1

Resetting single status
messages

A single reset of diagnostic parameters andmeasured data is not possible.

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63

Tests – Partial stroke test (PST)

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
Activation of the ramp function
â
â

No

Yes

x [%]

â

100

Ramp time (rising)
Ramp time (falling)

90

100
90

t [s]

t [s]

â

START-UP

Cancelation conditions
Max. test durationdelta y-monitoring
PST tolerance bandvalue

x control value

Status classification (NE 107)
PST/FSTâ
Observe start conditions(see u page 68 and page 68)!
â
Auto test timeââTarget PST testing mode
­Maximum test
durationexceeded or thevalve has not
moved before
reaching themax. breakaway
time.

â

Start testâTEST/PROCESS

Other cancelation causes: Solenoid valve
triggered/forced venting active; Supply
pressure too low; Too much friction; Step start
too large; Change in set point; Current too lowâ

PST Auto*â

The valve position
exceeds 'x control
value'.

âââ

PST ManâââFirst PST after defining parameters = ­ReferenceâStart further PSTâThe valve
position
deviationexceeds the
PST tolerance
band.

â

â

Other cancelation causes: Solenoid valve
triggered/forced venting active; Supply
pressure too low; Too much friction; Step start
too large; Change in set point; Current too lowâAnalysis (NE 107)/logged by operating hours counter
PST/FSTâ
Reset PST64

The drive signal
exceeds thecomparative value
given by the deltay-monitoring.

ââ* Note! The positioner is write-protected when tests are performed according to a schedule (local operation and operating software).

x [%]

â

EB 8389S EN

Tests

4.4 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 intervals.
A shut-off valve normally in its end position
can be prevented from seizing up or getting
jammed. The breakaway torque must be
overcome when the plug starts to move outof its open position. This breakaway torquedepends on the seal, deposits on the seatand plug, the process medium and friction in
the valve trim. After the breakaway torquehas been overcome, it can be assumed thatthe valve is able to completely close.

Recording the test results additionally allows
an analysis of the dynamic control response.
The partial stroke test can be performed
once (test immediately started) or, with anon/off valve in automatic mode, regularly(time-controlled), provided the start conditions are met (see u Table 4):−− A control valve is in the manual mode.
−− An on/off valve is in the manual or automatic mode. In automatic mode, the testis only started when the Set point w isgreater than the 'Limit fail-safe position'(Code 49 - h2).
The following listed parameters are changed
as specified below while the partial stroke
test is being performed:−− Characteristic selection (Code 20): Linear

Fig. 12: Diagnosis > Tests > Partial stroke test

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65

Tests−− 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 defined end value and back to the initial position again.
The change in travel can be performed either in steps or in a ramp function (Fig. 13).
For the test in a ramp function, additionallythe ramp times for the rising and falling
ramps need to be defined.

The PST diagnostic parameter 'Step start'
must be within the range of the current operating point ± 'Tolerance limit of step response' for the partial stroke test to start.
After being activated, the test does not start
until the 'Settling time before test start' haselapsed. Starting from the 'Step start', thevalve moves to 'Step end'. The valve remains
in this position for the time defined by the'Delay time after step' before performing asecond step change in the opposite direction
from 'Step end' to 'Step start'. After the 'Delay time after step' has elapsed, the valve
moves back to its operating point.

Start PSTx [%]Start PST

Operating point + Tolerance limit
Operating point
Start

Operating point – Tolerance limit

End

Settling time before test start

Delay time after step

∆tfalling∆trising‘Step start’ – ‘Step end’100
‘Step start’ – ‘Step end’100x

‘Ramp time (falling)’x‘Ramp time (rising)’

Settling time before
test start∆tfallingt [s]Delay timeafter step

∆trising

Fig. 13: Course of the partial stroke test with step response (left) and ramp function (right)

66

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TestsThe ‘Scan rate’ defines the time interval between which the measured values are recorded during the test.
Test cancelation conditions
Various cancelation conditions provide additional protection against the valve slamming
shut or moving past the end position.
The positioner cancels when one of the following cancelation conditions is fulfilled:−− 'Max. test duration': The test is canceledwhen the maximum permissible test duration is reached.
Cancelation condition - valve position x (tocheck the valve position)−− 'x control value': The test is canceled assoon as the valve position falls below theadjusted value.
This cancelation condition only becomes
effective after it has been activated ('Activation x control' = Yes).
Cancelation condition - drive signal y (tomonitor the friction of the plug)
A higher drive signal from the positioner iscaused by increased plug friction and the resulting increased breakaway torque. This
may result in overshooting. To prevent this,the drive signal y can be monitored and thetest canceled in the event that an error is detected.
−− 'delta y-monitoring value': The test iscanceled as soon as the drive signal yfalls below or exceeds the reference
value. The reference value is made up of
the diagnostic parameters ''delta y-monitoring reference value' and 'delta y-mon-

EB 8389S EN

itoring value'. The 'delta y-monitoringvalue' is entered in % and is based on
the entire drive signal range (10000 1/s).
This cancelation condition only becomes
effective after it has been activated ('Activation delta y-monitoring' = Yes).
−− This cancelation condition only becomes
effective when the full actuator thrust isrequired to move the valve due to theprocess conditions.
Note−−The partial stroke test must be performed
with deactivated cancelation conditions forvalves with double-acting actuator andpneumatic booster as well as for valves
that have been initialized using the SUB
mode (substitute calibration).
−−Excessive overshooting may occur in valvesfitted with boosters. In this case, the cancelation conditions must be adapted accordingly.
Additionally, the partial stroke test is canceled when one of the following events arises:−− 'Aborted by int. solenoid valve/forced
venting': The test was canceled by theactivation of the solenoid valve/forced
venting function.
−− 'Supply pressure/friction': An insufficient
supply pressure or excessive friction occurred during the test.
−− 'Difference w - step start too high': The'Step start' is outside the range of operating point ± 'Tolerance limit of step response'.

67

Tests−− 'Reference variable was changed': The
test was started according to a schedule(time-controlled). Due to a set pointchange before the step was started, the'Step start' is outside the range of the operating point ± 'Tolerance limit of step response'.
−− 'Current too low'Note
The 'Measured data storage out of memory'
reading (Maintenance alarm) is generated
when the 'Scan rate' 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'Status of partial stroke test' reading indicates 'Not successful'. The reason for cancelation is marked by the 'Maintenance alarm'message in the Analysis of measured data
folder (> Current test).
Defining parameters
1. Define parameters for partial stroke test.
See u Note concerning setting the PST
diagnostic parametersetting the PST diagnostic parameters on page 69.
2. Define parameters for cancelation conditions.
3. Select classification for status message.
4. Start the partial stroke test.
The 'Test information' status indicates'Test active'. 'd4' and 'tEST' are indicatedin alternating sequence on the positioner

68

display. 'Function check'as the condensed state.

is activatedDiagnosis > Tests > Partial stroke test
1. −−Step start (Code 49 - d2):
0.0 to [100.0 %]−−Step end (Code 49 - d3):
0.0 to 100.0 % [90.0 %]−−Tolerance limit of step response:
0.1 to 10.0 %, [2.0 %]−−Activation of the ramp function(Code 49 - d4): Yes, [No]−− Settling time before test start (Code 49 - d7):
1 to 240 s, [1 s]−−Delay time after step (Code 49 - d8):
1.0 to 240.0 s, [2.0 s]−−Scan rate (Code 49 - d9):
0.2 to 250.0 s, [0.8 s]−−Number of step responses: 1, [2]Only when the ramp function is activated:−−Ramp time (falling) (Code 49 - d5):
0 to 9999 s, [600 s]−−Ramp time (rising) (Code 49 - d6):
0 to 9999 s, [60 s]
2. −−Max. test duration(Code 49 - E7): 30 to 25000 s, [90 s]−−Max. breakaway time: 0.0 to 25000.0 s,[7.5 s]−−Activation x control (Code 49 - E0): Yes/[No]−−x control value (Code 49 - E1):
–10.0 to 110.0 %, [0.0 %]−−Activation delta y-monitoring(Code 49 - A8): Yes, [No])−−delta y-monitoring value (Code 49 - A9):0 to 100 %, [0 %]EB 8389S EN

Tests−−PST tolerance band (Code 49 - E6):
0.1 to 100.0 %, [5.0 %]In TROVIS-VIEW the test information andprogress flag of the test are displayed. The'Test information' status indicates 'Test not
active' after the test is finished.

Settings > Positioner > Error control >Classification report > Extended > PST/FST

Note concerning setting the PST diagnostic
parameters−−Activation PST tolerance band control(Code 49 - E5): Yes, [No]3. −−PST/FST - Status active:, [ ], ,Diagnosis > Tests > Partial stroke test
4. Either:−−Target PST testing mode (Code 49 - A2):
[PST Man]−−Start test
Or: (with a control valve only in manual mode
(MAN), with an on/off valve only in automatic mode (AUTO))−−Target PST testing mode (Code 49 - A2) =PST Auto, [PST Man]−−Auto test time (Code 49 - A3):
[1 h] to 2345 d! NOTICE

The positioner is write-protected when tests
are performed according to a schedule (local
operation and operating software).
Code 0 reading: "OC" and "PST" in alternating sequence
Code 3 reading: "PST" blinks.

Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner.
After the test has been canceled, the positioner remains in selected mode. The 'Statusof partial stroke test' reading indicates 'Not
successful'.

EB 8389S EN−− We recommend only to start the partial
stroke test when the valve is in the end
position. In on/off valves, the start value
must be the same as the operating point.
−− The 'Ramp time (rising)' must be greaterthan the corresponding value for 'Minimum transit time close' (Code 41) determined during initialization.
−− The 'Ramp time (falling)' must be greaterthan the corresponding value for 'Minimum transit time open' (Code 40) determined during initialization.
Tip
Users with expert knowledge of valve diagnostics can determine appropriate ramp
times by performing a full stroke test. See
u Section 7.4.
−− The 'Scan rate' must not be lower than
the indicated 'Min. recommended scan
rate'. The 'Min. recommended scan rate'is calculated from the 'Duration of the
test'.

69

Tests

4.4.1

Start triggered by theset point

The partial stroke test of on/off valves is triggered when the set point w moves in therange between 25 and 50 % of the travel
and remains there for longer than six seconds. See u Section 3.1.
'Step start' must be within the range of thedefined position ± 'Tolerance limit of step
response' for the partial stroke test to start.
The test and its cancelation are described inu Section 4.4, while the test assessment is
described in u Section 4.4.3.

4.4.2

Start triggered by thebinary input

If the positioner is fitted with the optional binary input, the partial stroke test can bestarted by the binary input when the conditions to start the partial stroke test are met:−− A control valve is in the manual mode.
−− An on/off valve is in the manual or automatic mode. In automatic mode, the testis only started when the 'Fail-safe reference value' is greater than the 'Limit failsafe position' (Code 49 - h2). In manualmode, the test is only started when 'Target PST testing mode' = 'PST Man'.
The test and its cancelation are described inu Section 4.4, while the test assessment is
described in u Section 4.4.3.
It is important to make sure that the diagnostic parameter 'Step start' of the partial
stroke test is within the range of the 'Fail-70

safe reference value' ± 'Tolerance limit ofstep response'.
Settings > Positioner > Options−−Action at active binary input:
Start partial stroke test (PST)−−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

Note
Further details on optional binary input
u Section 6.

4.4.3

Analysis and monitoring

The analysis of the last three partial stroke
tests are saved with a time stamp in the
Analysis of measured data folder. A graphof the last partial stroke test is shown in thePartial stroke test folder.
Test completed successfully
When a partial stroke test has been completed successfully, the analyzed parameters are
displayed separately for the increasing anddecreasing characteristics.
Analysis of measured data (step responsetest):−− 'Overshoot' (relative to the step height)[%]−− 'Dead time' [s]−− 'T63' [s]EB 8389S EN

Tests−− 'T89' [s]−− 'Rise time' [s]−− 'Settling time' [s]Analysis of measured data (ramp test):−− 'Overshoot' (relative to the step height)[%]
The results of the first partial stroke test areused as the reference measurement.
Note
Changes in the diagnostic parameters listed
below affect the test. The results of the next
following partial stroke test are used as the
new reference measurement:−−'Step start'−−'Step end'−−'Activation of the ramp function'−−'Ramp time (rising)'−−'Ramp time (falling)'−−'Delay time after step'
Test not completed
If the test was not completed, the reason forcancelation is indicated in the corresponding
reading by the 'Maintenance alarm' message. The positioner generates a 'PST/FST'
message with the selected status classification. 'Extended diagnosis' (Code 79) is activated regardless of the status classification.
Diagnosis > Status messages > Extended
PST/FST:,EB 8389S EN

,

,

,

Note
The 'No test available' status remains active
until a partial stroke test is completed successfully.

4.4.4

Resetting single status
messages

The diagnostic parameters and measured
data analysis of the partial stroke test are reset by selecting and executing the command'Reset PST'.
The positioner saves the measured data
analysis of the last three partial stroke tests.
The analysis of the penultimate test is deleted
when another test is performed.
Diagnosis > Status messages > Reset−−Reset PST

4.4.5

Step response

The dynamic performance of the control
valve can be tested by plotting its step response.
The step response of the valve is recorded by
performing the partial stroke test with sudden changes in the valve position.
In addition, the following settings are recommended:−− Deactivate all cancelation conditions of
the partial stroke test, providing the process allows it.

71TestsOn/off valve

Control valve

Application type

Table 4: Start options for the partial stroke test (PST)
PST start
byRotary pushbutton or operating
softwareTest interval(time-controlled)

Set point w

Binary input

See page 65

See page 65

See section 4.4.1

See section 4.4.2

ManualAutomatic

Automatic

Automatic

Automatic
mode AUTO

Not possible

Not possible–

Not possible

Manual mode
MAN

Possible

Not possible–

Possible

Automatic
mode AUTO

Possible

Possible

Possible

Possible

Manual mode
MAN

Possible

Possible

Not possible

Possible'Auto test
time' elapsed

Set point is six
seconds long in
the range
between 25 and
50 % of travel

Binary inputchanges to ‘On:
open switch’ or‘Off: closed switch’(see ‘Edge control
binary input’
parameter)

Operatingmode

Triggering event

72

Code 49 - A0 =YES or'Start test'
parameter
activated

EB 8389S EN

EB 8389S EN

73

Statistical information – Full stroke test (PST)

Prerequisite– Operating mode: Manualâ
Tolerance limit of step response, Settling time before test start,
Delay time after step, Scan rate
Activation of the ramp function

START-UP

â
x [%]
100

â

â

No 1)

Yes

x [%]
100

â
0

Ramp time (rising)
Ramp time (falling)

t [s]

0

t [s]

â
Cancelation condition
Max. test duration
Status classification

Manual mode (TEST)

PST/FST
Maximum test
duration or
allowed time toreach full closed
positionexceeded.

âStart FSTââ

The valve has not
moved before
reaching the max.
breakaway time.

âAnalysis (NE 107)/logged by operating hours
counter
PST/FSTâ
Reset FST

74

1)

Recommended

EB 8389S EN

Tests

4.5 Full stroke test (FST)The dynamic valve performance can be evaluated by performing the test.
The full stroke test is started in the manualmode.
The following listed parameters are activatedwhile the full stroke test is being performed:−− Characteristic selection (Code 20): Linear−− Required transit time OPEN (Code 21):
Variable−− Required transit time CLOSED (Code 22):
Variable
During the full stroke test, the valve moves
through its entire working range.
The first step ends in the fail-safe position. As
a result, the second step starts from the failsafe position.

The change in travel can be performed either in steps or in a ramp function (Fig. 15).
For the test in a ramp function, additionallythe times for the rising and falling ramps
need to be defined.
After being activated, the test does not start
until the 'Settling time before test start' haselapsed. This ensures that the valve hasreached the start position.
Starting from the start position, the valve
moves to the fail-safe position. The valve remains in this position for the time defined by
the 'Delay time after step' before performinga second step change in the opposite direction 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.

Fig. 14: Diagnosis > Tests > Full stroke test

EB 8389S EN

75

TestsThe 'Tolerance limit of step response' parameter defines the permitted valve positions forthe start value and the end value for the step.

−− 'Max. test duration': The test is canceledwhen the maximum permissible test duration is reached.

The 'Scan rate' defines the time interval between which the measured values are recorded during the test.

Additionally, the full stroke test is canceledwhen one of the following events arises:

Test cancelation conditions
Various cancelation conditions provide additional protection against the valve slamming
shut or moving past the end position. The
positioner cancels the full stroke test when
one of the following cancelation conditions isfulfilled:−− 'Aborted by int. solenoid valve/forced
venting': The test was canceled by theactivation of the solenoid valve/forced
venting function.
−− 'Supply pressure/friction': An insufficient
supply pressure or excessive friction occurred during the test.

x [%]Operating point + Tolerance limit
Operating point – Tolerance limit

100
Op. point

Settling time
before test start

Settling time
before test start

Delay timeafter step

Delay timeafter step

Ramp time falling

Delay timeafter stept [s]Ramp time rising

Delay timeafter step

Fig. 15: Course of the full stroke test with step response (left) and ramp function (right)

76

EB 8389S EN

TestsNote
The 'Measured data storage out of memory'
reading (Maintenance alarm) is generated
when the 'Scan rate' is too low. After recording 100 measured values per variable, logging is stopped, but the test continues until it
is completed.
After the full stroke test is canceled, the 'Status of full stroke test' reading indicates 'Not
successful'. The reason for cancelation ismarked by the 'Maintenance alarm' message in the Analysis of measured data folder (> Current test).
Defining parameters
1. Switch to manual mode.
2. Define parameters for full stroke test. Seeu Note concerning setting the FST diagnostic parameters on page 77.
3. Configure the cancelation conditions.
4. Select classification for status message.
5. Start full stroke test.
The 'Test information' status indicates'Test active'. 'd6' and 'tEST' are indicatedin alternating sequence on the positioner
display. 'Function check'is activatedas the condensed state.
Operation > Operating mode
1. −−Target mode (Code 0): Manual
Diagnosis > Tests > Full stroke test
2. −−Tolerance limit of step response:
0.1 to 10.0 %, [2.0 %]−−Activation of the ramp function: [Yes], No

EB 8389S EN−−Settling time before test start:
1 to 240 s, [10 s]−−Delay time after step:
2.0 to 100.0 s, [2.0 s]−−Scan rate: 0.2 to 250.0 s, [1.4 s]
Only when the ramp function is activated:−−Ramp time (rising): 0 to 9999 s, [60 s]−−Ramp time (falling): 0 to 9999 s, [60 s]
3. −−Max. test duration:
30 to 25000 s, [150 s]
Settings > Positioner > Error control >Classification report > Extended > PST/FST
4. −−PST/FST - Status active:, [ ], ,Diagnosis > Tests > Full stroke test
5. −−Start test

Note
Cancel the test by right-clicking 'Stop test'
and selecting 'Execute' or by pressing the rotary pushbutton at the positioner. After thetest has been canceled, the positioner remains in manual mode.
Note concerning setting the FST diagnostic
parameters−− The 'Ramp time (rising)' must be greaterthan the corresponding value for 'Minimum transit time close' (Code 41) determined during initialization.
−− The 'Ramp time (falling)' must be greaterthan the corresponding value for 'Minimum transit time open' (Code 41) determined during initialization.

77

Tests−− The 'Scan rate' must not be lower than
the indicated 'Min. recommended scan
rate'. The 'Min. recommended scan rate'is calculated from the 'Duration of the
test'.

4.5.1

Analysis and monitoring

The analysis of the last three full stroke tests
are saved with a time stamp in the Analysisof measured data folder.
Test completed successfully
When a full stroke test has been completed
successfully, the analyzed parameters are
displayed separately for the increasing anddecreasing characteristics.
Analysis of measured data (step responsetest):−− 'Overshoot' (relative to the step height) [%]−− 'Dead time' [s]−− 'T63' [s]−− 'T89' [s]−− 'Rise time' [s]−− 'Settling time' [s]Analysis of measured data (ramp test):−− 'Overshoot' (relative to the step height) [%]The results of the first full stroke test are usedas the reference measurement.
Note
Changes in the diagnostic parameters listed
below affect the test. The results of the next
following full stroke test are used as the newreference measurement:

78−−'Activation of the ramp function'−−'Ramp time (rising)'−−'Ramp time (falling)'−−'Delay time after step'
Test not completed
If the test was not completed, the reason forcancelation is indicated in the corresponding
reading by the 'Maintenance alarm' message. The positioner generates a 'PST/FST'
message with the selected status classification. 'Extended diagnosis' (Code 79) is activated regardless of the status classification.
Diagnosis > Status messages > Extended−−PST/FST:
, , ,

Note
The 'No test available' status remains active
until a full stroke test is completed successfully.

4.5.2

Resetting single status
messages

The diagnostic parameters of the full stroke
test are reset by selecting and executing thecommand 'Reset FST'. The measured data
analysis and the 'PST/FST' message cannot
be reset.
The positioner saves the measured data
analysis of the last three full stroke tests. The
analysis of the penultimate test is deleted
when another test is performed.

EB 8389S EN

TestsDiagnosis > Status messages > Reset
Reset FST

EB 8389S EN

79

Dynamic HART® variables

5 Dynamic HART® variables
The HART® specification defines four dynamic variables consisting of a value and an engineering unit. These variables can be assigned to device parameters as required. The
universal HART® command 3 reads the dynamic variables out of the device. This allows manufacturer-specific parameters to also be transferred using a universal command.
Depending on the positioner, the dynamic
HART® variables can be assigned by the DD
or in TROVIS-VIEW[Settings > Operation unit] as shown in Table 5:
Settings > Operating unit−−Assignment secondary variable: Variable selected according to Table 5 [Valve position]−−Assignment tertiary variable: Variable selectedaccording to Table 5 [Set point deviation e]−−Assignment quaternary variable: Variable selected according to Table 5 [Total valve travel]

The resetting of HART® variables causes all
variables to be reset at the same time.
Operation > Reset−−Reset 'HART parameter'80

EB 8389S EN

Dynamic HART® variables

Table 5: Dynamic HART® variables assignment
Variable

Meaning

Unit

Reference variable

Reference variable%

Valve set point

Valve set point%

Target position

Target position%

Valve position

Valve position%

Set point deviation e

Set point deviation e%

Absolute total valve travel

Absolute total valve travel–

Binary input status

0 = Not active
1 = Active
255 = –/––

Internal solenoid valve/forced venting status

0 = De-energized
1 = Energized
2 = Not installed–

Condensed state

0 = No message
1 = Maintenance required
2 = Maintenance demanded
3 = Maintenance alarm
4 = Out of specification
7 = Function check–

Temperature

Temperature°C

EB 8389S EN

81

Binary input

6 Binary input
The following description only applies to positioners fitted with an optional binary input.
The optional binary input can be used to activate various functions:−− [Transfer switching state]
The switching state of the binary input islogged.
−− Set local operation write protection
After the first initialization, a local write
protection can be activated. While thebinary input is active, no settings can bechanged at the positioner. The positioner
cannot be re-initialized. Enabling configuration over Code 3 is not active.
−− Start partial stroke test (PST)The positioner starts a single partial
stroke test. The test is performed with thesettings in Code 49 - d2 to Code 49 d9. See u Section 4.4.
−− Go to fail safe reference value
An on/off valve moves to the predetermined fail-safe set point when the positioner is in automatic mode. This function
is not performed if the positioner is in the
manual mode or fail-safe position mode.

−− Reset diagnosis
Active functions of statistical informationand tests are stopped and the diagnostic
data is reset once.
−− External solenoid valve connected
The positioner recognizes and logs thatan external solenoid valve is connected.
The optional binary input can only be
configured using the TROVIS-VIEW softwareand using the DD parameters. In the default
setting, the switch state is logged with aclosed switch.
Settings > Positioner > Options−−Action at active binary input: [Transfer switching state], Set local operation write protection,
Start partial stroke test (PST), Go to fail safe
reference value, Switch between AUTO/
HAND, Start data logger, Reset diagnosis, External solenoid valve connected−−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−− Switch between AUTO/MAN
The positioner changes from the automatic mode to the manual mode or viceversa. This function is not performed if
the positioner is in the fail-safe positionmode.
−− Start data logger
Activation of the binary input causes thedata logger to start. See u Section 3.2.

82

EB 8389S EN

Binary input

EB 8389S EN

83

Appendix

7 Appendix
7.1 Code list
Code Parameter – Readings/
no. values [default setting]Description

Note: 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 positioner(accuracy ±3 %)Read only

d1 Minimum temperature The lowest temperature [°C] below 20 °C that has ever occurred.
[20]
Read only
d2 Maximum temperature The highest temperature [°C] above 20 °C that has ever occurred.
[20]
Read only
d3 Numberof zero calibrations

Indicates number of zero calibrations performed since the last initialization
Read only

d4 No. of initializations

The total number of initializations that have been performed since
the last reset
Read only

d5 Zero limit

Limit for zero monitoring

0.0 to 100.0 % of the Used for error monitoring of the zero shift.
nominal range, [5.0 %]d6 Condensed state

Condensed state, made up from the individual states.
OK OK
C

Maintenance required

CR Maintenance demanded
B

Maintenance alarmS

Out of specification

Read only
d7 Start reference test
[No], YES, ESC

84

Triggering of a reference test for the functions: Drive signal y steadystate (d1) and drive signal y hysteresis (d2)
The reference test can only be activated in manual mode as the valve
moves through its entire travel range.

EB 8389S EN

Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: 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 Initialization withreference test
[No], YES, ESC

Initialization with reference test(the reference graphs for drive signal y steady-state (d1) and drive
signal y hysteresis (d2) (Tests) are recorded during the reference test).

h1 Results of reference test No No reference test has been performed.
[No], YESYES The reference graphs for drive signal y steady-state (d1) anddrive signal y hysteresis (d2) (Tests) have been plotted successfully.
Read only

h2 Unassigned
h3 Auto reset diAG[0] to 365 days

After an adjustable time period, the diagnosis data are reset automatically according to the settings in Code 36 - diAG.
Example: A start-up behavior of the plant which is untypical for theprocess is not to be included in the total diagnosis.

h4 Remaining time for au- Remaining time until the diagnosis data are reset automatically acto reset diAG
cording to the settings in Code 48 - h3.
Read only
49* Partial stroke test (PST)/full stroke test (FST) · Application typeA

Partial stroke test (PST)

A0 Starting the partial
stroke test

Operating mode and PST testing mode must be set to MAN.

[No], YES, ESC
A1 Time until next automatic PSTRemaining time [d_h] until the next partial stroke test is performed.
Only applies to PST Auto mode.
Read only

A2 Target PST testingmode

Activates (PST Auto) or deactivates (PST Man) the scheduled automatic partial stroke test.

Auto, [Man], ESC
A3 Auto test time

EB 8389S ENTime [h] between for partial stroke tests (PST)85

Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
49* A4 Status classification of C
PST status
OK

Maintenance required
No message

CR

Maintenance demandedb

Maintenance alarmS

Out of specification

Read only
A5 Recommended min.
sampling time

Scan time [s] required to plot the complete step response test in agraph.
Read only

A6 Unassigned
A7 Δy-monitoring reference value

The valve moves to the valve position Step start (Code 49 - d2) andStep end (Code 49 - d3) with certain control pulses. The difference
between these control pulses creates the Δy value [1/s].
The Δy-monitoring reference value applies to the adjusted step values (Code 49 - d2 and Code 49 - d3) and for the selected ramp
times (Code 49 - d5 and Code 49 - d6). The Δy-monitoring reference value must be determined again if any of the above mentioned
values change.
Read only

A8 Activation Δy-monitor- Activates or deactivates Δy-monitoring.
ing[No], YES, ESC
A9 Δy-monitoring value
0 to 100 %,
[0 %]

d

The percentage [%] of the entire range of the control pulse between 1
and 10000 1/s (example: 10 % = 1000 1/s)
The partial stroke test is canceled if the change in drive signal (Δy)
varies from the Δy-monitoring reference value by this amount.

Step parameters for the partial stroke test (PST)

d1 Unassigned
d2 Step start

Start value for step response

0.0 to [100.0]

86

EB 8389S EN

Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
49* d3 Step end

Stop value for step response

0.0 to 100.0 %,[90.0 %]
d4 Activation of rampfunction

Activates or deactivates ramp function.

[No], YES
d5 Ramp time (increasing) Ramp time for 0 to 100 % travel (increasing) of ramp function
0 to 9999 s, [60 s]
d6 Ramp time (decreasing)

Initialization provides a sensible value that is not to be undercut, if
possible.
Ramp time for 100 to 0 % travel (decreasing) of ramp function

0 to 9999 s,[600 s]

Initialization provides a sensible value that is not to be undercut, if
possible.

d7 Settling time before
starting test

Waiting time before test is started to ensure that value for step startcan be reached safely.

[1.0] to 240.0 s
d8 Waiting time after step Waiting time between first step change and start of second stepchangechange
1.0 to 240.0 s [2.0 s]
d9 Scan time

Scan time of step response measurement[0.2] to 250.0 s
ECancelation conditions of the partial stroke test (PST)

E0 Activation x control

Activates or deactivates x monitoring.

[No], YES
E1 x control value–10.0 to 110.0 % of
total travel,[0.0 %]The test is canceled when the valve position– falls below the adjusted value (step end < step start)– exceeds the adjusted value (step end > step start)

E2 Unassigned
E3 Unassigned

EB 8389S EN

87Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
49* E4 Unassigned
E5 Activation PST tolerance band control

Activates or deactivates PST tolerance band monitoring.

[No], YES
E6 PST tolerance band
0.1 to 100.0 %,[5.0 %]
E7 Max. test duration,user-defined

The test is automatically canceled as soon as the Step end (Code 49- d3) exceeds this percentage.

Maximum time within which a test can be completed before the test
is canceled automatically.

[30] to 25000 s
F

Partial stroke test (PST) information · Read only

F0 No test available

No test available or test canceled manually.

F1 Test OK
F2 x cancelation

The test was canceled by x cancelation function.

F3 y cancelation

The test was canceled by y cancelation function.

F4 Tolerance band exceeded

The test was canceled. The x-values are outside the tolerance band.

F5 Max. test duration ex- The test was not completed within the max. test time and was autoceeded
matically canceled.
F6 Test canceled manually The test has been manually canceled by the user.
F7 Measured data memo- Max. memory capacity for measured data reached. After recording
ry full
100 measured values per variable, logging is stopped, but the test
continues until it is completed.

88

F8 Int. solenoid valve

The test was canceled by the activation of the solenoid valve.

F9 Supply pressure/friction

The test was canceled due to insufficient supply pressure or excessive
friction.

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Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
49* hApplication type (valve)

h0 Application typeNo

Control valve[No], YES, ESC

YESOpen/close (on/off) valve

Depending on the adjusted application type, the positioner responds
differently in automatic mode and there are differences in the diagnostic functions.
h1 Operating point

The valve is moved to this valve position as soon as the reference

h2 Limit fail-safe position

The valve is moved to its fail-safe position (SAFE) when the value
falls below this limit.

0.0 to [100.0 %] of the variable exceeds the limit operating point (Code 49 – h5).
valve position

0.0 to 20.0 % of thereference variable,[12.5 %]

h3 Lower limit to start test The valve remains in its last valid position between the fail-safe position limit and the lower test limit. A partial stroke test is performed[25.0 % of reference
after six seconds when the valve is between the upper and lower test
variable]
limit.
Read only
h4 Upper limit to start test The valve remains in its last valid position between the upper test limit and the operating point limit.
[50.0 % of reference
variable]h5 Operating point limit
55.0 to 100.0 % ofreference variable,[75.0 %]

Read only

Valve is moved to the operating point when the operating point limit
is exceeded.

h6 Unassigned
h7 Travel time assessment Time limit for difference between reference value and currently relimit
corded value. Determines the difference at which a message is generated.
[0.6] to 30.0 s
h8 Travel assessment limit Travel limit for difference between reference value and currently re0.1 to 100.0 % of the corded value. Determines the difference at which a message is genvalve position, [0.3 %] erated.

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Appendix

Code Parameter – Readings/
no. values [default setting]Description

Note: Codes with marked with an asterisk (*) must be enabled with Code 3 prior to configuration.
49* h9 Status classification for C
on/off
OK

Maintenance required
No message

CR

Maintenance demandedb

Maintenance alarmS

Out of specification

Read only90

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Appendix

7.2 Error messages and recommended corrective action
Message

Status classification

Single reset•–

Possible reasons

Recommended action

Control loop (Code 57)−− Actuator is blocked.
−− Positioner attachment has
shifted subsequently.
−− Insufficient supply pressure−− Check attachment.
−− Check supply pressure.

Zero point (Code 58)−− Mounting arrangement
or linkage has slipped.
−− Valve trim, particularly
with soft seat, is worn.

−− Check valve and positioner attachment.
−− Calibrate zero.

Autocorrection (Code 59)

Data section error in positioner.

–

–

•

Fatal error (Code 60)−− Error detected in safety-relevant data. Possible
cause: EMC disturbances.
The valve is moved to failsafe position.

–

–

–

w too small (Code 63)

The set point (w) is smaller
than 3.7 mA.

Check set point (w). If necessary, adjust the current
source's lower limit so thatno values lower than
3.7 mA can be applied.

Total valve travel exceeded'Absolute total valve travel'
exceeded 'Total valve travel
limit'.

–

Temperature exceeded––

Extended diagnosis(Code 79)

Extended diagnostics messages generated by EXPERTplus. See Diagnosis > Status
messages > Extended.

–

Diagnosis > Status messages

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[

[

•

]

]

•

−− We recommend to
re-initialize the positioner if zero deviates
by more than 5 %.

[

[

[

•

•

•

]

]

]

–

–

–

–

91

Appendix

Statusclassification

Single reset––

Message

Possible reasons

Recommended action

Reference variable outside range

Set point smaller than 4 mAor greater than 20 mA.

If possible, limit current
source at lower (4 mA)
and/or upper (20 mA) limit.

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 of i/p converter interrupted.

Return positioner to SAMSON for repair.

Hardware (Code 65)−− Hardware error
The valve is moved to fail-safe
position.

Confirm error and select'Automatic' operating
mode. If not successful, reset
initialization and re-initialize the positioner.

Data memory (Code 66)−− No more data can be
written to the data memory.
The valve is moved to fail-safe
position.

Confirm error and select'Automatic' operating
mode. If not successful, reset
initialization and re-initialize the positioner.

Control calculation (Code67)

Hardware error has occurred.

Confirm error. If error cannot be confirmed, return positioner to SAMSON for repair.

Program load error(Code 77)−− A program has been loaded that does match the positioner.
The valve is moved to fail-safe
position.

Interrupt current signal andrestart the positioner. If thisis not possible, return positioner to SAMSON for repair.

x > range (Code 50)−− Pin not mounted properly.
−− NAMUR attachment:
bracket slipped or follower
pin not properly seated on
the follower plate's slot.
−− Follower plate not mounted properly.

−− Check attachment andpin position.
−− Re-initialize positioner.

[

Delta x < range (Code51)−− Pin not mounted properly.
−− Wrong lever mounted.
−− Pressure limit set too low.

−− Check attachment andpressure limit.
−− Re-initialize positioner.

[

92

[

•

]

–

[

•

–

]

–

[

•

•

•

–

]

–

•

–

•

–

]

]

•

•

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Appendix

Status classification

Single reset••

Message

Possible reasons

Recommended action

Attachment (Code 52)−− Wrong lever mounted.
−− Supply pressure too low;valve cannot be moved todesired position.
−− Nominal range could not
be reached during nominal range initialization(NOM).

−− Check attachment andsupply pressure.
−− Re-initialize positioner.

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.
−− Positioner cannot findfixed travel/angle stops.

−− Check supply pressure.
−− Install a booster.
−− Adjust travel/angle
stops.
−− Re-initialize positioner.

Transit time not reached(Code 55)

Actuator transit times detected during initialization are soshort (< 0.3 s) that optimal
positioner tuning is impossible.

−− Activate volume restriction in positioner output.
−− Re-initialize positioner.

Pin position/fail-safe
switch (Code 56)

Pin position not entered fornominal range (NOM) or
substitute (SUB) initialization.

−− Enter pin position andnominal range.
−− Re-initialize positioner.

ATO/ATC switch defective.

Return positioner to SAMSON for repair.

No emergency mode
(Code 76)

Positioner detected during initialization that actuator permits no emergency control
mode without feedback. In
case of a travel sensing error,
positioner vents Output or A1
in double-acting actuators.

For your information only.
No further action required.

[

Reference test aborted(Code 81)

Error while the referencegraph 'Drive signal diagram
steady-state (d1)' or 'Drive
signal diagram hysteresis(d2)' is automatically plotted
during initialization

Check and perform newreference test, if necessary.

[

Control parameters(Code 68)

Error in control parameters.

Confirm error. If not successful, reset initialization
and re-initialize the positioner.

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[

[

[

[

[

•

•

•

•

•

•

]

]

]

]

]

]

]

•

•

•

–

–

•

93

Appendix

Status classification

Single reset••

Message

Possible reasons

Recommended action

Potentiometer parameter(Code 69)

Error in digital potentiometerparameter.

Confirm error. If not successful, reset initialization
and re-initialize the positioner.

Adjustment (calibration)
parameter (Code 70)

Error in data from production
calibration.

Return positioner to SAMSON for repair.

General parameters(Code 71)

Error in parameters not critical to control operation.

Confirm error.

Internal device error 1(Code 73)

Internal device error

Return positioner to SAMSON for repair.

[

HART parameter (Code74)

Error in HART® parameters
not critical to control operation.

Confirm error and change
parameter, if necessary.

[

Options parameter(Code 78)

Error in option parameters.

Return positioner to SAMSON for repair.

[

Diagnosis parameter(Code 80)

Error in parameters not critical to control operation.

Confirm error. Perform newreference test, if necessary.

[

[

[
[

•
•
•
•

•
•

]

]
]
]
]

]
]

–
•
–
•

–
•

Diagnosis > Status messages > Extended
Air supply

Shifting working range

Leakage pneumatics

Limit working range

94−− The supply pressure haschanged.
−− The supply pressure is insufficient.
−− The supply pressure is
working at full capacity.

Check supply pressure.

The working range has shifted towards CLOSED or max.
OPEN position.

Rethink the working range.

A leak in the pneumatics exists.

Check that pneumatic installations and connections
are tight.

−− The working range is limited at upper or lower
range value.
−− The valve has seized up(no change possible).

−− Check that pneumatic
installations and connections are tight.
−− Check supply pressure.
−− Check plug stem for external influences that
could be blocking it.

[

•

]

•
u Sec. 3.6.2
u Sec. 4.1.2

[

[

•

•

•

]

u Sec. 3.3.2]

u Sec. 3.6.2•
u Sec. 4.1.2

[

•

]

•
u Sec. 3.4.2

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Appendix

Message

Possible reasons

Recommended action

Status classification

Observing end position−− Course of end position
monotonically increasing/decreasing.
−− Course of end position alternates.

Check seat and plug.

•−− No optimal travel transmission.
−− The mechanical link isloose.
−− The working range is limited.

Check attachment.

−− The working range ismainly close to the
CLOSED/max. OPEN position.
−− The working range ismainly in the CLOSED/max. OPEN position.

Rethink the working range.

−− The friction is much higher/lower over the entire
working range.
−− The friction is much higher/lower over a section.

Check the valve's packing.

−− The spring stiffness is reduced (spring failure).
−− The spring pre-loading is
reduced.
−− The actuator springs areworking at full capacity.

Check actuator springs.

Seat leakage exists.

Check seat and plug.

Positioner-valve linkage

Working range

Friction

Actuator springs

Inner (seat) leakage
External leakage

External leakage may possibly exist or is to be expected
soon.

[

[

[

[

•

•

•

EB 8389S EN

The partial stroke test or thefull stroke test has not been
completed successfully.

•]

u Sec. 3.8.2]

u Sec. 3.4.2]

u Sec. 3.3.2]

u Sec. 3.7.2•••
u Sec. 4.2.2

[

•

]

•
u Sec. 3.6.2
u Sec. 4.1.2

Check the valve's packing.

[
[

•
•

•

]

u Sec. 3.4.2]

u Sec. 3.5.2••

External leakage is perhaps
soon expected.
PST/FST

Single resetu Sec. 3.7.2
Check test cancelation conditions. See section 4.4
and section 4.5.

[

•

]

•
u Sec. 4.4.4
u Sec. 3.5.2

95

Appendix

Message

Possible reasons

Recommended action

Open/Close (on/off)−− The breakaway time ortransit time differs from thereference value by theamount entered in 'Limitvalue time analysis'.
−− The valve end position differs from the reference
value by the amount entered in 'Limit value travel
analysis'.
−− The end position cannot
be reached.

−− Check that pneumatic
installations and connections are tight.
−− Check supply pressure.
−− Check plug stem for external influences that
could be blocking it.

96

Status classification[•]

Single reset•u Sec. 3.1.3

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Appendix

7.3 Diagnostic parameters and measured data saved in a
non-volatile memory
Data saved in a non-volatile memory:

Saved directly after they change

Saved cyclically every 24 h

Open/Close (on/off)'Limit value time analysis', 'Limit value
travel analysis'.

Assessment

Data logger'Selection', 'Trigger status', 'Scan rate','Trigger value', 'Trigger band', 'Trigger
edge', 'Pre-trigger time', 'Trigger via
condensed state'

Statistical information

Reference assessment

Travel histogram x
Short-term monitoring

Measured values
Scan rate, short-term histogram

Set point deviation histogram e
Short-term monitoring

Measured values
Scan rate, short-term histogram

Cycle counter histogram

Measured values

Short-term monitoring
Drive signal diagram steady-state

Measured values

Short-term monitoring
Drive signal diagram hysteresis (d5)

Measured values'Start test', 'Enable time distance','Min. time distance from test', 'Tolerance band of hysteresis'

Measured values

Short-term monitoring
Lower end position

Measured data

Tests
Drive signal diagram steady-state (d1)

Values of the reference test
'Reference time stamp'

Drive signal diagram hysteresis (d2)Values of the reference test
Reference time stamp

Static characteristic (d3)

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97

Appendix

Data saved in a non-volatile memory:

Saved directly after they change

Partial stroke test (d4)'PST testing mode', 'Step start', 'Stepend', 'Tolerance limit of step response','Activation of the ramp function','Ramp time (rising)', 'Ramp time (falling)', 'Settling time before test start','Delay time after step', 'Scan rate','Max. test duration', 'Number of step
responses', 'Activation x control', 'x
control value', 'Activation delta y-monitoring', 'delta y-monitoring value','Activation PST tolerance band control', 'PST tolerance band'

Saved cyclically every 24 hdelta y-monitoring reference value,course of step response, analysis ofmeasured data, number of tests
Full stroke test (d6)'Tolerance limit of step response', 'Activation of the ramp function', 'Ramp
time (rising)', 'Ramp time (falling)','Settling time before test start', 'Delaytime after step', 'Scan rate', 'Max. test
duration', 'Number of step responses','Max. breakaway time', "Activation'Max. breakaway time'", 'Allowed
time to reach full closed position', "Activation 'Allowed time to reach fullclosed position'"
Course of step response, analysis ofmeasured data, number of tests

GeneralActuator and valve data specifications

Yes

Logging

YesClassification of status messages

Yes

98

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Appendix

7.4 Determining the ramp times of the partial stroke test
Suitable ramp times for the partial stroke test can be determined by performing a full stroke
test.
! NOTICE
See section 4.5 on how to perform a full stroke test.
1. Adjust the FST diagnostic parameters as follows:'Tolerance limit of step response' = 2.0 % (WE)
'Activation of the ramp function' = Yes (WE)
'Ramp time (rising)' = 900 s'Ramp time (falling)' = 900 s'Settling time before test start' = 10 s
'Delay time after step' = 4.0 s'Scan rate' = 'Min. recommended scan rate'
2. Adjust 'Scan time' of the data logger to 0.2 s and start the data logger ('Selection' = Permanent). See section 3.2.
3. Start full stroke test and change directly to the data logger graph.
4. After the full stroke test is finished, stop the data logger and save the data.
5. Analyze the logged data: If the valve position follows the set point closely, the adjusted
ramp times can be used for the partial stroke test. If this is not the case, repeat the fullstroke test with different ramp times until the valve position follows the set point (Fig. 16).

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99

Appendix

Fig. 16: Full stroke test to determine the ramp times for the partial stroke test
The valve position closely follows the set point in the example shown here100

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101

102

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Abbreviations usede

Set point deviation

BE

Binary input

pout Signal pressure

FV

Forced ventingpsSupply pressure

SV

Solenoid valvexValve position

ZP

Zero point

x0

Valve position when the valve istightly shutw

Set point, reference variable

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103

SAMSON AKTIENGESELLSCHAFT
Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
samson@samson.de · www.samson.de

2018-09-25 · English

EB 8389S EN