MASONEILAN SVI ® EW2000

01/99

SMART VALVE INTERFACE

Digital
Positioner
and Controller

INSTRUCTION
MANUAL
Masoneilan is a registered trademark of Dresser Industries Inc., A Halliburton Company
SVI is a registered trademark of Dresser Industries, Inc.
ValVue is a trademark of Dresser Industries, Inc.
HART is a registered trademark of the Hart Foundation
Pentium is a trademark of Intel Corporation

Copyright 1999 by Dresser Equipment Group, Inc.

All rights reserved
 TABLE OF CONTENTS

Chapter 1 - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SVI Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Safety Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pushbutton Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
EPC (Electropneumatic Converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Sensors (Position, Pressure and Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SVI Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
System Description-Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
System Description- PID Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Chapter 2 - Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Standard Rotary Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Standard Reciprocating Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Mounting the SVI on Masoneilan 87/88 Multi-Spring actuators. . . . . . . . . . . . . . . . . . .23
Mounting the SVI on other Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Lever and Linkage Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Hazardous Area Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Factory Mutual approved model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
CSA (Canadian Standards Association) approved model . . . . . . . . . . . . . . . . . . . . . . .35
CENELEC Approved Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
SVI Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Basic Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Positioner or Controller with HART Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Impedance Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Noise Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Interference with DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Cabling and Interconnection Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Split Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Chapter 3 - Operation - SVI Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Pushbuttons/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
NORMAL OPERATE Mode and Manual Mode Menus . . . . . . . . . . . . . . . . . . . . . . . . .46
Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Examine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

I
 Normal Operation - Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Parameters and Options Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Local Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Return to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Examine Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Examine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Display/Clear FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Positioner Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Chapter 4 - Operation-SVI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Pushbuttons/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Normal Operate Mode and Manual Mode Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Controller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Examine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Normal Operation - Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Parameters and Options Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Controller Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Local Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Return to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Examine Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Examine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Display/Clear FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Controller Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Operation - SVI Positioner / Controller using HART Handheld Communicator . . . . . . . . . . .76
Operation - SVI Positioner / Controller using ValVue Software . . . . . . . . . . . . . . . . . . . . . .76

Chapter 5 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Factory Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

II
 Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Verifying Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Verify Wiring and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Ground Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
HART Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Power-on Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84-85
Testing Valve Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Confirming Configuration, Setup, Calibration, and Limit Stops . . . . . . . . . . . . . . . . . . . . . .86
Initiate Valve Movement (50%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Initiate Valve Movement (95%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fail-Safe Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
AutoTune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
AutoTune Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Auto Tune Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Damping Coefficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Unacceptable Response Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Position Instability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Limit Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Bias Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Bias Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Spool Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
HART Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Setup and Administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Communication Port and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Use of Laptop Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Mouse Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Hand Held Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Failure to Communicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fatal and Non-Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Fatal Errors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Non-fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Diagrams
Figure 1. Smart Valve Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2. Block Diagram of SVI Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3. Block Diagram of SVI Controller/Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 3a. SVI Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 4. Input/Output Diagram of SVI Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 5. System Diagram – Intrinsically Safe Installation . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 6. System Diagram – Explosionproof (Flameproof) Installation . . . . . . . . . . . . . . . . .16
Figure 7. Single Loop PID Configuration with No Process Feedback . . . . . . . . . . . . . . . . . .17
Figure 8. Single Loop PID Configuration with Process Feedback . . . . . . . . . . . . . . . . . . . . .17
Figure 9. Intrinsically Safe Single Loop PID Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 10. Local Set with Voltage Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 11. Local Set with Voltage Source-Two Leads to Field . . . . . . . . . . . . . . . . . . . . . . . .19
Figure 12. SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves . . . . . . . .21
Figure 13. SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves .21
Figure 14. Orientation of SVI Lever and SVI Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

III
Figure 15. SVI Mounting on Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 16. Top View of SVI Mounted on a Reciprocating Valve . . . . . . . . . . . . . . . . . . . . . . .23
Figure 17. SVI Lever for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 19. Side View of SVI Mounted on a Reciprocating Valve . . . . . . . . . . . . . . . . . . . . . . .25
Figure 18. SVI Mounting Bracket for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . . .25
Figure 20. Typical SVI Mounting on 37/38 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 21. Typical SVI Mounting on 84/85 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 21a. Smart Valve Interface Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 22. SVI Mounting Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Figure 23. SVI Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Figure 24. Electrical Connections to Main Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 24a. Electrical Connections to Main Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 24b. General Area Purpose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Figure 25. Approved Intrinsically Safe Installation Control Drawing . . . . . . . . . . . . . . . . . . . .36
Figure 26. Impedance vs Frequency for Typical Current Source . . . . . . . . . . . . . . . . . . . . . .39
Figure 27. Resistor Add in Series with Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Figure 28. Split Range - Active Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Figure 29. Compliance Voltage Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Figure 30. Local Display and Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Figure 30a. Pushbutton Guide for SVI Version 1.0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Figure 30b. Pushbutton Guide for SVI Version 1.0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Figure 31. NORMAL OPERATE, MODE SELECT, and MANUAL Menu Structures . . . . . . . . .46
Figure 32. CONFIGURE Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Figure 33. CALIBRATE Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Figure 34. EXAMINE Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Figure 35. Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 36. Local Display and Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Figure 36a. Hand Held Communicator Guide for SVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Figure 36b. Pushbutton Guide for SVI Version 1.0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Figure 37. Normal Operate, Mode Select, and Manual Mode Menus . . . . . . . . . . . . . . . . . . .62
Figure 38. Configure Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Figure 39. Calibrate Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Figure 40. Controller Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Figure 41. Examine Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Figure 42. Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Figure 43. Exhaust, Actuator and Air Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Figure 44. Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Figure 44a. Wiring Connections - 1999 Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Figure 45. Pilot Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Tables
Table 1. Performance Specifications (Positioner Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Table 2. Electrical Safety Design Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Table 3. SVI Lever Hole Locations for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . .24
Table 4. Recommended Lever Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Table 5. Recommended Linkage Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 6. Local Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Table 7. Positioner Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56-57
Table 8. Local Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Table 9. Controller Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-75

IV
Use of DANGER, WARNING, CAUTION, and NOTE.

These instructions contain DANGER, WARNING, CAUTION, and NOTE where necessary to alert you to
safety related or other important information.

DANGER - Hazards which result in severe personal injury or death.

WARNING - Hazards which could result in personal injury.
CAUTION - Hazards which could result in equipment or property damage
NOTE - Alerts you to pertinent facts and conditions

Although DANGER and WARNING hazards are related to personal injury, and the CAUTION hazards involve
equipment or property damage, it should be understood that operation of damaged equipment could, under
certain operational conditions, result in degraded process system performance which may lead to personal
injury or death. Therefore, comply fully with all DANGER, WARNING, and CAUTION notices.

IMPORTANT: SAFETY WARNING

Please read these instructions carefully BEFORE c) Only be maintained by qualified personnel
this instrument is installed or maintained. with adequate training on hazardous area
instrumentation.
These positioners and controllers are intended for
use with industrial compressed air systems only. Before using these products with fluids other than
Ensure that adequate pressure relief provision is air or for non-industrial applications, consult
installed if application of system supply pressure Dresser Masoneilan. Not intended for use in life
could cause downstream equipment to malfunc- support systems.
tion. Installation should be in accordance with
local and national compressed air and instrumen- Items sold by Dresser Masoneilan are warrantied
tation codes. to be free from defects in materials and workman-
ship for a period of one year from the date of ship-
Products certified for use in explosionproof / ment, provided said items are used according to
flameproof or intrinsically safe installations Dresser Masoneilan’s recommended usages.
MUST:
Dresser Masoneilan reserves the right to discon-
a) Be installed in accordance with local and tinue manufacture of any product or change prod-
national codes for hazardous area installa- uct materials, design, or specifications without
tions. notice.
b) Only be used in situations which comply
with the certification conditions stated in
this handbook.

1
 Chapter 1 - Overview
Scope of Manual
This manual describes the procedures for installing,configuring, calibrating, operating and troubleshooting
the Masoneilan® Smart Valve Interface (SVI®) Positioner and Controller. A companion software product,
ValVue®, can be used to configure, calibrate, and perform valve diagnostics with the SVI from a remote
Windows-based computer. In addition, SVI can be configured, calibrated and perform valve diagnostics
with a HART hand-held communicator.

Product Description
The Smart Valve Interface, as shown in Figure 1, is a digital valve positioner and/or process controller that
can be either configured, calibrated, and operated locally or remotely. Local functions are controlled by
means of local pushbuttons and digital display. Remote operation requires the use of the ValVue product,
or a hand-held unit loaded with the registered HART Device Description (DD).

The SVI controller version can also function as a single-loop PID controller which accepts standard inputs
for process variable and set point. It positions the valve to achieve the desired value of the process vari-
able. The Controller version can be configured as either a positioner or controller; however entering of
some of the controller parameters requires use of either ValVue software or a HART protocol hand-held
unit.

ValVue, the software for remote communication of the SVI, runs on standard IBM-compatible computers
such as 486 or Pentium. Minimum requirements are 4 MB RAM, Windows 3.1 or better, one available ser-
ial port with a HART® modem, and a hard disk drive. The basic functions performed by ValVue are:

• Remote display of valve position, actuator pressure, set point, calibration parameters, con
figuration parameters, and status/error indicators
• Remote calibration of the SVI
• Remote configuration of the SVI
• Remote operation of the SVI
- Manual control of valve position
- Perform valve diagnostics and display results (signature, friction, stroking speed, cumulative
travel, cycles, and operation in near-closed position)
- Recall previous test results for comparison with current data

For more details on ValVue software, refer to the ValVue Users Manual.

These remote functions can also be performed with a hand-held unit, however, the handheld unit cannot
display graphical representation of the diagnostics.

2
Figure 1. Smart Valve Interface

3
SVI Features and Functions
• Precision valve positioning control
• Advanced valve diagnostics
• Automatic setup and tuning
• Local operation/calibration/configuration using optional explosionproof pushbuttons and
digital display
• Two-way data communication using industry-standard HART protocol
• Remote operation/calibration/configuration/diagnostics using ValVue software or a HART
hand-held
• User-configurable tight shutoff adjustment
• Optional PID controller with remote set point and process variable input
• User-adjustable response times
• Direct or reverse acting operation
• Compatible with air-to-close or air-to-open actuators
• Span and zero configurable for split-range operation
• Local operation functions include:
- Calibrate valve stroke range, tight shutoff point, position limit stops
- Display and/or set parameters for valve configuration
- Select characterization (linear, equal percentage 50, equal percentage 30, quick opening, or
custom)
- Display/clear fault codes
• Display valve position
• Display faults
• Remote operation functions include all of the above plus:
- Display totalized stem travel, number of valve cycles and other data useful for predicting
valve life
- Run valve diagnostics

4
 Performance Specifications
Table 1. Performance Specifications (Positioner Mode Only)
CAUTION: Do not exceed operative limits. This may cause damage and/or performance of the positioner
or controller.

Item Specification
Positioner Inputs 4-20 mA signal input with HART protocol.

Split Range Capabilities Programmable zero and span adjustments, 5 mA mini-

mum span.
Minimum Current for Operation 3.6 mA operating minimum.

Compliance Voltage 12 volts maximum loop voltage drop in mA mode

(typical 10.5 volts).
Digital Communication HART ® Communication protocol signal from ValVue®
software on personal computer or from HART Hand-held
Communicator. HART slave and burst modes multidrop,
up to 5 loops with 20 volts minimum at SVI. 4 mA load at
20 volts.

Controller (Process Variable) Input Nominally 1-5 volts or 4-20 mA with a 250 Ohm resistor.

Local Display - Liquid Crystal One seven character line of 14 segment alpha numeric.
(optional) One six character line of 7 segment numeric.
22 segment bar graph.

Push Button Three (3) explosionproof / flameproof push buttons.

Limit Switch Input Two SPST with common. Cold contacts. Non isolated.

Remote Position Sensing 10 K Ohms potentiometer.

Accuracy Total accuracy 0.5% of span (typical 0.25%).

Linearity (conformity) < 0.2% (typical 0.1%).

Hysteresis Plus Deadband < 0.2% of span (typical 0.1%).

Actuator Pressure Measurement < 0.3% of full scale.

Accuracy
Start-Up Drift Less than 0.02% during first hour.

Long Term Drift Less than 0.003% per month

Supply Pressure 20-100 psi (1.4 - 7 bar)

Air Delivery at 60 PSI 25 cubic meters / hour (15 SCFM)

Air Consumption 0.4 cubic meters / hour (7SLPM)

5
 Table 1. Performance Specifications (cont.)

Item Specification
Operating Temperature Limits - 40° C to 80° C

Storage Temperature Limits - 45° C to + 93° C

Temperature Effect < 0.01% / degree C typical.

Supply Pressure Effect 0.05% psi

Relative Humidity 0 to 100%

Humidity Effect Less than 0.2% after 2 days at 40° C, 95% RH.

Insulation Resistance Greater than 10 G Ohms at 50% RH.

MTBF 50 years based on MIL handbook calculation for electron-

ic parts and field data on mechanical parts.
Electromagnetic Compatibility Electrostatic discharge -- No effect with contact discharge
level of 4KV and air discharge level of 8 KV
(IEC 1000-4-2).
Radio frequency interference -- Less than 0.2% at 10
volts per meter (EN 50140).

Fast Transient Burst No effect at 2 KV (Coupling clamp IEC 1000-4-4).

Magnetic Field Negligible at 30 A/m (EN61000-4-8).

EC MARK certified to EN50081-2 and EN50082-2.

Connections: Pneumatic - 1/4 inch NPT

Electrical - Two (2) 1/2 inch NPT or M20

Enclosure Rating IP 65, NEMA 4X.

Suitable for coastal environment, atmosphere with acids,
atmosphere with dust (fly ash).

Position Travel Limits Rotary:

18 to 100 degrees (short travel version 9 - 50 degrees).
Reciprocating:
12 to 64 mm, 0.5 to 4.5 inches.
Short travel version 6 to 32 mm, 0.25 to 1.25 inches.
Above 64 mm consult factory for mounting.

Flow Characterization Linear

Equal percentage (50:1 or 30:1)
Quick opening (inverse of 50:1 equal percentage)
User configurable for 10 segments
Tight Shut-off (0 - 20% of input)

6
 Table 1. Performance Specifications (cont.)

Item Specification
Positioner Auto Tune SVI performs an automatic determination of the optimal
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 the user can further adjust the
positioner tuning parameters to more conservative or to
more responsive values to produce various dynamic
response to the control signal.

Proportional gain: 0 to 5000%

Integral time: 0 to 1000 seconds
Derivative: 0 to 200 seconds
Dead Zone: 0 to 1% (0 to 2% deadband)
Padj: +/- 3000 (depends on P)
NL Coefficient: -8 to -9
Damping: 0 to 9
Full open position*: 60 to 100%
* (if not at stop)

Action Direct, increasing signal increases output.

Reverse, increasing signal decreases output (software or
hardware reversible).

Instrument Air Best performance is obtained with supply pressure regu-

lated 5 to 10 psi higher than spring range of actuator.
Air quality requirement per ISA S7.3.

Vibration Limits 4 mm at 5 to 15 Hz -- negligible.

Measured at the SVI Housing 2 G at 15 to 150 Hz -- less than 2% of span.
1 G at 150 to 2000 Hz -- less than 2% of span.
Shock Limit 5G

Security Timeout of hardware watchdog timer clamps output to fail-

safe condition and initiates CPU reset. Timeout of soft-
ware (microprocessor COP) watchdog timer initiates CPU
reset.
Pushbuttons include four levels of authorization. Level is
set using ValVue or HART hand-held controller.
ValVue includes six levels of authorization. Password pro-
tected.

Positioner Alarms Hi / Low limits (not latched)

Deviation * time (not latched)
Deviation* time (latched, initiates failsafe)
Failsafe
Unread status messages

7
 Table 1. Performance Specifications (cont.)

Item Specification
Controller Alarms Programmable Hi / Lo process alarms 0 to 100%,
absolute or deviation
Process Controller Functions Local setpoint, remote setpoint, manual.
Ratio control with setpoint bias
Local setpoint tracking.

Process Controller Settings Output rate limit: 0 to 61% per sampling period.
Manual reset: 0 to 90%.
Proportional gain: 0 to 1,000%
Integral time: 0 to 1,000 seconds
Derivative time: 0 to 32 seconds
Derivative gain: 2 to 100
Gain non-linearity: - 9 to 9
Dead zone: 0 to 20%
Hi/lo set point limits: 25% above hi PV or below low PV.
Status Messages POSITION ERROR
PRESSURE ERROR
POSITION SENSOR ERROR
PRESSURE SENSOR ERROR
CURRENT SENSOR ERROR
REFERENCE VOLTAGE ERROR
BIAS OUT OF RANGE
SELF CHECK FAILURE
HART ERROR
SOFTWARE ERROR
RESET OCCURRED
DATA OVERRUN
INTERNAL TEMP ERROR
EEPROM WRITE FAILED
FIND STOPS FAILED
Diagnostics Stored in SVI Non- Friction (in units of pressure)
Volatile Memory Lo spring (in units of pressure)
Hi spring (in units of pressure)
(can be accessed using a HART Lo pressure (full exhaust)
Hand-held Communicator or Hi pressure (full supply)
ValVue Software). Time to open
Time to close
Time open
Time closed
Time near closed
Reversals (cycles)
Total accumulated stem travel
Diagnostics Plots Using ValVue Position vs. time
Stem position vs. actuator pressure
Stem position vs. position setpoint
Process, process setpoint, position, position setpoint vs.
time (90 second window)

8
Electrical Safety Specifications

Table 2. Electrical Safety Design Specifications

Agency Service Applicable Class

Factory Mutual Explosionproof Class I, Division 1, Groups B, C, and D
Approvals Dust-ignitionproof Class II, III, Division 1, Groups E, F, and G
Intrinsically Safe Class I, II, III, Division 1, Groups A, B, C, D, E, F, and G
Non-incendive Class I, Division 2, Groups A, B, C, and D
Suitable for Class II, III, Division 2, Groups F and G
Enclosure Rating NEMA 4X
CSA Approvals Explosionproof Class I, Division 1, Groups B, C, and D
Dust-ignitionproof Class II, III, Division 1, Groups E, F, and G
Intrinsically Safe Class I, II, III, Division 1, Groups A, B, C, D, E, F, and G
Non-incendive Class I, Division 2, Groups A, B, C, and D
Suitable for Class II, III, Division 2, Groups F and G
Enclosure Rating Type 4X
CENELEC Flameproof EEx d IIB + H2 T5 (ambient temp. not to exceed 80°C)
Approvals per EN 50014 and EN 50018
Intrinsic Safety EEx ia IIC T4 (ambient temperature not to exceed 80°C)
per EN 50014 and EN 50020
Enclosure Rating IP 65 per EN 60529
CE Conformity Yes

9
10
11
Principle of Operation
When configured as an electropneumatic valve positioner, (Figure 2) the SVI accepts a 4-20 mA current
signal from a controller or other device,(i.e. HART protocol digital signal) and compares the input signal
to the valve position. The difference between the input and position feedback is conditioned by the posi-
tion control algorithm and converted to a pneumatic signal. This signal is boosted by a pneumatic relay
and 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 of SVI Positioner

When configured as a PID controller, (Figure 3) the SVI accepts a local control setting, (4-20 mA signal or
a HART communications protocol signal). The primary process measurement made by the process trans-
mitter is fed to the controller as a voltage signal of 1 to 5 V dc. The difference between the set point and
process measurement is conditioned by both the PID controller algorithm and position control algorithm
and converted to a pneumatic signal. This signal is boosted by a pneumatic relay and drives the actuator.
When primary measurement and set point signals agree there is no further movement of the actuator and
system is in stable control.

Figure 3. Block Diagram of SVI Controller/Positioner

12
Hardware Description
The SVI is housed in a rugged, weatherproof, corrosion resistant aluminum housing which has been
designed for operation in hazardous areas as listed in Table 2.

Two 1/2 NPT conduit entries and three 1/4 NPT pneumatic ports provide signal connections to the SVI.

Within the housing are the following components interconnected as shown in Figure 3a, "SVI Block
Diagram".

• Electronics Module
• Display and Pushbuttons
• Electropneumatic Converter (EPC)
• Spool Valve
• Sensors (position, pressure and temperature)

Figure 3a. SVI Block Diagram

13
Electronics Module
The electronics module contains the power supply, 16 Bit A/D Converters, 12 Bit D/A Converters and the
microprocesser. Using the internal programmed Positioner and/or Process Control algorithm, it computes
the required output based on information received from the measurement sensors. If the display and push-
button option is selected it contains the electronics for these functions.

Pushbutton Switches
Three pushbutton switches operating in conjunction with the display permit reading and modification of the
instrument operating parameters without a PC or HART hand-held communicator.
These switches perform "generic" functions - Increase, Decrease, and Accept by movement through a
conventional menu structure.
The switches can be operated in a hazardous environment without compromising the flameproof enclo-
sure.

EPC (Electropneumatic Converter)

The EPC converts a current signal to a pressure signal in the following manner. A coil operating in a mag-
netic field is mechanically connected to a flapper. Movement of the coil when current is changed causes
the flapper to move towards a nozzle and restrict the air flow through the nozzle. The restricting action
causes the back pressure on the nozzle to increase with an increase in the coil current.

Removing electrical power from the EPC causes the output pressure to go low. This defines the startup
and fail-safe characteristics of the SVI.

Spool Valve
The spool valve is a two way, air-piloted valve that can supply or exhaust air. The pilot pressure, which is
controlled by the EPC, in turn controls the rate of air flow that fills or exhausts the actuator.

Sensors (Position, Pressure and Temperature)

Position sensing of the valve stem is accomplished by use of an internally mounted potentiometer
mechanically linked to the stem. The output of the potentiometer is connected to the electronics module
and provides the input signal to the position control algorithm.
The potentiometer resistance is 10,000 ohms and has a full scale travel range of 120 degrees rotation.
Full valve stroke must provide 18 degrees minimum * and 100 degrees maximum rotation from reference
position. "Open" or "Closed" valve settings establish the reference position.
The position sensor also provides, through the electronics module, readout of valve position on the dis-
play, communication of valve position via HART protocol and on newer SVI models a 4-20 mA signal pro-
portional to valve position transmitted on a separate pair of leads.
If the SVI cannot be mounted on the valve, an optional remote feedback potentiometer can be used to sup-
ply the position signal to the SVI.
The pressure sensor measures the pressure to the actuator with a range of 0 to 100 psi. This pressure
can be read out on the internal display, Hart communicator or Val Vue PC.
The temperature sensor is located in the electronics module and measures ambient temperature. This
measurement is used to provide temperature compensation for the pressure sensor and other internal
electronic components.

* A short stroke version SVI is available; Consult Factory.

14
 SVI Inputs/Outputs
As shown in the block diagram below, the SVI unit has the following inputs and outputs:

Figure 4. Input/Output Diagram of SVI Unit

NOTES:
1. Set point signal can come from a 4-20 mA current input or from HART protocol digital input. With
digital input, operating power can be from 4-20 mA input or from 12/24 V dc Multidrop Supply.

2. PID Controller Process Variable signal must be dc voltage signal of 1.0-5.0 V dc or a 4-20 mA sig-
nal through a 250 Ohm resistor.

3. User configurable as dictated by actuator operating pressure range.

NOTE:
When SVI Positioner or Controller are ordered without pushbuttons or display, configuration
and calibration must be done using HART protocol Handheld Communicator or from ValVue
software on personal computer.

The SVI unit accepts the following inputs:

• Set point signal for valve position (when configured as a positioner) or for a PID controller
(when configured as a controller)
• Actuator pressure
• Valve position
• Remote valve position

As an alternative, the remote valve position input connection can be assigned as follows:
• Up to two “cold” contact closures (unpowered for intrinsic safety), or
• A process variable input signal (when the PID controller function is configured)

15
System Description-Positioner
Typical system setups are shown in Figures 5 and 6. In these diagrams, the SVI is configured as a posi-
tioner and is located in a hazardous area (wiring diagrams are descriptive only, actual wiring must adhere
to Electrical Installation section of manual and local electrical codes). Valve position is determined by an
internal feedback potentiometer mechanically linked to the valve stem. The SVI input signal can be a 4-20
mA or a HART communication protocol signal from ValVue software on a personal computer or from a
HART Hand Held Communicator. The process controller (or other source of input signal to the SVI) is
located in a non-hazardous location and an intrinsic safety barrier (with ground) may be placed between
the controller and the SVI or the system can be installed as explosionproof (flameproof). Communication
with the remote PC is handled via a modem connected to the remote PC through a serial port.
Communication can also be established from a HART Hand-held Communicator. The PC, which is not
intrinsically safe, must be connected to the circuit on the non-hazardous side of the intrinsic safety barrier
if the valve is located in a hazardous area. The SVI unit can be operated, calibrated, configured, and inter-
rogated either by using local pushbuttons/display, or using a remote PC running ValVue software or with
the Hand-held Communicator.

Figure 5. System Diagram – Intrinsically Safe Installation

Figure 6. System Diagram – Explosionproof (Flameproof) Installation

16
System Description- PID Controller
When the SVI unit is configured as a PID controller, the + and - terminals are used to power SVI and to
remotely set the controller’s input. The primary process measurement, made by the process transmitter is
fed to the controller as a 1-5 V dc signal, and connected to terminals marked A and B. Various configura-
tion schemes using remote set point input are illustrated in Figure 7, Figure 8, and Figure 9. (Wiring dia-
grams are descriptive only, actual wiring must adhere to Electrical Installation section of manual).

Figure 7. Single Loop PID Configuration with No Process Feedback

Figure 7 is the simplest configuration for the controller. It requires two 2-wire lines to the field. The sense
resistor is located across the A and B terminals of the SVI unit. There is no sensing of the controlled vari-
able in the control room - which is acceptable for applications such as a heat exchanger where the primary
variable is temperature and the secondary is flow. In such a case, the SVI is the flow controller and the
control room temperature controller sets flow based on the requirements of the temperature loop (with no
need to monitor flow in the control room).

In the configuration shown in Figure 8, there are three 2-wire connections to the field. With this connec-
tion the process transmitter output can be monitored in the control room. The 250 Ohm resistor is locat-
ed in the control room in this configuration.

Figure 8. Single Loop PID Configuration with Process Feedback

17
The circuit shown in Figure 9 is an intrinsically safe configuration. The 788R+ barrier supplies the operat-
ing power to the 4-20 mA process transmitter. This barrier contains a 250 ohm resistor in its current return
leg across which a 1-5 V dc voltage is developed. This voltage is fed through the 710+ or 728+ barrier to
the A and B (process variable input) terminals in the SVI Controller. The 4-20 mA remote control setpoint,
and power to the SVI are supplied through the 728+ barrier.

Figure 9. Intrinsically Safe Single Loop PID Configuration

18
The circuits shown in Figures 10 and 11 are Controllers with local setpoint set by the pushbuttons on the
housing. The 24 V dc supply with a series current limiting resistor replaces the 4-20 mA source and can
also be used to power the process transmitter. If these circuits are used in hazardous areas, the wiring
and mounting of the external resistors must conform to explosionproof requirements, or I.S. barriers must
be used on all wiring between the control room and the hazardous area.

Figure 10. Local Set with Voltage Source

Figure 11. Local Set with Voltage Source-Two Leads to Field

19
 Chapter 2 - Mounting
WARNING:
If the SVI is to be mounted on an existing valve in a process line, the following procedures and pre-
cautions are mandatory.
• If valve is located in a hazardous area make sure area has been certified as “safe” or that all
electrical power to the area has been disconnected before removing any covers or disconnecting any
leads.
• Shut off air supply to the actuator and to any valve mounted equipment.
• Ensure the valve is isolated from the process by either shutting off process or using bypass valves
for isolation. Tag shutoff or bypass valves to guard against turn-on while work is in progress.
• Bleed air from actuator and check that valve is in its un-energized position.

It is now safe to disconnect and remove any valve mounted equipment that is being replaced.

NOTE:
The SVI should be mounted with the conduit connections down in order to facilitate drainage of condensate
from the conduit and ensure the best dynamic performance.

Standard Rotary Valve Mounting

This section describes the procedure for mounting the SVI on all Masoneilan rotary control valves.
Tools required:

• 3/16 inch Hex Wrench

• 4 mm Hex Wrench
• 7/16 inch Combination Wrench

1. Mount the SVI mounting bracket to the valve actuator using two (2) 5/16 - 18 UNC flat-head cap
screws. Unless otherwise specified the SVI will be mounted assuming the actuator/valve will be
mounted in the normal upright position (i.e., lettering on actuator right side up). This requires the long
end of the mounting bracket to be to your right when facing the actuator. Note that the mounting brac-
ket for ball and butterfly valves differs slightly from the Camflex and Varimax bracket but the mounting
is identical.

2. Bolt the valve side lever to the valve position take-off shaft using a 1/4 - 28 UNF cap screw, spacer
and washer. The spacer goes between the take off shaft and lever, and the washer under the head of
the cap screw. On Camflex and Varimax valves, orientate valve side lever 90( from valve position indi-
cator as shown in Figure 12 and securely tighten cap screw. On ball and butterfly valve actuators, ori-
entate the lever so it is midway between the two bracket mounting holes (45o from horizontal) as
shown in Figure 13 and tighten cap screw. Alternatively, for all rotary mountings, the actuator can be
pressurized to mid-stroke and lever secured in a horizontal position.

20
 Figure 12. SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves

Figure 13. SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves

3. Clamp the SVI lever to the SVI shaft. The flat on the SVI shaft must always face the pneumatic block
with the lever orientated facing the cover as shown in Figure 14. When using a standard lever, the
orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft. Leave
approximately 1/16 space the SVI housing and back of lever. See Figure 15.

4. Loosely assemble the SVI to the mounting bracket using only the two top 1/4 - 20 UNC socket-head
cap screws. Pull the SVI away from the actuator to allow the pin on the valve side lever to be insert-
ed into the slot in the SVI lever under the anti-backlash spring. See Figure 15. Assemble the two bot-
tom bolts and securely tighten all four bolts.

21
Figure 14. Orientation of SVI Lever and SVI Shaft

Figure 15. SVI Mounting on Rotary Valves

22
Standard Reciprocating Valve Mounting

Mounting the SVI on Masoneilan 87/88 Multi-Spring actuators.

Tools required:

• 7/16 inch Combination Wrench (2 required)

• 3/8 inch Combination Wrench
• 1/2 inch Combination Wrench
• 4 mm Hex Wrench
• 3/16 inch Hex Wrench

1. Mount the SVI mounting bracket to the actuator using two (2) 5/16 - 18 UNC cap screws. Unless
otherwise specified, the SVI mounting assumes that the actuator is in the normal upright position.
The slotted opening of the mounting bracket is to be to the left when facing the actuator.

2. Clamp the SVI lever to the SVI shaft. The flat on the SVI shaft must always face the pneumatic
block with the lever orientated facing the cover as shown in Figure 14. When using a standard
lever, the orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft.
Leave approximately 1/16 space the SVI housing and back of lever. See Figure. 16.

Figure 16. Top View of SVI Mounted on a Reciprocating Valve

23
 3. Attach the right hand threaded rod end to the SVI lever using a 1/4 - 20 x 1” cap screw. The lever
hole position to be used is dependent upon the specific valve stroke. Refer to Figure 17 and Table
3 (shown below).

Figure 17. SVI Lever for 87/88 Multi-Spring Actuator

Valve Stroke mm (inches) Lever Hole

20.3 (0.8) A

25.4 (1.0) A

38.1 (1.5) B

50.8 (2.0) C

63.5 (2.5) C

Table 3. SVI Lever Hole Locations for 87/88 Multi-Spring Actuator

Note: For valve strokes less than 19.1 mm (.75 in.) use the “Short Stroke” model SVI with the rod end
attached to the lever “A” hole.

4. Mount the SVI to the mounting bracket using four 1/4 - 20 UNC socket-head cap screws. The set of
mounting holes to be used is dependent upon the specific valve stroke. Refer to Figure 18.
5. Screw the take-off rod to the actuator stem connector, refer to Figure 19. Ensure that the travel
pointer is correctly positioned.
6. Bolt the left hand threaded rod end to the take-off rod with 1/4 - 20 UNC nut.
7. Connect turnbuckle and lock nuts to each rod end. Refer to Figure 19. Turnbuckle length is a
function of actuator size. Verify proper length per following: #6 and #10 Actuators, length = 1.25”.
#16 Actuator, length = 2.90”. #23 Actuator, length = 5.25”.
8. Position valve at mid-stroke by supplying air to the actuator or using a manual handwheel if
applicable.
9. Adjust the turnbuckle such that the SVI lever is horizontal. Tighten the turnbuckle lock nuts.

24
Figure 18. SVI Mounting Bracket for 87/88 Multi-Spring Actuator

Figure 19. Side View of SVI Mounted on a Reciprocating Valve

25
Mounting the SVI on other Valves
The SVI can be mounted on many other valve types of both Masoneilan design and those of other man-
ufacturers. Typical mounting on Masoneilan Type 37/38 and 84/85 Actuators is shown in Figures 20 and
21. Figure 21a “Smart Valve Interface Outline Drawing” shows mounting and overall dimensions. When
mounting the SVI to other valves use it as a guide to ensure proper clearances, access room for cover
removal and making of pneumatic and electrical connections.

The following section describes the general requirements for mounting the SVI on any valve.

This section is intended to be used by an Engineering group with basic understanding of instrument
mounting on control valves. The following minimum technical requirements must be adhered to:

Minimum SVI shaft rotation for full travel is 18°.

Maximum recommended linkage assembly non-linearity is +/- 1.0%.
Minimum mounting bracket thickness is 5.0 mm.

In order to mount a SVI on a valve the following parts are required:

• Mounting Bracket
• SVI Lever and Linkage for Position Feedback (Reciprocating)
• SVI Lever and Valve Side Lever for Position Feedback (Rotary)

To ensure that the SVI position feedback performs correctly, the plane of the flat on the SVI shaft must be
vertical and facing the pneumatic block of the SVI when the valve is at mid travel. The lever must point
away from the pneumatic block. See Figure 14.

For a reciprocating valve,the bracket, lever, and linkages should be designed such that the lever is per-
pendicular to the actuator stem when the valve is at mid-stroke. The linkage pivot point on the SVI lever
should be on the same centerline as the valve stem at mid-stroke. (turnbuckle centered on and parallel to
stem).

For a rotary valve it is recommended that the Masoneilan design valve side lever and SVI lever be used
since they incorporate an anti-backlash spring feature.

The mounting bracket should accommodate the four mounting holes of the SVI. Adequate space must be
left between the SVI and the Actuator to accommodate the lever and linkage or the rotary lever coupling.
Clearance space is required for the output air connection and SVI end cover. See Figure 22 for mounting
interface requirements.

26
Figure 20. Typical SVI Mounting on 37/38 Actuator

Figure 21. Typical SVI Mounting on 84/85 Actuator

27
Figure 21a. Smart Valve Interface Outline Drawing

28
 Figure 22. SVI Mounting Interface

Lever and Linkage Design

A lever length should be chosen depending on the stroke of the given actuator. Table 4 can be used as
a guide in determining lever lengths.

The recommended lever material is aluminum 6061 temper Tl, anodized for corrosion protection. This
lever should be designed to the basic dimensions as shown in Figure 23. If designed in a material other
than aluminum, the clamping effort for the M5 screw must be reviewed to ensure proper attachment to
the SVI shaft.

Valve Stroke mm (inches) Lever Length mm (inches)

12.7 (0.5) 19.1 (0.75)

25.4 (1.0) 31.8 (1.25)

50.8 (2.0) 76.2 (3.00)

101.6 (4.0) 139.7 (5.50)

152.4 (6.0) 203.2 (8.00)

Table 4. Recommended Lever Lengths

29
 Figure 23. SVI Lever Design

The linkage design is usually made up of two rod ends. One each attached to the SVI lever and the valve
stem. A turnbuckle is used to attach the rod ends together and for final adjustment. Table 5 may be used
as a guide to determine the proper linkage lengths. Lock nuts should be provided to ensure that the set
length of the linkage is not changed. See Figure 19 for typical mounting on a reciprocating actuator.

Valve Stroke mm (inches) Linkage Length mm (inches)

12.7 (0.5) 25.4 (1.00)

25.4 (1.0) 50.8 (2.00)

50.8 (2.0) 76.2 (3.00)

101.6 (4.0) 127.0 (5.00)

152.4 (6.0) 228.6 (9.00)

Table 5. Recommended Linkage Lengths

30
 Pneumatic Installation

The SVI Positioner and Controller are designed to operate only with clean, dry, oil-free, instrument grade
air to ANSI/ISA-57.3 1975 (R1981) or ISA-S7.3-1975 (R1981).

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

Particulate matter: Filtered to below 5 microns.

Oil content: Less than 1 ppm w/w or v/v.

Contaminant’s: Free of all corrosive contaminants and hazardous gasses, flammable or toxic.

The supply, output and exhaust connections for the SVI (located on the pneumatic block) are tapped 1/4”
NPT. The output connection is located on the back of the block. The supply and exhaust are located on
the side of the block with the exhaust above the supply and fitted with a plastic plug. Two pressure gauges,
output on top, supply on bottom, are located on the front of the pneumatic block.

The use of a Masoneilan filter regulator with a 5 micron filter is recommended for the air supply. Tubing
used for piping between filter regulator, SVI , and actuator should be 1/4” minimum with 3/8” used for larg-
er actuators.

CAUTION: Do not use pipe thread sealant tapes on pneumatic fittings as it tends to shred small particles
which can cause instrument malfunction.
The use of a soft setting anaerobic hydraulic seal such as Loctite Hydraulic Seal 542 is recommended.
Follow manufacturers instructions.

CAUTION: Do not use an excessive amount as it will not set and may migrate into the instrument.

Maximum allowable air supply pressure to the SVI varies according to actuator and valve size and type.
See pressure drop tables in valve specification sheets to determine correct positioner supply pressure.
Minimum supply pressure should be no less than 10 psi above maximum spring pressure.

DANGER: Never exceed actuator or SVI maximum supply pressure. Damage to equipment or injury to
personnel may result.

31
Electrical Installation
Electrical connections are made to the main terminal board as shown on Figure 24. The terminals will
accept wire sizes up to A.W.G 14

Figure 24 shows layout of terminal board currently in production.

Figure 24. Electrical Connections to Main Terminal Board

(Current Production)

32
Figure 24a reflects a design change to be released in early 1999 which incorporates the following
enhancements.

• Additional terminals D and E allow the contact input feature to be used with the controller
option.
• Optional terminals POS + and POS - provide an isolated 4-20 mA signal related to charac-
terized valve stem position. The voltage compliance of the position output terminals is 11-50
V dc. The HART® signal is not available on the position terminals. The HART protocol is
available on the +/- LOOP terminals.
• The software revision reported by the HART ID command is 6.

All terminals (both versions) accept wire sizes up to A.W.G. 14.

Figure 24a. Electrical Connections to Main Terminal Board

33
 When operated with current input, the loop controller or any other current source must be capable of sup-
plying 4-20 mA with an output voltage compliance of at least 12 V. Before applying power to the SVI make
sure current/voltage jumper is in correct position.

The available output voltage of a current source will be reduced by loop wiring resistance. This can be
checked by connecting a resistor of value (600 ohms + loop resistance ) across the output of the current
source and verifying that 20 mA is obtainable at full scale output.

The SVI is normally supplied with two 1/2” NPT conduit entries. (M20 adapters are available) Internal and
external ground terminals are provided for use if grounding is required.

WARNING: The SVI must be installed in accordance with local and national codes of prac-
tice in both general purpose and hazardous area locations. The electrical components are
fully isolated from ground and therefore grounding is unnecessary for functional purposes.
Grounding may be necessary to conform to installation codes.

Figure 24b is a composite wiring installation diagram applicable to both SVI versions and to the controller
option. It is suitable for general purpose locations and to explosionproof (flameproof) installations when
applicable wiring codes are observed.

Figure 24b. General Area Purpose Installation

34
 Hazardous Area Installations
The SVI is available in versions suitable for use in hazardous areas. The labeling on the positioner indi-
cates approved areas of use.

WARNING: Installation of any hazardous area equipment must be made in accordance with
the appropriate hazardous area installation codes and the manufacturers installation and
operating instructions. The user must make no changes or attempt any repairs of a certi-
fied instrument since this will invalidate the certified design.If a certified instrument should
fail it must be returned to the manufacturer for repair.

Factory Mutual approved model

Explosionproof: Class I, Division 1, Groups B, C, and D. Temperature Classification T6 @ 75° C

ambient, T5 @ 82° C ambient, indoor and outdoor (NEMA Type 4X) hazardous
(classified) locations.

Dust-Ignitionproof: Class II / III, Division 1, Groups E, F, and G.

Non-Incendive: Class I, Division 2, Groups A, B, C, and D.

Suitable for: Class II / III, Division 2, Groups F and G.

Installation must be in accordance with the current edition of the National Electrical Code ANSI / NFPA-
70, any applicable local codes and manufacturers instructions.

Intrinsically Safe: Class I / II / III, Division 1, Groups A, B, C, D, E, F, and G hazardous indoor /

outdoor NEMA 4X locations. Temperature Classification T4 @ 40° C ambient,
T3B @ 70° C ambient, T3A @ 82° C ambient.

Installation must be in accordance with the current edition of the National Electrical Code ANSI / NFPA-
70, ANSI / ISA RP 12.6 “Installation of Intrinsically Safe Instrument Systems in Class I Hazardous
(Classified) Locations”, Figure 25 - Installation Control Drawing ES-641 - on Page 34, and manufacturers
instructions.

CSA (Canadian Standards Association) approved model

Explosionproof: Class I, Groups B, C, and D, Class II, Groups E, F, and G, Class III. Supply 28
Vdc, 4-20 mA. Enclosure Type 4X, Temp. Code T6 @ 75° C, T5 @ 82° C. Max.
Ambient 82° C.

Division 2: Class I, Division 2, Groups A, B, C, and D, Class II, Division 2, Groups F and G,
Class III. Supply 28 Vdc, 4-20 mA, Enclosure Type 4X, Temp. Code T6 @ 75°
C Ambient, T5 @ 82° C. Max Ambient 82° C.

Installation must be in accordance with the current edition of the Canadian National Electrical Code Part
I, any applicable local codes and manufacturers instructions.

35
Intrinsically Safe: Class I, Groups A, B, C, and D, Class II, Groups E, F, and G, Class III. Supply
28 Vdc 4-20 mA. Enclosure Type 4X. Temp. Code T4 @ 40° C Ambient; T3B @
70° C Ambient; T3A @ 82° C Ambient. Max. Ambient 82° C.

Installation must be in accordance with the current edition of the Canadian National Electrical Code Part
1, Figure 25 - Installation Drawing ES-641 - (shown below), and manufacturers instructions.

SVI (SMART VALVE INTERFACE)

FACTORY MUTUAL AND CANADIAN STANDARDS ASSOCIATION
APPROVED INTRINSICALLY SAFE INSTALLATION CONTROL DRAWING

Figure 25. Approved Intrinsically Safe Installation Control Drawing

36
Notes:

1. The electrical circuit in the hazardous area must be capable of withstanding an A.C. test voltage of
500 volts R.M.S. to earth or frame of the apparatus for 1 minute.

2. Entity Parameters:
SVI (+) and (-) LOOP Terminals

Vmax = 30 Vdc Imax = 125 mA Ci = 2.2 nF Li = 96 uH Pmax = 900 mW

SVI (+) and (-) POS Terminals

Vmax = 30 Vdc Imax = 125 mA Ci = 2.2 nF Li = 96 uH Pmax = 900 mW

SVI (A), (B), (C), (D), AND (E) Terminals

Vmax = 30 Vdc Imax = 125 mA Ci = 0 nF Li = 0 uH

3. Terminals (C), (D), and (E) may be connected to an external position sensing potentiometer or to
unpowered switch contacts, both of which fall in the category of “simple apparatus” and located in the
hazardous area within 10 feet of the SVI positioner.

4. Cable capacitance and inductance plus the I.S. apparatus unprotected capacitance (Ci) and induc-
tance (Li) must not exceed the allowed capacitance (Ca) and inductance (La) indicated on the asso-
ciated apparatus. If the optional Hand Held Communicator is used, then the capacity and induc-
tance must be added. Also, the current output of the Hand Held Communicator must be included in
the current output of the associated equipment.

5. Positive polarity shunt zener diode safety barrier approved by FMRC or CSA for groups A, B, C, D,
E, F, and G with output parameters:

Voc or Vt < 30 Vdc Isc or It < 125 mA Ca > Ci + C cable La > Li + L cable

6. The intrinsically Safe Transmitter is any transmitter approved by FMRC or CSA for groups A, B, C,
D, E, F, and G having entity parameters consistent with the connecting FM or CSA approved barrier.

7. The installation including the barrier earthing requirements must comply with the installation require-
ments of the country of use, i.e., ANSI/ISA RP12.6 (Installation of Intrinsically Safe Systems for
Hazardous (Classified) Locations) and the National Electrical Code. ANSI/NFPA 70 or Canadian
Electrical Code Part 1. Installation must be in accordance with manufacturers guidelines. Division 2
installations must be installed per the National Electrical Code. ANSI/NFPA 70 or Canadian Electrical
Code Division 2 Wiring Methods.

8. SVI Temp Code: T4 at 40° C. Maximum Ambient Temperature

T3B at 70° C. Maximum Ambient Temperature
T3A at 82° C. Maximum Ambient Temperature

9. Dust-tight conduit seal must be used when installed in Class II and Class III environments.

10. The model 275 Hand Held Communicator is Factory Mutual approved with the entity parameters
printed on the 275 label.

37
CENELEC Approved Model

Flameproof: Coded as EEx d IIB + H2 T5 (Ta +80° C.)

Installation must be in accordance with current editions of applicable country codes and manufacturers
instructions.

Intrinsically Safe: Coded as EEx ia IIC T4 Tamb = - 40° C to +80° C

Installation must be in accordance with current editions of applicable country codes and manufacturers
instructions. The intrinsic safety barriers must be suitable for use with the SVI safety description given
below:

Field Connector, +, - (Power Input)

Ui = 30 Vdc Ii = 125 mA Pi = 0.9 W Ci = 2.2nF Li = 96 uH

Field Connector, A, B, C (Controller Link)

Ui = 30 Vdc Ci = 0 uF Li = 0 mH

Housing Protection Rating: IP 65

38
SVI Interconnections
Basic Positioner
The basic positioner functions to position the valve in response to the magnitude of the 4-20 mA current
input. The connection between the positioner and control system is by a two conductor cable. The rec-
ommended configuration is use of twisted pair, shielded cable, with the shield and loop grounded at one
point only.

Positioner or Controller with HART Communication

Impedance Constraints
HART communication is based on the “talking” device generating an AC current superimposed on the 4-
20 mA control signal. Two frequencies are generated; one representing the digital value “0” and one rep-
resenting the digital value “1”. the “listening” device responds to the voltage generated when the AC cur-
rent flows through the loop impedance. (In order to generate a voltage from a current there must be an
impedance.) HART Protocol required that this impedance be at least 220 Ohms at the tone signaling fre-
quencies. At DC (zero frequency) a current source presents a very high impedance. (Little change in cur-
rent for a large change in voltage.)

Figure 26. Impedance vs Frequency for Typical Current Source

However, at higher frequencies, the impedance may be lower. For example, a noise reduction capacitor
across the output of a current source will lower the impedance at higher frequency and thus lower the sig-
naling voltage. Ideally the current source will be supplied with an impedance versus frequency charac-
teristic (see fig 26). The heavy band in the sketch represents the range of frequencies for signaling tones.
In practice, this detailed information is seldom available. To be certain that at least 220 Ohms of imped-
ance is presented by the current source a resistor may be added in series with the current source (see fig-
ure 27). However, this will reduce the effective compliance voltage of the current source by 20 mA times
the value of the series resistor. for example, a 250 Ohm resistor will reduce the effective compliance volt-
age by 5 Volts. Consider that the compliance voltage of a typical current source is 24 Volts, and the volt-
age requirement of the SVI is 12 Volts (typically only about 10.5 Volts) there is plenty of compliant voltage
even with 5 volts dropped by the series resistor.

Figure 27. Resistor Add in Series with Current Source

39
Noise Constraints
Hart Communication depends on converting two frequencies into digital values “0” and “1”. Noise can
cause errors in the conversion. Conventional good wiring practice such as use of twisted shielded pair
cable with the shield and signal loop grounded at one point only will minimize the effects of noise.

Interference with DCS

The HART signaling frequencies are a 1mA peak AC current. This AC current, flowing in the DSC out-
put, can cause a shift in the DCS 4/20 mA DC signal. both Honeywell and Moore Products DCS require
a filter between the DCS and the HART signaling devices to prevent the HART frequencies from upset-
ting the DCS output. The filter also serves to establish a minimum impedance of greater then 250
Ohms, and to prevent AC frequencies generated in the DCS from interfering with the HART communica-
tion.

Cabling and Interconnection Constraints

Interconnections should be made using shielded twisted pair cables. The shield must be connected to
ground at one point only. The signal loop should also be grounded at one point only.

40
Split Range
Split range SVI requires special consideration of the compliance voltage. the SVI requires about 11
Volts (the spec is 12 Volts). Two SVI in series will therefore require about 22 Volts. But the typical cur-
rent source can only deliver about 24 Volts, so the system will be “Voltage starved”.

One solution is to use an active barrier for each loop. Using an active barrier allows up to three SVI to
be operated from a single 4/20 mA DCS output. Each barrier has a low compliance Voltage input
requirement and a high voltage output capacity. So three barriers can be connected in series input.
Figure 28 shows the same barriers as are used in the multiplexer.

Figure 28. Split Range - Active Barrier

Another approach is to boost the compliance voltage of the DCS using a power supply (see figure 29).
The DCS vendor should be contacted to validate this approach.

Figure 29. Compliance Voltage Boost

A further constraint on the split range system is that the minimum span is 5 mA, the upper range value
is 8 to 20 mA and the lower range value is 4 to 14 mA. (Example 4-9 mA; 9-14 mA, 14-20 mA.

41
 Chapter 3 - Operation - SVI Positioner

Introduction
Operation of the SVI Positioner as a local device is controlled through the optional device-mounted push-
buttons and digital display, as shown in Figure 30. Using the display, you can read: (1) the input signal
(2) pneumatic output signal, and (3) valve position. The display sequences from one variable to the next
every 1.5 seconds.

Using the pushbuttons, you can exit from operating mode at any time and step through a menu structure
to perform a wide range of manual operation, calibration, configuration, and monitoring functions, all of
which are described later in this section. Before you can perform any of these functions, however, you
must first ensure that the ValVue software (if used) has placed the pushbuttons in the “unlocked” mode.
(See ValVue User Manual for more details.) The pushbuttons do not support any diagnostics functions.

NOTE: If the SVI unit is specified without local pushbuttons and display, local operation is not available.

Pushbuttons/Display
As shown in Figure 30, the upper line is a 7-digit numeric display and the lower line is a 7-digit alphanu-
meric display. The upper line is used for displaying values such as input signal or valve position, and the
lower one is primarily used for messages and parameter identification.

Figure 30. Local Display and Pushbuttons

42
 The three pushbuttons perform the following functions:

• The left button, marked with *, permits you to “select” or “accept” the value or parameter
option currently displayed.

• The middle button, marked (–), permits you to move back through the menu structure to the
previous item in the menu, or to decrement the value currently shown in the digital display.
When used to decrease a displayed value, holding this button down causes the value to
decrease at a faster rate.
• The right button, marked (+), permits you to move down through the menu structure to the
next item in the menu, or to increment the value currently shown in the digital display. When
used to increase a displayed value, holding this button down causes the value to increase at
a faster rate.

To determine how to display and/or select a particular parameter value or configuration option, refer to the
menu structure diagrams in Figure 31 through Figure 35. By using these diagrams as a map, you can
quickly move through the menus to the function you want to perform.

NOTE:
If the buttons are pushed after being locked by the ValVue software, the message “LOCKED” will
appear. Please refer to ValVue Software Manual to unlock pushbuttons.

NOTE:
When an SVI is turned on, it is advisable to apply the air supply before applying the electrical input
signal.

43
44
Figure 30a. Pushbutton Guide for SVI Version 1.0.6
45
Figure 30b. Pushbutton Guide for SVI Version 1.0.5
Menu Structure
The menu structure for operating the SVI from the local pushbuttons and display is shown in Figure 31 to
Figure 35 on the following pages.

NORMAL OPERATE Mode and Manual Mode Menus

Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode, the valve is placed in
the last position it was in when it left NORMAL OPERATE. When in the MANUAL mode, the device will not
respond to the 4-20 mA signals. However, the SVI unit can still respond to HART commands, including
HART commands to position the valve. Note also that when you go to EXAMINE from the normal OPER-
ATE MODE MENU, the valve is still in “NORMAL OPERATE” mode and still responds to the 4-20 mA sig-
nal.

Figure 31. NORMAL OPERATE, MODE SELECT, and MANUAL Menu Structures

46
Configure Menu
Because calibration depends on certain configuration options, you must perform “Configuration” before
you perform “Calibration” when installing the SVI the first time.

Figure 32. CONFIGURE Menu Structures

47
Calibrate Menu
If a change is made in the Air-to-Open/Air-to-Close or Direct/Reverse configuration options, or if you move
the SVI to a different valve or make any change to the valve position linkage, you must run the find
“STOPS” calibration again.

Figure 33. CALIBRATE Menu Structures

48
Examine Menu
This menu can be entered either from the Manual Mode Menu or from the NORMAL OPERATE Mode
Menu. The EXAMINE menu allows the user to read the current configuration, calibration, and status infor-
mation. This information, however, cannot be changed from the EXAMINE menu.

When you exit from the EXAMINE menu, you return to the menu from which you entered.

Figure 34. EXAMINE Menu Structure

49
Figure 35. Parameter and Message Displays

50
Normal Operation - Positioner
Functions
In normal operation, the SVI unit operates as a positioner using a 4-20 mA input signal as set point. The
local digital display sequentially displays valve position, input signal, and actuator pressure on a 1.5-sec-
ond interval. Pressing any button moves you to the (OPER option in the OPERATE MODE MENU, as
shown in Figure 31 on page 34.

The OPERATE MODE MENU has 3 options: –› MAN (put valve in manual mode and go to MANUAL
Menu), –› EXAMINE (go to EXAMINE Menu), and –› OPER (return to display of current position, pres-
sure, and signal). Use the pushbuttons to move from one option to the next. Press the * button to go to
the item displayed in the menu.

Configuration
Parameters and Options Available
You can configure the following options by pressing the local pushbuttons in the procedure described
below. We recommend that you use the menu structure diagrams in Figure 31 to Figure 35 on pages 34
to 38 as a road map in following the procedures described.

As noted previously, configuration should be performed before calibration. Also note that configuration can
be performed only when the valve is in manual mode.

The configurable options are as described in Table 6.

MENU ITEM DESCRIPTION OF OPTIONS

SINGLE (or DOUBLE) Select single or double acting actuator (not presently available)
CTL OFF (or ON) Select PID Controller function (OFF or ON)
ATO (or ATC) Select Air-to-Open or Air-to-Close actuator operation
LINEAR (or EQUAL 50, Select desired valve characteristic curve (linear, equal percent-
EQUAL 30, QUICK, age 50, equal percentage 30, quick opening, or custom curve).
CUSTOM) The custom curve must have been entered through the remote
PC.
TS (OFF or ON) Display and set value of tight shutoff point. Default is 0.0%
PL (OFF or ON) Display is set value of the lower software position limit stop.
Default is 0.0%
PU (OFF or ON) Display is set value of the upper software position limit stop.
Default is 0.0%
ENGLISH (or FRENCH) Select language for displays (English or French)

Table 6. Local Configuration Options

51
Procedures

To configure the SVI unit, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button. –› OPER will be displayed. Press + to get to the
–› MAN menu item.
2. Press * to move to MANUAL menu. (“POS MAN” displayed) This locks the valve in position and
places it in Manual Mode.
3. Press + twice to move to –› CONFIG option.
4. Press * to put the SVI in the configure mode and display the first item in the CONFIGURE menu.
5. If Single or Double displayed is the one desired, press + to move to the next item. If not, press *
to select the alternate choice. When OK, press + to move to next item. (Note: DOUBLE is not
presently implemented.)
6. In CTL ON (OFF), OFF should be displayed for positioner. If display shows ON press * to select
OFF. Press + to move to the next item.
7. In ATO (ATC), if option displayed is correct, press + to move to the next item. If not, press * to
select the alternate choice. When OK, press + to move to the next item.
8. In LINEAR (or other curve), if option displayed is the one desired, press + to move to the next item.
If not, press * to select the other options. When OK, press + to move to next item. If “custom” is
selected, the custom curve must have been entered through the ValVue software program. The
curve itself cannot be entered from the local pushbuttons.
9. The tight shutoff (TS) option allows the user to configure the positioner to apply full supply pres-
sure (or atmospheric pressure) to the actuator whenever the signal directs the valve “near” the
closed position. If the tight shutoff option is on, the value of the TS option determines the “near”
value at which the valve is forced fully shut. In TS OFF (ON), if status and value displayed are sat-
isfactory, press + to move to next item. If not, press * to change on/off status and display value.
Then press + or - buttons to increase or decrease value displayed. (When status is changed from
ON to OFF, no value is displayed). When value is OK, press * to accept value and move to next
item.
10. The SVI allows the user to configure a lower (PL) and upper (PU) software position limit stop. When
in operation with these limits on, the valve will not move below the lower limit stop or above the upper
limit stop. (Caution: These are software limit stops. If the SVI fails for any reason including power fail
ure or air failure, the SVI cannot enforce these limit stops and the valve will go to fail-safe.
Furthermore, the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls.
If safety requires the use of limit stops, mechanical limit stops should be used). In PL OFF (ON), if sta-
tus and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off
status and display value. Then press + or - buttons to increase or decrease value displayed. (When
status is changed from ON to OFF, no value is displayed). When value is OK, press * to accept value
and move to next item.
11. In PU OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not,
press * to change on/off status and display value. Then press + or - buttons to increase or decrease
value displayed. (When status is changed from ON to OFF, no value is displayed.) When value is OK,
press * to accept value and move to next item.
12. The SVI local display may be configured to display English or French. If the language displayed is cor-
rect, press + to move to next item. If not, press * repeatedly to display other language options. When
the desired language is displayed, press + to move to next item.
13. At –› MAN, press + to move to the top of the CONFIGURATION menu or - to move back to the pre-
vious item. To leave the CONFIGURATION menu, press *. This returns you to the MANUAL menu.
(“POS MAN” displayed)
This completes the configuration procedure
14. To continue with calibration press - to move to –› CAL option. Continue with Step 4 below.

52
 Local Calibration
NOTE:
Perform configuration before running calibration functions.

Functions
You can perform the following calibration functions with the SVI product:
• Low and high values for input signal
• Low and high values for actuator pressure output
• Set the minimum and maximum stops for valve position

Procedures
Refer to the menu structure diagrams in Figures 31 through 35 on pages 46 to 50 for assistance in fol-
lowing the procedures described.

To “calibrate” the SVI unit using the local pushbuttons, execute the following procedure:
CAUTION:
Since some calibration functions stroke the valve over its full range, the valve should be iso
lated from the process before starting calibration.

1. If in NORMAL OPERATE mode, press any button, –› OPER will be displayed. Press + to get to the
–› MAN menu item.
2. Press * to move to MANUAL MENU (POS MAN displayed)
3. Press + to move to –› CAL option.
4. Press * to go to CALIBRATE menu. STOPS will be displayed.
5. In STOPS, press * to initiate the operation, which moves the valve to fully closed, then fully open,
and then returns to the starting position. (This operation calibrates the end points for the position
feedback potentiometer.) When the operation is complete, press + to move to the next item.
CAUTION:
This function strokes the valve over its full range. Do not execute while valve is controlling the
process.

6. On some valves, the full travel is larger than the nominal travel of the valve and it may be desirable to
have the reported 100% position correspond to the nominal travel rather than the full stroke. The
STOP OP option allows this correction. If a correction is to be made, press * to move valve to the 100%
position. Using the + and - buttons, position the valve to the nominal full open position. Press * to
accept this position as the new 100% position.
7. The Bias is the signal sent to the internal I/P that causes the actuator to neither fill nor exhaust. The
pneumatics are adjusted at the factory and should not need further adjustment. If the pneumatics need
to be readjusted for any reason, the BIAS option should be selected by pressing *. This will output a
value of 2750 to the I/P. The adjustment screw on the top of the pneumatics section can be adjusted
until the valve is nearly stationary near mid travel. See “Bias Adjustment” in “Troubleshooting”. Press
+ to move to the next menu item.
8. The TUNE menu item allows the user to initiate the automatic position control tuning function which
will select appropriate PID parameters for the position controller. Press * to initiate AUTO TUNE func-
tion. This procedure may take from 1 to 5 minutes. During this time the valve will make a series of
steps (Caution: This procedure should not be performed while the valve is controlling the process.)
When the function is completed, you return to TUNE. Press + to advance to the next item.

53
9. SIG LO displays the input signal that should correspond to the full closed or full open position of the
valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is
direct or reverse). In SIG LO, if the displayed value is correct, press + to advance to the next item. If
not, press * to display value of SIG LO. Use + and – buttons to change the value. When OK, press *
to return to menu and move to next item.
10. SIG HI displays the input signal that should correspond to the full open or full closed position of the
valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is
direct or reverse. SIG HI must be larger than SIG LO by at least 5 mA. In SIG HI, if the displayed value
is correct, press + to advance to the next item. If not, press * to display value of SIG HI. Use + and –
buttons to change the value. When OK, press * to return to menu and move to next item.
11. The PRES HI menu item allows the user to enter the supply pressure. This pressure is used for scal-
ing of the pressure data in the SVI. In PRES HI, if the displayed value is correct, press + to advance
to the next item. If not, press * to display value of PRES HI. Use + and – buttons to change the value.
When OK, press * to return to menu and move to next item.
12. Calibration as a positioner is now complete. At –› MAN, press * to return to the MANUAL mode. (POS
–› MAN displayed)

Return to Normal Operation

To return to NORMAL OPERATE mode from any menu, press + or - repeatedly until –› MAN ( or –› OPER)
is displayed. If –› OPER appears, press * to return to NORMAL OPERATE mode. If –› MAN appears,
press * to return to Manual Mode Menu. Then press + repeatedly until –› OPER appears. Then press * to
return to NORMAL OPERATE mode and normal operation.

Examine
Functions
The EXAMINE menu permits you to display calibration parameters, configuration parameters, and to dis-
play and/or clear fault status messages and codes. (Refer to the Table 8 for explanations of fault mes-
sages.)

You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode. When
entered from NORMAL OPERATE mode the valve still responds to changes in set point input signal and
the values displayed change in accordance with changes in input signal.When entered from Manual mode,
the valve is locked in position.

When you exit from the EXAMINE menu, you return to the menu from which you entered.

Procedures
Examine Calibration Parameters
To examine the calibration parameters, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to
EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press +
repeatedly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *CALIB is reached. Press * to display
the list of calibration values. To move forward through the calibration parameters in sequence, press
+. To move back through the list, press –. Press * at any time to return to *CALIB in the EXAMINE
menu.

54
Examine Configuration Parameters
To examine the configuration parameters, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAM
INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated
ly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *CONFIG is reached. Press * to display
the list of configuration values.
4. To move forward through the configuration parameters in sequence, press +. To move back through
the list, press –.
5. At any time, to return to *CONFIG in the EXAMINE menu, press *.

Display/Clear FAULTS
To examine and /or clear fault codes and messages, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAM
INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated
ly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *FAULTS is reached. Press * to display
the list of status values. To move forward through the faults in sequence, press +. To move back
through the list, press –. The last item in the list is CLEAR. When this message is displayed, you can
clear all faults by pressing *. This will also return you to FAULTS in the EXAMINE menu. If you do not
want to clear all fault messages, press + or - to move to another item in the list. You can then press *
to return to FAULTS in the EXAMINE menu without clearing fault messages.

This completes the EXAMINE functions.

55
Positioner Fault Messages
Table 7 lists the fault codes/messages that may appear on the display. The table also explains the mean-
ing of each message, the probable cause of the fault, and recommended action you should take to correct
the fault.
Table 7. Positioner Fault Messages

Display Code Fault Message Meaning Latched Probable Cause

Error *
POS ERR Position Error Valve position did not Valve is stuck or
agree with SVI output feedback linkage is
command within disconnected or bro-
acceptable time ken

BIAS ERR I/P Output at null Bias is out of range Supply pressure too
point low or incorrect pneu-
is out of range ✓ matic block adjust-
ment
POS SEN Position Sensor The position sensor Failed or linkage
Error has failed or is not aligned incorrectly
aligned properly

PRES SEN Pressure Sensor The pressure sensor Failure

Error has failed

SIG SEN Current Sensor The primary signal Failure

Error (4-20) sensor has
failed

REF ERR Reference Voltage The A/D reference Failure

Error voltage is incorrect
✓
SW ERR Self Check Failure SVI failed self-check Failure
diagnostics

RESET Reset SVI has reset since Power loss

last status clear
✓
OVER RUN Data Overrun Internal check failed Hardware failure
to process data in
time

* Latched Errors are historical data that may or may not effect valve operation. To check Latched
Errors, use the “Clear Status” command via pushbuttons, valve, or HART handheld.

56
 Table 7. Positioner Fault Messages (continued)

Display Code Fault Message Meaning Latched Probable Cause

Error *

TEMP ERR Circuit Temperature Internal SVI

Error temperature out ✓
of range

WRT ERR EEP Prom Write Device failed to write Hardware failure
Failed to nonvolatile memory

TIMER SEN Watchdog Timer SVI failed to send Hardware failure

Timeout D/A output within
timeout

CAL FAIL Calibration Failed Signal or pressure Bad value set in

calibration calibration mode

STOP ERR Find Stops Failed The auto POS Pressure sensor not
calibration failed working or bias adj.
not correct, or valve
will not move

FAIL SAFE Fail-Safe Position Valve has been Primary sensor failure
placed in the fail-safe or linkage not aligned
position correctly on the
potentiometer

* Latched Errors are historical data that may or may not effect valve operation. To check Latched
Errors, use the “Clear Status” command via pushbuttons, valve, or HART handheld.

57
 Chapter 4 - Operation-SVI Controller

Introduction

NOTE: The SVI must have the controller option installed at the factory. With this option installed, the SVI
can be operated as either a positioner or controller, selectable by Val-Vue, HART Communicator or
the local pushbuttons. (Local pushbuttons support limited controller functions.)

Operation of the SVI Controller with firmware version 1.0.5 requires that all controller operating parame-
ters be entered from either ValVue software or from a HART 275 Hand Held Communicator with
Masoneilan SVI Software. The operating parameters that are used for both controllers and positioners can
be entered either from the local pushbuttons or ValVue or the Hand-held. The primary process measure-
ment, made by the process transmitter is fed to the controller as a 1-5 V dc signal and connected to ter-
minals “A” and “B” on the SVI terminal board.

An SVI with firmware version 1.0.6 allows local pushbutton entry of setpoint values and choice of local or
remote setpoint. The main controller operating parameters (P, I, D, etc.) still must be entered via ValVue
or HART Handheld Communicator.
The version 1.0.6 display shows: (1) setpoint-remote or local as configured (2) process variable (3) valve
position and (4) pneumatic output signal pressure. The display sequences from one variable to the next
every 1.5 seconds.

Using the pushbuttons, you can exit from operating mode at any time and step through a menu structure
to perform a wide range of manual operation, calibration, configuration, and monitoring functions, all of
which are described later in this section. Before you can perform any of these functions, however, you
must first ensure that the ValVue software (if used) has placed the pushbuttons in the “unlocked” mode.
(See ValVue User Manual for more details).

NOTE: If the SVI unit is specified without local pushbuttons and display, local operation is not available,
therefore, ValVue Software or a HART handheld communicator is required.

NOTE: When an SVI is turned on, it is advisable to apply the air supply before applying the electrical input
signal.

58
 Pushbuttons/Display
As shown in Figure 36, the upper line is a 7-digit numeric display and the lower line is a 7-digit alphanu-
meric display. The upper line is used for displaying values such as input signal or valve position, and the
lower one is primarily used for messages and parameter identification.

Figure 36. Local Display and Pushbuttons

The three pushbuttons perform the following functions:

• The left button, marked with *, permits you to “select” or “accept” the value or parameter option
currently displayed.
• The middle button, marked (–), permits you to move back through the menu structure to the
previous item in the menu, or to decrement the value currently shown in the digital display.
When used to decrease a displayed value, holding this button down causes the value to
decrease at a faster rate.
• The right button, marked (+), permits you to move down through the menu structure to the next
item in the menu, or to increment the value currently shown in the digital display. When used to
increase a displayed value, holding this button down causes the value to increase at a faster
rate.

To determine how to display and/or select a particular parameter value or configuration option, refer to
the menu structure diagrams in Figure 37 through Figure 42. By using these diagrams as a map, you
can quickly move through the menus to the function you want to perform.

NOTE: If the buttons are pushed after being locked by the ValVue software, the message “LOCKED” will
appear. Please refer to ValVue Software Manual to unlock pushbuttons.

59
60
Figure 36a. Hand Held
Communicator Guide for SVI
61
Figure 36b. Pushbutton Guide
for SVI Version 1.0.6
Menu Structure
The menu structure for operating the SVI from the local pushbuttons and display is shown in Figures 37
through 42 on the following pages.

Normal Operate Mode and Manual Mode Menus

Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode, the valve is placed in
the last position it was in when it left NORMAL OPERATE. When in the MANUAL mode, the device will
not respond to the 4-20 mA signals. However, the SVI unit can still respond to HART commands,
including HART commands to position the valve. Note also that when you go to EXAMINE from the
NORMAL OPERATE MODE MENU, the valve is still in “NORMAL OPERATE” mode and still responds to
the 4-20 mA signal.

Figure 37. Normal Operate, Mode Select, and Manual Mode Menus

62
Configure Menu
Because calibration depends on certain configuration options, you must perform “Configuration” before
you perform “Calibration” when installing the SVI the first time.

Figure 38. Configure Menu Structures

63
Calibrate Menu
If a change is made in the Air-to-Open/Air-to-Close or Direct/Reverse configuration options, or if you move
the SVI to a different valve or make any change to the valve position linkage, you must run the find
“STOPS” calibration again.

Figure 39. Calibrate Menu Structures

64
Controller Menu

This menu can be entered from either the MANUAL Mode Menu or the NORMAL OPERATE Mode Menu.
The Controller menu allows the user to read and change the controller mode, local setpoint, and startup
setpoint. When you exit from the CONTROLLER menu, you return to the menu from which you entered.

Figure 40. Controller Menu Structures

65
Examine Menu
This menu can be entered either from the MANUAL Mode or from the NORMAL OPERATE Mode. The
EXAMINE menu allows the user to read the current configuration, calibration, and status information.
This information, however, cannot be changed from the EXAMINE menu.

When you exit from the EXAMINE menu, you return to the menu from which you entered.

Figure 41. Examine Menu Structures

66
Parameter and Message Displays

Figure 42. Parameter and Message Displays

67
Normal Operation - Controller
Functions
In normal operation, the SVI unit operates as a controller using a local or remote input signal as set point.
The primary process measurement, made by the process transmitter, is fed to the controller as a 1-5 Vdc
signal. The local digital display sequentially displays set point-remote or local as configured, process vari-
able, valve position, and actuator pressure on a 1.5-second interval. Pressing any button moves you to
the –› OPER option in the OPERATE MODE MENU, as shown in Figure 37 on page 62.

The OPERATE MODE MENU has 4 options: –› MAN (put valve in manual mode and go to MANUAL
Menu), (CTLR (go to CONTROLLER Menu), –› EXAMINE (go to EXAMINE Menu), and –› OPER (return
to display of current position, pressure, and signal). Use the pushbuttons to move from one option to the
next. Press the * button to go to the item displayed in the menu.

Configuration
Parameters and Options Available
The Controller version of SVI must have the controller parameters configured from either Val-Vue or a
HART Hand Held Communicator. Normally all of the operating parameters will be configured from Val-Vue
or the Hand Held Communicator, however any parameters common to both the positioner and controller
versions can be entered or changed via the pushbuttons. Controller setpoint values and selection of local
or remote setpoint can also be entered via the pushbuttons. You can configure the following options by
pressing the local pushbuttons in the procedure described below. We recommend that you use the menu
structure diagrams in Figures 37 through 42 (pages 62 to 67) as a road map in following the procedures
described.

As noted previously, configuration should be performed before calibration. Also note that configuration
can be performed only when the valve is in manual mode.

The configurable options are as described in Table 8.

MENU ITEM DESCRIPTION OF OPTIONS

SINGLE (or DOUBLE) Select single or double acting actuator (not presently available)
CTL OFF (or ON) Select PID Controller function (OFF or ON)
ATO (or ATC) Select Air-to-Open or Air-to-Close actuator operation
LINEAR (or EQUAL 50, Select desired valve characteristic curve (linear, equal percent-
EQUAL 30, QUICK, age 50, equal percentage 30, quick opening, or custom curve).
CUSTOM), L-RECIP The custom curve must have been entered through the remote
PC.
TS (OFF or ON) Display and set value of tight shutoff point. Default is 0.0%
PL (OFF or ON) Display is set value of the lower software position limit stop.
Default is 0.0%
PU (OFF or ON) Display is set value of the upper software position limit stop.
Default is 100.0%
ENGLISH (or FRENCH) Select language for displays (English or French)

Table 8. Local Configuration Options

68
Procedures
To configure or modify the SVI controller pushbutton configurable parameters, execute the following pro-
cedure:
1. If in NORMAL OPERATE mode, press any button. –› OPER will be displayed. Press + to get to the
–› MAN menu item.
2. Press * to move to MANUAL menu. (“POS MAN” displayed) This locks the valve in position and
places it in Manual Mode.
3. Press + twice to move to –› CONFIG option.
4. Press * to put the SVI in the configure mode and display the first item in the CONFIGURE menu.
5. If Single or Double displayed is the one desired, press + to move to the next item. If not, press * to
select the alternate choice. When OK, press + to move to next item. (Note: DOUBLE is not pres-
ently implemented.)
6. In CTL ON (OFF), ON should be displayed for controller. If display shows OFF press * to select ON.
Press + to move to the next item. NOTE: Any SVI that has been factory set for controller operation
can be operated as a positioner by simply changing CTL ON-OFF back to OFF.
7. In ATO (ATC), if option displayed is correct, press + to move to the next item. If not, press * to select
the alternate choice. When OK, press + to move to the next item.
8. In LINEAR (or other curve), if option displayed is the one desired, press + to move to the next item. If
not, press * to select the other options. When OK, press + to move to next item. If “custom” is select-
ed, the custom curve must have been entered through the ValVue software program. The curve itself
cannot be entered from the local pushbuttons.
9. The tight shutoff (TS) option allows the user to configure the positioner to apply full supply pressure
(or atmospheric pressure) to the actuator whenever the signal directs the valve “near” the closed pos-
ition. If the tight shutoff option is on, the value of the TS option determines the “near” value at which
the valve is forced fully shut. In TS OFF (ON), if status and value displayed are satisfactory, press +
to move to next item. If not, press * to change on/off status and display value. Then press + or - but-
tons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is
displayed.) When value is OK, press * to accept value and move to next item.
10. The SVI allows the user to configure a lower (PL) and upper (PU) software position limit stop. When
in operation with these limits on, the valve will not move below the lower limit stop or above the upper
limit stop. (Caution: These are software limit stops. If the SVI fails for any reason including power fail
ure or air failure, the SVI cannot enforce these limit stops and the valve will go to fail-safe.
Furthermore, the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls.
If safety requires the use of limit stops, mechanical limit stops should be used). In PL OFF (ON), if sta-
tus and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off
status and display value. Then press + or - buttons to increase or decrease value displayed. (When
status is changed from ON to OFF, no value is displayed.) When value is OK, press * to accept value
and move to next item.
11. In PU OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not,
press * to change on/off status and display value. Then press + or - buttons to increase or decrease
value displayed. (When status is changed from ON to OFF, no value is displayed.) When value is OK,
press * to accept value and move to next item.
12. The SVI local display may be configured to display English or French. If the language displayed is co-
rrect, press + to move to next item. If not, press * repeatedly to display other language options. When
the desired language is displayed, press + to move to next item.
13. At –› MAN, press + to move to the top of the CONFIGURATION menu or - to move back to the previ-
ous item. To leave the CONFIGURATION menu, press *. This returns you to the MANUAL menu.
(“POS MAN” displayed). This completes the configuration procedure.

69
 Controller Functions

If the controller set point parameters were not set during initial configuration using Val-Vue or HART Hand
Held, they may be set by the following procedure.

1. Press + to move to CONTROLLER Menu

2. Press * to toggle between “REMOTE” AND “LOCAL.” Leave on desired action and press + to move to
SETPOINT.
3. Press + or - to enter new value. Press * to exit back to SETPOINT. Press + to move to “I SETPOINT.”
4. Press + or - to enter new value. Press * to exit back to I SETPOINT. Press + to move to “CANCEL.”
5. Press * to return to NORMAL or MANUAL Menu without saving changes. Press + to move to “OK.”
6. Press * to return to NORMAL or MANUAL Menu with changes saved.
7. To continue with calibration press - twice to move to –› CAL option. Continue with Step 4 below.

Local Calibration
NOTE: Perform configuration before running calibration functions.

Functions
You can perform the following calibration functions with the SVI product:

• Low and high values for input signal

• Low and high values for actuator pressure output
• Set the minimum and maximum stops for valve position

Procedures
Refer to the menu structure diagrams in Figures 37 through 42 (pages 62 to 67) for assistance in follow-
ing the procedures described.

CAUTION:
Since some calibration functions stroke the valve over its full range, the valve should be isolated from the
process before starting calibration.

To “calibrate” the SVI unit using the local pushbuttons, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button, (OPER will be displayed.) Press + to get to the
–› MAN menu item.
2. Press * to move to MANUAL MENU (POS MAN displayed.)
3. Press + to move to –› CAL option.
4. Press * to go to CALIBRATE menu. (STOPS will be displayed.)
5. In STOPS, press * to initiate the operation, which moves the valve to fully closed, then fully open, and
then returns to the starting position. (This operation calibrates the end points for the position feedback
potentiometer.) When the operation is complete, press + to move to the next item.

CAUTION:
This function strokes the valve over its full range. Do not execute while valve is controlling the process.

70
6. On some valves, the full travel is larger than the nominal travel of the valve and it may be desirable
to have the reported 100% position correspond to the nominal travel rather than the full stroke. The
STOP OP option allows this correction. If a correction is to be made, press * to move valve to the
100% position. Using the + and - buttons, position the valve to the nominal full open position. Press *
to accept this position as the new 100% position.
7. The Bias is the signal sent to the internal I/P that causes the actuator to neither fill nor exhaust. The
pneumatics are adjusted at the factory and should not need further adjustment. If the pneumatics
need to be readjusted for any reason, the BIAS option should be selected by pressing *. This will out
put a value of 2750 to the I/P. The adjustment screw on the top of the pneumatics section can be
adjusted until the valve is nearly stationary near mid travel. See “Bias Adjustment” in
“Troubleshooting”. Press + to move to the next menu item.
8. The TUNE menu item allows the user to initiate the automatic position control tuning function which
will select appropriate PID parameters for the position controller. Press * to initiate AUTO TUNE func-
tion. This procedure may take from 1 to 5 minutes. During this time the valve will make a series of
steps (Caution: This procedure should not be performed while the valve is controlling the process.)
When the function is completed, you return to TUNE. Press + to advance to the next item.
9. SIG LO displays the input signal that should correspond to the full closed or full open position of the
valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is
direct or reverse). In SIG LO, if the displayed value is correct, press + to advance to the next item. If
not, press * to display value of SIG LO. Use + and – buttons to change the value. When OK, press *
to return to menu and move to next item.
10. SIG HI displays the input signal that should correspond to the full open or full closed position of the
valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is
direct or reverse). SIG HI must be larger than SIG LO by at least 5 mA. In SIG HI, if the displayed
value is correct, press + to advance to the next item. If not, press * to display value of SIG HI. Use +
and – buttons to change the value. When OK, press * to return to menu and move to next item.
11. The PRES HI menu item allows the user to enter the supply pressure. This pressure is used for sca-
ling of the pressure data in the SVI. In PRES HI, if the displayed value is correct, press + to advance
to the next item. If not, press * to display value of PRES HI. Use + and – buttons to change the value.
When OK, press * to return to menu and move to next item.
12. Calibration as a positioner is now complete. At –› MAN, press * to return to the MANUAL mode. (POS
MAN displayed)

71
Return to Normal Operation
To return to NORMAL OPERATE mode from any menu, press + or - repeatedly until –› MAN ( or –› OPER)
is displayed. If –› OPER appears, press * to return to NORMAL OPERATE mode. If –› MAN appears,
press * to return to Manual Mode Menu. Then press + repeatedly until –› OPER appears. Then press *
to return to NORMAL OPERATE mode and normal operation.

Examine
Functions
The EXAMINE menu permits you to display calibration parameters, configuration parameters, and to dis-
play and/or clear fault status messages and codes. (Refer to Table 9 for explanations of fault messages.)

You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode. When
entered from NORMAL OPERATE mode the valve still responds to changes in set point input signal and
the values displayed change in accordance with changes in input signal.When entered from Manual mode,
the valve is locked in position.

When you exit from the EXAMINE menu, you return to the menu from which you entered.

Procedures
Examine Calibration Parameters
To examine the calibration parameters, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAM-
INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeat
edly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *CALIB is reached. Press * to display
the list of calibration values. To move forward through the calibration parameters in sequence, press
+. To move back through the list, press –. Press * at any time to return to *CALIB in the EXAMINE
menu.

Examine Configuration Parameters

To examine the configuration parameters, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAM-
INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated
ly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *CONFIG is reached. Press * to display
the list of configuration values.
4. To move forward through the configuration parameters in sequence, press +. To move back through
the list, press –.
5. At any time, to return to *CONFIG in the EXAMINE menu, press *.

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Display/Clear FAULTS

To examine and /or clear fault codes and messages, execute the following procedure:

1. If in NORMAL OPERATE mode, press any button.

2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to
EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press +
repeatedly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
3. Press + repeatedly to move through the EXAMINE menu until *FAULTS is reached. Press * to dis-
play the list of status values. To move forward through the faults in sequence, press +. To move
back through the list, press –. The last item in the list is CLEAR. When this message is displayed,
you can clear all faults by pressing *. This will also return you to FAULTS in the EXAMINE menu.
If you do not want to clear all fault messages, press + or - to move to another item in the list. You
can then press * to return to FAULTS in the EXAMINE menu without clearing fault messages.
This completes the EXAMINE functions.

73
Controller Fault Messages
Table 9 lists the fault codes/messages that may appear on the display. The table also explains the mean-
ing of each message, the probable cause of the fault, and recommended action you should take to correct
the fault.

Table 9. Controller Fault Messages

Display Code Fault Message Meaning Latched Probable Cause

Error *
POS ERR Position Error Valve position did not Valve is stuck or
agree with SVI output feedback linkage is
command within disconnected or bro-
acceptable time ken

BIAS ERR I/P Output at null Bias is out of range Supply pressure too
point low or incorrect pneu-
is out of range ✓ matic block adjust-
ment
POS SEN Position Sensor The position sensor Failed or linkage
Error has failed or is not aligned incorrectly
aligned properly

PRES SEN Pressure Sensor The pressure sensor Failure

Error has failed

SIG SEN Current Sensor The primary signal Failure

Error (4-20) sensor has
failed

REF ERR Reference Voltage The A/D reference Failure

Error voltage is incorrect
✓
SW ERR Self Check Failure SVI failed self-check Failure
diagnostics

RESET Reset SVI has reset since Power loss

last status clear
✓
OVER RUN Data Overrun Internal check failed Hardware failure
to process data in
time

74
 Table 9. Controller Fault Messages (cont.)

Display Code Fault Message Meaning Latched Probable Cause

Error *

TEMP ERR Circuit Temperature Internal SVI

Error temperature out ✓
of range

WRT ERR EEP Prom Write Device failed to write Hardware failure
Failed to nonvolatile memory

TIMER SEN Watchdog Timer SVI failed to send Hardware failure

Timeout D/A output within
timeout

CAL FAIL Calibration Failed Signal or pressure Bad value set in

calibration calibration mode

STOP ERR Find Stops Failed The auto POS Pressure sensor not
calibration failed working or bias adj.
not correct, or valve
will not move

FAIL SAFE Fail-Safe Position Valve has been Primary sensor failure
placed in the fail-safe or linkage not aligned
position correctly on the
potentiometer

75
Operation - SVI Positioner / Controller using HART Handheld
Communicator
A HART 275 Handheld Communicator with Masoneilan SVI Software can be used to set up and calibrate
an SVI Positioner or Controller. It’s capabilities extend well beyond the range of pushbutton functions in
that it allows positioner tuning and controller tuning parameters to be individually entered, and it also sup-
ports limited diagnostics.

Refer to HART Communicator Manual MAN 4250 for basic instructions on using the Handheld communi-
cator. The manual covers General Instructions, Hot Key customization, connections, and Off-line func-
tions.

The menu structure on Page 60 is a guide to all the operations which can be performed on both SVI
Positioners and SVI Controllers using the HART Handheld.

Operation - SVI Positioner / Controller using ValVue Software

Use of ValVue Software provides the most comprehensive menu selections for configuring, calibrating and
monitoring the SVI Positioner and Controller. All operating and calibration parameters be entered and
additionally a very comprehensive diagnostics program is available. The diagnostics program allows
recall of stored test data to compare current performance of the valve, positioner and actuator with previ-
ous test results or factory data.

Operation of the SVI Positioner and Controller with ValVue is covered in the separate manual furnished
with ValVue software.

76
 Chapter 5 - Troubleshooting

Introduction
This section of the manual offers procedures and options to confirm setup and configuration and allows
you to exhaust many service options before seeking assistance from a factory-trained technician. By first
following these procedures, you can save time, prevent costly downtime, and provide the service techni-
cian with more detailed information about the possible problem.

Although this section is written primarily for use with the pushbutton/local display version of the SVI
Positioner, it also applies to Val-Vue and HART handheld operation and in applicable areas, to the PID
Controller version.

Factory Service
Trained service personnel perform high-level SVI troubleshooting and servicing. Should the SVI unit
require replacement of internal parts, the unit will be replaced with a new or rebuilt unit. An extensive
replacement inventory is available for immediate shipment. If this service is needed, contact your local
salesperson or contact Masoneilan Dresser at www.masoneilan.com.

Common Problems
The troubleshooting checklist guides the user through a number of possible faults. However prior to utiliz-
ing this list, the user should make an initial assessment of the installation; looking at the following items:

● Is the mounting of the SVI correct and the linkage orientation proper? Are all linkage mechanical
connections securely tightened?

● Are all pneumatic connections tight and is the supply pressure the correct value for actuator being
used?

● Are electrical connections made to the correct terminals and securely tightened?

● Assuming the display is active, the user should carefully check that all configuration parameters
are compatible with the valve under control and properly entered in to the positioner.

● If the SVI has been under control of ValVue and left in the full open or full closed position, the
buttons cannot take control of position in the Manual Mode. To regain control, go to Normal Mode
in ValVue and then to Manual before exiting ValVue or power down/power up the SVI.

77
 Pneumatic Connections
The SVI requires a regulated air supply of clean, dry, oil-free instrument air conforming to the requirements
od ISA-S-7.3, Quality Standard for Instrument Air. Figure 43 shows the locations of supply, output,and
exhaust connections on the pneumatic block.

Figure 43. Exhaust, Actuator and Air Supply Connections

Additionally the following conditions must be met:

• Ensure that the exhaust port can vent to atmosphere (e.g., no obstructions or foreign matter block-
ing ports).

• Connect the actuator port (behind the pneumatic block) to the actuator. For best response times
use 3/8 tubing.

• Confirm that the supply pressure gauge reads the supply pressure and that the supply pressure
registers 20 psi minimum. (Actual supply pressure used is a function of actuator supply rating).

• Momentarily disconnect the supply current (voltage) to the SVI and verify that the output pressure
registers close to 0 psi and that the valve sits against a stop.

Note: Air-to-open (ATO) requires a normally closed valve; Air-to-close (ATC) requires a normally open
valve.

78
 Supply Pressure
SVI requires sufficient supply pressure to drive the valve against the stops. For best results the supply
pressure should be 5 to 10 psi higher than the actuator nominal pressure range as shown on the data
plate.

For example, if the spring range is 11-23 psi, set supply to between 28 and 33 psi. The maximum pres-
sure rating of the SVI is 100 psi; however in most cases the actuator pressure rating is the controlling fac-
tor in determining supply pressure. If pressures higher than 100 psi are required, consult factory.

DANGER:
Never exceed actuator or SVI maximum pressure. Damage to equipment or injury to personnel may result.
Verifying Supply Pressure
The following procedure may be used to verify whether supply pressure is sufficient to drive valve against
stops.

Close the holes in the exhaust plug by blocking air path. The output pressure should slowly rise to supply
pressure and the valve should drive to the high pressure stop.

• If output pressure does not go to or close to supply pressure, there may be a leak within the pneu-
matic block. Consult Factory.

• If the valve does not drive against the stops when the output gauge reads a pressure higher than
the actuator specification, then the actuator may be defective or improperly installed, the valve
may be jammed due to improperly installed packing, or the valve body contains an obstruction.

79
 Electrical Connections
The SVI requires an electrical input from a 4-20 mA current source or a voltage input from a 12/24 V dc
Multidrop supply. The 4-20 mA signal can provide both operating power and signal information, or if a dig-
ital input signal is used, provide only operating power. The 12/24 V dc Multidrop supply can be used only
when the input signal is digital. Selection of current or voltage input is by position of a jumper on the main
terminal board. See Figures 44 and 44a.

Caution:
Make sure the voltage/current jumper is in the proper position (V or mA) before applying power . Failure to do
so may result in damage to the SVI.

Figure 44. Wiring Connections

80
The terminal board shown in Figure 44a reflects a design change to be released in early 1999 which incor-
porates the following enhancements.

• Additional terminals D and E allow the contact input feature to be used with the controller
option.
• Optional terminals POS + and POS - provide an isolated 4-20 mA signal related to charac-
terized valve stem position. The voltage compliance of the position output terminals is 11-50
V dc. The HART® signal is not available on the position terminals. The HART protocol is
available on the +/- LOOP terminals.
• The software revision reported by the HART ID command is 6.

Figure 44a. Wiring Connections - 1999 Release

81
 The SVI is polarity sensitive so the positive lead must be connected to the positive (+) terminal and the
negative lead to the negative (-) terminal. Reversal of input will not cause damage but the unit will not func-
tion.

Verify Wiring and Connections

Check that the SVI is properly powered per following:

Connect a dc voltmeter across the input terminals.

Note: Test pins, located adjacent to the terminal strip facilitate connection of the voltmeter. For any input
current value between 3.8 and 22 mA the voltage should be between 9.5 and 11 V.

• If voltage exceeds 11.5 V check that polarity is correct and that V/mA jumper is in correct
position.

• If voltage is less than 9.5 volts and polarity and jumper are correct, voltage compliance of
current source may be inadequate. Connect milliammeter in series with current signal and
verify that source can supply 20 mA to SVI input. If 20 Ma is not attainable, current source
may be inadequate for this type of service, or other loads or inclusion of Intrinsic Safety
barriers may be limiting the source drive capability.

Ground Practice
Make sure that case, signal and if utilized, process controller, ground connections are made in compliance
with plants normal grounding practices.

The case grounding screw is located on the outside of the case to the lower right of the display cover.
Signal grounding should follow normal rules for the facility. Any point in the loop may be referenced to
ground but there should never be more than one ground point.

If the SVI has the Process Controller option, auxiliary terminal “B” must be connected to the same ground
reference as the negative input current terminal.

Note: Improper or inadequately grounded installations may cause noise in or instability of the control
loop.

If noise or instability are present, set positioner to “Manual Mode” of operation and manually position valve
over its entire range. If valve is stable in manual mode, then problem may be noise in control loop. Re-
check all wiring connections and ground points. If noise and instability are still present in manual mode,
problem is most likely with electronics module. Consult Factory.

82
 HART Compliance
SVI requires a HART-compliant communications loop. The HART protocol specifies the noise level,
impedance requirements and configuration of the loop.

Note: When an intrinsically safe barrier separates the communicating device, a HART-compliant barrier
must be used.

Conventional current output loops consisting of the following components usually meet requirements for
HART compliance.

• Quality current source (e.g. low noise, high impedance)

• Minimum loop impedance of 250 ohms
• Twisted pair cable suitable for 4-20 mA current loops

Note: If there are suspected HART compliance problems, prepare a detailed description of the loop,
including all devices on the loop, type of wiring used, loop length, and presence of any possible
interference sources before contacting the factory for assistance.

Power-on Check
After checking pneumatic and electrical connections, apply power to the SVI.

Restoring power will result in one of five possible images on the local display.

• 1RUPDO

• %ODQN

• ³)DLO6DIH´

• 5DQGRPVHJPHQWVGLVSOD\HG

• ³5HVHW´

The normal display is an alpha-numeric reading in the manual or operate mode. The display may
sequence between three variables (four in controller) at a 1.5 second rate.

If a normal display is seen, no further action is required.

If the display is not normal, go to appropriate problem listing in “Troubleshooting Checklist”.

83
 TROUBLESHOOTING CHECKLIST

PROBLEM POSSIBLE CAUSE ACTION

Totally unresponsive SVI; Instrument not receiving
no display on LCD read- power due to:
out • Improper Wiring See “Electrical
Connections”

• Faulty Electronics Contact Factory Service

module
LCD readout shows ran- • Faulty Electronics Contact Factory Service
dom segments module
LCD readout active with • Pneumatic supply/ See “Pneumatic
unresponsive or incorrect connection problem Connections”
valve position
• Improper Configuration See “Testing valve
Performance” and
• Improper Calibration / continue with sections
Bias Error following

“FAILSAFE” shown on • Potentiometer shaft Check that mounting and

display orientation or linkage linkage are correctly
incorrect installed. Refer to
“Mounting” in instructions

• Hardware/Software Use “Examine” menu to

fault view error(s). Take
required corrective
action. See “Fail-Safe
Display”
“RESET” appears on • Momentary display on
display power-up is normal

• Continued display Contact Factory Service

indicates problem

84
 TROUBLESHOOTING CHECKLIST (CONT.)
PROBLEM POSSIBLE CAUSE ACTION
Valve will not stroke over • Insufficient compliance See “Electrical
full travel range voltage from current Connections”
source

• Potentiometer shaft Check that mounting and

orientation or linkage linkage are correctly
incorrect installed. Refer to
“Mounting” in instructions

• Insufficient pressure to See “Pneumatic

fully stroke actuator Connections”

• Incorrect software See “confirming

position limits Configuration...”

Valve position exhibits • Improperly grounded See “Electrical

unstable oscillation or unit Connections”
hunting behavior
• Slipping or loose Check and tighten
linkage

• Defective spool sub- See “Spool Valve

assembly Maintenance”

• Incorrect positioner See “Testing Valve

PID values Performance”

Valve works for some • Potentiometer shaft Check that mounting and
input values, and goes orientation or linkage linkage are correctly
to “Fail-Safe” operation incorrect installed. Refer to
for others “Mounting” in instructions

• Linkage produces more Check that mounting and

than 120 degrees of linkage are correct for
potentiometer shaft actuator travel
rotation

85
Testing Valve Performance
The following preliminary valve performance test checks the physical part of the system and isolates sev-
eral potential problems. It bypasses the microprocessor configuration.

1. Place the SVI in Manual mode using pushbuttons, Val Vue or handheld. If using pushbuttons, in
Manual mode select “POS MAN”

2. By holding the “+” and “-” buttons down confirm that the valve moves to open and closed positions.
This may take some time with a large actuator. (If using ValVue or handheld, use the “FULL OPEN”
and “FULL CLOSED” commands).

• If the valve correctly performs the open/close command in manual mode, continue
with “Confirming Configuration” procedure below.

• If the valve does not perform the open/close command, review the following:

1. Confirm that the air pressure is on, set to proper pressure and connected to proper port.

2. Check that spool valve is not sticking. Refer to “Spool Valve Maintenance” on Page.

3. See “Bias Adjustment” on Page 92 and adjust bias if necessary.

4. If “FAILSAFE” shows on display refer to “FAILSAFE” on Troubleshooting Checklist for appropriate

action.

5. If items 1, 2, 3, and 4 above are OK, the EPC (electropneumatic converter) may be faulty.
SVI must be returned to factory for service on this component.

Confirming Configuration, Setup, Calibration, and Limit Stops

If the valve has performed properly in the manual mode, continue with following procedure. This series of
checks confirms proper configuration, setup, calibration, and establishes parameters for further testing.

1. Place the SVI in the Manual Mode using ValVue, the handheld, or the pushbuttons.

2. Check the following conditions:

• Confirm the accuracy of configuration and setup parameters by going to “Configure”

and “Calibrate” menus and verifying that the parameters are correct.

• Run “Find Stops”.

• Perform an “Auto Tune” from the Calibration section.

• If continuing to experience problems, run “AutoTune” again. If using ValVue or the

handheld set the PID parameters to values recommended in the PID parameters list.
If problems persist, consult factory.

3. If above test results are satisfactory, continue with “Initiate Valve Movement (50%)”

86
Initiate Valve Movement (50%)
Use the series of checks in this procedure to confirm that the configuration is correct.

1. Place the SVI in Manual Mode using ValVue, handheld or the pushbuttons. Set the
position setpoint to 50%.

2. Confirm whether valve moved to set position.

• If valve is in proper position; continue with Initiate Valve Movement (95%)

procedure below.

• If valve is not in proper position, set to full open and check whether position is at
100%. If not, re-run “Find Stops”. If this does not correct problem return unit to
factory.

• If valve oscillates review the following conditions:

1. Check for improper tuning. Perform either another Auto Tune or if ValVue or handheld are
available, input manual values from the parameters table and re-test.
(Manually inputting values of P=50, I=100, D=10, Padj=0, Beta=8, PosComp=6, and
Damping=0 should produce stable but perhaps sluggish operation on any valve.)

2. Check that ground connections are made to correct ground points and that connections are
secure.

3. Check the linkage between the position sensor and valve for excessive play.

4. Check that spool valve is not sticking.

5. Check for excessive friction in the valve packing; it is one cause of limit cycling.

Limit cycling can be caused by tight valve stem packing, an undersized actuator,
or foreign material in the spool valve. Identify limit cycling conditions by a process
of elimination (e.g. not noise, not oscillation). Install valve packing only tight
enough to prevent leakage. Evaluate the valve packing by running the ValVue
diagnostic program to determine if the friction is consistent with the type of valve.
If you determine that the spool valve is the source of limit cycling, it should
be cleaned or replaced.

Initiate Valve Movement (95%)

Use this procedure to confirm that the SVI and valve systems are performing properly.

1. Place the SVI in Manual mode using ValVue, handheld or the pushbuttons. Set the
position setpoint to 95%.

2. Confirm that valve is in the set position (95%).

• If valve is in proper position, the SVI and valve systems are functioning properly.
Place the SVI in “OPERATE” mode. It is recommended that if possible the valve be
cycled through its full stroke using the control room 4-20 mA source. This will verify

87
 that the valve control loop is not noisy and that compliance voltage is high enough to
properly drive the SVI.

• If the valve does not travel to 95%, review the following:

1. Check that air supply pressure is adequate for actuator.

2. Repeat previous tests as necessary to determine cause of problem. If consistent

and proper operation cannot be obtained, return SVI to factory.

Fail-Safe Display
A reading of Fail-Safe on the display indicates a fatal or non-fatal error in the SVI and acknowledges that
the computer holds the output in a fail-safe condition. Use the pushbuttons, Hand Held or ValVue to see
the cause of the fail-safe condition, a list of error codes, and the necessary corrective action.

Note: Not all errors are fatal (e.g., not all errors cause a fail-safe condition.)

Latches:

Certain errors occur and self-correct. The SVI clears the bit in the status when the error disappears and
uses latches to show you an error occurred (although it is not currently an error). Errors that latch include
RESET, POSSEN, PRESSEN, REFERR, and TEMPERR. Table contains a description of fatal and non-
fatal SVI errors. The following list of error latches defines each term:

DRIFT Drifting of bias

HARTERR Continuous communication error
HWERR Hardware failed self-check
OVERRUN Data overrun error (processor error)
POSERR Position error
POSSEN Position sensor error
PRESSEN Pressure sensor error
REFERR Reference voltage error
RESET Reset occurred
SIGSEN Current sensor error
STOPERR Find stops procedure failed
SWERR Software error
TEMPERR Circuit board temperature out of range
WRT ERR A write to the EPROM failed

88
 AutoTune
Running the positioner AutoTune procedure automatically determines position control parameters such as
P, Padj, I, D, and dead zone. If the SVI is a Positioner/Controller model running autotune sets the posi-
tioner tuning parameters; the controller tuning parameters have to be entered via a Hand Held or ValVue.

Note: Confirm that the Bias settings appear in a reasonable range, with a low signal-noise level, before
running AutoTune.

AutoTune Procedures
Initiate positioner AutoTune either by selecting the AutoTune button in the ValVue SVI Calibration Window
or by using the SVI local buttons (Refer to Calibrate menu in Operation section of manual) or by initiating
auto tuning from the hand-held. The AutoTune procedure includes three steps:

• Bias search
• Estimate control parameters
• Refine control parameters

In Bias Search, the SVI local displays values (such as 23530 and 27610) that approach, or converge on,
a real Bias value. Expect the valve to move back and forth, slow down, and remain still by the end of this
step.

In estimating control parameters, SVI displays three types of values: input step sizes (such as 80 and 320),
valve relative opening (such as 1874 and 1756), and dead time (such as 4.00 and 7.00). Expect the valve
to move back and forth several times. SVI uses these tests to estimate the preliminary control parameters
based on position control characteristics.

In refining the estimated control parameters, SVI displays several numbers (such as 1211 and 6). Interpret
the number 1211 as the rising time (T98 is 12 x 0.05 sec = 0.6 sec) and overshoot is 11%. The code num-
ber 6 indicates a specific control parameter adjustment.

89
 Auto Tune Results
A successful AutoTune provides position step responses, in both air fill and exhausting directions, that
meet the tuning criteria. Overshoots range between 0 and 8%, and rising times range from 0.3 second for
a small actuator to 1.5 second for a large actuator. A successful AutoTune updates the previous control
parameters.

AutoTune usually results in fast position responses (0 to 8% overshoots). If you prefer a smooth response
without overshoots, reduce the P value by 10 to 20%. If you prefer a slow response, set the damping coef-
ficient at 1 to 9 (e.g., zero equals no damping, 9 equals maximum damping)

Damping Coefficient
The following chart lists the damping coefficient, which displays after AutoTune and indicates the AutoTune
result:

Damping
Coefficient Message Action
0 Self-tuning is successful None

44 Bias searching fails after 20 Stabilize the SVI in the

times trying range between 20-80% open
and wait until the valve is
stable at its setpoint. Then
re-run the self-tuning again.

55 The found Bias is not in the Adjust the Bias

required range, and
self-tuning is cancelled

66 Self-tuning for air fill direction Check supply pressure;

fails after 30 times trying check noise; check the
pneumatic block, especially
spool S/A

77 Self-tuning for air exhausting Check the pneumatic block,

direction fails after 30 times especially spool S/A
trying

Note: The Damping Coefficient adjustment range is 0 to 9. The out-of-range value is equivalent to 0, or
no damping.

90
 Unacceptable Response Characteristics
Valve position responses depend on many factors including the condition of the valve, actuator, and
process; ambient temperature; noise; the SVI itself; supply pressure; and the setup and step change size
for the positioner control parameters.

Note: A 5% step change should be made when the valve is in the 20 to 80% opening range.

With damping coefficient of zero (no damping), consider the following valve responses unacceptable:

• Overshoot greater than 20%

• Rising time (T98) greater than 1.5 seconds for small actuators and 2.5 seconds for large
actuators
• Dead time greater than 0.5 seconds
• Limit cycling peak-to-peak measurement greater than 0.5%
• Position steady-state error greater than 0.5% if the dead zone is less than 0.2%.

Position Instability
The possible sources of position instability include:

• Control loop (measurement) noise

• Process noise
• Line frequency noise
• Oscillation
• Limit cycling

Control loop noise only appears in the Normal mode (never the Manual mode). For best control, reduce
control loop noise by re-tuning the process controller (in the SVI or an external controller). You may also
dampen the SVI response.

Process noise results from process pressure and flow changes that apply forces to the valve plug and
cause changes in position. Although the SVI restores the plug position, the response is not instantaneous.

Poor grounding of the signals and case, or power supply ripple in the 4-20 mA control signal, can intro-
duce line frequency noise. Line frequency noise converts to low-frequency noise when a noisy signal sam-
pling occurs during a period not integrally related to the line frequency. The resulting frequency measures
more than 1 Hz, a frequency too high for resolution by the process trend record.

A pulsating sound of escaping air at the exhaust port usually indicates line frequency noise. In extreme
cases, the valve stem may appear to pulsate

Correct a line frequency noise problem by proper grounding (page 82) or by eliminating ripple noise from
the current source. (HART compliance requires less than 4 *A of current ripple).

91
 Oscillation
If using a HART Communicator or ValVue, set the following values to identify PID oscillation: If SVI is push-
button model, re-run auto-tune. If oscillations persist contact factory.

P = 20 Padj = 0
I = 0 Beta = 0
D=0 Damping = 0
Dead zone = 0 Position Compensation Coefficient = 0

If the position remains stable, then the problem is related to the positioner settings of the PID. Re-run
AutoTune.

Limit Cycling
The characteristics of limit cycling include at least a 4-second period and a squared off (as opposed to
sinusoidal) trend record. Excessive friction in the valve/actuator assembly, or dirt in the spool valve assem-
bly, can cause limit cycling. The SVI diagnostic identifies excessive friction in the valve/actuator assembly
as a reported friction value greater than 30% of the actuator span.

Bias Adjustment
Masoneilan adjusts the bias of the pneumatic block at the factory in order to accommodate most environ-
mental effects. This setting usually makes bias adjustment neither necessary or desirable. Situations do
arise, however, when bias adjustment becomes necessary. For example, after replacing the spool valve,
or when the unit experiences extreme environmental conditions, adjusting the bias can optimize position-
er performance.

For either of the following cases, do not adjust bias:

• After calibrating the limit stops of the valve and setting the parameters, an offset may occur between
the SVI position indicated on ValVue (or in the push-button display) and the actual valve position.

• On start-up, after leaving the unit without power for an extended period of time, an offset sometimes
occurs between the signal and actual valve position. On startup, this offset begins moving slowly. This
offset exists because the present bias setting differs from the setting recorded when the unit last saved
the bias.

Note: These offsets resolve themselves because the SVI saves the bias value every hour, which
provides a more accurate signal/valve position reading. For more rapid adjustment, select the
Calibrate screen and return to Manual Mode which automatically saves the value.

For the following case bias may need to be adjusted:

If full open or full close won't cause the valve to move fully to the stops, you may need to adjust the bias.

92
 Bias Adjustment Procedure
An SVI-generated pilot pressure controls the spool position. The pilot pressure range is displayed as a
dimensionless value between 0 and 5500. The exact number can be displayed when using ValVue or a
Handheld Configurator for calibrating the SVI. The value is not displayed when using pushbuttons, but is
automatically set to the calibrate value of 2750 when in bias adjust mode.

If using pushbutton model SVI, follow menu steps to "CAL" and then to "BIAS" . Press the "*" button.

If using Handheld or ValVue, go to manual screen, click Calibrate button, enter 2750 in "Output Value to
I/P" box, then click on "Output"

Note valve position. If near to 50%, adjustment is not required. If adjustment is required, using a 7 mm
open end wrench, remove the cap nut on the top of the pneumatic block and loosen the locknut. Using a
2 mm hex wrench, adjust the bias screw until the valve is at 50% position and stable. If movement of the
adjusting screw does not re-position valve, return unit to factory for servicing.

After adjustment is complete, tighten locknut and replace cap nut.

Spool Valve Maintenance

If troubleshooting procedures have shown the spool valve to be a suspect component, use the following
procedures to clean the pilot subassembly and replace deteriorated parts.

This procedure describes the steps necessary to disassemble the spool valve. To minimize maintenance
time, Masoneilan recommends replacing the entire pilot subassembly. Using a replacement subassembly
allows you to work on the old unit as time permits. Prior to any disassembly, make sure new "O" rings of
proper material are available. The old rings should not be re-used.

Warning:
Cleaning the pilot subassembly and replacing deteriorated parts requires shutting down the positioner and
isolating the valve from the process. Failure to do so can result in damage to the system or personal injury.

Figure 45 illustrates the components of the pilot subassembly.

Figure 45. Pilot Subassembly

93
 Disassembly Procedure
Completely shut down the SVI.

• Isolate the valve from the process

• Put the positioner out of service

• Shut off air supply

• Install warning signs or lockouts as necessary to ensure against accidental re-activation of SVI.

WARNING:
Failure to completely shut down SVI can damage the system or result in personal injury.

Unscrew pilot subassembly and disengage it from the body.

Note: Turn the pilot subassembly while removing to prevent damage to "O" rings.

Remove the end plug and withdraw the spring, plug, and extension pin. Do not disassemble or adjust the
extension pin.

Wipe the parts with a clean soft cloth and blow clean compressed air through the orifices. Clean all sur-
faces with isopropyl alcohol only. Do not use chloride-based solvents

Reassembly
Install three new "O" rings on the pilot spool. Apply a light coating of a compatible lubricant to each ring.

Insert the extension pin and the plug into the pilot spool, with the countersunk end first. Note: The plug
should slide into the spool by its own weight.

Install the spring in the pilot spool with the small diameter end contacting the plug.

Screw the pilot end plug into the pilot spool.

Install the pilot subassembly into the body.

94
 HART Communications
This section contains information about computer and peripheral connections necessary to achieve prop-
er communication, so that SVI can communicate with ValVue or a Hand-Held device.

The ValVue manual contains setup and administration procedures for HART communications. Refer to
HART Communicator manual MAN 4250 for for basic instructions on using the Hand Held communicator.
The manual covers General Instructions, Hot Key Customization, Connections, and Off-Line functions.
Use of the Hand Held with SVI is facilitated by use of the Hand Held Communicator Guide flowchart in the
Instructions section of this manual.

Setup and Administration

Load ValVue version 1.0.4, or higher, for proper operation of the PC. The ValVue version number and the
SVI version number must match (or use a higher ValVue version than the SVI version software).

Note: ValVue demo software does not communicate with SVI.

Communication Port and Settings

Plug the modem into the serial port (COM1 or COM2) of the PC. The user selects the serial port during
ValVue installation, or in the properties of the ValVue icon, or you manually can set ValVue to use the same
port as the modem.

The user manual for your computer contains more information about proper use of serial ports.

Typical PC operation includes the following settings:

• COM1 or COM2 as the physical connector

• Default settings for the interrupt level and interrupt address (e.g., the correct BIOS settings use
the serial port with a modem and enable the interrupt)

Use of Laptop Computers

Laptop computers sometimes require non-conventional settings and support Power Management features
that can disable the COM ports. Check your laptop user manual for additional information.

Mouse Interference
Modem settings sometimes conflict with proper mouse operation, and the mouse "hangs up" after initiat-
ing ValVue. Select another port for either the mouse or the modem.

Hand Held Considerations

A hand-held terminal must include the SVI device description in order to perform diagnostic and calibra-
tion functions. The HART 275 hand-held terminal will report the primary and secondary variable, tag, mes-
sage, and other basic values.
Note: The communication connection of a PC with ValVue or a HART 275 hand-held terminal is not polar-
ity sensitive.

95
 Failure to Communicate
If the PC fails to communicate with the SVI (the PC displays the message "No Hart Device" or "Device Not
Responding") then the PC cannot establish a link to the SVI. Possible causes of communications failure
related to installation include:

• Poor wiring contacts

• Improper connection of the HART modem to the computer

• Incorrect serial port

• Using ValVue with another HART master terminal in service

• Insufficient loop impedance (Require a minimum of 250 ohms)

• Polling address set to non-zero value. The polling address, which can be set only by using the
HART 275 Hand-held must be set to 0 in order for ValVue to communicate with the SVI.
Do not change polling address from 0 with HART 275 Communicator.

Note: You cannot use ValVue and attempt to connect another HART master terminal device (e.g., a
hand-held device). ValVue will not operate with a second terminal device (either primary master
or secondary master).

96
Fatal and Non-Fatal Errors

Fatal Errors:
The following definitions describe typical fail-safe (fatal) errors:

Error Description Explanation Likely Cause(s)

POSERR Position The valve did not go to the • Valve lost air pressure
Error requested position within • Valve movement is
the time configured in blocked
“Position Error Time 2” • Setting of “Position Error
Time 2” is too low for the
size of valve
POSSEN Position Position sensor failed • Improperly adjusted
Sensor linkage resulting in the
Error potentiometer out of
range at one limit or the
other
• Potentiometer connector
is disconnected
• A broken wire
SIGSEN Current The input signal sensor Electronic failure within
Sensor has failed the module
Error
REFERR Reference The reference voltage Electronic failure within
Voltage within the SVI is out of the module
Error range
HWERR Self-Check The SVI failed an internal Electronic failure within
Failure self-check the module

OVERRUN Data The SVI could not process Electronic failure within
Overrun the input data the module

97
Non-fatal Errors

The following definitions describe typical non-fatal errors. SVI reports these errors; they do not cause a
fail-safe condition.

Error Description Explanation Likely Cause(s)

POSERR Position The valve did not go to the • Valve lost air pressure
Error requested position within • Valve movement is
the time configured in blocked
“Position Error Time 1” • Setting of “Position Error
Time 1” is too low for the
size of valve
Note: Setting “Position Error Time 2” to a positive number may cause the device to
fail-safe on a POSERR.
PRESSEN Pressure The pressure sensor failed While the SVI can function
Sensor in normal operation with a
Error failed pressure sensor,
other calibration functions
depend upon the pressure
sensor.
BIASERR Bias Out or The bias (the output to the • This error indicates an
Range EPC within the SVI that improperly adjusted bias.
controls the actuator Adjust the bias as
fill/exhaust) is out of normal needed.
range If the SVI once func-
tioned properly, this
error usually indicates
an improperly working
pneumatics section.

RESET Reset A SVI reset occurred SVI reset occurred

Occurred because of a power loss or
a command from ValVue.
STOPPERR Position The self-position calibration The most likely causes are
Calibration routine failed loss of air pressure or the
Failed pressure or position sensor
not working properly.
TEMPERR Circuit The internal SVI tempera-
Temperature ture is outside the normal
Error operating temperature
range in the SVI specifica-
tions

98
Non-Fatal Errors Continued.

Error Description Explanation Likely Cause(s)

WRTERR EEPROM A write of data to the inter- If you detect this error,
Write Failed nal permanent memory of issue a reset and check the
the SVI Failed. configuration and calibra-
tion parameters

TIMRERR Watchdog An internal timer that On watchdog timer time-

Timer checks proper SVI opera- out, the SVI issues a self
Time-out tion has timed out, indicat- reset. This error indicates
ing improper operation of that such a reset already
the SVI. occurred

CALFAIL Signal An attempt to recalibrate The normal cause is send-

Calibration the primary of secondary ing the SVI calibration val-
Failed signal or the pressure sen- ues outside the allowed
sors failed. range, or trying to calibrate
two values too close
together (e.g., with insuffi-
cient range for accurate
calibration).

99
AUSTRIA ITALY SAUDI ARABIA
Masoneilan HP+HP GmbH Masoneilan Division TIG-Masoneilan Arabia, Ltd. -
Hans Kudlich-Strasse 35 Dresser Italia S.p.A. TMAL
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