MN SVi1000 IOM GEA19527 RevF

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GE Oil & Gas

Masoneilan*
SVi*1000 Positioner
Instruction Manual (Rev F)

GE Data Classification: Public


About this Guide
This instruction manual applies to the following instruments and approved software:

SVi1000*
with firmware version 2.2.1 (for use with HART® 5) or 3.1.1 (for use with HART® 7).
with ValVue 3 version 3.20.0 or greater
with a HART® Communicator with DD published for SVi1000

The information in this manual is subject to change without prior notice.

The information contained in this manual, in whole or part, shall not be transcribed or copied without General Electric
Company’s written permission.

In no case does this manual guarantee the merchantability of the positioner or the software or its adaptability to a specific
client needs.

Please report any errors or questions about the information in this manual to your local supplier or visit
www.geoilandgas.com/valves.

DISCLAIMER
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES.
SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES
AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND
REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS
FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.
THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES
AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER
EQUIPMENT AT THE SITE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR
EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE.
SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED
SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE
EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE
ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.

Copyright
The complete design and manufacture of the SVi1000 Smart Valve Interface is the intellectual property of GE Oil &Gas. All
information contained herein is believed to be accurate at the time of publication and is subject to change without notice.

Copyright 2016 by General Electric Company. All rights reserved.

PN 720013363-779-0000 Rev. F

2 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Document Changes

Version/Date Changes

B/10-2012 Changed Load Limits section Simplified Switch Installation diagram and added Caution
about polarity.
Changed GEA number.

C/05-2013 Made changes to Figure 7 Rotary Kit Components

D/9-2013 Added cautions to reference Load Limits section in Install section. Changed Simplified Instal-
lation drawing in Load Limits section. Added Cautions about Position Low and Upper Limits.
Added text about the 4-20 retransmit galvanic isolation.

E/02-2014 Rework of the Load Limits section.

F/03-2016 Updated load limits section.


Updated wiring and general descriptions to include retransmit wiring and features.
Updated all references to ValVue to reflect on ValVue version 3, along with licensing
changes.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 3
Contents

1. Safety Information ........................................................................................................................................................................... 11


Documentation Symbols ............................................................................................................................................................ 11
SVi1000 Product Safety............................................................................................................................................................... 12
2. Introduction ....................................................................................................................................................................................... 15
About This Manual ......................................................................................................................................................................... 15
Conventions Used in This Manual .................................................................................................................................. 15
ValVue Software ............................................................................................................................................................................. 16
System Requirements.......................................................................................................................................................... 16
ValVue and SVi1000 DTM Trial Version........................................................................................................................ 17
Operational Overview .................................................................................................................................................................. 17
SVi1000 Features ........................................................................................................................................................................... 18
Functionality ..................................................................................................................................................................................... 19
Modes .................................................................................................................................................................................................. 21
LED Light Functions....................................................................................................................................................................... 23
3. Installation and Set Up ................................................................................................................................................................. 25
Overview............................................................................................................................................................................................. 25
SVi1000 Dimensions ............................................................................................................................................................. 26
Pre-Installation Issues.................................................................................................................................................................. 27
Storage........................................................................................................................................................................................ 27
Unpacking ................................................................................................................................................................................. 27
ValVue and SVi1000 DTM Software Installation .............................................................................................................. 27
ValVue Installation................................................................................................................................................................. 28
SVi1000 DTM Installation.................................................................................................................................................... 30
Mounting and Wiring.................................................................................................................................................................... 33
Step 1: Mounting the SVi1000 .......................................................................................................................................... 34
Step 2: Connecting the Tubing and Air Supply......................................................................................................... 43
Step 3: Wiring the SVi1000 ................................................................................................................................................ 44
4. Check Out and Power Up ............................................................................................................................................................ 49
Overview............................................................................................................................................................................................. 49
Step 1: Inspect the Actuator, Linkages, or Rotary Adapter......................................................................................... 50
Step 2: Verify Mounting and Linkage Adjustment........................................................................................................... 50
Step 3: Checking the Magnet.................................................................................................................................................... 50
Perform a Visual Inspection .............................................................................................................................................. 50
Use ValVue to Check Magnet Position ......................................................................................................................... 51
Step 4: Checking the Air Supply............................................................................................................................................... 51

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 4
Step 5: Verify Wiring Connections...........................................................................................................................................52
Step 6: Configuration ....................................................................................................................................................................53
Auto Find Stops .......................................................................................................................................................................53
Open Stops Adjustments ....................................................................................................................................................54
Tuning ..........................................................................................................................................................................................54
5. Full Wizard ..........................................................................................................................................................................................59
Full Wizard Screen..........................................................................................................................................................................59
Full Wizard Screen .................................................................................................................................................................59
Run the Full Wizard................................................................................................................................................................62
6. Operation and Maintenance ......................................................................................................................................................65
Principle of Operation...................................................................................................................................................................65
Physical and Operational Description...................................................................................................................................65
Electronics Module.................................................................................................................................................................66
Pneumatic Module.................................................................................................................................................................67
SVi1000 Maintenance and Repair ..........................................................................................................................................68
Adjusting I/P Zero ...................................................................................................................................................................68
Repair by Replacement................................................................................................................................................................68
Internal Diagnostics ......................................................................................................................................................................68
FAILSAFE Mode ........................................................................................................................................................................68
Upgrading Firmware.....................................................................................................................................................................68
7. Specifications, Spare Parts and References .......................................................................................................................69
Physical and Operational Specifications .............................................................................................................................69
Spare Parts ........................................................................................................................................................................................74
8. Using the Digital Interfaces .........................................................................................................................................................75
Overview .............................................................................................................................................................................................75
Hand Held Communicator .........................................................................................................................................................76
SVi1000 HART® Commands .....................................................................................................................................................77
ValVue ..................................................................................................................................................................................................80
9. Wiring Theory for an SVi1000 ....................................................................................................................................................81
Introduction.......................................................................................................................................................................................81
SVi1000 Setups................................................................................................................................................................................81
Split Range Applications..............................................................................................................................................................82
System Connections Considerations.....................................................................................................................................83
Wiring Guidelines............................................................................................................................................................................84
Grounding Practices .............................................................................................................................................................84
Compliance Voltage in Single Drop Current Mode .................................................................................................85
Wire Size and Conduit ..........................................................................................................................................................86
HART® Physical Layer Compliance of the Control System.........................................................................................87
Impedance Constraints .......................................................................................................................................................87
Noise Constraints ...................................................................................................................................................................87
Cabling and Interconnection Requirements .............................................................................................................88
Capacitance vs. Length of Cable for HART®.............................................................................................................88
HART® Filter Required for Certain Control System Output Circuits ............................................................... 88

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 5
10. Optional Switch Load Limits .....................................................................................................................................................89
Output Switches ..............................................................................................................................................................................89
Introduction...............................................................................................................................................................................89
Optional Retransmit Output ......................................................................................................................................................91
Introduction...............................................................................................................................................................................91
11. Air to Open and Air to Close Actuators ...............................................................................................................................93
Actuator Action................................................................................................................................................................................93
12. SVi1000 Fault Matrix ....................................................................................................................................................................97
Fault Matrix........................................................................................................................................................................................97
13. Air Supply Requirements ........................................................................................................................................................ 103
Air Supply Requirements .......................................................................................................................................................... 103
14. Adjusting Speed of Response ............................................................................................................................................... 105
Adjusting Speed of Response................................................................................................................................................. 105
15. Advanced Usage ........................................................................................................................................................................ 107
Technology to Maximize Savings and Process Performance ................................................................................. 107
Tight Shutoff Application to Protect from Seat Erosion..................................................................................... 107
Tight Shutoff Application to High Pressure Liquid Letdown Valve Trim..................................................... 107
16. Glossary .......................................................................................................................................................................................... 109

6 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Figures

1 Operator Controls - Standard......................................................................................................................................... 19


2 Optional Digital Switches and Gauges....................................................................................................................... 20
3 Optional Position Retransmit .......................................................................................................................................... 20
4 SVi1000 LEDs.......................................................................................................................................................................... 23
5 Example LED Pattern .......................................................................................................................................................... 23
6 SVi1000 Components ......................................................................................................................................................... 25
7 SVi1000 Dimensions With and Without Gauges ................................................................................................... 26
8 ValVue 3 Search Selections ............................................................................................................................................. 28
9 ValVue 3 Search Results.................................................................................................................................................... 28
10 Download Software Terms .............................................................................................................................................. 28
11 Registration Form................................................................................................................................................................. 29
12 Ready to Download............................................................................................................................................................. 29
13 DTM Download ...................................................................................................................................................................... 30
14 SVi1000 DTM Search Results .......................................................................................................................................... 30
15 Download Software Terms .............................................................................................................................................. 31
16 Registration Form................................................................................................................................................................. 31
17 Ready to Download............................................................................................................................................................. 32
18 DTM Download ...................................................................................................................................................................... 32
19 Rotary Kit Components ..................................................................................................................................................... 35
20 Camflex with Mounting Bracket (Side View) ............................................................................................................ 35
21 Rotary Mounting Bracket to Valve Actuator............................................................................................................ 36
22 Extension Shaft to the Valve Position Take-off Shaft .......................................................................................... 36
23 Camflex V-Seal ...................................................................................................................................................................... 39
24 Reciprocating Valve Mounting Bracket for Standard Lever............................................................................. 39
25 Magnet Holder and Standard Lever for Reciprocating Valves ....................................................................... 40
26 SVi1000 Take Off Rod Mounting.................................................................................................................................... 41
27 Ensure Position Linearity................................................................................................................................................... 42
28 SVi1000 Lever Installed to IM Assembly .................................................................................................................... 42
29 Air Ports..................................................................................................................................................................................... 43
30 Front Cover.............................................................................................................................................................................. 46
31 Connections to Electronics Module with Switches
(via Interface Board)............................................................................................................................................................ 46
32 Connections to Electronics Module with Position Retransmit
(via Interface Board)............................................................................................................................................................ 47
33 Open Stop Adjustment Screw......................................................................................................................................... 54
34 Preset Tuning Values .......................................................................................................................................................... 55
35 Configuration Selection Switch...................................................................................................................................... 55

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 7
36 Configuration Selection Switch ......................................................................................................................................57
37 Full Wizard Screen: Device Info......................................................................................................................................60
38 Block Diagram with I/P Converter.................................................................................................................................65
39 Pneumatic Module ...............................................................................................................................................................67
40 SVi1000 HART® Communicator Connections.........................................................................................................76
41 General Purpose Installation ...........................................................................................................................................81
42 Split Range with Supplemental Power Supply - Non-Hazardous ..................................................................82
43 Simplified Switch Installation Drawing: Correct Configuration .......................................................................90
44 Simplified Switch Installation Drawing: Configuration Not Allowed .............................................................90
45 Simplified Retransmit Option Installation Drawing...............................................................................................91
46 ATO and ATC Action with Linear Positioner Characteristics .............................................................................94
47 ATO and ATC Action in Percentage of Positioner Characteristics..................................................................95

8 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Tables

1 LED Light Patterns and Troubleshooting................................................................................................................... 23


2 Travel Sensor Alignment ................................................................................................................................................... 38
3 Reciprocating Valve Mounting Hole and Turnbuckle Length .......................................................................... 40
4 Air Supply Requirements................................................................................................................................................... 43
5 Actuator Settings Configuration Selection Switch Guidelines......................................................................... 56
6 Environmental Specifications ......................................................................................................................................... 69
7 Operational Specifications............................................................................................................................................... 70
8 Input Signal and Power, Specifications...................................................................................................................... 71
9 Construction Material Specifications .......................................................................................................................... 71
10 System Connectivity............................................................................................................................................................ 72
11 Pneumatics Single Acting Standard Flow................................................................................................................. 72
12 SVi1000 Model Numbering .............................................................................................................................................. 72
13 SVi1000 HART® Commands ........................................................................................................................................... 77
14 Command 48 Additional Status Return Bits ............................................................................................................ 78
15 Compliance Voltage for Single Channel Zener with 22 AWG Cable............................................................. 85
16 Compliance Voltage for Galvanic Isolator with 22 AWG Cable ...................................................................... 85
17 Compliance Voltage for No Barrier with HART® Filter and Resistor and 18 AWG Cable................... 86
18 Fault Matrix ............................................................................................................................................................................. 97
19 Tight Shutoff Parameters for High Pressure Liquid Letdown Trim..............................................................108

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 9
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1. Safety Information

This section provides safety information and defines the documentation symbols.

Documentation Symbols
SVi1000 instructions contain warnings, cautions and notes, where necessary, to alert you to
safety related or other important information. Read the instructions carefully before installing
and maintaining your instrument. Total compliance with all WARNING, and CAUTION notices is
required for safe operation.

WARNING Indicates a potentially hazardous situation, which if not avoided could result in
serious injury.

CAUTION Indicates a potentially hazardous situation, which if not avoided could result in
property or data damage.

NOTE Indicates important facts and conditions.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 11
SVi1000 Product Safety
For SVi1000 positioners intended for use with industrial compressed air: Ensure that an
adequate pressure relief provision is installed when the application of system supply pressure
could cause peripheral equipment to malfunction. Installation must be in accordance with
local and national compressed air and instrumentation codes.

General installation, maintenance or replacement

Products must be installed in compliance with all local and national codes and
standards by qualified personnel using safe site work practices. Personal Protective
Equipment (PPE) must be used per safe site work practices.
Ensure proper use of fall protection when working at heights, per safe site work
practices. Use appropriate safety equipment and practices to prevent the dropping of
tools or equipment during installation.
Under normal operation, compressed supply gas is vented from the SVi1000 to the
surrounding area, and may require additional precautions or specialized installations.

Intrinsically Safe Installation

Products certified for use in intrinsically safe installations MUST BE:

Installed, put into service, used and maintained in compliance with national and local
regulations and in accordance with the recommendations contained in the relevant
standards concerning those environments.
Used only in situations that comply with the certification conditions shown in this
document and after verification of their compatibility with the zone of intended use
and the permitted maximum ambient temperature.
Installed, put into service and maintained by qualified and competent professionals
who have undergone suitable training for instrumentation used in such areas.

WARNING Before using these products with fluids/compressed gases other


than air or for non-industrial applications, consult the factory. This
product is not intended for use in life support systems.

WARNING Do not use damaged instruments.

WARNING Installation in poorly ventilated confined areas, with any potential


of gases other than oxygen being present, can lead to a risk of
personnel asphyxiation.

12 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Use only genuine replacement parts which are provided by the manufacturer, to guarantee
that the products comply with the essential safety requirements of the European Directives.

Changes to specifications, structure, and components used may not lead to the revision of
this manual unless such changes affect the function and performance of the product.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 13
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2. Introduction

About This Manual


The SVi1000 Instruction Manual is intended to help an experienced field technician efficiently
install and setup an SVi1000. If you experience problems that are not documented in this guide,
call your local representative, go to www.geoilandgas.com/valves, contact our helpdesk at (+1)
888-784-5463 or email [email protected]. Sales offices are listed on the last page of this
document.

The SVi1000 is a high performance, digital valve positioner that combines a local display with
remote communication and diagnostic capabilities. The SVi1000 offers a multitude of options
that fulfills the broadest range of applications. It also communicates using the HART® protocol.

The local user interface and LEDs enables local operations of calibration and configuration
functions. Remote operations can be performed with ValVue software or any HART® Registered
host interface that has been pre-loaded with the Device Description file (DD) for SVi1000.

Conventions Used in This Manual


Conventions used in this manual are as follows:

Uppercase, italicized letters are used when referencing a term used in the SVi1000
display window. For example, when indicating the term mode, as in setup mode, and
referring to the display/software operation the convention is to spell mode is all
uppercase letters: MODE.
Italics is used for emphasis on important items.
Fields where data is entered or user-entered data is italicized.
Actions performed on buttons, checkboxes, etc. appear bolded. For example: Click Done.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 15
ValVue Software
This section generally discusses the ValVue software that can be used to configure the
SVi1000 from a HART® configured laptop.

NOTE A cloning feature is available for the SVi1000 positioner. Cloning


transfers the configuration and calibration parameters from one
device to another. Cloning operations are to be performed only by
GE personnel or qualified channel partners trained on properly
performing the cloning function. This feature is not available
during normal ValVue operation. Contact GE or a channel partner
for more information.

System Requirements
Minimum requirements for all versions of ValVue software are:

Windows® 2003 Server (SP3), Windows® 2008 Server (SP2), XP, Windows® 7,
Windows® 8, Windows® Server 2012
64 MB RAM
Hard drive available space 1 G
A serial or USB port connected to a HART® modem with appropriate cable (or
Bluetooth)
For software installation, a connection to the internet to download ValVue and the
SVi1000 DTM.

16 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
ValVue and SVi1000 DTM Trial Version
You must download the ValVue software and the SVi1000 DTM software, then install to
configure and use the SVi100. See “ValVue and SVi1000 DTM Software Installation” on
page 27.

The SVi1000 DTM software and the ValVue software comes with a trial version of ValVue. For
60 days after the initial installation, The ValVue software provides the FDT frame capability in
which the SVi1000 DTM software operates. The SVi1000 DTM software provides the capability
of configuring, calibrating, diagnosing, trending and much more. After the 60 day trial period
ValVue must be registered for continued use. The SVi1000 DTM software functionality
includes:

Setup Wizard Remote display of valve position, actua-


tor pressure (s)
Set calibration parameters Set configuration parameters
Monitor status⁄error indicators Input/Output configuration
Remote calibration of the SVi1000 Remote configuration of the SVi1000
Remote operation of the SVi1000 Backup and restore configuration
Trend setpoint, valve position, actuator
pressure

Operational Overview
The SVi1000 is a smart electro-pneumatic positioner that receives a 4 - 20 mA electrical
position setpoint signal from the controller and compares the position setpoint input signal to
the valve position feedback sensor. The difference between the position setpoint and position
feedback is analyzed by the position control algorithm that sets a servo signal for the I/P
converter. The output pressure of the I/P is amplified by a pneumatic relay that drives the
actuator. Once the error between the setpoint and the valve position feedback is within range,
no other correction is applied to the servo signal in order to maintain valve position.

The local user interface and LEDs provide configuration or calibration mode in all operating
environments.

The optional position retransmit version transmits the actual position via 4 - 20 mA signal to a
supervisory system.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 17
SVi1000 Features
The SVi1000 positioner (see Figure 1 on page 19) is suitable for installation indoors or
outdoors, and in a corrosive industrial or marine environment and is equipped with the
following features:
Extreme accuracy and reliability
Extreme digital precision
Preset values for quick configuration
Automated valve commissioning
Precise, quick, responsive control of valve position
One model for rotary or reciprocating valves
Local operation⁄calibration⁄configuration with a local user interface and LEDs
Compatible with air-to-close or air-to-open actuators
Non-contact magnet coupled (Hall Effect) position sensing for rotary and reciprocating
control valves
Sealed housing with no moving shafts, no shaft penetration, and fully potted
electronics
Digital switches (optional)
Position retransmit (optional)
Split range capability
User-adjustable response times
Configurable High and Low Position Limits
Characterize stroke
Linear
Equal Percentage 50:1 and Equal Percentage 30:1
Quick Opening
11 Point Custom Characterization
Camflex* Percentage
Valve Position Autotuning (not required if presets used)
Optimized performance regardless of actuator size
Linearity compensation for actuator linkages with ValVue software
User-configurable Tight Shutoff at Adjustable Input Signal
HART® compatible
HART® remote operation, calibration, and configuration using ValVue software or a
HART® handheld communicator, and any HART® compatible host

18 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Functionality
All connections to electronic module in the unit are made through the interface board. The
SVi1000 standard interface board has a terminal block with screw connectors.

Optionally, you can order a unit configured with two digital switches or with 4 - 20 mA position
retransmit output.

Figure 1 shows the standard interface and lists below the operator controls for all SVi1000
interfaces.

8 4

1 Auto Find Stops Button and 5 Cancel/ Status Button and


LED 1 LED 4

2 Upper Stop Button and LED 6 Ground


2

3 Auto Tune Button and LED 3 7 Configuration Selection


Switch

4 4- 20 mA Input Signal 8 Open Stop Adjustment


Screw
Figure 1 Operator Controls - Standard

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 19
Figure 2 shows the optional switch interface board and optional gauges.

Solid State
Switch SW #2
(Optional)

Solid State Switch


SW #1 (Optional)

Gauges
(Optional)

Figure 2 Optional Digital Switches and Gauges

Figure 3 shows the optional position retransmit interface board and optional gauges.

4- 20 mA
Output Signal (optional)

Gauges 4- 20 mA
(Optional) Input Signal

Ground

Figure 3 Optional Position Retransmit

20 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Modes
The SVi1000 provides the following modes of operation:

Normal mode
HART® Override mode (Formerly Manual and Setup Modes)
Failsafe mode
Commission Process (Via Local User Interface)
Find Stops via Local User Interface
Manual upper stops adjustment via Local User Interface
Autotune via Local User Interface

The SVi1000 always starts up in the mode that the unit was last in before power down, except
for failsafe mode when the condition causing fail safe has been corrected.

WARNING Always ensure the SVi1000 has returned to Normal mode after
any configuration activity.

Normal Mode In this mode the valve follows the 4-20 mA input signal.
HART® Override mode In HART® override mode, the local user interface buttons are dis-
abled until any button is pushed, then local control is reestablished.
This, from the instrument interface, functions as Manual and Setup
mode from the optional laptop-based software and other HART®
interface tools.
In HART® Override Mode the following tasks are supported over
HART® by ValVue or DTM based interface:

Set Characterization (Linear, Enable or Disable Bumpless Transfer


Equal%(30,50,Camflex), Quick Open and Cus-
tom
Set Near Closed Value Allow Tune to Override limits
Configure Tight Shutoff Set Lower and Upper Position Limits
Configure Position Fault Limits (Position Error Configure Switch I/O
Band and Time 1)
Run Find Stops Run AutoTune (Provided the option is set at
the local user interface)
Perform a Manual Find Stops Set Open Stop Adjustment
Set Valve Position Command valve to full open or closed

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 21
Configuration Selection This switch provides control to the following functions:
Switch
Actuator Air Action
Select autotuned or preset tuning parameters
Auto Find Stops This function automatically sets the lower and upper stops. See
“Auto Find Stops” on page 53 for this procedure.
Open Stop Adjustment Use the Open Stop Adjustment Screw to perform an upper stop
adjustment and save it to the device. See “Open Stops Adjustments”
on page 54 for this procedure.
Autotuning The autotune process determines optimum tuning parameters for
the valve being commissioned. This function is only active when the
Configuration Selector Switch is set to AutoTune. See “Auto Tune” on
page 57 for this procedure.
Failsafe Mode When a fault results in Failsafe mode being activated, the output
pressure of the SVi1000 is set low and the red status LED illuminates
continuously. If the fault is considered self-clearing, then once cor-
rected, the unit returns to Normal mode. If the fault is not self-clear-
ing, then the unit requires a reset after correcting the failsafe
condition.
Commission Processes These are temporary states activated when a local user interface
issued command dictates their use. When the positioner is in a Com-
mission Processes a status light indicates this activity (see “LED Light
Functions” on page 23). Examples of Commission Processes are Auto
Find Stops and Auto Tune. Once a task completes the unit returns to
Normal mode.

22 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
LED Light Functions
Figure 4 shows the local user interface LEDs and explains their patterns and timings.

LED 1 (Green)
LED 2 (Green)
LED 3 (Green)

LED 4 (Red)

Figure 4 SVi1000 LEDs

In Table 1 dots represent an LED being active and dashes represent the LEDs off. The pattern
shown recurs as long as that condition exists.

LED 1
LED 2
LED 3

LED 4

Figure 5 Example LED Pattern

Table 1 LED Light Patterns and Troubleshooting

Indication Pattern

Normal mode LED 1


LED 2
LED 3

Device Alert
LED 1
(Fault mode LED 2
(self-correcting)) LED 3

LED 4

Out of Service LED 1


®
(HART Override LED 2
LED 3
mode)
LED 4

Failsafe mode LED 1


LED 2
LED 3

LED 4

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 23
Table 1 LED Light Patterns and Troubleshooting (Continued)

Indication Pattern

Device is not pow- All LEDs off. Power is not sufficient.


ered or in Low
Power mode

Troubleshooting

Device is not pow- All LEDs off. Power is not sufficient.


ered or in Low
Power mode

Process Failure
or or

Pattern depends on which process failed and repeats until Cancel


button is pushed.

Setting out of If a setting is out of range the associated Green LED flashes at
range twice the rate as normal until an acceptable range is applied.

24 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
3. Installation and Set Up

Overview
CAUTION Prior to beginning the installation process review the safety information at the
beginning of this manual.

CAUTION Refer to “10. Optional Switch Load Limits” on page 89 for guidelines on safely
wiring switch load limits.

Figure 6 shows the unit’s major components for reference.

Pneumatic
Relay
Terminal
Board
(varies by type)
I/P

Electronics
Module

Figure 6 SVi1000 Components

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 25
SVi1000 Dimensions

Figure 7 SVi1000 Dimensions With and Without Gauges

26 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Pre-Installation Issues
Storage
If the SVi1000 is stored for a long duration, you must keep the housing sealed against
weather, fluids, particles, and insects. To prevent damage to the SVi1000:

Use the plugs provided with shipment to plug the ¼ NPT air connections, on the
positioner and on the air filter regulator set.
Do not allow standing water to accumulate.
Observe storage temperature requirements.

WARNING Do not connect a non-intrinsically safe approved PC or HART®


modem to an intrinsically safe circuit except on the safe area side
of the barrier. Do not operate a PC in a hazardous area without
compliance to local and plant regulations.

CAUTION Do not connect a HART® modem and PC to a control circuit


unless the controller is HART® compatible or has a HART® filter.
Loss of control or a process upset may occur if the controller
output circuit is not compatible with a HART® signal.

Unpacking
Exercise care when unpacking the positioner and its mounted accessories. The SVi1000
container includes a Quick Start manual.

ValVue and SVi1000 DTM Software Installation


This section discusses the ValVue software used to configure the SVi1000 from a HART®
configured laptop. Minimum requirements are:
Windows® 7, Windows® Server 2003 SP3, Windows® Server 2008 SP2, Windows® 8,
Windows® Server 2012
64 MB RAM
Hard drive available space 1 G
Available Serial or USB port (or Bluetooth)
A HART® modem and appropriate cables

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 27
ValVue Installation
1. From your web browser and go to the GE Oil and Gas Download Center at:
http://www.ge-mcs.com/en/download.html.
2. On the web page enter items in the pulldowns as in Figure 8 and click Search.

Figure 8 ValVue 3 Search Selections

3. Navigate through the list and find the latest ValVue 3.x FDT Frame Application software, as
in Figure 14.

Figure 9 ValVue 3 Search Results

4. Click the link and Figure 15 appears.

Figure 10 Download Software Terms

28 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
5. Review the information and click I Accept and Figure 16 appears.

Figure 11 Registration Form

6. Enter the required information in all fields, click Submit and Figure 17 appears.

Figure 12 Ready to Download

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 29
7. Click the link and Figure 18 appears.

Figure 13 DTM Download

8. Click Save File to automatically save to your Windows® Downloads folder.


9. Open the Downloads folder, double-click the zip file, then double-click the .exe and follow
the system prompts to install. Once installed, along with the SVi100 DTM file you are able
to access the online help.

SVi1000 DTM Installation


1. Open your web browser and go the GE Oil and Gas Download Center at:
http://www.ge-mcs.com/en/download.html.
2. On the web page and enter SVi1000 DTM Software in the Search for a particular product
field and click Search. Navigate through the list and find the DTM software as in Figure 14.

Figure 14 SVi1000 DTM Search Results

3. Click the link and Figure 15 appears.

30 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Figure 15 Download Software Terms

4. Review the information and click I Accept and Figure 16 appears.

Figure 16 Registration Form

5. Enter the required information in all fields, click Submit and Figure 17 appears.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 31
Figure 17 Ready to Download

6. Click the link and Figure 18 appears.

Figure 18 DTM Download

7. Click Save File, click OK and it automatically saves to your Windows® Downloads folder.
8. Open the Downloads folder, double-click the SVi1000_DTM_Installer zip file, then
double-click the .exe and follow the system prompts to install. Once installed, along with
the ValVue file you are able to access the online help.

32 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Mounting and Wiring
This section describes how to mount and wire the SVi1000, which includes:

“Step 1: Mounting the SVi1000” on page 34.


“Step 1: Mounting the SVi1000 on Rotary Valves” on page 35
“Step 1: Mounting the SVi1000 on Reciprocating Valves” on page 39
“Step 2: Connecting the Tubing and Air Supply” on page 43
“Step 3: Wiring the SVi1000” on page 44

WARNING Failure to adhere to the requirements listed in this manual may


cause loss of life and property.

Before installing or using this instrument, READ THE


INSTRUCTIONS CAREFULLY. Refer to “9. Wiring Theory for an
SVi1000” for detailed instructions.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 33
Step 1: Mounting the SVi1000
This guide provides installation instructions for mounting an SVi1000 on both rotary and
reciprocating style valves. The mounting process can be broken down into the following:

1. Attach the mounting bracket to the actuator.


2. Install the magnetic assembly.
3. Assemble the SVi1000 on the mounting bracket.

CAUTION The SVi1000 cover must be in place and secured using all four
screws during operation.

NOTE Mount the SVi1000 with the conduit connection down in order to
facilitate drainage of condensate from the conduit.

Necessary Precautions

To avoid injury or the process being affected when installing or replacing an SVi1000
positioner on a control valve, ensure that:

If the valve is located in a hazardous area, ensure the area has been certified as safe or
that all electrical power to the area has been disconnected before removing any
covers or disconnecting any leads.
Shut off air supply to the actuator and to any valve mounted equipment.
Ensure the valve is isolated from the process by either shutting off the process or using
bypass valves for isolation. Tag shutoff or bypass valves to guard against a turn-on
while work is in progress.
Bleed air from actuator and check that valve is in its de-energized position.

For the procedure to install rotary and reciprocating mounting kits on valves, refer to the
instructions contained in the valve’s mounting box kit.

34 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Step 1: Mounting the SVi1000 on Rotary Valves

This section describes the procedure for mounting the SVi1000 on rotary control valves that
have less than 60° rotation, such as the Camflex*.

Figure 19 shows the kit components.

Mounting Bracket

Mounting
Extension
Screw
Magnet

Figure 19 Rotary Kit Components

Figure 20 shows a side view of a Camflex actuator, the SVi1000, and a mounting bracket.

SVi1000

Rotary
Actuator

Mounting
Bracket

Figure 20 Camflex with Mounting Bracket (Side View)

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 35
Tools required:

M5 Hex Key
M4 Hex Key
M3 Hex Key

To mount the SVi1000:

1. Attach the mounting bracket to actuator (Figure 21).

Mounting
Bracket

Mounting
Long Side Holes

Flat Head Socket Cap Mount the long end of the


Valve Position mounting bracket to the
Screw, 5/16"-18UNC X Take Off Shaft left when facing the
0.62" Long actuator, if possible.
Figure 21 Rotary Mounting Bracket to Valve Actuator

2. Bolt the extension shaft to the valve position take-off shaft (Figure 22).

Magnet Holder
Assembly Tighten the M4
screw (one shown)
Extension
Shaft Install with a
flat head socket
Valve Position cap screw,
1/4"-28 UNF
Take Off Shaft

Figure 22 Extension Shaft to the Valve Position Take-off Shaft

36 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Internal valve pressure The valve plug shaft is pushed out to the mechanical stops, usually a
thrust bearing. On valves where the valve position take-off is
mounted directly on the end of the plug shaft, a Camflex for exam-
ple, the shaft must be bearing on its stop to properly set up the
SVi1000 positioner. During hydrostatic testing the shaft is thrust to
its stop and a normally tightened packing retains it in that position.
Vacuum service The valve shaft is drawn into the body by the vacuum acting on the
shaft, but the magnetic coupling must be assembled flush with the
mounting bracket.
3. Perform magnet install and travel sensor alignment by:
a. Sliding the magnet holder into the extension shaft. The magnets are in the magnet
holder ring. The magnetic axis is the imaginary line through the center of both
magnets.
b. Rotating the magnet holder so that the magnet axis is vertical when the valve is in the
closed position (Table 2). If mounting kit is installed on fail-open valve, apply air to the
actuator to close the valve before installing magnet holder.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 37
Table 2 Travel Sensor Alignment

Rotary Stroke Direction Magnet Valve Position Sensor Counts


Mounting Orientation
System

Rotary <60° Rotation Closed (0%) 0 +/- 1000


Clockwise or counter-
clockwise rotation

(0°)

>60° Rotation Full Open -8000 +/- 1500


Clockwise with increas- or or
ing setpoint Full Closed +8000 +/- 1500

(-45°)

>60° Rotation Full Open -8000 +/- 1500


Counter Clockwise or or
rotation with increasing Full Closed +8000 +/- 1500
setpoint

(+45°)

General Rule for Any amount of rotation 50% Travel 0 +/- 1000
other configu- Clockwise or counter- (Mid-Stroke)
rations clockwise

(0°)

c. Aligning the end of the magnet holder flush with the end of the mounting bracket.
Secure the magnet holder with two M4 set screws.
d. Sliding the V-Seal over the magnet holder. You can also check the magnet using
ValVue software by reading sensor counts and comparing them to Table 2.
4. Secure the SVi1000 onto the mounting bracket using four M6 x 20 mm socket head cap
screws.
5. Ensure no interference exists with the position sensor protrusion.

38 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
6. Ensure that the V-Seal makes contact with the skirt around the alignment ring on the
SVi1000 (Figure 23).

CAUTION Do not carry the positioner by the alignment ring.

Align the end of the magnet holder assembly with the end of the mounting
bracket

Alignment ring
V-seal in contact V-seal
with alignment ring

Figure 23 Camflex V-Seal

Step 1: Mounting the SVi1000 on Reciprocating Valves

This section describes the procedure for mounting the SVi1000 on Reciprocating Valves, using
Masoneilan’s 87⁄88 Multi-Spring actuators as an example. Figure 24 on page 39 shows the
standard lever for all size installations. See “Integrated Magnet Assembly” on page 42 for the
optional IM assembly. Tools required:

7⁄16" Combination Wrench (2 required) 3⁄8" Combination Wrench


1⁄2" Combination Wrench Phillips Head Screw Driver
M4 Hex Key M3 Hex Key

1. Mount the standard reciprocating mounting bracket to the valve using two (2) 5⁄16 - 18
UNC cap screws.

Figure 24 Reciprocating Valve Mounting Bracket for Standard Lever

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 39
2. Ensure that the lever is pinned to the magnet assembly and held securely by an M5 flat
head screw to ensure that the magnet axis is vertical when the lever is in the valve closed
position. Tighten the lever screw securely (Figure 25).

M5 Flat head screw


to install lever.

D
C
B
A

Figure 25 Magnet Holder and Standard Lever for Reciprocating Valves

3. Select mounting hole for the stroke of the valve. Unless otherwise specified, the SVi1000
mounting assumes that the actuator is in the normal upright position. The mounting hole
in the slotted opening of the mounting bracket must be left when facing the actuator, with
the actuator in the upright position.

Table 3 Reciprocating Valve Mounting Hole and Turnbuckle Length

Masoneilan Stroke Mounting Lever Turnbuckle


Actuator Size Hole Hole Length
87/88

6 and 10 0.5 - 0.8" A A 1.25"


(12.7 - 20.32 mm) (31.75 mm)

10 0.5 - 0.8" A A 1.25"


(12.7 - 20.32 mm) (31.75 mm)

10 >0.8 – 1.5" B B 1.25"


(20.32 - 41.5 mm) (31.75 mm)

16 0.5 - 0.8" B A 2.90"


(12.7 - 20.32 mm) (73.66 mm)

16 >0.8 – 1.5" C B 2.90"


(20.32 - 41.5 mm) (73.66 mm)

16 >1.5 – 2.5" D C 2.90"


(41.5 - 63.5 mm) (73.66 mm)

23 0.5 - 0.8" B A 5.25"


(12.7 - 20.32 mm) (133.35 mm)

23 >0.8 – 1.5" C B 5.25"


(20.32 - 41.5 mm) (133.35 mm)

40 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 3 Reciprocating Valve Mounting Hole and Turnbuckle Length (Continued)

Masoneilan Stroke Mounting Lever Turnbuckle


Actuator Size Hole Hole Length
87/88

23 >1.5 – 2.5" D C 5.25"


(41.5 - 63.5 mm) (133.35 mm)

4. Thread the take-off rod to the actuator stem connector (Figure 26).

Magnet
Housing
Install 1/4-20 x 1 Nut
Install 1/4-20 x
1 Cap Screw

Turnbuckle Length Right Hand Rod End


as per Table 3

Left Hand Rod End: Install 1/


Take Off Rod 4-20 x 1 Nut and Cap Screw

Figure 26 SVi1000 Take Off Rod Mounting

5. Attach the right hand threaded rod end to the lever using a 1⁄4 - 20 x 1" cap screw and nut
(Figure 26).
6. Thread the right hand lock nut and turnbuckle onto the right hand rod end approximately
two turns. Turnbuckle length is a function of actuator size. Refer to Table 3 on page 40.
7. Secure the magnet housing assembly, including the lever and right hand rod end, to the
bracket using four M5 X 10 mm flat head screws.
8. Attach the left hand threaded rod end to the take-off rod with 1⁄4 - 20 UNC nut and thread
the left hand lock nut onto the rod end.
9. Move the valve to its closed position. For air to:
Close: Requires using air pressure in the actuator to fully stroke the actuator.
Open: Vent the actuator of air pressure.
10. Thread the turnbuckle onto the left hand threaded rod end (Figure 26).
11. Adjust the turnbuckle until the hole in the lever is aligned with the alignment hole in the
bracket. Tighten both turnbuckle lock nuts (Figure 26).
12. Ensure the adjustable link turnbuckle is parallel to the valve stem. Verify that the hole in
the lever aligns with the alignment hole in the bracket when the valve is in the closed
position. Check that the bracket is mounted using the proper holes (Figure 27).

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 41
Mounting Holes
Mounting
Slot
Align lever with
alignment hole

Figure 27 Ensure Position Linearity

13. Mount the SVi1000 to the bracket and secure with four M6 socket head cap screws.

Integrated Magnet Assembly


The IM (Integrated Magnet) assembly kit is an optional assembly intended for custom
mounting by the end user for reciprocating actuators (Figure 28). This kit allows for more
leeway in installation.

A
B

Figure 28 SVi1000 Lever Installed to IM Assembly

NOTE You can use a custom bracket with the IM option. Refer to drawing
#720012413 for assistance.

42 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Step 2: Connecting the Tubing and Air Supply
To connect the air supply:

1. Install the tubing to the air supply port. Minimum tubing diameter 1⁄4" (Figure 29).

Actuator
Connection
1/4" NPT

Supply
Connection
1/4" NPT

Conduit
Connection

Figure 29 Air Ports

2. Pipe the output air from the output pressure port to the actuator. Minimum tubing
diameter: 1/4".

NOTE The SVi1000 is designed to operate with clean, dry, oil-free,


instrument grade air to ANSI-ISA-57.3 1975 (R1981) or
ISA-S7.3-1975 (R1981).

3. Ensure the air supply falls within the parameters in Table 4.

Table 4 Air Supply Requirements

Dew Point At least 18° F (10° C) below minimum anticipated ambient temperature

Particulate Matter Filtered to 5 microns

Oil Content Less than 1 ppm w/w

Contaminants Free of all corrosive contaminants

4. Supply clean, dry compressed air to the filter regulator.


5. Turn on the air supply.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 43
6. Adjust the filter regulator.
Supply pressure must be a minimum of 5 psi above the spring range of the actuator but
may not exceed the rated actuator pressure. Refer to the valve or actuator instruction
manual.

Step 3: Wiring the SVi1000

WARNING Comply with current national and local regulations for electrical
installation work.
Before carrying out any work on the device, power off the
instrument.

CAUTION Improperly or inadequately grounded installations can cause


noise or instability in the control loop. The internal electronic
components are isolated from ground. Grounding the case is
unnecessary for functional purposes but grounding the case may
be necessary to conform to local codes.

Refer to “10. Optional Switch Load Limits” on page 89 for


guidelines on safely wiring switch load limits.

Wiring Guidelines

Guidelines for a successful implementation of DC current signal, DC power, and HART®


communication to the SVi1000:

Compliance voltage at the SVi1000 is approximately 9 V at the current of 20 mA.


Signal to the SVi1000 must be a regulated current in the range 3.2 to 22 mA.
Controller output circuit must be unaffected by the HART® tones which are in the
frequency range between 1200 and 2200 Hz.
In the frequency range of the HART® tones, the controller must have a circuit
impedance of more than 220 Ohms, typically 250 Ohms.
HART® tones may be imposed by the positioner and a communication device located
anywhere on the signaling circuit.
Cabling must be shielded to prevent electrical noise that would interfere with the
HART® tones, with the shield grounded.
Shield must be properly grounded in only one place.
For details and calculation methods for wiring resistance, and capacitance and for
calculation of cable characteristics, refer to the HART® FSK Physical Layer
Specification.
For split range installations the output voltage must be sufficient to operate two
positioners (11 V @ 4 mA, 9 V @ 20 mA) and the expected voltage drop in the cable.

44 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Use of a low impedance voltage source damages the SVi1000. The current source
must be a true high impedance current limiting device. A proper current source
explicitly enables adjustment of the current, not the voltage.
When wiring a position retransmit:
Use the same gauge wires as the 4-20 mA control loop.
Ensure that the position retransmit signal is connected to the control system’s
analog input card.
Ensure the control loop is powered while making make measurements with a meter.

WARNING This process can cause the valve to move. Before proceeding be
sure the valve is isolated from the process. Keep hands clear from
moving parts.

Wiring an SVi100 Unit

Tools required:

Wire stripper
Flat head screwdrivers for cover and connectors

To connect:

CAUTION For proper operation, maintain signal polarity + and - respectively.

CAUTION You must read “10. Optional Switch Load Limits” on page 89
before proceeding. The load across these switches must conform
to the limits described in that discussion.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 45
1. Loosen the four (4) cover screws and remove the SVi1000 cover (Figure 30).

Figure 30 Front Cover

2. Connect the 4 - 20 mA input signal and the optional switches or position retransmit by:
a. Stripping the insulation at the end of both wires 0.43" / 11 mm.
b. Inserting the stripped end of the wires fully in to the appropriate terminal. Loosen the
terminal screw if required to insert the wire.
Refer to the label next to each screw terminal to determine the function of the terminal
and correct polarity (see Figure 31 for 4 - 20 mA connections and Figure 32 on page 47 on
for position retransmit).

Optional Solid
State Switches

4- 20 mA
Input Signal

Ground

Figure 31 Connections to Electronics Module with Switches


(via Interface Board)

46 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
4- 20 mA Output Signal
(Retransmit signal)

4- 20 mA Input Signal
(4 - 20 mA Control Loop)

Ground

Figure 32 Connections to Electronics Module with Position Retransmit


(via Interface Board)

3. Tightening the terminal screws (to a torque of 5 to 7 lb·in).


4. Proceed to “4. Check Out and Power Up”. Refer to “Troubleshooting Connections” if you
want to check the validity of your connections.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 47
Troubleshooting Connections

Basic Unit/Optional Switches Unit

To troubleshoot control loop connections:

1. Connect a DC voltmeter across the input terminals.


For an input current between 4 and 20 mA the voltage varies between 11V and 9 V
respective.
If voltage exceeds 11 V check that polarity is correct.
If the polarity is correct but the voltage is less than 8.05 V, then the current source
voltage is not compliant.
2. Verify that source can supply 20 mA to SVi1000 input. If 20 mA is not attainable,
troubleshoot the source.

Position Retransmit Units

To troubleshoot control loop connections:

1. Connect a DC voltmeter across the input and output terminals.


For an input current between 4 and 20 mA the voltage varies between 11V and 9 V
respective.
If voltage exceeds 11 V check that polarity is correct.
If the polarity is correct but the voltage is less than 8.05 V, then the current source
voltage is not compliant.
2. Verify that source can supply 20 mA to SVi1000 input. If 20 mA is not attainable,
troubleshoot the source.

To troubleshoot retransmit connections:

Ensure that the retransmit circuit has a minimum input voltage of 10 V


(maximum 30 V).
Ensure the minimum retransmit current is 3.2 mA. If the SVi1000 positioner loses power
and the retransmit circuit remains powered, the AO signal will be 3.2 mA.

48 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
4. Check Out and Power Up

Overview
This section provides the calibration procedures to ensure proper valve positioning, including:

1. “Step 1: Inspect the Actuator, Linkages, or Rotary Adapter” on page 50


2. “Step 2: Verify Mounting and Linkage Adjustment” on page 50
3. “Step 3: Checking the Magnet” on page 50
4. “Step 4: Checking the Air Supply” on page 51
5. “Step 5: Verify Wiring Connections” on page 52
6. “Step 6: Configuration” on page 53
NOTE Perform all procedures in this section before putting the SVi1000 into
operation.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 49
Step 1: Inspect the Actuator, Linkages, or Rotary Adapter
1. Verify that the mounting has not been damaged in shipment for a pre-mounted SVi1000,
physically inspect the actuator and linkage.
2. Record the following information for the configuration checkout:
Valve Air to Open (ATO) or Air to Close (ATC)
Actuator pressure rating
Actuator spring range
Inherent trim characteristic of the control valve; linear, equal percentage, or other.

NOTE Refer to the valve data sheet or control valve model number.

Step 2: Verify Mounting and Linkage Adjustment


Inspect the mounting and make any needed adjustments before running the positioner and
checking the digital configuration.

Step 3: Checking the Magnet


There are two methods of checking the SVi1000 magnet:

“Perform a Visual Inspection” on page 50


“Use ValVue to Check Magnet Position” on page 51

Perform a Visual Inspection

Rotary Valves

Ensure that mounting has been performed as per “Step 1: Mounting the SVi1000 on Rotary
Valves” on page 35.

Reciprocating Valves
1. Ensure the adjustable link turnbuckle is parallel to the valve stem.
2. Ensure proper mounting by verifying that the hole in the lever aligns with the alignment
hole in the bracket when the valve is in the closed position. Ensure the bracket is mounted
using the proper holes (see Table 3 on page 40).

50 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Use ValVue to Check Magnet Position
To check the magnet using ValVue:

1. Connect to the positioner in accordance with the ValVue instructions.


a. Ensure the positioner has been installed and set up with a HART® modem in a HART®
compliant communications loop, if required, install ValVue on the computer that is
connected to the HART® modem.
b. Run ValVue.
c. Select the installed positioner from the list of connected devices.
d. Select the Raw Data tab to view the current operating conditions of the selected
positioner.
2. Read Raw Position data. When the valve is:
Closed, the value should be between – 1000 and +1000 for a reciprocating valve or a
60° rotation rotary valve.
At mid-travel, the value should be between –1000 and +1000 for a greater than 60°
rotation rotary valve.

Step 4: Checking the Air Supply


To check the air supply:

1. Turn on the air supply.


2. Adjust the filter regulator.
3. Supply pressure must be a minimum of 5 psi greater than the spring range of the actuator
but may not exceed the rated actuator pressure. Refer to the valve or actuator instruction
manual.
4. Inspect the tubing connections between the filter-regulator and the positioner for leaks.
5. Verify that the tubing is not bent or crushed.
6. Verify that all fittings are leak tight.

CAUTION Do not use Teflon pipe seal tape. The Teflon tape can shred into
particles that are harmful to the pneumatic components.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 51
Step 5: Verify Wiring Connections
NOTE For split range installations the output voltage must be sufficient
to operate two positioners (11 V @ 4 mA, 9 V @ 20 mA) and the
expected voltage drop in the cable. See “Split Range Applications”
on page 82 for more information.

Use the following procedure to ensure that the SVi1000 is properly powered:

1. Connect a DC voltmeter across:


The input terminals for a basic switch or switch option unit.
The In and Out terminals for a position retransmit unit.
For an input current between 4 and 20 mA the voltage varies between 11V and 9 V
respectively.
When voltage exceeds 11 V check that polarity is correct.
If voltage is less than 9 V and polarity is correct, voltage compliance of current
source is inadequate.
2. Connect a milliampmeter in series with the current signal.
3. Verify that source can supply 20 mA to SVi1000 input. If 20 mA is not attainable,
troubleshoot the source.

NOTE Improperly or inadequately grounded installations can cause


noise or instability in the control loop. The internal electronic
components are isolated from ground. Grounding the case is
unnecessary for functional purposes but grounding the case may
be necessary to conform to local codes.

52 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Step 6: Configuration
This section describes configuration using the local user interface pushbuttons and the preset
switches available on the unit. You can also use ValVue and a PC with a HART® modem or a
HART® Handheld Communicator. Prior to changing the SVi1000 configuration, check the
existing configuration.

Use the procedures that follow to: run auto stops, run open stop adjustment and perform
preset or auto tune.

WARNING These procedures can cause the valve to move. Before proceeding
be sure the valve is isolated from the process. Keep hands clear
from moving parts.

NOTE All calibration and configuration procedures are described using


the SVi1000 local user interface. See “ValVue Software” on
page 16 for an overview of ValVue software functions.

Auto Find Stops


To perform auto find stops:

1. Set the air action (0-7 for ATO or 8-F for ATC).
2. Press auto find stops button until green LED 1 illuminates, then release (approximately 2
seconds to turn on and release before 7 seconds). The unit goes into a Commission Process
and green LED 1 blinks until the process completes. The auto find stops process occurs.
When the process is complete, the unit automatically returns to Normal mode.
Press Cancel to abort the process and the green LED 1 goes off, the device returns to
Normal mode and no changes occur.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 53
Open Stops Adjustments
To perform auto find stops:

1. Press the upper stop adjustment button for two to seven seconds, until green LED 2
illuminates, then release. Green LED 2 flashes.
2. Move the valve to the desired location via the Open Stop Adjustment Screw (Figure 33).

Upper Stop
Button and
LED 2

Open Stop
Adjustment
Screw

Cancel
Button and
LED 4

Figure 33 Open Stop Adjustment Screw

3. Press the upper stop adjustment button for more than two seconds.
The green light goes off, the new stop is saved in the device and the unit is put into Normal
mode.
Press Cancel to abort the process and the green LED 1 goes off, the device returns to
Normal mode and no changes occur.

Tuning
Methods for tuning the SVi1000:

Presets; The fastest is to use a preset tuning for the actuator in use ( “Preset Tune” on
page 55). Using presets saves time as you do not run Auto Tune.
Auto Tune: If desired, run Auto Tune ( “Auto Tune” on page 57).
PID Settings: The third method is to manually tune PID settings for fine tuning, if
desired. See the online help.

54 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Preset Tune

Preset tuning is done according to valve/actuator size. Figure 34 shows the graphic that
appears on the local user interface. As valve size increases values increase from 1 to 7 and 9
to F. 0 and 8 are reserved for auto tuning ATO and ATC valves, respectively.

Preset tuning becomes active immediately.

Gain
increases as
the tuning
value
increases.

Figure 34 Preset Tuning Values

To use preset tuning values:

Use the Configuration Selection Switch to select a preset tuning value (Figure 35).

Cancel
Button
and LED 4

Configuration Selection
Switch

Figure 35 Configuration Selection Switch

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 55
Table 5 gives a a guideline for setting the Configuration Selection Switch with regard to
actuator size.

Table 5 Actuator Settings Configuration Selection Switch Guidelines

ATO ATC Actuator Examples


Size

1 9 Small 1) 4.5" Camflex (7-15 SR)

2 A 2) 6" Camflex (7-15 SR)

3a) #6, 87(ATC), 3-15 SR


3b) #6, 88(ATO), 11-23 SR
3 B
3c) #10, 87 (ATC), 3-15 SR
3d) #10, 88(ATO), 11-23 SR

4a) #6, 87(ATC), 6-30 SR


4b) #6, 88(ATO), 21-45 SR
4 C
4c) #10, 87 (ATC), 6-30 SR
4d) #10, 88(ATO), 21-45 SR

5a) #16, 87(ATC), 3-15 SR


5b) #16, 88(ATO), 11-23 SR
5 D
5c) #23, 87 (ATC), 3-15 SR
5d) #23, 88(ATO), 11-23 SR

6a) 7" Camflex, 7-24 SR


6 E
6b) 9" Camflex, 7-24 SR

7a) #16, 87(ATC), 6-30 SR


7b) #16, 88(ATO), 21-45 SR
7 F Large
7c) #23, 87 (ATC), 6-30 SR
7d) #23, 88(ATO), 21-45 SR

56 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Auto Tune

Auto Tune takes three to ten minutes and strokes the valve in large and small steps to set the
PID positioning parameters for best response to an input signal change.

This procedure overrides any previous configuration done using presets.

To auto tune the SVi1000:

1. Set the Configuration Selector Switch to the auto tuning parameter (Figure 36):
0 for an ATO valve (Air to Open application)
8 for an ATC valve (Air to Close application).

Autotune
Button and
LED 3

Cancel
Button and LED 4

Configuration
Selection
Switch

Figure 36 Configuration Selection Switch

2. Press the Autotune button until green LED 3 lights, then release (approximately 2 to 7
seconds). The unit goes into a Commission Process and green LED 3 blinks.
When the autotune process is complete the unit automatically returns to Normal mode.
Press Cancel to abort the process and the green LED 3 goes off, the device returns to
Normal mode and no changes to the tuning parameters occur.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 57
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5. Full Wizard

Full Wizard Screen


From the Full Wizard screen you can rapidly setup the SVi1000 by configuring some basic
parameters. You can set the device identification, perform a travel calibration, and autotune the
positioning parameters. When the selected tasks are started a progress screen appears. To
customize the valve setup refer to the Calibration Manual Tune screen in the SVi1000 DTM help.
You can either run the entire wizard or pick and choose which components to run.

To run the Full Wizard you must first be in Setup mode.

Full Wizard Screen


Running the Full Wizard is one way to set up the SVi1000. When you decide to run the setup you
can either run the entire wizard or pick and choose which components to run. This wizard has
the advantage of accessing diagnostics tests, which is useful for troubleshooting and during
initial commissioning. If you choose not to use the Full Wizard, you can use the procedures it
accesses to configure the following separately:

Calibration Range screen to run Find Stops and Open Stop Adjustment
Calibration Autotune screen
Calibration Manual Tune screen
Calibration Calibration screen
Run diagnostics on the using the Diagnostics screen, including the Step Test.

The Device Information and Position fields are configurable when checked in the fields to the
right.

The valve must be Out-of-Service and isolated from the process


during this process.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 59
Procedures (e.g. Find Stops, Auto Tune, Step Test, Ramp Test)
should NOT be invoked if the ValVue sequencer is running.

Figure 37 Full Wizard Screen: Device Info

60 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Buttons and Fields

Procedure Area

No. Displays the number of the procedure.

Procedure Name Displays the procedure as listed on the tab where fields are configured. Use the
and checkbox checkbox to activate the procedure for use by the wizard. The options (except
Change Device Mode) are inactive until Setup mode is active. These options include:
1 Device Information:
Set Tag: Sets the physical device tag.
Descriptor: Enter a description for the device.
Message: Enter a device-related message.
Date: Enter date the device placed in service, etc.
Air Action: Displays the device air action that is factory set.
7 Long Tag (HART®6/7 only): Enter a tag for a HART® 7 device. This appears
only if connected to a HART® 7 device.
2 Find Stop: Runs all Find Stops operations. Click Edit Settings to open the Cali-
bration Range screen to configure settings.
3 Auto Tune: Runs all Auto Tune procedures, including; Aggressiveness and Sup-
ply Pressure. See Calibration Autotune screen in GEA31427 Masoneilan SVi1000
DTM Software Instruction manual.
4 Position: Sets the position related parameters as described on the Configura-
tion Position screen in GEA31427 Masoneilan SVi1000 DTM Software Instruction
manual.
5 Step Test: Runs a Step Test. See Diagnostics Start Step Test in GEA31427
Masoneilan SVi1000 DTM Software Instruction manual.
6 Ramp Test: Runs a Ramp Test. See Diagnostics Start Ramp T est in GEA31427
Masoneilan SVi1000 DTM Software Instruction manual.
7 Change Device Mode: Changes the positioner to mode selected in the Apply
Mode field.

Status Displays a progress bar during execution for each selected item.

Check All Click the checkbox to select/deselect all Procedure Name items.

Parameter Area

No. Displays a number for each parameter associated with the Procedure Name
selected in the procedure area.

Parameter Lists the parameters associated for the Full Wizard for the Procedure Name selected.

Value Lists the parameter value read from the tab where it is configured.

Click the button and you are taken to the tab where the values are input. Return to
the Full Wizard tab to continue the process.
Edit the settings
button

Full Wizard Graph Displays a graph of % (percentage of the procedure complete) vs. Time with Supply
Pressure (red) and Position (blue) traces during the procedure.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 61
General Graph functionality
All graphs have some common functionality, including:
Click-and-hold on any axis’ legend to drag along the axis.
Press the CTRL button and mouse drag to zoom/unzoom on the graph.
Right-click menu: There is a menu available by right-clicking any axis that has
three selections:
Tracking Enabled: Enables/disables tracking.
Update Resume Values: Store the axis scale for the Tracking Enabled. The
next time Tracking Enabled is engaged, the tracking restores the axis to the
stored scale instead the initial scale.
Zoom to Fit: Activates a function that sizes the graph to fit the selected dis-
play area.

Full Wizard Log Displays basic information about test run time and device, along with test-related
messages and outcome.

Click to begin execution of configured items.

Execute Full Wizard


button

Run the Full Wizard


To run the Full Wizard:

1. Set the Current Slot to either 0 for ATO or 8 for ATC.

This procedure moves the valve.

Procedures (e.g. Find Stops, Auto Tune, Step Test and Ramp Test)
should NOT be invoked if the ValVue sequencer is running.

1. Place the system in Out of Service mode.


2. Click an item in the Procedure Name list or click Check All.
3. Click and individual line in the Procedure Name list and the items related to that appear in
the Parameter Area.
4. Click and the tab related to the settings appears.

62 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
5. Enter values into fields as required.
6. Repeat steps 3, 4 and 5 as required.
7. Click and the wizard commences.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 63
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6. Operation and Maintenance

Principle of Operation
The SVi1000 Electro Pneumatic Valve Positioner receives an electrical position setpoint signal
from a controller or other device and compares the position setpoint input signal to the valve
position. The difference between the position setpoint and position feedback is interpreted by
the position control algorithm. This is used to compute a new output pressure. This output
pressure is amplified by a pneumatic relay that drives the actuator. When the valve position
agrees with the value called for by the position setpoint input signal the system stabilizes with no
further movement of the actuator.

Figure 38 Block Diagram with I/P Converter

Physical and Operational Description


The SVi1000 is housed in an industrial, tough, weatherproof, corrosion resistant polycarbonate
housing. Electrical connections are made through two 1/2" NPT conduit entries. Pneumatic
connections are made through two or three ¼" NPT ports.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 65
Electronics Module
The Electronics module consists of an electronic circuit encapsulated in a housing. The
electronics include a multiplexer, A/D, D/A, temperature sensor, Hall-Effect magnetic position
sensor, pressure sensors, a micro controller, and a power management/distribution circuit.
The programs controlling the SVi1000 positioner are stored in a flash memory that allows for
the downloading of upgraded firmware.

A separate non-volatile memory stores configuration information, and continuous diagnostic


results. Expansion capabilities include two digital software switches and manifold gauges.
Using the internal programmed positioner algorithm, the CPU computes the required output
based on information received from the measurement sensors.

Magnetic Position Sensor

A non-contact sensor uses a magnetic field to transfer the position through the wall of the
housing, without penetration, to sense the valve position. A Hall effect device, sealed within
the electronics housing, senses the rotation of a magnetic assembly mounted on the end of a
rotary valve shaft or on a driven linkage mounted on a reciprocating valve.

The output of the Hall sensor provides the position feedback signal to the position control
algorithm. The magnetic assembly is environmentally sealed and is entirely external to the
electronics housing. (See Figure 38 on page 65.) The Hall effect sensor has a maximum travel
range of up to 140° rotation.

Position Retransmit
The position transmission option provides a 4 - 20 mA signal proportional to valve position
transmitted on a separate pair of leads.

The 4-20 retransmit signal is galvanically isolated from the 4-20 input on the main board.

Temperature Sensor

A temperature sensor is located in the electronics module and measures ambient


temperature. This measurement is used to provide temperature compensation for the position
and pressure sensors and other internal electronic components. The temperature is read via
the HART® communication link to provide a warning of excessive ambient temperature at the
positioner.

66 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Pneumatic Module
The pneumatic module consists of an I/P and Relay assembly.

Current-to-Pressure Converter, I/P

The I/P converts a current signal to a pressure signal in the following manner:

1. A fixed coil creates a magnetic field proportional to the applied current.


2. The field magnetically pulls a flexure towards a nozzle to increase pressure on the flexure.
3. The pressure on the flexure increases in response to an increase in the coil current.
Encapsulation of the coil provides protection from the environment.

Single Acting Pneumatic Relay


The single acting pneumatic relay amplifies the pressure from the I/P and increases airflow as
required for stable, responsive, actuator performance. The single acting relay operates on any
supply pressure that is at least 5 psi (.345 bar, 34.5 kPa) above the required actuator pressure,
up to 100 psi (6.9 bar, 690 kPa).

Pneumatic
Relay

Terminal
Board
I/P

Electronics
Module

Figure 39 Pneumatic Module

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 67
SVi1000 Maintenance and Repair
Adjusting I/P Zero
The I/P Zero is calibrated at the factory prior to shipment. If there is a problem with I/P zero
please contact your Masoneilan representative.

Repair by Replacement
Using ValVue and repair-by-replacement is the fastest method to service an SVi1000. See the
ValVue SVI1000 DTM software instruction manual or help for details regarding uploading and
downloading configuration files. Upload all configuration information from the installed
positioner to ValVue, then install the replacement positioner and download the configuration
file into the replacement unit. Run STOPS, and AutoTune, and the repair is complete. The
positioner that was removed can be refurbished and reused.

NOTE Substitution of components can void safety approvals.

A series replacement kits are available and are listed in “Spare Parts” on page 74. Each of
these kits comes with a procedure for completing the replacement.

Internal Diagnostics
The SVi1000 performs internal self-diagnostics and hardware checks. When ValVue or HART®
Handheld or the local display indicates that there are error messages write them down for
troubleshooting.

FAILSAFE Mode
Several of the internal diagnostics tests puts the SVi1000 into FAILSAFE mode if the errors
continue for a preset time. When the SVi1000 goes into FAILSAFE, the valve is driven to its
Failsafe position. It remains in that position until the positioner automatically clears the cause
of the error and resets the instrument.

Upgrading Firmware
The SVi1000 is equipped with a nonvolatile re-writable Flash Memory for program storage.
The firmware can be updated as improvements and advances are made in the embedded
programs that operate the SVi1000. Firmware improvements for the SVi1000 can be obtained
by contacting the factory.

68 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
7. Specifications, Spare Parts and References

Physical and Operational Specifications


This section provides the physical and operational specifications for the SVi1000. Specifications
are subject to change without notice.

Table 6 Environmental Specifications

Parameter Storage & Transport (Packaged)

Operating Temperature Limits -40 °F to 185 °F (-40 °C to 85 °C)

Storage Temperature Limits -58 °F to 200 °F (-50 °C to 93 °C)

Temperature Effect < 0.005% / °F typical; -40 °F to 180 °F (< 0.01% / °C typical; -40 °C to 82 °C)

Supply Pressure Effect 0.05% per psi (.73% per bar)

Operating Relative Humidity 5 to 100% non-condensing

Storage Relative Humidity 0 to 100% non-condensing

Humidity Effect Less than 0.2% after 2 days at 104 °F (40 °C), 95% Relative Humidity.

Electromagnetic Compatibility IEC 61514 Industrial-Process Control systems - methods of evaluating the
Electrostatic performance of intelligent valve positioners with pneumatic outputs.
IEC 61326 Electrical equipment for measurement, control and laboratory
use - EMC requirements.

Fast Transient Burst No effect at 2 kV (Coupling clamp EN61000-4-4 or IEC1000-4-4).

Housing Tropicalized with positive pressure

Vibration Influence 4 mm at 5 - 15 Hz - Negligible


Measured at SVi1000 Housing 2 G at 15 - 150 Hz Less than 2% of span
1 G at 150 - 2000 Hz - Less than 2% of span

Magnetic Field Influence Negligible at 100 A/m 50/60 Hz (EN61000-4-8)


CE MARK
The SVi1000 conforms to the requirements of the ATEX 94/9/EC and EMC
2014/30/EU directives.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 69
Table 7 Operational Specifications

Accuracy +/- 1.0% (typical or less) Full Span

Hysteresis and Deadband +/- 0.3% Full Span

Repeatability +/- 0.3% Full Span

Conformity +/- 0.5% Full Span

Start-Up Drift Less than 0.02% in first hour

Long Term Drift Less than 0.003% per month

Position Travel Limits Rotary: 18 - 140°


Reciprocating: 0.25” - 2.5“ (6 mm - 64 mm)
Note: Above 2.5” (64 mm) consult factory for mounting instructions.

Tight Shut Off 0 -20% of input

Flow Characteristics Linear


Applied in addition to the con- Equal Percentage (of 50:1 or 30:1)
trol valve’s inherent Camflex
characteristic.
Quick Opening (inverse of 50:1 equal percentage)
User Configurable

Position Auto Tune Proportional gain: 0 to 5000


SVi1000 performs automatic Integral time: 0 to 100 seconds - displayed as 0 to 1000 (1/10s)
determination of the optimal Derivative time: 0 to 200 ms
valve position control parame-
Dead Zone: 0 to +/-5% (0 to 10% deadband)
ters. In addition to P, I, D, the
position algorithm uses damp- Padj: +/- 3000 (depends on P)
ing, symmetry for exhaust and Beta (non-linear gain factor): -9 to +9
fill time constants, dead zone Position compensation coefficient: 1 to 20
and magnitude characterization
Boost: 0 to 20
parameters. Auto Tune is opti-
mized for 5% step changes with
negligible overshoot. After the
Auto Tune process is completed,
the user can further adjust the
positioner tuning parameters to
more conservative or to more
responsive values.

Stroking Time 0 to 250 seconds

Full open position adjustment 60 to 100% of actual travel

Start Up Time (from no power) Less than 500 ms

70 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 7 Operational Specifications (Continued)

Minimum current to maintain 3.4 mA


®
HART
HART® Command#3 Mapping PV= Valve Position, 0-100%
SV = Actuator Pressure, configured engineering units
TV = Reserved
QV = Reserved

Table 8 Input Signal and Power, Specifications

Power Supply Loop powered from 4-20 mA control signal

Compliance Voltage Rating 9.0 V at 20 mA, 11.0 V at 4.0 ma

Minimum Current Signal to Start Up 3.2 mA

Minimum Input Span for Split Range 5 mA


Operation

Upper Range Value for Split Range Operation 8 mA to 20 mA

Lower Range Value for Split Range Operation 4 mA to 14 mA

Wire Size 12/28 AWG

Strip Length 0.43 in / 11 mm

Digital Communication HART® Communication protocol revision 5 (firm-


ware version 2.2.1) and 7 (firmware version 3.1.1
and later).

Table 9 Construction Material Specifications

Housing and Cover Low Copper Aluminum Alloy

Weight SVi1000: 3.2 lbs./ 1.451 kg


SVi1000 SW/G/IM: 4.1 lbs./ 1.860 kg

Relay Nitrile diaphragms, Polycarbonate

I/P Motor 430 stainless steel, Low Copper Aluminum Alloy, 300 series stain-
less steel, nitrile diaphragm

Magnet Holder Corrosion Protected Anodized Aluminum 6061 T6

Pole Ring 416 stainless steel

Levers 300 Series stainless steel

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 71
Table 10 System Connectivity

HART® Physical Device Type Positioner; HART


®
cmd rev 5 or 7, Device type 204 (0x00cc)

DD Registered with HART® Yes


Communication Foundation
®
Integration with HART Host ValVue standalone, ValVue AMS SNAP-ON application available,
® ®
software Plug-In Application For Yokogawa PRM, ValVue For Honeywell
® ®
FDM , Device Type Manager (DTM) for FDT Host

Table 11 Pneumatics Single Acting Standard Flow

Air Supply Dry, oil-free, 5 micron filtered air (per ISA S7.3)

Action Direct Acting

Supply Pressure 15 to 100 psi max. (1.03 to 6.9 Bar)


Regulate 5 psi (.34 Bar) minimum above actuator spring range. Do
not exceed actuator rating.

Air Delivery 10.0 scf/min. (283 L/min.) at 30 psi (2.1 bar) supply
16.6 scf/min. (470 L/min.) at 60 psi (4.2 bar) supply
23.3 scf/min. (660 L/min.) at 90 psi (6.3 bar) supply

Air Capacity Loading CV = 0.30


(flow coefficient) Venting CV = 0.40

Air Consumption 0.19 scf/min. (5.4 L/min.) at 30 psi (2.1 bar) supply
0.30 scf/min. (8.5 L/min.) at 60 psi (4.2 bar) supply
0.40 scf/min. (11.4 L/min.) at 90 psi (6.3 bar) supply

Air Supply Failure On supply failure the actuator output fails to atmosphere. Some
overshoot may occur when air pressure returns after a period
without air supply pressure.

Loss of Input Signal Actuator Output fails to atmosphere

Output Pressure 0-100 psi (6.9 bar) max

Table 12 SVi1000 Model Numbering

Model Number Configuration

SVi1000 Assembly

SVi1000 /SW Assembly with switches

SVi1000 /G Assembly with gauges

SVi1000 /SW/G Assembly with switches and gauges

SVi1000 /PR Assembly with position retransmit

72 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 12 SVi1000 Model Numbering (Continued)

Model Number Configuration

SVi1000 /PR/G Assembly with position retransmit and gauges

With Integrated Magnet

SVi1000 /IM Assembly with integrated magnet

SVi1000 /G/IM Assembly with gauges and integrated magnet

SVi1000 /SW/IM Assembly with switches and integrated magnet

SVi1000 /SW/G/IM Assembly with switches, gauges and integrated magnet

SVi1000 /PR/IM With position retransmit and integrated magnet

SVi1000 /PR/G/IM With position retransmit, gauges and integrated magnet

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 73
Spare Parts
Spare part kits available include:

SVi1000 Position Retransmit Main Electronics Assembly and Terminal Board


(Part Number 720045089-999-000)
SVi1000 IP Replacement (Part Number 720045087-999-000)
SVi1000 Housing Cover Replacement (Part Number 720045085-999-000)
SVi1000 Position Retransmit Terminal Board Electronic Assembly
(Part Number 720045084-999-000)
SVi1000 Switch Terminal Board Electronic Assembly
(Part Number 720045083-999-000)
SVi1000 Main Electronics Assembly (Part Number 720045081-999-000)
SVi1000 Basic Terminal Board Electronics Assembly (Part Number 720045082-999-000)
SVi1000 Pressure Gauges Mounting (Part Number 720023182-999-0000)
Integral magnet assembly (Part Number 720044034-999-0000)

74 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
8. Using the Digital Interfaces

Overview
This section describes the ways to communicate, configure, and calibrate the SVi1000. You can:

Streamline the valve positioning function


Improve precision of process control
Communicate critical information locally and remotely

The four available communication tools listed below offer increasing levels of functionality.

Local User Interface and LEDs. See “Functionality” on page 19.


“Hand Held Communicator” on page 76
“ValVue” on page 80
Any HART® capable Host loaded with the DD for the SVi1000.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 75
Hand Held Communicator
The HART® handheld communicator is a universally available tool that provides all the
accessibility of the local user interface. The HART® tool has the functionality to upload and
download configurations, enter alphanumeric messages and set the custom characteristic
numerical parameters. The GE DPI620, used as an example here, is approved for Intrinsically
Safe use in Hazardous Areas in accordance with SVi1000 Approvals and in accordance with
the HHC approvals. Additionally, you can use Emerson 475, Fluke 774, SMAR HPC301 or
Merram 4X00.

For communication to a HART® device, there is a Device Description Language. A Device


Description, DD, is published by registration with the HART® Communication Foundation.
When the DD is installed in a host communication device then the host can readily access all
the information in the smart field device. The SVi1000 registered DD will be available from
HART® Communication Foundation when it next publishes the HART® DD.

While the SVi1000 is equipped with a local user interface, checkout and configuration can
also be performed using the standard HART® communications interface.

Connect the HART® Handheld Communicator (HHC) to the SVi1000 as shown in Figure 40.
Refer to the HART® Communicator product manual included with the HHC or other HART®
Communication devices.

12.00 mA

Input Signal + -

GE DPI620

Figure 40 SVi1000 HART® Communicator Connections

76 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
SVi1000 HART® Commands

Table 13 SVi1000 HART® Commands

Command Description

Command 0 Read Unique Identifier

Command 1 Read Primary Variable

Command 2 Read Current

Command 3 Read Dynamic Variables

Command 6 Write Polling Address

Command 7 Read Loop Configuration

Command 8 (HART 7 only) Read Variable Classifications

Command 9 (HART 7 only) Read Device Variables with


Status

Command 11 Read Unique Identifier By Tag

Command 12 Read Message

Command 13 Read Tag and Descriptor

Command 14 Read PV Transducer


Information

Command 15 Read Device Information

Command 16 Read Assembly Number

Write Message Write Message

Command 18 Write Tag and Descriptor

Command 19 Write Assembly Number

Command 20 (HART 7 only) Read Long Tag

Command 21 (HART 7 only) Read Unique Identifier associ-


ated with Long Tag

Command 22 (HART 7 only) Write Long Tag

Command 33 Read Device Variables

Command 35 Write PV Range

Command 38 Reset Configuration Change


Flag

Command 42 Reset

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 77
Table 13 SVi1000 HART® Commands (Continued)

Command Description

Command 48 Read Additional Device Status


See Table 14 for return bits
information.

Command 54 Read Device Variable Info

Command 105 (HART 5only) Read burst Config

Command 107 (HART 5only) Write burst device variables

Command 108 (HART 5only) Write Burst Mode Command

Command 109 (HART 5only) Write Burst Mode Control

Command 128 Read Variable Address

Command 223 Write Hart Revision

Table 14 Command 48 Additional Status Return Bits

Byte/Bit Definition Byte/Bit Definition

0/0 Reset 4/0 Reference voltage error

0/1 Low power 4/1 Position sensor error


0/2 Actuator error 4/2 Current sensor error

0/3 Low air supply 4/3 Temperature sensor error

0/4 Position error 4/4 N/A

0/5 N/A 4/5 N/A

0/6 Keypad error 4/6 N/A

0/7 Marginal power 4/7 N/A

1/0 Calibration failed 5/0 I/P pressure sensor error


Find stops failed Atmospheric pressure sensor
1/1 5/1
error
1/2 Autotune failed 5/2 N/A

1/3 N/A 5/3 FRAM write error


1/4 Read Device Information 5/4 IRQ fault
1/5 RTOS scheduling 5/5 N/A

1/6 N/A 5/6 Self-check fault

78 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 14 Command 48 Additional Status Return Bits (Continued)

Byte/Bit Definition Byte/Bit Definition

1/7 N/A 5/7 Software error

Bias out of range Terminal module identifica-


2/0 6/0
tion error
N/A Terminal module data integ-
2/1 6/1
rity error
2/2 N/A 6/2 N/A

2/3 N/A 6/3 N/A

2/4 N/A 6/4 N/A

2/5 N/A 6/5 N/A

2/6 N/A 6/6 N/A

2/7 Auxiliary memory fault 6/7 N/A

3/0 FRAM checksum error


3/1 RAM checksum error

3/2 Flash checksum error

3/3 Stack error


3/4 Factory write

3/5 FRAM test

3/6 N/A

3/7 Factory mode

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 79
ValVue
ValVue combines the power of the PC with the features of the SVi1000 DTM software for ease
of use and automation of positioner operation and full access to all data. See “SVi1000 DTM
Full Wizard” on page 57 for further information. ValVue is used to configure and calibrate
valves with the SVi1000 utilizing HART® communications protocol.

See “ValVue and SVi1000 DTM Software Installation” on page 27 for download and installation
instructions. For assistance contact the nearest Masoneilan Sales Office, your local
Masoneilan representative or email [email protected].

80 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
9. Wiring Theory for an SVi1000

Introduction
The SVi1000 provides reliable operations of control valves with utmost simplicity in setup and
commissioning. It is uniquely equipped with a non-contact travel sensor allowing for accurate
positioning and maintenance free operations. The pneumatic train of the SVi1000 is a
dual-stage amplification system with stainless steel parts for durability. Using HART® eDDL and
FDT-DTM technologies, the Masoneilan SVi1000 positioner provides interoperability with leading
control systems suppliers.

SVi1000 Setups
Typical system setups are shown in Figure 41, General Purpose Installation schematic.

Wiring diagrams are generalized, actual wiring must adhere to the electrical installation section
of manual and local electrical codes.

SVi1000 Non-Hazardous Area Power


Supply

220 Ohms
HART compliant
control system
output card

HART
Modem
ValVue

GE DPI620

Figure 41 General Purpose Installation

For information and diagrams to install the SVi1000 when located in a hazardous area protected
by Intrinsically Safe wiring practices, refer to ES-761 the Intrinsically Safe Wiring Requirements
section in the SVi1000 Quick Start sent with the positioner.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 81
Split Range Applications
The SVi1000 is designed to operate in split range configurations supporting up to three
control valves connected to a single controller output. Minimum input current span for each
SVIi1000 is 5 mA. For each positioner the upper range value is between 8 and 20 mA and the
lower range value is between 4 and 14 mA. For example, three devices might be configured
with input current ranges of 4 - 9 mA; 9 - 14 mA, and 14 - 20 mA. Split range operation with
SVi1000 requires special consideration of the compliance voltage. The SVi1000 requires at
least 9.0 V. Two SVi1000 in series requires at least 18.0 V in addition to the voltage drops in
wiring and other series devices. Typical controller output current sources rarely deliver 24 V, so
the system can become voltage starved. It is possible to boost the compliance voltage of the
DCS using a series wired voltage source power supply, as shown in Figure 42. The total loop
voltage must not exceed the rating for the controller output current source. Contact the DCS
vendor to validate this approach. See the Position Retransmit screen in the SVi1000 DTM to
configure the software.

NOTE The internal electronic components are isolated from ground.


Grounding the case is unnecessary for functional purposes.
Grounding the case may be necessary to conform to local codes.

Power
Supply

HART Address = 1 Supplemental


(Voltage)
Power
HART
Supply Filter Control
System
Output
Card

HART
Modem

HART Address = 2

Figure 42 Split Range with Supplemental Power Supply - Non-Hazardous

82 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
System Connections Considerations
All system connections must comply with the HART® Communications Protocol
Specifications. For complete technical information refer to the HART® Communications
Foundations Document Number HCF-SPEC-11 and the references. The SVi1000 is a HART®
compliant device of type Actuator. It is therefore a receiver of 4 - 20 mA, and cannot have a
voltage source applied to its input terminals.

CAUTION Applying a voltage can cause damage and void the warranty.

When installing the SVi1000 in a 4 - 20 mA current loop, the engineer designing the loop must
consider a set of conflicting electrical requirements. The control signal to the positioner is a 4 -
20 mA current generated by the controller or DCS and transmitted to the positioner located
remotely in the field. The electrical characteristics of a current loop sending a signal to the
field device are different from the apparently similar loop bringing a signal to a controller from
a transmitter in the field.

The positioner receives its power from the current signal. It receives its control setpoint from
the value of the current and it must be able to communicate bi-directionally by
superimposing signal tones upon the current signal without distorting the current signal,
without the tones being affected by the electrical characteristics of the current signaling
device. All these conflicting requirements must be met with equipment manufactured by
various manufacturers, and work with long cables, in a noisy hostile plant environment.
Energy levels are often limited for safe installation in explosive environments. Special
engineering may be required to meet the signaling requirements at low energy levels.

The following will not cover all the details for a successful installation, in all cases. That is
beyond the scope of this instruction. It will suffice to explain the requirements as a guide use
to obtain necessary components from many sources for a successful installation.

CAUTION Do not connect a HART® modem and PC to a control circuit


unless the controller is HART® compatible or has a HART® filter.
Loss of control or a process upset may occur if the controller
output circuit is not compatible with HART® signals.

Install in compliance with Hazardous Area rules in accordance


with local electrical codes and plant standards by trained
specialists.

Do not connect a PC or HART® modem (that is not approved as


intrinsically safe) to an intrinsically safe circuit except on the safe
area side of the barrier. Do not operate a PC in a hazardous area
without compliance to local and plant regulations.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 83
NOTE A control circuit must be HART® compatible or have a HART® filter
installed. Contact the manufacturers of the controller or DCS. See
“HART Filter Requirements” on page 39.

Comply with current national and local regulations for


electrical installation work.
Before carrying out any work on the device, power off the
instrument or make sure that the locale conditions permit the
safe opening of the cover.

Wiring Guidelines
See “Wiring Guidelines” on page 44 for a list of guidelines for a successful implementation of
DC current signal, DC power, and HART® communication to the SVi1000.

Grounding Practices
To ensure proper grounding make sure that case, signal, and ground connections are made in
compliance with the plant’s normal grounding practices. Any point in the loop can be
referenced to ground, but there must never be more than one ground point. Normally ground
is connected at the controller or at the intrinsic safety barrier.

The case grounding screws are located on the outside of the case. The case is isolated from all
circuitry and can be grounded locally in accordance with applicable codes.

84 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Compliance Voltage in Single Drop Current Mode
The SVi1000 requires 9.0 Volts at 20 mA and 11.0 Volts at 4 mA. Typical smart devices require
MORE voltage at higher current. The controller supplying the current has LESS voltage
available at higher current. The SVi1000 is unique in that it requires LESS voltage at higher
current which complements the characteristic of the source requiring only 9 Volts at 20 mA.

NOTE Improperly or inadequately grounded installations can cause


noise or instability in the control loop. The internal electronics are
isolated from ground. Grounding the case is unnecessary for
functional purposes but grounding the case may be necessary to
conform to local codes.

Table 15 through Table 17 on page 86 provide examples of several SVi1000 installations and
calculating the compliance voltage necessary to supply 9 Volts at 20 mA.

Table 15 Compliance Voltage for Single Channel Zener with 22 AWG Cable

Voltage at SVi1000 at 20 mA 9.0 V

Drop in single channel Zener barrier with 342 Ohms end-to-end resistance 6.84 V

Drop in 22 AWG cable, 3000 ft. long (30 Ohms per 1000 feet) 1.8 V

Drop in passive HART® Filter1 0.0 V

Voltage required at controller 17.64 V

1Such as MTL HCU16AO

Conclusion: The control system must have a compliance voltage equal to or greater than
17.64 volts; contact the DCS vendor to verify compliance.

Table 16 Compliance Voltage for Galvanic Isolator with 22 AWG Cable

Voltage at SVi1000 at 20 mA 9.0 V

Drop in 22 AWG cable, 3000 ft. long (30 Ohms per 1000 feet) 1.8 V

Required voltage at Isolator 10.8 V

Voltage available from Isolator rated to drive 22 mA into 700 Ohms1 13.2 V

Voltage required at controller Not applicable - Isolator


supplies the power

1
Consult R. Stahl.

Conclusion: The compliance voltage issue is not present because the Isolator provides all the
necessary voltage.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 85
Table 17 Compliance Voltage for No Barrier with HART® Filter and Resistor and 18 AWG Cable

Voltage at SVi1000 at 20 mA 9.0 V

Drop in 220 Ohm resistor 4.4 V

Drop in 18 AWG cable, 6000 ft. long (12 Ohms per 1000 feet) 0.6 V

Drop in passive HART® Filter 2.3 V

Voltage required at controller 16.3 V

Conclusion: The control system must have a compliance voltage equal to or greater than 16.3
volts; contact the DCS vendor to verify compliance.

Wire Size and Conduit


Electrical connections are made to the electronics module terminal board. The terminals
accept wire sizes up to AWG 14. The SVi1000 is supplied with two 1/2" NPT conduit entries.
M20 adapters are available. Internal and external ground terminals are provided for use if
grounding is required.

NOTE When an intrinsic safety barrier separates the SVi1000 from the
modem or HHC a HART® compliant barrier must be used.

86 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
HART® Physical Layer Compliance of the Control System
Communications to a SVi1000 requires a HART®-compliant communications loop. The HART®
protocol specifies the noise level, impedance requirements, and configuration of the loop. The
controller or output card of the control system must comply with the Physical Layer
Specification.

Impedance Constraints
HART® communication is based on the talking device generating an AC current
superimposed on the 4 - 20 mA control signal. Two frequencies are generated; 1200 Hz
representing the digital value 1 and 2200 Hz representing the digital value 0. The listening
device responds to the voltage generated when the AC current flows through the loop
impedance. In order to generate a voltage from a current there must be impedance. HART®
Protocol requires that this impedance be at least 220 Ohms at the tone signaling frequencies.

HART® compliant current sources are supplied with the correct Impedance Versus Frequency
Characteristic. In Non-Compliant Current Sources there may be a noise reduction capacitor
across the output that lowers the impedance at higher frequencies and thus lowers the
signaling voltage. To be certain that at least 220 Ohms of impedance is presented by the
current source a resistor can be added in series with the current source. This reduces the
effective compliance voltage of the current source by 20 mA times the value of the series
resistor. An added resistor is unnecessary during tests with high impedance current
calibrators such as the Altek Model 334 Loop Calibrator.

Noise Constraints
HART® Communication depends on converting two frequencies (1200 and 2200 Hz) into
digital values 1 and 0. Noise can cause errors in the conversion. Conventional good wiring
practice, such as use of twisted shielded pair cable with the shield and signal loop grounded
at only one point, minimizes the effects of noise.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 87
Cabling and Interconnection Requirements
Interconnections are made using shielded twisted pair cables. The shield is connected to
ground at one point only. The signal loop is grounded at only one point in accordance with
plant electrical standards. It is customary to ground the signal at the controller or intrinsic
safety barrier. The SVi1000 is supplied with two 1/2" NPT conduit entries. M20 adapters are
available. Internal and external ground terminals are provided for case grounding
requirements.

WARNING Install the SVi1000 in accordance with local and national code in
both general and hazardous area locations. Substitution of
components can impair suitability for use in hazardous locations.

NOTE The internal electronic components are isolated for ground.


Grounding the case is unnecessary for functional purposes.
Grounding the case may be necessary to conform to local codes.

Capacitance vs. Length of Cable for HART®


The HART® Communications Foundations specifies cable capacitance requirements to
preserve signal strength. Refer to the standards for detailed calculation methods.

CAUTION Do not connect a HART® modem and a PC to a control circuit


unless the controller is HART® compatible or has a HART® filter.
Loss of control or a process upset can occur if the controller output
circuit is not compatible with HART® signals.

HART® Filter Required for Certain Control System Output Circuits


The SVi1000 is intended for use with all control systems. However, output circuits of several
major DCS systems are incompatible with the tones used for HART® signals. You must verify
that the DCS or controller works reliably with the HART® protocol. When the DCS is
incompatible an external HART® filter must be installed between the field wiring and the
output card. MTL manufactures the HART® filter HCU16AO. It is a 16 channel DIN rail mounted
device composed of passive circuitry that introduces negligible voltage drop. For additional
information, contact MTL.

NOTE A control circuit must be HART® compatible or have a HART® filter


installed. Contact the manufacturer of the controller or DCS. See
“HART Filter Requirements” on page 39. of this manual for more
information.

88 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
10. Optional Switch Load Limits

Output Switches
Introduction
The SVi1000 supports two identical contact outputs, SW #1 and SW #2 (Digital Output switches),
that can be logically linked to status bits. The Digital Output switch terminals are solid state
contacts. Each switch requires its own power source and must be connected to the appropriate
connector on the Electronics Module Terminal Board.

The switches are polarity sensitive and must be connected only to a DC circuit. The switch (+)
terminal must be electrically positive with respect to the (–) terminal. If the (+) terminal is
electrically negative with respect to the (–) terminal, then the switch will conduct.

There must be a series load in the circuit to prevent damage to the switch. If the switch is
connected directly across the power source the current will be limited only by the capacity
of the power source and the switch can be damaged.

This section discusses the necessary precautions when configuring a system. See “Optional
Retransmit Output” on page 91 for additional considerations for a retransmit equipped SVi1000.

Switch OFF Switch ON

VSWITCH 30 VDC max.  1 V (Switch saturation voltage)

 0.200 mA (Switch leakage current) 1 A max.


ISWITCH

CAUTION Incorrect polarity connection results in an effectively closed connection.

Consult with qualified personnel to ensure that electrical requirements for the
switch are met.

The maximum voltage that can be applied to the digital switch outputs is 30 VDC. This is an open
circuit parameter (the digital switch is in the open state). Under open circuit conditions, the
switch current will be less than 0.200 mA.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 89
The switch maximum current rating is 1 A. When the switch is ON, the typical voltage drop
across the switch is 1V. It is essential that the external circuit controls voltage such that the
switch saturation voltage is maintained.

When the switch is on (closed) the external voltage must be dropped across the load
(Figure 43).

CAUTION The load must be designed such that the current in the circuit is
1 A at all times. Some 3rd party devices, such as incandescent
lamps or solenoids, require surge and back EMI protection to limit
current to 1 A.

Load is designed to ensure that voltage across the switch is < 1 V.

LOAD

SVi1000 Switch Output: External


Voltage
1 V with switch ON
Source

Figure 43 Simplified Switch Installation Drawing: Correct Configuration

Without a load, when the switch is on (closed) the external voltage would be dropped across
the switch. This damages the switch (Figure 44).

Full voltage drop is


occurring across the SVi1000 External
switch (no current Switch NOT ALLOWED Voltage
limit in place) Output Source

Figure 44 Simplified Switch Installation Drawing: Configuration Not Allowed

90 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Optional Retransmit Output
Introduction
The SVi1000 supports a 4-20mA Position Retransmit Feedback option. The retransmit output
requires a DC power source (10V~30V) to properly function. The signal could be input into a
DCS/PLC analog input module to read out the current valve position.

The output terminals are polarity sensitive and must be connected only to a DC circuit. The
Retransmit (+) terminal must be electrically positive with respect to the (–) terminal. In normal
working conditions, the retransmit output follows the valve position by outputting a 4-20mA
analog signal. If the positioner stops working due to lose of loop power or malfunctioning, the
retransmit output stays at around 3.2 mA.

This section discusses the necessary precautions when configuring a system.

CAUTION An incorrect polarity connection will result


in device not properly functioning or with
internal circuitry damage.

CAUTION Consult with qualified personnel to ensure


that electrical requirements for the switch
are met.

The external series resistor is normally located in a DCS/PLC analog input module, so that the
valve position (current) can be transferred into voltage (Figure 45).

4 - 20 mA current flow

External
SVi1000 Switch Voltage
Retransmit Source:
10 V to 30 V

Figure 45 Simplified Retransmit Option Installation Drawing

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 91
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11. Air to Open and Air to Close Actuators

Actuator Action
It is important to correctly assign air actuator action for each control variable throughout a
control system. Even the control valve subsystem can be complex. Figure 46 and Figure 47 show
the action of air to open, ATO, and air to close, ATC, valves when used with SVi1000. The figures
show a direct acting positioner with linear and percentage characteristics. Some hysteresis is
shown for the actuator pressure signal that is caused by friction in typical actuators. The scales
are chosen to emphasize the relationships between input current and actuator pressure, so that
the failsafe valve position is shown at the lower left of each graph.

NOTE For an ATC valve, 4 mA represents 100% valve travel not the expected 0%. The
controller and other human machine interfaces must correctly show that the
valve is open 100% at 4 mA and closed 0% at 20.

The graph shows the valve movement and actuator pressure when the Tight Shut-off, T.S.,
option is set at about 5%. The valve movement and actuator pressure are also shown at the low
current lift-off point at about 3.6 mA, below which the positioner is initializing its settings until
power is stabilized.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 93
Figure 46 ATO and ATC Action with Linear Positioner Characteristics

94 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Figure 47 ATO and ATC Action in Percentage of Positioner Characteristics

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 95
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12. SVi1000 Fault Matrix

Fault Matrix
Table 18 describes SVi1000 faults and helps determine the cause and corrective action.

Table 18 Fault Matrix

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

1, 0, 0 RESET Reset Device reset 3 Device reboot. The power Reset the flag using the
indicator recovered. Incoming signal SVi100 Basic DTM or
was below 2.9 mA. HART® Host.

2, 0, 1 LOW_ Low Power Input current < 3 Device power is below 3.15 Increase mA only if calibra-
POWER 3.2 mA mA. tion or diagnostics are to
be performed.

3, 0, 2 ACTUATOR Actuator Error Unable to posi- 2 1: Air supply is insufficient. 1: Increase air supply
tion the valve 2: Handwheel or mechani- above spring final value +
normally. cal stop present. 10 psig.
3: Valve stuck of sticking 2: Verify if mechanical stop
excessively. is present.
4: Unbalance forces on 3: Perform valve signature
valve trim exceeds actua- using the SVi1000 Basic
tor capability. DTM.
4: If possible, perform valve
signature under process
conditions. Validate sizing
of actuator against process
condition using ValSpeQ.

4, 0, 3 AIR_SUPPLY_ Low Air Supply Supply Pressure 2 Air supply is not turned on Increase air supply above
LOW Warning below low limit or is set below 10 psig. spring final value + 10 psig.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 97
Table 18 Fault Matrix (Continued)

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

5, 0, 4 POSITION_ Position Error If T1 error is con- 2 1. Controller is slow to fol- 1: Perform valve signature
ERROR figured AND the low command signal due using the SVi1000 Basic
position error to physical valve wear, DTM.
outside the error such as tight packing, stem 2: Perform step test signa-
band for time T1. build up, throttling surface ture using the SVi1000
friction or actuator friction. Basic DTM. Verify that air
2. Valve is slow to follow supply droop during filling
command signal due to is less than 15% or the set
large volume actuator. pressure.
3: Valve will not follow 3: Validate that the air sup-
command signal due to ply set to the instrument is
insufficient or no air supply. greater that the spring final
4: Valve does not move + 10 psig.
because the device's mode 4: Set the mode to Normal
is not set to Normal. using the SVi1000 Basic
5:. Valve will not follow DTM or HART® Host.
command signal due to 5: Perform Autotune or
poor controller tuning for Manual tuning using the
current valve status. SVi1000 Basic DTM or
6: Valve will not follow HART® Host.
command signal due to 6: Verify if Bias Out Range
controller malfunction such or I/P Out of Range events
as I/P or Relay. are active.
7: Valve will not follow 7: Perform valve signature
command signal due to in using the SVi1000 Basic
line obstruction. DTM.

6, 0, 5 I2CBUS Hardware failure: Main


Board I2C bus failure.

7, 0, 6 KEYPAD Keypad Fault Possible mois- 2 The local user interface Replace the local user
ture inside or and display is defective or interface and display
connector or pushbutton pressed for assembly.
mechanical fail- more than seven seconds.
ure.

8, 0, 7 MARGINAL_ Marginal Power 2 The input current is less Increase loop current to 4
POWER than 3.85 mA. mA only if calibration and
diagnostics are to be per-
formed.

9, 1, 0 CALIBRA- Calibration Calibration of AO 3 Calibration of the input Using precision measuring


TION_ Failed or pressure sensors was outside the equipment, perform cali-
FAILED failed. acceptable range when bration according to
attempting to calibrate. boundary limits of input
sensors.

98 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 18 Fault Matrix (Continued)

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

10, 1, 1 FIND- Find Stops Failed Find Stops pro- 3 1: When calibrating stops 1: Using the SVi1000 Basic
_STOPS_- cess failed, (Zero / Span) the travel sen- DTM or HART® Host, verify
FAILED sor moved outside the that travel sensor counts is
acceptable limits. 0 +/- 1000 with the valve
2: A procedure timeout closed. For a 90° valve,
occurred due to an measured sensor count is
extremely large volume of done at 50% travel.
actuator to displace. 2: Using the SVi1000 Basic
3: Valve position could not DTM or HART® Host, per-
stabilize when deenergiz- forms a Manual Stop cali-
ing or when energizing the bration.
actuator. 3: Verify that air supply is
adequate. Verify that
accessories (boosters,
quick exhausts, etc.) are
not creating instability.

11, 1, 2 AUTOTUNE_ Autotune Failed Self tuning failed 3 1: When performing an 1: Using the SVi1000 Basic
FAILED to converge on Autotune, procedure failed DTM or HART ®Host, per-
acceptable to complete due valve hys- form an Autotune with an
parameters. teresis beyond 50%. aggressiveness level
2: Air supply is insufficient. between 2 and 4. Or man-
3: Air supply droops signifi- ual tune the parameters
cantly during actuator fill- according to the instruc-
ing. tion manual.
2: Increase air supply
above spring final value +
10 psig.
3: Perform 5 to10% steps
and observe air supply
gauge on the controller.

14, 1, 5 RTOS_ Operating Sys- An internal error 2


SCHEDUL- tem Fault. from which the
ING device recov-
ered automati-
cally

17, 2, 0 BIAS_OUT_ Bias Out Of An important 1 The servo signal to the cur-
OF_RANGE Range internal param- rent to pressure converter
eter is out of is outside of normal throt-
range. tling range.

18, 2, 1 IP_OUT_OF_ I/P Out Of Range I/P current feed- 1 The loop current to the
RANGE back is out of internal current to pressure
range. converter is outside of nor-
mal range.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 99
Table 18 Fault Matrix (Continued)

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

24, 2, 7 AUX_MEM0 Activation Activation related: indi-


related: indi- cates failure of the Serial
cates failure of Number Hardware.
the Serial Num-
ber Hardware.

25, 3, 0 NVM_- NVM Checksum The device failed 1 A permanent corruption of 1: Remove power to the
CHECKSUM0 Error to read critical the content in non volatile device for 2 minutes and
data from non memory occurred. restart the device.
volatile memory. 2: If the failure persist,
replace the device.

26, 3, 1 RAM_- RAM Checksum An internal error 2 A corruption of the content Notify GE at svisup-
CHECKSUM Error from which the in volatile memory [email protected].
device recov- occurred.
ered automati-
cally.

27, 3, 2 FW_ Flash Checksum A critical inter- 1 Invalid firmware check- 1: Remove power to the
CHECKSUM Error nal fault. sum due to data corrup- device for 2 minutes and
tion. restart it.
2: If the failure persists,
Replace device.

28, 3, 3 STACK Stack Error An internal error 2 A problem with the mem- Clear the condition using
from which the ory stack occurred. the DTM or HART ®Host.
device recov-
ered automati-
cally.

29, 3, 4 FACTORY- Factory Write Indicator of 1


WRITE Indicator writes to non
volatile memory
allowed only for
firmware
upgrade.

30, 3, 5 NVM_TEST NVM Test Error An error in non 2 A problem occurred when Clear the condition using
volatile memory testing non volatile mem- the DTM or HART® Host.
could not be ory.
repaired.

32, 3, 7 FACTORY- Factory Mode Device performs 1 Device is in the factory Replace device and report
MODE Indicator factory autho- mode. the problem at svisup-
rized operations. [email protected].

33, 4, 0 REF_ Ref Voltage Fault May indicate 1 A component problem is Replace device and report
VOLTAGE faulty A/D sub- affecting the circuit board's the problem at svisup-
system. reference voltage. [email protected].

34, 4, 1 POSITION_- Position Sensor 1 Electronic Hall sensor com- Replace device and report
SENSOR Fault ponent and related compo- the problem at svisup-
nents failed. [email protected].

100 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 18 Fault Matrix (Continued)

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

35, 4, 2 CURRENT_- Current Sensor 1 Electronic input loop cur- Replace device and report
SENSOR Fault rent sensor is damaged. the problem at svisup-
[email protected].

36, 4, 3 TEMPERA- Temperature 1 Electronic temperature Replace device and report


TURE_ Sensor Fault sensor is damaged. the problem at svisup-
SENSOR [email protected].

41, 5, 0 PRESSURE4 I/P Pressure Sen- 1 1: Pressure sensor has Replace device and report
sor Fault been overpressurized and the problem at svisup-
damaged. [email protected].
2: Pressure sensor has
failed due to some mal-
function.

42, 5, 1 PRESSURE5 Atmospheric 2 1: Pressure sensor has Replace device and report
Pressure Sensor been overpressurized and the problem at svisup-
Fault damaged. [email protected].
2: Pressure sensor has
failed due to some mal-
function.

44, 5, 3 NVM_WRITE NVM Write Fault A write to non 2 An error occurred when 1: Clear the condition using
NVM volatile memory attempting to write to non the DTM or HART® Host.
failed; data may volatile memory. 2: If condition persists,
be lost on reset. replace device and report
problem at svisup-
[email protected].

45, 5, 4 IRQ_FAULT IRQ Fault An internal error 2 The circuit board interrupt 1: Clear the condition using
from which the request failed. the DTM or HART ®Host.
device recov- 2: If condition persists,
ered automati- replace device and report
cally. problem at svisup-
[email protected].

47, 5, 6 SELF_CHECK MCU Internal A critical inter- 1 A general self check failed. 1: Clear the condition using
Malfunction nal fault. the SVi1000 Basic DTM or
HART ®Host.
2: If condition persists,
replace device and report
problem at svisup-
[email protected].

48, 5, 7 SOFTWARE Software Error An internal error 2 Operating system failed in 1: Clear the condition using
from which the conducting a task. the SVi1000 Basic DTM or
device recov- HART® Host.
ered automati- 2: If condition persists,
cally. replace device and report
problem at svisup-
[email protected].

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 101
Table 18 Fault Matrix (Continued)

Sequence, FAULT TEXT For HELP For Criticality Probable Cause Recommended Action
Byte #, Name SVi1000 Basic SVi1000 Basic
Bit # (Anchor) DTM English DTM English

49, 6, 0 HARDWARE_ Terminal Mod- Terminal Mod- 2 1. Board ID was not written Service required, report
MODULE_ ule ID error ule identifica- correctly during manufac- problem at svisup-
IDENT tion error turing. [email protected].
2. The Data Storage on the
Terminal Module is not
functioning correctly.
3. Hardware failure.

50, 6, 1 RETRAN_ Terminal Mod- Retransmit Mod- 2 1.Data on the Retransmit Service required, report
DATA_ ule data integrity ule Data Integ- Module were not written problem at svisup-
INTEGRITY error rity Error properly during manufac- [email protected].
turing.
2. Data on the Terminal
Module are corrupted.
3. The Data storage is not
functioning correctly.

102 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
13. Air Supply Requirements

Air Supply Requirements


A high quality air supply greatly improves the quality of control and reduce pneumatic
equipment maintenance costs. See ANSIISA-7.0.01-1996 - Quality Standard for Instrument Air.
Air supply failure requires special attention to minimize process effects. Design and apply all
process equipment to fail to a safe condition. This includes air supply failure. SVi1000 is designed
to fail to a condition of low or no air pressure. Choose control valve actuators to move the valve
to a safe condition when air pressure is low or absent. For example, a valve supplying fuel to a
combustion process is normally equipped with an Air to Open valve. In other words, the fuel flow
is shut off if air fails.

Additional process precautions can be taken. When the air supply recovers, the setpoint to the
valve must be at a value that continues to hold the valve in its safe condition, or to move it to a
known safe condition. To do so, put the control system sending the control valve position
setpoint into manual mode and set to 0%. After the air supply has stabilized at its correct
pressure, the setpoint can be moved to its operation point in accordance with the plant’s safe
start-up procedures. An additional precaution required on critical processes with an ATO control
valve is to install a shut-off valve that supplements the control valve by moving to a safe
condition on air failure, and remains in that condition until all necessary requirements for safe
start-up have been met.

WARNING Keep clear of moving parts. The SVi1000 can cause the valve to move when
the air supply returns.

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14. Adjusting Speed of Response

Adjusting Speed of Response


The SVi1000 provides in its calibration software the ability to automatically tune the connected
valve. The auto tune feature has robust tuning parameters designed to tolerate variations in
process characteristics. You can adjust the control valve speed of response by adjusting SVi1000
parameters using ValVue tuning parameters, or using the GE DPI620. See the SVi1000 DTM help
file for details.

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15. Advanced Usage

Technology to Maximize Savings and Process Performance


This section shows examples of techniques for achieving superior process results by using
ValVue with SVi1000 to simplify maintenance and to achieve the benefits of SVi1000’s advanced
diagnostics capabilities. It is assumed that you are using HART® communications with a modem
and ValVue. Refer to the ValVue SVi1000 help file for complete instructions on these and other
procedures.

Tight Shutoff Application to Protect from Seat Erosion


Program the Tight Shutoff feature to prevent valve seat erosion using the full actuator force to
eliminate damaging leakage. At a position setpoint of 2%, for example, this function allows full
thrust to occur when the input signal is less than 2%. This solves a common cause of valve
repair. Do not use tight shutoff if it is necessary to throttle the valve at very small flows.

Tight Shutoff Application to High Pressure Liquid Letdown Valve Trim


When staged trim is used in High Pressure Liquid Letdown Valves, adjust the Tight Shutoff to
move the valve from the seat to begin throttling at the minimum operable CV level. Using the
tight shut-off feature in SVi1000 prevents valve seat damage that can occur when throttling at
clearance flows. See recommended Tight Shutoff settings in Table 19. Adjust Tight shutoff using
front panel pushbuttons, with ValVue or a HART® communicator.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 107
Table 19 Tight Shutoff Parameters for High Pressure Liquid Letdown Trim

Masoneilan Valve Valve Trim Type Set Tight Shutoff Positioner


Type Characteristics

Lincoln Log Any 15% Linear

41000 VRT Type S Partial Stack 6% Linear

41000 VRT Type S Full Stack 3.5% Linear

41000 VRT Type C Cage 6% Linear

28000 Varilog 5% Linear

Any Class V Shutoff 2% Linear

108 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
16. Glossary

Accuracy In a control valve the position is measured between mechanical motion limits in
the valve. These limits can include position variations due to actuator and valve
rigidity. therefore, accuracy is referenced to positions within normal travel of the
valve independent of rigidity effects at the mechanical limits. Accuracy is the
greatest deviation from the expected position within the normal travel,
expressed as percent of normal travel.
Actuator Type An actuator is a device that transforms an input signal (mainly an electrical sig-
nal) into motion. A HART® compliant actuator receives a 4 - 20 mA control cur-
rent signal and causes an actuation function. There are many types of HART®
actuators; a positioner is type of actuator. A device of type Actuator can not be
connected to a circuit intended for a device of type Transmitter.
Algorithm An algorithm is a procedure or formula for solving a problem. There are several
algorithms entailed in SVi1000 operation. The SVi1000 has a position control
algorithm that is a modified PID. Other algorithms embedded in SVi1000 include
the STOPS method for calibrating stroke, and the autoTUNE method for estab-
lishing the best parameters for the PID algorithm.
ATC Air to Close The combination of a single acting actuator and the control valve where the
valve is closed when air pressure is applied to the actuator
ATO Air to Open The combination of a single acting actuator and the control valve where the
valve is open when air pressure is applied to the actuator
Characteristic The positioner input setpoint command can be selectively modified to provide a
desired relationship between setpoint and valve position. In the valve, the rela-
tionship between stroke and Cv is also called valve inherent characteristic. It is
often adjusted by design, to equal percentage, for example. The positioner char-
acteristic is applied to modify the setpoint to travel relationship of the actuator.
The characteristic of the positioner must be chosen to compliment the valve. If
the valve is equal percentage, set the positioner to linear. If a linear valve is
installed the positioner can be set to an equal percentage characteristic to
improve flow control. SVi1000 offers an eleven point custom characteristic
option that can be created and edited in ValVue.
Closed The valve position in which the flow is minimum or zero. See Tight Shutoff.

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Compliance Voltage The voltage that must be available at the control system output in
order to drive the control current through the SVi1000 and all the
resistive devices in series with it.
Conformity The closeness to which the position approaches the theoretical posi-
tion curve, for example equal percentage or quick opening. It is inde-
pendent of effects due to valve or actuator rigidity at the mechanical
limits of travel. See Accuracy.
Compliance, HART® Manufactured and tested in accordance with the HART® Communi-
cations Foundation standards.
Condition Monitoring A technology for measuring the performance of process equipment
and valves over a period of time to predict the need for maintenance.
The technology evolved to meet NRC requirements GL 89-10, and
has proven valuable to other process industries. SVi1000 and ValVue
offer a suite of diagnostic tools to implement condition monitoring.
Custom The custom characteristic in the SVi1000 has nine points to define
the relationship between the setpoint and the valve position. The Val-
Vue software allows selection of the custom characteristic that must
be downloaded as pairs of data using the HART® communications
from a HART® master. ValVue offers a graphical drag-and-drop
method to define the characteristic. It includes a method to correct
for geometric non-linearity of the positioner feedback linkage.
DCS Distributed Control System is a generic term for the common control
system architecture that generally performs process control in net-
worked computers and interacts with field devices through rack
mounted I⁄O cards. A positioner is usually connected to a DCS output
card which controls the 4- 20 mA current to the positioner.
Device Description, DD The software object installed in a HART® Handheld Communicator to
allow it to communicate and display the custom parameters avail-
able in a field device.
EEPROM An Electrically Erasable Programmable Read Only Memory. SVi1000
has two memories that are used for permanent storage of data that
changes during operation. The micro-controller has EEPROM which
permanently stores changing information such as number of actua-
tor cycles and totalized valve travel. The program is stored in flash
memory and can be upgraded.

110 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Equal Percentage A valve characteristic designed to compensate for the loss of pres-
sure in a pipeline as a control valve is opened. It is intended to linear-
ize the installed flow versus lift characteristic for improved control.
The theoretical curve is y= aexln(1⁄a), where a is.02, 1/R, and R=50 for a
50:1 equal percentage characteristic. However, the theoretical curve
leaves the valve unseated by 2% at 0% input. The actual curve,
shown here, is corrected to seat the valve at 0%. The corrected
curve is Y=(aexln(1⁄a) -a)/(1-a).
Error Messages The positioner stores the reasons for errors. The error messages can
be read by HART® or with ValVue.
Fail Safe A mode of the positioner where the valve position is controlled to a
predetermined safe position. This mode is forced by the positioner
program in response to errors. If the errors are cleared then the posi-
tioner to the mode prior to the error.
Flash Memory A computer memory that is not volatile. It stores all its data even
when the power is off. It performs high speed reads and can be
re-written many times. It is used to store programs and permanent
parameters.
FSK Frequency Shift Keying see HART® protocol.
Hall Effect Sensor A semiconductor magnetic-field sensor that measures the magnetic
flux perpendicular to the sensor.
HART® HART® is an acronym for Highway Addressable Remote Transducer.
The HART® protocol makes use of the Bell 202 Frequency Shift Key-
ing (FSK) standard to superimpose digital signals at a low level on
top of the 4-20 mA. This enables two-way communication to take
place and makes it possible for additional information beyond just
the normal process variable to be communicated to a smart field
instrument. The HART® protocol communicates without interrupting
the 4-20 mA signal and allows a host application (master) to get two
or more digital updates per second from a field device. As the digital
FSK signal is phase continuous, there is no interference with the 4-20
mA signal.
HART® Communication The HART® Communication Foundation is an independent, non-
profit foundation corporation specifically organized to coordinate
and support the application of HART® technology worldwide. Edu-
cating the industry on the capabilities and value of this important
technology is a key role.
Operating costs are offset by membership and training⁄support ser-
vice fees. Membership is open to all suppliers, end users, and others
interested in the use of HART® technology.

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HART® Filter A filter required with certain DCS systems that are not HART® com-
pliant. It allows the 4 - 20 mA output signal to pass from control sys-
tem to positioner, but blocks HART® FSK tones from passing from the
field wiring to the control system.
HART® Master A device, usually a PC which is controlling the communications over
a HART protocol network. The HART® master sends to a field device
a command and requires a response.
HART® Slave A device, normally a transmitter or positioner, that communicates
over a HART® protocol network only in response to a command from
a master.
Hazardous Area The area of the plant where explosion hazards are present, hazards
such as propane gas in a refinery, or dust in a flour mill.
Hot Swapable The SVi1000 in combination with ValVue enables a very brief Mean
Time To Repair by the following process: Upload all configuration
information from installed positioner to ValVue, then replace the
positioner and download the configuration file. Run STOPS, and
autoTUNE, and the repair is complete.
I⁄P Converter The current to pressure converting device. The SVi1000 sends an
analog current signal to the I⁄P which produces a controlled pressure
to the pneumatic amplifying relay.
ISA The International Society of Automation. ISA develops and publishes
international standards for use in process control. See www.isi.org.
Multidrop A variation of the HART® Communications Protocol that allows many
smart field devices to draw power from and to communicate over a
single pair of wires. Though most suited to multiple measurement
devices, it can be used with SVi1000 to permit digital communication
of setpoint as well as configuration data, to multiple positioners or a
combination of positioners and measurement transmitters. Such
communication may not be fast enough for flow control.
Multiplexer Several instrument suppliers offer equipment that can be connected
to multiple cables to monitor and communicate with the attached
positioners and transmitters using the HART® protocol. Often the
multiplexer is used with a DCS that does not support HART®.
NAMUR NAMUR is a European user association of process control technology
in chemical and pharmaceutical industries. “Recommendations and
Worksheets are experience reports and working documents pre-
pared by NAMUR for its members among process control users for
facultative utilization”. NAMUR issued a recommended accessory
mounting for control valves (NE 14 Anschluß von Schwenkantrieben
an Armaturen 06.08.96) which describes a method for mounting a
positioner on an actuator. See at www.namur.de.

112 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Neodymium Iron Boron A magnet alloy which provides the highest energy magnetism
available in a permanent magnet.
Non-Volatile Memory Computer memory that is not lost when power is turned off. Used to
permanently store calibration, configuration and diagnostic infor-
mation in SVi1000.
NORMAL Mode The control mode for normal use of a valve positioner. The positioner
receives a setpoint from a controller or DCS and applies pressure to
the actuator to move the valve to the required position.
PC As used in this manual, a personal computer or laptop running
under Windows XP or later operating system.
Position With a reciprocating valve, the position is the distance of the plug
from its seat, normally measured as a linear motion of the valve or
actuator stem. With a rotary valve the position is the angle of rota-
tion of the valve plug measured as angular rotation of the valve
shaft.
Position Limit The Actuator can be mechanically set to stop at a predetermined
position by setting an adjustment, sometimes with a handwheel or
screw stop. SVi1000 can be configured to provide the same limits
through software control of position.
Positioner Tuning The positioner requires six integer parameters to determine the
Parameters response of the positioner to a setpoint change. Internally, the posi-
tioner uses an improved PID control algorithm to control the valve’s
position.
Tuning Parameters
P P is a dimensionless gain factor related to the proportioning action
of the algorithm. It ranges from 0 to 5000. Common values for the
positioner are 50 for small valves up to 4000 for large valves.
I (0.1 sec): Integral time or reset time, is the time constant of integral
control. Higher values of I cause slower integral action. Common val-
ues are 10 (1 second) to 200 (20 seconds). A value of zero disables
integral action.
D (msec): Derivative time or rate time is the time constant of derivative
control expressed in milliseconds. It ranges from 0 to 200 msec.
Common values are 0 to 100. A value of zero disables derivative
action.
Beta Beta is a nonlinear dimensionless gain factor, ranging from -9 to 9.
When beta is 0, the controller gain is linear. Otherwise the gain is the
function of error. The larger the beta, the smaller the gain for small
error. Typical beta values for a valve position controller are between
–9 and 0.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 113
Padj (%) Valves often have significantly different response when filling versus
exhausting. The proportional gain is adjusted by adding Padj to P
when the valve is exhausting. Padj is normally less than P.
Position Compensation The response of the valve is different when the valve is nearly closed
Coefficient than when the valve is nearly open. The position compensation coef-
ficient, which is a number between 0 and 9, allow the control algo-
rithm to optimize the valve response.
Damping Coefficient The valve response can be made slower for some applications. A
value of 0 gives no damping, and a value of 9 gives maximum damp-
ing of valve motion.
Dead Zone(%) When the valve position is within the setpoint +⁄- the dead zone, no
additional position control is performed. This value is normally 0%,
however for high friction valves (e.g. valves with graphite packing) a
higher dead zone helps avoid limit cycling due to the stick⁄slip action
of the valve. In these cases the dead zone chosen might be 0.2% to
1%.
Quick Opening (see Characteristic)
Relay, Pneumatic The component that amplifies the pneumatic control signals to pro-
vide a wide range of actuation pressure and to supply and vent at
high flow rates for responsive control.
Safe Area The area of a plant where there never is an explosion hazard present,
such as the control room or a wire marshalling rack area.
Sig Hi In the SVi1000 configuration, the input current setting at which the
valve is fully open (ATO) or fully closed (ATC).
Sig Lo In the SVi1000 configuration, the input current setting at which the
valve is fully closed (ATO) or fully open (ATC).
Single Acting The action of a position with a single pneumatic output for operation
with a spring return actuator.
Split Range A control configuration where a single control output is sent to two
or more control valves. Each control valve positioner is calibrated to
respond to a separate portion of the control signal. An example is a
steam valve and a cooling water valve arranged to be both closed at
50% and the steam valve to open.
STOPS The SVi1000 runs STOPS procedure to adjust the positioner to actual
valve travel. First the output pressure is reduced to zero and the posi-
tion is recorded. That position corresponds to 0%. The output pres-
sure is raised to its maximum based on supply pressure. The position
is recorded and corresponds to 100%.
Stroke The total range of valve travel. Often used as a verb to describe the
process of moving the valve.

114 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Tag The formal designator the control valve used in control loop docu-
mentation.
Tight Shutoff (TS) A positioner property which is selected and adjusted when it is
desired to prevent operation of the valve at or near the closed posi-
tion. The positioner causes all available actuator force to be applied
to the valve seat at a position set point equal to or less than the TS
adjustable parameter. A dead band is applied to prevent cycling in
and out of this behavior.
VDE⁄VDI 3845 A Standard common in Europe for mounting positioners and acces-
sories on rotary valve actuators.

© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 115
DIRECT SALES OFFICE LOCATIONS
AUSTRALIA ITALY SOUTH AFRICA
Brisbane
Phone: +61-7-3001-4319 Phone: +39-081-7892-111 Phone: +27-11-452-1550
Fax: 88+61-7-3001-4399 Fax: 88+39-081-7892-208 Fax: 88+27-11-452-6542

Perth JAPAN SOUTH & CENTRAL AMERICA


Tokyo AND THE CARIBBEAN
Phone: +61-8-6595-7018 Phone: +81-43-297-9222 Phone: +55-12-2134-1201
Fax: 88+61-8-6595-7299 Fax: ==+81-43-299-1115 Fax: 88+55-12-2134-1238

Melbourne KOREA SPAIN


Phone: +61-3-8807-6002 Phone: +82-2-2274-0748 Phone: +34-93-652-6430
Fax: 88+61-3-8807-6577 Fax: 88+82-2-2274-0794 Fax: 88+34-93-652-6444

BELGIUM MALAYSIA UNITED ARAB EMIRATES


Phone: +32-2-344-0970 Phone: +60-3-2161-0322 Phone: +971-4-8991-777
Fax: 88+32-2-344-1123 Fax: 88+60-3-2163-6312 Fax: 88+971-4-8991-778

BRAZIL MEXICO UNITED KINGDOM


Bracknell
Phone: +55-19-2104-6900 Phone: +52-55-3640-5060 Phone: +44-1344-460-500
Fax: +44-1344-460-537

CHINA THE NETHERLANDS Skelmersdale


Phone: +86-10-5689-3600 Phone: +31-15-3808666 Phone: +44-1695-526-00
Fax: 88+86-10-5689-3800 Fax: 88+31-18-1641438 Fax: +44-1695-526-01

FRANCE RUSSIA UNITED STATES


Courbevoie Veliky Novgorod Massachusetts
Phone: +33-1-4904-9000 Phone: +7-8162-55-7898 Phone: +1-508-586-4600
Fax: 88+33-1-4904-9010 Fax: 88+7-8162-55-7921 Fax: 88+1-508-427-8971

GERMANY Ratingen Moscow Corpus Christi, Texas


Phone: +49-2102-108-0 Phone: +7 495-585-1276 Phone: +1-361-881-8182
Fax: 88+49-2102-108-111 Fax: 88+7 495-585-1279 Fax: 88+1-361-881-8246

INDIA SAUDI ARABIA Deer Park, Texas


Mumbai
Phone: +91-22-8354790 Phone: +966-3-341-0278 Phone: +1-281-884-1000
Fax: 88+91-22-8354791 Fax: 88+966-3-341-7624 Fax: 88+1-281-884-1010

New Delhi SINGAPORE Houston, Texas


Phone: +91-11-2-6164175 Phone: +65-6861-6100 Phone: +1-281-671-1640
Fax: 88+91-11-5-1659635 Fax: 88+65-6861-7172 Fax: 88+1-281-671-1735

Jacksonville, Florida
Phone: +1-844-VALVE-GE

www.geoilandgas.com/valves
*Denotes a trademark of the General Electric Company.
Other company names and product names used in this document are the
registered trademarks or trademarks of their respective owners.
© 2016 General Electric Company. All rights reserved.
GEA19527F 03/2016

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