Profiler Manual Version 5

ADVANCED VALVE DIIAGNOSTIIC TEST SYSTEM ADVANCED VALVE D AGNOST C TEST SYSTEM User Manual
PROFILER
SofTek Engineering, LLC

Computer Based Instrumentation
826 N. 100 E., Building 3B Spanish Fork, Utah 84660 801-794-0035
Profiler User Manual Version 5
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Using This Manual ...............................................................5

Profiler Overview & User Environment ..................................... 7 Profiler Hardware Connections ................................................ 8
Launching Profiler ................................................................. 15
Profiler Configuration ...................................................... 19
Database Search .............................................................. 23
Valve Information............................................................. 26
Calibration ....................................................................... 31
Valve Profile Test ............................................................. 35
Frequency Response Test .............................................. 39
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Hysteresis Test................................................................. 41
Resolution Test ................................................................ 44
Sensitivity Test................................................................. 46
Step Response Test......................................................... 48
Stroke Speed Test............................................................ 51
Transducer Test ............................................................... 54
Deadband .......................................................................... 57
Mini Cal ............................................................................. 59
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Sequencer ......................................................................... 60
Custom .............................................................................. 61
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Using This Manual

Caution: This icon marks items that may pose a risk to the user or equipment. Extra care and attention should be given to these items. Note: This icon denotes an item of extra importance.
Tip:
The tip icon denotes items that can make using the Profiler Suite easier
Important Information
Caution: When using string potentiometers, the cable must never be allowed to snap back, doing so may cause damage to the cable or pot. As a result the potentiometer may become inaccurate or none functioning, if this happens the device must be sent back for calibration and/or repair.
Caution: In the windows display properties under power, there is a feature called (Hibernate), set to disable. This feature must remain in the disabled state, if the computer goes into hibernate while profiler is running windows will cause an interrupt and the data acquisition card to be disabled. If this happens the computer must be shut down and restarted to reinitialize cards. . Caution: When running on batteries and the power runs out, windows will go into shutdown mode. Once power has been reestablished, it is possible that windows may shut down the data acquisition card. The computer must be shut down and restarted to reinitialize the cards. Note: Printouts will print to the default printer on the computer. If a default printer has not been selected or drivers not installed properly errors will occur during printing.
Tip:
To save time when testing, use the information screen to enter all data (and save the file) on each valve before testing begins. This is especially important if you are testing in the field on a service call.
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Profiler Overview & User Environment

Profiler Advanced Valve Diagnostic Test System was designed to be the most flexible,
powerful and easy to use control valve test system available.
Profiler System
Each Profiler system consists of the following: Rugged Case with Telescoping Arm/Wheels Computer Computer Backpack (field service) DAQ Card Fieldbus Card HART Modem Rugged Interface Box 4 String Potentiometers (2 - 6, 16 and 30) Stroke Length 2 String Potentiometer Mounting Straps Attachment Fixture kits (1-Linear and 1-Rotary) 1 String Potentiometer Cables (6) 1 String Potentiometer Extension Cable (10) 6 String Potentiometer Linkage Cables 4 Pressure Transducers o 3 (0-150 psi) o 1 (0-30 psi) 4 Pressure Transducer Cables (6) 4 Pressure Extension Cables (10) 1 Signal Cable (6) 1 Signal Cable (10) 3 Passive Monitor Cables (5) 1 Fieldbus Cable 4 Pressure Transducer Quick Connect Fittings User Manual
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Hardware
Pressure Transducers
Four pressure transducers are included in the rugged system.
Red and green pressure transducers (0-150 psi) are used in reading actuator pressures and in the calculation of friction. Red is also used for diaphragm actuator pressure readings. Yellow pressure transducer (0-30 psi) is used for calibrating and reading I/P pressures. Gray pressure transducer (0-150 psi) is used for reading supply pressures.
String Potentiometers
2 - 6 string potentiometers are used on linear valves with a stroke length of 6 or under (noted by a black or a blue stripe). It will also be used for calculating rotary valve stroke and accuracy. 16 string potentiometers are used on linear valves with a stroke length over 6 and under 16 (noted by a white stripe). 30 string potentiometers are used on linear valves with a stroke length over 16 and under 30 (noted by a orange stripe).
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Fixture Hardware Linear/Rotary

Basic hardware includes (3) take-off arm shafts, (2) rotary shaft clamps, and (16) clamp inserts, (2) small U-clamps, (1) large U-clamp, vise grips, Bessey clamp, and various adapters. The included hardware allows the user to easily attach to most valves.
Take-off arms are used to attach the string potentiometer to the actuator. (4) different threaded adaptors are included for attaching to the stem clamp/pillow block and diaphragm actuators. The slider hook secures the cable from the potentiometer. (2) rotary shaft clamps are provided and are used for measuring degrees of rotation. The 3.375 OD clamp is used for larger rotary yoke envelopes and will accommodate all (16) clamp inserts (the 3.375 OD must be entered into the configuration screen to be accurate). The 2 OD clamp is used for smaller rotary yoke envelops and will accommodate the (7) smallest ID inserts (again, the 2.0 OD must be entered into the configuration screen for accuracy). (2) straps are provided for attaching string potentiometers to linear and rotary actuators. Straps are 3 and 5 feet in length and may be combined if needed.
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Extension cables are included to lengthen the string potentiometer cable when necessary. This insures that the string potentiometer will not extend beyond its feedback range and allows for proper setup and attachment to linear take-off arms or rotary.
Cables
10 Extension Cables (Pressure Transducers and Position)
6 Interface Cable from Box to Computer
6 Cables (Pressure Transducers and Position)
6 Signal Cable
Interface Box
An interface box is provided for interconnecting the test system to the pressure transducers. The 6 cable is connected from the computer to the interface box.
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Signal
The top left 2-pin connector is for analog signals only. The top right 2-pin connector is for Fieldbus positioners only.
Caution: Should be taken not to get the Fieldbus and analog signals mixed up. Damage to the box or positioner may occur.
Position
The left 4-pin blue (main) connector is for the position or string potentiometer. The right 4-pin blue (spare) is not used at this time. Red 4-pin is for diaphragm valves and top actuator on piston valves. Yellow 4-pin is for I/P signal pressure only. Green 4-pin is for the bottom pressure on piston valves. Gray 4-pin is for supply pressure. 0-25mA signal for monitoring current. 0-25mA signal for monitoring current. 0-55mA signal for monitoring current. 1 +/- 10 volt DC 2 +/- 10 volt DC
Pressures

Monitor mA (passive monitoring only)

Monitor+/- 10VDC (passive monitoring only)

Solenoid Relay (testing solenoid or on/off valves) Fieldbus connection

2 pin black Fieldbus connector just above the 68-pin connector at the bottom of the interface box.
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Interface Cable connector

68-pin connector just below the 2- pin black Fieldbus connector at the bottom of the interface box.
Data Acquisition/Fieldbus Card Connections

Proper computer connection (below), the stainless steel connector is for the data acquisition card. When testing analog (4-20mA) valves, the bottom connection is the only one needed. The Velcro strain relief must be securely attached to the bottom of computer and top screws tightened to ensure that the cable is secured to the data acquisition card.
The PCMCIA strain relief that clamps the connectors is necessary to ensure that cards are not pulled out of socket. The strain relief has a stiff Velcro and will hold the cables secure during testing.
Note: Cards are made to be installed and un-installed. However, It is best to leave them in the sockets at all times, ensuring they are configured and initialized properly.
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Attaching to Linear Valves

Figure 1: using a threaded adapter that attaches to the extra thread on the stem clamp (secure). Figure 2: using the takeoff arm to attach the string potentiometer with the U-clamp that is attached to the lip of the diaphragm of a Masoneilan valve. This method will work for any diaphragm valve regardless of the manufacturer. Figure 3: take-off arm attached to the follower arm. This method will work for other manufactures valves with similar setup. Verify that it has been tightened and secured for accurate feedback on the position sensors.
Figure 1
Figure 2
Note: Configuration will be the same for air to open as well as air to close. Position transducers are rugged but are calibrated delicate instruments and should be handled with care.
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Figure 3 Attaching to Rotary Piston Actuators

The rotary shaft clamp has (16) different clamp inserts to accommodate varying shaft sizes. The string potentiometer and rotary shaft clamp must be lined up vertically (see figure 4). This ensures that during actuation the string is pulled out in a straight linear motion. The rotary shaft clamp has a groove on the OD for the attachment wire, which provides a place for the extension wire to run.
Figure 4
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Attaching to Fisher Linear Diaphragm Valves

There are many manufacturers of diaphragm valves and therefore many configurations and ways to attach the string potentiometer to the valve. Figure 5, 6 and 7 show different clamps, straps and slide combinations. The clamp can be attached to the actuator in any position around the valve. The slide allows the user to set up the string potentiometer and hold firmly to the shaft (rotates 360), which provides more flexibility during setup.
Note: It is very important that the string potentiometer is setup so that the string extends and retracts in linear motion and not off to the side. This can put undue ware on the string. The take-off arm is attached to the pillow block on the stem. This provides a stable and solid hook up. The takeoff arm also has a slider for flexibility in setup.
Figure 5
Figure 6
Figure 5, 6 and 7 show the string potentiometer used with a U-clamp, vise grips and attached with a strap. This allows the user to pull the strap tight until the string potentiometer is secure and directly over the slide. Using these methods gives the user the flexibility of positioning the string potentiometer in almost any configuration.
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Note: Regardless of the attachment method used the string potentiometer must be secured before attaching the hook to the slide of the take-off arm. Only when all fixtures are lined up should the slider thumbscrew be tightened (see caution below). Caution: There is no need to use pliers, which can damage the shaft finger tight works best. All fixtures have been designed to eliminate the need for hand tools.
Figure 7
Note: To see additional attachment pictures for all manufactures go to www.softekeng.com and down load the Valve attachment folder.
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Launching Profiler
To launch the Profiler Test Suite Double click on the Profiler Icon . The Log on will be seen. Enter the user name and password, click the appropriate control button located in the bottom right corner of the screen.
Profiler Log In Screen Configuration

User Name: Name of as entered by the administrator. Password: Language: Password for the user as assigned by administrator. English no other languages are available at this time.
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Control Buttons
Log On: Name of as entered by the administrator.
Note: Must use the administrator user name and password to access this screen. Accounts: Enter the Accounts Management Screen Exit: Exit and close Profiler Note: User name and passwords are case sensitive. Default log on is. User name: administrator Password: administrator
Tip:
Profiler has shortcut keys assigned to most functions. These

shortcut keys are shown on or near the button, and are typically assigned to one of the 12 function keys located at the top of the keyboard. Tapping the corresponding shortcut key is the same as moving the mouse cursor over the button and clicking the button.
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Accounts Management Screen

Only the administrator is allowed to access this screen, add or edit user names and passwords. To open the Accounts Management Screen log in with the User Name administrator. In the password field type the administrator password and click on the accounts button. Note: On new systems the administrative password is administrator. It is recommended that the administrator select a new password after logging in the first time.
Accounts Management Screen The accounts management screen is used to assign users a password and security level. In addition, the administrator password can be changed in this screen.
Configuration Administrative Password

The current administrative password is shown in the top left corner of the screen. To change enter the new administrative password in the lower left corner of the screen in the field labeled New Administrative Password.
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Caution: Care must be taken to remember the administrator password. If forgotten or entered incorrectly SofTek Engineering must be contacted to get a default file and all users and passwords must be re-entered.
User Table
User Name: Password: Security: Name to be used by tester for login and on reports. Unique name should be assigned for each person who will have access to Profiler. Password assigned to user. In order to login the password must be an exact match to the password assigned to the user in the User Table. Each user is assigned a security level, which will limit access to certain features, or allow access to more advanced features. Assign a security level to each user accordingly: Security Level 1: can only run test in default setting no rights given. Security Level 2: not used at this time. Security Level 3: given all rights to change test parameters and default settings. To add or edit any user simply click on the appropriate cell in the User Table and add or edit as desired.
Note: User names and passwords are case sensitive.
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Configuration
In order for the Test Software to accurately report position and pressure readings, calibration constants for each pressure transducer are stored in the system. SofTek enters the information for each pressure transducer during the installation of the Profiler System, and constants must be updated after the transducer is calibrated, or replaced. The Setup Screen has 3 tabs labeled Scalefactor, Pass/Fail and System Setup. Click on the Scalefactor tab, the following screen should now be visible.
Scale Factor Screen
Scale Factor Table Fields

Transducers: This column has 2 pull down Position transducers that are available. Main is the only one that is in use at this time. Pressure transducers are fixed and cannot be edited. SofTek assigns each transducer a serial number. The pressure transducers are color coded for easier identification.
Serial Number: Colors:
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Scale Factor:
The scale factor is determined at the time the pressure transducers and position sensors are calibrated. The Profiler System uses this value to accurately measure valve movement and actuator pressures. For calibration only, not for user to edit.
Offsets:
Click on the System Setup tab, the following screen should now be visible.
System Setup Fields

Engineering Units: Save Configuration As: System ID: Select the desired engineering units to be used. SAE and Metric units are currently available. Choose either the Tag (description) or Serial Number to save current configuration. When multiple Profiler systems will be sharing a common test result database, a unique two-digit system ID number is required. This information has been assigned by SofTek Engineering and must not be changedcontact SofTek Engineering for permission. Only applicable to string potentiometers and used for calculating rotary movement (example: 3.375 for large OD and 2.000 for small OD clamp inserts). Can be enabled or disabled by user.
Rotary Diameter:
Pass/Fail:
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Interface Box: Pressure: Travel: HART Comport:
(2) different interface boxes are available and set up by SofTek Engineering. User does not need to change. As engineering units are changed this selection will show either PSI or Bar. As engineering units are changed this selection will show either inches or mm. Assigns the comport number for HART (default for serial HART Modem is 1).
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Pass/Fail Criteria
Click on the Pass/Fail tab. The Pass/Fail panel has tabs for each test, click on the tab of desired test and fill in the minimum and maximum values for each parameter.
Pass/Fail Criteria Screen
Configuration
The left tab has different parameters that affect Pass/Fail criteria for each manufacturer. Each setup can be saved, once entered it will not have to be entered again, only modified as needed. These files will automatically be imported as tests are run if the enable button is selected and saved on the system setup tab. Information from previously saved files will automatically fill in tables as selections are made from the pull down menus.
Pass/Fail Criteria Table

The Pass/Fail Criteria Table contains a tab for each of the tests that the Profiler system performs. Each test lists the parameters measured. Enter the Pass/Fail Criteria for individual parameters. Note: For definitions of the parameters found on each test refer to the tests section of the manual.
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Control Buttons
Save & Exit: Defaults: Save & Exit: Cancel: Click to save Pass/Fail Criteria and exit. Click to restore test criteria back to defaults. Click to save scale factors and exit. Click to exit without saving any changes. Restore Defaults: Click to restore test Pass/Fail Criteria back to defaults.
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Database Search Profiler is equipped with a powerful database, all test results and data are stored for easy retrieval. Profiler has tools built in to quickly find previous test results or to
perform a comparison of multiple tests.
Database Search Tool

The Database Search Tool Screen is divided into three sections. The search configuration is found on the left side of the screen, Test Result Table occupying the largest portion of the screen, and the control buttons found at the top of the screen.
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Search Configuration
Serial #: Tag #: Customer PO #: Customer: Valve Manufacturer: Test #: Tested By: Positioner: Enter the serial number of the valve (only tests performed on valves with matching serial numbers will be shown). Enter the tag number of the valve (only tests performed on valves with matching tag numbers will be shown). Enter customers purchase order number (only tests run on valves with matching purchase orders will be shown). Enter customer name (only tests performed on valves purchased by the same customer will be shown). Enter manufacturer (only tests with matching manufacturer will be shown). Enter test number (only tests with matching test numbers will be shown). Enter the testers name - login (only tests performed by the specified tester will be shown). Enter the model of the positioner (only tests performed on valves with that model of positioner will be shown).
Tip:
Leaving a field blank will select all values for the given field. Use multiple fields to narrow the search, for example selecting all valves with a Logix Positioner, tested by John Doe, will result in all tests John Doe has ran on valves with a Logix positioner. Will search for the specific field entered. Will retrieve all tests under requested table name. Allows the user to review a specific test. Graphs are colored and much easier to read when printed on a color printer. Allows the user to select a different table (example: Customer Name). Allows the user to make a table for special testing.
Search Now: Get All: Print Review: Change Tables: Create New Table:
Copy Selected Files: Allows the user to copy selected files by holding the shift key and making multiple selections. This will create a table key with the selected files. Clear Selection: Manually select: Clears table. Allows user to select any test using windows explorer, bypassing table search.
Note: Profiler is set to a default table, if the user changes or creates a new table it will now become the new default table and test will be saved here.
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Viewing tests
Profile Test view screen example (above). To print select the print button, the test printout will be sent to the default printer in Windows. To create a screen capture press the Image button and name the image when prompted. A a .jpg file will be created in any folder that the user selected. Useful when a test must be forwarded via e-mail for analysis or save for future reference. Additional graphs are available that separate the data and look specifically at the positioners, I/P, travel, Pressures, etc.
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Valve Information all Manufacturers (Analog)

The Valve Information Screen records specific information about the valve being tested. There are two types of information: Required Information, and Optional Information (which includes valve information, additional valve information and customer information). Required Information (found within the dark box) must be entered accurately in order for the Profiler Test Suite to properly control the valve during testing. Any remaining information is optional, however, filling in all fields with the correct information will make searching the test result database much more efficient. Many manufacturers and their applicable information have already been entered. If a specific manufacturer is not listed use the other tab. Please contact SofTek Engineering to request implementation of additional valve manufacturers information.
Valve Information Screen (Analog)
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Required Information
Actuator Type Diaphragm choose this option if the valve actuator is a diaphragm type. Cylinder choose this option if the valve actuator is a cylinder type. Air Action Air to Open (ATO) select this option if air must be applied to the valve in order for it to open. Air to Close (ATC) select this option if air must be applied to the valve in order for it to close. Signal Source 4-20 mA select this option if the positioner to be tested requires a 4-20, 4-12, and 12-20 mA current source. 10-50 mA select this option if the positioner to be tested requires a 10-50 mA current source.
Note: This signal source is not available on Fieldbus Positioners. Type Linear select this option for linear actuated valves. Rotary select this option for rotary actuated valves. Nominal Stroke For linear actuated valves enter the expected nominal stroke in inches. For rotary actuated valves enter the expected nominal stroke in degrees. Note: Profiler automatically sets the units to inches or degrees based on the Type selection. Seat (Trim) Diameter Enter diameter of the seat/trim of valve to be tested (units are in inches). Actuator Size (in2) Enter the actuator size of valve to be tested. Valve Information All fields in this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier.
Tip:
If a new profile must be created, selecting a configuration that is similar to the new configuration and editing information fields that are incorrect will save time.
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Serial # Enter the valve serial number. Valve Mfgr Click on either the box or the drop down arrow and select a valve manufacturer from the list. Date Profiler automatically populates this field with the current date, based on the host PCs system calendar. Time Profiler automatically populates this field with the current time, based on the host PCs system clock. Valve Description/Comments This field is for any additional information that the user feels should be included with test results. For example: special configurations or unusual test parameters.
Tip:
Include in the Valve Description/Comments field any information that may not be available in the drop down boxes of other fields. For example, if the valve has a unique packing material select other for packing material and enter actual material used in the Valve Description/Comments box.
Additional Information All fields is this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier. Flow Direction Click on either the box or drop down arrow and select a flow direction from the list. If none of the options are appropriate select Other. Flow Characteristic Click on either the box or drop down arrow and select a flow characteristic from the list. If none of the options are appropriate select N/A. Pressure Class Click on either the box or drop down arrow and select the pressure class from the list. If none of the options are appropriate select Other. Hand Wheel Orientation Click on either the box or drop down arrow and select Hand Wheel Orientation from the list. If none of the options are appropriate select None. Positioner Type Click on either the box or drop down arrow and select positioner from the list. If none of the options are appropriate select Other. Type Click on either the box or drop down arrow and select valve type from the list. If none of the options are appropriate select Other.
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Body Size Click on either the box or drop down arrow and select body size from the list. If none of the options are appropriate select Other. Packing Matl Click on either the box or drop down arrow and select packing material from the list. If none of the options are appropriate select Other. Pbal Seal Matl Click on either the box or drop down arrow and select seal material from the list. If none of the options are appropriate select N/A. Solenoid Mfgr Click on either the box or drop down arrow and select solenoid manufacturer from the list. If solenoids are not used select None. If none of the options are appropriate select Other. Fail Mode Click on either the box or drop down arrow and select fail mode from the list. If none of the options are appropriate select Other. CV Enter the CV rating of valve. Quick Exhaust Enter the quick exhaust rating of valve. Booster If boosters are used enter booster information here. Customer Information All fields in this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier. Plant Name Enter the name of the plant or facility that valve is assigned to. Location Enter the location of the plant or location within the plant that valve is assigned to. Unit Name Enter unit name valve is assigned to. Valve Application Enter the application for which the valve is used. Return # If a return number was given for the customer, enter information here. Year of Installation Enter the year the valve was placed in service/installed. Once information is entered select the save button, this will open a Windows File Dialog Box. System will default to the valve serial number or tag number depending on the selection made in the configuration screen under the System Setup tab. Find file then click, OK. If asked to replace choose YES.
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Recall will open a dialogue box where the user can select previously saved configurations. This will save the user time (file can be edited and saved if needed). If the cancel button is selected, and the information was not saved in a configuration file, the next time valve is tested the information will be lost.
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Valve Information (HART)

Note: At this time Flowserve positioners Logix 3200IQ, 1200, 1210, 520 and 500 are available for setup and configuration. Fisher DVC6000h and DVC5000h positioners are next to be added to the information and setup screen. HART Positioners that are not available can still be tested but the download (Read) and upload (Write) of information is not available. To test the positioner must be in ANALOG MODE, go into analog from the main screen, choose the information screen and select the information as if you were testing an analog positioner.
Valve Information Screen (HART)
Note: The save and recall buttons are similar to the analog information screen. Default button puts in default information if needed. The Read button reads the information from the positioner and the Write button writes the information to the
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positioner. Once the information has been selected download (Write) to positioner and save the configuration file. Required Information Actuator Type Diaphragm Choose this option if the valve actuator is a diaphragm type. Cylinder Choose this option if the valve actuator is a cylinder type. Air Action Air to Open (ATO) Select this option if air must be applied to the valve in order for it to open. Air to Close (ATC) Select this option if air must be applied to the valve in order to close the valve. Signal Source 4-20 mA Select this option if the positioner to be tested requires a 4-20, 4-12, and 12-20 mA current source. 10-50 mA Select this option if the positioner to be tested requires a 10-50 mA current source. Type Linear Select this option for linear actuated valves Rotary Select this option for rotary actuated valves. Nominal Stroke For linear actuated valves enter the expected nominal stroke in inches. For rotary actuated valves enter the expected nominal stroke in degrees. Note: Profiler automatically sets the units to inches or degrees based on the Type selection. Seat (Trim) Diameter Enter the diameter of the seat/trim of the valve to be tested (units are in inches). Actuator Size (in2) Enter the actuator size of the valve to be tested. Valve Information All fields in this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier.
Tip:
If a new profile must be created, selecting a configuration that is similar to new configuration, and editing the information fields that are incorrect can save time.
Serial # Enter the valve serial number.
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Valve Mfgr Click on either the box, or the drop down arrow and select a valve manufacturer from the list. Date Profiler automatically populates this field with the current date, based on the host PCs system calendar. Time Profiler automatically populates this field with the current time, based on the host PCs system clock. Valve Description/Comments This field is for any additional information that the user feels should be included with test results. For example: special configurations or unusual test parameters.
Tip:
Include in the Valve Description/Comments any information that may not be available in the drop down boxes of other fields. For example, if the valve has a unique packing material select other for packing material and type the actual material used in the Valve Description/Comments box.
Additional Information All fields is this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier. Flow Direction Click on either the box or the drop down arrow and select a flow direction from the list. If none of the options are appropriate select Other. Flow Characteristic Click on either the box or the drop down arrow and select a flow characteristic from the list. If none of the options are appropriate select N/A. Pressure Class Click on either the box or the drop down arrow and select the pressure class from the list. If none of the options are appropriate select Other. Hand Wheel Orientation Click on either the box or the drop down arrow and select Hand Wheel Orientation from the list. If none of the options are appropriate select None. Positioner Type Click on either the box or the drop down arrow and select type of positioner from the list. If none of the options are appropriate select Other. Type Click on either the box or the drop down arrow and select the valve type from the list. If none of the options are appropriate select Other.
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Body Size Click on either the box or the drop down arrow and select the body size from the list. If none of the options are appropriate select Other. Packing Matl Click on either the box or the drop down arrow and select packing material from the list. If none of the options are appropriate select Other. Pbal Seal Matl Click on either the box or the drop down arrow and select the seal material from the list. If none of the options are appropriate select N/A.
Solenoid Mfgr Click on either the box or the drop down arrow and select the solenoid manufacturer from the list. If solenoids are not used select None. If none of the options are appropriate select Other. Fail Mode Click on either the box or the drop down arrow and select the Fail Mode from the list. If none of the options are appropriate select Other. CV Enter the CV rating of the valve. Quick Exhaust Enter the quick exhaust rating of the valve. Booster If boosters are used enter the booster information here. Customer Information All fields in this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier. Plant Name Enter the name of the plant or facility that the valve is assigned to. Location Enter the location of the plant or the location within the plant that the valve is assigned to. Unit Name Enter unit name the valve is assigned to. Valve Application Enter the application for which the valve is used. Return # If a return number was given for the customer, enter information here. Year of Installation Enter the year the valve was placed in service/installed.
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Once all information is entered, select the save button, this will open a Windows File Dialog Box. System will default to the valve serial number or tag depending on the selection made in the configuration screen under System Setup tab. Find file then click OK, if asked to replace select YES. Recall will open a dialogue box where the user can select previously saved configurations. This will save the user time (file can be edited and saved if needed). If the cancel button is selected and the information was not saved in a configuration file, the next time this valve is tested the information will be lost.
Valve Information (Fieldbus)
Valve Information Screen (Fieldbus) Required Information Actuator Type Diaphragm choose this option if the valve actuator is a diaphragm type. Cylinder choose this option if the valve actuator is a cylinder type.
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Air Action Air to Open (ATO) select this option if air must be applied to the valve in order for it to open. Air to Close (ATC) select this option if air must be applied to the valve in order to close the valve. Signal Source 4-20 mA select this option if the positioner to be tested requires a 4-20, 4-12, and 12-20 mA current source. 10-50 mA select this option if the positioner to be tested requires a 10-50 mA current source.
Note: This signal source is not available on Fieldbus Positioners. Type Linear select this option for linear actuated valves Rotary select this option for rotary actuated valves. Nominal Stroke For linear actuated valves enter the expected nominal stroke in inches. For rotary actuated valves enter the expected nominal stroke in degrees.
Note: Profiler automatically sets the units to inches or degrees based on the Type selection. Seat (Trim) Diameter Enter the diameter of the seat/trim of the valve to be tested (units are in inches). Actuator Size (in2) Enter the actuator size of the valve to be tested. Valve Information (Left Panel of the Valve Information Screen) All fields in this area are optional, however, it is recommended that they be populated as this information is attached to the test results and can make data management easier. Saved Configurations The valve information is saved as a valve configuration each time the Valve Information Screen is closed. To select a saved configuration click the drop down arrow and select the desired configuration from list.
Tip:
If a new profile must be created, selecting a configuration that is similar to new configuration, and editing the information fields that are incorrect can save time.
Serial # Enter the valve serial number.
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Valve Mfgr Click on either the box, or drop down arrow and select a valve manufacturer from list. Date Profiler automatically populates this field with the current date, based on the host PCs system calendar. Time Profiler automatically populates this field with the current time, based on the host PCs system clock. Valve Description/Comments This field is for additional information that the user feels should be included with test results. For example: special configurations or unusual test parameters.
Tip:
Include in the Valve Description/Comments any information that may not be available in the drop down boxes of other fields. For example, if the valve has unique packing material select other for packing material and type the actual material used in the Valve Description/Comments box.
Additional Information (Right Panel of the Valve Information Screen) All fields is this area are optional, however, it is recommended that they be populated as this information is attached to test results and can make data management easier. Flow Direction Click on either the box or drop down arrow and select a flow direction from list. If none of the options are appropriate select Other. Flow Characteristic Click on either the box or drop down arrow and select a flow characteristic from list. If none of the options are appropriate select N/A. Pressure Class Click on either the box or drop down arrow and select the pressure class from list. If none of the options are appropriate select Other. Hand Wheel Orientation Click on either the box or drop down arrow and select Hand Wheel Orientation from list. If none of the options are appropriate select None. Positioner Type Click on either the box or drop down arrow and select type of positioner from list. If none of the options are appropriate select Other. Type Click on either the box or drop down arrow and select the valve type from list. If none of the options are appropriate select Other. Body Size Click on either the box or drop down arrow and select the body size from list. If none of the options are appropriate select Other.
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Packing Matl Click on either the box or drop down arrow and select packing material from list. If none of the options are appropriate select Other. Pbal Seal Matl Click on either the box or drop down arrow and select the seal material from list. If none of the options are appropriate select N/A. Solenoid Mfgr Click on either the box or drop down arrow and select the solenoid manufacturer from list. If solenoids are not used select None. If none of the options are appropriate select Other. Fail Mode Click on either the box or drop down arrow and select the Fail Mode from the list. If none of the options are appropriate select Other. CV Enter the CV rating of the valve. Quick Exhaust Enter the quick exhaust rating of the valve. Booster If boosters are used enter the booster information here. Customer Information All fields in this area are optional, however, it is recommended that they be populated as this information is attached to test results and can make data management easier. Plant Name Enter the name of the plant or facility that the valve is assigned to. Location Enter the location of the plant or the location within the plant that the valve is assigned to. Unit Name Enter unit name the valve is assigned to. Valve Application Enter the application for which the valve is used. Return # If a return number was given for the customer, enter information here. Year of Installation Enter the year the valve was placed in service/installed. Once all information is entered click F1 found at the bottom right of the screen. This will open a Windows File Dialog Box. System will default to the valve serial number and location for the configuration file then click OK. Recall F2 will open a dialogue box where the user can select previously saved configurations. This will save the user time (file can be edited and saved if needed). Clear/Defaults F3 sets all to default setting. If the cancel button is selected the information will be lost.
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The NI-FBUS Configuration Manager (pictured below) will automatically start when testing a Fieldbus Positioner. If it is not running there will be no communication between the positioner and Fieldbus Card in the computer. Profiler currently uses version 3.1, do not upgrade without contacting SofTek Engineering.
When positioner has been selected to attach and communicate with the following screen will appear. This is a delay that allows the positioner time to power up and initialize before Profiler begins communication. This window will appear with all digital positioners.
Fisher Fieldbus DVC6000f positioner (example).
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To change the Tag on any Fieldbus Positioner Select the Chg Tag button (F5) and enter new tag number. It may take up to 2 minutes to make the change, follow the screen instructions (example below) and watch the status bar.
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Calibration
Once valve information is entered and all hardware properly connected Profiler must calibrate the string potentiometer (used for position measurement) before the valve may be tested. Calibration performed in calibration screen, pressure transducer readings are included for information.
Calibration Screen
Tip:
The Calibration Screen can be used to manually control the valve and verify that all pressure transducers are functioning correctly.
Caution: When connected to a valve the calibration screen can actuate the valve without warning. Proper safety and lockout procedures should be followed. Ensure that the valve is off line and all personnel understand that the valve may actuate without warning!
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Calibration Screen The calibration screen has been divided into three main areas. Position/Displacement is used to report position. Signal which drives the valve, typically controlling the 4 20 mA current signal. Pressure Transducers, four pressure gauges are labeled to match the label on the Profiler Interface box. It is important to verify that external pressure transducers are connected properly. Control Buttons Zero Position This button is used to zero the string potentiometer. Each time Profiler is connected to the valve, the string potentiometer will be located in a default position. Zeroing is required in order for the Profiler Software to the know string potentiometer displacement voltage when valve is closed. To zero the valve set the control signal to zero, wait for the valve to stop moving (string potentiometer signals will stabilize) and press the Zero button. Profiler sending a 0% signal to the string potentiometer should also report that the valve is at 0 in/mm or deg.
Quick Calibration Not available at this time. Cycle Valve Prior to testing, Profiler must cycle the valve to determine the open and close positions and verify that the actual travel of the valve is within tolerances of valve travel specified in Valve Information Screen.
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Exit Click this button to exit the calibration screen.
Note: Most of the controls on this screen have shortcut keys assigned. Position/Displacement Section This section of the screen reports all pertinent information regarding valve position. The string potentiometers output range is 0 3.0V. The calibration screen is used to ensure that string potentiometer can sense entire range of the valve travel, and read the string potentiometers output at the actual 0% and 100% valve position. The Position/Displacement section of the Calibration Screen has 3 fields, String potentiometer Volts, Range, and Displacement. Displacement is calculated based on the String potentiometers calibration scale factor. The calibration scale factor is entered in a file provided by SofTek and displayed in the Profiler Setup Screen. Refer to Setup Section for additional information.
Note: All Profiler systems are to be returned to SofTek Engineering on an annual basis for maintenance, calibration and software upgrade. The calibration service includes a NIST traceable calibration certificate for string potentiometer and pressure transducers. Contact SofTek Engineering for additional information regarding this service. String Potentiometer Volts This field reports actual voltage (0-3.00 Volts) read from the string potentiometer. Profiler uses this value to calculate the actual position. String Potentiometer Range The total measurable range of travel is shown in bar graph. The bar graph units are reported in inches or degrees based on the actuator type selected in the Valve Information Screen. As the valve is cycled in area of travel, verify that the slider does not reach either end of the indicator and that string potentiometer is in range. If the string potentiometer is not able to measure the full range of travel, adjustments to the string potentiometer mounting may be required, or a string potentiometer with longer range of travel must be used. See the Mounting Section for additional information regarding string potentiometer adjustments. Displacement Actual position as calculated by Profiler. Should read 0 after zeroing Profiler and setting the control signal to 0%. Reading should display in the engineering units selected (in/mm or deg). Drive Signal Control This screen has two variable slide bars that allow the user to manually adjust the control signal. Five green LED/Buttons which are activated by clicking on them. The active button is lit, for easy identification of signal level being used. The % Open converts the control signal to a percent value based on the signal range (i.e. 4 mA is reported as 5.55%, 12 mA as 50% and 20 mA as 94.45%). Signal box reports the actual signal as sent to the valve.
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Variable #1 & #2 The two variable slide bars located on either side of the signal panel can be used to manually set user values. The scale of both slides is based on the control signal. To adjust use the mouse and click on the top of the bar and slide it up and down to the desired level or type it in the Control Indicator. Both variables can be set independently of the other, to any value, within the control signal range of 3mA 0% and 21mA 100% LED Control Buttons These buttons are found in the center of the Signal Panel and will step the control signal value when clicked. The top button is always assigned to 5.55% (typically 4 mA) of the control signal, the middle button is always assigned to 50% (typically 12 mA) and the bottom button is always assigned to 94.45% (typically 20 mA). The two remaining buttons are assigned to variable #1 and variable #2. They are labeled accordingly, and have bold arrows pointing to the variable slide bar that controls them. Clicking between the different buttons allows the user to step valve between any two signal values.
Tip:
By selecting one of the variable buttons, the valve can be controlled manually when using the corresponding slide bar. This can be useful in watching the valve move slowly between two points, or viewing how the pressures react to slow signal changes. This is important for proper valve calibration. Pressure Sensors The four pressure gauges on the right side of the screen simply report the pressure (psi) of the pressure gauge connected to the corresponding sensor on the interface box. These sensors are active and anytime the valve is moved, the pressure gauges should react.
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Note: The Tune Boosters tab in the Calibration Screen is used to monitor the sensors in a strip chart format, showing the command, pressures and position. The user can visually see overshoot and adjust the positioner gains and/or boosters before testing begins. The user can choose different commands and step between them. Signals can be turned on or off to only show what is needed.
Tune Boosters Tab
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Valve Profile Test

The Profile Test is used to perform an overall health check of valve. Profiler ramps the control signal from 6.25% (3 mA) to 106.25% (21 mA), and back to 6.25%, while monitoring position and pressure. Control signal, position, and pressures are all plotted in both directions. At the conclusion of the test friction is calculated and plotted.
Profiler Test Screen

Caution: Tests in the Profiler Test Suite can actuate the valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Profiler Test Setup Little setup is required for this comprehensive overall health test. This test graphically displays, accuracy, friction and pressures during a ramp up and
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down. Setup Panel is located at the bottom center of the screen, where graphing options are turned on and off, ramp time (seconds), and hold time are also specified. Ramp Time Length of time in seconds that should elapse during ramp. Hold Time Time to hold the valve position at either end of ramp. This is useful in giving large actuators time to completely saturate the cylinder or diaphragm. Test Completed Indicator lights up at the conclusion of test, status bar will give % complete. Graphs The larger, profile plot, graphs the dynamic data (signals that change) during actual ramp. The smaller, friction graph plots pressure over the ramp, and calculated friction, at the conclusion of the test. The following parameters are plotted on the Profile Graph: % Open (Left y-axis) A percentage value representing actual valve position as measured by the string potentiometer. In/mm/Degrees (Left y-axis): Actual valve displacement in in/mm or degrees as measured by the string potentiometer. Pressure (Right y-axis): Pressure as measured by the pressure transducer and reported in psi/bar. Friction (Right y-axis): Stem or shaft friction based on the pressures, spring, actuator size and stem measured during the ramp. mA (x-axis): Value of milliamps sent to valve. Time (x-axis): Elapsed time of test reported in seconds. The following parameters are plotted on the Signal Graph: Pressure (Left y-axis): Pressure as measured by the I/P pressure transducer and reported in psi/bar. Friction (Right y-axis): Stem or shaft friction based on pressure differences measured during the ramp. The signals that are plotted on both graphs can be turned on and off to make the graphs easier to read and understand. Found on the right side of each graph is a legend that shows the label and line style for each of the plotted parameters. Next to each element in the legend is a green indicator, when lit the element is plotted. To turn off any element simply click on the corresponding indicator.
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Test Result Table The table on the right side of screen is populated with data collected and calculated from the Profile Test. Pass/Fail criteria are specified in the Profiler Setup screen if enabled. Displacement Actual valve travel measured from fully closed to fully open position. Units are reported in in/mm or degrees depending on valve type. Seat Contact Low value of control signal after which no more movement is measured as the valve moves in a closing direction. Full Open High value of control signal after which no more movement is measured, as the valve moves in an opening direction. Nominal Displacement Measures the mA command at the nominal stroke of actuator entered in Information Screen under stroke length. (For example @ .75 stroke the mA reading is 18.94) Dynamic Error % (max) Maximum error is calculated as difference between control signal vs. actual measured position, over the entire ramp. (Dynamic error is hysteresis, deadband and delay due to time). Dynamic Error % (mean) Mean error is calculated as difference of control signal vs. the actual measured position, over the entire ramp. Friction (max) Maximum calculated friction value. Friction (mean) Mean calculated friction value. Seat Load Load placed on seat when valve is fully closed. Spring Seat Load Force placed from the spring when the valve is fully closed if no air pressure is on the valve. Total Seat Force Total force placed on the seat of the valve (spring and air). Actuator Pressure Supply pressure to the valve. Seat Contact (signal) On 3 15 psi I/P positioners, value of the 3-15 psi signal at which seat contact occurs. Full Open (signal) On 3-15 psi I/P positioners, value of the 3-15 psi signal at which plug contact occurs. Control Buttons The control buttons on top of the screen are used start test and exit.
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Save & Exit Click this button to save test and return to main screen. Start After configuration click the start button to launch test. Cancel Click Cancel to exit to main screen (test is not saved). Image Creates a .jpg file of screen. This can be used to save tests for e-mail. View Allows user to view .jpg files that have been saved. Zoom Allows user to view the graph, zoom and annotate to point out problems in the seat for example.
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Other graphs Gives the user another view of positioner, I/P, pressures and travel. Graph is viewed like the Flow scanner printout for those users who may have previously viewed or used that system.
Other Graphs
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Frequency Response Test

The Frequency Response Test is used to determine the highest frequency that a valve can track. Profiler runs the test by producing a sinusoidal waveform with three different amplitudes at offset. Amplitude and offset are both user adjustable, to allow for easy testing with specific conditions. When launched test starts a frequency sweep from 0.1 Hertz, to a specified dB point.
Note: The 6 dB point is the point at which the amplitude of the valve movement is less than the amplitude of the control signal.
Frequency Response Test Screen Caution: Tests in the Profiler Test Suite can actuate the valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning!
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Test Configuration On the left side of Frequency Response Test screen, there are the five boxes used to configure test. Frequency Input the amplitude. Offset Center of the sinusoidal wave used to cycle valve. For example, if the first frequency is set to 50.00 and the offset is set 50% the valve will be cycled from 25% to 75% (50% signal amplitude centered at 50%). -dB Limit As frequency increases the valve will not be able to keep up and the total travel of valve will decay. This is the point of decay at which the test will stop. Test Results Like most tests in the Profiler system results are plotted both graphically and recorded in table format. Plots The three plots in the center of screen, plot amplitude vs. frequency and phase shift (lag) vs. frequency. Table For each amplitude, table lists first the frequency that valve exceeded the specified dB level, actual dB, and measured phase shift. Test Pass/Fail Criteria is specified in the Profiler Setup Screen. Control Buttons Control buttons on the top of the screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click the start button to lunch test. Cancel Click Cancel to exit to main screen. Test is not saved. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
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Hysteresis Test
The Hysteresis Response Test is used to determine how accurately and repeatable the valve steps when moved from different directions. This test will cycle through a series of equal steps (between 0% to 100%).
Hysteresis Test Screen
Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Test Configuration On the left side of the Hysteresis Test Screen, are three configuration fields; Settling Time, # of Steps, and Select Type.
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Settling Time After each step the Hysteresis Test will hold position for the time specified in seconds, giving the valve time to settle, prior to reading position. # Of Steps Hysteresis tests will take the number of steps specified. Tests are automatically calculated to be equal, but can be edited by the user by using the edit button. Select Type Hysteresis Test can calculate three different parameters Hysteresis, Repeatability, and Linearity. Hysteresis: Test measures the difference in final position when approached from different directions. Repeatability: Test measures the difference in final position when approached from the same direction. HRL: Performs Hysteresis, Repeatability and Linearity. Linearity is defined by how much valve deviates from a linear (straight line) if all the steps were plotted against the control signal.
Test Results Like most tests in the Profiler system results are plotted both graphically and recorded in table format. Plots Graph plots the Hysteresis and Repeatability for each of the two cycles: Hysteresis is calculated as the difference between measured errors with an increasing step vs. the measured error with a decreasing step. Repeatability is calculated as the difference between the measured error of the first increasing step vs. the measured error of the second increasing step. The same calculation is performed with decreasing steps.
Result Table Table shows actual steps and measured error for each step. The left column shows the command signal (in percent) for each of the steps. The four remaining columns show the measured error (difference between actual position and command signal).
Analysis Table At the conclusion of the test the maximum Hysteresis and Repeatability values are calculated, as well as Linearity. Hysteresis %FS: The maximum and average Hysteresis value recorded. Repeatability %FS: The maximum and average Repeatability value recorded. Linearity: Calculated over linearity based on the Hysteresis and Repeatability plots.
Control Buttons Control buttons on the top of screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click start button to lunch test.
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Cancel Click Cancel to exit to main screen. Test is not saved. Edit Steps % Click and edit the positions at which each Deadband test will be run. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
Resolution Test
Resolution Response Test performs four increasingly smaller steps and plots how well the valve is able to respond to steps.
Resolution Test Screen
Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning!
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Test Configuration Located on the left side of Resolution Test Screen, are seven configuration fields; Hold Time, Offset(%), # of Cycles, Step % #1, Step % #2, Step % #3, and Step % #4, Hold Time After each step will hold position for the time specified in seconds. Offset(%) This is the starting position for each step in test. # of Cycles Resolution Test has the ability to cycle through the four steps any number of times. Step % # 1-4 These four fields define the step size. Test Results The Resolution Test plots command signal steps vs. actual position. Control Buttons Control buttons on the top of the screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click start button to lunch test. Cancel Click Cancel to exit to main screen. Test is not saved. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
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Sensitivity Test
The Sensitivity Test performs a series of four increasingly smaller steps in an upward direction, then returns to the offset value and performs the same steps in a downward direction.
Sensitivity Test Screen
Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Test Configuration On the left side of Sensitivity Test Screen, are six configuration fields; Hold Time, Offset(%), Step % #1, Step % #2, Step % #3, and Step % #4, Hold Time After each step will hold the position for time specified in seconds.
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Offset(%) This is the starting position for each series of steps. Step % # 1-4 These four fields define step size for each of the four steps, in both the upward and downward series. Test Results Sensitivity Test plots command signal steps vs. actual position. Control Buttons Control buttons on top of screen are used start test and exit. Save & Exit Click button to save test and return to main screen. Start After configuration click start button to launch test. Cancel Click Cancel to exit to main screen. Test is not saved. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
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Step Response Test

Step Response Test performs a single step and detailed analysis of valve performance for the given step.
Step Response Test Screen
Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Test Configuration On the left side of the Step Response Test Screen are three configuration fields Hold Time, Offset(%), Step %. Hold Time Amount of time test will hold position at the offset value and the step. Offset(%) Starting position for step.
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Step % Size of step to make from offset. Test Results Step Response Test plots the command signal vs. actual position. In addition there are multiple parameters in the analysis table. Analysis Table Parameters Overshoot - % error and step size. Undershoot - % error and step size. Rise Time - total elapsed time the valve required to move from offset 10% to 90% of step, reported in seconds. Fall Time - total elapsed time the valve required to move from 90% to 10% of step, reported in seconds. Delay - elapsed time from control signal steps until the valve (= 1% of step) actually responds. Time Con. 1 Increase (sec) - first time constant for the increasing command. (063.2%) Time Con. 2 Increase (sec) - second time constant for the increasing command. (086.5%) Time Con. 3 Increase (sec) - third time constant for the increasing command. (095%) Time Con. 4 Increase (sec) - fourth time constant for the increasing command. (098%) Time Con. 5 Increase (sec) - fifth time constant for the increasing command. (0-99%) Time Con. 1 Decrease (sec) - first time constant for the decreasing command. (063.2%) Time Con. 2 Decrease (sec) - second time constant for the decreasing command. (086.5%) Time Con. 3 Decrease (sec) - third time constant for the decreasing command. (095%) Time Con. 4 Decrease (sec) - fourth time constant for the decreasing command. (098%) Time Con. 5 Decrease (sec) - fifth time constant for the decreasing command. (099%) Velocity Increase - velocity when stroking up, reported in inches per seconds. Velocity Decrease - velocity when stroking decreased, reported in inches per seconds. Stroke Speed increasing signal (sec) 0-100% Stroke Speed decreasing signal (sec) 100-0% Control Buttons Control buttons on top of screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click start button to lunch test. Cancel Click Cancel to exit to main screen. Test is not saved.
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Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
Stroke Speed Test

The Stroke Speed Test performs a single step and a detailed analysis of the valves speed performance for given step.
Stroke Speed Test Screen

Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Test Configuration On the left side of the Resolution Test screen are five configuration fields Hold Time, Offset(%), Step %, Start (%) Timer @, and Stop (%) Timer @.
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Hold Time Amount of time test will hold the position at the offset value and step. Offset(%) Starting position for step. Step (%) Size of the step to make from offset. Start (%) Timer @ Position to start the timer that velocity and speed calculations are based on. Stop (%) Timer @ Position to stop the timer that velocity and speed calculations are based on.
Note: All valves have a delay between when the command is given and when it actually responds (example: start time 5% - stop time 95% gives time from 5% to 95% of step size in seconds). In addition the valve requires a certain amount of time to get up to speed, the valve will begin to slow down as it approaches its final position. The start and stop timer fields make it possible to eliminate these slow areas of the step. Test Results Stroke Speed Test plots the command signal vs. actual position. In addition there are multiple parameters in the analysis table. Analysis Table parameters Offset - actual position when step command was given. Step Size - total step size based on valves max position lowest offset position. Amplitude - total valve travel above offset. Overshoot - % error of step size. Undershoot - % error of step size. Rise Time - total elapsed time valve required to move from 10% to 90% of step size, reported in seconds. Fall Time - total elapsed time valve required to move from 90% to 10% of step size, reported in seconds. Delay - elapsed time from when control signal steps until the valve actually responds to 1% of step. Delta Time Increase (sec) Delta Time Decrease (sec) Velocity Increase - velocity when stroking up reported in inches per seconds. Velocity Decrease - velocity when stroking decreased reported in inches per seconds. Control Buttons Control buttons on top of screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click start button to lunch test.
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Cancel Click Cancel to exit to main screen. Test is not saved. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
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Transducer Test
Transducer Test is used to determine how accurately and repeatable the signal psig pressure transducer strokes valve. Similar to the Hysteresis Test and will cycle through a series of equal steps between 0% and 100%.
Transducer Test Screen Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning! Test Configuration On the left side of the Transducer Screen are two configuration fields, # of Steps and Test Type. # Of Steps Transducer Test will take the number of steps specified and software will automatically scale the test to be equal in size. However, the user may edit test by clicking the steps field % signal immediately under the results graph.
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Select Type Transducer Test can run three types of tests Hysteresis, Repeatability, and Linearity. Select which of the 3 to calculate. Hysteresis - test measures the difference in final position when approached from different directions. Repeatability - test measures the difference in final position when approached from the same direction. HRL - performs the above two tests plus linearity. Linearity is defined by how much the valve deviates from a linear (straight line) if all steps were plotted against the control signal.
Test Results Like most tests in the System results are plotted both graphically and recorded in a table format. Plots Graph plots the Hysteresis and Repeatability for each of the two cycles. Hysteresis is calculated as the difference between the measured error when valve is stroked with an increasing step vs. the measured error with a decreasing step. Repeatability is calculated as the difference between the measured error between two steps to the same position and same direction. This calculation is performed for both increasing and decreasing steps.
Result Table Table shows the actual steps and measured error for each step. The left column (yellow background) shows the command signal (in percent) for each of the steps (these can be edited). The four remaining columns show the measured error (difference between actual position and command signal).
Analysis At the conclusion of the test the maximum hysteresis and repeatability values are calculated as well as linearity. Hysteresis %FS The maximum Hysteresis value recorded. Repeatability %FS: The maximum Repeatability value recorded. Linearity Calculated over linearity based on Hysteresis and Repeatability plots. Control Buttons Control buttons on the top of screen are used start test and exit. Save & Exit Click this button to save test and return to main screen. Start After configuration click start button to lunch test.
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Cancel Click Cancel to exit to main screen. Test is not saved. Edit Steps % Click and edit the positions at which each Deadband test will be run. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed.
Deadband
Deadband Test determines the minimum command signal change required for valve to respond. Profiler can test at multiple locations, and wait a specified amount of time at each position, to allow less responsive valves more time to move.
Deadband Test Screen Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line and all personnel understand that the valve may actuate without warning!
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Test Configuration
Settle Time After the command signal changes, how long Profiler waits (in seconds) for valve to respond. Enter the settling time in the upper right corner of the screen. Number of Positions Number of locations to run the Deadband test. Enter number of positions in the upper right corner of the screen. Positions Profiler automatically adjusts the positions table to match the number of positions and defaults to equal spacing between points (user can edit points). Click on location in table and enter new desired location.
Test Results
Results Graph Results graph plots position vs. error. Analysis Table Table reports position and calculated Deadband for each location. Control Buttons Control buttons on the top of screen are used start test and exit. Save & Exit Click button to save test and return to main screen. Start After configuration click start button to launch test. Cancel Click Cancel to exit to main screen. Test is not saved. Image Creates a .jpg file of screen. This can be used to save tests that can be e-mailed. Edit Steps % Click and edit the positions at which each Deadband test will be run. Start Test After configuration click start button to launch the test. Cancel Click Cancel to exit the Dead Band Test and return to main screen. Test is not saved.
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Mini Cal
Mini Cal Screen This screen is an optional calibration screen. Two adjustable 4-20 mA settings can be adjusted by sliding the arrow on the large blue indicators. Click the middle indicator and a drop down box will appear with 5 possible outputs, select the desired output. Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line and all personnel understand that the valve may actuate without warning!
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Sequencer
The sequencer tool allows the operator to select multiple tests and permits the Profiler system to automatically run all selected tests, saving the technician time and hassle normally spent babysitting the system while running multiple tests.
Sequencer Screen Sequencer Configuration To select a sequence of tests to run, Shift+Click on each test. When the continue button is selected the Sequencer will commence running all tests selected. Control Buttons Control buttons in the bottom right corner of screen are used start test and exit.
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Continue Click this button to begin running selected tests. Cancel Click Cancel to exit Sequencer and return to main screen. Settings Screen This screen is to setup or change standard default settings for all tests in Profiler, they may be saved and recalled at a later time. Useful if there are customer requirements for testing differ from program defaults. Dynamic Tab is for tests that calibrate data when valve moves. Static tests are calculated when valve has stopped moving.
Settings
Caution: Tests in the Profiler Test Suite can actuate valve without warning. Proper safety and lockout procedures must be followed. Ensure that the valve is off line, and all personnel understand that the valve may actuate without warning!
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Passive Monitoring
Passive Monitoring To begin passive monitoring fill in the header information at the bottom right and choose amount of data to file. Select the config button on tool bar and name the file that data will be saved to. Select the Go button and the graph will display data. There are no control capabilities in this test only monitoring of signals. Position 1 and 2 will record displacement. Pressures include top/dia, bottom, I/P, and supply. The three mA signals can also be monitored. Two 0-25mA and one 0-55mA for the recording of valve signal or flowmeters etc. There are three voltage signals that must fall into the range of +/- 10 VDC. For example if the control signal (mA) of the valve needs to be monitored, the signal cable must be used and placed in the ground side of the control signal. Once every signal is reading on the screen press the Save button and it will stay depressed. Data is now being saved to the file. Press it again and it will stop saving data. Press again and it will continue to append to the same file.
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Pressing the Zero button will Zero the position transducer. This can be done before the valve has moved to position or after. The user must remember what the zero position was before data is collected.
Custom
This feature is currently unavailable.
Contact Information
SofTek Engineering 826 N. 100 E., Building 3B Spanish Fork, UT 84660 www.Softekeng.com JamesD@Softekeng.com 801-602-7841 (Mobile) 801-794-0035 (office) 801-798-0310 (Fax)
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IMPORTANT NOTICE SofTek Engineering, LLC (SofTek) reserves the right to make changes to their products, product specification, or service without notice. All products are sold subject to the terms and conditions of sale supplied at the time of order acknowledgment, including those pertaining to warranty, patent infringement, and limitation of liability. SofTek warrants performance of its products to the specifications applicable at the time of sale. Testing and other quality control techniques are utilized to the extent SofTek deems necessary to support this warranty. Specific testing of all parameters of each device is not necessarily performed. Customers are responsible for the safety of their operators, and equipment when using SofTek products. In order to minimize risks associated with the use of SofTeks products, the customer must take adequate operating safe guards to minimize inherent and procedural hazards. SofTek is not liable for any injuries to the customer, or personnel resulting from the use or misuse of SofTeks products. SofTek is not responsible for damage to equipment of facilities due to the use or misuse of this or other SofTek Products. SofTek assumes no liability for providing assistance or custom designs. SofTeks publication of information regarding any third partys products or services does not constitute SofTeks approval, warranty or endorsement there of.
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Profiler Manual Version 5

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ADVANCED VALVE DIIAGNOSTIIC TEST SYSTEM ADVANCED VALVE D AGNOST C TEST SYSTEM User Manual

SofTek Engineering, LLC

Using This Manual ...............................................................5

Launching Profiler ................................................................. 15

Profiler Configuration ...................................................... 19

Database Search .............................................................. 23

Valve Profile Test ............................................................. 35

Frequency Response Test .............................................. 39

Profiler User Manual Version 5

Resolution Test ................................................................ 44

Step Response Test......................................................... 48

Stroke Speed Test............................................................ 51

Transducer Test ............................................................... 54

Mini Cal ............................................................................. 59

Profiler User Manual Version 5

Profiler User Manual Version 5

Using This Manual

Profiler User Manual Version 5

Profiler Overview & User Environment

Profiler User Manual Version 5

Profiler User Manual Version 5

Fixture Hardware Linear/Rotary

Profiler User Manual Version 5

10 Extension Cables (Pressure Transducers and Position)

6 Interface Cable from Box to Computer

6 Cables (Pressure Transducers and Position)

Profiler User Manual Version 5

Monitor mA (passive monitoring only)

Monitor+/- 10VDC (passive monitoring only)

Solenoid Relay (testing solenoid or on/off valves) Fieldbus connection

Profiler User Manual Version 5

Interface Cable connector

Data Acquisition/Fieldbus Card Connections

Profiler User Manual Version 5

Attaching to Linear Valves

Profiler User Manual Version 5

Figure 3 Attaching to Rotary Piston Actuators

Profiler User Manual Version 5

Attaching to Fisher Linear Diaphragm Valves

Profiler User Manual Version 5

Profiler User Manual Version 5

Profiler Log In Screen Configuration

Profiler User Manual Version 5

Profiler has shortcut keys assigned to most functions. These

Profiler User Manual Version 5

Accounts Management Screen

Configuration Administrative Password

Profiler User Manual Version 5

Note: User names and passwords are case sensitive.

Profiler User Manual Version 5

Scale Factor Screen

Scale Factor Table Fields

Serial Number: Colors:

Profiler User Manual Version 5

System Setup Fields

Profiler User Manual Version 5

Interface Box: Pressure: Travel: HART Comport:

Profiler User Manual Version 5

Pass/Fail Criteria Screen

Pass/Fail Criteria Table

Profiler User Manual Version 5

Profiler User Manual Version 5

Database Search Tool