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MASONEILAN SVI®

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4. CONTROLLING THE PROCESS DETERMINES WHAT VALVE MOVES VALVE CLOSED AND OPEN STOPS AND CORRESPOND RETURNS TO STARTING VALUE VALVE MUST TO FULLY OPEN P STOPS OFF PROCESS IF BUTTON IS PUSHED WHILE AND FULLY 4 RUNNING THIS TASK THE TASK IS INTERRUPTED CLOSED AND THE VALVE RETURNS TO STARTING POSITION RESETS 100 POINT HHEH Eaa DispLay DISPLAYS VALUE OF OPEN STOP TO NOMINAL STOP OP VALUE PRESS OR TO ENTER NEW VALUE MAXIMUM TRAVEL PRESS TO ACCEPT NEW VALUE CALIBRATE BIAS PRESSURE ON PNEUMATIC BLOCK BIAS SETS THE I P CURRENT TO THE NORMAL BIAS VALUE PRESS OR TO RETURN TO CALIBRATE MENU i PARTIALLY IMPLEMENTED NOW INITIATES AUTO TUNE FUNCTION AND RETURNS TO USE TO DETERMINE TUNE TUNE WHEN FINISHED PRESSING ANY BUTTON POSITIONERS TUNING 4 STOPS THE TUNING PROCESS PARAMETERS 4 THES ________ DISPLAYS VALUE OF SIG LO FOR FULLY CLOSED SIG LO DISPLAY PRESS OR TO ENTER NEW VALUE OR FULLY OPEN VALUE PRESS TO ACCEPT NEW VALUE AND CE PROCEED TO NEXT MENU ITEM Y VALUE OF INPUT 7 DISPLAYS VALUE OF SIG HI SIGNAL SIG HI KDISPLAY PRESS OR TO ENTER NEW VALUE FOR FULLY CLOSED Ja 1 VALUE 1 PRESS TO ACCEPT NEW VALUE AND OR FULLY OPEN L PROCEED TO NEXT MENU ITEM A HEH DISPLAYS VALUE OF SUPPLY SOUS pispLAY
5. 14 SM I Inputs OUIDUIS 559 15 System Description Positioner 16 System Description PID Controller 17 Chapter 2 MOUNTING ua eame Cum CARCER ap ail ax 20 Standard Rotary Valve Mounting 20 Standard Reciprocating Valve Mounting 23 Mounting the SVI on Masoneilan 87 88 Multi Spring actuators 23 Mounting the SVI on other Valves 26 Lever and Linkage Design 2 000 eee 29 Pneumatic installation 222222 944 ogee Gan deaddaded RF EUR RO hee 31 Electrical Installation 222222255552 44 RES REESE dees saa 32 Hazardous Area Installations 4 35 Factory Mutual approved model 35 CSA Canadian Standards Association approved model 35 CENELEC Approved Model 38 Interconnections 2 222222 39 Basic Positioner oe Bee ee we s 39 Positioner or Controller with HART Communication 39 Impedance Constraints 39 Noise Constrain
6. PRESS OR TO ENTER NEW VALUE A PRESS TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM ENGLISH FRANCAIS 14 TO MOVE NEXT OPTION PRESS PRESS TO ACCEPT AND PROCEED TO NEXT MENU ITEM Figure 38 Configure Menu Structures 63 Calibrate Menu If a change is made in the Air to Open Air to Close or Direct Reverse configuration options or if you move the SVI to a different valve or make any change to the valve position linkage you must run the find STOPS calibration again CALIBRATE MENU FROM CAL IN MANUAL MENU CAUTION THIS FUNCTION STROKES THE VALVE OVER ITS FULL RANGE DO NOT EXECUTE WHILE THE VALVE IS CONTROLLING THE PROCESS DETERMINES WHAT VALVE Y POSITIONS MOVES VALVE TO CLOSED AND OPEN STOPS AND CORRESPOND 5 Je RETURNS TO STARTING VALUE VALVE MUST BE TO FULLY STOPS OFF PROCESS IF BUTTON IS PUSHED WHILE OPEN AND 4 RUNNING THIS TASK THE TASK IS INTERRUPTED CLOSED x AND THE VALVE RETURNS TO STARTING POSITION RESETS 100 POINT BH gt pispLay DISPLAYS VALUE OF OPEN STOP TO NOMINAL STOP OP VALUE PRESS OR TO ENTER NEW VALUE MAXIMUM TRAVEL PRESS TO ACCEPT NEW VALUE i gt TO CALIBRATE BIAS PRESSURE ON PNEUMATIC BLOCK BIAS SETS THE CUR
7. 60 Figure 36b Pushbutton Guide for SVI Version 1 0 6 61 Figure 37 Normal Operate Mode Select and Manual Mode Menus 62 Figure 38 Configure Menu Structures 2 63 Figure 39 Calibrate Menu Structures 64 Figure 40 Controller Menu Structures 65 Figure 41 Examine Menu Structures 1 66 Figure 42 Parameter and Message Displays 67 Figure 43 Exhaust Actuator and Air Supply Connections 78 Figure 44 Wiring Connections 80 Figure 44a Wiring Connections 1999 Release 81 Figure 45 Pilot Subassembly 93 Tables Table 1 Performance Specifications Positioner Mode Only 5 8 Table 2 Electrical Safety Design Specifications 9 Table 3 SVI Lever Hole Locations for 87 88 Multi Spring Actuator 24 Table 4 Recommended Lever Lengths 29 Table 5 Recommended Linkage Lengths 30 Table 6 Local Configuration Options 51 Table 7 Positioner
8. Figure 31 NORMAL OPERATE MODE SELECT and MANUAL Menu Siructures 46 Configure Menu Because calibration depends on certain configuration options you must perform Configuration before you perform Calibration when installing the SVI the first time CONFIGURE MENU FROM CONFIG IN MANUAL MENU SELECT TYPE OF ACTUATOR LAN PRESS TO SELECT OPTION peas NOT IMPLEMENTED AT SINGLE DOUBLE PRESS OR TO ACCEPT AND PROCEED TO NEXT MENU ITEM SELECT CONTROLLER OPTION CTL OFF IS ALWAYS PRESS TO SELECT OPTION SELECTED IF NO CONTROLLER CTL OFF CTL ON PRESS OR TO ACCEPT AND IS PRESENT EVEN IF NO LIMIT PROCEED TO NEXT MENU ITEM SW IS USED Si y 1 PRESS TO SELECT OPTION SELECT AIR TO CLOSE OR AIR ATO ATG PRESS OR TO ACCEPT AND TO OPEN VERY IMPORTANT TO lt q PROCEED TO NEXT MENU ITEM SET CORRECTLY Y LINEAR EQUAL 50 gt EQUAL 30 SELECT CHARACTERIZATION t E al CUSTOM Quick DISPLAYS TS VALUE IF TURNED ON TURN TIGHT SHUTOFF OFF OR HHH gt PRESS TO CHANGE ON OFF STATUS ON PROVIDES MAX SEATING x DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON FORCE AT 0 POSITION TS ON 4 PRESS OR TO ENTER NEW VALUE i PRESS TO ACCEPT NEW VALUE
9. AE cts ee na 54 Examine Calibration Parameters 54 Examine Configuration Parameters 55 Display Clear 5 2 4 55 Positioner Fault Messages 56 Chapter 4 Operation SVI Controller 58 INt FOGUCIION LIT 58 P shbuttons Display sess rarasan a ia Rack ee Ue UR ee oa 59 Memu wow cac e eene 24 62 Normal Operate Mode and Manual Mode Menus 62 Configure Menu 1 63 Calibrate 64 Controller Ree Sce e ddr 65 Examine 1 66 Parameter and Message Displays 67 Normal Operation Controller 68 gie cec rcr IDOL 68 Gonfig ratlom i esca d dado fed d 68 Parameters and Options Available 68 ues Re qu od e cec RO D c 69 Controller FONCIONS 42 533 4 Y 70 Local Calibratlori sis 5 50 eue 70 FUN
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11. 152 4 6 0 203 2 8 00 Table 4 Recommended Lever Lengths 29 5 11 201 DRILL 250 20 UNC 28 THRU 3 HOLES 12 00 5 20 HOLE 10 00 Figure 23 SVI Lever Design n T l i 12 70 The linkage design is usually made up of two rod ends One each attached to the SVI lever and the valve stem A turnbuckle is used to attach the rod ends together and for final adjustment Table 5 may be used as a guide to determine the proper linkage lengths Lock nuts should be provided to ensure that the set length of the linkage is not changed See Figure 19 for typical mounting on a reciprocating actuator Valve Stroke mm inches 12 7 25 4 50 8 101 6 152 4 0 5 1 0 2 0 4 0 6 0 Linkage Length mm inches 25 4 50 8 76 2 127 0 228 6 1 00 2 00 3 00 5 00 9 00 Table 5 Recommended Linkage Lengths 30 Pneumatic Installation The SVI Positioner and Controller are designed to operate only with clean dry oil free instrument grade air to ANSI ISA 57 3 1975 R1981 or ISA S7 3 1975 R1981 Dew Point At least 18 F 10 C below minimum anticipated ambient temperature Particulate matter Filtered to below 5 microns Oil content Less than 1 ppm w w or v v Contaminant s Free of all corrosive contaminants and hazardous gasses flammable or toxic The supply output and exhaust connections for the SVI located on the pneumatic block are tappe
12. to Fail Safe operation incorrect installed Refer to for others Mounting in instructions Linkage produces more Check that mounting and than 120 degrees of linkage are correct for potentiometer shaft actuator travel rotation 85 Testing Valve Performance The following preliminary valve performance test checks the physical part of the system and isolates sev eral potential problems It bypasses the microprocessor configuration 1 Place the SVI in Manual mode using pushbuttons Val Vue or handheld If using pushbuttons in Manual mode select POS MAN By holding the and buttons down confirm that the valve moves to open and closed positions This may take some time with a large actuator If using ValVue or handheld use the FULL OPEN and FULL CLOSED commands If the valve correctly performs the open close command in manual mode continue with Confirming Configuration procedure below If the valve does not perform the open close command review the following Confirm that the air pressure is on set to proper pressure and connected to proper port Check that spool valve is not sticking Refer to Spool Valve Maintenance on Page See Bias Adjustment on Page 92 and adjust bias if necessary If FAILSAFE shows on display refer to FAILSAFE on Troubleshooting Checklist for appropriate action If items 1 2 3 and 4 above are OK the EPC electropneumatic converter may be faulty
13. 31vHu3do 9 0 UOISJOA a 3NIAVX3 1199185 4 H3TlOHINOO 1 IAS uonisod NVliSOd MEN i NOLLOS8 HSNd 61 Menu Structure The menu structure for operating the SVI from the local pushbuttons and display is shown in Figures 37 through 42 on the following pages Normal Operate Mode and Manual Mode Menus Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode the valve is placed in the last position it was in when it lett NORMAL OPERATE When in the MANUAL mode the device will not respond to the 4 20 mA signals However the SVI unit can still respond to HART commands including HART commands to position the valve Note also that when you go to EXAMINE from the NORMAL OPERATE MODE MENU the valve is still in NORMAL OPERATE mode and still responds to the 4 20 mA signal NORMAL OPERATE MODE DISPLAY HAF R SP or LSP Y OPERATE MODE MENU pp PRESS PV HAA ANY BUTTON Y OPER T 2 mum Y TO CONFIG IN POS EXAMINE MENU gt VALVE IS STILL IN Y MAN OPERATE MODE UT PRES TO REMOTE IN CIR CONTROLLER MENU IN OPERATE MODE THE DISPLAY SEQUENCES THROUGH PROCESS VARIABLE VALVE POSITION EXAMINE MANUAL MENU A
14. DANGER Never exceed actuator or SVI maximum pressure Damage to equipment or injury to personnel may result Verifying Supply Pressure The following procedure may be used to verify whether supply pressure is sufficient to drive valve against stops Close the holes in the exhaust plug by blocking air path The output pressure should slowly rise to supply pressure and the valve should drive to the high pressure stop e f output pressure does not go to or close to supply pressure there may be a leak within the pneu matic block Consult Factory Ifthe valve does not drive against the stops when the output gauge reads a pressure higher than the actuator specification then the actuator may be defective or improperly installed the valve may be jammed due to improperly installed packing or the valve body contains an obstruction 79 Electrical Connections The SVI requires an electrical input from a 4 20 mA current source or a voltage input from a 12 24 V dc Multidrop supply The 4 20 mA signal can provide both operating power and signal information or if a dig ital input signal is used provide only operating power The 12 24 V dc Multidrop supply can be used only when the input signal is digital Selection of current or voltage input is by position of a jumper on the main terminal board See Figures 44 and 44a Caution Make sure the voltage current jumper is in the proper position V or mA before applying power Failure to do
15. Groups C and D Temperature Classification T6 75 C ambient T5 82 C ambient indoor and outdoor NEMA Type 4X hazardous classified locations Dust Ignitionproof Class II Ill Division 1 Groups E F and G Non Incendive Class Division 2 Groups A B C and D Suitable for Class 11 Ill Division 2 Groups F and Installation must be in accordance with the current edition of the National Electrical Code ANSI NFPA 70 any applicable local codes and manufacturers instructions Intrinsically Safe Class 1 Il Ill Division 1 Groups A B C D E F and hazardous indoor outdoor NEMA 4X locations Temperature Classification T4 40 C ambient 70 C ambient T3A 82 C ambient Installation must be in accordance with the current edition of the National Electrical Code ANSI NFPA 70 ANSI ISA RP 12 6 Installation of Intrinsically Safe Instrument Systems in Class Hazardous Classified Locations Figure 25 Installation Control Drawing ES 641 on Page 34 and manufacturers instructions CSA Canadian Standards Association approved model Explosionproof Class Groups B C and D Class Groups F and G Class Supply 28 Vdc 4 20 mA Enclosure Type 4X Temp Code T6 75 C T5 82 C Max Ambient 82 C Division 2 Class Division 2 Groups A B C and D Class II Division 2 Groups F and G Class Ill Supply 28 Vdc 4 20 mA Enclosure Type 4X Temp Code T6 75 C
16. POSERR The valve did not go to the requested position within the time configured in Position Error Time 1 Valve lost air pressure Valve movement is blocked Setting of Position Error Time 1 is too low for the size of valve Note Setting Position Error Time 2 to a positive number may cause the device to fail safe on a POSERR PRESSEN Pressure Sensor Error BIASERR Bias Out or Range ESET Reset Occurred R STOPPERR Position Calibration Failed TEMPERR Circuit Temperature Error The pressure sensor failed The bias the output to the EPC within the SVI that controls the actuator fill exhaust is out of normal range SVI reset occurred The self position calibration routine failed The internal SVI tempera ture is outside the normal operating temperature range in the SVI specifica tions 98 While the SVI can function in normal operation with a failed pressure sensor other calibration functions depend upon the pressure sensor This error indicates an improperly adjusted bias Adjust the bias as needed If the SVI once func tioned properly this error usually indicates an improperly working pneumatics section SVI reset occurred because of a power loss or a command from ValVue The most likely causes are loss of air pressure or the pressure or position sensor not working properly Non Fatal Errors Continued Error Description Explanation Likely Ca
17. SOFTWARE UPPER LIMIT STOP SETTINGS VALUE DISPLAYED IF SET TO ON IF ON VALVE CANNOT GO BEYOND LIMIT SELECT DISPLAY LANGUAGE RETURN TO POS MAN IN MANUAL MENU CONFIGURE MENU PRESS SELECT OPTION SINGLE y DOUBLE PRESS OR TO ACCEPT AND PROCEED TO NEXT MENU ITEM PRESS TO SELECT OPTION CTL OFF CTL ON PRESS OR TO ACCEPT AND PROGEED TO NEXT MENU ITEM 4 __ PRESS SELECT OPTION m ATC PRESS OR TO ACCEPT AND PROCEED NEXT MENU ITEM o LINEAR pe EQUAL 50 EQUAL 30 4 CUSTOM 144 QUICK L RECIP DISPLAYS TS VALUE IF TURNED ON HEH p PRESS CHANGE ON OFF STATUS i DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON TS ON 44 PRESS OR TO ENTER NEW VALUE PRESS TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM DISPLAYS PL VALUE IF TURNED ON PRESS TO CHANGE ON OFF STATUS DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON PL ON 4 PRESS OR TO ENTER NEW VALUE PRESS ACCEPT NEW VALUE AND PROCEED NEXT MENU ITEM DISPLAYS PU VALUE IF TURNED ON _ PRESS TO CHANGE ON OFF STATUS P DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON
18. The local digital display sequentially displays valve position input signal and actuator pressure on a 1 5 sec ond interval Pressing any button moves you to the OPER option in the OPERATE MODE MENU as shown in Figure 31 on page 34 The OPERATE MODE MENU has options MAN put valve in manual mode and go to MANUAL Menu EXAMINE go to EXAMINE Menu and OPER return to display of current position pres sure and signal Use the pushbuttons to move from one option to the next Press the button to go to the item displayed in the menu Configuration Parameters and Options Available You can configure the following options by pressing the local pushbuttons in the procedure described below We recommend that you use the menu structure diagrams in Figure 31 to Figure 35 on pages 34 to 38 as a road map in following the procedures described As noted previously configuration should be performed before calibration Also note that configuration can be performed only when the valve is in manual mode The configurable options are as described in Table 6 LINEAR or EQUAL 50 Select desired valve characteristic curve linear equal percent EQUAL 30 QUICK age 50 equal percentage 30 quick opening or custom curve CUSTOM The custom curve must have been entered through the remote PC TS OFF or ON Display and set value of tight shutoff point Default is 0 0 PL OFF or ON Display is set value of the lower
19. previous item in the menu or to decrement the value currently shown in the digital display When used to decrease a displayed value holding this button down causes the value to decrease at a faster rate The right button marked permits you to move down through the menu structure to the next item in the menu or to increment the value currently shown in the digital display When used to increase a displayed value holding this button down causes the value to increase at a faster rate To determine how to display and or select a particular parameter value or configuration option refer to the menu structure diagrams in Figure 37 through Figure 42 By using these diagrams as a map you can quickly move through the menus to the function you want to perform NOTE If the buttons are pushed after being locked by the ValVue software the message LOCKED will appear Please refer to ValVue Software Manual to unlock pushbuttons 59 peeg dwog 3nT1vVA dureq ejag Las sumone 5 AsIGOW 8 3NIAVX3 4 A ainsseid Sdojs PUL 4 ge sdojs puy 2 ysn pe dojs p gt 512065 g 2500 se o o uedo pesojo ei e30 95013 euin uedo euim eunsseud ainssaid Buuds
20. A of current ripple 91 Oscillation If using a HART Communicator or ValVue set the following values to identify PID oscillation If SVI is push button model re run auto tune If oscillations persist contact factory 20 Padj 0 0 0 D 0 Damping 0 Dead zone 0 Position Compensation Coefficient 0 If the position remains stable then the problem is related to the positioner settings of the PID Re run AutoTune Limit Cycling The characteristics of limit cycling include at least a 4 second period and a squared off as opposed to sinusoidal trend record Excessive friction in the valve actuator assembly or dirt in the spool valve assem bly can cause limit cycling The SVI diagnostic identifies excessive friction in the valve actuator assembly as a reported friction value greater than 3096 of the actuator span Bias Adjustment Masoneilan adjusts the bias of the pneumatic block at the factory in order to accommodate most environ mental effects This setting usually makes bias adjustment neither necessary or desirable Situations do arise however when bias adjustment becomes necessary For example after replacing the spool valve or when the unit experiences extreme environmental conditions adjusting the bias can optimize position er performance For either of the following cases do not adjust bias After calibrating the limit stops of the valve and setting the parameters an offset may occur be
21. AND PROCEED TO 2 DISPLAYS PL VALUE IF TURNED ON SOFTWARE LOWER LIMIT STOP HEH PRESS TO CHANGE ON OFF STATUS SETTINGS VALUE DISPLAYED IF DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON SET TO ON IF ON VALVE PLON CANNOT GO BEYOND LIMIT 4 PRESS OR TO ENTER NEW VALUE A PRESS TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM DISPLAYS PU VALUE IF TURNED ON SOFTWARE UPPER LIMIT STOP H g PRESS TO CHANGE ON OFF STATUS SETTINGS VALUE DISPLAYED IF s V DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON SET TO ON IF ON VALVE PU OFF CANNOT GO BEYOND LIMIT PRESS OR TO ENTER NEW VALUE i PRESS TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM SELECT DISPLAY LANGUAGE ENGLISH P FRANCAIS TO MOVE TO NEXT OPTION PRESS PRESS TO ACCEPT AND PROCEED TO NEXT MENU ITEM RETURN TO POS MAN IN MANUAL MENU Figure 32 CONFIGURE Menu Structures 47 Calibrate Menu If a change is made in the Air to Open Air to Close or Direct Reverse configuration options or if you move the SVI to a different valve or make any change to the valve position linkage you must run the find STOPS calibration again FROM CONFIG IN MANUAL MENU CALIBRATE MENU CAUTION THIS FUNCTION STROKES THE VALVE OVER ITS FULL RANGE DO NOT EXECUTE WHILE THE VALVE IS
22. Actuator length 2 90 23 Actuator length 5 25 8 Position valve at mid stroke by supplying air to the actuator or using a manual handwheel if applicable 9 Adjust the turnbuckle such that the SVI lever is horizontal Tighten the turnbuckle lock nuts 24 SVI 87 88 Mounting Bracket PN 055000 253 002 0 8 and 1 0 STROKE NR M 1 5 STROKE 2 0 and 2 5 STROKE Figure 18 SVI Mounting Bracket for 87 88 Multi Spring Actuator Turnbuckle Locknut Nut Rod End Take off Rod and Travel Pointer Figure 19 Side View of SVI Mounted on a Reciprocating Valve 25 Mounting the SVI on other Valves The SVI can be mounted on many other valve types of both Masoneilan design and those of other man ufacturers Typical mounting on Masoneilan Type 37 38 and 84 85 Actuators is shown in Figures 20 and 21 Figure 21a Smart Valve Interface Outline Drawing shows mounting and overall dimensions When mounting the SVI to other valves use it as a guide to ensure proper clearances access room for cover removal and making of pneumatic and electrical connections The following section describes the general requirements for mounting the SVI on any valve This section is intended to be used by an Engineering group with basic understanding of instrument mounting on control valves The following minimum technical requirements must be adhered to Minimum SVI shaft rotation for full travel is 18 Maximum recommende
23. B C D E Class Division 2 Groups B C and D Class Il Division 2 Groups F and NEMA 4X Class Division 1 Groups D Class Il Division 1 Groups Class 1 Division 1 Groups A B C D Class Division 2 Groups A B and D Class Il Division 2 Groups F and Type 4X EEx d IIB H2 T5 ambient temp not to exceed 80 C per EN 50014 and EN 50018 EEx ia IIC T4 ambient temperature not to exceed 80 C per EN 50014 and EN 50020 IP 65 per EN 60529 Yes aovssali 11 NfiHH3AO 3oNanoas MH3MH IQON TVWSON OL NOLLNG 5 MdddH Juawainseaw WIWATVO 64316 s3svasdoaad ne A euo X Te YALL 007 pue Jeyijuep pees 000 PUBLULUOD esf 9315 31 1VA S3SV3HONI pajiey sdoys puy MM3dOls Seq ANIWA 6319901 612
24. CLEAR FAULTS AND RETURN TO FAULTS IN EXAMINE MENU NOTE In order to quit EXAMINE MENU if entry is from MANUAL MENU then at step MAN it is necessary to key which displays OPER and key again to return to MANUAL MENU Figure 34 EXAMINE Menu Structure 49 CONFIGURATION PARAMETERS FROM CONFIG IN EXAMINE MENU SINGLE 1 CTL OFF 1 age ATO re LINEAR 5 0 TS OFF 0 v RETURNS 0 0 TO CONFIG IN EXAMINE MENU A 100 0 lt q PU OFF ENGLISH CALIBRATION PARAMETERS FROM CALIB IN EXAMINE MENU RETURNS TO IN EXAMINE MENU A NM 4 00 SIG LO 1 20 00 SIG HI 30 00 PRES CES FAULT MESSAGES FROM FAULTS IN EXAMINE MENU n t POS ERR RESET v RETURNS TO TE OTHER FAULTS FAULTS IN EXAMINE MENU A E OTHER FAULTS CLEAR TE MESSAGES Figure 35 Parameter and Message Displays 50 OE Normal Operation Positioner Functions In normal operation the SVI unit operates as a positioner using a 4 20 mA input signal as set point
25. Fault Messages 56 57 Table 8 Local Configuration Options 68 Table 9 Controller Fault Messages 74 75 Use of DANGER WARNING CAUTION and NOTE These instructions contain DANGER WARNING CAUTION and NOTE where necessary to alert you to safety related or other important information Hazards which result in severe personal injury or death Hazards which could result in personal injury Hazards which could result in equipment or property damage Alerts you to pertinent facts and conditions Although DANGER and WARNING hazards are related to personal injury and the CAUTION hazards involve equipment or property damage it should be understood that operation of damaged equipment could under certain operational conditions result in degraded process system performance which may lead to personal injury or death Therefore comply fully with all DANGER WARNING and CAUTION notices IMPORTANT SAFETY WARNING Please read these instructions carefully BEFORE this instrument is installed or maintained These positioners and controllers are intended for use with industrial compressed air systems only Ensure that adequate pressure relief provision is installed if application of system supply pressure could cause downstream equipment to malfunc tion Installation should be in accordance with local and
26. If the SVI fails for any reason including power fail ure or air failure the SVI cannot enforce these limit stops and the valve will go to fail safe Furthermore the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls If safety requires the use of limit stops mechanical limit stops should be used In PL OFF ON if sta tus and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item In PU OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item The SVI local display may be configured to display English or French If the language displayed is co rrect press to move to next item If not press repeatedly to display other language options When the desired language is displayed press to move to next item At gt MAN press to move to the top of the CONFIGURATION menu or to move back to the previ ous item To leave the CONFIGURATION menu press This returns you
27. In SIG LO if the displayed value is correct press to advance to the next item If not press to display value of SIG LO Use and buttons to change the value When OK press to return to menu and move to next item 10 SIG HI displays the input signal that should correspond to the full open or full closed position of the valve depending upon whether the valve is air to open or air to close and whether the positioner is direct or reverse SIG HI must be larger than SIG LO by at least 5 mA In SIG HI if the displayed value is correct press to advance to the next item If not press to display value of SIG HI Use and buttons to change the value When OK press to return to menu and move to next item 11 The PRES HI menu item allows the user to enter the supply pressure This pressure is used for scal ing of the pressure data in the SVI In PRES if the displayed value is correct press to advance to the next item If not press to display value of PRES HI Use and buttons to change the value When OK press to return to menu and move to next item 12 Calibration as a positioner is now complete At gt MAN press to return to the MANUAL mode POS MAN displayed Return to Normal Operation To return to NORMAL OPERATE mode from any menu press or repeatedly until MAN or OPER is displayed If OPER appears press to return to NORMAL OPERATE mode If MAN appears press to return
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29. Ohms potentiometer Accuracy Total accuracy 0 5 of span typical 0 25 Linearity conformity lt 0 2 typical 0 1 Hysteresis Plus Deadband lt 0 2 of span typical 0 1 Actuator Pressure Measurement lt 0 3 of full scale Accuracy Start Up Drift Less than 0 02 during first hour Long Term Drift Less than 0 003 per month Supply Pressure 20 100 psi 1 4 7 bar Air Delivery at 60 PSI 25 cubic meters hour 15 SCFM Air Consumption 0 4 cubic meters hour 7SLPM Table 1 Performance Specifications cont Temperature Effect lt 0 01 degree C typical Humidity Effect Less than 0 2 after 2 days at 40 C 95 RH Insulation Resistance Greater than 10 G Ohms at 50 RH MTBF 50 years based on MIL handbook calculation for electron ic parts and field data on mechanical parts Electromagnetic Compatibility Electrostatic discharge No effect with contact discharge level of 4KV and air discharge level of 8 KV IEC 1000 4 2 Radio frequency interference Less than 0 2 at 10 volts per meter EN 50140 Fast Transient Burst No effect at 2 KV Coupling clamp IEC 1000 4 4 Magnetic Field Negligible at 30 A m EN61000 4 8 EC MARK certified to EN50081 2 and EN50082 2 Connections Pneumatic 1 4 inch NPT Electrical Two 2 1 2 inch NPT or M20 Enclosure Rating IP 65 NEMA 4X Suitable for coastal environment atmosphere with acids atmosphere with dust fly ash Position Travel Limits R
30. SVI must be returned to factory for service on this component Confirming Configuration Setup Calibration and Limit Stops If the valve has performed properly in the manual mode continue with following procedure This series of checks confirms proper configuration setup calibration and establishes parameters for further testing 1 2 3 Place the SVI in the Manual Mode using ValVue the handheld or the pushbuttons Check the following conditions Confirm the accuracy of configuration and setup parameters by going to Configure and Calibrate menus and verifying that the parameters are correct e Run Find Stops e Perform an Auto Tune from the Calibration section e If continuing to experience problems run AutoTune again If using ValVue or the handheld set the PID parameters to values recommended in the PID parameters list If problems persist consult factory If above test results are satisfactory continue with Initiate Valve Movement 50 86 Initiate Valve Movement 50 Use the series of checks in this procedure to confirm that the configuration is correct 1 Place the SVI in Manual Mode using ValVue handheld or the pushbuttons Set the position setpoint to 50 Confirm whether valve moved to set position If valve is in proper position continue with Initiate Valve Movement 95 procedure below If valve is not in proper position set to full open and check whether
31. Subassembly 93 Disassembly Procedure Completely shut down the SVI Isolate the valve from the process Put the positioner out of service Shut off air supply Install warning signs or lockouts as necessary to ensure against accidental re activation of SVI WARNING Failure to completely shut down SVI can damage the system or result in personal injury Unscrew pilot subassembly and disengage it from the body Note Turn the pilot subassembly while removing to prevent damage to O rings Remove the end plug and withdraw the spring plug and extension pin Do not disassemble or adjust the extension pin Wipe the parts with a clean soft cloth and blow clean compressed air through the orifices Clean all sur faces with isopropyl alcohol only Do not use chloride based solvents Reassembly Install three new O rings on the pilot spool Apply a light coating of a compatible lubricant to each ring Insert the extension pin and the plug into the pilot spool with the countersunk end first Note The plug should slide into the spool by its own weight Install the spring in the pilot spool with the small diameter end contacting the plug Screw the pilot end plug into the pilot spool Install the pilot subassembly into the body 94 HART Communications This section contains information about computer and peripheral connections necessary to achieve prop er communication so that SVI can communicate with ValVue or a Hand He
32. and exhaust connections on the pneumatic block EXHAUST ACTUATOR SUPPLY AIR SUPPLY Figure 43 Exhaust Actuator and Air Supply Connections Additionally the following conditions must be met Ensure that the exhaust port can vent to atmosphere e g no obstructions or foreign matter block ing ports Connect the actuator port behind the pneumatic block to the actuator For best response times use 3 8 tubing Confirm that the supply pressure gauge reads the supply pressure and that the supply pressure registers 20 psi minimum Actual supply pressure used is a function of actuator supply rating e Momentarily disconnect the supply current voltage to the SVI and verify that the output pressure registers close to 0 psi and that the valve sits against a stop Note Air to open ATO requires a normally closed valve Air to close ATC requires a normally open valve 78 Supply Pressure SVI requires sufficient supply pressure to drive the valve against the stops For best results the supply pressure should be 5 to 10 psi higher than the actuator nominal pressure range as shown on the data plate For example if the spring range is 11 23 psi set supply to between 28 and 33 psi The maximum pres sure rating of the SVI is 100 psi however in most cases the actuator pressure rating is the controlling fac tor in determining supply pressure If pressures higher than 100 psi are required consult factory
33. at one point only The signal loop should also be grounded at one point only 40 Split Range Split range SVI requires special consideration of the compliance voltage the SVI requires about 11 Volts the spec is 12 Volts Two SVI in series will therefore require about 22 Volts But the typical cur rent source can only deliver about 24 Volts so the system will be Voltage starved One solution is to use an active barrier for each loop Using an active barrier allows up to three SVI to be operated from a single 4 20 mA DCS output Each barrier has a low compliance Voltage input requirement and a high voltage output capacity So three barriers can be connected in series input Figure 28 shows the same barriers as are used in the multiplexer Figure 28 Split Range Active Barrier Another approach is to boost the compliance voltage of the DCS using a power supply see figure 29 The DCS vendor should be contacted to validate this approach 10 Volt Figure 29 Compliance Voltage Boost A further constraint on the split range system is that the minimum span is 5 mA the upper range value is 8 to 20 mA and the lower range value is 4 to 14 mA Example 4 9 mA 9 14 mA 14 20 mA 41 Chapter 3 Operation SVI Positioner Introduction Operation of the SVI Positioner as a local device is controlled through the optional device mounted push buttons and digital display as shown in Figure 30 Using the display you can r
34. custom curve must have been entered through the remote PC TS OFF or ON Display and set value of tight shutoff point Default is 0 096 PL OFF or ON Display is set value of the lower software position limit stop Default is 0 096 PU OFF or ON Display is set value of the upper software position limit stop Default is 100 096 ENGLISH or FRENCH Select language for displays English or French Table 8 Local Configuration Options 68 Procedures To configure or modify the SVI controller pushbutton configurable parameters execute the following pro cedure 1 If in NORMAL OPERATE mode press any button OPER will be displayed Press to get to the MAN menu item Press to move to MANUAL menu POS MAN displayed This locks the valve in position and places it in Manual Mode Press twice to move to CONFIG option Press to put the SVI in the configure mode and display the first item in the CONFIGURE menu If Single or Double displayed is the one desired press to move to the next item If not press to select the alternate choice When OK press to move to next item Note DOUBLE is not pres ently implemented In CTL ON OFF ON should be displayed for controller If display shows OFF press to select ON Press to move to the next item NOTE Any SVI that has been factory set for controller operation can be operated as a positioner by simply changing CTL ON OFF back to OFF In ATO A
35. in the list is CLEAR When this message is displayed you can clear all faults by pressing This will also return you to FAULTS in the EXAMINE menu If you do not want to clear all fault messages press or to move to another item in the list You can then press to return to FAULTS in the EXAMINE menu without clearing fault messages This completes the EXAMINE functions 55 Positioner Fault Messages Table 7 lists the fault codes messages that may appear on the display The table also explains the mean ing of each message the probable cause of the fault and recommended action you should take to correct the fault Table 7 Positioner Fault Messages Display Code Fault Message Meaning Latched Probable Cause Error POS ERR Position Error BIAS ERR Output at null point is out of range POS SEN Position Sensor Error PRES SEN Pressure Sensor Error SIG SEN Current Sensor Error REF ERR Reference Voltage Error SW ERR Self Check Failure RESET OVER RUN Data Overrun Valve is stuck or feedback linkage is disconnected or bro ken Valve position did not agree with SVI output command within acceptable time Bias is out of range Supply pressure too low or incorrect pneu matic block adjust ment J The position sensor has failed or is not aligned properly Failed or linkage aligned incorrectly 4 J Hardware failure The pressure sensor has failed The primary signal 4 20 sensor h
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37. option installed at the factory With this option installed the SVI can be operated as either a positioner or controller selectable by Val Vue HART Communicator or the local pushbuttons Local pushbuttons support limited controller functions Operation of the SVI Controller with firmware version 1 0 5 requires that all controller operating parame ters be entered from either ValVue software or from a HART 275 Hand Held Communicator with Masoneilan SVI Software The operating parameters that are used for both controllers and positioners can be entered either from the local pushbuttons or ValVue or the Hand held The primary process measure ment made by the process transmitter is fed to the controller as a 1 5 V dc signal and connected to ter minals A and B on the SVI terminal board An SVI with firmware version 1 0 6 allows local pushbutton entry of setpoint values and choice of local or remote setpoint The main controller operating parameters P I D etc still must be entered via ValVue or HART Handheld Communicator The version 1 0 6 display shows 1 setpoint remote or local as configured 2 process variable 3 valve position and 4 pneumatic output signal pressure The display sequences from one variable to the next every 1 5 seconds Using the pushbuttons you can exit from operating mode at any time and step through a menu structure to perform a wide range of manual operation calibration configuration and monitoring functio
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39. range the valve should be isolated from the process before starting calibration To calibrate the SVI unit using the local pushbuttons execute the following procedure 1 NORMAL OPERATE mode press any button OPER will be displayed Press to get to the MAN menu item 2 Press to move to MANUAL MENU POS MAN displayed 3 Press to move to CAL option 4 Press to go to CALIBRATE menu STOPS will be displayed 5 In STOPS press to initiate the operation which moves the valve to fully closed then fully open and then returns to the starting position This operation calibrates the end points for the position feedback potentiometer When the operation is complete press to move to the next item CAUTION This function strokes the valve over its full range Do not execute while valve is controlling the process 70 On some valves the full travel is larger than the nominal travel of the valve and it may be desirable to have the reported 100 position correspond to the nominal travel rather than the full stroke The STOP OP option allows this correction If a correction is to be made press to move valve to the 100 position Using the and buttons position the valve to the nominal full open position Press to accept this position as the new 100 position The Bias is the signal sent to the internal I P that causes the actuator to neither fill nor exhaust The pneumatics are adjusted at the fac
40. so may result in damage to the SVI Terminals for Connecting 4 20 mA Current Input or 12 24 V DC Multi Drop Digital Input Signal HART Protocol Jumpers to Select Voltage Multi Drop or Current Input Signal Set Point Input Signal Internal Ground External Ground Located Beneath Display Pushbutton Cover External Position Feedback Pot Terminals for Connecting External Pot for Position Feedback or for Process Variable Input When 5 is Used as a PID Controller t A B c Ao Contact Closure Bo Inputs gt Lil Process Variable Voltage Signal A 250 OHM Resistor is necessary for Current Input Signal only if this resistor does not already exist in the B wiring in the control room Figure 44 Wiring Connections 80 The terminal board shown in Figure 44a reflects a design change to be released in early 1999 which incor porates the following enhancements Additional terminals D and E allow the contact input feature to be used with the controller option e Optional terminals POS and POS provide an isolated 4 20 mA signal related to charac terized valve stem position The voltage compliance of the position output terminals is 11 50 V dc The HART signal is not available on the position terminals The HART protocol is available on the LOOP terminals software revision reported by the HART ID command is 6 OPTIONAL POSITION OUTPUT 4 20 Ma S
41. supply pressure regu lated 5 to 10 psi higher than spring range of actuator Air quality requirement per ISA S7 3 Vibration Limits 4 mm at 5 to 15 Hz negligible Measured at the SVI Housing 2 Gat 15 to 150 Hz less than 2 of span 1 G at 150 to 2000 Hz less than 2 of span Security Timeout of hardware watchdog timer clamps output to fail safe condition and initiates CPU reset Timeout of soft ware microprocessor COP watchdog timer initiates CPU reset Pushbuttons include four levels of authorization Level is set using ValVue or HART hand held controller ValVue includes six levels of authorization Password pro tected Positioner Alarms Hi Low limits not latched Deviation time not latched Deviation time latched initiates failsafe Failsafe Unread status messages Table 1 Performance Specifications cont ____ O Specification Controller Alarms Programmable Hi Lo process alarms 0 to 100 absolute or deviation Process Controller Functions Local setpoint remote setpoint manual Ratio control with setpoint bias Local setpoint tracking Process Controller Settings Output rate limit 0 to 6196 per sampling period Manual reset 0 to 90 Proportional gain 0 to 1 000 Integral time 0 to 1 000 seconds Derivative time 0 to 32 seconds Derivative gain 2 to 100 Gain non linearity 9109 Dead zone 0 to 20 Hi lo set point limits 25 above hi PV or below low PV Status Messages POSITION ERRO
42. tee tege lied dae bei E ode 94 HART Communications 95 Setup and Administration 2 1 95 Communication Port and Settings 95 Use of Laptop Computers 95 Mouse Interference 95 Hand Held Considerations 95 Failure to Communicate 96 Fatal and Non Fatal Errors 97 cic M PME 97 Non fatal Errors 1 98 Diagrams Figure 1 Smart Valve Interface 4 3 Figure 2 Block Diagram of SVI Positioner 12 Figure 3 Block Diagram of SVI Controller Positioner 12 Figure SVI Block Diagram 13 Figure 4 Input Output Diagram of SVI Unit 15 Figure 5 System Diagram Intrinsically Safe Installation 16 Figure 6 System Diagram Explosionproof Flameproof Installation 16 Figure 7 Single Loop PID Configuration with No Process Feedback 17 Figure 8 Single Loop PID Configuration
43. the controller option It is suitable for general purpose locations and to explosionproof flameproof installations when applicable wiring codes are observed 24 VDC from DCS Optional 4 20 mA Position Output 1 to 5 Volts POSITION FEEDBACK to DCS Optional POSition eosin Output Communicator Terminals 2 Model 275 4 to 20 mA SETPOINT from DCS Optional Screen Optional Connection For Potentiometer or Un Powered Contacts Optional 1 5 Volt Process Variable Input to SVI Optional Screen Optional Process Variable Transmitter 4420 Transmitterg Optional 4 20 mA Process Variable i 1 to 5 Volts Process Variable to DCS Figure 24b General Area Purpose Installation 34 Hazardous Area Installations The SVI is available in versions suitable for use in hazardous areas The labeling on the positioner indi cates approved areas of use WARNING Installation of any hazardous area equipment must be made in accordance with the appropriate hazardous area installation codes and the manufacturers installation and operating instructions The user must make no changes or attempt any repairs of a certi fied instrument since this will invalidate the certified design If a certified instrument should fail it must be returned to the manufacturer for repair Factory Mutual approved model Explosionproof Class Division 1
44. times the value of the series resistor for example a 250 Ohm resistor will reduce the effective compliance volt age by 5 Volts Consider that the compliance voltage of a typical current source is 24 Volts and the volt age requirement of the SVI is 12 Volts typically only about 10 5 Volts there is plenty of compliant voltage even with 5 volts dropped by the series resistor Current Source Figure 27 Resistor Add in Series with Current Source 39 Noise Constraints Hart Communication depends on converting two frequencies into digital values O and 1 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 one point only will minimize the effects of noise Interference with DCS The HART signaling frequencies are a 1mA peak AC current This AC current flowing in the DSC out put can cause a shift in the DCS 4 20 mA DC signal both Honeywell and Moore Products DCS require a filter between the DCS and the HART signaling devices to prevent the HART frequencies from upset ting the DCS output The filter also serves to establish a minimum impedance of greater then 250 Ohms and to prevent AC frequencies generated in the DCS from interfering with the HART communica tion Cabling and Interconnection Constraints Interconnections should be made using shielded twisted pair cables The shield must be connected to ground
45. to A W G 14 Figure 24 shows layout of terminal board currently in production Jumpers to Select Voltage Terminals for Connecting 4 20 Multi Drop mA Current Input or 12 24 V DC Multi Drop Digital Input Signal or Current Input Signal HART Protocol Set Point Input Signal Internal Ground External Ground Located Beneath Display Pushbutton Cover External Position Feedback Pot Terminals for Connecting External Pot for Position Feedback or for Process Variable Input When is Contact Closure Used as a PID Controller Inputs Process Variable Voltage Signal A 250 OHM Resistor is necessary for Current Input Signal only if this resistor does not already exist in the B wiring in the control room Figure 24 Electrical Connections to Main Terminal Board Current Production 32 Figure 24a reflects a design change to be released in early 1999 which incorporates the following enhancements Additional terminals D and E allow the contact input feature to be used with the controller option e Optional terminals POS and POS provide an isolated 4 20 mA signal related to charac terized valve stem position The voltage compliance of the position output terminals is 11 50 V dc The HART signal is not available on the position terminals The HART protocol is available on the LOOP terminals software revision reported by the HART ID command is 6 All terminals both
46. to Manual Mode Menu Then press repeatedly until OPER appears Then press to return to NORMAL OPERATE mode and normal operation Examine Functions The EXAMINE menu permits you to display calibration parameters configuration parameters and to dis play and or clear fault status messages and codes Refer to the Table 8 for explanations of fault mes sages You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode When entered from NORMAL OPERATE mode the valve still responds to changes in set point input signal and the values displayed change in accordance with changes in input signal When entered from Manual mode the valve is locked in position When you exit from the EXAMINE menu you return to the menu from which you entered Procedures Examine Calibration Parameters To examine the calibration parameters execute the following procedure 1 If in NORMAL OPERATE mode press any button 2 Press to move through the options until you reach the EXAMINE menu item Press to go to EXAMINE menu This leaves valve in NORMAL OPERATE mode If in MANUAL mode press repeatedly until the EXAMINE menu item is reached Press to select the EXAMINE mode 3 Press repeatedly to move through the EXAMINE menu until CALIB is reached Press to display the list of calibration values To move forward through the calibration parameters in sequence press To move back through the list press Press
47. to connect another HART master terminal device e g a hand held device ValVue will not operate with a second terminal device either primary master or secondary master 96 Fatal and Non Fatal Errors Fatal Errors The following definitions describe typical fail safe fatal errors Error Description Explanation Likely Cause s POSERR Position The valve did not go to the Valve lost air pressure Error requested position within Valve movement is the time configured in blocked Position Error Time 2 Setting of Position Error Time 2 is too low for the size of valve POSSEN Position Position sensor failed Improperly adjusted Sensor linkage resulting in the Error potentiometer out of range at one limit or the other Potentiometer connector is disconnected A broken wire SIGSEN Current The input signal sensor Electronic failure within Sensor has failed the module Error REFERR Reference The reference voltage Electronic failure within Voltage within the SVI is out of the module Error range HWERR Self Check The SVI failed an internal Electronic failure within Failure self check the module OVERRUN _ The SVI could not process Electronic failure within Overrun the input data the module 97 Non fatal Errors The following definitions describe typical non fatal errors SVI reports these errors they do not cause fail safe condition Error Description Explanation Likely Cause s
48. to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item In PU OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item The SVI local display may be configured to display English or French If the language displayed is cor rect press to move to next item If not press repeatedly to display other language options When the desired language is displayed press to move to next item At MAN press to move to the top of the CONFIGURATION menu or to move back to the pre vious item To leave the CONFIGURATION menu press This returns you to the MANUAL menu POS displayed This completes the configuration procedure 14 To continue with calibration press to move to CAL option Continue with Step 4 below 52 Local Calibration NOTE Perform configuration before running calibration functions Functions You can perform the following calibration functions with the SVI product Low and high values
49. to the MANUAL menu POS MAN displayed This completes the configuration procedure 69 Controller Functions If the controller set point parameters were not set during initial configuration using Val Vue or HART Hand Held they may be set by the following procedure 1 Press to move to CONTROLLER Menu 2 Press to toggle between REMOTE AND LOCAL Leave on desired action and press to move to SETPOINT 3 Press or to enter new value Press to exit back to SETPOINT Press to move to I SETPOINT 4 Press or to enter new value Press to exit back to SETPOINT Press to move to CANCEL 5 Press to return to NORMAL or MANUAL Menu without saving changes Press to move to OK 6 Press to return to NORMAL or MANUAL Menu with changes saved 7 To continue with calibration press twice to move to CAL option Continue with Step 4 below Local Calibration NOTE Perform configuration before running calibration functions Functions You can perform the following calibration functions with the SVI product Low high values for input signal Low and high values for actuator pressure output Set the minimum and maximum stops for valve position Procedures Refer to the menu structure diagrams in Figures 37 through 42 pages 62 to 67 for assistance in follow ing the procedures described CAUTION Since some calibration functions stroke the valve over its full
50. unit An extensive replacement inventory is available for immediate shipment If this service is needed contact your local salesperson or contact Masoneilan Dresser at www masoneilan com Common Problems The troubleshooting checklist guides the user through a number of possible faults However prior to utiliz ing this list the user should make an initial assessment of the installation looking at the following items Is the mounting of the correct and the linkage orientation proper Are all linkage mechanical connections securely tightened Areall pneumatic connections tight and is the supply pressure the correct value for actuator being used Are electrical connections made to the correct terminals and securely tightened Assuming the display is active the user should carefully check that all configuration parameters are compatible with the valve under control and properly entered in to the positioner lf the SVI has been under control of ValVue and left in the full open or full closed position the buttons cannot take control of position in the Manual Mode To regain control go to Normal Mode in ValVue and then to Manual before exiting ValVue or power down power up the SVI 77 Pneumatic Connections The SVI requires a regulated air supply of clean dry oil free instrument air conforming to the requirements od ISA S 7 3 Quality Standard for Instrument Air Figure 43 shows the locations of supply output
51. versions accept wire sizes up to A W G 14 OPTIONAL POSITION OUTPUT 4 20 Ma SETPOINT INPUT SIGNAL Pos SUPPLY CONNECTION WIRING MUST BE RATED FOR 85 C MINIMUM PROCESS VARIABLE 1 5 VOLTS UNPOWERED AB CONTACT INPUT C D E Figure 24a Electrical Connections to Main Terminal Board 33 When operated with current input the loop controller or any other current source must be capable of sup plying 4 20 mA with an output voltage compliance of at least 12 V Before applying power to the SVI make sure current voltage jumper is in correct position The available output voltage of a current source will be reduced by loop wiring resistance This can be checked by connecting a resistor of value 600 ohms loop resistance across the output of the current source and verifying that 20 mA is obtainable at full scale output The SVI is normally supplied with two 1 2 NPT conduit entries M20 adapters are available Internal and external ground terminals are provided for use if grounding is required WARNING The SVI must be installed in accordance with local and national codes of prac tice in both general purpose and hazardous area locations The electrical components are fully isolated from ground and therefore grounding is unnecessary for functional purposes Grounding may be necessary to conform to installation codes Figure 24b is a composite wiring installation diagram applicable to both SVI versions and to
52. 0 Typical SVI Mounting on 37 38 Actuator Figure 21 Typical SVI Mounting on 84 85 Actuator 27 108 2 52 6 OUTPUT NPT 91 Minimum to Remove Cover 187 0 AIR TM 2 1 4 NPT 245 4 VIEW A A 157 0 4 5 13 0 81 be Minimum to CONOUIT ENTRY 2 1 2 NPT I 388 7 Figure 21a Smart Valve Interface Outline Drawing 28 Actuator Centerline SVI Centerline 053 8 Clearance for Clearance for Air Output Through hole or 1 4 Thread or M6 Thread Clearance for SVI Cover Figure 22 SVI Mounting Interface Lever and Linkage Design A lever length should be chosen depending on the stroke of the given actuator Table 4 can be used as a guide in determining lever lengths The recommended lever material is aluminum 6061 temper anodized for corrosion protection This lever should be designed to the basic dimensions as shown in Figure 23 If designed in a material other than aluminum the clamping effort for the M5 screw must be reviewed to ensure proper attachment to the SVI shaft Valve Stroke mm inches Lever Length mm inches 12 7 0 5 19 1 0 75 25 4 1 0 31 8 1 25 50 8 2 0 76 2 3 00 101 6 4 0 139 7 5 50
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54. 5 Terminals 2 4 to 20 mA SETPOINT from DCS Optional Screen Shunt Zener Diode i Safety Barrier 1 Controller output type example Optional MTL 728 See Note 5 Connection For Potentiometer or Un Powered Contacts See Notes 1 4 Optional 1 5 Volt Process Variable Input to SVI Shunt Zener Diode Safety Barrier Transmitter type with sensing Process Variable resistor for Transmitter example MTL 788R See Notes 5 6 24 VDC from DCS Optional Intrinsically Safe I See Notes 1 4 1 to 5 Volts Process Variable to DCS 4 Figure 25 Approved Intrinsically Safe Installation Control Drawing 36 Notes 1 10 The electrical circuit in the hazardous area must be capable of withstanding an A C test voltage of 500 volts R M S to earth or frame of the apparatus for 1 minute Entity Parameters SVI and LOOP Terminals Vmax 30 Imax 125 mA Ci 2 2 nF Li 96 uH Pmax 900 mW SVI and POS Terminals Vmax 30 Imax 125 mA Ci 2 2 nF Li 96 uH Pmax 900 mW SVI D AND E Terminals Vmax 30 Imax 125 mA Ci 0 nF Li 2 0 uH Terminals C D and E may be connected to an external position sensing potentiometer or to unpowered switch contacts both of which fall in the category of simple apparatus and located in the hazardous area within 10 feet of the SVI positioner Cable capacitance and
55. 610 that approach or converge on a real Bias value Expect the valve to move back and forth slow down and remain still by the end of this step In estimating control parameters SVI displays three types of values input step sizes such as 80 and 320 valve relative opening such as 1874 and 1756 and dead time such as 4 00 and 7 00 Expect the valve to move back and forth several times SVI uses these tests to estimate the preliminary control parameters based on position control characteristics In refining the estimated control parameters SVI displays several numbers such as 1211 and 6 Interpret the number 1211 as the rising time T98 is 12 x 0 05 sec 0 6 sec and overshoot is 11 The code num ber 6 indicates a specific control parameter adjustment 89 Auto Tune Results A successful AutoTune provides position step responses in both air fill and exhausting directions that meet the tuning criteria Overshoots range between 0 and 8 and rising times range from 0 3 second for a small actuator to 1 5 second for a large actuator A successful AutoTune updates the previous control parameters AutoTune usually results in fast position responses 0 to 8 overshoots If you prefer a smooth response without overshoots reduce the P value by 10 to 20 If you prefer a slow response set the damping coef ficient at 1 to 9 e g zero equals no damping 9 equals maximum damping Damping Coefficient The following chart lists the
56. AL DISPLAY AND COMMUNICATION 3 PUSHBUTTONS Figure 5 System Diagram Intrinsically Safe Installation NONHAZARDOUS LOCATION HAZARDOUS LOCATION PROCESS 5 CONTROLLER SMART VALVE INTERFACE OOD TO SERIAL PORT ON PERSONAL RS 232 HART POSITION FEEDBACK COMPUTER MODEM FROM VALVE STEM HART PROTOCOL EXPLOSION PROOF COMMUNICATION DIGITAL DISPLAY AND 3 PUSHBUTTONS Figure 6 System Diagram Explosionproof Flameproof Installation 16 System Description PID Controller When the SVI unit is configured as a PID controller the and terminals are used to power SVI and to remotely set the controller s input The primary process measurement made by the process transmitter is fed to the controller as a 1 5 V dc signal and connected to terminals marked and B Various configura tion schemes using remote set point input are illustrated in Figure 7 Figure 8 and Figure 9 Wiring dia grams are descriptive only actual wiring must adhere to Electrical Installation section of manual PROCESS TRANSMITTER Q 24V DC 280 POWER SUMS SUPPLY ne B SVI CONTROLLER COMMON REMOTE SETPOINT INPUT 4 20mA Figure 7 Single Loop PID Configuration with No Process Feedback Figure 7 is the
57. ATE SEE NOTE BELOW ENTRY STATE NOTE In order to quit EXAMINE MENU if entry is from MANUAL MENU then at step gt MAN it is necessary to key which displays OPER and key again to return to MANUAL MENU Figure 41 Examine Menu Structures 66 CONFIGURATION PARAMETERS FROM CONFIG IN EXAMINE MENU SINGLE ATO EN LINEAR 5 0 v RETURNS TO SCONFIG IN EXAMINE Parameter and Message Displays CALIBRATION PARAMETERS FROM CALIB IN EXAMINE MENU RETURNS TO sCALIB IN EXAMINE MENU FAULT MESSAGES FROM FAULTS IN EXAMINE MENU POS ERR RETURNS IN EXAMINE MENU CLEAR MESSAGES Figure 42 Parameter and Message Displays 67 Normal Operation Controller Functions In normal operation the SVI unit operates as a controller using a local or remote input signal as set point The primary process measurement made by the process transmitter is fed to the controller as a 1 5 Vdc signal The local digital display sequentially displays set point remote or local as configured process vari able valve position and actuator pressure on a 1 5 second interval Pressing any button moves you to the OPER option in the OPERATE MODE MENU as shown in Figure 37 on page 62 The OPERATE MODE MENU has 4 options MAN put
58. Ambient T5 82 C Max Ambient 82 C Installation must be in accordance with the current edition of the Canadian National Electrical Code Part I any applicable local codes and manufacturers instructions 35 Intrinsically Safe Class Groups A and D Class Groups F and Class Ill Supply 28 Vdc 4 20 mA Enclosure Type 4X Temp Code T4 40 C Ambient T3B 70 C Ambient T3A 82 C Ambient Max Ambient 82 C Installation must be in accordance with the current edition of the Canadian National Electrical Code Part 1 Figure 25 Installation Drawing ES 641 shown below and manufacturers instructions SVI SMART VALVE INTERFACE FACTORY MUTUAL AND CANADIAN STANDARDS ASSOCIATION APPROVED INTRINSICALLY SAFE INSTALLATION CONTROL DRAWING Non Hazardous Location Unspecified Except That Barriers Must Not Be Supplied From Nor Contain Under Normal or Abnormal Conditions A Source of Potential With Respect to Earth in Excess of 250 Volts Hazardous Location i RMS or 250 Volts DC Class Il Ill Division 1 amp 2 Groups A B C D E F and G l See Notes l 1 4 1 Optional 4 20 mA i 24 VDC from DCS Position Output 1 to 5 Volts POSITION FEEDBACK to DCS Optional POSition Optional Shunt Zener Diode Output Hand Held Optional Screen Safety Barrier Communicator Transmitter type with sensing Model 275 resistor example MTL 788R See Note
59. CIONS DP 70 ses oor oa dew ie eh ba 70 Return to Normal Operation 72 2C 72 6 72 72 Examine Calibration Parameters 72 Examine Configuration Parameters 72 Display Clear 5 1 73 Controller Fault Messages 74 Operation SVI Positioner Controller using HART Handheld Communicator 76 Operation SVI Positioner Controller using ValVue Software 76 Chapter 5 Troubleshooting 77 Oe es 77 Factory SENICE 5224 5 54 77 Common Problems 77 5 22s a sed Gee eee 78 Supply Pressufe seas dcc ee a ae a ee 79 Verifying Supply Pressure 79 Electrical Connections 4 80 Verify Wiring and Connections 1 82 Ground Pra
60. CTUATOR PRESSURE AND LSP or R SP ON A 1 5 vv 3 SECOND INTERVAL PRESS gt INCRIDECR VALVE OSITION POS PRESS ACCEPT TO DISPLAY y 4 i SEQUENCE fH CALIBRATE TO STOPS IN CALIBRATE MENU ty zu HHH Ck i TO SINGLE OR _ DOUBLE IN CONFIG H MENU ty THER TO REMOTE IN CONTROLLER MENU ty aA HHH gt TO CONFIG IN EXAMINE EXAMINE MENU A i THE THER DISPLAY OPER DISPLAY t SEQUENCE E Figure 37 Normal Operate Mode Select and Manual Mode Menus 62 Configure Menu Because calibration depends on certain configuration options you must perform Configuration before you perform Calibration when installing the SVI the first time FROM BM coNric IN MANUAL MENU SELECT TYPE OF ACTUATOR DOUBLE NOT IMPLEMENTED AT PRESENT SELECT CONTROLLER OPTION CTL OFF 15 ALWAYS SELECTED IF NO CONTROLLER IS PRESENT EVEN IF NO LIMIT SW IS USED SELECT AIR TO CLOSE OR AIR TO OPEN VERY IMPORTANT TO SET CORRECTLY SELECT CHARACTERIZATION TURN TIGHT SHUTOFF OFF OR ON PROVIDES MAX SEATING FORCE AT 0 POSITION SOFTWARE LOWER LIMIT STOP SETTINGS VALUE DISPLAYED IF SET TO ON IF ON VALVE CANNOT GO BEYOND LIMIT
61. ETPOINT INPUT SIGNAL Pos SUPPLY CONNECTION WIRING MUST BE RATED FOR 85 C MINIMUM PROCESS VARIABLE 1 5 VOLTS AB UNPOWERED CONTACT INPUT C D E Figure 44a Wiring Connections 1999 Release 81 The SVI is polarity sensitive so the positive lead must be connected to the positive terminal and the negative lead to the negative terminal Reversal of input will not cause damage but the unit will not func tion Verify Wiring and Connections Check that the SVI is properly powered per following Connect a voltmeter across the input terminals Note Test pins located adjacent to the terminal strip facilitate connection of the voltmeter For any input current value between 3 8 and 22 mA the voltage should be between 9 5 and 11 V f voltage exceeds 11 5 V check that polarity is correct and that V mA jumper is in correct position If voltage is less than 9 5 volts and polarity and jumper are correct voltage compliance of current source may be inadequate Connect milliammeter in series with current signal and verify that source can supply 20 mA to SVI input If 20 Ma is not attainable current source may be inadequate for this type of service or other loads or inclusion of Intrinsic Safety barriers may be limiting the source drive capability Ground Practice Make sure that case signal and if utilized process controller ground connections are made in compliance with plants normal grounding pract
62. H ALIANT NOILISOd 330 NOILVZIMSLOVYVHD SIS NOILISOd IH NOILOV YOLYNLOV SIS NOILISOd 01 3 ALVLS YATIONLNOD H JO 3fY IVA AV1dSI0 YOLYNLOV ainssaid JO AN TWA AV1dSI0 gt 5 TVNANYN SOW TVIAHON SVIONVUS HSITSNA NOLLISOd IH NOLLISOd O1 440 NO 440 LNHS LHOIL WOLSND MDINO 0E 0S MVANIT i gt FYNDIANOD DLVIOLY 440 NO t3 110H1NOO a18nodmnsNis SLINVA amp SLINVA 31vugrivo 11241435 antes SIS H3NOILISOd YANOILISOd ANNA OLNV Seiwa tigde dole IAS SdO1S ANIJ 0 UOISISA 1199135 3NIWVX3 91n5IHNO2 uonisod eae IAS NOLLNG 5 45 Menu Structure The menu structure for operating the SVI from the local pushbuttons and display is shown in Figure 31 to Figure 35 on the following pages NORMAL OPERATE Mode and Manual Mode Menus Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode the valve is placed in the last
63. MASONEILAN SVI SMART VALVE INTERFACE Digital Positioner and Controller INSTRUCTION MANUAL VALVE DRESSER DIVISION Masoneilan is a registered trademark of Dresser Industries Inc A Halliburton Company SVI is a registered trademark of Dresser Industries Inc ValVue is a trademark of Dresser Industries Inc HART is a registered trademark of the Hart Foundation Pentium is a trademark of Intel Corporation Copyright 1999 by Dresser Equipment Group Inc All rights reserved TABLE OF CONTENTS Chapter 1 Overview 2 SCOPE Ol A 2 Product Description ean RR saga 2 Features and Functions 4 Performance Specifications 1 5 Electrical Safety Specifications 9 Principle of Operation isses dede RRxGGexT erc S EE E ve 12 Hardware Descriptlon asus kk ee Ree a ER EE ew ee eee ds 13 CT 13 Electronics Module iier e eue m aviar es 14 Pustibutton SWICHES esses 14 EPC Electropneumatic Converter 14 Spool sees oe ee eda Soe ee GU ER NUN M RR 14 Sensors Position Pressure and Temperature
64. OL NOLLNG 5 1 ebueijojnojuesumunseeu QuHVMMOVS 54315 AN IVA S3svadoad YAIANIL 5 TS euo 12 1 3007 pue 000 PUBLULUOD 1 8SN 64315 635 pajiey sdoys MH3dOls Joue seq ANTVA 6319901 HO 5123136 10418 Josues aJnssed Nasadd jese1 l3S3H uonisod NN3asod 39Vn9NV1 1n v3 AV Idsia NOLLISOd A NOILISOd 140 LNHS LHOIL NOILVZIMSLOVYVHO 915 NOILISOd NOILOV HOLVNLOV 215 NOILISOd 1 ALVLS YATIONLNOO es ae ee aunssaid uo1vnlov H JO AN TVA jeubis uonisod dO AV1dSI0 A gt 3oNanoss Av1dsid WANE 45450 IQON SVIONVHJ HSI15N3 NOLLISOd S 11nv4 NOLLISOd 44O NO 440 LMHS LHOIL ilvugarivo 3ilvHugarivo ONILYOOUdIOTY 16 2 06 06 r it DLVIOLV 44O NO YATIONLNOO g18nod 219NIs 1123135 lt ue disi
65. PRESSURE AS ENTERED SUPPLY FRESSURE PRES HI PRESS TO ENTER NEW VALUE 4 3 1 PRESS TO ACCEPT NEW VALUE AND 5 9 PROCEED TO NEXT MENU ITEM Y RETURNS 5 MANUAL MENU Figure 33 CALIBRATE Menu Siructures 48 Examine Menu This menu can be entered either from the Manual Mode Menu or from the NORMAL OPERATE Mode Menu The EXAMINE menu allows the user to read the current configuration calibration and status infor mation This information however cannot be changed from the EXAMINE menu When you exit from the EXAMINE menu you return to the menu from which you entered EXAMINE MENU FROM gt EXAMINE IN MANUAL MENU OR FROM OPERATE MENU Y CONFIG RETURNS TO MANUAL OR OPERATE MENU DEPENDS ON ENTRY STATE SEE NOTE BELOW CALIB ty FAULTS gt gt OPER gt MAN OR DEPENDS ON ENTRY STATE A PRESS OR TO STEP THROUGH CONFIGURATION PARAMETERS IN SEQUENCE PRESS RETURN TO CONFIG AT ANY TIME PRESS OR TO STEP THROUGH CALIBRATION PARAMETERS IN SEQUENCE PRESS TO RETURN TO CALIB AT ANY TIME PRESS OR TO STEP THROUGH FAULT MESSAGES IN SEQUENCE PRESS TO RETURN AT ANY TIME DISPLAYS CLEAR AT END OF SEQUENCE PRESS TO
66. R PRESSURE ERROR POSITION SENSOR ERROR PRESSURE SENSOR ERROR CURRENT SENSOR ERROR REFERENCE VOLTAGE ERROR BIAS OUT OF RANGE SELF CHECK FAILURE HART ERROR SOFTWARE ERROR RESET OCCURRED DATA OVERRUN INTERNAL TEMP ERROR EEPROM WRITE FAILED FIND STOPS FAILED Diagnostics Stored SVI Non Friction in units of pressure Volatile Memory Lo spring in units of pressure Hi spring in units of pressure can be accessed using a HART Lo pressure full exhaust Hand held Communicator or Hi pressure full supply ValVue Software Time to open Time to close Time open Time closed Time near closed Reversals cycles Total accumulated stem travel Diagnostics Plots Using ValVue Position vs time Stem position vs actuator pressure Stem position vs position setpoint Process process setpoint position position setpoint vs time 90 second window Electrical Safety Specifications Agency Factory Mutual Approvals CSA Approvals CENELEC Approvals CE Conformity Table 2 Electrical Safety Design Specifications Service Explosionproof Dust ignitionproof Intrinsically Safe Non incendive Suitable for Enclosure Rating Explosionproof Dust ignitionproof Intrinsically Safe Non incendive Suitable for Enclosure Rating Flameproof Intrinsic Safety Enclosure Rating Applicable Class Class Division 1 Groups B and D Class Il Division 1 Groups E F and G Class Il Division 1 Groups A
67. RENT TO THE NORMAL BIAS VALUE 44 PRESS OR TO RETURN TO CALIBRATE MENU PARTIALLY IMPLEMENTED NOW p INITIATES AUTO TUNE FUNCTION AND RETURNS USE TO DETERMINE TUNE TUNE WHEN FINISHED PRESSING ANY BUTTON POSITIONER TUNING 4 STOPS THE TUNING PROCESS PARAMETERS POT HEE 7 DISPLAYS VALUE OF SIG LO FOR FULLY CLOSED SIG Lo DISPLAY PRESS OR TO ENTER NEW VALUE OR FULLY OPEN 8 VALUE PRESS TO ACCEPT NEW VALUE AND 1 4 PROCEED TO NEXT MENU ITEM 1 VALUE OF INPUT M NE 1 DISPLAYS VALUE OF SIG HI SIGNAL SIG HI i DISPLAY PRESS OR TO ENTER NEW VALUE FOR FULLY CLOSED VALUE PRESS TO ACCEPT NEW VALUE OR FULLY OPEN 1 AND PROCEED TO NEXT MENU ITEM TU E7777777777 4 DISPLAYS VALUE OF SUPPLY DISPLAY PRESSURE AS ENTERED PRESHI VALUE PRESS OR TO ENTER NEW VALUE PRESS TO ACCEPT NEW VALUE 9 9 AND PROCEED TO NEXT MENU ITEM RETURNS POS MAN IN MANUAL MENU Figure 39 Calibrate Menu Structures 64 Controller Menu This menu can be entered from either the MANUAL Mode Menu or the NORMAL OPERATE Mode Menu The Controller menu allows the user to read and change the controller mode local setpoint and startup setpoint When you exit from the CONTROLLER menu you return to the menu from which y
68. S AIR SUPPLY CONFIGURED 25 TO 100 PSI 3 LOCAL DIGITAL PUSHBUTTONS DISPLAY Figure 4 Input Output Diagram of SVI Unit NOTES 1 Set point signal can come from a 4 20 mA current input or from HART protocol digital input With digital input operating power can be from 4 20 mA input or from 12 24 V dc Multidrop Supply 2 PID Controller Process Variable signal must be dc voltage signal of 1 0 5 0 V dc or a 4 20 mA sig nal through a 250 Ohm resistor 3 User configurable as dictated by actuator operating pressure range NOTE When SVI Positioner or Controller are ordered without pushbuttons or display configuration and calibration must be done using HART protocol Handheld Communicator or from ValVue software on personal computer The SVI unit accepts the following inputs Set point signal for valve position when configured as a positioner or for a PID controller when configured as a controller e Actuator pressure Valve position Remote valve position As an alternative the remote valve position input connection can be assigned as follows Upto two cold contact closures unpowered for intrinsic safety or A process variable input signal when the PID controller function is configured 15 System Description Positioner Typical system setups are shown in Figures 5 and 6 In these diagrams the SVI is configured as a posi tioner and is located in a hazardous area wiring diagrams are descr
69. TC if option displayed is correct press to move to the next item If not press to select the alternate choice When OK press to move to the next item In LINEAR or other curve if option displayed is the one desired press to move to the next item If not press to select the other options When OK press to move to next item If custom is select ed the custom curve must have been entered through the ValVue software program The curve itself cannot be entered from the local pushbuttons The tight shutoff TS option allows the user to configure the positioner to apply full supply pressure or atmospheric pressure to the actuator whenever the signal directs the valve near the closed pos ition If the tight shutoff option is on the value of the TS option determines the near value at which the valve is forced fully shut In TS OFF ON if status and value displayed are satisfactory press to move to next item If not press to change on off status and display value Then press or but tons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item The SVI allows the user to configure a lower PL and upper PU software position limit stop When in operation with these limits on the valve will not move below the lower limit stop or above the upper limit stop Caution These are software limit stops
70. 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 POSITION ERROR SET POINT DETECTOR PID VALVE INPUT POSITION POSITION 2 SET POINT CONTROL CONVERTER RELAY CURRENT OR ALGORITHM DIGITAL POSITION FEEDBACK Figure 2 Block Diagram of SVI Positioner When configured as a PID controller Figure 3 the SVI accepts a local control setting 4 20 mA signal or a HART communications protocol signal The primary process measurement made by the process trans mitter is fed to the controller as a voltage signal of 1 to 5 V dc The difference between the set point and process measurement is conditioned by both the PID controller algorithm and position control algorithm and converted to a pneumatic signal This signal is boosted by a pneumatic relay and drives the actuator When primary measurement and set point signals agree there is no further movement of the actuator and System is in stable control PROCESS SET POINT LOCAL CURRENT OR DIGITAL ERROR DETECTOR PID CONTROLLER ALGORITHM POSITION CONTROL ALGORITHM PROCESS POSITION VARIABLE FEEDBACK INPUT Figure 3 Block Diagram of SVI Controller Positioner 12 Hardware Description The SVI is housed in a rugged weatherproof corrosion resistant aluminum housing which has been designed for operation in hazardous areas as listed in T
71. able 2 Two 1 2 NPT conduit entries and three 1 4 NPT pneumatic ports provide signal connections to the SVI Within the housing are the following components interconnected as shown in Figure 3a SVI Block Diagram Electronics Module Display and Pushbuttons Electropneumatic Converter EPC Spool Valve Sensors position pressure and temperature Supply Pressure Pressure Sensor Display 4 20 Oto BN Electronics 1 4 mA Module EPC Spool Valve 2 AQ 2 2 2 2 1 Exhaust Buttons Feedback Potentiometer Figure 3a SVI Block Diagram 13 Electronics Module The electronics module contains the power supply 16 Bit A D Converters 12 Bit D A Converters and the microprocesser Using the internal programmed Positioner and or Process Control algorithm it computes the required output based on information received from the measurement sensors If the display and push button option is selected it contains the electronics for these functions Pushbutton Switches Three pushbutton switches operating in conjunction with the display permit reading and modification of the instrument operating parameters without a PC or HART hand held communicator These switches perform generic functions Increase Decrease and Accept by movement through a conventional menu structure The switches can be operated in a hazardous environment without compromising the fl
72. alve position Perform valve diagnostics and display results signature friction stroking speed cumulative travel cycles and operation in near closed position Recall previous test results for comparison with current data For more details on ValVue software refer to the ValVue Users Manual These remote functions can also be performed with a hand held unit however the handheld unit cannot display graphical representation of the diagnostics Figure 1 Smart Valve Interface SVI Features and Functions Precision valve positioning control Advanced valve diagnostics s Automatic setup and tuning Local operation calibration configuration using optional explosionproof pushbuttons and digital display Two way data communication using industry standard HART protocol Remote operation calibration configuration diagnostics using ValVue software or a HART hand held User configurable tight shutoff adjustment Optional PID controller with remote set point and process variable input User adjustable response times Direct or reverse acting operation Compatible with air to close or air to open actuators Span and zero configurable for split range operation Local operation functions include Calibrate valve stroke range tight shutoff point position limit stops Display and or set parameters for valve configuration Select characterization linear equal percentage 50 equal percentage 30 quick opening or cu
73. ameproof enclo sure EPC Electropneumatic Converter The EPC converts a current signal to a pressure signal in the following manner A coil operating in a mag netic field is mechanically connected to a flapper Movement of the coil when current is changed causes the flapper to move towards a nozzle and restrict the air flow through the nozzle The restricting action causes the back pressure on the nozzle to increase with an increase in the coil current Removing electrical power from the EPC causes the output pressure to go low This defines the startup and fail safe characteristics of the SVI Spool Valve The spool valve is a two way air piloted valve that can supply or exhaust air The pilot pressure which is controlled by the EPC in turn controls the rate of air flow that fills or exhausts the actuator Sensors Position Pressure and Temperature Position sensing of the valve stem is accomplished by use of an internally mounted potentiometer mechanically linked to the stem The output of the potentiometer is connected to the electronics module and provides the input signal to the position control algorithm The potentiometer resistance is 10 000 ohms and has a full scale travel range of 120 degrees rotation Full valve stroke must provide 18 degrees minimum and 100 degrees maximum rotation from reference position Open or Closed valve settings establish the reference position The position sensor also provides through the
74. as failed The A D reference voltage is incorrect SVI failed self check diagnostics SVI has reset since last status clear Internal check failed to process data in time Latched Errors are historical data that may or may not effect valve operation To check Latched Errors use the Clear Status command via pushbuttons valve or HART handheld 56 Table 7 Positioner Fault Messages continued Display Code Fault Message Mening Latched Probable Cause Error TEMP ERR Circuit Temperature Internal SVI temperature out of range WRT ERR EEP Prom Write Failed TIMER SEN Watchdog Timer Timeout CAL FAIL Calibration Failed STOP ERR Find Stops Failed FAIL SAFE Fail Safe Position Device failed to write to nonvolatile memory SVI failed to send D A output within timeout Signal or pressure calibration The auto POS calibration failed Valve has been placed in the fail safe position Hardware failure Hardware failure Bad value set in calibration mode Pressure sensor not working or bias adj not correct or valve will not move Primary sensor failure or linkage not aligned correctly on the potentiometer Latched Errors are historical data that may or may not effect valve operation To check Latched Errors use the Clear Status command via pushbuttons valve or HART handheld 57 Chapter 4 Operation SVI Controller Introduction NOTE The SVI must have the controller
75. at any time to return to CALIB in the EXAMINE menu 54 Examine Configuration Parameters To examine the configuration parameters execute the following procedure 1 2 If in NORMAL OPERATE mode press any button Press to move through the options until you reach the EXAMINE menu item Press to go to EXAM INE menu This leaves valve in NORMAL OPERATE mode If in MANUAL mode press repeated ly until the EXAMINE menu item is reached Press to select the EXAMINE mode Press repeatedly to move through the EXAMINE menu until CONFIG is reached Press to display the list of configuration values To move forward through the configuration parameters in sequence press To move back through the list press At any time to return to CONFIG in the EXAMINE menu press Display Clear FAULTS To examine and or clear fault codes and messages execute the following procedure 1 2 If in NORMAL OPERATE mode press any button Press to move through the options until you reach the EXAMINE menu item Press to go to EXAM INE menu This leaves valve in NORMAL OPERATE mode If in MANUAL mode press repeated ly until the EXAMINE menu item is reached Press to select the EXAMINE mode Press repeatedly to move through the EXAMINE menu until FAULTS is reached Press to display the list of status values To move forward through the faults in sequence press To move back through the list press The last item
76. atures that can disable the COM ports Check your laptop user manual for additional information Mouse Interference Modem settings sometimes conflict with proper mouse operation and the mouse hangs up after initiat ing ValVue Select another port for either the mouse or the modem Hand Held Considerations A hand held terminal must include the SVI device description in order to perform diagnostic and calibra tion functions The HART 275 hand held terminal will report the primary and secondary variable tag mes sage and other basic values Note The communication connection of a PC with ValVue or a HART 275 hand held terminal is not polar ity sensitive 95 Failure to Communicate If the PC fails to communicate with the SVI the PC displays the message No Hart Device or Device Not Responding then the PC cannot establish a link to the SVI Possible causes of communications failure related to installation include e Poor wiring contacts Improper connection of the HART modem to the computer e Incorrect serial port Using ValVue with another HART master terminal in service e Insufficient loop impedance Require a minimum of 250 ohms Polling address set to non zero value The polling address which can be set only by using the HART 275 Hand held must be set to 0 in order for ValVue to communicate with the SVI Do not change polling address from 0 with HART 275 Communicator Note You cannot use ValVue and attempt
77. continue with sections Bias Error following FAILSAFE shown on Potentiometer shaft Check that mounting and display orientation or linkage linkage are correctly incorrect installed Refer to Mounting in instructions Hardware Software Use Examine menu to fault view error s Take required corrective action See Fail Safe Display RESET appears on Momentary display on display power up is normal Continued display Contact Factory Service indicates problem 84 TROUBLESHOOTING CHECKLIST CONT PROBLEM POSSIBLE CAUSE ACTION Valve will not stroke over Insufficient compliance See Electrical full travel range voltage from current Connections source Potentiometer shaft Check that mounting and orientation or linkage are correctly incorrect installed Refer to Mounting in instructions Insufficient pressure to See Pneumatic fully stroke actuator Connections Incorrect software See confirming position limits Configuration Valve position exhibits Improperly grounded See Electrical unstable oscillation or unit Connections hunting behavior Slipping or loose Check and tighten linkage Defective spool sub See Spool Valve assembly Maintenance Incorrect positioner See Testing Valve PID values Performance Valve works for some Potentiometer shaft Check that mounting and input values and goes orientation or linkage linkage are correctly
78. ctice Losses de eb eee ee 1 82 HART Compliance mem dower seeded s 83 Power on Check 83 Troubleshooting Checklist 2 84 85 Testing Valve Performance 86 Confirming Configuration Setup Calibration and Limit Stops 86 Initiate Valve Movement 50 87 Initiate Valve Movement 95 87 Fail Safe Display messini Lee ai Ww auus ae ee Be 88 AUW TUNE 265 TIT 89 AutoTune Procedures 89 Auto Tune Results 90 Damping Coefficient 90 Unacceptable Response Characteristics 91 Position Instability 22 91 ecu C 92 Broderie 92 Bias Adjustment xcd ARI Ever e up C eeu yes dene PE GR cene 92 Bias Adjustment Procedure 93 Spool Valve Maintenance 93 Disassembly Procedure 94 Heassembly 2220523
79. d 1 4 NPT The output connection is located on the back of the block The supply and exhaust are located on the side of the block with the exhaust above the supply and fitted with a plastic plug Two pressure gauges output on top supply on bottom are located on the front of the pneumatic block The use of a Masoneilan filter regulator with a 5 micron filter is recommended for the air supply Tubing used for piping between filter regulator SVI and actuator should be 1 4 minimum with 3 8 used for larg er actuators CAUTION Do not use pipe thread sealant tapes on pneumatic fittings as it tends to shred small particles which can cause instrument malfunction The use of a soft setting anaerobic hydraulic seal such as Loctite Hydraulic Seal 542 is recommended Follow manufacturers instructions CAUTION Do not use an excessive amount as it will not set and may migrate into the instrument Maximum allowable air supply pressure to the SVI varies according to actuator and valve size and type See pressure drop tables in valve specification sheets to determine correct positioner supply pressure Minimum supply pressure should be no less than 10 psi above maximum spring pressure DANGER Never exceed actuator or SVI maximum supply pressure Damage to equipment or injury to personnel may result 31 Electrical Installation Electrical connections are made to the main terminal board as shown on Figure 24 The terminals will accept wire sizes up
80. d linkage assembly non linearity is 1 0 Minimum mounting bracket thickness is 5 0 mm In order to mount a SVI on a valve the following parts are required Mounting Bracket SVI Lever and Linkage for Position Feedback Reciprocating SVI Lever and Valve Side Lever for Position Feedback Rotary To ensure that the SVI position feedback performs correctly the plane of the flat on the SVI shaft must be vertical and facing the pneumatic block of the SVI when the valve is at mid travel The lever must point away from the pneumatic block See Figure 14 For a reciprocating valve the bracket lever and linkages should be designed such that the lever is per pendicular to the actuator stem when the valve is at mid stroke The linkage pivot point on the SVI lever should be on the same centerline as the valve stem at mid stroke turnbuckle centered on and parallel to stem For a rotary valve it is recommended that the Masoneilan design valve side lever and SVI lever be used since they incorporate an anti backlash spring feature The mounting bracket should accommodate the four mounting holes of the SVI Adequate space must be left between the SVI and the Actuator to accommodate the lever and linkage or the rotary lever coupling Clearance space is required for the output air connection and SVI end cover See Figure 22 for mounting interface requirements 26 Figure 2
81. damping coefficient which displays after AutoTune and indicates the AutoTune result Damping Coefficient Message 44 Bias searching fails after 20 Stabilize the SVI in the times trying range between 20 8096 open and wait until the valve is stable at its setpoint Then re run the self tuning again 55 7 The found Bias is not in the Adjust the Bias required range and self tuning is cancelled EN Self tuning for air fill direction Check supply pressure fails after 30 times trying check noise check the pneumatic block especially spool S A 7 Self tuning for air exhausting Check the pneumatic block direction fails after 30 times especially spool S A Note The Damping Coefficient adjustment range is 0 to 9 The out of range value is equivalent to 0 or no damping 90 Unacceptable Response Characteristics Valve position responses depend on many factors including the condition of the valve actuator and process ambient temperature noise the SVI itself supply pressure and the setup and step change size for the positioner control parameters Note A5 step change should be made when the valve is in the 20 to 80 opening range With damping coefficient of zero no damping consider the following valve responses unacceptable e Overshoot greater than 20 Rising time T98 greater than 1 5 seconds for small actuators and 2 5 seconds for large actuators Dead time greater than 0 5 seconds Limit cycling
82. e must have been entered through the ValVue software program The curve itself cannot be entered from the local pushbuttons The tight shutoff TS option allows the user to configure the positioner to apply full supply pres sure or atmospheric pressure to the actuator whenever the signal directs the valve near the closed position If the tight shutoff option is on the value of the TS option determines the near value at which the valve is forced fully shut In TS OFF ON if status and value displayed are sat isfactory press to move to next item If not press to change on off status and display value Then press or buttons to increase or decrease value displayed When status is changed from ON to OFF no value is displayed When value is OK press to accept value and move to next item The SVI allows the user to configure a lower PL and upper PU software position limit stop When in operation with these limits on the valve will not move below the lower limit stop or above the upper limit stop Caution These are software limit stops If the SVI fails for any reason including power fail ure or air failure the SVI cannot enforce these limit stops and the valve will go to fail safe Furthermore the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls If safety requires the use of limit stops mechanical limit stops should be used In PL OFF ON if sta tus and value displayed are satisfactory press
83. ead 1 the input signal 2 pneumatic output signal and 3 valve position The display sequences from one variable to the next every 1 5 seconds Using the pushbuttons you can exit from operating mode at any time and step through a menu structure to perform a wide range of manual operation calibration configuration and monitoring functions all of which are described later in this section Before you can perform any of these functions however you must first ensure that the ValVue software if used has placed the pushbuttons in the unlocked mode See ValVue User Manual for more details The pushbuttons do not support any diagnostics functions NOTE If the SVI unit is specified without local pushbuttons and display local operation is not available Pushbuttons Display As shown in Figure 30 the upper line is a 7 digit numeric display and the lower line is a 7 digit alphanu meric display The upper line is used for displaying values such as input signal or valve position and the lower one is primarily used for messages and parameter identification 7 DIGIT NUMERIC DISPLAY 7 DIGIT ALPHANUMERIC DISPLAY 55H POSITNR LOCAL PUSHBUTTONS SELECT OR ACCEPT BUTTON INCREASE VALUE OR MOVE DOWN NEXT IN MENU BUTTON DECREASE VALUE OR MOVE UP BACK IN MENU BUTTON Figure 30 Local Display and Pushbuttons 42 The three pushbuttons perform the following functions The left button ma
84. ection is to be made press to move valve to the 100 position Using the and buttons position the valve to the nominal full open position Press to accept this position as the new 100 position The Bias is the signal sent to the internal 1 that causes the actuator to neither fill nor exhaust The pneumatics are adjusted at the factory and should not need further adjustment If the pneumatics need to be readjusted for any reason the BIAS option should be selected by pressing This will output a value of 2750 to the The adjustment screw on the top of the pneumatics section can be adjusted until the valve is nearly stationary near mid travel See Bias Adjustment in Troubleshooting Press to move to the next menu item The TUNE menu item allows the user to initiate the automatic position control tuning function which will select appropriate PID parameters for the position controller Press to initiate AUTO TUNE func tion This procedure may take from 1 to 5 minutes During this time the valve will make a series of steps Caution This procedure should not be performed while the valve is controlling the process When the function is completed you return to TUNE Press to advance to the next item 53 9 SIGLO displays the input signal that should correspond to the full closed or full open position of the valve depending upon whether the valve is air to open or air to close and whether the positioner is direct or reverse
85. electronics module readout of valve position on the dis play communication of valve position via HART protocol and on newer SVI models 4 20 mA signal pro portional to valve position transmitted on a separate pair of leads If the SVI cannot be mounted on the valve an optional remote feedback potentiometer can be used to sup ply the position signal to the SVI The pressure sensor measures the pressure to the actuator with a range of 0 to 100 psi This pressure can be read out on the internal display Hart communicator or Val Vue PC The temperature sensor is located in the electronics module and measures ambient temperature This measurement is used to provide temperature compensation for the pressure sensor and other internal electronic components short stroke version SVI is available Consult Factory 14 SVI Inputs Outputs As shown in the block diagram below the SVI unit has the following inputs and outputs SET POINT SIGNAL FOR 0 100 PSI AIR PRESSURE VALVE POSITION Jde OUTPUT OR ACTUATOR PID CONTROLLER SEE NOTE 3 SET POINT INPUT SEE NOTE 1 2 UNPOWERED CONTACT SMART PRESSURE CLOSURE INPUTS VALVE 0 100 PSI FROM OR ACTUATOR REMOTE FEEDBACK POT INTERNFACE SEE NOTE 3 FOR VALVE POSITION WHEN CONFIGURED OR PROCESS VARIABLE WHEN CONFIGURED M c con AS A PID CONTROLLER FEEDBACK SEE NOTE 2 pies FROM VALVE STEM NOT USED WHEN REMOTE FEEDBACK POT I
86. er The 4 20 mA remote control setpoint and power to the SVI are supplied through the 728 barrier Lu 788R PV to DCS Controller SP to DCS Figure 9 Intrinsically Safe Single Loop PID Configuration 18 The circuits shown in Figures 10 and 11 are Controllers with local setpoint set by the pushbuttons on the housing The 24 V dc supply with a series current limiting resistor replaces the 4 20 mA source and can also be used to power the process transmitter If these circuits are used in hazardous areas the wiring and mounting of the external resistors must conform to explosionproof requirements 1 5 barriers must be used on all wiring between the control room and the hazardous area 750 Ohms 250 Ohms Figure 10 Local Set with Voltage Source 220 Ohms Figure 11 Local Set with Voltage Source Two Leads to Field 19 Chapter 2 Mounting WARNING If the SVI is to be mounted on an existing valve in a process line the following procedures and pre cautions are mandatory e f valve is located a hazardous area make sure 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 process or using bypass valves for isolation Tag shutoff or bypass valv
87. es to guard against turn on while work is in progress Bleed air from actuator and check that valve is in its un energized position It is now safe to disconnect and remove any valve mounted equipment that is being replaced NOTE The SVI should be mounted with the conduit connections down in order to facilitate drainage of condensate from the conduit and ensure the best dynamic performance Standard Rotary Valve Mounting This section describes the procedure for mounting the SVI on all Masoneilan rotary control valves Tools required 3 16 inch Hex Wrench 4mm Hex Wrench 7 16 inch Combination Wrench 1 Mount the SVI mounting bracket to the valve actuator using two 2 5 16 18 UNC flat head cap screws Unless otherwise specified the SVI will be mounted assuming the actuator valve will be mounted in the normal upright position i e lettering on actuator right side up This requires the long end of the mounting bracket to be to your right when facing the actuator Note that the mounting brac ket for ball and butterfly valves differs slightly from the Camflex and Varimax bracket but the mounting is identical 2 Bolt the valve side lever to the valve position take off shaft using a 1 4 28 UNF cap screw spacer and washer The spacer goes between the take off shaft and lever and the washer under the head of the cap screw On Camflex and Varimax valves orientate valve side lever 90 from valve position indi cator as shown
88. for input signal Low and high values for actuator pressure output Setthe minimum and maximum stops for valve position Procedures Refer to the menu structure diagrams in Figures 31 through 35 on pages 46 to 50 for assistance in fol lowing the procedures described To calibrate the SVI unit using the local pushbuttons execute the following procedure CAUTION aro Since some calibration functions stroke the valve over its full range the valve should be iso lated from the process before starting calibration If in NORMAL OPERATE mode press any button gt OPER will be displayed Press to get to the MAN menu item Press to move to MANUAL MENU POS MAN displayed Press to move to CAL option Press to go to CALIBRATE menu STOPS will be displayed In STOPS press to initiate the operation which moves the valve to fully closed then fully open and then returns to the starting position This operation calibrates the end points for the position feedback potentiometer When the operation is complete press to move to the next item CAUTION 6 This function strokes the valve over its full range Do not execute while valve is controlling the process On some valves the full travel is larger than the nominal travel of the valve and it may be desirable to have the reported 100 position correspond to the nominal travel rather than the full stroke The STOP OP option allows this correction If a corr
89. g and back of lever See Figure 16 Bolt SVI Lever Rod End Air Output 1 4 NPT Approx 1 16 10000000004 Space Between Lever amp Housing Hub Figure 16 Top View of SVI Mounted on a Reciprocating Valve 23 3 Attach the right hand threaded rod end to the SVI lever using a 1 4 20 x 1 cap screw The lever hole position to be used is dependent upon the specific valve stroke Refer to Figure 17 and Table 3 shown below 055000 276 600 Figure 17 5 Lever for 87 88 Multi Spring Actuator Valve Stroke mm inches Lever Hole 20 3 0 8 A 25 4 1 0 A 38 1 1 5 B 50 8 2 0 G 63 5 2 5 C Table 3 SVI Lever Hole Locations for 87 88 Multi Spring Actuator Note For valve strokes less than 19 1 mm 75 in use the Short Stroke model SVI with the rod end attached to the lever A hole 4 Mount the SVI to the mounting bracket using four 1 4 20 UNC socket head cap screws The set of mounting holes to be used is dependent upon the specific valve stroke Refer to Figure 18 5 Screw the take off rod to the actuator stem connector refer to Figure 19 Ensure that the travel pointer is correctly positioned 6 Bolt the left hand threaded rod end to the take off rod with 1 4 20 UNC nut 7 Connect turnbuckle and lock nuts to each rod end Refer to Figure 19 Turnbuckle length is a function of actuator size Verify proper length per following 6 and 10 Actuators length 1 25 16
90. ices The case grounding screw is located on the outside of the case to the lower right of the display cover Signal grounding should follow normal rules for the facility Any point in the loop may be referenced to ground but there should never be more than one ground point If the SVI has the Process Controller option auxiliary terminal B must be connected to the same ground reference as the negative input current terminal Note Improper or inadequately grounded installations may cause noise in or instability of the control loop If noise or instability are present set positioner to Manual Mode of operation and manually position valve over its entire range If valve is stable in manual mode then problem may be noise in control loop Re check all wiring connections and ground points If noise and instability are still present in manual mode problem is most likely with electronics module Consult Factory 82 HART Compliance SVI requires a HART compliant communications loop The HART protocol specifies the noise level impedance requirements and configuration of the loop Note When an intrinsically safe barrier separates the communicating device a HART compliant barrier must be used Conventional current output loops consisting of the following components usually meet requirements for HART compliance e Quality current source e g low noise high impedance e Minimum loop impedance of 250 ohms e Twisted pair cable sui
91. in Figure 12 and securely tighten cap screw On ball and butterfly valve actuators ori entate the lever so it is midway between the two bracket mounting holes 459 from horizontal as shown in Figure 13 and tighten cap screw Alternatively for all rotary mountings the actuator can be pressurized to mid stroke and lever secured in a horizontal position 20 Valve Side Lever 5 16 18 UNC Flat Head Cap Screw Valve Actuator 1 4 28 UNF Cap Screw SVI Mounting Bracket Figure 12 SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves Actuator Valve Side 1 4 28 UNF Lever Cap Screw 5 16 18 UNC Flat Head Cap Screw SVI Mounting Bracket Figure 13 SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves 3 Clamp the SVI lever to the SVI shaft The flat on the SVI shaft must always face the pneumatic block with the lever orientated facing the cover as shown in Figure 14 When using a standard lever the orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft Leave approximately 1 16 space the SVI housing and back of lever See Figure 15 4 Loosely assemble the SVI to the mounting bracket using only the two top 1 4 20 UNC socket head cap screws Pull the SVI away from the actuator to allow the pin on the valve side lever to be insert ed into the slot in the SVI lever under the anti backlash spring See Figure 15 Assemble the
92. inductance plus the 1 5 apparatus unprotected capacitance Ci and induc tance Li must not exceed the allowed capacitance Ca and inductance La indicated on the asso ciated apparatus If the optional Hand Held Communicator is used then the capacity and induc tance must be added Also the current output of the Hand Held Communicator must be included in the current output of the associated equipment Positive polarity shunt zener diode safety barrier approved by FMRC or CSA for groups A B C D E F and G with output parameters Voc or Vt 30 Vdc Isc or It 125 mA Ca gt Ci cable La gt Li L cable The intrinsically Safe Transmitter is any transmitter approved by FMRC or CSA for groups A B C D E F and G having entity parameters consistent with the connecting FM or CSA approved barrier The installation including the barrier earthing requirements must comply with the installation require ments of the country of use i e ANSI ISA RP12 6 Installation of Intrinsically Safe Systems for Hazardous Classified Locations and the National Electrical Code ANSI NFPA 70 or Canadian Electrical Code Part 1 Installation must be in accordance with manufacturers guidelines Division 2 installations must be installed per the National Electrical Code ANSI NFPA 70 or Canadian Electrical Code Division 2 Wiring Methods SVI Temp Code T4 at 40 C Maximum Ambient Temperature T3B at 70 C Maximum Ambient Temperature T3A at 82 C Ma
93. iption of fatal and non fatal SVI errors The following list of error latches defines each term DRIFT Drifting of bias HARTERR Continuous communication error HWERR Hardware failed self check OVERRUN Data overrun error processor error POSERR Position error POSSEN Position sensor error PRESSEN Pressure sensor error REFERR Reference voltage error RESET Reset occurred SIGSEN Current sensor error STOPERR Find stops procedure failed SWERR Software error TEMPERR Circuit board temperature out of range WRT ERR A write to the EPROM failed 88 AutoTune Running the positioner AutoTune procedure automatically determines position control parameters such as P D and dead zone If the SVI is a Positioner Controller model running autotune sets the posi tioner tuning parameters the controller tuning parameters have to be entered via a Hand Held or ValVue Note Confirm that the Bias settings appear in a reasonable range with a low signal noise level before running AutoTune AutoTune Procedures Initiate positioner AutoTune either by selecting the AutoTune button in the ValVue SVI Calibration Window or by using the SVI local buttons Refer to Calibrate menu in Operation section of manual or by initiating auto tuning from the hand held The AutoTune procedure includes three steps Bias search Estimate control parameters e Refine control parameters In Bias Search the SVI local displays values such as 23530 and 27
94. iptive only actual wiring must adhere to Electrical Installation section of manual and local electrical codes Valve position is determined by an internal feedback potentiometer mechanically linked to the valve stem The SVI input signal can be a 4 20 mA or a HART communication protocol signal from ValVue software on a personal computer or from a HART Hand Held Communicator The process controller or other source of input signal to the SVI is located in a non hazardous location and an intrinsic safety barrier with ground may be placed between the controller and the SVI or the system can be installed as explosionproof flameproof Communication with the remote PC is handled via a modem connected to the remote PC through a serial port Communication can also be established from a HART Hand held Communicator The PC which is not intrinsically safe must be connected to the circuit on the non hazardous side of the intrinsic safety barrier if the valve is located in a hazardous area The SVI unit can be operated calibrated configured and inter rogated either by using local pushbuttons display or using a remote PC running ValVue software or with the Hand held Communicator NONHAZARDOUS LOCATION HAZARDOUS LOCATION SET POINT gt PROCESS SVI PROCESS CONTROLLER 24V SMART VARIABLE BE POWER INTERFACE SUPPLY TO SERIAL HART UU PERSONAL MODEM COMPUTER EXPLOSION PROOF HART PROTOCOL DIGIT
95. ld device The ValVue manual contains setup and administration procedures for HART communications Refer to HART Communicator manual MAN 4250 for for basic instructions on using the Hand Held communicator The manual covers General Instructions Hot Key Customization Connections and Off Line functions Use of the Hand Held with SVI is facilitated by use of the Hand Held Communicator Guide flowchart in the Instructions section of this manual Setup and Administration Load ValVue version 1 0 4 or higher for proper operation of the PC The ValVue version number and the SVI version number must match or use a higher ValVue version than the SVI version software Note ValVue demo software does not communicate with SVI Communication Port and Settings Plug the modem into the serial port COM1 or COM2 of the PC The user selects the serial port during ValVue installation or in the properties of the ValVue icon or you manually can set ValVue to use the same port as the modem The user manual for your computer contains more information about proper use of serial ports Typical PC operation includes the following settings or 2 as the physical connector Default settings for the interrupt level and interrupt address e g the correct BIOS settings use the serial port with a modem and enable the interrupt Use of Laptop Computers Laptop computers sometimes require non conventional settings and support Power Management fe
96. national compressed air and instrumen tation codes Products certified for use in explosionproof flameproof or intrinsically safe installations MUST a Be installed in accordance with local and national codes for hazardous area installa tions b Only be used in situations which comply with the certification conditions stated in this handbook c Only be maintained by qualified personnel with adequate training on hazardous area instrumentation Before using these products with fluids other than air or for non industrial applications consult Dresser Masoneilan Not intended for use in life support systems Items sold by Dresser Masoneilan are warrantied to be free from defects in materials and workman ship for a period of one year from the date of ship ment provided said items are used according to Dresser Masoneilan s recommended usages Dresser Masoneilan reserves the right to discon tinue manufacture of any product or change prod uct materials design or specifications without notice Chapter 1 Overview Scope of Manual This manual describes the procedures for installing configuring calibrating operating and troubleshooting the Masoneilan9 Smart Valve Interface SVI Positioner and Controller A companion software product ValVue can be used to configure calibrate and perform valve diagnostics with the SVI from a remote Windows based computer In addition SVI can be configured calibrated and perfo
97. nections to Main Terminal Board 32 Figure 24a Electrical Connections to Main Terminal Board 33 Figure 24b General Area Purpose Installation 34 Figure 25 Approved Intrinsically Safe Installation Control Drawing 36 Figure 26 Impedance vs Frequency for Typical Current Source 39 Figure 27 Resistor Add in Series with Current Source 39 Figure 28 Split Range Active Barrier 41 Figure 29 Compliance Voltage Boost 41 Figure 30 Local Display and Pushbuttons 42 Figure 30a Pushbutton Guide for SVI Version 1 0 6 44 Figure 30b Pushbutton Guide for SVI Version 1 0 5 45 Figure 31 NORMAL OPERATE MODE SELECT and MANUAL Menu Structures 46 Figure 32 CONFIGURE Menu Structures 47 Figure 33 CALIBRATE Menu Structures 48 Figure 34 EXAMINE Menu Structure 49 Figure 35 Parameter and Message Displays 50 Figure 36 Local Display and Pushbuttons 59 Figure 36a Hand Held Communicator Guide for SVI
98. ng upon whether the valve is air to open or air to close and whether the positioner is direct or reverse SIG HI must be larger than SIG LO by at least 5 mA In SIG HI if the displayed value is correct press to advance to the next item If not press to display value of SIG HI Use and buttons to change the value When OK press to return to menu and move to next item The PRES HI menu item allows the user to enter the supply pressure This pressure is used for sca ling of the pressure data in the SVI In PRES HI if the displayed value is correct press to advance to the next item If not press to display value of PRES HI Use and buttons to change the value When OK press to return to menu and move to next item Calibration as a positioner is now complete At gt MAN press to return to the MANUAL mode POS MAN displayed 71 Return to Normal Operation To return to NORMAL OPERATE mode from any menu press or repeatedly until gt MAN or OPER is displayed If OPER appears press to return to NORMAL OPERATE mode If MAN appears press to return to Manual Mode Menu Then press repeatedly until OPER appears Then press to return to NORMAL OPERATE mode and normal operation Examine Functions The EXAMINE menu permits you to display calibration parameters configuration parameters and to dis play and or clear fault status messages and codes Refer to Table 9 for explanati
99. ns all of which are described later in this section Before you can perform any of these functions however you must first ensure that the ValVue software if used has placed the pushbuttons in the unlocked mode See ValVue User Manual for more details NOTE If the SVI unit is specified without local pushbuttons and display local operation is not available therefore ValVue Software or a HART handheld communicator is required NOTE When an SVI is turned on it is advisable to apply the air supply before applying the electrical input signal 58 Pushbuttons Display As shown in Figure 36 the upper line is a 7 digit numeric display and the lower line is a 7 digit alphanu meric display The upper line is used for displaying values such as input signal or valve position and the lower one is primarily used for messages and parameter identification 7 DIGIT NUMERIC DISPLAY 7 DIGIT ALPHANUMERIC DISPLAY 56 4 POSITNR LOCAL PUSHBUTTONS SELECT OR ACCEPT BUTTON DECREASE VALUE OR MOVE UP BACK IN MENU BUTTON INCREASE VALUE OR MOVE DOWN IN MENU BUTTON Figure 36 Local Display and Pushbuttons The three pushbuttons perform the following functions The left button marked with permits you to select or accept the value or parameter option currently displayed e The middle button marked permits you to move back through the menu structure to the
100. nternal SVI temperature out of range WRT ERR EEP Prom Write Failed TIMER SEN Watchdog Timer Timeout CAL FAIL Calibration Failed STOP ERR Find Stops Failed FAIL SAFE Fail Safe Position Device failed to write to nonvolatile memory SVI failed to send D A output within timeout Signal or pressure calibration The auto POS calibration failed Valve has been placed in the fail safe position 75 Hardware failure Hardware failure Bad value set in calibration mode Pressure sensor not working or bias adj not correct or valve will not move Primary sensor failure or linkage not aligned correctly on the potentiometer Operation SVI Positioner Controller using HART Handheld Communicator HART 275 Handheld Communicator with Masoneilan SVI Software can be used to set up and calibrate an SVI Positioner or Controller It s capabilities extend well beyond the range of pushbutton functions in that it allows positioner tuning and controller tuning parameters to be individually entered and it also sup ports limited diagnostics Refer to HART Communicator Manual MAN 4250 for basic instructions on using the Handheld communi cator The manual covers General Instructions Hot Key customization connections and Off line func tions The menu structure on Page 60 is a guide to all the operations which can be performed on both Positioners and SVI Controllers using the HART Handheld Operation SVI Positi
101. oner Controller using ValVue Software Use of ValVue Software provides the most comprehensive menu selections for configuring calibrating and monitoring the SVI Positioner and Controller All operating and calibration parameters be entered and additionally a very comprehensive diagnostics program is available The diagnostics program allows recall of stored test data to compare current performance of the valve positioner and actuator with previ ous test results or factory data Operation of the SVI Positioner and Controller with ValVue is covered in the separate manual furnished with ValVue software 76 Chapter 5 Troubleshooting Introduction This section of the manual offers procedures and options to confirm setup and configuration and allows you to exhaust many service options before seeking assistance from a factory trained technician By first following these procedures you can save time prevent costly downtime and provide the service techni cian with more detailed information about the possible problem Although this section is written primarily for use with the pushbutton local display version of the SVI Positioner it also applies to Val Vue and HART handheld operation and in applicable areas to the PID Controller version Factory Service Trained service personnel perform high level SVI troubleshooting and servicing Should the SVI unit require replacement of internal parts the unit will be replaced with a new or rebuilt
102. ons of fault messages You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode When entered from NORMAL OPERATE mode the valve still responds to changes in set point input signal and the values displayed change in accordance with changes in input signal When entered from Manual mode the valve is locked in position When you exit from the EXAMINE menu you return to the menu from which you entered Procedures Examine Calibration Parameters To examine the calibration parameters execute the following procedure 1 NORMAL OPERATE mode press any button 2 Press to move through the options until you reach the EXAMINE menu item Press to go to EXAM INE menu This leaves valve in NORMAL OPERATE mode If in MANUAL mode press repeat edly until the EXAMINE menu item is reached Press to select the EXAMINE mode 3 Press repeatedly to move through the EXAMINE menu until CALIB is reached Press to display the list of calibration values To move forward through the calibration parameters in sequence press To move back through the list press Press at any time to return to CALIB in the EXAMINE menu Examine Configuration Parameters To examine the configuration parameters execute the following procedure 1 NORMAL OPERATE mode press any button 2 Press to move through the options until you reach the EXAMINE menu item Press to go to EXAM INE menu This leaves val
103. otary 18 to 100 degrees short travel version 9 50 degrees Reciprocating 12 to 64 mm 0 5 to 4 5 inches Short travel version 6 to 32 mm 0 25 to 1 25 inches Above 64 mm consult factory for mounting Flow Characterization Linear Equal percentage 50 1 or 30 1 Quick opening inverse of 50 1 equal percentage User configurable for 10 segments Tight Shut off 0 2096 of input Table 1 Performance Specifications cont ____ o Specification Positioner Auto Tune SVI performs an automatic determination of the optimal valve position control parameters In addition to P D the position algorithm uses damping symmetry for exhaust and fill time constants dead zone and magnitude characterization parameters Auto Tune is optimized for 596 step changes with negligible overshoot After the Auto Tune process is completed the user can further adjust the positioner tuning parameters to more conservative or to more responsive values to produce various dynamic response to the control signal Proportional gain 0 to 500096 Integral time 0 to 1000 seconds Derivative 0 to 200 seconds Dead Zone to 1 0 to 2 Padj 3000 depends on P NL Coefficient 8 to 9 Damping 0 to 9 Full open position 60 to 100 if not at stop Direct increasing signal increases output Reverse increasing signal decreases output software or hardware reversible Instrument Air Best performance is obtained with
104. ou entered CONTROLLER MENU FROM gt PRESS TO TOGGLE REMOTE OR LOCAL PRESS OR TO ENTER NEW VALUE PRESS TO EXIT BACK TO SETPOINT PRESS OR TO ENTER NEW VALUE PRESS TO EXIT BACK TO SETPOINT RETURN TO NORMAL OR MANUAL MENU WITHOUT SAVING CHANGES RETURN TO NORMAL OR MANUAL MENU WITH SAVING CHANGES Figure 40 Controller Menu Structures 65 Examine Menu This menu can be entered either from the MANUAL Mode or from the NORMAL OPERATE Mode The EXAMINE menu allows the user to read the current configuration calibration and status information This information however cannot be changed from the EXAMINE menu When you exit from the EXAMINE menu you return to the menu from which you entered EXAMINE MENU FROM gt EXAMINE gt PRESS OR TO STEP THROUGH CONFIGURATION IN MANUAL MENU OR CONFIG PARAMETERS IN SEQUENCE FROM OPERATE MENU PRESS TO RETURN TO CONFIG AT ANY TIME PRESS OR TO STEP THROUGH CALIBRATION CALIB PARAMETERS IN SEQUENCE PRESS TO RETURN TO CALIB AT ANY TIME PRESS OR TO STEP THROUGH FAULT MESSAGES IN SEQUENCE gt PRESS TO RETURN AT ANY TIME FAULTS DISPLAYS CLEAR AT END OF SEQUENCE 7 PRESS TO CLEAR FAULTS AND RETURN TO FAULTS IN EXAMINE MENU RETURNS TO MANUAL gt MAN OR OR OPERATE MENU gt OPER DEPENDS ON ENTRY DEPENDS ON ST
105. peak to peak measurement greater than 0 5 Position steady state error greater than 0 5 if the dead zone is less than 0 2 Position Instability The possible sources of position instability include Control loop measurement noise Process noise Line frequency noise e Oscillation Limit cycling Control loop noise only appears in the Normal mode never the Manual mode For best control reduce control loop noise by re tuning the process controller in the SVI or an external controller You may also dampen the SVI response Process noise results from process pressure and flow changes that apply forces to the valve plug and cause changes in position Although the SVI restores the plug position the response is not instantaneous Poor grounding of the signals and case or power supply ripple in the 4 20 mA control signal can intro duce line frequency noise Line frequency noise converts to low frequency noise when a noisy signal sam pling occurs during a period not integrally related to the line frequency The resulting frequency measures more than 1 Hz a frequency too high for resolution by the process trend record A pulsating sound of escaping air at the exhaust port usually indicates line frequency noise In extreme cases the valve stem may appear to pulsate Correct a line frequency noise problem by proper grounding page 82 or by eliminating ripple noise from the current source HART compliance requires less than 4
106. position is at 10095 If not re run Find Stops If this does not correct problem return unit to factory If valve oscillates review the following conditions Check for improper tuning Perform either another Auto Tune or if ValVue or handheld are available input manual values from the parameters table and re test Manually inputting values of 50 12100 D 10 Padj 0 Beta 8 PosComp 6 and Damping 0 should produce stable but perhaps sluggish operation on any valve Check that ground connections are made to correct ground points and that connections are secure Check the linkage between the position sensor and valve for excessive play Check that spool valve is not sticking Check for excessive friction in the valve packing it is one cause of limit cycling Limit cycling can be caused by tight valve stem packing an undersized actuator or foreign material in the spool valve Identify limit cycling conditions by a process of elimination e g not noise not oscillation Install valve packing only tight enough to prevent leakage Evaluate the valve packing by running the ValVue diagnostic program to determine if the friction is consistent with the type of valve If you determine that the spool valve is the source of limit cycling it should be cleaned or replaced Initiate Valve Movement 9596 Use this procedure to confirm that the SVI and valve systems are performing properly 1 Place the SVI in Manual mode using ValV
107. position it was in when it left NORMAL OPERATE When in the MANUAL mode the device will not respond to the 4 20 mA signals However the SVI unit can still respond to HART commands including HART commands to position the valve Note also that when you go to EXAMINE from the normal OPER ATE MODE MENU the valve is still in NORMAL OPERATE mode and still responds to the 4 20 mA sig nal OPERATE MODE DISPLAY POSITIONER THEE OPERATE MODE MENU POS PRESS Y BUTTON hs Np sic gt A HEH y TO CONFIG IN THERE EXAMINE MENU PRES EXAMINE VALVEIS STILLIN i A LEE HEH PRESS OR TO INCR DECR VALVE p OPER MANUAL MENU POSITION PRESS IN OPERATE MODE THE TO ACCEPT DISPLAY SEQUENCES THROUGH ox A VALVE POSITION INPUT SIGNAL AND ACTUATOR vy PRESSURE ON A 1 5 SECOND pr INTERVAL P CHANGE gt POS M N POSITION TODISPLAY A SEQUENCE NAM 0255 A Hi TO STOPS IN CALIBRATE CALIBRATE i T SINGLE HEH OR DOUBLE IN CONFIG CONFIG MENU THES TO CONFIG IN EXAMINE A y HEH OPER
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109. rked with permits you to select or accept the value or parameter option currently displayed The middle button marked permits you to move back through the menu structure to the previous item in the menu or to decrement the value currently shown in the digital display When used to decrease a displayed value holding this button down causes the value to decrease at a faster rate The right button marked permits you to move down through the menu structure to the next item in the menu or to increment the value currently shown in the digital display When used to increase a displayed value holding this button down causes the value to increase at a faster rate To determine how to display and or select a particular parameter value or configuration option refer to the menu structure diagrams in Figure 31 through Figure 35 By using these diagrams as a map you can quickly move through the menus to the function you want to perform NOTE If the buttons are pushed after being locked by the ValVue software the message LOCKED will appear Please refer to ValVue Software Manual to unlock pushbuttons NOTE When an SVI is turned on it is advisable to apply the air supply before applying the electrical input signal 43 9071 UOISIAA IAS 10 egg 4 J9YSSIN 1 NNYYSAO 3oNanoas 42992 195 AW1dSI0
110. rm valve diagnostics with a HART hand held communicator Product Description The Smart Valve Interface as shown in Figure 1 is a digital valve positioner and or process controller that can be either configured calibrated and operated locally or remotely Local functions are controlled by means of local pushbuttons and digital display Remote operation requires the use of the ValVue product or a hand held unit loaded with the registered HART Device Description DD The SVI controller version can also function as a single loop PID controller which accepts standard inputs for process variable and set point It positions the valve to achieve the desired value of the process vari able The Controller version can be configured as either a positioner or controller however entering of some of the controller parameters requires use of either ValVue software or a HART protocol hand held unit ValVue the software for remote communication of the SVI runs on standard IBM compatible computers such as 486 or Pentium Minimum requirements are 4 MB RAM Windows 3 1 or better one available ser ial port with a HART modem and a hard disk drive The basic functions performed by ValVue are Remote display of valve position actuator pressure set point calibration parameters con figuration parameters and status error indicators Remote calibration of the SVI Remote configuration of the SVI Remote operation of the SVI Manual control of v
111. simplest configuration for the controller It requires two 2 wire lines to the field The sense resistor is located across the A and B terminals of the SVI unit There is no sensing of the controlled vari able in the control room which is acceptable for applications such as a heat exchanger where the primary variable is temperature and the secondary is flow In such a case the SVI is the flow controller and the control room temperature controller sets flow based on the requirements of the temperature loop with no need to monitor flow in the control room In the configuration shown in Figure 8 there are three 2 wire connections to the field With this connec tion the process transmitter output can be monitored in the control room The 250 Ohm resistor is locat ed in the control room in this configuration PROCESS TRANSMITTER C 24 V DC POWER SUPPLY 4 20mA SVI CONTROLLER o A REMOTE SETPOINT INPUT COMMON COMMON Figure 8 Single Loop PID Configuration with Process Feedback 17 The circuit shown in Figure 9 is an intrinsically safe configuration The 788R barrier supplies the operat ing power to the 4 20 mA process transmitter This barrier contains a 250 ohm resistor in its current return leg across which 1 5 V voltage is developed This voltage is fed through the 710 or 728 barrier to the A and B process variable input terminals in the SVI Controll
112. software position limit stop Default is 0 0 PU OFF or ON Display is set value of the upper software position limit stop Default is 0 0 ENGLISH or FRENCH Select language for displays English or French Table 6 Local Configuration Options 51 Procedures To configure the SVI unit execute the following procedure 1 If in NORMAL OPERATE mode press any button OPER will be displayed Press to get to the MAN menu item Press to move to MANUAL menu POS MAN displayed This locks the valve in position and places it in Manual Mode Press twice to move to gt CONFIG option Press to put the SVI in the configure mode and display the first item in the CONFIGURE menu If Single or Double displayed is the one desired press to move to the next item If not press to select the alternate choice When OK press to move to next item Note DOUBLE is not presently implemented In CTL ON OFF OFF should be displayed for positioner If display shows ON press to select OFF Press to move to the next item In ATO ATC if option displayed is correct press to move to the next item If not press to select the alternate choice When OK press to move to the next item In LINEAR or other curve if option displayed is the one desired press to move to the next item If not press to select the other options When OK press to move to next item If custom is selected the custom curv
113. ssages This completes the EXAMINE functions 73 Controller Fault Messages Table 9 lists the fault codes messages that may appear on the display The table also explains the mean ing of each message the probable cause of the fault and recommended action you should take to correct the fault Table 9 Controller Fault Messages Display Code Fault Message Latched Probable Cause Error POS ERR Position Error BIAS ERR Output at null point is out of range POS SEN Position Sensor Error PRES SEN Pressure Sensor Error SIG SEN Current Sensor Error REF ERR Reference Voltage Error SW ERR Self Check Failure RESET OVER RUN Data Overrun Valve is stuck or feedback linkage is disconnected or bro ken Valve position did not agree with SVI output command within acceptable time Bias is out of range Supply pressure too low or incorrect pneu matic block adjust ment J The position sensor has failed or is not aligned properly Failed or linkage aligned incorrectly E i The pressure sensor has failed The primary signal 4 20 sensor has failed J 4 E Hardware failure The A D reference voltage is incorrect SVI failed self check diagnostics SVI has reset since last status clear Internal check failed to process data in time 74 Table 9 Controller Fault Messages cont Display Code Fault Message Latched Probable Cause Error TEMP ERR Circuit Temperature I
114. stom Display clear fault codes Display valve position Display faults Remote operation functions include all of the above plus Display totalized stem travel number of valve cycles and other data useful for predicting valve life Run valve diagnostics Performance Specifications Table 1 Performance Specifications Positioner Mode Only CAUTION Do not exceed operative limits This may cause damage and or performance of the positioner or controller mem Specification Positioner Inputs 4 20 mA signal input with HART protocol Split Range Capabilities Programmable zero and span adjustments 5 mA mini mum span Minimum Current for Operation 3 6 mA operating minimum Compliance Voltage 12 volts maximum loop voltage drop in mA mode typical 10 5 volts Digital Communication HART amp Communication protocol signal from ValVue amp software on personal computer or from HART Hand held Communicator HART slave and burst modes multidrop up to 5 loops with 20 volts minimum at SVI 4 mA load at 20 volts Controller Process Variable Input Nominally 1 5 volts or 4 20 mA with a 250 Ohm resistor Local Display Liquid Crystal One seven character line of 14 segment alpha numeric optional One six character line of 7 segment numeric 22 segment bar graph Push Button Three 3 explosionproof flameproof push buttons Limit Switch Input Two SPST with common Cold contacts Non isolated Remote Position Sensing 10 K
115. superimposed on the 4 20 mA control signal Two frequencies are generated one representing the digital value O and one rep resenting the digital value 1 the listening device responds to the voltage generated when the AC cur rent flows through the loop impedance In order to generate a voltage from a current there must be an impedance HART Protocol required that this impedance be at least 220 Ohms at the tone signaling fre quencies At DC zero frequency a current source presents a very high impedance Little change in cur rent for a large change in voltage IMPEDANCE VS FREQUENCY FOR TYPICAL CURRENT SOURCE Log Impedance Log Frequency Figure 26 Impedance vs Frequency for Typical Current Source However at higher frequencies the impedance may be lower For example a noise reduction capacitor across the output of a current source will lower the impedance at higher frequency and thus lower the sig naling voltage Ideally the current source will be supplied with an impedance versus frequency charac teristic see fig 26 The heavy band in the sketch represents the range of frequencies for signaling tones In practice this detailed information is seldom available To be certain that at least 220 Ohms of imped ance is presented by the current source a resistor may be added in series with the current source see fig ure 27 However this will reduce the effective compliance voltage of the current source by 20 mA
116. table for 4 20 mA current loops Note If there are suspected HART compliance problems prepare a detailed description of the loop including all devices on the loop type of wiring used loop length and presence of any possible interference sources before contacting the factory for assistance Power on Check After checking pneumatic and electrical connections apply power to the SVI Restoring power will result in one of five possible images on the local display Normal Blank Fail Safe Random segments displayed Reset The normal display is an alpha numeric reading in the manual or operate mode The display may sequence between three variables four in controller at a 1 5 second rate If a normal display is seen no further action is required If the display is not normal go to appropriate problem listing in Troubleshooting Checklist 83 TROUBLESHOOTING CHECKLIST PROBLEM POSSIBLE CAUSE ACTION Totally unresponsive Instrument not receiving no display on LCD read power due to out Improper Wiring See Electrical Connections Faulty Electronics Contact Factory Service module LCD readout shows ran Faulty Electronics Contact Factory Service dom segments module LCD readout active with Pneumatic supply See Pneumatic unresponsive or incorrect connection problem Connections valve position Improper Configuration See Testing valve Performance and Improper Calibration
117. tory and should not need further adjustment If the pneumatics need to be readjusted for any reason the BIAS option should be selected by pressing This will out put a value of 2750 to the The adjustment screw on the top of the pneumatics section can be adjusted until the valve is nearly stationary near mid travel See Bias Adjustment in Troubleshooting Press to move to the next menu item The TUNE menu item allows the user to initiate the automatic position control tuning function which will select appropriate PID parameters for the position controller Press to initiate AUTO TUNE func tion This procedure may take from 1 to 5 minutes During this time the valve will make a series of steps Caution This procedure should not be performed while the valve is controlling the process When the function is completed you return to TUNE Press to advance to the next item SIG LO displays the input signal that should correspond to the full closed or full open position of the valve depending upon whether the valve is air to open or air to close and whether the positioner is direct or reverse In SIG LO if the displayed value is correct press to advance to the next item If not press to display value of SIG LO Use and buttons to change the value When OK press to return to menu and move to next item SIG HI displays the input signal that should correspond to the full open or full closed position of the valve dependi
118. tput Value to box then click on Output Note valve position If near to 50 adjustment is not required If adjustment is required using a 7 mm open end wrench remove the cap nut on the top of the pneumatic block and loosen the locknut Using a 2 mm hex wrench adjust the bias screw until the valve is at 50 position and stable If movement of the adjusting screw does not re position valve return unit to factory for servicing After adjustment is complete tighten locknut and replace cap nut Spool Valve Maintenance If troubleshooting procedures have shown the spool valve to be a suspect component use the following procedures to clean the pilot subassembly and replace deteriorated parts This procedure describes the steps necessary to disassemble the spool valve To minimize maintenance time Masoneilan recommends replacing the entire pilot subassembly Using a replacement subassembly allows you to work on the old unit as time permits Prior to any disassembly make sure new O rings of proper material are available The old rings should not be re used Warning Cleaning the pilot subassembly and replacing deteriorated parts requires shutting down the positioner and isolating the valve from the process Failure to do so can result in damage to the system or personal injury Figure 45 illustrates the components of the pilot subassembly Pilot Subassembly 8 Pilot Spool Extension Pin Plug Spring End Plug Figure 45 Pilot
119. ts 40 Interference with DCS 40 Cabling and Interconnection Constraints 40 Split Range ye tute ed nb baal saa gg d qus 41 Chapter 3 Operation SVI Positioner 42 INtFOGUCTION 4 42 Pushbuttons Display 42 Menu 52522118 __________ oe Ls 46 NORMAL OPERATE Mode and Manual Mode Menus 46 Configure Menu wc oes emis eee tab 47 Calibrate xax ee E dee SX ER ee RC Rom ad 48 Examine Ment uses es eo ted eto oo Reo P NOE xor A ee lace ge 49 Normal Operation Positioner 51 FUNCIONS 55 n diia deus a SI Gandia deeded Gee 51 CONMTIQUIATION MT 51 Parameters and Options Available 51 PROCEGUIES ed ERU BERE A ted 52 deer ien eG ea Ou dea e Ie 53 aine d ETT 53 Procedures c 53 Return to Normal Operation 54 EXGMING e 54 andi A Ic 54
120. tween the SVI position indicated on ValVue or in the push button display and the actual valve position On start up after leaving the unit without power for an extended period of time an offset sometimes occurs between the signal and actual valve position On startup this offset begins moving slowly This Offset exists because the present bias setting differs from the setting recorded when the unit last saved the bias Note These offsets resolve themselves because the SVI saves the bias value every hour which provides a more accurate signal valve position reading For more rapid adjustment select the Calibrate screen and return to Manual Mode which automatically saves the value For the following case bias may need to be adjusted If full open or full close won t cause the valve to move fully to the stops you may need to adjust the bias 92 Bias Adjustment Procedure An SVI generated pilot pressure controls the spool position The pilot pressure range is displayed as a dimensionless value between 0 and 5500 The exact number can be displayed when using ValVue or a Handheld Configurator for calibrating the SVI The value is not displayed when using pushbuttons but is automatically set to the calibrate value of 2750 when in bias adjust mode If using pushbutton model SVI follow menu steps to CAL and then to BIAS Press the button If using Handheld or ValVue go to manual screen click Calibrate button enter 2750 in Ou
121. two bot tom bolts and securely tighten all four bolts 21 Lever Orientation Pneumatic P Block Flat On Shaft Must Be Orientated Toward Block As Shown Air Supply 114 NPT Air Output NN 1 4 NPT Figure 14 Orientation of SVI Lever and SVI Shaft Valve Actuator SVI Rotary Mounting Bracket Spacer SVI Valve Side Lever with Pin Approx 1 16 Space Bet L amp Hou s b Anti Backlash Spring SVI Lever Figure 15 SVI Mounting on Rotary Valves 22 Standard Reciprocating Valve Mounting Mounting the SVI on Masoneilan 87 88 Multi Spring actuators Tools required 7 16 inch Combination Wrench 2 required 3 8 inch Combination Wrench 1 2 inch Combination Wrench 4mm Hex Wrench 3 16 inch Hex Wrench 1 Mount the SVI mounting bracket to the actuator using two 2 5 16 18 UNC cap screws Unless otherwise specified the SVI mounting assumes that the actuator is in the normal upright position The slotted opening of the mounting bracket is to be to the left when facing the actuator 2 Clamp the SVI lever to the SVI shaft The flat on the SVI shaft must always face the pneumatic block with the lever orientated facing the cover as shown in Figure 14 When using a standard lever the orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft Leave approximately 1 16 space the SVI housin
122. ue handheld or the pushbuttons Set the position setpoint to 95 Confirm that valve is in the set position 95 If valve is in proper position the SVI and valve systems are functioning properly Place the SVI in OPERATE mode It is recommended that if possible the valve be cycled through its full stroke using the control room 4 20 mA source This will verify 87 that the valve control loop is not noisy and that compliance voltage is high enough to properly drive the SVI e If the valve does not travel to 95 review the following 1 Check that air supply pressure is adequate for actuator 2 Repeat previous tests as necessary to determine cause of problem If consistent and proper operation cannot be obtained return SVI to factory Fail Safe Display A reading of Fail Safe on the display indicates a fatal or non fatal error in the SVI and acknowledges that the computer holds the output in a fail safe condition Use the pushbuttons Hand Held or ValVue to see the cause of the fail safe condition a list of error codes and the necessary corrective action Note Not all errors are fatal e g not all errors cause a fail safe condition Latches Certain errors occur and self correct The SVI clears the bit in the status when the error disappears and uses latches to show you an error occurred although it is not currently an error Errors that latch include RESET POSSEN PRESSEN REFERR and TEMPERR Table contains a descr
123. use s EEPROM Write Failed Watchdog Timer Time out Signal Calibration Failed write of data to the inter nal permanent memory of the SVI Failed An internal timer that checks proper SVI opera tion has timed out indicat ing improper operation of the SVI An attempt to recalibrate the primary of secondary signal or the pressure sen sors failed 99 If you detect this error issue a reset and check the configuration and calibra tion parameters On watchdog timer time out the SVI issues a self reset This error indicates that such a reset already occurred The normal cause is send ing the SVI calibration val ues outside the allowed range or trying to calibrate two values too close together e g with insuffi cient range for accurate calibration
124. valve in manual mode and go to MANUAL Menu CTLR go to CONTROLLER Menu EXAMINE go to EXAMINE Menu and OPER return to display of current position pressure and signal Use the pushbuttons to move from one option to the next Press the button to go to the item displayed in the menu Configuration Parameters and Options Available The Controller version of SVI must have the controller parameters configured from either Val Vue or a HART Hand Held Communicator Normally all of the operating parameters will be configured from Val Vue or the Hand Held Communicator however any parameters common to both the positioner and controller versions can be entered or changed via the pushbuttons Controller setpoint values and selection of local or remote setpoint can also be entered via the pushbuttons You can configure the following options by pressing the local pushbuttons in the procedure described below We recommend that you use the menu structure diagrams in Figures 37 through 42 pages 62 to 67 as a road map in following the procedures described As noted previously configuration should be performed before calibration Also note that configuration can be performed only when the valve is in manual mode The configurable options are as described in Table 8 LINEAR or EQUAL 50 Select desired valve characteristic curve linear equal percent EQUAL 30 QUICK age 50 equal percentage 30 quick opening or custom curve L RECIP The
125. ve in NORMAL OPERATE mode If in MANUAL mode press repeated ly until the EXAMINE menu item is reached Press to select the EXAMINE mode 3 Press repeatedly to move through the EXAMINE menu until CONFIG is reached Press to display the list of configuration values 4 To move forward through the configuration parameters in sequence press To move back through the list press 5 Atany time to return to CONFIG in the EXAMINE menu press 72 Display Clear FAULTS To examine and or clear fault codes and messages execute the following procedure 1 2 If in NORMAL OPERATE mode press any button Press to move through the options until you reach the EXAMINE menu item Press to go to EXAMINE menu This leaves valve in NORMAL OPERATE mode If in MANUAL mode press repeatedly until the EXAMINE menu item is reached Press to select the EXAMINE mode Press repeatedly to move through the EXAMINE menu until FAULTS is reached Press to dis play the list of status values To move forward through the faults in sequence press To move back through the list press The last item in the list is CLEAR When this message is displayed you can clear all faults by pressing This will also return you to FAULTS in the EXAMINE menu If you do not want to clear all fault messages press or to move to another item in the list You can then press to return to FAULTS in the EXAMINE menu without clearing fault me
126. with Process Feedback 17 Figure 9 Intrinsically Safe Single Loop PID Configuration 18 Figure 10 Local Set with Voltage Source 19 Figure 11 Local Set with Voltage Source Two Leads to Field 19 Figure 12 SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves 21 Figure 13 SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves 21 Figure 14 Orientation of Lever and SVI Shaft 22 Figure 15 SVI Mounting on Rotary Valves 22 Figure 16 View of SVI Mounted on a Reciprocating Valve 23 Figure 17 SVI Lever for 87 88 Multi Spring Actuator 24 Figure 19 Side View of SVI Mounted on a Reciprocating Valve 25 Figure 18 SVI Mounting Bracket for 87 88 Multi Spring Actuator 25 Figure 20 Typical SVI Mounting 37 38 Actuator 27 Figure 21 Typical SVI Mounting on 84 85 Actuator 27 Figure 21a Smart Valve Interface Outline 0 28 Figure 22 SVI Mounting Interface 29 Figure 23 SVI Lever Design 1 3 30 Figure 24 Electrical Con
127. ximum Ambient Temperature Dust tight conduit seal must be used when installed in Class Il and Class environments The model 275 Hand Held Communicator is Factory Mutual approved with the entity parameters printed on the 275 label 37 CENELEC Approved Model Flameproof Coded as EEx d IIB H2 T5 Ta 480 Installation must be in accordance with current editions of applicable country codes and manufacturers instructions Intrinsically Safe Coded as EEx ia T4 Tamb 40 C to 80 C Installation must be in accordance with current editions of applicable country codes and manufacturers instructions The intrinsic safety barriers must be suitable for use with the SVI safety description given below Field Connector Power Input Ui 30 Vdc li 2 125 mA Pi 0 9 W Ci 2 2nF Li 96 uH Field Connector A B C Controller Link Ui 30 Vdc Ci 0 uF Li 0 mH Housing Protection Rating IP 65 38 SVI Interconnections Basic Positioner The basic positioner functions to position the valve in response to the magnitude of the 4 20 mA current input The connection between the positioner and control system is by a two conductor cable The rec ommended configuration is use of twisted pair shielded cable with the shield and loop grounded at one point only Positioner or Controller with HART Communication Impedance Constraints HART communication is based on the talking device generating an AC current

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