EB 8389-2S EN
Translation of original instructions

EXPERTplus Valve Diagnostics
TROVIS SAFE 3793 Electropneumatic Positioner

Firmware version 1.00.xxx
Edition March 2017

Note on these mounting and operating instructions
These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices.
ÎÎ For the safe and proper use of these instructions, read them carefully and keep them forlater reference.
ÎÎ If you have any questions about these instructions, contact SAMSON‘s After-sales Service
Department (aftersalesservice@samson.de).

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 8389-2S EN

Contents

1

Safety instructions and measures....................................................................5

1.1

Notes on possible property damage.................................................................72

Operation......................................................................................................7

2.1

On-site operation............................................................................................7

2.2

Operation using TROVIS-VIEW........................................................................83

Start-up.........................................................................................................94

Device state.................................................................................................10

4.1
4.1.1

Information parameters and limits..................................................................10
Reset............................................................................................................12

4.2
4.2.1

Status classification.......................................................................................12
Reset............................................................................................................13

4.3
4.3.1

Status messages............................................................................................13Group and condensed states..........................................................................14

4.4
4.4.1

Logging........................................................................................................14
Reset............................................................................................................14

4.5
4.5.1

Temperature.................................................................................................14
Reset............................................................................................................16

5

Statistical information...................................................................................16

5.1
5.1.1
5.1.2

On/off.........................................................................................................16
On/off diagnosis..........................................................................................16
Reset............................................................................................................17

5.2
5.2.1
5.2.2
5.2.3
5.2.4

Histograms...................................................................................................17
Reset............................................................................................................20
Valve position...............................................................................................20
Set point deviation........................................................................................22
Load cycle....................................................................................................23

5.3
5.3.1
5.3.1.1
5.3.2
5.3.2.1

Course of end position..................................................................................25
Course of lower end position.........................................................................25
Reset............................................................................................................27
Course of upper end position.........................................................................27
Reset............................................................................................................28

6

Tests............................................................................................................28

6.1
6.1.1

Step response test (PST).................................................................................28
Test cancellation criteria.................................................................................30

EB 8389-2S EN

3Contents

6.1.2
6.1.2.1
6.1.2.2
6.1.2.3
6.1.3
6.1.4

Test start.......................................................................................................32
Manual start.................................................................................................32
Automatic start after 'Test interval' has elapsed................................................32
Start triggered by the binary input.................................................................33
Analysis and monitoring................................................................................33
Reset............................................................................................................35

6.2
6.2.1
6.2.2
6.2.2.1
6.2.2.2
6.2.3
6.2.4

Step response test (FST).................................................................................36
Test cancellation criteria.................................................................................36
Test start.......................................................................................................37
Manual start.................................................................................................37
Start triggered by the binary input.................................................................38
Analysis and monitoring................................................................................38
Reset............................................................................................................40

7

Error messages and recommended corrective action......................................41

4

EB 8389-2S EN

Safety instructions and measures

1 Safety instructions and measures
Intended use
EXPERTplus is a diagnostic firmware integrated into the positioner which allows the predictive, status-oriented maintenance of valves with pneumatic actuators.
EXPERTplus records the valve condition while the process is running (in automatic mode) andgenerates messages on the required maintenance work. In addition, numerous tests can be
performed in manual mode to pinpoint emerging faults.
The diagnostic functions of EXPERTplus are completely integrated into the positioner.
Diagnostic data are compiled, saved and analyzed in the positioner itself. Classified status
messages on the state of the valve are generated from the analysis.
Reasonably foreseeable misuse
While the tests are being performed, the valve does not follow the set point. Instead, it is
moved according to the test specifications. Therefore, the tests can only be started when theconditions in the plant allow it.
Qualifications of operating personnel
The devices are to be configured and set by trained and experienced personnel only.
According to these operating instructions, trained personnel refers to individuals who areable to judge the work they are assigned to and recognize possible hazards due to their
specialized training, their knowledge and experience as well as their knowledge of theapplicable standards.
Personal protective equipment
No personal protective equipment is required.
Revisions and other modifications
Revisions or other modifications to the product are not authorized by SAMSON. They are
performed at the user's own risk and may lead to safety hazards, for example. Furthermore,
the product may no longer meet the requirements for its intended use.
Safety features
The software in offline mode has no influence on the connected device.

EB 8389-2S EN

5

Safety instructions and measures

Warning against residual hazards
The software in online mode has a direct influence on the connected device, and, as a result,on the valve. To avoid personal injury or property damage, plant operators and operating
personnel must prevent hazards that could be caused in the control valve by the process medium, the operating pressure, the signal pressure or by moving parts by taking appropriate
precautions. They must observe all hazard statements, warning and caution notes in the referenced documents.
Responsibilities of the operator
The operator is responsible for proper operation and compliance with the safety regulations.
The operator is obliged to provide these operating instructions as well as the referenced documents to the operating personnel and to instruct them in proper operation. Furthermore, theoperator must ensure that operating personnel or third persons are not exposed to any danger.
Responsibilities of operating personnel
Operating personnel must read and understand these operating instructions as well as thereferenced documents and observe the hazard statements, warning and caution notes specified in them. Furthermore, the operating personnel must be familiar with the applicablehealth, safety and accident prevention regulations and comply with them.
Referenced standards and regulations
None
Referenced documentation
The following documents apply in addition to these operating instructions:−− Mounting and operating instructions (EB), safety manual (SH), and configuration manual(KH) for mounted device:u EB 8493S, u SH 8493S, and u KH 8384-3−− Mounting and operating instructions for the associated control valve (actuator, valve, andother valve accessories)

6

EB 8389-2S EN

Operation

1.1 Notes on possible property damage! NOTICE
Valve malfunction due to a configuration that does not meet the requirements of theapplication.
Settings for the EXPERTplus valve diagnostics can be made in the TROVIS-VIEW
software. In online mode of this software, the configuration and parameter settings
take effect immediately in the connected positioner and affect the control valve as aresult.
ÎÎ Only activate the online mode when configurations, parameter settings, andmeasured values are to be transferred from or to the device.

2 Operation
Operation using TROVIS-VIEW/DD/DTM/eDD
EXPERTplus allows the parameters to be viewed or changed using the TROVIS-VIEW software or DD/DTM/eDD.
−− TROVIS-VIEW · SAMSON operator interface used to configure various SAMSON devices−− DTM · Device type manager to describe the device and communication properties−− DD/eDD · Device description/enhanced device description
Note
All parameter settings and configurations must also be downloaded onto the positioner toallow them to become effective.

2.1 On-site operation
Some parameters can be changed at the positioner as well as over the operator interface.
Refer to the mounting and operating instructions of the TROVIS SAFE 3793 Positioner(u EB 8493S) for a list of all parameters that can be changed at the positioner.

EB 8389-2S EN

7

Operation

2.2 Operation using TROVIS-VIEW
Operation using TROVIS-VIEW is described in these operating instructions. The following applies in this case:−− The default settings of parameters are written in square brackets [ ].
−− Operation applies to the "Diagnosis" user level.
Note
The installation and operation of the TROVIS-VIEW software is explained in detail in the Operating Instructions uEB 6661. These instructions are available on the Internet and in the [?]menu in TROVIS-VIEW.
Tip
The [Find...] function in the menu bar can be used to look for parameters:

8

EB 8389-2S EN

Start-up

3 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 thefollowing initialization modes: MAX, NOM
or MAN. All functions of EXPERTplus cannot
be used when a positioner has been initialized in the SUB mode.
1. Connect the positioner with the configuration and operating software.
ÎÎ The TROVIS-VIEW software on acomputer can be connected to thepositioner using an isolated USB
interface adapter (order no. 14009740).
2. Put the positioner into operation as described in the Mounting and Operating
Instructions u EB 8493S.
Tip
We recommend initialization with valve
signature when the positioner is fittedwith pressure sensors.
When initialization fails, the positioner
generates a status message with the assigned status classification. See section 4.
If a status message is generated duringinitialization, the group status 'Start-up'
and 'Initialization' are also generated
with the assigned status classification.
See section 4.

EB 8389-2S EN> Diagnosis/maintenance > Device state >Status classification−−Start-up:
, , ,

,

, [highest classification]−−Initialization:, , , ,

, [highest classification]],−−Init: incorrect operating mode: [,−−Init: travel too small:

,[

],

,

,

,

,

,

,

−−Init: rated travel not achieved:, [ ], , ,−−Init: pin position:,[−−Init: no movement:

,[

],

,
],

,
,

,

−−Init: canceled (control accuracy):, , [highest classification],−−Init: low control accuracy:, [highest classification]

,

,

,

,

−−Positioner not initialized:

,

,[

],

,

−−Init: canceled externally:

,[

],

,

,

−−Init: angle limitation:, , , , , [highest classification]−−Init: time-out:, , , ,

, [highest classification]> Diagnosis/maintenance > Device state >Status messages−−Start-up−−Initialization−−Init: incorrect operating mode−−Init: travel too small−−Init: rated travel not achieved−−Init: pin position−−Init: no movement−−Init: canceled (control accuracy)−−Init: low control accuracy−−Positioner not initialized

9

Device state−−Init: canceled externally−−Init: angle limitation−−Init: time-out

3. Read out positioner data.
ÎÎ In TROVIS-VIEW: select menu [Device> Read].

−− 'Time stamp for min. supply pressure'
Time at which the pressure displayed in'Min. supply pressure' occurred−− 'Max. supply pressure':highest supply pressure−− 'Time stamp for max. supply pressure'
Time at which the pressure displayed in'Max. supply pressure' occurred−− 'Lower press. limit'
The 'Low supply pressure' status message
is generated with the assigned statusclassification when the supply pressure
falls below the lower pressure limit.
> Diagnosis/maintenance > Device state

4 Device state
4.1 Information parameters
and limits
The [Device state] folder contains information
parameters on the positioner state and thelimits used to generate status messages.
Pressure sensors
Information parameters only displayedwhen the positioner is fitted with the optional pressure sensors:−− 'OUTPUT 138: pressure':
current pressure at output 138−− 'OUTPUT 238: pressure':
current pressure at output 238−− 'Supply pressure':
current supply pressure−− 'Min. supply pressure':
lowest supply pressure

10−−Pressure sensors exist: Yes, [No]−−Lower press. limit: 0.01 to 10.00 bar,
[2.50 bar]** The 'Lower press. limit' parameter is automatically recalculated on creating the valve
signature.

Stress factor
The stress factor range is directly linked to
the load cycle histogram. See section 5.2.4.
Total valve travel−− 'Total valve travel':
Totaled full valve travel cycle−− 'Total valve travel limit':
The 'Total valve travel' status message is
generated when the total valve travel exceeds the limit.
> Diagnosis/maintenance > Device state−−Total valve travel:
1000 to 90,000,000, [1,000,000]

EB 8389-2S EN

Device stateFig. 1: > Diagnosis/maintenance > Device state

EB 8389-2S EN

11

Device state

Set point deviation−− 'Number of zero calibrations'−− 'Lag time for set point deviation':
The lag time is determined during initialization. It is the reset criterion for the 'Set
point deviation' status message.
A transit time of less than 180 s determined during initialization causes the'Lag time of set point deviation' to be set
to 30 s.
A transit time of 180 s or more determined during initialization causes the'Lag time of set point deviation' to be set
to six times the transit time.

Save> Diagnosis/maintenance > Device state−−Tolerance band for set point deviation +/-:
0.1 to 10.0 %, [5.0 %]'Reset(standard)''Reset(advanced)'

Reset'Resetdiagnosis'

4.1.1

Initialization−− 'Tolerance band for set point deviation+/-':
A set point deviation is recognized as asystem deviation when the valve position
deviates from the set point by the value
adjusted in this parameter.

−− 'Diagnostic data'
The diagnostic data are saved in a
non-volatile memory (EEPROM).

Reset information parameters without operating hours counter

YES

NO

YES

YES

Reset operating hours
counter

NO

NO

NO

NO

1)

YES

YES

YES

Reset limits
1)

Reset depending on limit

4.2 Status classificationTime

The following classifications are possible:

Temperature−− 'Operating hours counter'−− 'Device switched on since last initialization'−− 'Device in closed-loop operation'−− 'Device in closed-loop operation sincelast initialization'
Counter−− 'Number of initializations'

12

Priority−− See section 4.5 for [Temperature] folder.

A status classification is assigned to the status messages of the EXPERTplus valve diagnostics. This assigned status appears when astatus message is generated.
−−

No message
If an event is classified as “No message”, this event does not have any
affect on the condensed state.

−−

Maintenance required
The positioner still performs its control task (with restrictions). A maintenance demand has been determined.
The wear tolerance will soon be ex-

EB 8389-2S EN

Device 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 theprocedure is taking place.

−−

FailureThe positioner cannot perform its
control task due to a functional fault
in the positioner itself or in one of its
peripherals.

−− Highest classification
Status classification of a group status(see section 4.3.1). The group status depends on the status classification assigned to the status messages: the status
message with the highest classification
determines the group status.
Note
In the "On-site" user levels, the active
status messages are visible. In some cases, only the active group status is visible
without the assigned status messages.
The status classification is predetermined inthe [> Diagnosis/maintenance > Device state> Status classification] folder. All status messages are assigned to a status by default.

EB 8389-2S EN

4.2.1

Reset

Reset statusclassification'Reset(advanced)'−−'Reset(standard)'

Out of specification
The positioner is running outside thespecified operating conditions or has
not yet been initialized.

'Resetdiagnosis'

−−

Note
The 'Out of specification' status is assigned
to a positioner that has not yet been initialized.

Initialization

Priority

hausted or is reducing at a faster rate
than expected. Maintenance is necessary in the medium term.

NO

NO

NO

YES

4.3 Status messages
The valve diagnostics integrated into the positioner generates classified status messages.
All status messages with their assigned status
are listed in the [> Diagnosis/maintenance >Device state > Status classification] folder.
Note
The "
No message" status is generated
when:−−The conditions to generate a status message are not fulfilled.
−−The conditions to generate a status message are fulfilled, but the status message isassigned the "No message" status.
ÎÎ We recommend following the instructions
listed in the Appendix when a status
message occurs.

13Device state

4.4 Logging
EXPERTplus can log up to 400 events. They
are listed in the [> Diagnosis/maintenance >Device state > Logging] folder together withadditional information on the event and thetime it occurred.
Logging starts automatically. It does notneed to be activated by the user.

−− A test was successfully completed.
Tip
Use [Find...] function to find a certain event:

4.4.1

Reset

Reset logging'Reset (advanced)'

Tip
The condensed state is indicated on theright-hand corner of the status bar in TROVIS-VIEW.

−− A generated status message has beencanceled.

'Reset (standard)'

The condensed state is summary of all status
messages. To provide a better overview on
the condition of the valve, 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 status message with the highest priority determines the condensed state.

−− EXPERTplus generates a status message.

'Reset diagnosis'

To provide a better overview on the individual status messages, various status messages
are summarized in a group status. If a status
message assigned to a group is active, thegroup status is generated according to thepredefined status classification.

−− The positioner was successfully initialized.

'Reset logging'Group and condensed
states

Initialization

4.3.1

NO

YES

NO

YES

YES

4.5 Temperature
The temperature inside the device is displayed:−− 'Temperature inside device':current temperature inside the device−− 'Min. temperature inside device':the lowest temperature inside the device
while in service

The following events are logged:−− The positioner was started up.

14

EB 8389-2S EN

Device stateFig. 2: > Diagnosis/maintenance > Device state > Logging

EB 8389-2S EN

15

Statistical information−− 'Max. temperature inside device':
the highest temperature inside the device
while in service−− 'Minimum temperature limit':
The 'Temperature inside device below
min. limit' status message is generated
with the assigned status classification
when the temperature inside the device
falls below the limit. The status message
is canceled as soon as the temperaturerises above the limit again.

5 Statistical information
The Statistical information compiles data
while the process is running without disrupting the process. The data are saved and analyzed in the positioner, i.e. the positioner
follows the set point to position the valve. A
classified status message is generated when
the positioner detects an event.

5.1 On/off−− 'Maximum temperature limit':
The 'Temperature inside device above
max. limit' status message is generated
with the assigned status classification
when the temperature inside the device
exceeds the limit. The status message iscanceled as soon as the temperature falls
below the limit again.

The travel range of open/close (on/off) isdefined by the fail-safe position and the operating point.

Note
The 'Minimum temperature' and 'Maximum
temperature limit' parameters are set to–60 °C and 80 °C respectively by default.
These settings can only be changed in the"Customer expert" user level.

5.1.1

16

'Reset(standard)''Reset(advanced)'

Reset temperature
values'Resetdiagnosis'

Reset
Initialization

4.5.1

YES

NO

NO

YES

The discrete analysis of the set point is performed in automatic mode (see Fig. 3). Depending on the set point change, the valve
performs a step response test (PST). See
Fig. 4.

On/off diagnosis

Every time a demand for the valve to moveoccurs, the on/off diagnosis records the following measuring data separately for the direction from open to closed and from closed
to open:−− 'Start value': current valve position whena demand for the valve to move fromopen to closed or from closed to open is
detected−− 'Breakaway time': the time taken after
the demand for the valve to move is detected until the 'Breakaway threshold' isexceeded−− 'Transit time': the time it takes to detectboth limits

EB 8389-2S EN

Statistical information»» Demand to move the valve from open
to closed: 'Limit to detect open position' and 'Limit to detect closed position'−−Reason for movement (not write-enabled)»» Demand to move the valve from closed
to open: 'Limit to detect closed position' and 'Limit to detect open position'

Note
The 'Breakaway threshold', 'Limit to detect
open position', and 'Limit to detect closed
position' parameters can only be changed inthe "Customer expert" user level.

»» Fail-safe position: the fail-safe position
has been activated.
»» Binary input: the 'Fixed value over binary input' (only with positioners with
option module [T] or [V])Every demand to switch causes the status of
the last measurement to be saved and displayed.
> Diagnosis/maintenance > Statisticalinformation > On/off−−Breakaway threshold: [2.0 %]−−Limit to detect open position: [98.0 %]−−Limit to detect closed position: [2.0 %]−−Time stamp (not write-enabled)−−Start value (not write-enabled)

Reset measured
data

YES

YES

YES YES YES'Reset (standard)'»» Set point: the set point has changed(see Fig. 3).

'Reset (advanced)'

Reset'Reset diagnosis'

5.1.2'Reset histograms'−− 'Reason for movement': trigger for demand to switch

Initialization−− 'End value of transit time measurement':
current valve position at the end of the
movement "Open to closed" or "Closed
to open"−−Status of last measurement (not write-enabled)

5.2 Histograms
Histograms are statistical analysis which are
performed by the positioner in the AUTO
and SAFE modes. For this purpose, data arelogged every second and saved in a
non-volatile memory every 24 hours.
Data logging and analysis do not need to be
activated.

−−Dead time (not write-enabled)

EXPERTplus has histograms on the following
topics:−−Transit time (not write-enabled)−− Valve position (see section 5.2.2)−−End value of transit time measurement (notwrite-enabled)−− Set point deviation (see section 5.2.3)

EB 8389-2S EN−− Load cycle (see section 5.2.4)

17

Statistical information

On/off valve with ATO setting

On/off valve with ATC setting

If the set point (w, ) is below 75 % when theautomatic mode starts, the valve (x, ) closes. If
the set point rises and exceeds 75 %, the valve
fully opens. If the set point continues to drop under 12.5 %, the valve closes.

If the set point (w, ) is above 12.5 % when theautomatic mode starts, the valve (x, ) fully
opens. If the set point drops below 12.5 %, thevalve closes. If the set point continues to riseand exceeds 75 %, the valve fully opens.

x [%]
w [%]

x [%]
w [%]

x

100

100

w

w

12.5
0

t [s]

If the set point (w, ) is above 75 % when theautomatic mode starts, the valve (x, ) fully
opens. If the set point continues to drop under
12.5 %, the valve closes.
x [%]
w [%]

100
75

x

75

75

12.5
0

t [s]

If the set point (w, ) is below 12.5 % when theautomatic mode starts, the valve (x, ) closes.
If the set point continues to rise and exceeds
75 %, the valve fully opens.
x [%]
w [%]

x

100

w

12.5
0

75

t [s]

12.5
0

w
x
t [s]

Fig. 3: Discrete set point analysis

18

EB 8389-2S EN

Statistical information

On/off valve with ATO setting

On/off valve with ATC setting

Triggering the step response test

Triggering the step response test (PST)

A step response test (PST) is started when the set
point (w, ) moves into the range between 25
and 50 % of the travel (x, ) and remains there
for longer than six seconds. See section 6.1.

A step response test (PST) is started when the set
point (w, ) moves into the range between 25
and 50 % of the travel (x, ) and remains there
for longer than six seconds. See section 6.1.

The test is not started when the operating
point (100 %) is outside the range: 'Start value' ± 'Start value of tolerance band +/–'.

The test is not started when the operating
point (0 %) is outside the range: 'Start value' ±'Start value of tolerance band +/–'.

After the step response test (PST) is completed,the valve moves back to its previous position(open or closed).

After the step response test is completed, thevalve moves back to its previous position (openor closed).

Canceling the step response test (PST)

Canceling the step response test

The step response test is canceled whenever theset point (w, ) leaves the range between 25
and 50 %. After the step response test is canceled, the valve (x, ) moves back to its previous position (open or closed).

The step response test is canceled whenever theset point (w, ) leaves the range between 25
and 50 %. After the step response test is canceled, the valve (x, ) moves back to its previous position (open or closed).

x [%]
w [%]
100

x [%]
w [%]

x

100

w

w
50
25
0

50
25

w
t>6s

PST

t [s]

0

w

x
t>6s

PST

t [s]

Fig. 4: Step response test (PST)

EB 8389-2S EN

19

Statistical information

Reset

With 'Archive type' setting = Weeks:−−Weeks: [This week], Last week, Week before
last, Three weeks ago

YES

YES

YES YES YES

Reset archived
data

YES

YES

YES YES YESWith 'Archive type' setting = Months:−−Months: [This month], Last month, Month before
last, Three months ago, …, Eleven weeks ago'Reset (standard)''Reset diagnosis'

Reset measured
data−−Archive type: [Service life], Days, Weeks,Months, Years
With 'Archive type' setting = Days:−−Day: [Today], Yesterday, Day before yesterday,
Three days ago, …, Six days ago'Reset (advanced)'

The valve position, set point deviation, andload cycle histograms are all reset. It is notpossible to reset single histograms.

'Reset histograms'> Diagnosis/maintenance > Statisticalinformation > Histograms > Valve position> Diagnosis/maintenance > Statisticalinformation > Histograms > Set point deviation> Diagnosis/maintenance > Statisticalinformation > Histograms > Load cycle

5.2.1

Initialization

The histograms can be displayed for different monitoring periods. The monitoring periods are defined using the 'Archive type' parameter.

With 'Archive type' setting = Years:−−Years: [This year], Last year, Year before last,Three years ago, …, Five years ago

20

EB 8389-2S EN

Statistical information

5.2.2

Valve position

The valve position histogram provides information about the range in which valve mainly works during its service life and whether
the operating range is possibly shifting.
The positioner records the valve position every second and assigns the data into predefined valve position classes. The distribution showing how often the sound level occurred within a valve position class is shownin a bar graph.
Analysis and monitoring
The first and last class indicate how often the'End position w ≤' and 'End position w ≥'functions have been triggered.

when the valve position reaches an adjustable set point.
−− The 'End position w ≥' function causes
the valve to move to the open position
when the valve position reaches an adjustable set point.
The functions can be adjusted in the [> Configuration > Set point processing] folder.
A valve position that is mainly located close
to the closed or open position pinpoint to avalve that is too large or too small.
ÎÎ We recommend checking the valve sizing.

−− The 'End position w ≤' function causes
the valve to move to the closed position

Fig. 5: > Diagnosis/maintenance > Statistical information > Histograms > Valve position

EB 8389-2S EN

21

Operation

5.2.3

Set point deviation

The set point deviation histogram provides
information on to which extent a set point
deviation has occurred and whether faults
may occur due to a restricted working range.
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.
Analysis and monitoring
Ideally, the set point deviation should be as
close to 0 % as possible.
Set point deviations greater than 1 % following in quick succession pinpoint to a limitation of the upper working range.

ÎÎ We recommend checking the attachment.
Set point deviations smaller than 1 % following in quick succession pinpoint to a limitation of the lower working range or to seatleakage.
ÎÎ We recommend checking the attachment
as well as the seat and plug for wear.
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.
ÎÎ We recommend checking the plug stem
for external influences that could beblocking it.

Fig. 6: > Diagnosis/maintenance > Statistical information > Histograms > Set point deviation

22

EB 8389-2S EN

Operation

5.2.4

Load cycle

The load cycle histogram provides a statistical analysis of the cycles that the valve has
moved through. As a result, the cycle counter
also provides information on the dynamic
stress of a bellows seal and/or packing.
The positioner records the height of the cycles that the valve has moved through taking
the selected stem seal into account.
The cycles are assigned to classes. The distribution showing how often the cycle occurred
within a class is shown in a bar graph.
Note
A valve cycle span starts at the point wherethe valve stroke changes direction until the
point where it changes direction again.

x [%]
1

3

2

4
t [s]

> Diagnosis/maintenance > Device state−−Stem seal: [Not selected], Self-adjusting, Adjustable, Bellows, Other−−Max. cycle count:
1 to 1000000000, [1000000]! NOTICE
No analysis of 'Dynamic stress factor' with
'Stem seal' = "Not selected" (= default setting).

Fig. 7: > Diagnosis/maintenance > Statistical information > Histograms > Load cycle

EB 8389-2S EN

23

Operation

Set 'Stem seal' parameter to allow an analysis of the load cycle histogram to be performed.
Analysis and monitoring
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.
A 'Dynamic stress factor exceeded' status
message is generated with the assigned status classification whenever:> Diagnosis/maintenance > Device state−−Dynamic stress factor> Diagnosis/maintenance > Device state > Status classification−−Dynamic stress factor exceeded:, [ ], , ,> Diagnosis/maintenance > Device state > Status messages−−Dynamic stress factor exceededÎÎ We recommend checking the conditionof the packing when the status message
is generated to prevent external leakage.

−− The number of measured cycle spans exceeds 2,000,000 when 'Self-adjusting' isselected as the stem seal.
−− The number of measured cycle spans exceeds 800,000 when 'Adjustable' is selected as the stem seal.
−− The number of measured cycle spans exceeds 90 % of the 'Max. cycle count'when 'Other' is selected as the stem seal.
−− The number of measured cycle heights
exceeds 8,473,930 when 'Bellows' is selected as the stem seal.
Tip
The level of stress that the packing is exposed to depends on other factors besides
load cycles, e.g. on the process medium andthe operating conditions. Therefore, in the"Customer expert" user level, it is possible toadapt the limits to trigger the 'Dynamic stressfactor exceeded' status message as required.

24

EB 8389-2S EN

Operation

5.3 Course of end position
Data are recorded in the background regardless of the operating mode selected
when the conditions for logging data are fulfilled (see sections 5.3.1 and 5.3.2). Data
logging does not need to be activated.
The course of end position function records
the measured data when the valve moves tothe end position:−− Valve position−− Temperature−− Time stamp of operating hours counter
The new recorded end position is comparedto the last saved end position. If the valve
position deviates by 0.3 % from the last value, the data of the new end position are
saved.
A graph of the recorded end positions isplotted over time.
The positioner saves the valve positions in acircular buffer, which holds 30 measured
values at one time.
Analysis and monitoring
The 'Course of lower end position' and'Course of upper end position' status messages are generated with the assigned statusclassification whenever a new recorded end
position deviates from the reference value by
the 'Threshold for end position shift'. The reference value is determined during initialization (see sections 5.3.1 and 5.3.2). It isshown as a straight line in the graph.

EB 8389-2S EN> Diagnosis/maintenance > Statistical information > Course of end position−−Threshold for end position shift:
0.3 to 100.0 %, [5.0 %]Note
When temperature fluctuations occur andwith valves with a long insulating section, the'Course of lower end position' and 'Courseof upper end position' status messages may
be generated at an early stage.

5.3.1

Course of lower end
position

To record data for the course of lower end
position (behavior during tight closing), thefollowing conditions must exist:−− The positioner was initialized in the MAX
or NOM mode.
−− The tight-closing function is active ('Lower end position' parameter = "Active").
> Configuration > Set point processing−−Lower end position: [Active]

Note
When the end position function is active, thevalve shuts off tightly as soon as the set point
is lower or equal to the value entered in 'End
position w <='.
The reference value for the course of the lower end position is reference zero. This is de-25

Operation

Fig. 8: > Diagnosis/maintenance > Statistical information > Course of lower end position

Fig. 9: > Diagnosis/maintenance > Statistical information > Course of upper end position

26

EB 8389-2S EN

Operation

termined during a MAX or NOM initialization and during a zero calibration.
> Diagnosis/maintenance > Device state >Status classification−−Lower end position shifted:, [ ], , ,> Diagnosis/maintenance > Device state >Status messages−−Lower end position shifted

The generation of the 'Lower end position
shifted' status message in combination witha shift of the course of the end position
downward pinpoints to signs of wear between seat and plug in metal-seated valves.
ÎÎ We recommend checking the seat andplug for wear.
Note
The 'Lower end position shifted' status message is generated briefly after the initialization of soft-seated valves for design reasons.
The soft seal settles after a few load cycles

causing zero to be shifted. In these valves, a
repeated generation of the status message
after a long time service first indicates signs
of wear.
The generation of the 'Lower end position
shifted' status message in combination witha shift of the course of the end position upward pinpoints to a blockage of the plug
stem, e.g. due to dirt particles.
ÎÎ We recommend checking the plug stem
for mechanical blockage.

5.3.1.1 Reset
Refer to Table 1

5.3.2

Course of upper end
position

The positioner must be initialized in the MAX
mode to allow course of end position data to
be recorded.

InitializationZerocalibration'Reset courseof endposition''Resetdiagnosis''Reset(standard)''Reset(advanced)'

Table 1: Reset the course of end position

Reset reference
value

Lower end position

YES

YES

NO

NO

NO

NO

Upper end position

YES

NO

NO

NO

NO

NO

Reset measured
data

Lower end position

NO

NO

YES

YES

YES

YES

Upper end position

NO

NO

YES

YES

YES

YES

Reset status
message

Lower end position

YES

YES

NO

YES

YES

YES

Upper end position

YES

NO

NO

YES

YES

YES

EB 8389-2S EN

27

Tests

The reference value for the course of the top
zero point is the travel at the open valve position. It is determined only in the MAX initialization mode.
Analysis and monitoring
If the analysis of course of the upper end position pinpoints a fault, the positioner generates the 'Upper end position shifted' status
message with the assigned status classification.
> Diagnosis/maintenance > Device state >Status classification−−Upper end position shifted:, [ ], , ,> Diagnosis/maintenance > Device state >Status messages−−Upper end position shiftedÎÎ We recommend checking the plug stem
for mechanical blockage when the status
message is generated.

5.3.2.1 Reset
Refer to Table 1

28

6 Tests
Similar to the statistical information, data arecompiled, saved, and analyzed in the positioner for the tests. However, in this case,the valve position is not determined by theset point, but by the active test. 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 ofsafety, these tests, except for step response
test (PST), can only be performed in the
MAN mode.
Note
An active test is stopped and the positioner
changes to the fail-safe position when theelectrical signal falls below a certain level orwhen the forced venting function is triggered.

6.1 Step response test (PST)The step response 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 beprevented from seizing up or getting
jammed. The initial breakaway torque mustfirst be overcome after the valve starts tomove from its end position. The initial breakaway torque depends on the plug/seat seal,
deposits on the plug, the process medium
and friction at the valve trim. After the initial

EB 8389-2S EN

Testsbreakaway torque has been overcome, it
can be assumed that the valve is able toclose completely. The recording of the test results additionally allows an analysis of the
dynamic control response.
During the step response test, the valve
moves from its current operating point by thedefined change in travel and back to the initial position again. The change in travel iscalculated from the 'Start value' and 'Stepheight'.
The change in travel can be performed either in steps or in a ramp function (Fig. 10).
The test is performed with the ramp function
when the ramp times ('Ramp 1' and 'Ramp2') are set to ≠ 0 s.

tion'. The valve remains in this position for
the time defined in 'Waiting time' before
performing a second step change in the opposite direction to the operating point. The'Sampling time' defines the time interval between which the measured values are recorded during the test.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Start value: –20 to 120 %, [100 %]−−Step height: 2 to 100 %, [10 %]−−Test direction: [Minus], Plus−−Ramp 1: 0 to 9999 s, [60 s]−−Ramp 2: 0 to 9999 s, [6 s]−−Sampling rate (not write-enabled)

The test starts after reaching the 'Start value'
and the 'Waiting time' has elapsed. Startingfrom the 'Start position', the valve moves
through the 'Step height' in the 'Test direcTest start

Test start

Waitingtime

Waitingtime

Operating point
Start value
Step height

2 x Start value
Tolerance band +/–

x [%]

t [s]
Waitingtime

Waiting time
Ramp 1

Ramp 2

Fig. 10: Course of the step response test (PST): step response (left) and ramp function (right)

EB 8389-2S EN

29

Tests6.1.1

Test cancellation criteria

Various test cancellation conditions provide
additional protection against the valve slamming shut or moving further than step height.
The positioner cancels the step response testwhen one of the following cancellation conditions is fulfilled:Time−− 'Canceled: max. test duration': the test iscanceled when the maximum permissible
test duration is reached.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Canceled: max. test duration (not write-enabled)−− 'Canceled: max. test duration': the test iscanceled when the adjusted 'Waiting
time' has elapsed without the valve having moved by the value 'Dead time limit
determined'.
This cancellation criterion only takes effect when 'Dead time limit determined' is
set to ≠ 0 %.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Canceled: max. dead time (not write-enabled)−−Dead time limit determined: 1 to 10 %,[2 %]Tolerance bands−− 'Start value of tolerance band +/–': thetest is not started when the operating

30

point is outside the range: 'Start value' ±'Start value of tolerance band +/–'.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Start value of tolerance band +/–:
1 to 100 %, [3 %]−− 'Canceled: tolerance band (ramp) +/–','Canceled: tolerance band (step) +/–':The test is canceled as soon as the deviation of the valve position (in relation to
the theoretical step end value, calculated
from the 'Start position' and 'Stepheight') exceeds the adjusted value.
This cancellation criterion only takes effect when 'Canceled: tolerance band(ramp) +/–' or 'Canceled: tolerance
band (step) +/–' is set to ≠ 0 %.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Canceled: tolerance band (step) +/–:
can only be selected in the "Customer expert" user level−−Canceled: tolerance band (ramp) +/–:
1 to 100 %, [5 %]Valve position−− 'Canceled: x monitoring': the test is canceled when 'Minus' is selected as the'Test direction' as soon as the valve position falls below the adjusted value.
The test is canceled when 'Plus' is selected as the 'Test direction' as soon as thevalve position exceeds the adjusted value.

EB 8389-2S EN

TestsThis cancellation criterion only takes effect when 'Canceled: x monitoring' is set
to ≠ 0 %.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Canceled: x monitoring: –20 to 120 %,[ATO: 85 %; ATC: 15 %]Pressure criteria
Analysis of the pressure only possible when
the positioner is fitted with the optionalpressure sensors.
−− 'Canceled (press. limit)': the test is canceled through venting when the valve
moves to the test end value after thepressure is below this limit. The test iscanceled through supplying air when thevalve moves to the test end value after
the pressure exceeds this limit.

Notes on cancellation criteria−−The step response test must only be performed with the cancellation conditions(time or valve position) for valves with double-acting actuator and pneumatic booster
as well as for valves that have been initialized using the SUB mode.
−−Excessive overshooting may occur in valvesfitted with volume boosters. In this case, thetest cancellation criteria 'Canceled: x monitoring' and 'Canceled: tolerance band(ramp) +/–' or 'Canceled: tolerance band(step) +/–' must be increased accordingly.
The reason why the test was canceled can beread in the 'Results of last test' parameter.
Besides cancellation due to the adjusted test
cancellation criteria, further events lead tothe test being canceled, for example:

This cancellation criterion only takes effect when the 'Activate pressure monitoring' is set to "Active".

−− The internal forced venting function istriggered.

Tip
The minimum or maximum pressure of
the reference test can be used as a guidefor the limit defined in 'Canceled (press.
limit)'. See section 6.1.3.

−− The test is manually canceled:> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Activate pressure monitoring: Active−−Canceled (press. limit): [0.00] to 1.00 bar−− The current is lower than 3.8 mA.
ÎÎ On site by pressing the rotary pushbutton
ÎÎ By software with the 'Stop test' parameter−− The positioner switches to the SAFE
mode.
−− At the start of the step response test overthe binary input, the edge control changes again to the state which starts the step
response test.
−− In AUTO mode, the edge control changes to the state in which the valve moves

EB 8389-2S EN

31

Teststo a fixed value which is outs the range:'Start value' ± 'Start value of tolerance
band +/–'.

6.1.2

Test start

YES

YES

YES

MAN

YES

NO

YES

Start triggered by thebinary input (seesection 6.1.2.3)

Automatic start after 'Test
interval' has elapsed (seesection 6.1.2.2)

AUTO

Operating modeSee section 6.1.2.1 formanual start (on site orusing software)

Table 2: Start conditions of step response
test (PST)

6.1.2.1 Manual startOn-site operation

ÎÎ Use the rotary pushbutton to go to the'Step response test (PST)' command(menu item: [10 Diagnosis/maintenance> Tests]). See u EB 8493S.
ÎÎ Pressto start test.

Note
A test can be canceled manually by pressing
the rotary pushbutton again.
Software command via TROVIS-VIEW/
integration> Diagnosis/maintenance > Tests > Step
response test (PST)!! Start test
Note
The test can be manually canceled by selecting the 'Stop test' command.

6.1.2.2 Automatic start after 'Test
interval' has elapsed
The step response test (PST) is started in AUTO mode regularly after the time entered in'Test interval' has elapsed when the functionis activated. The 'Delay time interval' parameter allows the test to be postponed once.
Note
The time until the next regular test can beadapted in the 'Time until next test' information parameter.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Test interval: 1 to 365 d, [7 d]−−Activate test interval: [Not active], Active−−Delay test interval: [0] to 2160 h

32

EB 8389-2S EN

Tests> Diagnosis/maintenance > Tests > Step
recsponse test (PST)−−Time until next test (not write-enabled)

6.1.2.3 Start triggered by the binary input
Function only possible when positioners has
option module [T] or [V].
> Configuration > Slot options > Slot C option−−Action upon active binary input: start PST−−Edge control:[Active = switch closed], Active = switch open

6.1.3

Analysis and monitoring

The analysis of the last fifty step response test
(PST) are saved with a time stamp in the [>Diagnosis/maintenance > Tests > Step response test (PST) > Reports and diagrams]
folder. The last seven graphs at the maximum
are shown.
The result of the last test can be read in the[> Diagnosis/maintenance > Tests > Step
response test (PST) folder.
Note
In total, seven step response tests (PST plus
FST) with report and diagram can be displayed.
Test completed successfully
The following analysis parameters are shown
during a completed step response test (PST).

EB 8389-2S EN

Two test reports can be shown at one time
for comparison. The comparison test can beselected as required.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Reports and diagrams−−Time stamp (not write-enabled)−−Dead time (not write-enabled)−−T86 (not write-enabled)−−Overshooting (not write-enabled)−−Pressure (only with pressure sensors) (notwrite-enabled)−−Test status (not write-enabled)

The results of the first step response test performed with the current configuration areused as a reference test and are write-protected. All other step response tests can be
write-protected manually:
ÎÎ Checkbox.

Test not completed
If the test is canceled and no results are produced which activate the fail-safe position,
the positioner changes to the 'Target operating mode'.
The fail-safe position can be activated, forexample, when the forced venting is triggered and when the current is lower than
3.8 mA.
A test cancellation causes the 'PST: cancellation criteria met' status message to be generated with the assigned status classification.
If the test cannot be started, the 'PST: start
criteria not met' status message with the assigned status classification is generated.

33

TestsNote
No graph is plotted when a test cannot be
started.

> Diagnosis/maintenance > Device state >Status messages−−PST: cancellation criteria met−−PST: start criteria not met> Diagnosis/maintenance > Device state >Status classification−−PST: cancellation criteria met:
, [ ], , ,−−PST: start criteria not met:[ ], , , ,Fig. 11: > Diagnosis/maintenance > Tests > Step response test (PST) > Reports and diagrams

34

EB 8389-2S EN

TestsStart criterion

Test canceled

Table 3: Recommended action when the status message is generated> Diagnosis/maintenance > Tests > Step
response test (PST)

Test result

We recommend:−−Number of successful tests (not write-enabled)

Current

ÎÎ Check input signal−−Number of canceled tests (not write-enabled)

Internal error

ÎÎ Restart test

TimeoutÎÎ Check seat and plugfor deposits or foreign
particles−−Number of failed start criteria (not writeenabled)

No movement
possible

6.1.4

Reset

Refer to Table 4Start criteria

ÎÎ Check test
configuration

Function
activeÎÎ Wait for the active test
to finish and restart
test.

Incorrect
operatingmodeÎÎ Set operating mode
corresponding toTable 2 and restart
test.

Statistical analysis
Every time a step response test is started,
one of the following counters counts thisevent depending on the test status.

Initialization'Resetdiagnosis''Reset PST
configuration''Clear reports''Reset(standard)''Reset(advanced)'

Table 4: Reset step response test (PST)

Reset configuration

YES

YES

YES

NO

YES

YES

Reset reports

YES

YES

YES

YES

YES

YES

Reset histograms

YES

YES

YES

YES

YES

YES

Reset reference test

YES

YES

YES

NO

YES

YES

Reset status messages

YES

YES

YES

NO

YES

YES

EB 8389-2S EN

35

Tests

6.2 Step response test (FST)The dynamic valve performance can be evaluated by performing the test. During the step
response test (FST), the valve moves throughits entire working range.
The valve can move through the working
range either in steps or with a ramp function(Fig. 14). The test is performed with theramp function when the ramp time ('Ramp')
is set to ≠ 0 s.
The test starts after the 'Waiting time' haselapsed. This ensures that the valve hasreached the open position.
Starting from the open position, the valve
moves to the closed position. The valve remains in this position for the time defined by
the 'Waiting time' before performing a second step change in the opposite direction
from the closed position to the open position.
The 'Sampling time' defines the time interval

End value
Tolerance band +/–Start value
Tolerance band +/–x [%]between which the measured values are recorded during the test.
> Diagnosis/maintenance > Tests > Step
response test (PST) > Configuration−−Ramp 1: 0 to 9999 s, [60 s]−−Waiting time: 0 to 240 s, [2 s]6.2.1

Test cancellation criteria

The positioner cancels the step response test
(FST) when one of the following cancellation
conditions is fulfilled:Time−− 'Canceled: max. test duration': the test iscanceled when the maximum permissible
test duration is reached.
> Diagnosis/maintenance > Tests > Step response test (FST) > Configuration−−Canceled: max. test duration (not write-enabled)

Test start

Test start

Waitingtime

Waiting
time

100

0

t [s]
Waitingtime

Waiting time
Ramp

Ramp

Fig. 12: Course of the step response test (FST): step response (left) and ramp function (right)

36

EB 8389-2S EN

TestsTolerance bands−− 'Start value of tolerance band +/–': thetest is not started when the operating
point is outside the range: open position– 'Start value of tolerance band'.
> Diagnosis/maintenance > Tests > Step
response test (FST) > Configuration

es again to the state which starts the step
response test (FST).

6.2.2

Table 5: Start conditions of step response
test (FST)

Additionally, the step response test (FST) is
canceled when one of the following events
arises:−− The internal forced venting function istriggered.

1)Start triggered by thebinary input (seesection 6.2.2.2)> Diagnosis/maintenance > Tests > Step
response test (FST) > Configuration

See section 6.2.2.1 formanual start (on site orusing software)−− 'End value of tolerance band +/–': thetest is not started when the valve position
after the first step does not reach therange: closed position + 'End value oftolerance band +/–'.

Operating mode−−Start value of tolerance band +/–:
1 to 100 %, [3 %]−−End value of tolerance band +/–: 1 to
100 %, [3 %]Test start

AUTO

NO 1)

NO 1)

MAN

YES

YES

Default setting
By activating the 'Allow start in AUTO mode'parameter in the "Customer expert" user level,
the test can also be started in AUTO mode.

6.2.2.1 Manual startOn-site operation−− The current is lower than 3.8 mA.
−− The test is manually canceled:ÎÎ On site by pressing the rotary pushbutton
ÎÎ By software with the 'Stop test' parameter−− The positioner switches to the SAFE
mode.
−− At the start of the step response test overthe binary input, the edge control chang-EB 8389-2S EN

ÎÎ Use the rotary pushbutton to go to the'Step response test (FST)' command(menu item: [10 Diagnosis/maintenance> Tests]). See u EB 8493S.
ÎÎ Pressto start test.

37

TestsNote
A test can be canceled manually by pressing
the rotary pushbutton again.

Note
In total, seven step response tests (PST plus
FST) with report and diagram can be displayed.

Software command via TROVIS-VIEW/
integration

Test completed successfully> Diagnosis/maintenance > Tests > Step
response test (FST)The following analysis parameters are shown
during a completed step response test (FST).

!! Start test

Two test reports can be shown at one time
for comparison. The comparison test can beselected as required.

Note
The test can be manually canceled by selecting the 'Stop test' command.

> Diagnosis/maintenance > Tests > Step response test (FST) > Reports and diagrams−−Time stamp (not write-enabled)−−Dead time (rising) (not write-enabled)

6.2.2.2 Start triggered by thebinary input
Function only possible when positioners has
option module [T] or [V].
> Configuration > Slot options > Slot C option−−Action upon active binary input: start FST−−Edge control:[Active = switch closed], Active = switch open

6.2.3

Analysis and monitoring

The analysis of the last six step response test
(FST) at the maximum and graphs are savedwith a time stamp in the [> Diagnosis/maintenance > Tests > Step response test (FST) >Reports and diagrams] folder.
The result of the last test can be read in the[> Diagnosis/maintenance > Tests > Step response test (FST) folder.

38−−Dead time (falling) (not write-enabled)−−T86 (rising) (not write-enabled)−−T86 (falling) (not write-enabled)−−T98 (rising) (not write-enabled)−−T98 (falling) (not write-enabled)−−Test status (not write-enabled)

The results of the first step response test (FST)
performed with the current configuration areused as a reference test and are write-protected. All other step response tests can be
write-protected manually:
ÎÎ Checkbox.

Test not completed
If the test is canceled and no results are produced which activate the fail-safe position,
the positioner changes to the 'Target operating mode'.

EB 8389-2S EN

Tests

The fail-safe position is activated when theforced venting is triggered and when the current is lower than 3.8 mA.
A test cancellation causes the 'FST: cancellation criteria met' status message to be generated with the assigned status classification.
If the test cannot be started, the 'FST: start
criteria not met' status message with the assigned status classification is generated.

Note
No graph is plotted when a test cannot be
started.
> Diagnosis/maintenance > Device state >Status classification−−FST: cancellation criteria met:
, [ ], , ,−−FST: start criteria not met:[ ], , , ,Fig. 13: > Diagnosis/maintenance > Tests > Step response test (FST) > Reports and diagrams

EB 8389-2S EN

39

Tests> Diagnosis/maintenance > Device state > Status messages−−FST: cancellation criteria met−−FST: start criteria not met

Start criterion

Test canceled

Table 6: Recommended action when thestatus message is generated
Test result

We recommend:

Current

ÎÎ Check input signal

Internal error

ÎÎ Restart test

TimeoutÎÎ Check seat and plugfor deposits or foreign
particles

No movement
possible

Statistical analysis
Every time a step response test is started,
one of the following counters counts thisevent depending on the test status.
> Diagnosis/maintenance > Tests > Step response test (FST)−−Number of successful tests (not write-enabled)−−Number of canceled tests (not write-enabled)

Start criteria

ÎÎ Check test
configuration

Function
activeÎÎ Wait for the active test
to finish and restart
test.

Incorrect
operatingmodeÎÎ Set operating mode
corresponding toTable 5 and restart
test.

−−Number of failed start criteria (not writeenabled)

6.2.4

Reset

Refer to Table 7

Initialization'Resetdiagnosis''Reset FST configuration''Clear reports''Reset (standard)''Reset(advanced)'

Table 7: Reset step response test (FST)Reset configuration

YES

YES

YES

NO

YES

YES

Reset reports

YES

YES

YES

YES

YES

YES

Reset histograms

YES

YES

YES

YES

NO

NO

Reset reference test

YES

YES

YES

NO

NO

NO

Reset status messages

YES

NO

YES

NO

NO

NO

40

EB 8389-2S ENError messages and recommended corrective action

7 Error messages and recommended corrective action
Message

Recommended action

Status classification> Diagnosis/maintenance > Device state > Status classification
No supply pressure

ÎÎ Check air supply.
ÎÎ Check air lines/connections.

Low supply pressure

ÎÎ Check air supply.
ÎÎ Check supply pressure regulator.

YES [

]

YES [

]

YES [

]

ÎÎ Check air lines/connections.
Supply pressure > 10 bar

ÎÎ Check air supply.
ÎÎ Check supply pressure regulator.

PST: cancellation criteria met

See section 6.1.

YES [

]

PST: start criteria not met

See section 6.1.

YES [

]

FST: cancellation criteria met

See section 6.2.

YES [

]

FST: start criteria not met

See section 6.2.

YES [

]

P3799: failureÎÎ Check air quality.

YES [highest classification]

ÎÎ Contact SAMSON's After-sales
Service department.
P3799: movement impaired

ÎÎ Check air supply.

YES [highest classification]

ÎÎ Contact SAMSON's After-sales
Service department.
P3799: maintenance required

ÎÎ Check air supply.

YES [highest classification]

P3799: initialization errorÎÎ Contact SAMSON's After-sales
Service department.

YES [highest classification]

AMR signal outside range

ÎÎ Check attachment.

YES [Hardware errorÎÎ Confirm error and select AUTO
operating mode.

YES [highest classification]]

ÎÎ Re-initialize positioner.
Limit for total valve travel exceededÎÎ Check valve and attachment forsigns of wear.

YES [

]

Lower end position shifted

See section 5.3.

YES [

]

Upper end position shifted

See section 5.3.

YES [

]

Dynamic stress factor
exceededSee section 5.2.4.

YES [

]

EB 8389-2S EN

41

Error messages and recommended corrective action

Message

Recommended action

Set point deviation

Status classification
YES [

]

BrownoutÎÎ Check input signal.

YES [

]

Current too low

ÎÎ Check input signal.

YES [

]

IP shutdown

ÎÎ Check input signal.

YES [

]

Current too highÎÎ Check input signal.

YES [

]

Angle limitation

ÎÎ Check attachment.

YES [highest classification]

Temperature inside device
below min. limit

ÎÎ Check operating conditions.

YES [

]

Temperature inside device
above max. limit

ÎÎ Check operating conditions.

YES [

]

The positioner is not impaired. The
message no longer appears as soon as
the positioner starts logging again.

YES [

]

Logging suspended

42

EB 8389-2S EN

EB 8389-2S EN

43

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

2018-09-26 · English

EB 8389-2S EN