MN SVi1000 IOM GEA19527 RevF
MN SVi1000 IOM GEA19527 RevF
MN SVi1000 IOM GEA19527 RevF
Masoneilan*
SVi*1000 Positioner
Instruction Manual (Rev F)
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 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.
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.
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.
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 3
Contents
© 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
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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
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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.
© 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.
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.
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.
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.
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2. Introduction
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.
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.
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:
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
© 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)
Gauges
(Optional)
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
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:
© 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)
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
Indication Pattern
Device Alert
LED 1
(Fault mode LED 2
(self-correcting)) LED 3
LED 4
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
Troubleshooting
Process Failure
or or
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.
Pneumatic
Relay
Terminal
Board
(varies by type)
I/P
Electronics
Module
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 25
SVi1000 Dimensions
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.
Unpacking
Exercise care when unpacking the positioner and its mounted accessories. The SVi1000
container includes a Quick Start manual.
© 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.
3. Navigate through the list and find the latest ValVue 3.x FDT Frame Application software, as
in Figure 14.
28 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
5. Review the information and click I Accept and Figure 16 appears.
6. 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 =| 29
7. Click the link and Figure 18 appears.
30 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Figure 15 Download Software Terms
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
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:
© 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:
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*.
Mounting Bracket
Mounting
Extension
Screw
Magnet
Figure 20 shows a side view of a Camflex actuator, the SVi1000, and a mounting bracket.
SVi1000
Rotary
Actuator
Mounting
Bracket
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 35
Tools required:
M5 Hex Key
M4 Hex Key
M3 Hex Key
Mounting
Bracket
Mounting
Long Side Holes
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
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
(0°)
(-45°)
(+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).
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
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:
1. Mount the standard reciprocating mounting bracket to the valve using two (2) 5⁄16 - 18
UNC cap screws.
© 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).
D
C
B
A
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.
40 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 3 Reciprocating Valve Mounting Hole and Turnbuckle Length (Continued)
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
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
13. Mount the SVi1000 to the bracket and secure with four M6 socket head cap screws.
A
B
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
2. Pipe the output air from the output pressure port to the actuator. Minimum tubing
diameter: 1/4".
Dew Point At least 18° F (10° C) below minimum anticipated ambient temperature
© 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.
WARNING Comply with current national and local regulations for electrical
installation work.
Before carrying out any work on the device, power off the
instrument.
Wiring Guidelines
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.
Tools required:
Wire stripper
Flat head screwdrivers for cover and connectors
To connect:
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).
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
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
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 47
Troubleshooting Connections
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4. Check Out and Power Up
Overview
This section provides the calibration procedures to ensure proper valve positioning, including:
© 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.
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:
CAUTION Do not use Teflon pipe seal tape. The Teflon tape can shred into
particles that are harmful to the pneumatic components.
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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:
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.
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
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.
Gain
increases as
the tuning
value
increases.
Use the Configuration Selection Switch to select a preset tuning value (Figure 35).
Cancel
Button
and LED 4
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.
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.
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
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.
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5. Full Wizard
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.
© 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.
60 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Buttons and Fields
Procedure Area
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.
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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.
Procedures (e.g. Find Stops, Auto Tune, Step Test and Ramp Test)
should NOT be invoked if the ValVue sequencer is running.
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.
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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.
© 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 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
66 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Pneumatic Module
The pneumatic module consists of an I/P and Relay assembly.
The I/P converts a current signal to a pressure signal in the following manner:
Pneumatic
Relay
Terminal
Board
I/P
Electronics
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.
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
Temperature Effect < 0.005% / °F typical; -40 °F to 180 °F (< 0.01% / °C typical; -40 °C to 82 °C)
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.
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 69
Table 7 Operational Specifications
70 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 7 Operational Specifications (Continued)
I/P Motor 430 stainless steel, Low Copper Aluminum Alloy, 300 series stain-
less steel, nitrile diaphragm
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Table 10 System Connectivity
Air Supply Dry, oil-free, 5 micron filtered air (per ISA S7.3)
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 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.
SVi1000 Assembly
72 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 12 SVi1000 Model Numbering (Continued)
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 73
Spare Parts
Spare part kits available include:
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:
The four available communication tools listed below offer increasing levels of functionality.
© 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.
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
76 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
SVi1000 HART® Commands
Command Description
Command 42 Reset
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 77
Table 13 SVi1000 HART® Commands (Continued)
Command Description
78 | =GE Oil & Gas © 2016 General Electric Company. All rights reserved.
Table 14 Command 48 Additional Status Return Bits (Continued)
3/6 N/A
© 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.
220 Ohms
HART compliant
control system
output card
HART
Modem
ValVue
GE DPI620
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.
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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.
Power
Supply
HART
Modem
HART Address = 2
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.
© 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.
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.
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
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
Conclusion: The control system must have a compliance voltage equal to or greater than
17.64 volts; contact the DCS vendor to verify compliance.
Drop in 22 AWG cable, 3000 ft. long (30 Ohms per 1000 feet) 1.8 V
Voltage available from Isolator rated to drive 22 mA into 700 Ohms1 13.2 V
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
Drop in 18 AWG cable, 6000 ft. long (12 Ohms per 1000 feet) 0.6 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.
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.
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.
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.
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The switch maximum current rating is 1 A. When the switch is ON, the typical voltage drop
across the switch is 1V. 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
Without a load, when the switch is on (closed) the external voltage would be dropped across
the switch. This damages the switch (Figure 44).
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.
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
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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
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12. SVi1000 Fault Matrix
Fault Matrix
Table 18 describes SVi1000 faults and helps determine the cause and corrective action.
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.
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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.
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.
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.
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.
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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
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.
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].
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
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
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15. Advanced Usage
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Table 19 Tight Shutoff Parameters for High Pressure Liquid Letdown Trim
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.
© 2016 General Electric Company. All rights reserved. Masoneilan SVi1000 Positioner Instruction Manual =| 109
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= aexln(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=(aexln(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
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Phone: +1-844-VALVE-GE
www.geoilandgas.com/valves
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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