GE Baker Hughes Masoneilan SVI FF Installation And Operation Manual

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Masoneilan

SVI* FF Digital Positioner

Advanced Performance

Installation and Operation Manual (Rev F)

BHGE Data Classification: Public

About this Guide

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

 SVI FF

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

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

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

DISCLAIMER

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

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

 with firmware version 1.0.0.1 or higher

 with ValVue* version 3.0

 with handheld communicator with DD published for SVI FF

Copyright

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

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

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

All information contained herein is believed to be accurate at the time of publication and is subject to change without notice.

Document Changes

Version/Date Changes

A/03-2014 Original release

B/05-2014 Made changes to specification for Conformity, Linearity and Repeatability.

Made changes to the Remote Positioner installation section,

C/05-2014 Made formatting changes.

D/06-2014 Omitted Link Master chapter.

Made modifications to the Transducer Blocks Parameters table.

Made modifications to the Foundation Fieldbus: Process Example appendix.

Made modifications to the Fault State Processing appendix.

Removed Remote Position Sensor section from install. Now a standalone manual.

E/08-2017 Added Appendix for Continuous Valve Diagnostics Concept.

Made modifications to Transducer Block Parameters table.

Added Diagnostics Comparison table to Introduction.

Modified the Adv Setup pushbutton menu.

Added LO mode appendix.

F/07-2019 Added Configuring the SVI FF and a Yokogawa Centum DCS.

Updated Troubleshooting.

Changed graphics for DCS switches installation.

Updated download site url.

Masoneilan SVI FF Instruction Manual =| 3

Contents

1. Safety Information ........................................................................................................................................................................... 9

Safety Symbols ............................................................................................................................................................................... 9

SVI FF Product Safety.................................................................................................................................................................10

2. Introduction ......................................................................................................................................................................................13

ValVue Software...........................................................................................................................................................................14

ValVue Standard Edition ..................................................................................................................................................14

Operational Overview................................................................................................................................................................14

SVI FF Features .............................................................................................................................................................................15

Available Options.................................................................................................................................................................16

Characterization ..................................................................................................................................................................16

Control Sets............................................................................................................................................................................16

Continuous Diagnostics ...................................................................................................................................................17

Diagnostic Versions............................................................................................................................................................19

Block Modes ...................................................................................................................................................................................20

Resource Block Modes......................................................................................................................................................20

Transducer Block Modes..................................................................................................................................................20

Overview of Available Tools....................................................................................................................................................22

Principle of Operation................................................................................................................................................................23

Physical and Operational Description................................................................................................................................24

Electronics Module..............................................................................................................................................................24

Output Switch........................................................................................................................................................................25

Pneumatic Module..............................................................................................................................................................26

Optional Display and Pushbuttons..............................................................................................................................29

Link Active Scheduler.................................................................................................................................................................29

About This Manual.......................................................................................................................................................................30

Conventions Used in This Manual................................................................................................................................30

3. Quick Start .........................................................................................................................................................................................31

Step 1: Install the Positioner on the Valve........................................................................................................................31

Step 2: Connect Pressure Supply..........................................................................................................................................31

Step 3: Wire the SVI FF...............................................................................................................................................................32

Step 4: Set Tag and Address...................................................................................................................................................32

Step 5: Basic Configuration.....................................................................................................................................................33

Step 6: Run Find Stops METHOD...........................................................................................................................................34

Step 7: Run Auto Tune METHOD ...........................................................................................................................................34

Downloads......................................................................................................................................................................................34

4. Mechanical Installation ...............................................................................................................................................................35

Overview ..........................................................................................................................................................................................35

SVI FF Positioner Types .............................................................................................................................................................35

Single Acting Positioner Description...........................................................................................................................35

Double Acting Positioner Description ........................................................................................................................41

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Installation......................................................................................................................................................................................44

Pre-Installation Issues.......................................................................................................................................................44

Installation Steps.................................................................................................................................................................46

Installation Notes ................................................................................................................................................................47

Control Sets Configuration..............................................................................................................................................48

Mounting the SVI FF on Rotary Valves ......................................................................................................................50

Mounting the SVI FF on Reciprocating Valves.......................................................................................................55

Dismantling the SVI FF from Reciprocating Valves.............................................................................................58

Installing the SVI FF for Double- Acting Operation..............................................................................................59

Connecting the Tubing and Air Supply......................................................................................................................62

Wiring the SVI FF..................................................................................................................................................................65

5. Check Out and Power Up ...........................................................................................................................................................73

Overview..........................................................................................................................................................................................73

Check Out Procedures ..............................................................................................................................................................73

Physical Inspection.............................................................................................................................................................73

Check the Electronic Module Connections..............................................................................................................77

Operational Checkout ...............................................................................................................................................................77

Connect to the H1 Network............................................................................................................................................77

Power Up the SVI FF...........................................................................................................................................................78

6. Failsafe/OOS Considerations ....................................................................................................................................................79

Failsafe Mode vs. OOS Mode..................................................................................................................................................79

Exiting Failsafe Using AMS..............................................................................................................................................81

7. Maintenance ....................................................................................................................................................................................83

SVI FF Maintenance and Repair............................................................................................................................................83

Repair........................................................................................................................................................................................83

Tools Needed.........................................................................................................................................................................83

Display Cover Removal and Installation...................................................................................................................83

I⁄P Module Removal and Installation ..........................................................................................................................85

Relay Removal and Installation....................................................................................................................................88

Adjusting I/P Zero................................................................................................................................................................88

Connecting Components to the Electronics Module ..........................................................................................88

Repair by Replacement ............................................................................................................................................................89

Internal Diagnostics ...................................................................................................................................................................89

FAILSAFE Mode.....................................................................................................................................................................89

Viewing Firmware Versions ....................................................................................................................................................90

Spare Parts .....................................................................................................................................................................................91

Appendix A. Specifications and References ...........................................................................................................................95

Physical and Operational Specifications..........................................................................................................................95

Appendix B. About Fieldbus ........................................................................................................................................................103

Outline............................................................................................................................................................................................103

Internal Structure of SVI FF.................................................................................................................................................. 103

Logical Structure of Each Block......................................................................................................................................... 105

System Configuration............................................................................................................................................................. 106

Connection of Devices ................................................................................................................................................... 107

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Integration of DD ......................................................................................................................................................................107

Appendix C. Foundation Fieldbus: Process Example .......................................................................................................109

Overview .......................................................................................................................................................................................109

Reference Model Process......................................................................................................................................................109

P & I D.............................................................................................................................................................................................110

Function Block Links................................................................................................................................................................ 111

Device Operational States and Block Modes...............................................................................................................113

Block Modes........................................................................................................................................................................ 113

Multiple Modes and States..........................................................................................................................................115

Examples of Operational States................................................................................................................................115

Transferring Modes ......................................................................................................................................................... 116

RCas Mode...........................................................................................................................................................................116

Appendix D. Troubleshooting .....................................................................................................................................................117

What to Do First ........................................................................................................................................................................117

Troubleshooting Communications...................................................................................................................................118

Troubleshooting Function Block Parameters ..............................................................................................................119

Troubleshooting Valve Control........................................................................................................................................... 120

Troubleshooting Auto Tuning..............................................................................................................................................123

Troubleshooting Tuning.........................................................................................................................................................125

Troubleshooting Position, Pressure, and Temperature Sensors.........................................................................126

Appendix E. Using the Pushbuttons and Digital Interfaces .......................................................................................... 127

Overview .......................................................................................................................................................................................127

Local Display and Pushbuttons .................................................................................................................................127

Handheld Communicator.............................................................................................................................................128

ValVue....................................................................................................................................................................................128

Pushbuttons and Local Display..........................................................................................................................................128

Pushbuttons........................................................................................................................................................................ 129

Pushbutton Locks and Configuration-Lock Jumper ........................................................................................130

Hardware Configuration Lock .................................................................................................................................... 130

Hand Held Communicator ...................................................................................................................................................131

Check-out with a Handheld Communicator........................................................................................................132

ValVue ............................................................................................................................................................................................133

Installation of ValVue Software, and Registration ............................................................................................133

Installation of Cover ................................................................................................................................................................ 133

Display Menus ............................................................................................................................................................................133

NORMAL Operating Mode Menus .............................................................................................................................133

BAS SETUP Menu............................................................................................................................................................... 134

ADV SETUP Menu..............................................................................................................................................................137

VIEW DATA Menu.............................................................................................................................................................. 139

VIEW ERROR Menu...........................................................................................................................................................142

MAN POS Menu..................................................................................................................................................................148

METHOD Menu...................................................................................................................................................................148

Appendix F. Transducer Block Parameters ..........................................................................................................................149

Appendix G. Static Parameters During Restore to Defaults ........................................................................................197

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Appendix H. Notes on Characterization ................................................................................................................................ 199

Valve Over/Under Reaction Near Endpoints ............................................................................................................... 199

Configuration of Position Limits, Position Rate Limits and FINAL_VALUE_CUTOFF and Characterization 200

Relationship Between Alerts, Alert Response Type and Block Error......................................................... 202

Appendix I. Fault State Processing .......................................................................................................................................... 203

Initiate Fault State from the Host ............................................................................................................................. 203

Fault State Conditions Detected by AO Block..................................................................................................... 204

Fault State Conditions Detected by Transducer Block ................................................................................... 204

Fault State Condition is Detected and Processed by the Position Control Hardware and Software 205

Appendix J. Configuring the SVI FF and a Yokogawa Centum DCS ......................................................................... 207

Purpose and Scope.................................................................................................................................................................. 207

Status of SVI FF interoperability with Yokogawa DCS............................................................................................. 208

Special Notes When Working with Yokogawa DCS ......................................................................................... 208

Procedure..................................................................................................................................................................................... 209

1. Preparation for Device Connection .................................................................................................................... 209

2. Connecting the SVI FF ............................................................................................................................................... 215

3. Edit Block Parameters............................................................................................................................................... 217

4. Set Device Information ............................................................................................................................................. 220

Appendix K. Views ........................................................................................................................................................................... 225

Views ..............................................................................................................................................................................................225

Appendix L. References ................................................................................................................................................................ 229

Appendix M. Continuous Valve Diagnostics Concept .....................................................................................................231

Introduction................................................................................................................................................................................. 231

Off Line Diagnostics ........................................................................................................................................................ 232

On Line Diagnostics ........................................................................................................................................................ 232

Continuous Diagnostics......................................................................................................................................................... 233

Positioner Diagnostics ................................................................................................................................................... 233

Valve/Actuator Diagnostics......................................................................................................................................... 234

Supporting Information for Diagnostic Configuration.................................................................................... 237

Application Specific Categorization......................................................................................................................... 241

Reporting Diagnostic Condition to the Host ................................................................................................................242

Diagnostic Events Reported by Block Error ......................................................................................................... 242

Diagnostic Events Reported by Alarms.................................................................................................................. 244

Diagnostic Events Reported According to FF-912 Field Diagnostic Profile Specification.............. 246

Discrete Switch Configuration ................................................................................................................................... 249

Processing to DI Block.................................................................................................................................................... 249

Conclusion ................................................................................................................................................................................... 249

Appendix N. Changing Out of LO Mode ................................................................................................................................ 251

Local Display............................................................................................................................................................................... 251

Device DTM.................................................................................................................................................................................. 252

Handheld...................................................................................................................................................................................... 253

DD Method...................................................................................................................................................................................256

Masoneilan SVI FF Instruction Manual =| 7

DD Host .........................................................................................................................................................................................258

Appendix O. Air to Open/Air to Close Configuration ........................................................................................................259

Standard DD-based Configuration Tool: Transducer Block - Fail Action Parameter................................260

SVI FF DTM....................................................................................................................................................................................261

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1. Safety Information

CAUTION

WARNING

CAUTION

NOTE

This section provides safety information including safety symbols that are used on the SVI FF and the safety symbol definition.

Read this entire section before installation and operation.

Safety Symbols

SVI FF instructions contain WARNINGS, CAUTIONS labels and Notes, where necessary, to alert

you to safety related or other important information. Total compliance with all WARNING, and CAUTION notices is required for safe operation.

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

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

Indicates important facts and conditions.

Masoneilan SVI FF Instruction Manual =

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SVI FF Product Safety

NOTE

The SVI FF digital valve positioner is intended for use with industrial compressed air or, natural gas systems only.

Ensure that an adequate pressure relief provision is installed when the application of system supply pressure could cause peripheral equipment to malfunction. Installation must be in accordance with local and national compressed air and instrumentation codes.

General installation, maintenance or replacement

 Products must be installed in compliance with all local and national codes and

standards by qualified personnel using safe site work practices. Personal Protective Equipment (PPE) must be used per safe site work practices.

 Ensure proper use of fall protection when working at heights, per safe site work

practices. Use appropriate safety equipment and practices to prevent the dropping of tools or equipment during installation.

Installations using natural gas are Zone 0 or Div 1 installations.

 Under normal operation, compressed supply gas is vented from the SVI FF to the

surrounding area, and may require additional precautions or specialized installations.

Intrinsically Safe Installation

Products certified as explosion proof or flame proof equipment or for use in intrinsically safe installations MUST BE:

 Installed, put into service, used and maintained in compliance with national and local

regulations and in accordance with the recommendations contained in the relevant standards concerning potentially explosive atmospheres.

 Used only in situations that comply with the certification conditions shown in this

document and after verification of their compatibility with the zone of intended use and the permitted maximum ambient temperature.

 Installed, put into service and maintained by qualified and competent professionals

who have undergone suitable training for instrumentation used in areas with potentially explosive atmospheres.

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Before using these products with fluids/compressed gases other

WARNING

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

Under certain operating conditions, the use of damaged instruments could cause a degradation of the performance of the system, which can lead to personal injury or death.

Under certain operating conditions the SVI FF High Flow unit can produce noise levels greater than 85 dBA. Perform proper site monitoring and testing to verify the need for engineering or administrative controls to eliminate or reduce hazardous noise levels.

Installation in poorly ventilated confined areas, with any potential of gases other than oxygen being present, can lead to a risk of personnel asphyxiation.

Use only genuine replacement parts which are provided by the manufacturer, to guarantee that the products comply with the essential safety requirements of the European Directives.

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

Masoneilan SVI FF Instruction Manual =| 11

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2. Introduction

The SVI FF (Smart Valve Interface) is the next generation of Masoneilan’s intelligent digital valve positioners with the FOUNDATION Fieldbus interface. The SVI FF is a high performance, digital valve positioner that combines a local display with remote communication and diagnostic capabilities. The SVI FF offers a multitude of options that fulfill the broadest range of applications, using the FF protocol. The High Flow version is capable of 2.2 C

An optional pushbutton and LCD display enables local operations of calibration and configuration functions. Remote operations can be performed with ValVue (Version 3) software, with any FDT-based frame application or any FF Registered host interface that has been pre-loaded with the Device Description files (DD) for SVI FF.

The SVI FF is provided with Masoneilan’s ValVue software. The user-friendly interface facilitates the setup and diagnostics of a control valve.

air throughput.

Figure 1 SVI FF

Masoneilan SVI FF Instruction Manual =

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ValVue Software

Not only does ValVue provide the ability to quickly and easily set up the SVI FF you can also monitor operation and diagnose problems with ValVue’s advanced diagnostic capabilities.

ValVue Standard Edition

ValVue Standard Edition software is downloadable and is used with each SVI FF for positioner calibration and configuration. ValVue Standard Edition software is freeware. It provides functions to properly set up and start up an SVI FF digital valve positioner on any type of control valve, along with diagnostics, Sequence, Audit Trial, and Monitoring Device. After a 30 day trail period the Sequence, Audit Trial, and Monitoring Device functionality will become inoperable.

Contact

For the most recent software visit our SVI FF web site at:

https://valves.bhge.com/resource-center

Operational Overview

The SVI FF is a smart electro-pneumatic positioner that:

1. Receives a digital setpoint from the controller and compares the setpoint input to the valve position reported by the position sensor.

2. Uses the position control algorithm to analyze the difference between the position setpoint and position feedback and sets a servo signal for the I/P converter.

3. Uses the output pressure of the I/P, which is amplified by a pneumatic relay that drives the actuator. Once the error between the setpoint and the valve position feedback is eliminated, no other correction is applied to the servo signal in order to maintain valve position.

The local explosion proof LCD/Buttons (if equipped) display provides information about the device. The LCD can display data from blocks on other devices, if the system is so configured. The switch board provides a user-configurable discrete output, which is optionally used to indicate different controller states.

14 | BHGE

SVI FF Features

The SVI FF Digital Valve Positioner is suitable for installation indoors or outdoors, and in a corrosive industrial or marine environment and is equipped with the following features:

 Extreme Accuracy, Reliability and Digital Precision

 Automated Valve Commissioning

 Precise, Quick, Responsive Control of Valve Position

 Valve Position Auto Tuning

 One Model for Rotary or Reciprocating Valves

 Local Operation⁄calibration⁄configuration with Optional Flameproof Push Buttons and

LCD Digital Display

 Compatible with Air-to-Close or Air-to-Open Actuators

 Non-contact Magnet Coupled (Hall Effect) Position Sensing for Rotary and

Reciprocating Control Valves

 Sealed Housing with No Moving Shafts, No Shaft Penetration, and Fully Potted

Electronics

 Uniform Hazardous Area Approvals for ATEX, FMc, and FM with Other Approvals

Available Upon Request

 Local, On-line Diagnostic Condition Monitor: Total Stem Travel, Number of Valve Cycles,

Predictive Maintenance Data

 Advanced Valve Diagnostics with ValVue Software and the Pressure Sensor Option

 User-adjustable Response Times

 Split-range Capability

 Configurable High and Low Position Limits

 Characterize Stroke:

Linear  Equal Percentage 50:1



 Equal Percentage 30:1  Quick Opening

 2 up to 21 Point Custom Characterization  Camflex Percentage

 Optimized Performance Regardless of Actuator Size

 Linearity Compensation for Actuator Linkages with ValVue Software

 User Configurable Tight Shutoff/Tight Open at Adjustable Input Threshold

 Remote Operation Calibration Configuration Diagnostics Using ValVue software or a

handheld communicator

 Single or Double Acting (not available for the High Flow version)

Masoneilan SVI FF Instruction Manual =| 15

Available Options

NOTE

Some of the options available for the SVI FF include:

 Remote Position Sensor

 A Contact Output User Linked to Various Status and Alarm Flags

 Offshore Construction - Stainless Steel Housing and Components

 Pushbutton Display

Characterization

A characterization defines the relationship between the input signal and the output position of the valve. The SVI FF has a five built-in characterization curves. The additional Custom characterization requires manually entering values and is only for experts and under special circumstances.

The characterization may contain up to 21 configurable XY pairs and the position is linearly interpolated between the pairs. The first position is always 0, 0 and the last position is always 100,100. You can specify how many points to define between the start point (0, 0) and the endpoint (0, 100). The points are added as xy pairs.

The algorithm posts a failure if the curve slope violates the slope limitations: x/y or y/x < 20.

When you change characterization type, the Transducer block and AO block must be in OOS and the system is de-energized.

Control Sets

The position controller is a type of non-linear PID control algorithm with eight parameters listed below, as well as Auto Tune and Custom.

The preferred method is Auto Tune, which automatically tunes the valve. Custom requires manually entering values and is only for experts and under special circumstances. A Custom control set with out of range PID parameters is rejected by the system.

Configure the parameters using the parameter name or using FF parameter. Also see the “Control Sets Configuration” on page 48.

When the characteristic is linear, the displays of position setpoint and target valve position all match. For all other (non-linear) characteristics the valve target position differs from the setpoint.

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Continuous Diagnostics

Alerts

Most systems monitor block errors and these can be linked for alert reporting in the DCS. See Table 31 on page 149 for a full list of Transducer blocks parameters used for configuration. Also see “Continuous Valve Diagnostics Concept” on page 231 for an in depth discussions of this topic.

Alert configuration is available for the following areas:

 Deviation alerts: You can configure a Deviation Value, a Position Error (Alert Point), a

Deadband around the Position Error and a Time before the alert is set. Active and historical alerts are indicated.

 HI, HI HI, LO and LO LO Alerts (): You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Near Closed Alert: You can configure a desired Position Closed value and an Alert Point

in hours after which the alert is set. Active and historical alerts are indicated.

 Setpoint Timeout Alert: You can configure a desired Alert Point and Maximal Detect

Time. Active and historical alerts are indicated.

 Pressure Alarms for HI, LO and LO LO: You can configure a desired Position, an Alert

Point, and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Temperature Alarms for HI and LO: You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 IP Output Alarms for HI and LO: You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Travel Alerts: You can configure two sets of travel accumulation alarms based on an

Alert Point and a Deadband. Active and historical alerts are indicated.

 Counter Alerts: You can configure two sets of cycle counter accumulation alarms

based on an Alert Point and a Deadband. Active and historical alerts are indicated.

 Operating Time Alerts: You can configure an operating time alarms based on an Alert

Time. Active and historical alerts are indicated.

Masoneilan SVI FF Instruction Manual =| 17

Alarm/Alert Causes

Some causes of alarms/alerts include:

Low Supply Pressure  High friction



 Obstacle  Bad Tuning

 Valve Sticking  Position Alerts

 Position HI HI: Position Feedback Slip  Position HI: Process out of range or Control

 Position LO: Process out of range  Position LO LO: Position Feedback Slip

Trends

There are three trends available in the ValVue FF DTM or using a handheld device:

Travel Accumulation Trend Displays travel accumulation for the following areas:

Loop is not tuned

 Yearly Travel Accumulation Trend (%)

 Monthly Travel Accumulation Trend (%)

 Weekly Travel Accumulation Trend (%)

Cycle Counter Trend Displays cycle counter accumulation for the following areas:

Position Error Trend Displays a trend of average error over time. for the following areas:

Histograms

Position Histogram Displays how many cycles are spent in each 10% position increment

 Daily Travel Accumulation Trend (%)

 Yearly Cycle Counter (Counts)

 Monthly Cycle Counter (Counts)

 Weekly Cycle Counter (Counts)

 Daily Cycle Counter (Counts)

 Yearly Average Error Over Time

 Monthly Average Error Over Time

 Weekly Average Error Over Time

 Daily Average Error Over Time

There are two histograms available in the ValVue FF DTM or using a handheld device:

and to you can reset the total operating time for the histogram.

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Position Error Histogram Displays the position error as function of position and you can reset

the histogram.

Diagnostic Versions

There are two versions – Standard and Advanced. Table 1 illustrates the capabilities of each version.

Table 1 Advanced versus Standard SVI FF Diagnostic Versions

Feature Sub-feature Advanced Standard

Device States Positioner State XX

Configuration Control Configuration XX

Positioner Alert Log XX

Trend and Position Setup X-

Device State XX

Extended RB Configuration X -

Extended TB Configuration X -

Alerts XX

LCD Display XX

Calibration Find Stops XX

Auto Tune XX

Quick Wizard X-

Full Wizard X-

Diagnostics Step Test X-

Ramp Test X-

Signature Test X-

Histograms X-

Trends X-

Identification XX

Security X-

Print XX

Write Notes XX

Masoneilan SVI FF Instruction Manual =| 19

Block Modes

WARNING

Resource Block Modes

Resource block has two major modes:

 OOS – The block configuration parameters can be changed.

 AUTO – This is normal operational mode.

BLOCK_ERROR_DESCR_1 provides additional details if the target mode is AUTO and the actual mode cannot be switched to AUTO (stays in OOS).

Transducer Block Modes

You can request the block to switch to one of the following block modes by writing MODE_BLK.TARGET parameter:

ALL blocks are switched to OOS mode when the Resource block is switched to OOS mode.

When the TB is in OOS mode, the valve moves to its de-energized position.

 OOS – The device de-energizes the valve. This mode also may be necessary for setting

SETPOINT SOURCE, ACTUATOR_3.ACT_FAIL_ACTION and CHAR_SELECTION.TYPE, that can trigger a large movement of the valve if the valve is not de-energized.

 MAN – You are in control of the valve position. You can use this mode for most of the

configuration, maintenance and diagnostic procedures. If the SETPOINT_SOURCE=AO-Final Value, you can move the valve by writing a value to FINAL_VALUE parameter.

 AUTO – The valve is under FF blocks control. Depending on the configuration of the

SETPOINT_SOURCE, the SETPOINT is set from FINAL_VALUE, FINAL_VALUE_D or FINAL_VALUE_DINT.

Depending on the Transducer block configuration, valve position control and valve condition, the transducer block (MODE_BLK.ACTUAL) may be in one of the following states:

 OOS – This is an indication that the valve is in de-energized position. The valve cannot

be moved until the block is in this mode. The TB goes to OOS mode if one of the following condition exists:

 The Transducer block MODE_BLOCK.TARGET = OOS mode. You must change the

Transducer block target mode to make the device operational.

 The Resource block MODE_BLOCK.TARGET = OOS mode

20 | BHGE

 The device has detected an abnormal condition, that does not allow it to operate.

You must review the value of parameter 87.COMPLETE_STATUS for more

information about the reason for failure. You must correct the condition (e.g.

WARNING

connect the air supply if Air Supply Low error is reported or remove obstacle, stopping the valve if Actuator or Position Error is reported). When the condition is corrected, clear faults by writing the appropriate value to parameter

88.CLEAR_STATUS. In some cases you may need to restart the device.

 A failure condition exists in the valve position control algorithm that won’t allow the

valve to operate. Verify that state by reading parameter 74.FAILED_STATE. For more information see the previous point.

 You have set the device to Fault State from the local LCD display. Review this by

reading the value of parameter 86. APP_MODE. Correct the condition by switching the Application mode to Normal from the local display or by setting the parameter

86.APP_MODE to Normal.

Changing the Application to Normal mode may switch the TB to MAN or AUTO mode and move the valve. It may be dangerous if someone is still working with the valve.

 LO – This is an indication that the valve is controlled from the local display. Verify this

by reading parameter 86.APP_MODE – it has a value of Setup. Transfer the control back to the FF interface by switching the local LCD display to Normal mode. The mode can be switched remotely through FF, by writing to parameter

86.APP_MODE the value Normal.

Changing the Application to Normal mode may switch the TB to MAN or AUTO mode and move the valve. It may be dangerous if someone is still working with the valve.

 MAN – You are in control of the valve positioner. You can execute configuration,

maintenance and diagnostic procedures. If the SETPOINT_SOURCE=AO-Final Value, you can move the valve by writing a value to FINAL_VALUE parameter.

 AUTO – The valve position is being set from the function block, configured for that

purpose. The following cases are possible:

 SETPOINT_SOURCE=AO-Final Value, the Analog Output block is in control and

SETPOINT is set from FINAL_VALUE

 SETPOINT_SOURCE= DO-Final Value D in Open/Close mode, one of the Discrete

Output blocks is in control and SETPOINT is set from FINAL_VALUE_D.

 SETPOINT_SOURCE= DO-Final Value D in 1% steps mode, one of the Discrete

Output blocks is in control and SETPOINT is set from FINAL_VALUE_DINT.

Masoneilan SVI FF Instruction Manual =| 21

Overview of Available Tools

There are several different tools for use in configuring and operating the SVI FF including:

 Local pushbuttons and display: Uses the optional pushbutton and LCD display to

monitor, configure and operate the unit (see“Using the Pushbuttons and Digital Interfaces” on page 127).

 Handheld Communicator: Use any FF-capable handheld communicator, along with the

Masoneilan FF DD to control operations.

 SVI FF DTM: Use the Masoneilan DTM to operate the unit inside a DTM program such as

PACTWare or ValVue’s SVI FF DTM.

 Full ValVue software: Use the ValVue Suite software (see“ValVue Software” on page 14).

22 | BHGE

Principle of Operation

The SVI FF Electro- Pneumatic Digital Valve Positioner receives an electrical position setpoint signal as depicted in Figure 2. The output pressure is amplified by a pneumatic relay that drives the actuator. When the valve position agrees with the value called for by the position setpoint input signal, the system stabilizes with no further movement of the actuator.

Figure 2 Block Diagram with I/P Converter and Pressure Sensor

Masoneilan SVI FF Instruction Manual =| 23

Physical and Operational Description

The SVI FF is housed in an industrial, tough, weatherproof, corrosion resistant aluminum housing that has been designed for operation in hazardous areas as listed in Appendix B. Electrical connections are made through two 1/2" NPT conduit entries. Pneumatic connections are made through two or three ¼" NPT ports.

Electronics Module

The Electronics module consists of an electronic circuit encapsulated in a housing. The electronics include a multiplexer, A/D, D/A, temperature sensor, Hall-Effect magnetic position sensor, pressure sensors, a micro controller, and a power management/distribution circuit. The programs controlling the SVI FF digital valve positioner are stored in a flash memory that allows for the downloading of upgraded firmware.

A separate non-volatile memory stores configuration information, and continuous diagnostic results. Expansion capabilities include connectors for the addition of the optional local display with pushbuttons. Using the internal programmed positioner algorithm, the CPU computes the required output based on information received from the measurement sensors. The base module has no user repairable components.

Magnetic Position Sensor

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

The output of the Hall sensor provides the position feedback signal to the position control algorithm. The magnetic assembly is environmentally sealed and is entirely external to the electronics housing (See Figure 26 on page 57). The Hall effect sensor has a maximum travel range of up to 140° rotation.

Position Display

The position sensor also provides, through the electronics module, a readout of valve position on the optional display and communication of valve position via FF protocol.

Pressure Sensor

The pressure sensor located in the Electronics Module measures the output of the single acting relay. The pressure measurement is displayed on the local display or read by an FF communication device.

24 | BHGE

Temperature Sensor

A temperature sensor is located in the electronics module and measures ambient temperature. This measurement is used to provide temperature compensation for the position and pressure sensors and other internal electronic components. The temperature is read via the FF communication link to provide a warning of excessive ambient temperature at the positioner.

Output Switch

The SVI FF supports a contact output, SW #1 (Discrete Output switch), that can be logically linked to status bits. The Discrete Output switch terminal is a solid state contact. The switch requires its own power source and must be connected to the appropriate connector on the Electronics Module Terminal Board. See “Output Switches” on page 67.

Masoneilan SVI FF Instruction Manual =| 25

Pneumatic Module

Vent

Relay (Pneumatic Amplifier)

I/P Current to Pneumatic Converter

The pneumatic module consists of an I/P and Relay assembly.

Current-to-Pressure Converter, I/P

The I/P converts a current signal to a pressure signal in the following manner. A fixed coil creates a magnetic field proportional to the applied current. The field magnetically pulls a flexure towards a nozzle to increase pressure on the flexure. The pressure on the flexure increases in response to an increase in the coil current. Encapsulation of the coil provides protection from the environment.

Single Acting Pneumatic Relay

The single acting pneumatic relay amplifies the pressure from the I/P and increases airflow as required for stable, responsive, actuator performance. The single acting relay operates on any supply pressure that is at least 5 psi (.345 bar, 34.5 kPa) above the required actuator pressure, up to 150 psi (10.3 bar, 1034 kPa).

26 | BHGE

Figure 3 SVI FF Pneumatic Module with Single Acting Relay

SVI FF High Flow

IP Current to Pneumatic Converter

Vent

Relay (Pneumatic Amplifier)

Figure 4 SVI FF High Flow Pneumatic Module with Single Acting Relay

Masoneilan SVI FF Instruction Manual =| 27

Double Acting Pneumatic Relay

I/P Current to Pneumatic Converter

Double Acting

Vent

Output 2 Gauge

Output 1 Gauge

Output 1 Act 1

Output 2 Act 2

Supply Inlet

Supply Gauge

Relay

The double acting pneumatic relay amplifies the pressure from the I/P and provides a pair of high flow output signals for operating a double acting cylinder actuator. The double acting relay operates on any supply pressure that is at least 5 psi (.345 bar, 34.5 kPa) above the required actuator pressure, up to 150 psi (10.3 bar, 1034 kPa). The two output pressures may be balanced by means of an adjustable seat assembly. The average of the two pressures is adjusted to equal 70% of the supply pressure. The double acting relay is rated for supply pressure to 150 psi (10.3 bar, 1034 kPa).

Figure 5 Double Acting Pneumatic Relay

Double Acting Supply Pressure Balance

After installation on the actuator, set supply pressure in accordance with actuator specifications. Do not exceed the maximum pressure rating of the actuator. The double acting relay is adjusted at the factory and set to 70% of supply pressure. If adjustment is required consult the factory.

28 | BHGE

Optional Display and Pushbuttons

The optional display and buttons (Figure 6) are mounted on the SVI FF cover plate. The three pushbutton switches operating in conjunction with the display permit reading and modification of the instrument operating parameters without a PC or hand-held communicator. These switches perform generic functions - Increase, Decrease, and Accept by movement through a conventional menu structure, see“Using the Pushbuttons and Digital Interfaces” on page 127. The switches are operated in a hazardous environment without compromising the flameproof enclosure.

Link Active Scheduler

To use the SVI FF in a link active scheduler configuration refer to the documentation for the specific DCS.

Figure 6 Optional Display

Masoneilan SVI FF Instruction Manual =| 29

About This Manual

The SVI FF Instruction Manual is intended to help a field engineer install, setup, and calibrate an SVI FF in an efficient manner. This manual also provides in-depth information on SVI FF software, digital interfaces, operation, intrinsic safety configurations, and specifications. If you experience problems that are not documented in this guide contact the factory or your local representative. Sales offices are listed on the back cover of this manual.

Conventions Used in This Manual

Conventions used in this manual are as follows:

 Uppercase, italicized letters are used when referencing a term used in the SVI FF

display window. For example, when indicating the term mode, as in setup mode, and referring to the display/software operation the convention is to spell mode is all uppercase letters: MODE.

 Italics is used for emphasis on important items.

 Fields where data is entered or user-entered data is italicized.

 Actions performed on buttons, checkboxes, etc. appear bolded. For example: Click

Done.

30 | BHGE

3. Quick Start

Output

Supply

Step 1: Install the Positioner on the Valve

See:

1. “Pre-Installation Issues” on page 44 before starting.

2. “Mounting the SVI FF on Rotary Valves” on page 50 or “Mounting the SVI FF on Reciprocating Valves” on page 55 or “Installing the SVI FF for Double- Acting Operation” on page 59. Additionally, if using a remote sensor, refer to GEA31195 Masoneilan Valve Solutions Remote Sensor Quick Start.

Step 2: Connect Pressure Supply

Perform connections as in Figure 7 for the single acting. See Figure 10 on page 36 for High Flow connections and Figure 15 on page 41 for double acting air ports.

Figure 7 SVI FF Air Ports on Single Acting Positioner

Masoneilan SVI FF Instruction Manual =

| 31

Step 3: Wire the SVI FF

Display

Remote

I/P Connector

Position Sensor

Configuration Lock Jumper

9 - 32 V Foundation Fieldbus

Discrete Out

Input

Discrete Input

AI PV 1-5 VDC (Not Used in this release)

Shield (on FF unit

Input Signal

(polarity independent)

housing)

NOTE

CAUTION

Perform wiring as per Figure 8.

Step 4: Set Tag and Address

32 | BHGE

Figure 8 Connections to Electronics Module (via Terminal Board)

Refer to FOUNDATION Fieldbus instructions for shield connections on the FF H1 bus.

Using NI Configurator as an example:

1. Import DD/CFF files.

Do not navigate to the NI DD folder and copy the DD file onto itself.

2. Right-click on the device, select Set Tag, follow the prompts to enter a Tag.

3. Click Set.

Do not deactivate the Set to OOS mode checkbox. The block must be in

CAUTION

OOS to change the Tag.

4. Right-click on the device, select Set Address, follow the prompts to enter an Address.

If the device is at the Visitor’s or Temporary address range (248 (0xF8)- 251 (OxFB)), you must set the address outside of that range.

5. Click Set.

Do not deactivate the Set to OOS mode checkbox. The block must be in OOS to change the Address.

Step 5: Basic Configuration

This section serves as an example where the AO block and TB block are configured. However, there are a number of combinations that can be configured. This discussion is valid if the positioner is controlled by the AO block.

1. For the Transducer block set:

 ACTUATOR_3.ACT_FAIL_ACTION_1 = either 1. Valve Closed (most common) or 2. Valve

Open

 ACCESSORY.REMOTE_SENSOR = 0, if remote sensor is not in use (internal Hall

sensor is used - most common)

 ACTIVATE_CONTROL_SET to one of:

 0: Activate Custom

Control Set (required for Autotune as well - most common)

 3: Activate Control Set 3  4: Activate Control Set 4  5: Activate Control Set 5

 6: Activate Control Set 6

(Double Acting - Slow)

 1: Activate Control Set 1

(Slowest)

 7: Activate Control Set 7

(Double Acting- Fast)

 2: Activate Control Set 2

(Fastest)

Masoneilan SVI FF Instruction Manual =| 33

 CHAR_SELECTION.TYPE to one of:



0. Linear  1. Equal Percentage (30:1)  2. Equal Percentage (50:1)

 3. Quick Open (reversal

from Equal Percentage (50:1))

See “Transducer Block Parameters” on page 149. for further settings.

2. For the AO block set as below:

 PV_SCALE.UNIT INDEX = %  XD_SCALE.UNIT INDEX = %  CHANNEL = Position

 SHED_OPT = NORMAL

SHED NORMAL RETURN

Step 6: Run Find Stops METHOD

WARNING This procedure moves the valve.

Use a configuration tool (DD, SVI FF local pushbuttons or software) to run METHOD.

 4. Custom  5. Camflex Percentage

Step 7: Run Auto Tune METHOD

WARNING This procedure moves the valve.

Use a configuration tool (DD, SVI FF local pushbuttons or software) to run METHOD.

When finished, ensure the Transducer block is returned to Auto.

CAUTION If the Transducer block is switched to Auto, it then follows the

setpoint received from the AO block (if scheduled).

if you fail to switch the Transducer block to Auto, then the valve will not be in control.

Downloads

To download the complete user manual, DD, SVI FF Advanced DTM and the ValVue Suite trial program, visit: https://valves.bhge.com/resource-center

34 | BHGE

4. Mechanical Installation

NOTE

Overview

The SVI FF single acting (Figure 11 on page 37) and double acting (Figure 16 on page 42) are high performance, digital valve positioners that combine a local display with remote communication and diagnostic capabilities. The SVI FF is available with a variety of options to fulfill diverse

applications.

Prior to beginning the installation process review the “Safety Information” on page 9.

SVI FF Positioner Types

SVI FF positioner types include:

 “Single Acting Positioner Description” on page 35, including a high flow version

 “Double Acting Positioner Description” on page 41

Single Acting Positioner Description

The supply and output connections for the SVI FF (Figure 9), located on bottom of the pneumatic block, are tapped 1⁄4" NPT. Output is toward the front, supply is toward the back. Two pressure gauges, output on top, supply on bottom, are located on the front of the pneumatic block.

The supply and output connections for the SVI FF High Flow (Figure 10), located on bottom and leftside of the pneumatic block, are tapped 1⁄2" NPT.

Maximum allowable air supply pressure to the SVI FF varies according to actuator, valve size, and valve type. See Pressure Drop tables in valve specification sheets to determine the correct positioner supply pressure. Minimum supply pressure must be 5 psi to 10 psi (.345 bar - .69 bar)

(34.485 - 68.97 kPa) above maximum spring range but cannot exceed the rated actuator pressure.

Masoneilan SVI FF Instruction Manual =

| 35

Figure 9 SVI FF Air Ports on Single Acting Positioner

Output

Supply

Output

Supply

36 | BHGE

Figure 10 SVI FF High Flow Air Ports on Single Acting Positioner

SVI FF Cover

SVI FF Single Acting Assembled

Electronics Module

Pneumatic Train and Cover (I/P Module

Relay)

I/P

Manifold

Relay

Figure 11 SVI FF Single Acting Components

Masoneilan SVI FF Instruction Manual =| 37

SVI FF CoverSVI FF High Flow Assembled

Electronics Module

Pneumatic Train and Cover (I/P Module

Relay)

I/P

Manifold

Relay

Figure 12 SVI FF High Flow Components

38 | BHGE

SVI FF Single Acting and High Flow Dimensions

Figure 13 illustrates the SVI FF single-acting dimensions.

Figure 13 SVI FF Single-Acting Dimensions

Masoneilan SVI FF Instruction Manual =| 39

Figure 14 illustrates the SVI FF high flow dimensions.

40 | BHGE

Figure 14 SVI FF High Flow Dimensions

Double Acting Positioner Description

Output I

Supply

Output II

The Double Acting (DA) relay has a pair of opposed pneumatic outputs. When Output 1 delivers air to one side of the actuator, Output 2 vents air from the opposite side of the actuator piston. The volume of air trapped in each determines the position of the actuator.

The Action (ATO or ATC) is applied with respect to Output 1. When Output 1 is connected to deliver air to extend the actuator, the action is ATC, on a down-seating valve.

Figure 15 Air Ports on Double Acting Positioner

Masoneilan SVI FF Instruction Manual =| 41

Balance Pressure

SVI FF Cover

SVI FF Double Acting Assembled

Electronics Module

I/P

Manifold

Relay

Pneumatic Train and Cover (I/P Module, Relay)

The double-acting relay is designed to deliver pressure on both sides of a piston type actuator, so that the cylinder can provide the required thrust and stiffness. This stiffness is factory adjusted to 70% of the supply pressure. This means that, without any unbalance forces from the valve stem, both outputs deliver roughly 70% of air supply pressure.

Although it is not recommended, the stiffness can be adjusted by moving the Adjustable Seat assembly up or down.

Figure 16 SVI FF Double Acting Components

42 | BHGE

SVI FF Double Acting Dimensions

Figure 17 illustrates the SVI FF double-acting dimensions.

Figure 17 SVI FF Double-Acting Dimensions

Masoneilan SVI FF Instruction Manual =| 43

Installation

This section discusses:

 “Pre-Installation Issues” on page 44

 “Installation Steps” on page 46

 “Installation Notes” on page 47

 “Mounting the SVI FF on Rotary Valves” on page 50

 “Mounting the SVI FF on Reciprocating Valves” on page 55

 “Installing the SVI FF for Double- Acting Operation” on page 59

 “Connecting the Tubing and Air Supply” on page 62

 “Wiring the SVI FF” on page 65

Pre-Installation Issues

Storage

If the SVI FF is stored for a long duration, you must keep the housing sealed against weather, fluids, particles, and insects. To prevent damage to the SVI FF:

 Use the plugs provided with shipment to plug the ¼ NPT air connections, on the

positioner and on the air filter regulator set.

 Do not allow standing water to accumulate.

 Observe storage temperature requirements.

44 | BHGE

Unpacking

Exercise care when unpacking the control valve and its mounted accessories. The ValVue software is downloadable from https://valves.bhge.com/resource-center.

Figure 18 shows the unit tag that comes attached to the unit.

Figure 18 Unit Tag

The tag lists the following items:

ID: Unique factory-set identifier for the



device.

 Factory Node Address: Lists the factory-set

field bus node address.

 Tag: User-defined. This can be changed for

the specific application.

 Device Manufacturer: The six digits comprise

the first part of the ID and Tag. Used to identify the DD.

 Device Type: A four digit code.  Device and Minimum DD Revision: Represents

the original firmware revision flashed during manufacture. This DD may have been upgraded since installation.

 Communications: Lists the protocol in use.  Diagnostics: Lists the level of diagnostics with

which the device was shipped. This may have been upgraded since installation.

 Pneumatic Train: Single Acting or Double

Acting.

 Display: Indicates whether the LED display

and pushbuttons are installed.

 Pneumatic Flow: Standard Flow or High Flow.

 Housing: Aluminum only.

Masoneilan SVI FF Instruction Manual =| 45

Installation Steps

WARNING

CAUTION

If you experience problems that are not documented in this guide call the factory or your local representative. Sales offices are listed on the last page of this document.

The steps necessary to complete the SVI FF installation and software setup are outlined in Table 2.

Failure to adhere to the requirements listed in this manual can cause loss of life and property. Before installing, using, or carrying out any maintenance tasks associated with this instrument, READ THE INSTRUCTIONS CAREFULLY.

Refer to “Output Switch” on page 25 for guidelines on safely wiring switch load limits.

Table 2 SVI FF Installation Steps

Step No. Procedure Reference

1 Attach mounting bracket to the actuator. See page 50 for rotary valve and page 55

for reciprocating valve instructions.

2 Install the SVI FF magnetic assembly (rotary valves only). See page 54 for instructions.

3 Assemble the SVI FF on the bracket that is mounted to

the valve actuator.

4 Install the Remote Position Sensor, if necessary. See GEA31195 Masoneilan Valve Solutions

5 Connect the pneumatic tubing to the SVI FF. See page 62 for instructions.

6 Connect the air supply to the SVI FF. See page 62 for instructions.

7 Connect the positioner to the FF Control Loop segment

by installing the SVI FF wiring.

8 Configure/Calibrate using LCD Pushbutton display See page 128 for instructions

See page 50 for rotary valve and page 55 for reciprocating valve instructions.

Remote Sensor Quick Start for instructions. Also see SVI FF DTM help for software configuration.

See page 66 for instructions.

46 | BHGE

Configure/Calibrate using a Hand Held Communicator. See page 131 for instructions

Configure/Calibrate using ValVue See page 133 for instructions.

Installation Notes

 The installation must comply with local and national regulations concerning the

 Installation and maintenance must be performed only by qualified personnel. Repairs

 Area Classification, Protection Type, Temperature Class, Gas Group, and Ingress

 Wiring and conduit must conform to all local and national codes governing the

 Approved wire seals against ingress of water and dust are required and the 1/2" NPT

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

 If the valve is located in a hazardous area make sure the area has been certified as

compressed air supply and the SVI FF instrument.

to the SVI FF beyond the scope of this manual must be performed by the factory.

protection must conform to the data indicated on the label.

installation. Wiring must be rated for at least 85º C (185º F) or 5º C (41º F) above maximum ambient, whichever is greater.

fittings must be sealed with tape or pipe dope in order to meet the highest level of ingress protection.

safe or that all electrical power to the area has been disconnected before removing any covers or disconnecting any leads.

 Shut off air supply to the actuator and to any valve mounted equipment.

 Ensure the valve is isolated from the process by either shutting off the process or using

bypass valves for isolation. Tag shutoff or bypass valves to guard against a turn-on while work is in progress.

 Purge air from actuator and check that valve is in its unenergized position.

Masoneilan SVI FF Instruction Manual =| 47

Control Sets Configuration

Table 3 and Table 4 give guidelines for configuring various actuator sizes with corresponding control sets. Table 5 lists the FF parameters.

Table 3 Actuator Settings: Control Sets for Single Acting

Set # Actuator

Size

1 Small 4.5" Camflex (7-15 Spring Range)

#6, 87(ATC), 3-15 Spring Range

5 Large

#6, 88(ATO), 11-23 Spring Range

#10, 87 (ATC), 3-15 Spring Range

#10, 88(ATO), 11-23 Spring Range

#6, 87(ATC), 6-30 Spring Range

#6, 88(ATO), 21-45 Spring Range

#10, 87 (ATC), 6-30 Spring Range

#10, 88(ATO), 21-45 Spring Range

#16, 87(ATC), 3-15 Spring Range

#16, 88(ATO), 11-23 Spring Range

#23, 87 (ATC), 3-15 Spring Range

#23, 88(ATO), 11-23 Spring Range

#16, 87(ATC), 6-30 Spring Range

#16, 88(ATO), 21-45 Spring Range

#23, 87 (ATC), 6-30 Spring Range

#23, 88(ATO), 21-45 Spring Range

Examples

48 | BHGE

Table 4 Actuator Settings: Control Sets for Double Acting

Set # Actuator

Size

6Small

7 Large

51, #12, Rated Travel 3.75"

51, #16, Rated Travel 2"

51, #20, Rated Travel 1.25"

51, #12, Rated Travel = 4"

51, #16, Rated Travel

51, #20, Rated Travel

Model 70 Camflex, Double Acting, #10

Examples

2.5"

1.5"

Table 5 Control Set Settings

FF Parameter

ACTIVATE_CONTROL_SET

0: Activate Custom Control Set

  1: Activate Control Set 1 (Slowest)  2: Activate Control Set 2  3: Activate Control Set 3  4: Activate Control Set 4  5: Activate Control Set 5 (Fastest)  6: Activate Control Set 6 (Double

Acting - Slow)

 7: Activate Control Set 7 (Double Acting- Fast)  10: Restore Control set (make Backup Control

Set Active)

 11: Make active control set as Custom control

set

ACTIVE_CONTROL_SET

Masoneilan SVI FF Instruction Manual =| 49

Mounting the SVI FF on Rotary Valves

This procedure is used to mount the SVI FF on rotary control valves that have less than 60° rotation, such as a Camflex or a Varimax to “Rotary - 90°” on page 54.

Required Tools

The following tools are needed to complete the rotary valve installation:

 3⁄16" Hex Key with tee handle

 5⁄32" Hex Key

 3 mm, 4 mm, 5 mm Hex Key

 7⁄16" Wrench

To mount the SVI FF:

1. Attach the SVI FF rotary mounting bracket to the valve actuator using two (2) 5⁄16 - 18 UNC flat-head cap screws. Mount the SVI FF as shown in Figure 19, ATO or in Figure 20 on page 51, ATC. In the preferred mounting position, the long end of the mounting bracket is on your left when facing the actuator, for any position of the valve and actuator.

. For valves that have rotation greater than 60° refer

50 | BHGE

Figure 19 Camflex Air-To-Open Mounting (Front View)

Figure 20 Mounting Bracket on Air-to-Close Actuator

Air-to-close (ATC) Set magnet when actuator is energized

Magnet axis

Long end of bracket to left

2. Bolt the extension shaft to the valve position take-off shaft using a 1⁄4 - 28 UNF socket flathead screw. Secure the machine screw holding the extension shaft with a torque of 144 in-lbs (16.269 N-m).

Upon internal valve pressure the thrust shaft is pushed out to the mechanical stops, usually a thrust bearing. On valves where the valve position take-off is mounted directly on the end of the plug shaft, a Camflex for example, the shaft must be bearing on its stop to properly set up the SVI FF digital valve positioner. During hydrostatic testing the shaft is thrust to its stop and a normally tightened packing retains it in that position.

On vacuum service, the valve shaft can be drawn into the body by the vacuum acting on the shaft, but the magnetic coupling must be assembled flush with the mounting bracket with the shaft pulled fully out to its thrust bearing.

3. Ensure that the end play from the vacuum position to the fully extended position is less than 0.06 in. (1.524 mm).

4. Slide the magnet holder into the extension shaft . The location of the magnets is in the ring of the magnet holder. The magnetic axis is the imaginary line through the center of both magnets.

5. Rotate the magnet holder so that the magnet axis is vertical when the valve is in the closed position. See Figure 19 on page 50 and Figure 20.

6. Align the end of the magnet holder flush with the end of the mounting bracket. Secure the magnet holder with two M6 set screws.

7. Slide the V-Seal over the magnet holder.

8. Secure the SVI FF onto the mounting bracket using four M6 x 20 mm Socket Head Cap screws.

Masoneilan SVI FF Instruction Manual =| 51

9. Ensure no interference exists with the position sensor protrusion.

Lock magnet assembly

Flush w/top of bracket

Extension shaft

Magnet holder

V-seal

10. Ensure that the V-Seal makes contact with the skirt around the position sensor protrusion on the SVI FF housing.

Figure 21 Camflex with Mounting Bracket (Side View)

52 | BHGE

Table 6 shows the general guidelines for travel sensor alignment. Review the table prior to installing the SVI FF on a rotary valve actuator for proper alignment of the magnet. Proper alignment is required for proper Hall sensor operation.

Table 6 Travel Sensor Alignment

Rotary

Mounting

System

Rotary <60° Rotation

Stroke Direction Magnet

Clockwise or counterclockwise rotation

>60° Rotation

Clockwise with increasing setpoint

>60° Rotation

Counter clockwise rotation with increasing setpoint

Orientation

(0°)

(-45°)

Valve

Position

Closed (0%) 0 ± 1000

Full Open

Full Closed

Full Open

Full Closed

Sensor Counts

(TB: RAW_POSITION)

-8000

± 1500

+8000

± 1500

-8000

± 1500

+8000

± 1500

General Rule for other configurations

Any amount of rotation clockwise or counterclockwise

(+45°)

(0°)

50% Travel

(Mid-Stroke)

± 1000

Masoneilan SVI FF Instruction Manual =| 53

Rotary - 90°

Magnet axis

WARNING

For actuators with 60 to 120° rotation, follow the instructions in “Mounting the SVI FF on Rotary Valves” on page 50, except mount the magnet at plus or minus 45° while the actuator is de-energized as shown in Figure 22.

Figure 22 Model 33 Actuator

Magnet Orientation on Rotary Valve Shafts

The same mounting hardware is used for Models 35, 30 actuators. For each actuator type the magnetic coupling must be properly oriented to the active sensing angle of the positioner’s Hall Effect sensor. The active range of the Hall Effect sensor is plus⁄minus 70° from the null magnet axis.

If the total valve travel is less than 60°, allowing a margin for tolerances, the best accuracy is achieved by mounting the magnet with the axis vertical in the valve-closed position. The axis of the magnets is the line through the centers of both magnets.

If travel of the valve exceeds 60°, the magnet must be assembled to the rotary valve shaft so that the magnet axis is vertical when the valve is at mid-scale.

Dismantling the SVI FF from Rotary Valves

Before carrying out any work on the device, power off the instrument or make sure that the device’s location conditions for potentially explosive atmosphere permit the safe opening of the cover.

54 | BHGE

To remove the SVI FF digital valve positioner from a rotary valve perform the steps in “Mounting the SVI FF on Rotary Valves” on page 50 in reverse.

Mounting the SVI FF on Reciprocating Valves

This section describes the procedure for mounting the SVI FF on Reciprocating Valves (using Masoneilan’s 87⁄88 Multi-Spring actuators as an example).

Tools required:

 7⁄16" Combination Wrench (2 required)

 3⁄8" Combination Wrench

 1⁄2" Combination Wrench

 Phillips Head Screw Driver

 5 mm Hex Key Wrench

Mounting the SVI FF on a Reciprocating Actuator

1. Ensure that the lever is pinned to the magnet assembly and held securely by an M5 flat head screw to ensure that the magnet axis is vertical when the lever is in the valve closed position. Tighten the lever screw securely.

2. Mount the SVI FF reciprocating mounting bracket to the actuator using two (2) 5⁄16 - 18 UNC cap screws. The mounting location of the bracket depends on the size and stroke of the actuator. Refer to Figure 23 and Table 7 on page 57.

Figure 23 Reciprocating Valve Mounting Bracket

Masoneilan SVI FF Instruction Manual =| 55

3. Select mounting hole A, B, C or D for the stroke of the valve. For example, hole B is shown

Lever

1-4-20 x 1 nut

Right hand thread rod end

Left hand thread rod end

Turnbuckle length

Magnet housing

1-4-20 x 1 cap screw

Take off rod

in Figure 24 on page 56 for a size 10 actuator with 1.0" stroke. Unless otherwise specified, the SVI FF mounting assumes that the actuator is in the normal upright position. The mounting hole in the slotted opening of the mounting bracket must be left when facing the actuator, with the actuator in the upright position.

Figure 24 Lever for Model 87/88 Multispring Actuator

4. Move the valve to its closed position. For air to extend, this requires using air pressure in the actuator to fully stroke the actuator. For air to retract, actuators vent the actuator of air pressure.

5. Thread the take-off rod to the actuator stem connector. Refer to Figure 25. Ensure that the travel pointer located on the coupling is correctly positioned.

56 | BHGE

Figure 25 Reciprocating Linkage

6. Attach the right hand threaded rod end to the SVI FF lever using a 1⁄4 - 20 x 1" cap screw and nut as shown. The lever hole position to be used depends upon the specific valve stroke. Refer to Figure 24 on page 56 and the Reciprocating Valve Linkage Selection, Table 7 on page 57.

7. Thread the right hand lock nut and turnbuckle onto the right hand rod end approximately

Lever

Magnet holder assembly

Housing

Magnets

Ring

two turns. Turnbuckle length is a function of actuator size. (Refer to Table 7 on page 57.).

8. Secure the magnet housing assembly, including the lever and right hand rod end, to the bracket using four M5 X 10 mm flat head screws.

9. Attach the left hand threaded rod end to the take-off rod with 1⁄4 - 20 UNC nut and thread the left hand lock nut onto the rod end.

10. Thread the turnbuckle onto the left hand threaded rod end. Refer to Figure 25 on page 56.

11. Adjust the turnbuckle until the hole in the SVI FF lever is aligned with the indicating hole in the bracket. Tighten both turnbuckle lock nuts. See Figure 23 on page 55.

12. Mount the SVI FF to the bracket and secure with four M6 socket head cap screws.

Figure 26 Magnet Holder for Reciprocating Valves

Table 7 Reciprocating Valve Mounting Hole and Turnbuckle Length

Actuator Size

Masoneilan

6 and 10 0.5 - 0.8"

(12.7 - 20.32 mm)

10 0.5 - 0.8"

10 >0.8 – 1.5"

16 0.5 - 0.8"

(12.7 - 20.32 mm)

(20.32 - 38.1 mm)

(12.7 - 20.32 mm)

Stroke Mounting Hole Lever Hole Turnbuckle Length

A A 1.25"

(31.75 mm)

A A 1.25"

(31.75 mm)

B B 1.25"

(31.75 mm)

B A 2.90"

(73.66 mm)

Masoneilan SVI FF Instruction Manual =| 57

Table 7 Reciprocating Valve Mounting Hole and Turnbuckle Length (Continued)

WARNING

Actuator Size

Masoneilan

16 >0.8 – 1.5"

(20.32 - 38.1 mm)

16 >1.5 – 2.5"

(38.1 - 63.5 mm)

23 0.5 - 0.8"

(12.7 - 20.32 mm)

23 >0.8 – 1.5"

(20.32 - 38.1 mm)

23 >1.5 – 2.5"

(38.1 - 63.5 mm)

Stroke Mounting Hole Lever Hole Turnbuckle Length

C B 2.90"

D C 2.90"

B A 5.25"

C B 5.25"

D C 5.25"

Dismantling the SVI FF from Reciprocating Valves

Before carrying out any work on the device, power off the instrument or make sure that the device’s location conditions for potentially explosive atmosphere permit the safe opening of the cover.

(73.66 mm)

(133.35 mm)

To remove the SVI FF digital valve positioner from a reciprocating valve perform the steps in “Mounting the SVI FF on Reciprocating Valves” on page 55 in reverse.

58 | BHGE

Installing the SVI FF for Double- Acting Operation

Lever

Rod-end

Kit Mount Bracket

NOTE

Hole A: .50" to .80"

Hole B: 1.00" to 1.50"

Hole C: 2.00" to 2.50"

Hole D: 3.00" to 4.50"

Hole E: 5.00" to 6.00"

This section explains how to mount the SVI FF for the 84/85/86 kit for double-acting valve positioner configurations.

To mount the kit:

1. Set valve to the closed position.

2. Install the mounting assembly to the yoke (Figure 27) using helical spring washer 5/16, flat washer 5/16 and hex screw 5/16-18x44.5 [1.75] LG.

3. Set rod-ends and brackets to stroke and size of actuator. The default setting is a 4.00” stroke. Other stroke settings are as in Figure 28.

Figure 27 85/86 Valve

Mount all components snug enough to stay in place but loose enough to tap with rubber hammer into final position.

Figure 28 Stroke Settings

Masoneilan SVI FF Instruction Manual =| 59

4. Mount take-off bracket to stem block at angle which keeps turnbuckle assembly parallel

2.00" to 2.50" stroke

.50" to 1.50" stroke

Bracket configuration Strokes .50" to 2.50"

3.00" to 6.00" stroke

Bracket configuration Strokes 3.00" to 6.00"

Position of magnets with valve closed

to stem (Figure 29) using:

a. For top: two plain 5/16 flat washers, helical spring washer 5/16, two hex nuts 5/16-18

regular.

b. For bottom: hex nut regular 1/4-20 and hex screw 1/4-20 UNC x 22.2 [.88] LG.

Figure 29 Bracket Configuration Strokes .5 - 2.50” and 3-6”

5. Ensure the turnbuckle assembly is parallel to the stem and the magnets are in the valve closed position (Figure 30) and connect to take-off bracket.

Figure 30 Magnet Position with Valve Closed

60 | BHGE

6. Verify lever is in correct position with valve closed. Adjust rod-ends, if necessary.

Align lever to edge

Figure 31 Lever Alignment

7. Mount the SVI FF with M6-1 screws.

8. Cycle the valve open to close verifying proper components movement and that rod-ends move free and clear from other components.

Masoneilan SVI FF Instruction Manual =| 61

Connecting the Tubing and Air Supply

WARNING

NOTE

The last step in hardware installation for the SVI FF is to connect the air supply to the positioner. This section describes the process for connecting the tubing and air supply to a single and double acting positioner.

Isolate the valve from the process and disconnect air tubing from the positioner. Disconnect air fully to avoid injury or process damage.

The use of a Masoneilan filter regulator with a 5-micron filter is recommended for the air supply. Use 1⁄4" (6.35 mm) minimum tubing between filter regulator, the SVI FF and the actuator, with 3⁄8" (9.53 mm) used for larger actuators. Use a soft setting anaerobic hydraulic seal such as Loctite Hydraulic Seal 542 for sealing the pneumatic pipe threads. Follow manufacturer’s instructions.

Maximum allowable air supply pressure to the SVI FF 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 must be 5 to 10 psi (.345 bar - .69 bar) (34.485 - 68.97 kPa) above maximum spring pressure.

1. Install the tubing to the air supply port,

S

(arrow only for High Flow).

2. For a

 Single acting actuator - pipe the outbound air from the output pressure port (

the actuator

 Double acting actuator - pipe output pressure port one (

actuator and output pressure port two (

(arrow only for High Flow).



I) for one side of the



II) for the other side of the actuator

3. Air supply:

 Supply pressure for the single acting SVI FF:

20 -150 psi max. (1.4 - 10.3 bar) (138 - 1034 kPa)

 Supply pressure for the double acting and FF High Flow SVI FF:

25 - 150 psi (1.73 - 10.3 bar) (172 - 1034 kPa)

 Minimum tubing diameter 1⁄4" (6mm x 4mm)

 Supply pressure must be 5 psi - 10 psi (.345 bar - .69 bar)

(34.485 - 68.97 kPa) greater than the spring range of the actuator but may not exceed the rated actuator pressure. Refer to the valve or actuator instruction manual.



I) to

62 | BHGE

For High Flow installations above 125 psi (8.6 bar, 861 kPa),

CAUTION

NOTE

WARNING

CAUTION

perform a manual find stops and use preset tuning, especially with large volume actuators. If possible, use a Quick Exhaust.

The SVI FF Digital Valve Positioner is designed to operate with clean, dry, oil-free, instrument grade air to ANSI-ISA-57.3 1975 (R1981) or ISA-S7.3-1975 (R1981) or with a sweet natural gas supply (SVI FF models SVI FF-2 through SVI FF-3).

Table 8 Air Supply Requirements

Dew Point At least 18° F (-7° C) below minimum anticipated ambient temperature

Particulate Matter Filtered to 5 microns

Oil Content Less than 1 ppm w/w

Contaminants Free of all corrosive contaminants

Never exceed the actuator maximum rated supply pressure: 150 psi (10.3 bar, 1030 kPa). Damage to equipment or injury to personnel can result.

The SVI FF High Flow digital valve positioner cannot be placed in parallel with another volume booster. Contact the factory for further instructions regarding configuration with boosters as well as other non-standard configurations.

Do not use pipe thread sealant tape on pneumatic fittings. It may shred into small particles that can cause instrument malfunction. Remove any excess pipe thread sealant from the first and second threads to prevent uncured sealant from entering the air lines.

Masoneilan SVI FF Instruction Manual =| 63

Actuator Piping

Air to Open

FINAL_VALUE = 0%

FINAL_VALUE = 100%

Air to Close

FINAL_VALUE = 0%

FINAL_VALUE = 100%

Connect Output 1, labeled ACT 1 to the inlet port of the actuator in accordance with Figure 32. Output 2 labeled ACT 2 connects to the opposing actuator port.

64 | BHGE

Figure 32 Double Acting Positioner ATO⁄ATC Settings for Reciprocating Valves

Wiring the SVI FF

WARNING

CAUTION

The procedure below outlines wiring the SVI FF.

 Comply with current national and local regulations for

electrical installation work.

 Comply with national and local explosive atmosphere

regulations.

 Before carrying out any work on the device, power off the

instrument or make sure that the local conditions for potentially explosive atmosphere permit the safe opening of the cover.

Refer to “Output Switch” on page 25 for guidelines on safely wiring switch load limits.

Masoneilan SVI FF Instruction Manual =| 65

Connecting to the Control Loop

Display

Remote

I/P Connector

Position Sensor

Configuration Lock Jumper

9 - 32 V Foundation Fieldbus

Discrete Out

Input

Discrete Input

AI PV 1-5 VDC (Not Used in this release)

Ground

Shield (on FF unit

Input Signal

(polarity independent)

housing)

The SVI FF digital valve positioner MUST BE grounded according to local regulations. Physically connect the SVI FF to the control loop using a cable specified by the FF cable is recommended.

To communicate using FF:

1. Connect one end of the cable to the control loop's 9 - 32 VDC output.

2. Remove the threaded wiring covers on the positioner.

3. Connect the other end of the cable to the SVI FF. There are two threaded openings on the positioner. Use the opening with the red plastic insert.

Foundation. A shielded

Making Connections to the Terminal Board

66 | BHGE

Figure 33 Connections to Electronics Module (via Terminal Board)

Connect the wires from the option as follows (wire size 12 to 22 AWG on the 9 - 32 VDC FF input and 14 to 26 AWG on the PV, SW, DI, and Remote):

1. If the wires have not been stripped, strip approximately 1/4 in (6.35 mm) of the insulation at the end of wires.

2. Locate the correct terminal block on the terminal board (see Figure 33).

3. Loosen the screw until the opening is sufficient for wire insertion.

4. Insert the wire into the opening and retighten the screw.

Verify Wiring and Connections

CAUTION

SVI FF Switch Output

External Voltage Source

NOT ALLOWED

Full voltage drop is occurring across the switch (no current limit in place)

Use the following procedure to ensure that the SVI FF is properly powered:

Output Switches

The SVI FF supports a contact output, SW #1 (Discrete Output switch), that can be logically linked to status bits.

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

If the switch is connected directly across the power source the current will be limited only by the capacity of the power source and the switch can be damaged.

 Use an FOUNDATION

 Fieldbus approved device to ensure that the voltage is between

9 and 32 V. If voltage is less than 9 V, the voltage is out of range. If 9 V is not attainable, see “Troubleshooting” on page 117.

Improperly or inadequately grounded installations can cause noise or instability in the control loop. The internal electronic components are isolated from ground. Refer to FOUNDATION Fieldbus website for documentation and further instruction.

Without a load, when the switch is on (closed) the external voltage would be dropped across the switch. This damages the switch (Figure 34).

Figure 34 Switch Installation Drawing without Load: Configuration Not Allowed

General Configuration Notes

This section discusses the necessary precautions when configuring a system.

SWITCH

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

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

Switch OFF Switch ON

Masoneilan SVI FF Instruction Manual =| 67

Incorrect polarity connection results in an effectively closed

CAUTIONS

SVI FF Switch Output:  1 V with switch ON

External Voltage Source

LOAD

Load is designed to limit current through the switch to < 1 A.

If the load is inductive (solenoid, incandescent lamp, etc.), then install a Freewheel or Flyback diode to prevent switch damaging EMF voltage spikes.

connection.

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

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

The switch maximum current rating is 1 A. When the switch is ON, the typical switch voltage is



1V.

When the switch is on (closed) the external voltage must be dropped across the load (Figure 35).

CAUTION The load must be designed such that the current in the circuit is



1 A at all times. Some 3rd party devices, such as incandescent lamps or solenoids, require surge and back EMF protection to prevent voltage spikes.

Inductive Load, Solenoid, Incandescent Lamp Configuration

Figure 35 Switch Installation Drawing: Correct Configuration with Load

68 | BHGE

Distributed Control Systems Configurations

Power source can be part of DCS/PLS card. Power source requirements: V  30 V. I

max

1 A.

SVI Switch

Add resistor so load with resistance ≥

30 (including

wire resistance)

Negative switch pole must be directly wired to negative pole of power supply.

Wiring Option #1

SVI Switch

Add resistance sized to limit in-rush current < 50 mA.

Wiring Option #2

Power source can be part of DCS/PLS card. Power source requirements: V  30 V. I

max

1 A.

Any load. Power source is not directly connected to the switch. Load can be a circuit within DCS/PLS card, between power source and switch.

This section gives guidance for configuration in a DCS application. Figure 36 gives two generalized drawings that cover DCS applications to ensure switch safety.

Figure 36 DCS Switches Wiring Options

Configuration Considerations

 A typical value for 24 AWG cable about 0.025 Ohm/ft (see Wiring Option #1)).

 If IS barrier is a combination of fuse, resistor and Zener diode then the connection is

shown in Option #2. The barrier must have adequate resistance to limit inrush current, as the fuse cannot limit inrush current (see Wiring Option #2).

Masoneilan SVI FF Instruction Manual =| 69

Switch Settings

NOTE

The discrete output switch can be opened or closed in response to conditions that the SVI FF detects. This action is defined via DISCRETE_SWITCH_1_CONF (Discrete Switch 1 on the SVI FF software) and are:

0. Disabled - the switch is always inactive (default).

1. DO Block - the switch’s state is linked to the state of a DO block. If the

2. Fault State - the switch is activated whenever a fault occurs and the

The directional state of the switch is set using the Software Switches tab or using the DD’s DISCRETE_SWITCH_1_CONF.DIRECTION.

DO block feedback configuration changes, then the switch changes state. The DO switch auto-detects which DO block has the matching CHANNEL and translates 0 to inactive and non-0 to active. This is configured using the Software Switches tab on the DTM or using the DD.

switch remains activated until the SVI FF status is cleared.

3. Not in Normal - the switch is activated whenever the mode in not Normal.

4. Maintenance Required - the switch is activated whenever the device has an alert that requires maintenance.

5. Warning Data - the switch is activated whenever the TB block error Warning Data bit is set. This is manifested as a maintenance needed

soon indication.

6. Air Supply Alert - the switch is activated whenever there is an air sup- ply alert. This is configured using the Pressure Alarms tabs on the DTM or using the DD.

7. Travel Deviation Alert - the switch is activated whenever a travel deviation alert occurs. This is configured using the Travel Alarms tabs on the DTM or using the DD.

8. Position HI Alert - the switch is activated whenever a user-configured Position HI alert setting is exceeded. This is configured using the Position Alarms tabs on the DTM or using the DD.

9. Position LO Alert - the switch is activated whenever a user-config-

ured Position LO alert setting is exceeded. This is configured using the Position Alarms tabs on the DTM or using the DD.

70 | BHGE

10. Always Active - the switch is always active and does not change state.

11. Always Inactive - the switch is always inactive.

NOTE

12. Reset Occurred - the switch is active when a reset occurs and moves to configured default state.

13. Tight Cutoff - the switch is active when a tight cutoff is reached. At that time it closes if Normally Open and opens if Normally Closed. The switch resets once the threshold condition clears.

DISCRETE_SWITCH_2_CONF (Virtual Switch 2 on the SVI FF software), functions with the same settings. However, in this case, it drives a Virtual Discrete Switch (register) only. This register is usable to connect to the Discrete Input block.

The contacts are OPEN when the SVI FF is unpowered and may be configured (via the DTM or DD) to be open or closed when the flag is asserted after boot.

Masoneilan SVI FF Instruction Manual =| 71

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5. Check Out and Power Up

NOTE

Overview

This section provides the checkout procedures required to determine if the SVI FF is in working order and to power up the unit.

Perform all procedures in this section before putting the SVI FF into operation.

Check Out Procedures

SVI FF checkout consists of physical and operational checkout procedures.

Physical Inspection

The physical checkout procedures include:

 “Inspect Actuator, Linkages, or Rotary Adapter” on page 74

 “Verify Mounting and Linkage Adjustment” on page 74

 “Check the Magnet” on page 74

 “Check the Electronic Module Connections” on page 77

 Valve Mounting

 Air Supply

Masoneilan SVI FF Instruction Manual =

| 73

Inspect Actuator, Linkages, or Rotary Adapter

NOTE

Magnet Axis with Valve Closed

Verify that the mounting has not been damaged in shipment for a pre-mounted SVI FF, physically inspect the actuator, linkage. Record the following information for the configuration checkout:

1. Valve Air to Open (ATO) or Air to Close (ATC)

2. Actuator pressure rating

3. Actuator bench range

4. Inherent trim characteristic of the control valve; linear, equal percentage, or other.

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

Verify Mounting and Linkage Adjustment

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

Check the Magnet

There are two methods of checking the SVI FF magnet:

 “Perform a Visual Inspection”

 “Use ValVue to Check Magnet Position” on page 76

Perform a Visual Inspection

You must remove the positioner from the bracket to visually inspect the magnet orientation.

For rotary valves, such as a Camflex, or for actuators with rotation of less than 60°, the magnet assembly must be aligned as shown in Figure 37.

74 | BHGE

Figure 37 Magnet Orientation for Rotary Valves with Valve Closed

For rotary valves, or for actuators with rotations greater than 60°, the magnet assembly must

Magnet

Axis

with

Valve Closed

Increasing Signal = CCW Rotation

NOTE

be aligned as shown in Figure 38.

Figure 38 Magnet Orientation for 90° Valve Rotation with De-energized Actuator

For a reciprocating valve, it is not necessary to remove the positioner to visually inspect the magnet setting and linkage of a reciprocating valve.

For reciprocating valves the adjustable link turnbuckle must be parallel to the valve stem. To ensure linearity in positioning verify that the hole in the lever aligns with the indicating hole in the bracket when the valve is in the closed position. Check that the bracket is mounted on the correct holes. (See Figure 39 for details).

Figure 39 Reciprocating Valve Mounting Bracket

Masoneilan SVI FF Instruction Manual =| 75

Use ValVue to Check Magnet Position

CAUTION

Use this procedure to check the magnet using ValVue:

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

a. Run ValVue.

b. Select the installed positioner from the list of Connected Devices.

c. Select the: Check tab to view the current operating conditions of the selected

positioner.

2. The Raw Position Value should be between – 1000 and +1000 when:

 A reciprocating or less than 60° rotation rotary valve is closed.

 A greater than 60° rotation rotary valve is at 45° of rotation (mid stroke for a 90°

rotation rotary valve).

Check the Air Supply

1. Turn on the air supply.

2. Adjust the filter regulator.

3. Supply pressure must be a minimum of 5 (.35 bar, 34.5 kPa) to 10 psi (.69 bar, 68.97 kPa) greater than the spring range of the actuator but may not exceed the rated actuator pressure. Refer to the valve or actuator instruction manual.

4. Inspect the tubing connections between the filter-regulator and the positioner for leaks.

5. Verify that the tubing is not bent or crushed.

6. Verify that all fittings are leak tight.

Do not use Teflon pipe seal tape as it can shred into particles harmful to the pneumatic components.

76 | BHGE

Check the Electronic Module Connections

WARNING

NOTE

Do not remove the instrument cover or connect to an electrical circuit in a Hazardous Area unless power is disconnected.

The SVI FF terminal board has terminal blocks with screw connectors. Not all options are available for every model. Confirm the correctness of all applicable connections to the electronics module.

When an SVI FF is turned on, apply the air supply before applying the electrical input signal.

Operational Checkout

The operational checkout of the SVI FF consists of:

1. “Connect to the H1 Network”

2. “Power Up the SVI FF” on page 78

Connect to the H1 Network

Connect to the Fieldbus power supply, then check and configure with the local display and pushbuttons, if so equipped. Refer to “Pushbuttons and Local Display” on page 128 for further details.

If the SVI FF is not equipped with local display use ValVue and a PC with an FF setup or a handheld communicator.

When an SVI FF is turned on, apply the air supply before applying the electrical power.

Masoneilan SVI FF Instruction Manual =| 77

Power Up the SVI FF

WARNING

CAUTION

NOTE

Before powering up the SVI FF:

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

Always power the SVI FF from a fieldbus power supply that supplies 9 to 32 VDC.

When an SVI FF is turned on, apply the air supply before applying the electrical input signal.

1. Verify that the pneumatic connections and electronic cover screws are tightened. This is important to maintain the ingress protection level and the integrity of the flameproof enclosure.

2. If the installation is Intrinsically Safe, check that the proper barriers are installed and the field wiring meets local and national codes for an IS installation.

3. If the installation is non-incendive, then check that all the electrical connections are to approved devices and wiring meets local and national codes.

4. Verify that the markings on the label are consistent with the application.

For Hazardous Location Installation information refer to “Specifications and References” on page 95.

5. Proceed to perform a Calibration and Configuration.

If the SVI FF is specified without local pushbuttons and display, local operation is not available. Configure and calibrate with ValVue or using the DD a handheld Communicator.

78 | BHGE

6. Failsafe/OOS Considerations

CAUTION

Failsafe Mode vs. OOS Mode

In the FF device certain hardware and firmware failures (Table 9) cause OOS mode. These failures are reported as a Failsafe condition on the Local User Interface. Failsafe can be caused by the position sensor condition when the magnets are out of range. See “Mounting the SVI FF on Rotary Valves” on page 50 or “Mounting the SVI FF on Reciprocating Valves” on page 55 to adjust the magnets. Failsafe can also be caused by SVI FF internal damage.

To change the mode from OOS to any of the working modes, you must correct the Failsafe condition cause. Possibly the device electronics may need replacement, which involves contacting BHGE technical support.

Normally, the device Failsafe condition results in the OOS mode for the Transducer block. However, this behavior is configurable and may be changed using the parameter FAILED_STATE, sub-parameter PROPAGATE_APFS_TO_RB. By default this flag is set. If you set this flag, the

following sequence occurs as a result of Failsafe:

1. The Transducer block transitions to the OOS, which transitions the Resource block to OOS.

2. The Resource block then sets OOS for the downstream blocks.

If the faults in Table 9 occur several times in a row, ensure that environmental noise is not the cause. If the environment is not noisy contact Masoneilan.

Masoneilan SVI FF Instruction Manual =

| 79

Table 9 Failsafe Faults

Fault Name Description

POSITION_SENSOR If upon request temperature compensated remote position sensor reading is

outside of range in degrees or internal position sensor reading is outside of range in degrees for five reads in a row. Indicates a slipping or blocked sensor.

TEMPERATURE_ SENSOR

If, upon request, temperature compensated temperature sensor reading is outside of range in °C for five reads in a row. Indicates environment temperature is too hot/ cold.

I2CBUS Internal serial bus fault. Indicates a hardware problem - may require replacing the

positioner.

NVM_CHECKSUM0 If an FRAM record and its copy both have CRC errors (as detected by read on

initialization,) OR if the temperature calibration table has not been written in its entirety (detected by a CRC of column CRCs) OR bad FRAM signature. Indicates a hardware problem- may require replacing the positioner.

REF_VOLTAGE If temperature compensated reference voltage is out of range for five reads in a row,

or if the raw reading is outside the range

±5% of nominal. Indicates a hardware

problem- may require replacing the positioner.

PRESSURE4 If temperature compensated pressure sensor 4 (pilot) reading is outside of range.

Indicates a hardware problem - may require replacing the positioner.

SELF_CHECK A valid hidden record (in RAM) existing upon reset indicating that a fatal event

(watchdog, illegal interrupt, stack overflow, data checksum) occurred twice in a row. Indicates a hardware problem - may require replacing the positioner.

FSTATE_REQ Failed state requested by FF.

80 | BHGE

Exiting Failsafe Using AMS

To exit Failsafe:

1. Inspect the (current) faults/status flags (Figure 40).

Figure 40 AMS Status/Faults

2. If there are:

 No failsafe faults, the method change app mode works, but in most cases it is

unnecessary, and simply changing the Transducer block mode works fine.

 Failsafe faults, they should be addressed (removed) first by:

a. Correcting the underlying cause.

b. Clearing the faults by:

i.) Scrolling down and pressing the button at the bottom of Figure 40.

ii.) Reviewing the screen for repeating faults.

iii.) Switch mode to Manual or Auto as required.

Failsafe faults are listed in Table on page 80.

Masoneilan SVI FF Instruction Manual =| 81

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7. Maintenance

WARNING

NOTE

SVI FF Maintenance and Repair

Do not remove the instrument cover or connect to an electrical circuit in a Hazardous Area unless the power is disconnected.

Repair

See “Spare Parts” on page 91 for kits available for permitted field repairs.

Only qualified service personnel are permitted to make repairs.

Only parts supplied by the factory are permitted. This includes not only the major assemblies but also mounting screws and O-rings. No substitutions with parts other than Masoneilan are permitted.

Tools Needed

 5 mm hex key

 3 mm hex key

Display Cover Removal and Installation

The display cover (shown in Figure 41) is provided as an option for the SVI FF. If you have an SVI FF with a solid cover and would like to replace the solid cover with a display cover follow the instructions below for removal and installation.

Masoneilan SVI FF Instruction Manual =

| 83

Removing the SVI FF Display Cover

Cover

Display

Cover

Pneumatic

NOTE

To remove the SVI FF display cover:

1. Using a 5 mm Hex key unscrew the four screws around the perimeter of the SVI FF cover.

2. Lift the cover off the positioner.

Figure 41 SVI FF Display and Pneumatic Covers

Installing the SVI FF Display Cover

The replacement display cover is shipped with a lanyard to prevent the cable (that connects from the display to the Terminal Board) from breaking. The lanyard must be inserted under the screw in the lower left corner, that attaches the terminal board to the SVI FF housing.

To install the cover:

1. Install the lanyard and tighten the screw to 5 in-lbs (.565 N-m).

2. Using the 3 mm hex key, remove the screw from the lower left corner, connecting the terminal board to the SVI FF housing.

3. Connect the cable from the display into the LCD connector on the terminal board.

4. Ensure that the gasket is in its groove in the housing.

After replacing the SVI FF Display Cover you must power up the unit (see “Power Up the SVI FF” on page 78 of this guide).

84 | BHGE

5. Place the cover over the screw mounts.

6. Tighten the four screws with the 5 mm hex key.

CAUTION

7. After installing the new display power up the unit (refer to “Power Up the SVI FF” on page 78).

The cover of the SVI FF is a critical component for safety in Hazardous Areas. To ensure safe operation the flat surfaces of the cover and the housing must be clean and absolutely free of particles or dents. There must be no gap between the housing and cover; torque spec is 50 in-lbs (5.65 N-m).

Make sure that:

 The gasket is seated in the groove in the housing flange.

 No wires or retaining cable can be trapped under the cover flange.

 The flange area is not corroded and the surface is not scarred.

 The four cover bolts are securely tightened to 50 in-lbs (5.65 N-m).

I⁄P Module Removal and Installation

Prior to removing the pneumatic components it is necessary to remove the electronics module cover (see “Removing the SVI FF Display Cover” on page 84) and the pneumatic cover first.

Do not remove the I/P module in a hazardous area unless the power is disconnected.

Application of more than 1.6 mA to the I/P motor can permanently damage it.

The I/P is rigidly assembled to a wire way sleeve that is a critical component for explosion proof service. Use care to slide the sleeve from the pneumatic module without applying a strain to it.

Masoneilan SVI FF Instruction Manual =| 85

Pneumatic Cover Removal: FF and High Flow

To remove the FF pneumatic cover:

1. Using a 3 mm hex key, remove the six screws from around the perimeter of the cover

2. Lift the cover off and put aside for re-installation.

To remove the FF High Flow pneumatic cover:

1. Using a 3 mm hex key, remove the four screws from around the perimeter of the cover (Figure 42 or Figure 43).

Figure 42 Pneumatic Cover Screws: High Flow

2. Lift the cover off and put aside for installation.

Pneumatic Cover Removal

To remove the pneumatic cover:

1. Using a 3 mm hex key, remove the six screws from around the perimeter of the cover

2. Lift the cover off and put aside for re-installation.

86 | BHGE

Figure 43 Pneumatic Cover Screws: FF (Four Shown)

I/P Module Removal

To remove I⁄P module:

1. Disconnect the I/P wire from the terminal board.

2. Using a 3 mm hex key, remove the four screws from around the perimeter of the I⁄P module.

Figure 44 SVI FF High Flow Pneumatic Module with Single Acting Relay

3. Lift the module off the positioner.

I/P Module Installation

To install I⁄P module:

1. Place the module in the designated area on the positioner.

2. Using a 3 mm hex key, install the four screws around the perimeter of the I⁄P module.

3. Replace the I/P wire connector on the terminal board.

4. Replace the Display Cover (see “Installing the SVI FF Display Cover” on page 84).

Ensure that:

 The wire is not damaged when feeding it through the housing.

 A single O-ring is in place on the wire-sleeve and is not damaged.

 The four retaining screws are tight and torque to 15 in-lb (1.7 N-m).

 Inserting the wire sleeve through the housing does not require force.

Pneumatic Cover Installation

To install the pneumatic cover:

1. Place the cover over the pneumatic module.

2. Using a 3 mm hex key, install the six screws around the perimeter of the cover and torque to 8 in-lb (.9 N-m).

Masoneilan SVI FF Instruction Manual =| 87

Relay Removal and Installation

CAUTION

To remove the pneumatic relay:

1. Using a 3 mm hex key, remove the three screws from around the perimeter of the relay.

2. Lift the relay off the positioner.

Relay Installation

To install pneumatic relay:

1. Place the relay in the designated area on the positioner.

2. Using a 3 mm hex key, install the three screws around the perimeter of the relay.

Make sure that:

1. The five O-rings are seated in the base of the relay and are not damaged.

2. The three mounting screws are tight and torque to 15 in-lb (1.7 N-m).

When you have completed maintenance on the pneumatic relay it is necessary to reinstall the pneumatic cover. Refer to on “Pneumatic Cover Installation” on page 87.

Adjusting I/P Zero

The I/P Zero is calibrated at the factory prior to shipment. If there is a problem with I/P zero please contact your representative.

Connecting Components to the Electronics Module

If it is necessary to remove and install any SVI FF component you may need to reconnect the component to the SVI FF Electronics Module via the SVI FF Terminal Board. Refer to “Wiring the SVI FF” on page 65 of this manual for instructions.

88 | BHGE

Repair by Replacement

NOTE

Using ValVue and repair-by-replacement is the fastest method to service an SVI FF. See the ValVue instruction manual for details regarding uploading and downloading configuration files. Upload all configuration information from the installed positioner to ValVue, then install the replacement positioner and download the configuration file into the replacement unit. Run STOPS, and Auto Tune, and the repair is complete. The positioner that was removed can be refurbished and reused.

Internal Diagnostics

The SVI FF performs internal self-diagnostics and hardware checks. When ValVue or handheld or the local display indicates that there are error messages write them down for troubleshooting.

FAILSAFE Mode

Substitution of components can void safety approvals.

See “Failsafe/OOS Considerations” on page 79. for further discussions.

Several of the internal diagnostics tests puts the SVI FF into FAILSAFE mode if the errors continue for a preset time. When the SVI FF goes into FAILSAFE, the valve is driven to its Failsafe position. It remains in that position until a technician clears the cause of the error and resets the instrument. Reset is performed in two ways:

 Connect a FF H1 segment and ValVue, and then change the Transducer block mode (if

faults are already cleared).

 Turn the power off and on.

To prevent the valve from moving after reset, put the controller in manual, and set the valve position setpoint to the failsafe position 0% if ATO, 100% if ATC.

Masoneilan SVI FF Instruction Manual =| 89

Viewing Firmware Versions

Firmware versions can be viewed using the:

 SVI FF DTM on the Positioner tab. The firmware revision is Software Revision (Figure 45).

Where the first digit , here 1, represents the DD Revision.

Figure 45 Positioner Tab

 By creating/printing the SVI FF Configuration Report by:

1. Selecting View > Network View > Topology Pane.

2. Selecting the positioner, right-clicking and selecting Additional Functions > Report.

 Handheld by selecting Online > SVI FF Device > Resource Block > Device >

Identification.

90 | BHGE

Spare Parts

Item Description Quantity

1 ELECTRONIC ASSEMBLY SVI II AP 1 2 SILICONE GASKET, COVER ELECTRONICS 1

3 SCR HEX SHCS M4 X 0.7 X 27 MICROSPHERES 593 PATCH 6 4 O-RING, REF NO. 2-006 6

5 INSTRUCTIONS 1

Item

No.

Description Quantity

1 SCR HEX SHCS M4 X 0.7 X 25 MICROSPHERES 593 PATCH 6 2 GASKET MANIFOLD S/A 1

3 REINFORCED PNEUMATICS COVER SA 1

Item

No.

Description Quantity

1 SCR HEX SHCS M4 X 0.7 X 25 MICROSPHERES 593 PATCH 4 2 GASKET I/P COVER D/A SVI2AP 1

3 REINFORCED COVER PNEUMATICS DA 1

Item

No.

Description Quantity

1I/P, ASSY 1 2 O-RING, I/P STEM 2

3 SCR HEX SHCS M4 X 0.7 X 60 MICROSPHERES 593 PATCH 4 4 REINFORCED PNEUMATICS COVER 1

5 PNEUMATICS COVER GASKET 1 6 SCR HEX SHCS M4 X 0.7 X 25 MICROSPHERES 593 PATCH 6 7 INSTRUCTIONS 1

Electronics:

 SVI FF-2 (720024064-999-0000)  SVI FF-3 (720024066-999-0000)  SVI FF-2 Double Acting (720024067-999-0000)  SVI FF-3 Double Acting (720024068-999-0000)

SA Reinforced Pneumatic Cover Kit (720028475-999-0000)

DA Reinforced Pneumatic Cover Kit (720028476-999-0000)

SA IP Assembly Reinforced Cover (720028473-999-0000)

Masoneilan SVI FF Instruction Manual =| 91

DA IP Assembly Reinforced Cover (720028474-999-0000)

Item

No.

Description Quantity

1 IP ASSEMBLY, SVI II ESD

2 O-RING, I/P STEM 2 3 SCR HEX SHCS M4 X 0.7 X 60 MICROSPHERES 593 PATCH 4 4 REINFORCED PNEUMATICS COVER 1

5 PNEUMATICS COVER GASKET 1 6 SCR HEX SHCS M4 X 0.7 X 25 MICROSPHERES 593 PATCH 4 7 INSTRUCTIONS 1

Item

No.

Description Quantity

1 ASSY, COVER WINDOW 1 2 Silicone Gasket, Cover, Electronics 1 3 Instructions 1

Item

No.

Description Quantity

1 ASSY COVER WINDOW, MARINE 1 2 Silicone Gasket, Cover, Electronics 1 3 Instructions 1

Standard Push Button Display Silicone Gasket (720028469-999-0000)

Offshore Push Button Display Silicone Gasket (720028471-999-0000)

92 | BHGE

SA Standard and Offshore Relay Reinforce Cover

Item

No.

Description Quantity

1RELAY, SA 1 2 SCR HEX SHCS M4 X 0.7 X 60 MICROSPHERES 593 PATCH 3 3 REINFORCED PNEUMATICS COVER 1

4 PNEUMATICS COVER GASKET 1 5 SCR HEX SHCS M4 X 0.7 X 25 MICROSPHERES 593 PATCH 6 6 INSTRUCTIONS 1

No.

Description Quantity

1 RELAY, DA Standard 12:1 1 2 SCR HEX SHCS M4 X 0.7 X 60 MICROSPHERES 593 PATCH 4 3 O-RING, CONTOURED, DA 12:1 RELAY 1 4 INSTRUCTIONS 1

No.

Description Quantity

1 RELAY, DA Offshore 12:1 1 2 SCR HEX SHCS M4 X 0.7 X 60 MICROSPHERES 593 PATCH 4 3 O-RING, CONTOURED, DA 12:1 RELAY 1 4 INSTRUCTIONS 1

No.

Description Quantity

SCREW CAPTIVE PANEL

PIVOT PIN PUS H BUTTON COVER SVI II

CIRCLIP SHAFT PUSH B

COVER PUSHBUTTON SVI2AP

GASKET COVER PUSHBUTTON SVI2

No.

Description Quantity

1 Relay SA HC 1 2 M4 X 0.7 X 60 SHCS 5 3 O-RING ID 9.19 [0.362] WIDTH 2.62 [0.103] REF NO 2-110 3 4 O-RING ID 29.87 [1.176] WIDTH 1.78 [0.0703] REF NO 2-025 1

5 O-RING ID 9.137.82 [1.498] WIDTH 1.78 [0.0703] REF NO 2-1029 1 6 INSTRUCTIONS 1

(720028472-999-0000)

DA Standard Relay (720003881-999-0000)

Item

DA Offshore Relay (720003882-999-0000)

Item

Pushbutton Door, Kit (720002448-999-0000)

Item

HC SA Standard Relay (720014541-999-0000)

Item

Masoneilan SVI FF Instruction Manual =| 93

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Appendix A. Specifications and References

Physical and Operational Specifications

This section provides the physical and operational specifications for the SVI FF.

Table 10 Environmental Specifications

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

Storage Temperature Limits -58° F to 185° F (-50° C to 85° C)

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

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

Ambient Humidity 10 to 95% non-condensing

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

Electromagnetic Compatibility Electrostatic

IEC\EN61326-1 Ed 2 compliant

 Immunity Table 62 Industrial and Electromagnetic Environment  Emission Limits CISPR 11 Group 1 Class A

Vibration Influence Measured at SVI FF Housing

4 mm at 5 - 15 Hz - Negligible 2 G at 15 - 150 Hz Less than 2 % of span 1 G at 150 - 2000 Hz - Less than 2% of span

Masoneilan SVI FF Instruction Manual =

| 95

Table 11 Operational Specifications*

Accuracy ± 0.5% (typical ±0. 10% or less) Full Span

Hysteresis and Deadband

Repeatability

Conformity/Linearity

Start-Up Drift Less than 0.02% in first hour

Long Term Drift Less than 0.003% per month

Position Travel Limits Rotary: 18 - 140°

Flow Characteristics Applied in addition to the control valve’s inherent

characteristic.

Position Auto Tune SVI FF performs automatic determination of the opti-

mal valve position control parameters. In addition to P, I, D, the position algorithm uses damping, symmetry for exhaust and fill time constants, dead zone and magnitude characterization parameters. Auto Tune is optimized for 5% step changes with negligible overshoot. After the Auto Tune process is completed, you can further adjust the positioner tuning parameters to more conservative or to more responsive values.

± 0.3% Full Span

± 0.5% Full Span

Reciprocating: 0.25” - 4“(6 mm - 100 mm); Extended mounting: > 4" (100 mm)

Note: Above 4” (100 mm) consult factory for mounting instructions.

Linear Equal Percentage (of 50:1 or 30:1) Camflex Quick Opening (inverse of 50:1 equal percentage) User Configurable Tight Shut Off (0 -20% of input)

Proportional gain: 0 to 5, displayed as 0 to 5000 Integral time: 0 to 100 seconds - displayed as 0 to 1000 (1/10s) Derivative time: 0 to 200 milliseconds Dead Zone: 0 to

± 3000 (depends on P)

Padj: Beta (non-linear gain factor): -9 to +9 Stroking Time: 0 to 250 seconds Position compensation coefficient: 1 to 20 Boost: 0 to 20

±5% (0 to 10% deadband)

96 | BHGE

* Specifications are subject to change without notice

Table 12 Input Signal, Power, and Display Specifications

Input voltage 9 - 32 V polarity independent

Normal/Maximum current 17.4/ 18.3 mA

Wire Size

 FF input: 12 to 22 AWG  All others: 14 to 26 AWG

Digital Communication Protocol FOUNDATION Fieldbus registered device

Physical Layer Type (s)

 121 - Low-power signaling, bus powered, Entity Model I.S.  511 - Low-power signaling, bus powered, FISCO I.S.

Local Display (optional) LCD, explosion proof

Push Buttons External, Three Explosion Proof / Flameproof push buttons

Table 13 Construction Material Specifications

Housing and Cover

Weight Standard Flow Model:

Aluminum ASTM B85 SG100A standard Stainless Steel optional

 Aluminum - 7.4 lbs./ 3.3 kg  Stainless Steel - 16 lbs/ 7.3 kg

High Flow Model:

 With Display: 9.4 lbs./ 4.2 kg  Without Display: 8.9 lbs./ 4.0 kg

Relay and Manifold Standard Flow Model:

 Single Acting - PPS, 300 Series Stainless Steel, nitrile diaphragms  Double Acting - 300 Series Stainless Steel, Ryton

Aluminum 6061 T6, Ryton

High Flow Model:

 300 Series Stainless Steel, Ryton

Aluminum 6061 T6, Ryton

I/P Motor 430 stainless steel, PPS, 300 series stainless steel

Mounting Bracket 300 series stainless steel

Magnet Holder Corrosion Protected Anodized Aluminum 6061 T6

Pole Ring 416 stainless steel

Levers 300 Series stainless steel

Masoneilan SVI FF Instruction Manual =| 97

Table 14 System Connectivity

DD Registered with FOUNDATION Fieldbus Foundation

Diagnostics Options include: Valve signature, ramp, friction, stroking speed, step response,

Yes, available through foundation website

cumulative travel, cumulative cycles, and time of operation in near-closed position. Some diagnostics require pressure sensor and ValVue software.

Table 15 Pneumatics Single Acting Standard Flow

Air Supply Dry, oil-free, 5 micron filtered and regulated air and sweet natural gas

(See ISA S7.3)

Action Direct Acting

Supply Pressure 20 -150 psi max. (1.4 - 10.3 bar)

Regulate 5 - 10 psi (.345 bar - .69 bar) above actuator spring range. Do not exceed actuator rating.

Air Delivery - Single Acting Relay 10.0 scf/min (280 L/min) at 30 psi (2.1 bar) supply

16.6 scf/min (470 L/min) at 60 psi (4.2 bar) supply

23.3 scf/min (660 L/min) at 90 psi (6.3 bar) supply

Air Capacity (flow coefficient) Loading

Venting Cv = 0.53

= 0.57

Air Consumption 0.20 scf/min (5.7 L/min) at 30 psi (2.1 bar) supply

0.28 scf/min (8 L/min) at 60 psi (4.2 bar) supply

0.42 scf/min (12 L/min) at 90 psi (6.3 bar) supply

Air Supply Failure Single Acting Relay

On supply failure the actuator output drops. Some overshoot may occur when air pressure returns after a period without air supply pressure. Always set control set point to 0%, and put the process control system in manual, for smooth recovery from air supply failure.

Loss of Input Signal Output drops to low pressure.

Output Pressure 0 - 150 psi (10.3 bar) max

98 | BHGE

Table 16 High Flow Pneumatics Single Acting High Flow

Air Supply Dry, oil-free, 5 micron filtered, filtered and regulated air and sweet

natural gas (See ISA S7.3)

Action Direct Acting

Supply Pressure 20 -150 psi max. (1.4 - 10.3 bar)

Regulate 5 - 10 psi (.345 bar - .69 bar) above actuator spring range. Do not exceed actuator rating.

Air Delivery - Single Acting Relay 39.0 scf/min (1104 L/min) at 30 psi (2.1 bar) supply

70.6 scf/min (2000 L/min) at 60 psi (4.2 bar) supply

102.0 scf/min (2888 L/min) at 90 psi (6.3 bar) supply

134.0 scf/min (3794 L/min) at 120 psi (8.4 bar) supply

Air Capacity (flow coefficient) Loading

Venting

Air Consumption 0.20 scf/min (5.8 L/min) at 30 psi (2.1 bar) supply

0.45 scf/min (12.6 L/min) at 60 psi (4.2 bar) supply

0.65 scf/min (18.3 L/min) at 90 psi (6.3 bar) supply

0.84 scf/min (23.9 L/min) at 120 psi (8.4 bar) supply

Air Supply Failure Single Acting Relay

Loss of Input Signal Output drops to low pressure.

Output Pressure 0-150 psi (10.3 bar) max.

= 2.2

Masoneilan SVI FF Instruction Manual =| 99

Table 17 Pneumatics Double Acting Standard Flow

Air Supply Dry, oil-free, 5 micron filtered, filtered and regulated air and sweet natural gas (see ISA S7.3)

Action Output 1 increases with increasing

Output 2 decreases with increasing

Supply Pressure for Double Acting

Air Delivery for Double Acting

Air Consumption for Double Acting

Air Supply Failure Positioner cannot control the failure position of an actuator without a spring. The actuator

Loss of Input Signal Output 1 drops to low pressure.

25 - 150 psi max. (1.73 to 10.3 bar) Do not exceed actuator rating.

7.2 scf/min (204 L/min) at 30 psi (2.1 bar) supply

12.8 scf/min (362 L/min) at 60 psi (4.2 bar) supply

18.3 scf/min (518 L/min) at 90 psi (6.3 bar) supply

23.8 scf/min (674 L/min) at 120 psi (8.4 bar) supply

0.42 scf/min (12 L/min) at 30 psi (2.1 bar) supply

0.57 scf/min (16 L/min) at 60 psi (4.2 bar) supply

0.85 scf/min (24 L/min) at 90 psi (6.3 bar) supply

1.06 scf/min (30 L/min) at 120 psi (8.4 bar) supply

can, under different conditions, fail in place, fail open, or fail close. In cases where the valve must fail to a required position additional control equipment is required.

Some overshoot can occur when air pressure returns after a period without air supply pressure. Always set control set point to 0%, and put the process control system in manual, for smooth recovery from air supply failure.

Output 2 rises to supply pressure.

Table 18 FOUNDATION Fieldbus Block Times

100 | BHGE

Analog Output (AO) 12 ms Arithmetic (AR) 20 ms

(2) Enhanced Process Control (PID) 12 ms Input Selector (SEL) 15 ms

(2) Discrete Output (DO) 12 ms Multiple Analog Input (AI) 15 ms

Output Splitter (OS) 20 ms Control Selector (CS) 20 ms

(3) Analog Input (AI) 12 ms (2) Discrete Input (DI) 12 ms

GE Baker Hughes Masoneilan SVI FF Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

About this Guide

DISCLAIMER

Copyright

1. Safety Information

Safety Symbols

SVI FF Product Safety

2. Introduction

ValVue Software

ValVue Standard Edition

Operational Overview

SVI FF Features

Available Options

Characterization

Control Sets

Continuous Diagnostics

Diagnostic Versions

Block Modes

Resource Block Modes

Transducer Block Modes

Overview of Available Tools

Principle of Operation

Physical and Operational Description

Electronics Module

Output Switch

Pneumatic Module

Optional Display and Pushbuttons

Link Active Scheduler

About This Manual

Conventions Used in This Manual

3. Quick Start

Step 1: Install the Positioner on the Valve

Step 2: Connect Pressure Supply

Step 3: Wire the SVI FF

Step 4: Set Tag and Address

Step 5: Basic Configuration

Step 6: Run Find Stops METHOD

Step 7: Run Auto Tune METHOD

Downloads

4. Mechanical Installation

Overview

SVI FF Positioner Types

Single Acting Positioner Description

Double Acting Positioner Description

Installation

Pre-Installation Issues

Installation Steps

Installation Notes

Control Sets Configuration

Mounting the SVI FF on Rotary Valves

Mounting the SVI FF on Reciprocating Valves

Dismantling the SVI FF from Reciprocating Valves

Installing the SVI FF for Double- Acting Operation

Connecting the Tubing and Air Supply

Wiring the SVI FF

5. Check Out and Power Up

Overview

Check Out Procedures

Physical Inspection

Check the Electronic Module Connections

Operational Checkout

Connect to the H1 Network

Power Up the SVI FF

6. Failsafe/OOS Considerations

Failsafe Mode vs. OOS Mode

Exiting Failsafe Using AMS

7. Maintenance

SVI FF Maintenance and Repair

Repair

Tools Needed

Display Cover Removal and Installation

I⁄P Module Removal and Installation

Relay Removal and Installation

Adjusting I/P Zero

Connecting Components to the Electronics Module

Repair by Replacement

Internal Diagnostics