SECTION 2.9 FLOW CONTROL VALVE MANUALGE Oil & Gas 28000 Series Masoneilan* VariPak* Adjustable-C,, Control Valves Instruction Manual GEDoteCassiieaton PubleTHESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR'S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES ‘ANO AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED. ‘THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE. THESE INSTRUCTIONS 00 NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRE OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE. THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS. ‘THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT 8E REPRODUCED IN WHOLE OR IN PART WITHOUT THE WRITTEN APPROVAL OF GE.Contents 1. General 4 11 Spare Parts. 4 12 After Sales Department 4 13 Training 4 2 Operation. 5 2.1 Precise Adjustment of the Varipak 28002 Adjustable-C, Volve 5 22 Flow Coefficient of Voripak 28001 Single-Lever and 28002 Adjustable-Cy Valves 5 23 Actuator 7 24 Handwheel ? 25 Reversing the Valve Action 8 3 Installation 10 3.1 Preliminary Steps. 10 3.2 Valve installation 10 3.3 Pneumatic and Electrical Circutt n 3.4 Limt Switches u 4 Calibration. 12 4.1 Piston Rod Clevis Adjustment 2 4.2 Plug Stem Adjustment 2 4 3 Limit Stop Adjustment B 4.4 Varipak 28002 C, Adjustment Mw 4 5 Positioner Start-Up Pressure Adjustment M4 5 Maintenance 14 51 Actuator Diaphragm Removal ww 52 Adding Packing Ring mw 5.3 Disossembly as 54 Reassembly 16 5.5 Packing Quick Change Method (Only For Valves With Mox Cy Of 06 To 38) 18 56 7700P or 7700E Positioner Maintenance 18 57 Maintenance Operations Specific to the 7700E Positioner 19 58 Converting a 7700? Positioner Pneumatic) into a 7700E Positioner (Electro-Preumatic] 20 ©2015 Generel lene Company lights reserved osoneian VaPok Cntr Vave Instruction Manvel | 3Safety Information Important - Please Read Before Installation Masonellan 28000 Series instructions contain DANGER, WARNING, and CAUTION label, where necessary, to alert you to safety related fF other important information Read the instructions corelvly before instaling and maintcining your contro! vave DANGER tend WARNING hozords are related to personal inury CAUTION 5 involve equipment or properly damage Operation of omaged equipment can, under certan operational conditons, result m degraded process system performance that can lead to Injury or deoth Total camplionce with oli DANGER, WARNING, and CAUTION notices s required for sofe operation A his is the sofety alert symbol It alerts you to potential personal injury hazards Obey all safety messoges thot follow this symbol to avoid possibie jury or death Indicates a potential hazardous situation which, not avorded. could resultin death oF serous iury A.WARNING Indicates a patently hazardous situation which f not avoided, could resultin serous uty ACAUTION Indicates a patently hazardous situation which, f not avoided, could result minor or moderate nury CAUTION When used without the sefety alert symbol indicates potentially hazerdous stuation which, not avoided, could result in property damage Note: Indicates important facts and conditions About this Manual + The information inthis manual s subyect to change without rior notice + The information contamed in thes manual n whole oF pe not be transcribed or coped without GE's written germission + Please report any errors orquestions about the information in ths ‘anual to your local supplier + These instuctons are writen soecteally for the 28000 Seres control valves, and do not apply for other valves outside of ths product ine Life Period The current estimated useful Ife period for the Masoneian 28000 Senes control volve 1s 25+ years To moxmize the uselul fe of the product itis essentisl to conduct annual inspections, routine mantenance and ensure proper nstallauon to evod ony unintended stresses on the product The specie operating conditions wil also impact the use! life of the product Consult the factay for guidance (on specie oppications requred pror to instalation Warranty tems sold by General Electric ore worranted to be free from defects in matenals and workmanship for 2 penod of one year from the date of shipment provided sad ems ore used according to GE recommended usages GE reserves the right to dscontnue manufacture of ory product ar change product matenals, desiga or specications vathout notice Ths instruction manvol applies to the Masonellan 28000 Senes control The Control Valve MUST BE + Installed, put nto service and moi and competent professioncls who sutable taining med by qualified hove undergone Under certarn operating conditions, the use of damaged equipment could cause o degradation of the performance of the system which moy lead to personal injury or death ‘Changes to specticatons structure, ond components used may not lead to the revision of ths manual unless such changes: affect the function ond performance of the product All surrounding pipe ines must be thoroughly flushed to ensure all entrained debris has been remaved from the system1. General These installation, operation, and maintenance instructions apply to Masonellan VariPak 28000 series control valves. They also include a ports reference list with recommended spare parts {see page 21) IMPORTANT REMARKS. Before installing, operating, or performing maintenance on this equipment, you should read these instructions carefully and make sure you have understood them. Work on this equipment should only be carried out by qualified personnel Failure to follow the instructions and precautions given in this document could lead to a malfunction and seriously damage the equipment. 1.1 SPARE PARTS For maintenance purposes, always use original Masoneiion spore parts obteined through your local GE representotve or Spare Parts Department When ordering, always give the references of the original order for the equipment concerned and, in particulor, the number indicated on the serial plate (135) 1.2 AFTER SALES DEPARTMENT GE has o highly skiled After Sales Department to assist customers with start-up, maintenance, and reparr of valves andinstruments Contact your nearest GE Sales Office or Representotive 1.3 TRAINING GE organizes regular training courses in the operation, maintenance ond application of its Masonelon control valves and instruments for customer service ‘and instrumentation personnel For further details, please contact your local GE representative or Training Department2. Operation The Masoneilan VaniPok microflow control vaive features @ very wide range of rated flow coefficients (Cy, from 0.004 to 38 Two types of actustors are available - The VeriPok 28001 with a single lever, designed for just one rated C, This version is used when enough is known about the operating conditions when sizing the valve - The VoriPok 28002 with an odjustable rated C, This valve uses a patented lever system to adjust the rated Cy on site to suit the actual operating conditions, thereby avoiding ony oversizing in flow capocity. Each plug and seat ring combination can be adusted without changing the contro! signal 2.1 PRECISE ADJUSTMENT OF THE VARIPAK 28002 ADJUSTABLE-C, VALVE The valve is adjusted using ¢ simple, but robust, crossed- lever system with an adjustable fulerum This can be done easily by hand, either before installation or during operation For example, an application requiring a theoretical Cy of 0.006 could be handled using o VoriPak 28002 with 0 maximum C, of 0010. that con subsequently be calibrated onsite between 0.004 and 0019 2.2 FLOW COEFFICIENT OF VARIPAK 28001 SINGLE-LEVER AND 28002 ADJUSTABLE-C, valves 2211 Plug/sect rng combinations Itrim} Eight plugs ond five seat rings are used to make up the ten avaliable plug and sea mbinations, identified by codes from 0 to 9 [see figure 2) The shape of each plug and the port diameter of the seat ring can be used to match parts with the toble infigure 2 The difference between the four plugs in t to9 lies in the angle of the flat machined or The same seat ring {Se} and the same spacer (3) fre used in oll four cases ise figure 2) Use the table in figure 1 to select the plug and sect, ‘ing combination to obtein the Cy value or ronge of Cy values you require Bete a FigureDOOC . IN NF se xo a = bE once =| Jali or =| + | ees following parts = if necessary the actuator spring 134) (see figure 3 to ~The plug and seat ring (see figures 1 and 2 to select the ccheck the spring range corresponding to t oe ae 2.51009 28 - 6-28 Red 2.11801 2.1180) | 2.1 130) 121005 (0) 1660 0610025, 0.25 t01:10 0.10%0 0.08 207 0.050%0 0.020 a7 : sas Green 14201 14,20) | 1.4.20), 0.025 t0 0.010 es) 1035 0.010 00.008 0.004 t0 0.0016 foo Lona Aan ray Cire No. 58to1s Figure Aclualor spring ranges and Supply pressuresFollow the procedure described in the ‘Disossembly/ Reassembly” section of the "Maintenance" chapter on pages 14 to 18 ‘Also chonge the serial plote (135} or correct the information on the existing plate ACAUTION If the valve in question includes a 1/2" or 3/4" NPT threaded end, the maximum capacity of the body is respectively limited to trim Nos. 9 to 3 inclusive or 9 to 2 inclusive. A trim No. 9 cannot be installed in a VariPak valve body designed for a trim No. 0. Likewise, a trim No. 0 cannot be installed in valve bodies designed for other trim numbers. 22.3 Adjusting the Cy of @ Varipak 28002 vaive for each plug and seat ning combination This is done by moving adjustment knob (24) along ‘adjustment plote 125) fostened to the top of lever No 1 raul The adjustment plate (25) gwes the range of C, volues offered by the selected plug ond seat ring combination Carry out this adjustment operation as follows = Figure Adjusting te C of vorPak 28002 valve fr each plughset ing combination \ariPak nandwncet = Loosen adjustment knob (24) and slide it long the lever to the required value Tighten the adjustment knob ‘gain firmly Note: = This operation entails moving lever No 2, either pneumatically Iby allowing air into the actuator! ‘or manually iby pressing piston clevis (1406) with o screwdriver or similar tool so thot the slides of the two levers are perfectly parallel = Imay be necessary to reset the zero to calibrate the closure point ofler changing the Cy 2.3 ACTUATOR A single actuator allows VaniPak volves to act in direct Ar to-Close (ATO), or reverse A-to-Open IATO! Valve action can be changed with no additional part by simply shifting ~ the pivot pin and the ottachment hole of the positioner balance spring clamp for the singlelever VariPak 28001 ~ the two pivot pins for the adustable-C, VariPak 28002 valve, then calibrating os required Follow the instructions given under “Reversing the valve action” on page 8 2.4 HANOWHEELIFigure 5) The handwheel's on optional feature located on top of| the cover and fitted with a locking lever Access can be gained to it directly without removing any other parts It consists of ¢ threaded rod, equipped with a handwheel (120! anda lever orm stop 122) The threaded rod rests freely on the actuator bracket [108) and is guided through the cover {110] by handwheel bushing (119) The stop consists of a block screwed onto the threaded rod The block is guided by the actuator bracket 1081 12s i= ‘0 tm os 1 : Limi stop Figures‘When the handwhee! [120s turned clockwise, the stop 22) moves up the threaded rad, compressing the spring 1134] and raising lever No 2 (22) VoriPak 28002! or (113) VeriPak 28001! This closes the valve f the vaive is equipped with @ direct-action actuator {A-to-Closel and opens the valve if itis equipped with a reverse-action actuator [A\r-to- Open) The valve can be returned to automatic mode (neutral position}, by turning the handwheel counterclockwise until the stop 1122) comes into contact with the bracket (108) Note: uring this operation, the compression is released when the stop (122) moves away from the lever (22) VarlPak 28002! or (113) (VonPok 28001) Continue the operation unt! 0 sight tension reappears, then tighten the handwheel lock ‘ail VariPak actuators are equipped with a lim stop This consists of ports (180) and (181), and 1s designed to prevent damage to the plug and seat ring assembly and/or the plug stem in the event of handwheel or actuator overstroke Note: The limit stop is not used with air-to-open valves fitted with @ hondwheel. and must be screwed down ot the bottom of the piston 2.5 REVERSING THE VALVE ACTION IFigures 5,6, 26, 27 and 29) ACAUTION The valve must be isolated and pressure vented before disassembly. ‘A Loosen and remove cover (110) On valves equipped with a hendwheel, loosen cover screw 1108), back off handwhee! lock [121), and turn handwheel 120) counter- clockwise to release cover (110) 8 Adjust the signal so that the valve closes Change the signal slightly so that the plug just moves off the seat ring On the VoriPak 28002 adjustable-C, valve, set the adjustment knob (24! to the minimum C, setting C Loosen locknut {103} and, using a screwdriver, turn the plug stem one ond three-quarter turns counter. clockwise Shut off the signal and the supply pressure Slightly tighten locknut 1203} against the clev's Unlock nut (117) and completely loosen screw (1 Unhook spring {2141 from spring clamp (151 25.1 VariPok 28002 single-lever valve E Remove retainer clips (112b) from pin 18), and remove the pin from lever {113} and plug clevis {1040} Note: This operation willbe simplified by relieving the ood exerted on the plug clevis by the conical compression spring 106) To do this push against the plug stem end with a screwdnver while dnving out the pins F Remove the two retainer clips (1120) from the pin {105) and disengage it to uncouple the lever (1131 from the bracket (108) G Refit the levers (1131 making sure thot the pin 1105) 1s fitted into the correct holes in the lever ond bracket for the new action of the actuator (see figure 6) Fit the spring clamp (115) nto the corresponding lever hole Note: Ensure that the clewis is correctly positioned before fitting the lever on the bracket H Couple the plug ster clevis [1040] to the lever 223), following the normal reassembly procedure istep | in the Reassembly” section on page 17} Then follow the some procedure os for the VariPck 28002 agjusteble-C, valve as from step L 252 VoriPak 28002 adjustable-Cy valve (2 levers! E Remove retainer clips (112b) from each of the two pins {184} ond remove pins from lever 1113) and plug clevis nodal Note: This operation will be simplified by relieving the load exerted on the plug clevis by the conical compression spring (196) To do this push against the plug stem end with a screwdriver while driving out the pins F Remove the two retainer clips (1120) from pin No 1 {105} cand disengage it to uncouple lever No 1 from bracket (108) Loosen adjustment knob (24) and slide it to the maximum C, setting Disengage the smooth end of the ‘adjustment pin (23) from the groove in ever No 2 while removing lever No 1 G Drive out pin No 3118} and remove lever No 2 [221 from the bracket H Remove the two screws (26] and refit C, adjustment plate [251 after turning it round to comply with the new action | Refit levers No 1 and 2 n sequence, making sure that pins 8) ore fitted into the correct holes in the levers for the new action of the actuator (see figureNote: Ensure that the clews is correctly positioned before fittng the lever No 1 on the bracket (108) J Reset adjustment knob (24 the minimum Cy position K Couple plug stem clevis 11040) to lever No 1 following the normal reassembly procedure step L in the Reassembly” section on page 17) L Hook spring [2141 1n the appropriate hole in spring clamp (115) see figure 6) M. Admit supply and signal pressures and complete calibration Refit cover (110) using the two screws (109) IF the vaive is equipped with a handwheel, refit the cover ‘ond turn the handwheel clockwise so that it engages in lever arm stop {122} Tighten cover screws (209) See eo kes N Pat the valve back into service Note: = When replacing an Aur-to-Close actuator with an Aur-to- Open actuator, do nat forget to neutralize the limit stop by screwing it down ot the bottom of the piston When replacing an Aur-to-Open actuator with an Aur-to- Close actuator, set the limit stop to the opening position PMS a ESL oy VariPak 28001 errs Alleles td Rae ae oma ses) *only with type 7700 positione Figures identification of lever pivot pinholes3. Installation 3.1 Preliminary Steps A Before installing the valve in the line, eemove all traces of foreign material from the piping such as welding chips, se, ol. grease, etc 8 Note down oll the date gwen on the serial plate For valve inspection without interrupting process operation, a hond-operated stop valve will be required on either side of the VariPak, together with o hand-operated throttling valve mounted on a bypass line 3.2 Valve installation (Figures 7, 8 and 9) Connections The body of the ANS! Class 1500* rated VoriPak valve can be - Bolted between 25 mm It" pipe flanges machined to standords ISO-PN 10 to PN 250 {ANSI 150 - 300 - 600 - 900 fond 1500 Ib) \se ASTM A 193 Gr 8 7 for equivalent) carbon steel bolting for temperatures between -29° and +350 °C For corrosive cr eryagenic service, use ASTM A 193 Gr 88 strain: hordened stainless steel All the ine bolting required for installation can be supplied by GE on request B Figure ?-VoriPak flanged connection nected by 25 mm flanges machined to standards ISO PN 20, 50 and 100 (ANSI 150, 300 ond 600 Ib) Fit gaskets compatible with service conditions between the valve body and the pipe flanges OI Hf Figure 8 - Var Pok flanged body q The VanPok valve body can be supplied on request with 1/2, 31", or Y NPT threaded ends Apply PTFE tope or o sealing compound compatible with the process to the threaded pipe ends Figure 9 - VasiPok screwed connection (option) Alignment This valve s small and light, making it easy to instoll on the piping Support the valve body when fitting studs Suitably shaped bosses are provided to center the valve in the line ond prevent rotation before the studs ore finally tightened The valve must alwoys be installed with “flow tending to open” The flow arrow on the valve body must be pointing in the direction of flow Fit the bolts and tighten in criss: foshionInsulation |f the valve is to be insulated, ensure thet the insulation does not exceed the shaded area shown in figure: 10 below Figure 10- Insulation limit fore VariPak valve 3.3 Pneumatic and Electrical Circuit (Figures 3, 11 and 12) = On-off valve connect the air supply line directly to the 1/8 NPT threaded connection in diaphragm cover: = Control valve with 7700? positioner (air signal connect the supply and instrument signal ines to the appropriate connections on the manifold block (144) figure 12) Use 4 x 6mm {1/4 00} tubing = Control valve with 7700E positioner (electrical signall connect the manifold block (144! air supply line and make the electrical connection for the I module (20} (figure 12) Use 4 x 6 mm {1/4" 0.0} tubing for the ar line Note: Check that the supply pressure is that indicated on the senal plate 7700? or 7700€ positioners can be installed on both VoriPak 28001 single-lever and VaniPok 28002 adjustable-Cy valves f\_@ a7, wwf ue nefeuppy ue ner nciument Mt connection “Gonnestion ‘egnateennection Connections with 7700P positioner g a7 Etecroa! ermPTeweiy “Yee ner ‘lonet ‘onpesiton ‘ocanection 8 Figure 12 - Connections with 7700€ positione 3.4 Limit Switches [Figure 13) In some cases, limit switches can be provided for the VariPak valve, on request These are wired and adjusted in, the factory to customer order The black wire is connected to etther the normally open or normaly closed terminal Of the upper limit switch The black and white wire 1s connected to the common terminal of this switch The red wire is connected to either the normally open or normally closed terminal of the lower limit switch The red and white wire is connected to the common terminal of this switch To adjust lim switches, loosen their fasteners and move the valve to the required position Adjust the position of the switch until it trips. Tighten fasteners (160 - 161 - 1621 omer amt Upper nt ents yeo-ner-162. sais: Figure 13 - Limit switch installa4. Calibration VoriPak valves are factory-calibrated according to the components specified in the customer order If for any reason this calibration has been disturbed eg after changing from direct to reverse valve action, or replacing the plug end sect ring, all or some of the adjustments below must be carried out in the following order - Piston rod clevis (LO4b} adjustment Plug stem adjustment Limit stop adjustment cy adjustment Positioner start-up pressure adjustment 4.1 PISTON ROD CLEVIS ADJUSTMENT 411 Adjusting the piston rod clevis on the VoriPak 28001, sngle-lever valve (Figures 14 ond 26) This adjustment is only required if the piston (131) has been removed. In this case, it should be carried out during reassembly, before coupling the lever (113) to the clevises (chap. MAINTENANCE - Reassembly. step H., page 17). With the piston resting against diophragm cover 137), turn clevis [104b) so that the top of actuator bracket (108) 1s 0 mm to 1 mm from the bottom of indicator (126) A shim will simplify this operation Admit enough air pressure to disengage locknut 1125) and tighten it against indicotor Check that indicator (126) s correctly positioned Release air pressure 41.2 Adjusting the piston rod clevis on the 00. o ae LO stom ss. sos. 1 a ss) 437. = Figure 14 - Piston rod clevis (104) adjustment VariPak 28002 adjustable-Cy valve (Figures 14 and 27) This adjustment is only required if the piston (131) has been removed. In this case, it should be carried out during reassembly, before coupling the levers (21) and (22) to the clevises (chap. MAINTENANCE - Reassembly. step K., page 17). With the piston resting against diophragm cover (1371, turn levis {104b) so that the top of the actuator bracket (108) 1s 0.5 mmto 1 mm from the bottom of indicator (126) A shim will simplify this operation Couple lever No 2 [22)1n this clevis position Admit enough tir pressure to disengage locknut 1125) and tighten it ‘against the indicator Check that indicator {126} s correctly positioned Release air pressure 4.2 PLUG STEM ADJUSTMENT 4.2.1 Adjusting the plug stem on the VariPak 28001 single. lever valve (Figures 15, 16 and 26) This adjustment should be carried out during reassembly, before coupling the lever (113) to the clevises. ‘A Loosen nut (103) ond turn the plug stem using a screwdriver while blocking clevis [104a) until the clevis isin the position shown in figure 15 Lock nut (103) ale Figure 15 - Preset 3 the plug stem positionB Fit lever (21,31 with spring clamp (115) positioning hole facing upwords, fit pin (105) nto hole A, then fit pin (18) into clevis (104al Note All pins should be greased slightly before fitting C Press the lever on the actuator side to check for plug/seat ring leaks at AP 3 5 borg 150 psigl If the valve is equipped with o handwheel, lever 113] should not touch lever arm stop 1122) If the valve leoks, release the pressure at the inlet and remove pin {181 of clevis (1049), then loosen nut {1031 Loosen the plug stem in order to move the clevis up {104a) A complete turn moves the position up by 1 mm Then tughten the locknut (103) again D Check that the distonce between clevis (1046! pin and the hole in lever (1131: approximately 2mm Ifnecessary, ‘adjust the position of clevis (1040! to obtain this distance, see figure 16 This value provides the initiol compression of actuator spring [134) F ‘mim. + toopen= 15mm [pur w eloce = 17m Figure 16 - Adjusting the lever 1131 E Admit enough air pressure to the actuator to drwve piston levis {104b) upwards Couple the clewis to lever (113) using pin (124) F Release the actuator pressure and repeot the plug/seat ring leak test ot AP 3.5 barg (50 psig) Dimension A should bbe the same os in figure 16 Release the valve pressure once this step is completed 4 22 Adjusting the plug stem on the VaniPak 28002 adustable-C, valve (Figures 27, 28 and 23) Once all the coupling operations are completed, proceed as follows ‘A Admit enough pressure to the actuator to drive out the piston rad far enough to place a shim under the indicator, (126) Use 0.1.5 mm shim for on Ar-to-Open actuotor, and 4.25 mm shim for an A\r-to-Close actuator Release the air pressure after inserting the shim At this closing point where the plug is not tightened onto the seating, the slides of levers No. 1 and 2 should be perfectly parallel. This characteristic makes it possible to change the adjustment knob (24) position later to obtain the required real Cy value. B Loosen adustment knob (24) and slide it along lever No 1 to the moximum Cy position on adjustment plate I25} Fully tighten adjustment knob (24), € Loosen locknut {1031 and, using o screwdriver plug stem until the plug is just touching the seat ring if the valve has been removed from the pipe, a bubble test can be performed on the calibration bench to obtain a very accurate adjustment Using the screwdrwver to hold the plug stem in position, tighten locknut (2031 against clevis 11040) D Admit air pressure again to remove the shim, then release the pressure Note: On an Air-to-Open actuator, shim thickness may be increased or decreased by one or two-tenths of a millimeter to ensure that levers No 1 and 2 are perfectly parallel and to obtoin the required tightness on closing, especialy for very ow Cy values (C, < 0 10) 4.3 LIMIT STOP ADJUSTMENT (Figure 5) VariPok valves include a limit stop to prevent damoge to the plug ond seat ring and/or plug stem in the event of actuator or handwhee! overstroke This device consists of a nut (180) acting as a stop, screwed onto the piston rod inside the spring chamber, and a locknut (1 If necessary, this device should be odjus ofter plug stem adustment isee section 4 21 immediately ‘A Remove the shim for VanPak 28002 adjustable- Cy valve onlyl and admit sufficient supply pressure to close the valve Turn locknut [281] on the piston rod unt it touches locknut {125) Turn limit stop {180) until tjust touches the inside of actuator bracket (108) 8 Hold the limit stop with @ 12 mm wrench and tighten locknut (181) Release the air pressure44 VARIPAK 28002 Cy ADJUSTMENT This adjustment is carried out by moving adjustment knob [241 along adjustment plote (25) fastened to the top of lever No 1211 See section “Adjusting the C, of a Varipak 28002 valve for each plug and seat ring combination’, page ? 4.5 POSITIONER START-UP PRESSURE ADJUSTMENT. (Figures 7, 25, 26 and 27) A Connect the air supply and signal lines to the 7700? o 7700E (with electrical signal) positioner @ Set the supply pressure (see the table in figure 3) C Set the signal to the minimum value for an Avr-to- Open actuator, and to the maximum value for an Ar-to-Close actuator Turn toke-up screw {116 until the piston rod just begins to move Tighten locknut (117) 5. Maintenance ACAUTION Always ensure that there is no pressure in the valve, actuator, or positioner before maintenance or disassembly. 5.1 ACTUATOR DIAPHRAGM REMOVAL (Figures 17, 24, 25, 26 and 27) A Unscrew the two pressure connection nuts 11380] and pull tubing (140) out Remove the four cap screws (139) and diaphragm cover (137) Remove the worn diaphragm Form new diaphragm [136] and fit ton the piston as. shown in figure 17 Fit the diaphragm roll into the bracket groove Toke care not to twist or bend the diophragm during replacement Refit diaphragm cover (137) with the four screws (133] and reconnect the tubing with, the two pressure connection nuts (1380) Check that all connections are lecktight Figure 17 - Diophragm replacement 5.2 ADDING PACKING RING (Figures 18, 26 and 271 A Before adding packing ring, the valve must be isolated ond all pressure released Remove packing flange nuts (ab), It the packing flange and follower, and insert o new packing ring Tighten nuts (8b) finger tight and tl tighten one full turn with the wrench Jp Figure 18- Adding @ packing ring5.3 DISASSEMBLY (Figures 5, 24, 25, 26, 27, 28 and 23) In some cases, t may be necessary to disassemble the VoriPak valve, for example, to replace the plug/seat ring assembly [fitting new parts or changing the maxmum Cy, value) or to change the packing rings when the maximum Cyisless than 06 Note: Ifthe maximum C, 2 08, a quick change method can be used to avoid aisassembiing the valve (see page 18) ACAUTION The valve must be isolated and pressure vented before disassembly. A Loosen cover screws (109) and remove cover (110) If the valve is equipped with a handwheel, loosen cover screws 1109) and handwheel fock (1211, then turn handwheel [120) counterclockwise to release cover {110} Disassembly procedure for the Vor'Pak 28001 single-lever valve 8 Unlock nut 11171 and completely loosen screw (116) Remove spring clamp [115) from lever (1131 and remove ‘spring (124) from the positioner Remove the two retainer clips {L12cl from pin (1241 and disengage the pin to uncouple piston clevis {L04b) from lever (113) Note: To simplify this operation, admit air pressure to the actuator to drive the piston clevis[104b) upwards, then release the air pressure D Remove retainer clips (112b] from pin (18) and d'sengage the pin from lever 1113] and plug clevis (1040) E Remove two retainer clips (112a) from pin (105) and disengage the pin to uncouple lever (1131 from actuator bracket (108) Now proceed in the same way as for the VoriPak 28002 adustable- C, valve, as from step | Disossembly procedure for the VoriPak 28002 adjustable-C, valve @ Adjust the signal to close the valve Change the signal slightly so that the plug just moves off the seat ring Set ‘adjustment knob (24! to the minimum C, position € Loosen locknut {103} and, using a screwdriver, turn the plug stem one and three-quarter turns counter. clockwise Shut off signal and supply pressure Slightly lughten locknut [103) against the clevis D Completely loosen locknut (117) and screw (116) Remove spring clamp 1115) from lever No 2 ond remove balance spring (114) from the positioner E Remove the retainer clip [112b1 from each of the two pins 4} ond disengage the pins from lever No 1 ond clevis [04a Note: This operation will be simplified by relieving the load exerted on the plug clevis by the conical compression spring (196) To do this push against the plug stem end with a screwdriver while driving out the pins F Remove the two retainer clips {112cl from pivot pin No. 4 1124) and disengage the pin to uncouple piston clevis (10401 from lever No 21221 G Remove the two retainer clips (1129) from pivot pin No 1 {105} and disengage the pin to uncouple lever No. 1 from the actuator bracket (108) Disengage the smooth end of adjustment pin (231 from the groove in lever No 2 and remove adjustment knob (24 and adjustment pin (231 from lever No 1 H Drive out pivot pin No 3 (18) and remove lever No 2 1221 | Hold the plug stem in place using a screwdriver and unlock nut 1103) Loosen clevis [10401 ond locknut {103} Remove spring button (2021, spring {206}, end grommet plate (103) J. Remove the two packing flange nuts (8b), packing flange [NO} and packing follower {9} Remove the two bracket mounting nuts (8a) as well as the bracket (108) K Using @ packing hook, remove as many packing rings (6) 15 possible from the packing box Remove safety pin [11! ‘ond pull the plug stem to remove the packing spacer (5 the plug and its stem and, if necessary, the rest of the packing L Using a 9/16" oF 14 mm piece of hex stock and a wrench, unlock and pull out the seat-ring retainer (4) M Remove seat ring (3} and gasket [2] using a hook made from steel wire, approx diometer 3 mm Carefully fettle the hook end Note: - The seat-ring of VanPok valves with Cy max-< 0 10 consists of two ports the seat rng proper (3). ond a spacer [Sf These ports have o small onfce and so cannot be removed using @ hook tis therefore necessary to remove the body from the pipe and turn it over and, sFnecessary, hit the bottom with @ wooden mallet Ifthe seat ring (3a) s jammed ints housing it can be removed by inserting a screwdrver through the outlet onfce= VanPok valves with Cy max 3 8 do not have seatring gaskets 2) 5.4 REASSEMBLY (Figures 5, 15, 19, 20, 24, 25, 26, 27, 28 and 29) Before reassembly, thoroughly clean the inside of the valve body and parts, paying particular ottention to gasket seoting surfaces and contact surfaces Moke sure to use a new seat-ring gasket [2} and new packing (6! during reassembly A Insert a new seat-ring gasket (2! nto valve body (13), then fit seat ring {3}, making sure that the gosket is correctly centered on the seat-ring shoulder Turn itso that one of Its ports is lined up with the valve body outlet orifice Note: ifthe maximum C, 1s less than 0 10, first fit the seat ring (Sel on the new gasket 2), toking the same precautions ‘as above Then fit the spacer (51, turning it so that one of ts ports 1s turned towards the body outlet onfice VarPok valves with a maximum Cy of 38 do not include o seat-ring gasket (2) 8 Carefully apply Never Seez grease or equivalent to the threads and bottom of the seat-ring retainer [4 Using 9/16" oF 14 mm piece of hex stock and a wrench, torque the retainer to $9 ftlb or 8 doN m for stamnless-steel reinforced graphite gaskets or 40 ft-lb or § 5 daN m for gloss-filed PTFE gaskets Isee figure 19) Note: Torque the retainer to 30 ft-lb or 4 daN m for valves with a maximum C, of 38 C Insert the plug and stem assembly into the seat ring For valves with a maximum Cy < 0.10, check that there are ro friction points n the plug stroke Ifo friction point is detected, loosen retainer (a) and reposition seat ring (Sel Unt the stem slides smoothly Fit spacer IS) turning itso. that one of its holes is aligned with safety pin (11) halen the valve body Note: For valves with a maximum C, less than 0.10, check that the retaining ring (182115 fitted on the plug before fitting the plug in the spacer (3f| Ifthe retaining ring is worn or damaged, replace it ©2015 Generel lene Company lights reserved Figure 19 - Tightening the seat-ring cetainer (a © Wind two layers of PTFE tope around the safety pin (11) Screw the pin into the bonnet five and a half to si turns € from the thread engagement pomnt Note: To determine the thread engagement point ~ Screw the safety pin about one turn - Pull the sofety pin out while unserewing i € Fit the packng, makng sure that the skive cut of each packing rings located 120° away from the that of the adjacent ring, Push the rings down sightly using o 1/2" sch, size 160 tube Fit the packing follower {9} onto the plug stem F Fit octuator bracket 1108) and secure t with two nuts (Bo) Sip packing flange [101 onto plug stem Handtighten the two packing flange nuts and add one fll turn with the wrench G Fit, n the folowing order, grommet plate (101), conieal ‘compression spring (106! and its spring button {1021 (see position in figure 26 and 27) Screw nut 1103) and clevs {1049} on the plug stem Adjust the nut and clevis without locking them together unt the clevsholes are positioned opproxmately ~ 23 mm below the alignment of the pin holes in the ‘cluator bracket (108! for the VoriPok 28001 single- lever valve see figure 151 = 15 mm above the alignment of the pin holes in the actuator bracket (108 for the VariPok 28002 eqjustable-C, valve see figure 201 Note: Measuring this distance can be simplified by ting pins (2081, {1841 and (18) into therr holes ‘Sasane on vor Contl vous Instruction anual | 371.5mm Figure 20 - Plug stern pre-adjustment for VoriPok 28007 adjustabie-Cy Reassembly procedure for the VoriPak 28001 single-lever, valve (continued! H Couple leve 1113) to actuotor bracket {108) using pin 1105) (122a) Ensure that the holes in lever {113} where spring clamp 1115) s fitted s located Note: Check that the clevis{104a! is correctly positioned before fitung the lever (113) on the actuator support (108) To identify the position of the lever connecting holes and the spring clamp (115) attachment hole, with respect to the required action, see figure 6 | Couple clevis 104! to lever (1131 To do this, press the end of the plug stem with o screwdriver until the holes in the clewss ond lever ore aligned Couple using the pin (28) and ‘etainer clips (112b) Note: Slightly grease all pins before fitung Perform the ‘adjustment operation described in “Calibration” section 4 2.1, page 12 J If piston rod clevis (104b) has not been disturbed during disassembly, couple it to the end of lever 1131 by admitting oir pressure to the actuator to dive clevis, 04b) upwards Couple the clevis to ever 123) using pin 1124) and two retainer clips 212c} Note: ifthe clevis 11040) has been disturbed proceed with ‘adjustment and coupling as described in “Calibration”, section 411, page 12 K Release the pressure from the actuator and check lightness again (see “Calibration”, section & 21, page 12) Then continue from step M of the VariPak 28002 procedure Reassembly procedure for the VoriPak 28002 adjustable-C, valve (continued) H Couple lever No 2 221 to the actuator bracket (208) using pin (18) Ensure that the hole in lever No 2 where spring clamp (1151's ited is located above and in ine with balonce spring 1114), | Fit adjustment pin 23} n the side of lever No 1 and screw ‘adjustment knob (24! on its threaded end Insert the ‘smooth end of pin (23) into the groove in lever No 2 ond place lever No 1 on support bracket (108) Couple lever No 1 t0 actuator bracket (208! using pin (105) ond two retainer, clips 111201 Note: Check that the clevis(204o! is correctly positioned before fitting lever No 1 on the actuator support (108) To identify the position of the connecting holes of levers No 1 ond 2 with respect to the required action, see figure 6 J Set adjustment knob (24) to the minimum C, position K If piston rod clevis 1104b) has not been disturbed dunng disassembly, couple it to the end of lever No 2 using pin 1124) and two retainer clips 1112c) Note: This operation willbe simplified by applying air pressure fo the diaphragm {136} to set the piston red to. an Intermediate position. ond by setting the adjustment knob to ‘a position where lever No 2 1s most accessible Ifthe clevis (1046) has been disturbed, proceed with adjustment and coupling as described in "Colibrotion’, section 4 1 1, page 12 L Couple clevis 11040! to lever No 1 To do this, press the end of the plug stem with 9 screwdriver until the holes in the clevis and lever No 1 are aligned Couple using the ‘two pins (184) and retaner clips (1126) Note: The clips are inserted on the pins between the sides of the clevis and lever No.1. M Fully unscrew take-up screw (116) from spring clamp. (115), then fit clamp, after hooking balance spring 1114) first to the positioner spring bracket of the diaphragm SW (152), and then to spring clamp (115) Note: The spring clamp (115) has two holes. fan Arr-to-Open ‘actuator is used, the spring must be hooked to the top hole fan Aur-to-Close actuator is used, the spring must be hooked to the bottom hole isee figure 6)'N Admit the signal and supply pressure and complete calibration Refit cover (110) using the two screws {109) If the valve is equipped with a handwheel, refit the cover. then turn the handwheel clockwise unti itis engaged in lever orm stop 1122) Tighten cover screws (109) 0 If the valve body has been removed, reinstall t taking the precautions given under "Valve Installation” on page 10 Put the valve back into service 5.5 PACKING QUICK CHANGE METHOD [ONLY FOR VALVES WITH MAX. C, OF 0.6 TO 3.8), (Figures 21, 26 and 27) The quickest ond easiest way to replace packing is to remove the entire actustor from the valve body, taking care not to modify the actuator setting This method is not recommended, however, for volves with a moximum Cy less. than 06 because of their extremely fine plugs For these valves, disassemble the valve to replace the packing (see DISASSEMBLY", page 15), ecco ure 21 - Packing replacement fo! Dos! Vent the valve pressure and proceed as follows ‘A Check that the plug is not resting on the seat ring For valves equipped with on Airto-Open actuator, admit air pressure under the digphragm ond turn the handwheel to move the plug off ts seat ring 8 Remove sofety pin (11) from the valve body The sofety pin stub engages with the hole in packing spacer (5) The function of the safety pin and spacer is to prevent the plug from being pushed out the actuator is accidentally removed while the valve is still pressurized The internal ports of the volve connot be removed unless the safety pins removed first Remove the two packing flange nuts lab) and bock off the two actuator bracket mounting nuts. {80} as far as possible Remove the actuator-plug assembly from the valve body, tapping it off with a black of wood end mallet necessary Clean the packing box n the valve body Remove the worn packing, then clean the plug stem thoroughly Carefully fit new packing rings around the stem, positioning the skive cut of each ring 120" from that of the adjacent ing Refit the actuator-plug assembly on the valve body, taking care to - align hole in packing spacer {5} with safety pin {211 hole, cond refit the two mounting nuts (8a) Take extra care when guiding each packing ring into the packing box E Wind two layers of PTFE tape around the safety pin Screw the pin into the bonnet five and a holt to six turns 9s from the thread engagement point Note: To determine the thread engagement point - Screw the safety pin about one turn, ull che safety pin out while unscrewing it F Refit the packing follower, packing flange, and flange nuts (8b) Tighten the packing assembly correctly Ifthe valve 's equipped with on Ar-to- Open actuator, release the air pressure or turn the handwheel to bring the plug back into contact with the seat ring Put back into service 5.6 7700P OR 7700E POSITIONER MAINTENANCE [Figures 22, 23, 24, 25, 26 and 27) ACAUTION Shut off the signal and supply pressure. Isolate and depressurize the valve body. A Disconnect the two pressure connection nuts (1580! and pull tubing 1140) out8 Loosen the two cap screws (1410) ond remove manifold block (144), spring (1581, gasket (146) ond its three O-rings, pilot valve assembly {285 to 17), shims [145 cond O-nin ACAUTION Caution: Handle the shims carefully (145). € Loosen locknut {L17) ond take-up screw I226}, unhook the spring clamp from lever (22) or 213) D Unscrew cap screws (141! rom positioner biock (147) tand remove the positioner black from the actuator bracke Remove screws (148) to separate positioner diaphragm ‘assembly 1152) ond spring (154) from the positioner block Examine all the parts ond replace if worn or damaged E Refit positioner diaphragm assembly {1521 and spring {154) to positioner black and tighten screws [148] Check that the small signal port Oring isin its recess in the diophragm assembly F Reinstall the block assembly on the actuator bracket Note: When instaling the positioner block (1471, turn it so that when the manifold block i144): installed, the gaugels) Islorel facing in the right direction figure 22) Figure 22 - Positioner assembly Note how the positioner |147) and gasket (1461 are oviented G Check that gosket (146), three O-rings, and seats are not worn or damaged and replace f necessary, H. Fit O-ring {153}, shims (145), pilot valve assembly, gasket (1481 and its three O-rings, spring (158) ond manifold block (144) Tighten the screws (1410), refit tubing (140) ‘and tighten pressure connection nuts (138a) Note: The ports im gasket (146) must be oligned with those 1m the positioner block (147) To ensure correct positioner performance, check that oll gaskets are perfectly leaktight | Hook spring clamp (1151 to lever (22! or 1113) In the case of VariPack 28001 valve, see figure 6 to position the spring clamp 1115) according to the actuator required faction Admit the supply pressure and the signal Set the stort-up pressure following the instructions given in the Calibration” chapter Put back into service oxy | SPring ef. | Spring color Cae er ald eS Bas or ue Yellow 6-30 or 1s Red 77007 327 ne White 8 154 Blue ne White eas 1s4 Green ne Yellow rove | 4-20ma bn Se Figure 23 - Color code for positoner springs 14 and 1544 5.7 MAINTENANCE OPERATIONS SPECIFIC TO THE 77006 POSITIONER REFER TO ATEX INSTRUCTION MANUAL No. 185977 FOR ALL MAINTENANCE ON THE ELECTRICAL PARTS OF THE 7700E POSITIONER. A Loosen screws (27) and remove I/P module 120) Note: If damaged, the /P module must be replaced 8 Check that O-rings (28, 29 end 30] and therr seats are not worn or damaged Note: All worn or damaged parts must be replaced ©. Fit O-rings (28, 29 and 30!,n their recesses on the I/P module (20) Refit /P module [20) on manifold block (144) Tighten screws (27) Note: To ensure correct positioner performance, check thot all gaskets are perfectly leaktight.5.8 CONVERTING A 7700P POSITIONER (PNEUMATIC) INTO A 7700E POSITIONER [ELECTROPNEUMATIC) Akit comprising the manifold block 244) ond the I/P module (20) 1s available from your local Masoneilan representative or the Spare Parts Deport ment REFER TO ATEX INSTRUCTION MANUAL No. 185977 FOR ALL MAINTENANCE ON ‘THE ELECTRICAL PARTS OF THE 7700E POSITIONER. Shut off the signol and supply pressure Isolate and depressurize the volve body A Disconnect the two pressure connection nuts 1380! tnd pull the tubing (140) out, 8 Loosen the two cop screws {1410) ond remove manifold block (244) The spring [1$8}, gasket [146) ond the three O-rings, the plat valve assembly (155 to 157}, shims (145), and O-nng {153} do not need to be removed unless you hove new parts, Otherwise, simply check thot ports ore in perfect condition before refitting. ACAUTION Handle the shims carefully (145). Ifthe parts mentioned above have been removed, proceed as follows Fit the O-ring (153), shims (145), plot valve assembly {155 to 157), gasket (146) and the three O-rings, the spring 158) ond manifold block [1441 - YP module (20) Tighten screws (1419), refit tubing (1401 and tighten pressure connection nuts (1380) Note: The ports in gasket (246) must be oligned with those in positioner block (147) To ensure correct positioner performance, check that all gaskets are perfectly leaktight D Hook spring clamp 1115) to lever 1221 (VanPok 28002) or (113) {VariPak 28001) In the case of VanPack 28001 valve, see figure 6 to position the spring clamp, {125} according to the actuator required action ‘Admit the supply pressure and enable the electrical signal Adjust the start-up pressure following the instructions under “Calibration” Put back into serviceFigure 24 - Cross-section of the VariPak 28002 adjustable-C, actuator and the 7700P positioner PARTS LIST ms ana wal 7 rartnone zea | rants 7a TET Bue ior Earet suppose —1® a0 roar 02 | lseccmsgece io smgbuter JS ew] fscew a] ]sesteneymox 38 io 3] Eerne IS is ocr souse Bf Wsccrngctmer iene | 2] eer eis nomen go. ose 1seveneae fend M pan 3 leis ontlesoc 4] 1)868tong6 mx 010 106 sJesresconmessonsorns fe us| 1:05] shem ne] afsectingcymar coro | oor 2]eeret So is eset ines 176372 Boa TP isc Brace ie in 1] ect le ic one ack 4 || afsteting eamee ios 2] cone re Jo ise 2) sites eter 5 | Proc Sosce be Eve gis poston epcon sik o | anegens Qvresa | efreine oe being + | Treen tone sta log Pearce ove Spins +o] 2feounra ms Ses Sma ciome Stee 8] Precis fone ge Sess so 1] rcang clover sm tout Seine | 3)racirg tong Kis econ Sing 1] scien wis cndutel bug 2] sch Jo | 3) runien cymes 34 # ie jensen clscew 2/8] Primos 23 ei onsen ck 2s © LE afoupistencymax trace | we tz ever a sop ane ja] iJougicencracczscoro | ™ iva coro “fice a fee? bo 2] eeeana os D ssxemerpm br rons eversog nm eerie et a ‘feat sow rato 8 ung oi mon ew tin 1280 CO tecrmended pr pri Osectbiem egies sony orcstboder Sees gts tinge Endigacar lame MOM rhandenernterehis9 Son, ngaarutnorgunel onload 003 Pony mreumerc estore serach, Ses rera cescemeaien omy QYRBE Les 22015 Generel tec Company A ght cesarFigure 25 - Cross-section of the VoriPok 28001 Figure 26 - Partial cross-sectio 28001 single-lever valveDIRECT SALES OFFICE LOCATIONS Prone 61-730014819 Prone <55-112:463600 Frone 6493600 aw sourn araca Veli Nougat saupv anew,GE Oil & Gas Masoneilan’ SVI' AP Advanced Performance Digital Positioner Installation and Maintenance Manual (Rev J) GE Dota Classification: Public Magination at workAbout this Guide DISCLAIMER Copyright ‘Ths instruction manuel opplies to the following instruments and approved softwore SVIIIAP-2 through SvII AP-5 inmwore version $11,312,321 and 412 with VolVue version 2.4 or greater with AMS" VolVue SNAP-ON" version 24 0° greater with Valve PRM Plugin with handheld communicator with OD published for SviI AP The informetion in this manual is subject to change without prior notice The information car permission ined in this manual. in whole or port, shall not be transcribed or copied without GE Oi & Gas’ written Inne case does this manual guarantee the merchantability ofthe positioner or the software orits adaptability to o specific client Please report any errors or questions about the information inthis manuel to your locel supplier or vist won geoilandga com THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION. IN ADDITION To THE CUSTOMER/OPERATOR'S NORMAL OPERATION AND MAINTENANCE PROCEOURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY ANO ITS SUBSIDIARIES AND AFFILIATES) OOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED. THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS, THEREFORE, ‘THESE INSTRUCTIONS SHOULD @E INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS /APPLICAGLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE. THESE INSTRUCTIONS 00 NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULO FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CCUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE. THE RIGHTS, OBLIGATIONS ANO LIABILITIES OF GE ANO THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT, NO ADDITIONAL REPRESENTATIONS. (OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS. ‘THESE INSTRUCTIONS CONTAIN PROPRIETARY INFORMATION OF GE, AND ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, ANO/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART NOR SHALL ITS CONTENTS BE DISCLOSED TO ANY THIRO PARTY WITHOUT THE WRITTEN APPROVAL OF GE, All sofwore isthe intellectual property of GE Oil & Gos. The complete design and manufacture isthe intelectual property of GE Oil Gos, Mosonellan’, FVP", SV, and Valve ore registered trodemarks of GE Oil & Gos, All information contained herein believed to be accurate ot the time of publication and is subject to change without notice All other Iredemarks and copyrights re properties oftheir respective corporations Copyright 2014 by GE Oi & Gos, Al rights reserved. PN 055201-241 Rev JVersion/Oate £/2-2011 Fl2-2012 G/t0-2012 4109-2013, yo2-2014 s/06-2024 Document Changes Changes Added to description of Switches configuration, See Operations and Main- tenance. ‘Added description relevant to introduction of the high throughput version, including Added text applicable to the addition of Hart 6 functionality ‘Added sections applicable to the addition of the High Flow unit to the product line. Removed reference to being Sil 2 compliant Updated for new Valvue 2.8 Options dialog, which includes polling address scan functions, Changed the specifications to reflect single acting supply pressure of up to 100 and double-acting up to 150 psi Changed Figure 45 on actuator piping Changed Simplified installation drawing in Output Switches section and ‘added cautions referring to that section in installation, Added Cautions in Position Low Limit and Position Upper Limit {the 4-20 retransmit galvanic isolation, Changed Simplified Installation drawing in Output Switches section and ‘amended the text Omitted the Remote Sensor install section Added section to show where gos normally bleeds from the unit, Added HART signal to the HART Command 3 specification.Contents About this Guide. DISCLAIMER, Copyright: Safety Information Safety Symbols SUI AP Product Sofety. Introduction Valvue Software. Volvue Lite. System Requirements. Value Trial Version Operational Overview SVIILAP Features. Available Options. ‘About This Manual. Conventions Used in This Manual Installation and Set Up Overview SULILAP Dimensions and Weights. Pre-instollotion Issues Storage Unpacking Installation Steps. Installation Notes. Before Powering Up. Mounting the Positioner. Filter Regulator and Tubing Mounting the SVI II AP on Rotary Valves. Required Tools. Rotary - 90° Magnet Orientation on Rotary Valve Shafts Dismantling the SVI II AP from Rotary Valves. Mounting the SVI Il AP on Reciprocating Valves ‘Mounting the SV1 II AP on o Reciprocating Actuator Dismantling the $VI II AP from Reciprocating Valves Installing the SVI Il AP for Double- Acting Operation Connecting the Tubing and Air Supply Single Acting Positioner Double Acting Positioner. Connecting the Air Supply 4] Geol eGes 13 4 a7 18 18 18 18 19 19 21 21 21 23 23 25 28 28 28 28 29 30 30 31 31 31 35 35 35 36 36 39 40 43 ae 46 4g © 2014 Genero levie Company Alrghts reservedWiring the SVL AP. 48 Connecting to the Control Loop. 4g Verify Wiring and Connections 49 Check Out and Power up 51 Overview. 51 Position Sensor Principles. SI Check Out Procedures 52 Physical Inspection s2 ‘Actuator, Linkages, or Rotary Adapter 52 Verify Mounting ond Linkage Adjustment. 53 Checking the Magnet 53 Checking the Air Supply 58 Checking the Electronic Module Connections 56 Operational Checkout 5? Connecting to the Current Source 57 Powering Up the SVIII AP. 58 Pushbutton Locks and Configuration-Lock Jumper. 59 Using the Digital interfaces 61 Overview. 61 Local Display and Pushbuttons 61 HART Hondheld Communicator. 62 valvue, 62 Pushbuttons and Local Display. 62 Pushbutton 63 Pushbutton Locks and Configuration-Lock Jumper. 64 Hordware Configuration Lock. 64 Display Menus 6s NORMAL Operating Mode ond MANUAL Made Menus. 65 Configure Menu 66 Colibrotion Menu, 70 VIEW DATA Menu. 7 FAILSAFE Mode. 73 VIEW ERR Diagnostics Messages. 74 Display and Clear Error Messages. 7 Positioner Fault Messages 7 Return to Normal Operation 7 Hand Held Communicator 78 Volvue. 79 Installation of ValVue Software, and Registration 79 Valvue Software. 79 System Requirements 80 HART 6 Squawk Command, 81 Configuration and Calibration Using Pushbuttons 83 Configuration and Calibration. 83 © 2014 General Electric Comoany lights reserved ‘Masoneian Sv AP instalation end Maintenance Manual |SConfiguration with Pushbutton Display Viewing Configuration Data VIEW DATA Settings. Calibrotion Calibrating the SVI Il AP Unit Using Pushbuttons Correct for Over Travel Adjust Input Signal Range. Check-out with a HART Handheld Communicator Configuring and Calibrating with ValVue. Installation of Cover Wiring an SII AP Overview. System Connections. Wiring Guidelines. SVIII AP Setups. Grounding Practices. Compliance Voltage in Single Drop Current Mode. Wire Size ond Conduit HART Physical Layer Compliance of the Control System Impedance Constraints. Noise Constraints Cabling and interconnection Requirements. Capacitance vs. Length of Cable for HART. HART Filter Required for Certain Control System Output Circuits Split Range Applications. Setting Loop Addresses for Split Range Systems. Multiple Output Circuit Control System. Isolators Supplemental Power Supply Verify Wiring and Connections, Required Practices for Explosion Proof installations Clarification of Terminology Recommended Practice for Severe or Humid Environments HART Communications with intrinsic Safety Overview. HART Barrier Compliance Output Channel Isolation. HART Filter Requirements Modem and Computer Use in intrinsically Sofe Circuits MACTek intrinsically Safe modem, Model 010005 MACTek Warning Use of Handheld Communicators In intrinsically Safe Circuits. Operation and Maintenance Principle of Operation. 83 8 25, 87 87 88 29 21 93 93 95 95. 95 96 97 100 100 101 102 102 102 103 103 103 104 105 106 108 110 110 12 112 112 113 113 114 11s 115 a7 17 17 17 119 119 6] seoua Ges © 2014 Genero levie Company Alrghts reservedPhysical and Operational Description 120 Electronics Module 120 Output Switches aaa Checking Switch Operation 124 Pneumatic Module. 128 SULILAP D/A Bleed Slots. 128 Optional Display ond Pushbuttons 129 SVIILAP Maintenance and Repair 129 Repair. 129 Tools Needed 130 Display Cover Removal and installation. 130 VP Module Removal and installation 132 Relay Removal and Installation 134 Adjusting IP Zero. 135 Connecting Components to the Electronics Module. 135 Repair by Replacement. 135 Internal Diagnostics 136 FAILSAFE Mode 136 Upgrading Firmware 137 Tools Required 137 Installing Firmware Upgrade. 137 Speeifications and References 139 Physical and Operational Specifications. 139 Spare Parts 146 Air to Open and Air to Close Actuators 151 Actuator Action isi Air Supply Requirements 155 Air Supply Requirements. 155 Adjusting Speed of Response 187 Adjusting Speed of Response 187 Advanced Usage 159 Technology to Maximize Savings and Process Performance. 159 Tight Shutoff Application to Protect from Seat Erosion 159 Tight Shutoff Application to High Pressure Liquid Letdown Valve Trim 159 Using Valvue Diagnostics. 160 Continuous Diagnostics 160 Monitoring a Valve Bellows Seal 160 Critical Service, Cavitation Control Trim 160 Diagnostic Vaive Tests. 161 Glossary 163 © 2014 General Electric Comoany lights reserved ‘Masoneian Sv AP instalation end Maintenance Manual |?Figures © 2014 General Electric Comoany lights reserved SVLILAP SVL AP Components, SVIII AP High Flow Components SVIILAP Single-Acting Dimensions, SVIII AP Double-Acting Dimensions. SVIILAP High Flow Dimensions. Camflex with Mounting Bracket (Side View) Camflex ATO Mounting (Front View. Mounting Bracket on Air-to-Close Actuator Model 33 Actuator. Magnet Holder for Reciprocating Valves Reciprocating Valve Mounting Bracket Lever for Model 87/88 Multispring Actuator. Reciprocating Linkage. 85/86 Valve Stroke Settings. Bracket Configuration Strokes 5 - 2.50" ond 3-6" Mognet Position with Volve Closed Lever Alignment. SVIII AP Air Ports on Single Acting Positioner SVIIL AP High Flow Air Ports on Single Acting Positioner Air Ports on Double Acting Positioner. Double Acting Positioner ATOATC Settings for Reciprocating Valves. Magnet Orientation for Rotary Valves with Valve Closed, Magnet Orientation for 90° Valve Rotation with De-energized Actuator Magnet Holder for Reciprocating Valves Reciprocating Valve Mounting Bracket. Connections to Electronics Module (via Terminal Board} SVIILAP Display NORMAL Operation and MANUAL Menu Structures CONFIGure Menu: CAUIBration Menu, VIEW DATA Menus FAILSAFE Menu Valvue Options HART Command 72 Squawk Function Configuration Pushbutton Guide Calibration Pushbutton Guide SVIII AP HART Communicator Connections General Purpose and Explosion Proof installation intrinsically Safe Installation Valvue Activate Set Options on Device Screen Value Setup Options for Multi-Drop. v7 24 20, 25 26 27 32 33 33 35 37 37 37 39 40 40 a a1 42 4s 45 46 47 53 5a sa. 54 56 63 65 66 70 72 B 80 81 86 90 91 98, 99 105 106 Masonslan Sv A installation and Maintenance Manual [944 Value Options for Wireless 107 45 Split Range with isolator. 109 46 Split Range with Supplemental Power Supply - Non-Hazardous at 47 Intrinsically Safe Installation with Zener Barrier and HART Filter a4 48 intrinsically Safe Installation with Galvanic Isolator. 116 49 Block Diagram with i/P Converter and Pressure Sensor. 119 50 Switch installation Drawing: Correct Configuration with Load 122 51 Switch Installation Drawing without Load: Configuration Not Allowed 122 52 VO Configure. 124 53 SVIIIAP Pneumatic Module with Single Acting Relay, 125 54 SVIIIAP High Flow Pneumatic Module with Single Acting Relay 126 55 Double Acting Pneumatic Relay. 127 56 Bleed Slots On Air Routing Plate 128 57 Bleed Slots on Complete Unit. 128 58 SVIIIAP Display and Peumatic Covers 130 59 Pneumatic Cover Screws: High Flow 132 60 Pneumatic Cover Screws: AP [Four Shown) 133 61 _SVIIIAPHigh Flow Pneumatic Module with Single Acting Relay 133 62 SVIIAP Mode Numbering 145 63 ATO and ATC Action with Linear Positioner Characteristics 152 64 ATO. and ATC Action in Percentage of Positioner Characteristics 153 10] ceonaces © 2014 Genero levie Company Alrghts reservedTables 1 SVIII AP instollation Steps 28 2 Travel Sensor Alignment 34 3 Reciprocating Valve Mounting Hole and Turnbuckle Length 38 4 Air Supply Requirements, 43 5 SVIII AP Models and Functionality. 56 6 Pushbutton Lock Security Level 59 7 Pushbutton Lock Security Level. 64 8 Guidelines for Characteristic Choice 6 9 Error Messages. 78 10 VIEW DATA Settings. 85 11 Compliance Voltage for Single Channel Zener with 22 AWG Cable. 100 12 Compliance Voltage for Galvanic isolator with 22 AWG Cable. 101 13 Compliance Voltage for No Barrier with HART Filter and Resistor and 18 AWG Cable 101 14 Supplemental Voltage for Split Range. 110 15 Environmental Specifications 139 16 Operational Specifications* 40 17 Input Signal, Power, and Display Specifications wi 18 Construction Moterial Specifications ai 19 System Connectivity a2 20 Pneumatics Single Acting Standard Flow aa 21 High Flow Pneumatics Single Acting High Flow. 143 22 Pneumatics Double Acting Standard Flow. a 23 Tight Shutoff Parameters for High Pressure Liquid Letdown Trim 160 © 2014 General Electric Comoany lights reserved Masoneiian Sv A9 installation and Maintenance Manual | 17Safety Information This section provides safety information including safety symbols that are used on the SVI AP ‘ond the safety symbol definition CAUTION Read this entire section before installation and operation, Safety Symbols SVIII AP instructions contain WARNINGS, CAUTIONS labels and Notes, where necessary, to alert you to safety related or other important information, Total compliance with all WARNING, ond CAUTION notices is required for safe operation. WARNING Indicates a potentially hazardous situation, which if not avoided could result in serious injury. CAUTION Indicates a potentially hazardous situation, which ifnot avoided could result in property or data damage Note Indicates important facts and conditions. 2014 Genero i Company. Allights reserved Masonelon Sv AP Instellaton ond Maintenance Manval | 13,SVIILAP Product Safety The SVI I AP digital valve positioner is intended for use with industrial compressed ci or, natural gas systems only. NoTe Installations using natural gas are Zone 0 or Div 2 installations. Ensure that an adequate pressure relief provision is installed when the application of syst supply pressure could cause peripheral equipment to malfunction, installation must be in accordance with local and national compressed air and instrumentation codes, General installation, maintenance or replacement Products must be installed in compliance with all local and national codes and standards by qualified personnel using safe site work practices. Personal Protective Equipment [PPE} must be used per safe site work practices Ensure proper use of fall protection when working at heights, per safe site work practices. Use appropriate safety equipment and practices to prevent the dropping of tools or equipment during installation. Under normal operation, compressed supply gas is vented from the SVIII AP to the surrounding area, ond moy require additional precautions or specialized installations. Intrinsically Safe installation Products certified as explosion proof or flame proof equipment or for use in intrinsically safe installations MUST BE: installed, put into service, used and maintained in compliance with national and local regulations ond in accordance with the recommendations contained in the relevant standards concerning potentially explosive atmospheres. Used only in situations that comply with the certification conditions shown in this document and after verification of their compatibility with the zone of intended use and the permitted maximum ambient temperature installed, put into service and maintained by qualified and competent professionals who have undergone suitable training for instrumentation used in areas with potentially explosive atmospheres. 14] ceoneces © 2014 Genero levie Company Alrghts reservedWARNING —_ Before using these products with fluids/compressed gases other than air or for non-industrial applications, consult the factory. This Lv product is not intended for use in life support systems. Under certain operating conditions, the use of damaged instruments could cause a degradation of the performance of the system, which can lead to personal injury or death, Under certain operating conditions the SVI Il AP High Flow unit can produce noise levels greater than 85 dBA. Perform proper site monitoring and testing to verify the need for engineering or administrative controls to eliminate or reduce hazardous noise levels. Installation in poorly ventilated confined areas, with any potential of gases other than oxygen being present, can lead to a risk of personnel asphyxiation, Use only genuine replacement parts which are provided by the manufacturer, to guarantee thot the products comply with the essential safety requirements of the European Directives. Changes to specifications, structure, and components used may not lead to the revision of this manuol unless such changes affect the function and performance of the product. © 2016 Genero electric Comaary Al rghts reserved. lon SV 1 APinstalation and Maintenance Manual [15Introduction The SVIII AP [Smart Valve Interfacel is the next generation of Masoneilan’s intelligent digital valve positioners. The SVI Il AP is o high performance, digital valve positioner that combines a local display with remote communication and diagnostic capabilities. The SVI II AP offers a multitude of options that fulfills the broadest range of applications. It also communicates using the HART protocol, The High Flow version is capable of 2.2 Cv air throughput ‘An optional pushbutton and LCD display enables local operations of calibration and configuration functions. Remote operations can be performed with Valvue software or any HART Registered host interface that has been pre-loaded with the Device Descriation file [DD) for SVIILAP. The SVI II AP is provided with Masoneilan’s ValVue software. The user-friendly interface facilitates the setup ond diagnostics of « contral valve. Figure 1 SVIIAP company. Al ght reserved Masonelon Sv AP Instellovn and Maintenence Monval | 17ValVue Software Not only does ValVue provide the ability to quickly and easily set up the SVIII AP you can also monitor operation and diagnose problems with ValVue's advanced diagnostic capabilites. ValVue Lite Value Lite software is shipped with each SV111AP for positioner calibration and configuration, Valve Lite software is freeware and does not require any registration. It provides functions to properly set up and start up an SVIII AP digital voive positioner on any type of control valve. System Requirements Valvue Lite runs on IM compatible computers, Minimum requirements for all versions of Value software are Windows XP, Windows Server 2003, Windows Server 2008, Windows 7, 64 MB RAM, serial or USB port connected to a HART madem, and @ CD-ROM drive. ValVue Trial Version The SVIII APis provided with o trial version of ValVue. For 60 days after the initial installat Value provides the capability of configuring, calibrating, diagnosing, cloning, trending and much more. After the 60 tril period ValVue must be registered for use. Value is a user-friendly What-You-See-Is-What-You-Get WYSIWYG}, graphical interface that allows an efficient setup of an SVI1i AP mounted on any control valve assembly. VolVue functionality includes: Setup Wizard Remote display of valve position, actuator pressurels) Set calibration parameters Set configuration parameters Monitor statuserror indicators nput/Output configuration Remote calibration of the SVIII AP Remote configuration of the SVI II AP Remote operation of the SVI II AP Backup and restore configuration (clone device) Trend setpoint, valve position, actuator pressure U_ Oisplay comparative test results [full version only} Perform diagnostic test procedures [full version only) 18] ceovaces © 2014 Genero levie Company Alrghts reservedAdvanced and Online Diagnostics The SVI11 AP offers various levels of control vaive diagnostics. Up to five pressure sensors that detect circuit board temperature, loop current, and reference voltage, are available for diagnostics For more details on the use of ValVue software, refer to the ValVue User's Guide. Contact the factory or your local representative to obtain licensing information, Contact GE For the most recent software visit our SVIII AP web site at: http://wwwge-mcs.com/en/ download htm. Operational Overview The SVIII APs a smart electro-pneumatic positioner that receives a 4 - 20 mA electrical position setpoint signal from the controller and compares the position setpoint input signal to the valve position feedback sensor. The difference between the position setpoint and position feedback is analyzed by the position control algorithm that sets a servo signal for the /P converter. The output pressure of the I/P is ampified by a pneumatic relay that drives the actuator. Once the error between the setpoint and the valve position feedback is within range, no ather correction is applied to the servo signal in order to maintain valve position. The local explosion proof LCD/Buttons lif equipped) display provides configuration or calibration mode in all operating environments. The limit switchtransmitter options board provides contact outputs that are software configurable, and an analog {4 - 20 mA) position feedback. SVI II AP Features The SVII AP Digital Vaive Positioner (see Figure 1 on page 17Iis suitable for installation indoors or outdoors, and in a corrosive industrial or marine environment and is equipped with the following features Extreme Accuracy Extreme Reliability Extreme Digital Precision ‘Automated Valve Commissioning Precise, Quick, Responsive Control of Vaive Position. Valve Position Autotuning One Model for Rotary or Reciprocating Valves Local Operation¢alibratiomconfiguration with Optional Flameproof Push Buttons and LCO Digital Bisplay © 2016 Genero electric Comaary Al rghts reserved. lon Sv APinstalation and Maintenance Manual |19Compatible with Air-to-Close or Air-to-Open Actuators Non-contact Magnet Coupled (Hall Effect] Position Sensing for Rotary and Reciprocating Control Valves Sealed Housing with No Moving Shafts, No Shaft Penetration, and Fully Potted Electronics Uniform Hazardous Area Approvals for ATEX, CSA and &M with Other Approvals Available Upon Request ‘cal, On-line Diagnostic Condition Monitor: Total Stem Travel, Number of Valve Cycles. Predictive Maintenance Data Advanced Valve Diagnostics with ValVue Software and the Pressure Sensor Option User-adjustable Response Times Split-range Capability Configurable High and Low Position Limits Characterize Stroke Lineor Equol Percentage 50:1 Equol Percentage 30:1 Quick Opening 11 Point Custom Characterization Camflex Percentage Optimized Performance Regardless of Actuator Size Linearity Compensation for Actuator Linkages with Valvue Software User Configurable Tight Shutoff at Adjustable Input Signal HART Compatible [HART § ond 6) HART Remote Operation Calibration Configuration Diagnostics Using ValVue software or a HART handheld communicator Single or Double Acting [not available for the High Flow version 20) ceowaces © 2014 Genero levie Company Alrghts reservedAvailable Options ‘Some of the options ovailable for the SVI II AP include: Remote Position Sensor Two Contact Outputs User Linked to Various Status and Alarm Flags Offshore Construction - Stainless Steel Housing and Components Pushbutton Display About This Manual he SVIILAP Instruction Manual is intended to help o Field Engineer install, setup, and colibrate an VIII AP in on efficient manner. This manual also provides in-depth information on SViII AP software, digital interfaces, operation, intrinsic sofety configurations, and specifications. f you experience problems that are not documented in this guide contact the factory or your local representative. Sales offices are listed on the back cover of this manua Conventions Used in This Manual Conventions used in this manual are as follows: Uppercase, italicized letters are used when referencing a term used in the SVII| AP disploy window. For example, when indicating the term mode, as in setup mode, and referring to the display/software operation the convention is to spell mode is al uppercase letters: MODE. Italics is used for emphasis on important items Fields where data is entered or user-entered date is italicized, Actions performed on buttons, checkboxes, etc. appear bolded. For example: Click Done. NoTE Indicates important facts and conditions. CAUTION Indicates a potentially hazardous situation, which if not avoided could result in property damage or data loss. WARNING Indicates a potentially hazardous situation, which if not avoided i could result in death or serious injury. lon SV AP nstalation and Maintenance Manual |21 © 2016 Genero electric Comaary Al rghts reserved.Installation and Set Up Overview The SVIII AP [Smart Valve Interface - see Figure 2 and Figure 3 on page 24) is a high performance, digital valve positioner that combines a local display with remote communication ‘ond diagnostic capabilities. The SVI II AP is available with o variety of options to fulfil diverse applications and it communicates using the HART protocol NoTe Prior to beginning the installation process review the “Sofety information” on page 13. Masonelon Sv AP nstellaton ond Maintenance Manval_ [23 1 2014 Genero lectre Company. rights reservedSUIILAP Cover SVIILAP Assembled 11 Pneumatic Tain and Cover II/P Module, Relay) J. Electronies ifold oo Module au 0 . \ Relay Figure 2 SVIII AP Components Manifold Cover {/P Module) Figure 3 SVIII AP High Flow Components 24 Geovaces © 2014 Genero levie Company Alrghts reservedSVIILAP Dimensions and Weights Figure 4 illustrates the dimensions and weight of the SVI Il AP single-octing. Center of Gravity Figure 4 SVIII AP Single-Acting Dimensions © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstalotion and Maintenance Mans! | 25Figure S illustrates the dimensions and weight of the SVI II AP double-acting, Figure 5 SVIII AP Double-Acting Dimensions 26] ceonaces © 2014 Genero levie Company Alrghts reservedFigure 6 illustrates the dimensions and weight of the SVI II AP High Flow. 3 i g = 3 3 Weight with display- 9.36 Ibs 1.426 kal Figure 6 SVIII AP High Flow Dimensions © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstaletion and Maintenance Manso! |2?Pre-Installation Issues Storage If the SVIII APs stored for a long duration, you must keep the housing sealed against weather, fluids, particles, and insects. To prevent damage to the SVI II AP Use the plugs provided with shipment to plug the % NPT air connections, on the positioner and on the air filter regulator set. Do not allow standing water to accumulate. Observe storage temperature requirements. Unpacking Exercise care when unpacking the control valve and its mounted accessories. The SVI II AP container includes a CD-ROM with ValVue Lite, ValVue Trial Version, and manuals Installation Steps I you experience problems that are not documented in this guide call the factory or your local representative, Soles offices are listed on the last page of this document. The steps necessary to complete the SVI II AP installation and software setup ore outlined in Table 1 Table 1 SVIILAP Installation Steps Step No. Procedure Reference 1 ‘Attach mounting bracket to the actuator ‘See page 31 for rotary valve and page 36 for reciprocating valve instructions. 2 Install the SvI IAP magnetic assembly [rotary valves _| See page 35 for instructions. only 3 ‘Assemble the SViII AP on the bracket that is mounted to | See page 31 for rotary valve ond page 36 the valve actuator. for reciprocating valve instructions. 4 Install the Remote Position Sensor, if necessary. ‘See GEA31195 Masoneilan Valve Solutions Remote Sensor Quick Start for instruc tions. 5 Connect the pneumatic tubing to the SVI i AP, See page 48 for instructions, 6 Connect the air supply to the SVIII AP. See page 48 for instructions. 7 Connect the positioner to the HART Control Loop seg- | See page 48 for instructions. ment by installing the SVIII AP wiring 28) ceonaces © 2014 Genero levie Company Alrghts reservedTable 1 SVIII AP Installation Steps (Continued) Step No. Procedure Reference a Configure/Calibrate using LCD Pushbutton display Configure/Calibrate using o Hart Hand Hela Communicator, Configure/Calibrate using Valvue See page 83 for instructions See page 91 for instructions See page 93 for instructions. WARNING Failure to adhere to the requirements listed in this manual can j cause loss of life and property. WARNING Before installing, using, or carrying out any maintenance tasks associated with this instrument, READ THE INSTRUCTIONS LA CAREFULLY. Installation Notes © 2016 Genero electric Comaary Al rghts reserved. The installation must comply with local and national regulations concerning the compressed air supply and SVI II AP instrument. Installation and maintenance must be performed only by quolified personnel, SVI II AP repairs beyond the scope of this manual must be performed by the factory. Area Classification, Protection Type, Temperature Class, Gas Group, and Ingress protection must conform to the data indicated on the label Wiring and conduit must conform to all local and national codes governing the installation. Wiring must be rated for at least 85° C {185° F) or 5° C (41° F} above mox ambient, whichever is greater. Approved wire seals against ingress of water and dust are required and the 1/2" NPT fittings must be sealed with tape or pipe dope in order to meet the highest level of ingress protection lon SV APInstalation and Maintenance Manual |29Before Powering Up Before powering up the SVI II AP. Verify that the pneumatic connections and electronic cover screws are tightened. This is important to maintain the ingress protection level and the integrity of the flameproof enclosure. 2, Ifthe installation is intrinsically Safe, then check that the proper barriers are installed and the field wiring meets local and national codes for an IS installation. 3. If the installation is non-incendive, then check that all the electrical connections are to approved devices and wiring meets local and national codes. 4 Verify that the markings on the label are consistent with the application. NoTE For Hazardous Location Installation information refer to “Specifications and References”, Mounting the Positioner This guide provides installation instructions for mounting an SVI Il AP on both rotary and reciprocating actuated valves. The mounting process can be broken down into Attach the mounting bracket to the actuator. install the magnetic assembly (rotary only Assemble the SVI II AP on the mounting bracket. CAUTION Mount the SVi1! AP with the conduit connections down in order to focilitate drainage of condensate from the conduit. Necessary Precautions To avaid injury or the process being offected when installing or replacing a positioner on a control valve, ensure that i the valve is located in a hazardous oreo moke sure the area has been certified as safe or that all electrical power to the area has been disconnected before removing any cavers or disconnecting any leads. Shut off air supply to the actuator and to any valve mounted equipment. Ensure the valve is isolated from the process by either shutting off the process or using bypass valves for isolation. Tag shutoff or bypass valves to guard against a turn-on while work is in progress. Purge air from actuator and check that valve isin its unenergized position. 30] ceovaces © 2014 Genero levie Company Alrghts reservedFilter Regulator and Tubing he use of o Masoneilan filter regulator with a S-micron filter is recommended for the air supply, Use 14° (6.35 mm) minimum tubing between filter regulator, SVIII AP and the actuator, with 38° (9.53 mm) used for larger actuators. Use a soft setting anaerobic hydraulic seal such as Loctite Hydraulic Seal $42 for sealing the pneumatic pipe threads. Follow manufacturer's si uctions, NOTE Moximum allowable air supply pressure to the SVI II AP varies according to actuator and valve size and type. See pressure drop tabies in valve specification sheets to determine correct positioner supply pressure, Minimum supply pressure should be 5 to 10 psi (345 bar - 69 bar) (34.485 - 68.97 kPa) above maximum spring pressure. Mounting the SVI II AP on Rotary Valves This procedure is used to mount the SVI II AP on rotary control valves that have less than 60° rotation, such as a Camflex or 0 Vorimax. For valves that have rotation greater than 60° refer to *Rotary - 90" on page 35 Required Tools The following tools are needed to complete the rotary valve installation: 3/6" Hex Key with tee hondle 952" Hex Key 3.mm, 4mm, § mm Hex Key a 706" Wrench To mount the SVI Il AP 1. Attach the SVI II AP rotary mounting bracket to the valve actuator using two (2) 516 - 18 UNC flat-head cap screws, Mount the SVIII AP as shown in Figure 8 on page 33, ATO or in Figure 9 on page 33, ATC. In the preferred mounting position, the long end of the mounting bracket is on your left when facing the actuator, for any position of the valve and actuator 2. Bolt the extension shaft to the valve position toke-off shaft using a V4 - 28 UNF socket flothead screw. Secure the machine screw holding the extension shoft with a torque of 1464 in-Ibs (16.269 N-m 3. Upon internal valve pressure the thrust shofl is pushed out to the mechanical stops, usually o thrust bearing. On valves where the valve position take-off is mounted directly on the end of the plug shaft, a Camflex for example, the shaft must be bearing on its stop to properly set up the SVi II AP digital valve positioner. Quring hydrostatic testing the shaft is thrust to its stop and « normally tightened packing retains it in that position. © 2016 Genero electric Comaary Al rghts reserved. lon SV APInstaletion and Maintenance Mana) | 3132 10. 11 (On vacuum service, the valve shaft can be drawn into the body by the vacuum acting on the shaft, but the magnetic coupling must be assembled flush with the mounting bracket with the shaft pulled fully out to its thrust bearing, Check that the endploy from the vacuum position to the fully extended position is less than 0.06 in. (1.524 mm) Slide the magnet holder into the extension shaft. The location of the magnets isin the ring of the magnet holder. The magnetic axis is the imaginary line through the center of both magnets Rotate the magnet holder so that the magnet axis is vertical when the valve isin the closed position. See Figure 8 and Figure 9 Align the end of the mognet holder flush with the end of the mounting bracket. Secure the magnet holder with two M6 set screws. Slide the V-Seal over the magnet holder. Secure the SVI II AP onto the mounting bracket using four M6 x 20 mm Socket Head Cap screws. Ensure no interference exists with the position sensor protrusion, Ensure that the V-Seal makes contact with the skirt around the position sensor protrusion on SII AP housing. (= Extension. Lock Magnet Shaft ‘Assembly Flush w/Top of Bracket ‘Magnet Holder V-Seal Figure 7 Camflex with Mounting Bracket (Side View) © 2014 Genero levie Company Alrghts reservedFigure 8 Camflex ATO Mounting (Front View) Air-to-Close (ATC) Set magnet when actuator is Energized Long end of bracket to left Figure 9 Mounting Bracket on Air-to-Close Actuator © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv aPnstaletion and Maintenance Manso! | 33,Table 2 shows the general guidelines for travel sensor alignment. Review the table prior to installing the SVI 11 AP on a rotary valve actuator for proper alignment of the magnet, Table 2 Travel Sensor Alignment Rotary Stroke Direction Sensor Counts Mounting Orientation | Position System -<60° Rotation Closed {0%4) | 0 +/- 1000) Clockwise or counter- clockwise rotation >60° Rotation FullOpen | -8000 +/- 1500 Clockwise with or or increasing setpoint FullClosed | +8000 +/- 1500) >60° Rotation Fullpen | -8000 +/- 1500 Counter Clockwise or or rotation with increas- FullClosed | +8000 +/- ing setpoint 1500 General Rule for | Any amount of rota- 50% Travel | 0 +/- 1000 other configu: | tion Clockwise or IMid-Stroket rations counterclockwise 34 Geovaces © 2014 Genero levie Company Alrghts reservedFigure 10 Model 33 Actuator Rotary - 90° For actuators with 60 to 120° rotation, follow the instructions in “Mounting the $VI II AP on. Rotary Valves" on page 31 except mount the magnet at plus or minus 45* while the octuator de-energized as shown in Figure 10 on page 35, Magnet Orientation on Rotary Valve Shafts The same mounting hardware is used for Models 35, 30 actuators. For each actuator type the magnetic coupling must be properly oriented to the active sensing angle of the positioners Hall Effect sensor. The active range of the Hal-Effect sensor is plusiminus 70° from the null magnet axis. Ifthe total valve travel is less than 60*, allowing o margin for tolerances, the best accuracy is achieved by mounting the magnet with the axis vertical in the valve-closed position, The location of the magnets in the ring of the magnet holder. The ax’s of the magnets i the line through the centers of both magnets. Mount the magnet holder with the magnet xis vertical on the 35, 30 when the valve is closed, If travel of the valve exceeds 60°, the magnet must be assembled to the rotary vaive shaft so that the magnet axis is vertical when the valve is at mid-scale. Dismantling the SVI II AP from Rotary Valves WARNING Before carrying out any work on the device, power off the instrument or make sure that the device's location conditions for LA potentially explosive atmosphere permit the safe opening of the cover. To remove the SVI II AP digital valve positioner from a rotary valve perform Steps 1-8 on page 28 in reverse © 2016 Genero electric Comaary Al rghts reserved. lon SV 1 APInstalation and Maintenance Manual | 3SMounting the SVI II AP on Reciprocating Valves This section describes the procedure for mounting the SVI II AP on Reciprocating Valves [using Masoneilan’s 8788 Multi-Spring actuators as an example} Tools required 76" Combination Wrench [2 required) 38" Combination Wrench Ve" Combination Wrench Phillips Head Screw Driver 5 mm Hex Key Wrench Mounting the SVI II AP on a Reciprocating Actuator 36 1. Ensure that the lever is pinned to the magnet assembly and held securely by an MS flat head screw to ensure thot the magnet axis is vertical when the lever is in the valve closed position. Tighten the lever screw securely. 2. Mount the SVIII AP reciprocating mounting bracket to the actuator using two [2] S16 - 18 UNC cap screws. The mounting location of the bracket depends on the size and stroke of the actuator. Refer to Figure 12 on page 37 and Figure 3 on page 38. 3. Select mounting hole A, 8, C or D for the stroke of the valve. For example, hole 8 is shown. in Figure 13 on poge 37 for a size 10 actuator with 1.0" stroke, Unless otherwise specified the SVI II AP mounting assumes that the actuator is in the normal upright position. The mounting hole in the slotted opening of the mounting bracket must be left when facing the actuator, with the actuator in the upright position. 4, Move the valve to its closed position. For air to extend, this requires using air pressure in the actuator to fully stroke the actuator. For air to retract, actuators vent the actuator of air pressure, 5. Thread the take-off rod to the actuator stem connector. Refer to Figure 14 on page 39. Ensure that the travel pointer located on the coupling is correctly positioned 6. Attoch the right hand threaded rod end to the SVIII AP lever using 0 V4 - 20 x 1" cap screw and nut as shown. The lever hole position to be used depends upon the specific valve stroke. Refer to Figure 13 on page 37 and the Reciprocating Valve Linkage Selection Table 3 on page 38. 7. Thread the right hand lock nut and turnbuckle ont two turns, Turnbuckle length is a function of actuat: the right hand rod end approximately size. Refer to Table 3 on page 38) 8. Secure the magnet housing assembly, including the lever and right hand rod end, to the bracket using four MS X 10 mm flat head screws 9, Attach the left hand threaded rod end to the take-off rod with 141 - 20 UNC nut and thread the left hand lock nut onto the rod end 10. Thread the turnbuckle onto the left hand threaded rod end. Refer to Figure 14 on page 39, ceovaces © 2014 Genero levie Company Alrghts reserved11, Adjust the turnbuckle until the hole in the SVI Il AP lever is aligned with the indicating hole in the bracket. Tighten both turnbuckle lock nuts, See Figure 12 on page 37. 12, Mount the SVIII AP to the bracket and secure with four M6 socket head cap screws. Housing ee J Lever Magnets. Ring Magnet holder assembly Figure 11 Magnet Holder for Reciprocating Valves Figure 13 Lever for Model 87/88 Multispring Actuator © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstaletion and Maintenance Manso! | 37,Table 3 Reciprocating Valve Mounting Hole and Turnbuckle Length ‘Actuator Size Stroke Mounting Hole | — Lever Hole Turnbuekle Length 6 and 10 05-08" A A 125" 112.7 2032 mm} 61,75 mm) 10 05-08" A A 125° 112.7 - 2032 mm (1.75 mm) 10 208-15" 8 8 12s" [20.32 - 38.1mm G1.75 mm) 16 05-08" 8 A 2.90" 112.7 - 2032 mm (73.66 mm) 16 208-15" c 8 290 [20.32 - 38.1 mm (73.66 mm) 16 >15-25" o c 2.90 (38.1- 63.5 mm) (73.66 mm) 23 05-08" 8 A 5.25" 112.7 - 20.32 mm (133.35 mm} 23 208-15" c 8 5.25 [20.32 -38.1mml (133.35 mm} 23 >15-25" ° c 5.28 (38.1- 63.5 mm) 1133.35 mm 38 ceovaces © 2014 Genero levie Company Alrghts reservedMagnet Housing Lever. ry 114-20 x1 114-20 x 1 Nut| LF E17 Cap Screw ht Hand Thread —T] Rod End i Left Hand Threat ee Rod End [_Turnbuckle Length Take Off Rod Figure 14 Reciprocating Linkage Dismantling the SVI II AP from Reciprocating Valves WARNING Before carrying out any work on the device, power off the instrument or make sure that the local conditions for potentially LA explosive atmosphere permit the safe opening of the cover To remove the SVIII AP digital valve positioner from a reciprocating valve perform Steps 1 - 12 on page 31 and page 32 in reverse © 2016 Genero electric Comaary Al rghts reserved. Masonelon Sv APinstalation and Maintenance Manual |39Installing the SVI II AP for Double- Acting Operation This section explains how to mount the SVIII AP for the 84/85/86 kit for double-acting valve positioner configurations. To mount the kit 1. Set valve to the closed position. 2. Install the mounting assembly to the yoke [Figure 15) using helical spring washer 5/16, flat washer 5/16 and hex screw 5/16-18x44.5 [1.75] LG Figure 15 85/86 Valve Note ‘Mount all components snug enough to stay in place but loose [1] enough to tap with rubber hammer into final position 3. Set rod-ends and brackets to stroke and size of actuator. The default setting is @ 4.00" stroke, Other stroke settings are as in Figure 16. Hole $0 to 80" Stroke Hole 1.00" to 1.50" Stroke. Hole ¢: 200" to 2.50" Stroke — Hole 0: 300" to & 50" Stroke Hole & 5.00" to 600" stroke: Figure 16 Stroke Settings 40 ceonaces © 2014 Genero levie Company Alrghts reserved4, Mount take-off bracket to stem block at angle which keeps turnbuckle assembly parallel to stem [Figure 17] using ©. For top: two plain 5/16 flat washers, helical spring washer 5/16, two hex nuts §/16-18 regular, b. For bottom: hex nut regular 1/4-20 and hex screw 1/4-20 UNC x 22.2 [8] LG. ar Figure 17 Bracket Configuration Strokes .5 - 2.50" and 3-6" stem and the magnets are in the valve 5, Ensure the turnbuckle assembly is parallel t closed position (Figure 18] and connect to toke-o' POSITION OF Figure 18 Magnet Position with Valve Closed © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv AP nstlotion and Maintenance Manu! | 46. Verify levers in correct position with valve closed. Adjust rod-ends, if necessary. Figure 19 Lever Alignment 7. Mount the SVI-II with M6-1 screws. 8. Cycle the valve open to close verifying proper components movernent and that rod-ends, move free and clear from other components. 42| ceowaces © 2014 Genero levie Company Alrghts reservedConnecting the Tubing and Air Supply The last step in hardware installation for the SVI II AP is to connect the air supply to the positioner. This section describes the process for connecting the tubing and air supply to a single and double acting positioner. Dew Poin WARNING —_ Isolate the valve fram the process and disconnect air tubing from the positioner. Disconnect air fully to avoid injury or process LN “me Install the tubing to the air supply port, AS (arrow only for High Flow) Fora single acting actuator - pipe the outbound air from the output pressure port (Cl to the actuator (arrow only for High Flow, For @ double acting actuator - pipe output pressure port one {¢-l for one side of the ‘actuator and output pressure port two [EI for the other side of the actuator (arrow only for High Flow! Air supply: Supply pressure for single acting SVI II AP and AP High Flow: 20-100 psi 1.4 - 6.9 bar) (138 - 690 kPa} Supply pressure for double acting SVI II AP. 25 - 150 psi (1.73 - 103 bar) (172 - 1030 kPa} Minimum tubing diameter V4 (6mm x 4mm) NOTE The SUI! AP Digital Valve Positioner is designed to operate with clean, dry, oil-free, instrument grade air to ANSI-SA-57.3 1975 (R1981) or ISA-S7.3-1975 [R1981) or with a sweet natural gas supply (SVI 11 AP models SWI II AP-2 through SVI Ii AP-3I Table 4 Air Supply Requirements Atleast 18°F (-7° C) below minimum anticipated ambient temperature Particulate Matte Filtered to 5 microns oil Content Less than 1 ppm wiw Contaminants Free of all corrosive contominants, CAUTION The SVIIIAP High Flow digital valve positioner cannot be placed in orale! with another volume baoster. Contact the factory for further instructions regarding configuration with boosters as well as other non-standard configurations. © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv aPnstaletion and Maintenance Manso! | 43CAUTION Do not use pipe thread sealant tape on pneumatic fittings. It may shred into small particles that can cause instrument malfunction. WARNING Never exceed the actuator maximum rated supply pressure 100 psi (69 bor, 689.7 kPo] for single acting or 150 psi (10.3 bar, 1030 Lv kPa} for double acting positioner. Damage to equipment or injury to personnel can result. CAUTION Remove any excess pipe thread sealant from the first and second threads to prevent uncured sealant from entering the air lines. Single Acting Positioner The supply and output connections for the SVI II AP (Figure 20}, located on bottom of the pneumatic block, are tapped 1/1” NPT. Output is toward the front, supply is toward the back. Two pressure gouges, output on top, supply on bottom, are lacated on the front of the pneumatic block. The supply and output connections for the SVI II AP High Flow (Figure 21), located on bottom ond leftside of the pneumatic block, are tapped 1/2" NPT Maximum allowable air supply pressure to the SVI IAP varies according to actuator, valve size and valve type. See Pressure Drop tables in valve specification sheets to determine the correct positioner supply pressure, Minimum supply pressure should be 5 psi to 10 psi 345 bar - 69 bar) (34.485 - 68.97 kPa) above moximum spring range but may not exceed the rated actuator pressure. 1. Pipe the outbound air from the output pressure port (€—I} (arrow only for High Flow) to the valve actuator 2. Connect air supply and actuator outputs [Y4" NPT or 1/2" NPT for High Flow units) Supply pressure is 20 -100 psi (1.4 - 6.9 bar} [138 - 690 kPal, Minimum tubing diameter 141" [6 mm xamm). 4a) ceoneces © 2014 Genero levie Company Alrghts reservedsupp\ Figure 20 SVIII AP Air Ports on Single Acting Positioner output Figure 21 SVII AP High Flow Air Ports on Single Acting Positioner © 2016 Genero electric Comaary Al rghts reserved. Masoceilon Sv aPnstalotion and Maintenance Mons! |SDouble Acting Positioner The Double Acting [DA) relay has « pair of opposed pneumatic outputs. When Output 1 delivers air to one side of the actuator, Output 2 vents cir from the opposite side of the actuator piston. The volume of air trapped in each determines the position of the actuator. The Action {ATO or ATC) is applied with respect to Output 1. When Output 1 is connected to deliver air to extend the actuator, the actian is ATC, on « down-seating valve. 1. Connect Output 1. labeled (eto the inlet port of the actuator and Output 2 labeled (CAN to the opposing actuator port [see Figure 22) 2. Connect air supply and actuator outputs {14" NPTI. Supply pressure is 25 - 150 psil1.7 - 103 bar [172 - 1030 kPa, Minimum tubing diameter V&" [6 mm x 4 mm) output Figure 22 Air Ports on Double Acting Positioner 46) ceowaces © 2014 Genero levie Company Alrghts reservedBalance Pressure The double-acting relay is designed to deliver pressure on both sides of a piston type actuator, so that the cylinder can provide the required thrust and stiffness. This stiffness is factory adjusted to 70% of the supply pressure. This means that, without any unbalance forces from the valve stem, both outputs deliver roughly 70% of air supply pressure Although itis not recommended, the stiffness can be odjusted by moving the Adjustoble Seat assembly up or down Actuator Piping Connect Output 1, labeled ACT 1 to the inlet port of the actuator in accordance with Figure 23. Output 2 labeled ACT 2 connects to the opposing actuator port. In allfour scenarios Pt and P2 are reversed cepanding on the sic contqustion ATO or ATC ea a=} 36 a5 een aoe ean a Soe Soe Seats Serato ‘att re ‘Wihsrne * thou spring requires actup a supply orresene tanto falsafe the va Figure 23 Double Acting Positioner ATO/ATC Settings for Reciprocating Valves lon SV AP Installation and Maintenance Mana! © 2016 Genero electric Comaary Al rghts reserved.Connecting the Air Supply After the tubing is installed, use the following procedure to connect the air supply. 1, Use a supply of clean, dry compressed air to the filter regulator 2, Turn on the air supply. 3. Adjust the fier requlotor 4, Supply pressure must be 5 psi - 10 psi 345 bor - 69 bar) (34.485 - 68.97 kPa) greater than the spring range of the actuator but may not exceed the roted actuator pressure. Refer to the valve or actuator instruction manucl Wiring the SVI II AP The procedure below outlines wiring the SVIII AP. WARNING Comply with current national and local regulations for electrical installation work ZN Comply with national and local explosive atmosphere regulations. Before carrying out any work on the device, power off the instrument or make sure that the local conditions for potentially explosive atmosphere permit the safe opening of, the cover. CAUTION Refer to “Output Switches” on page 121 for guidelines on safely wiring switch load limits. Connecting to the Control Loop a The SVI 1 AP digital valve positioner MUST BE grounded according to local regulations. itis, important to maintain correct polarity at all times, otherwise the positioner may not operate properly. Physically connect the SVI Il AP to the control loop using a cable specified by the HART Communication Foundation, A shielded cable is recommended To communicate using HART: 1. Connect ane end of the cable to the control loop's 4 - 20 mA output 2. Remove the threaded wiring covers on the positioner. 3. Connect the other end of the cable t the posit the SVIII AP. There ore two threaded openings on ner. Use the opening with the red plostic insert 4, Maintain polarity + and - respectively. ceovaces © 2014 Genero levie Company Alrghts reservedVerify Wiring and Connections NoTE For split range installations there are additional constraints on the split range system: the minimum span must be § mA; the upper range value must be 8 mA to 20 mA; the lower range values must be 4 ma to 14 ma Use the following procedure to ensure ‘ot the SVIII AP is properly powered: 1. Connect a DC voltmeter across the input terminals. 2. For on input current between 4 and 20 mA, the voltage varies between 11 Vand 9 V respectively, 3, Currents read from the local display or with a milliampmeter installed in series with the SVIIIAP, 4, When voltage exceeds 11 V check that the polarity is correct. 5. If voltage is less than 9 V and polarity is correct, voltage compliance of current source is inadequate. 6. Connect a milliampmeter in series with the current signal. Verify that the source can supply 20 mA to SVI II AP input 7. If 20 mAis not attainable, see troubleshooting NOTE Improperly or inadequately grounded installations can cause noise or instability in the control foop. The internal electronic components are isolated from ground. Grounding the case is unnecessary for functional purposes but grounding the case may be necessary to conform to local codes. Wiring Considerations For a detoiled description of wiring guidelines refer to “Wiring Guidelines” on page 96 of monual © 2016 Genero electric Comaary Al rghts reserved. lon SV APInstalation and Maintenance Manual | 49Check Out and Power Up Overview This section provides the checkou order and to power up the unit, rocedures required to determine if the SV! IIAP isin working NOTE Perform all procedures in this section before putting the SVI1\ AP into operation. Position Sensor Principles The motion of the control valve (position! is precisely transmitted to the SVIII AP by a pair of rotating magnets located outside the instrument housing. Rotation of the magnets is sensed internally by a Hall Effect sensor. Because the only connection through the case is a magnetic: field there are no seals or bearings to wear or corrode. The rotation of the magnet is linked to the valve position by the mounting hardware provided, For a rotary control valve the magnet assembly is normally attached directly to the actuator shaft, For 6 reciprocating control valve the mounting kit includes the magnet assembly mounted ina sealed bearing with a lever that must be linked to the valve stem. The positioner must be installed with the gauges to the left and the housing display and cover to the right. The % NPT conduit entries must be facing down to drain condensate away from the housing, The positioner can be moved on the valve for best drainage depending on the position of the valve in the pipeline. company. Al ght reserved Masonelan Sv AP Instolotion and Maintenonce Manual |$1Check Out Procedures SVIILAP checkout consists of physical and operational checkout procedures, The physica checkout procedures include: inspect the Actuator, Linkages, or Rotory Adapter Verify the Mounting and Linkage Adjustment Check the Magnet U Cheek the Air Supply Check the Electronic Module Connections Physical Inspection SVIILAP checkout consists of physical and operational checkout procedures, The physica checkout procedures include: inspect the Actuator, Linkages, or Rotory Adapter Verify the Mounting and Linkage Adjustment Check the Magnet Check the Air Supply U Check the Electronic Module Connections Valve Mounting U The Air Supply Actuator, Linkages, or Rotary Adapter Verify that the mounting has not been damaged in shipment for a pre-mounted SVI Il AP, physically inspect the actuator, linkage. Record the following information for the configuration checkout 1. Valve Air to Open (ATO! or Arto Close [ATC Actuator pressure rating Actuator bench range inherent trim characteristic of the control valve; linear, equal percentage, or other, NoTe Refer to the valve data sheet or model number of control valve, 52] ceovaces © 2014 Genero levie Company Alrghts reservedVerify Mounting and Linkage Adjustment Inspect the mounting and make any needed adjustments before running the positioner and checking the digital configuration. Checking the Magnet ‘There are two methods of checking the SVI II AP magnet: 1 Perform a visual inspection Use Value to check the magni Performing a Visual Inspection You must remove the positioner from the bracket to visually inspect the magnet orientation. For rotary valves, such os & Camfex, or for actuators with rotation of less than 60°, the magnet assembly must be aligned as shown in Figure 24 on page S3. For rotary valves, or for actuators with rotations greater than 60°, the magnet assembly must. be oligned os shown in Figure 25 on page 54 NoTe For a reciprocating valve, itis not necessary to remove the positioner to visually inspect the magnet setting and linkage of 0 reciprocating valve For reciprocating valves the adjustable link turnbuckle must be parallel to the valve stem. To ensure linearity in positioning verify that the hole in the lever aligns with the indicating hole in the bracket when the valve is in the closed position. Check that the bracket is mounted on the correct holes. (See Figure 27 on page $4 for details) Figure 24 Magnet Orientation for Rotary Valves with Valve Closed lon SV 1 APinstalation and Maintenance Manual | $3 © 2016 Genero electric Comaary Al rghts reserved.Increasing Signal = CCW Rotation ° 3 Valve Closed © ° 9 Figure 25 Magnet Orientation for 90° Valve Rotation with De-energized Actuator Housing Disk Washer Magnets, Ring Magnet holder assembly Figure 26 Magnet Holder for Reciprocating Valves Figure 27 Reciprocating Valve Mounting Bracket S| Geovacas © 2014 Genero levie Company Alrghts reservedUsing ValVue to Check Magnet Position Use this procedure to check the magnet using ValWue: 1. Connect to the positioner in accordance with the ValVue instructions. For further information refer to the ValVue Instruction Manual o. Run valvue. bb. Select the installed positioner from the list of Connected Devices Cc. Select the: Check tab to view the current operating conditions of the selected positioner. 2. The Raw Position Value should be between - 1000 and +1000 when ‘reciprocating or less than 60° rotation rotary valve is closed ‘A greoter than 60° rotation rotary valves at 45° of rotation {mid stroke for a 90° rotation rotary valvel. Checking the Air Supply Use this procedure to check the air supply. 1. Tum on the air supply. 2. Adjust the filter regulator. 3. Supply pressure must be @ minimum of 10 psi {69 bar, 68.97 kPa} greater than the spring range of the actuator but may not exceed the rated actuator pressure, Refer to the valve or actuator instruction manual 4. Inspect the tubing connections between the filter-regulator and the positioner for leoks. 5. Verify that the tubing is not bent or crushed. 6. Verify that all fittings are leak tight. © 2016 Genero electric Comaary Al rghts reserved. CAUTION Do not use Teflon pipe seal tape as it can shred into particles harmful to the pneumatic components. lon SV APinstalation and Maintenance anual |SChecking the Electronic Module Connections WARNING Do not remove the instrument cover or connect to an electrical j circuit in a Hazardous Area unless power is disconnected. The SVI II AP terminal board has terminal blocks with cage clamp connectors. Not all options ‘ore available for every model. Refer to Table S for available functionality, Table S SVIII AP Models and Functionality Available Functionality Positioner Model Number SVIILAP-2 SVIIAP-3 4-20 mA Input Setpoint Vv Vv Display/ Pushbuttons Optional Optional Remote Mount input, v v SW #1 ond #2 Optional Optional 4-20 mA Out Position Transmit Optional Optional 1. Confirm the correctness of all applicable connections to the electronics module. Configuration Lock Jumper Position Retransmit sw #1 swe Ve Connector Process Variable on Remote Position Sensor 4-20mA Input Input Signal Display Figure 28 Connections to Electronics Module (via Terminal Board) 56] ceovaces © 2014 Genero levie Company Alrghts reservedNoTE When an SVI II AP is turned on, apply the oir supply before applying the electrical input signal Making Connections to the Terminal Board Connect the wires from the option os follows (wire size 14 to 28 AWG, 2.5 mm? to 08 mm?}: 1. If the wires have not been stripped, strip approximately 1/4 in (6.35 mm! of the insulation at the end of wires. 2. Locate the correct terminal black on the terminal board {see Figure 28 on page 56} 3. Push back the lever at the top connector until you see the opening for wire insertion, The connectors are spring activated and may require a lot of pressure to move the lever, 4, Insert the wire into the opening and release the lever. Operational Checkout The operational checkout of the SV! Il AP consists of: 1. Connecting the SVI I AP to a current source. 2. Powering up the SVIII AP. 3. Checking the pushbutton locks. Connecting to the Current Source Connect to @ DC mA current source then check and configure with the local display and pushbuttons, if so equipped. The following section describes configuration and calibration With the optional local display and pushbuttons, If the SVIII AP is not equipped with local display use ValVue Lite and a PC with o HART modem or a HART Handheld Communicator. Note When an SUI II AP is turned on itis advisable to apply the air supply before applying the electrical input signal. © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv APinstalation and Maintenance Manual |S?Powering Up the SVI Il AP WARNING This process can cause the valve to move. Before proceeding be sure the valve is isolated fram the process, Keep hands clear from Lv moving parts, NOTE When an SVI11 AP is turned on it is advisable to apply the air supply before applying the electrical input signal. CAUTION Use of a low impedance voltage source damages the SVI {I AP. The SVI11 AP input must be a current controlled source. The SVI il AP will not function normally if connected directly to a voltage source. However, direct connection to a current source of up to 30 V will not the damage the SVI 1! AP A proper current source explicitly enables adjustment of the current in mA, not V. To power up the SVI Il AP: Loosen the four {él cover screws and remove the SVIII AP cover, 2. Connect the + terminals from the SV Il AP to the current source. Connect + to + and - to - (Figure 28 on page 56) 3. Reinstall the cover and display. 4, Adjust current to 12 mA. On initial power up of « newiy installed SVI II AP, the positioner starts up in NORMAL mode and is operational in the default factory configuration. The positioner cycles through the NORMAL cycle menu and the following values appear PRES; [Pressure - unit of measurement and value) SIGNAL POS (Position) ‘An exclamation point (tin the top left corner of the display window indicates that there is further instrument status available.” 5. Proceed to Calibration and Configuration * For firmware version 3.2.1, the supply pressure appears on the LCD. Additionally, Stops results and Autotune results, stay displayed until cleared Note If the SVIII AP is specified without local pushbuttons and display, local operation is not available, Configure and calibrate with Value or a Hand Held HART Communicator. S8| ceovaces © 2014 Genero levie Company Alrghts reservedPushbutton Locks and Configuration-Lock Jumper Before performing any of these functions with the local display you must first ensure thot the pushbuttons are placed in the unlocked mode using ValVue Lite. The positioner ships in the unlocked mode. See ValVue documentation for more details The SVII AP offers several levels of plant security. It may be desirable, after initial setup, to lack the pushbuttons so that the SVI II AP parameters cannot be inadvertently changed by the buttons, Several levels of software modifiable pushbutton locks are provided Table 6 Pushbutton Lock Security Level Level Access Security Level3_| Allow Local Buttons: Buttons on t SULIIAP are fully enabled Security Level2 | Lock Out Local Calibration and Configuration: Use the buttons to perform operations in normal operating mode and manual mode. Do not go to configure or calibrate mode. Security Level | Lock Out Locol Manuol: Examine variables in normal operating mode but do not put the valve in manual operating mode. Access to calibrate or configure modes is not ovailable, Security Level 0 | Lock Out All Buttons: The buttons are disabled llevel 0} Hardware Configuration Lock Additional security is achieved using the hardware configuration-lock jumper shown in Figure 28 on page $6. When set to the secure position, by shorting the two-pin header, configuration and colibrotion are not possible using the local interface or any HART ‘communication tool. Pushbuttons, ValVue and GE's 0P1620 are locked out, except to examine configuration, calibration, and position. This is similar to Security Level 1 shown in the Pushbutton Lock Security Level table © 2016 Genero electric Comaary Al rghts reserved. lon Sv APinstalation and Maintenance Manual |S9Using the Digital Interfaces Overview This section describes three ways to communicate, configure, and calibr Smart Valve interface is truly a smart device capable of the SVIIIAP. The Streamlining the valve positioning function Providing diagnostic information improving precision of process contro! Communicating critical information locally and remotely The four available communication tools listed below offer increasing levels of functionality Local Display and Push Buttons HART Handheld Communicator Valvue Any HART capable Host loaded with the DD for the SVIII AP Local Display and Pushbuttons The most basic and easiest digitol interface is the local pushbutton and display option mounted ‘on the SVI II AP Itis available at any time and provides immediate local access to most configuration, calibration, and fault messages. itis cpproved for use in Explosion Proof and Intrinsically Sofe installations in Hazardous Areas. Additionally, in Normal mode the local display scrolls sequentially displaying setpoint, pressure ‘and position information. The display sequences from one variable to the next every 1.5 seconds. company. Al ght reserved Masonelan Sv AP Instolotion and Maintenonce Manual |61HART Handheld Communicator ValVue The HART handheld communicators a universally available tool that provides all the accessibility of the local button and display. The HART tool has the functionality to upload and download configurations, enter alphonumeric messages and set the custom characteristic numerical parameters. The GE DPI620 is approved for Intrinsically Safe use in Hazardous ‘Areas in accordance with VIII AP approvals. See "HART Communications with intrinsic Sofety’ on page 113 and "Wiring an SVIII AP" on page 95 for additional information concerning this device. Value combines the power of the PC with the features of the SVIII AP for ease of use and outomation of positioner operation and full access to all data. ValVue Lite is provided with al SII AP positioners and is recommended for set up, service and maintenance where a PC or laptop is permitted. See “Configuring and Calibrating with ValVue" on page 93 for further information. Pushbuttons and Local Display This section covers the optional local interface consisting of the LCD alphanumeric display and pushbuttons. Operation of the SVI II AP Digital Valve Positioner as a local device is controlled through the optional device-mounted pushbuttons and digital display, shown in Figure 29 on page 63. Using the display you can read the input signal, valve position, and actuator 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 that are described later in this section. ValVue is used to perform all diagnostics functions. The pushbuttons do not support diagnostics functions. The SVIII AP has two operational modes: Normal [normal operating mode} and Manual {manual operating mode) and two setup modes, Configuration and Calibration, The SII AP also has two modes for handling of faults and power-up: Reset and Failsafe. When commissioning or checking a control valve with SVI II AP fully installed the following steps are recommended 1. Change mode to Manual mode Examine ond agjust all Configuration items. Enter Calibration mode Run Stops to automatically calibrate stroke. 2 3 4 5, Run Auto Tune to set dynamic response. 6 Examine the device stotus 7 introduce manuol set point changes to verify dynamic performance. 62| ceovaces © 2014 Genero levie Company Alrghts reservedPushbuttons The local pushbuttons are located behind a hinged cover, directly below the display window. To open the cover loosen the screw and swing the cover down. Always re-fasten the cover cofter use to protect the pushbuttons from environmental contamination. The three pushbuttons perform the following functions: 17 Left Button - Marked with *, permits you to select or accept the value or parameter option currently displayed. Middle Button - Marked ~, permits you to move back through the menu structure to the previous item in the menu or decrement the value currently shown in the digital display. When used to decrease a displayed value, holding the button down causes the value to decrease at a faster rate. ©) Right Button - Marked +, permits you to move forward 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 NOTE An exclamation point (in the SVI I AP display window indicates that there is instrument status available, (select) / (Forward) (Gack! Figure 29 SVIII AP Display © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstaletion and Maintenance Mans! | 63To determine how to display and select o specific parameter value or configuration option refer to the menu structure diagrams shown in Figure 30 on page 65 through Figure 33 on page 72. When using these diagrams os a map you can move through the menus to the function you needed NoTE If the pushbuttons are pushed after being locked by ValVue software, the message LOCKED appears. Refer to the Valvue User's Guide for instruction about unlocking the pushbuttons. Pushbutton Locks and Configuration-Lock Jumper Before performing any of these functions with the local display you must first ensure that the pushbuttons are placed in the unlocked mode using ValVue Lite. The positioner ships in the unlocked mode. See Valvue documentation for more details The SVI I AP offers several levels of plant security. it may be desirable, after initial setup, to lock the pushbuttons so that the SvI II AP parameters cannot be inadvertently changed by the buttons. Several levels of software modifiable pushbutton locks are provided. Table 7 Pushbutton Lock Security Level Access Security Level3 | Allow Local Buttons: Buttons on the SVIII AP are fully enabled. Security Level2 | Lock Out Local Calibration and Configuration: Use the buttons to perform operations in normal operating mode and manual mode. Oo not go to configure or calibrate mode. Security Level Lock Out Local Manual: Examine variables in normal operating mode but do not put the valve in manual operating mode, Access to calibrate or configure modes is not available Security Level | Lock Out All Buttons: The but! ns are discbled (level 0, Hardware Configuration Lock 64 Additional security is achieved using the hardware configuration-lock jumper shown in Figure 28 on page $6. When set to secure position. shorting the two-pin header, configuration ond calibration are not permitted by the local interface or by remote communications, Pushbuttons, Value and GE's DPI620 are locked out, except to examine configuration, calibration, and position. This is similar to Security Level 1 shown in the Pushbutton Lock Security Level table. The following pages display the menu structure for operating the SVIII AP using local pushbuttons ceovaces © 2014 Genero levie Company Alrghts reservedDisplay Menus NORMAL Operating Mode and MANUAL Mode Menus. When you leave the NORMAL mode to go to MANUAL mode the valve is placed in the last position it wos in when leaving NORMAL, When in the MANUAL mode the device does not respond to the 4 - 20 mA signal. However, the SVIII AP unit can still respond to HART ‘commands, including HART commands to position the valve. When you switch to the VIEW DATA or VIEW ERR menus from the NORMAL operate mode menu the valve is still in NORMAL mode and stil responds to the 4 - 20 mA signal. entte tome! mee t NORMAL Cycling lve Le | Men T—>| normar [>| manvar {| Baia [OY viewer >| curen [+ | Y Y ony ke | [Tmanuat Hoge view view Instant ) |] ting Men onTa ERfors hetion - Mena Menu 7 : iz vaTae3| + ’ + [wen . Th seacpos PT SEP fH] NORMAL FH] Manuar |} Data viewers |S] cirerr | value>] | ¥ : contig |—*—»] cai |_—* 5] anuat | —_+ CONFIG cau Menu Mena Figure 30 NORMAL Operation and MANUAL Menu Structures 1 2014 Genel lecrc Compory Allights reserved Masoseilon Sv aPnstaletion and Maintenance Mans! | 65Configure Menu Because calibration depends on certain configuration options you must perform Configuration before you perform Calibration when installing the SVI Il AP for the first time. Ifa change is made in the Alr-to-Open / Air-to-Close configuration option or if you move the SVIII AP to @ different valve or make any change to the valve position linkage, you must run the find STOPS calibration again. conn! CCONFIGuration Menu | |eonic > Gat reese Lgl rancsnacor | [erm | TL fenu Units Menu Menu Menu i Tarn tight shutoff on oof press to selec option prods moron octtor Press vor tocceept and foeectore procesdto next menuitem. char act Pressure Units Tight Shutoff Language Menu tena era menu Aito..Men 10 LINEAR Pst TS, OFF ENGLISH f t Ue cower can Jee | erence arc + Ae cls al Has 0% 50:1 KPA | tune |] te stor oP sig Low sic wae RUNNING “ALU steps Waves “ates fr srep2r3 STEP 3/3 ranwuRe FAILURE ngerror reve brety Figure 32 CALIBration Menu 70] ceovaces © 2014 Genero levie Company Alrghts reservedVIEW DATA Menu his menu can be entered either from the MANUAL Mode menu or fram the NORMAL Mode menu. The VIEW DATA menu allows you to read the current configuration, calibration, and status nnformation. This information cannot be changed from the VIEW DATA menu. Exiting from the VIEW DATA menu returns the previous menu. When entered from NORMAL mode the valve still responds to chongesin 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, The parameters viewable by pressing + and - are: 5 SINGLE or DOUBLE ATO or ATC LINEAR, £0% 30:1, £% 50:1, €Q% CAMFX, QUICKSO, or CUSTOM 3 PSI, BAR, KPA, TS. ON, TS, OFF SIGNAL LOW value (typically 4.00) SIGNAL HI value (typically 20.00) Viewing Configuration and Calibration Parameters To view configuration and calibration parameters use the following procedure 1. fin the NORMAL operating mode, press any button. 2. Press + to move through the options until you reach the VIEW DATA menu item 3. Press * to go to VIEW DATA menu. (This leaves the valve in NORMAL mode!) fin MANUAL mode, press + repeatedly until the VIEW DATA menu item is reached. Press * to select the VIEW DATA mode 4, To exit from the VIEW DATA menu, press * at any menu line, You return to the last menu disployed. © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv AP nstlotion and Maintenance Manual |71actuator Ty8€ SINGLE oR DOUBLE [ACTION TvPE 0 oF at r VALVE CHARACTERISTICS LUNEAR, 69M 30:1, €9% 50:1, £9% CAMFK, QUICK 50, CUSTOM PRESSURE UNITS 5), BAR, KPA TS.ONOR TS.OFF a Figure 33 VIEW DATA Menu 72] ceonaces © 2014 Genero levie Company Alrghts reservedFAILSAFE Mode FAILSAFE mode cannot be selected from any of the previous menus. FAILSAFE mode and display are initioted by detection of a critical fault in the positioner or the valve system, There ‘re two ways to deol with a FAILSAFE condition: correct the problem and cleor the error messages or run through the FAILSAFE menu, view error messages, enter MANUAL mode and RESET. RESET restarts operation When failsafe occurs: 1. Press + to move to VIEW ERR. 2. Press * to view the first error message. Press + to scroll through all fault messages. 3. Correct the couse of the problem and press + to move to CLR ERR. 4, Press* to remove all error messages from memory. 5. Move to the MANUAL menu. If you have cleared the errors RESET no longer appears. or 1. Press + to move to VIEW ERR. 2. Press * to view the first error message. Press + to scroll through oll the fault messoges in tur, 3. Move to MANUAL menu and enter Manual mode. 4. Select RESET to start the valve from its failsafe condition, 5, Identify and correct errors and select RESET to ret error messages from memory) Irn to the prior mode without removing FAILSAFE Menu MANUAL MODE CYCLING MENU FaILsAFE |—ae] view ear >| CLR ERR -—> 4 MANUAL, Reset |< : instant y Pressing {aston displays the first Quickly Flashes error, pressing a second time displays the second error. Keep pressing to see all erors Until VIEW ERR appears. Figure 34 FAILSAFE Menu wart © 2016 Genero electric Comaary Al rghts reserved. lon SV APInstalation and Maintenance Manual [73VIEW ERR Diagnostics Messages Diagnostic messages are viewed with VIEW ERR from the MANUAL Mode menu or from NORMAL Mode menu, The VIEW ERR menu item allows you to read the current status. information. To clear the error messages: Press * at CLR ERR on either the MANUAL or NORMAL mode menus. 2. Exiting from the VIEW ERR menu returns the previous menu. 74] ceonaces © 2014 Genero levie Company Alrghts reservedTable9 Error Messages Leo Description ‘Action Cause RESET Reset occurred due to command or power up. Always | Warning Normal operation present after power up fon power up olways sets RESET. RESETis sent by HART com- munications. Use CLEAR ERR to remove warning Low POWER | input current < 3.6 ma Tokes the device to low power ACT ERR Positioner unable to position @ valve normally Warning AIR LOW Supply pressure option is configured and supply pres- | Warning Mechanical or sure is < 10 psi( 69 bar, 69 KPol, Otherwise IP pressure is pneumatic problem below 0.8 psi (05 bar, 5.5 kPa} POS ERR The position error exceeds configured limit for more | Warning ofter T1_ | Pneumatic! than configured time ond Failsafe mechanical, config- Urotion, oose mag- net KevBOARD | LCD/Button Failure Warning Damaged buttons or LCD electronics MARGN PWR. | Inout signals insufficient to proceed CALIBER | Calibrate failed Warning Invalid values for current calibration ond input range by HART commands STOP ERR —_| Calibration error Find STOPS was unsuccessful Warning Configuration, cali- bration TUNE ERR | Auto tune failed Warning Mechanical or pneumatic problem couses tuning fol ure STDOIAG —_| Astandard diagnostic procedure failed to complete | Warning Pneumatic / mechanical, confi uration EXTOIAG —_| Anextended diagnostic procedure failed to complete | Warning Pneumatic / mechanical, config- uration © 2014 General Electric Comoany lights reserved Masonilon Sv APInstalation and Maintenance Manual | 75Table 9 Error Messages {Contin ued) Leo Description Action cause cMo sto? | HART command aborted warring Bad dats range or ate limitotion Bias ERR | Posttion algorithm errorin output bias Warning Pneumatic! mechanical uPLmit [1/2 current too high or too low Worning Electronic hardware Temp ERR | internal circuit temperature high (80° C. 176° Florlow | Worning Environment {e-40" C,-40* FL AVMERR.R | An FRAM record and its copy both have CRC errors(os | Failsafe detected by read on initialization! or if temperature cali bration table has not been written inits entirety Idetected by CRC of column CRCs} RAM ERR | RAM data item had a bad checksum Worning FLASH ERR | Flash memory filed checksum test Folsofe Flash memory filed checksum test STACK ERR | Avolid hidden record (in RAM) ex'sting upon reset indi- | Weorning Coting that a stack overflow had occurred FcravMope | Factory mode failure Falsafe NM ERR-T | An FRAM record andits copy both have CRC errors | Worning ReFvoT | Temperature compensated /P currentis out of range | Failsafe for § reads in a row or the raw reading it out of range POSSENSR — | internal errorin Hal Effect sensor Warning Electronic hardware SIGSENSR Internal errorin sensing of 4 - 20 ma Warning Electronic hardwore PRESIER | Temperature compensated pressure sensor 1 readings | Worning outside the range PREs2.ER | Temperature compensated pressure sensor 2 reading is | Warning outside the range PRES3ER —_| Temperature compensated pressure sensor 3 reading is | Warring outside the range or supply pressure recorded is >120 psi (8.28 bar, 828 kPa) PRESHER | Temperature compensated pressure sensor 4 reading is | Warring outside the range or pilat pressure recorded is >120 psi 18.28 bor 828 kPa} PRESSER —_| Temperature compensated pressure sensor 5 reading is | Warring outside the range 76| Geos cas © 2014 Genero levie Company Alrghts reservedTable 9 Error Messages (Continued) Leo Description Action cause NVMERR-W | Writer to FRAM fails or dote repoiring in FRAM foils | Warning IRQFAULT | Valid hidden record lin RAMI existing upon reset that | Warning indicotes thot anillegal interrupt occurred DATAER® | internal software error dato overrun Foilsole Pulfirmwvore MCUERR1 | Miero-Contraler Self Check flied Failsafe Sw ERR Software self check error Failsafe CPUlfirmore Display and Clear Error Messages Use this procedure, VIEW ERR. to view fault codes and messages listed in Toble 9 of this menual 1. Press + in NORMAL or MANUAL mode to move through the options until you reoch the VIEW ERR menu item, Press * to go to VIEW ERR menu Press * to display the list of status values. Press + to move forward trough the list in sequence. Press - to move back through the list Press * at any status message to return to the VIEW ERR option in your previous mode. Press + to move to Clear ERR. Press * to clear all messages (recommended! or press + to move to the next option. Positioner Fault Messages Table 9 on page 75 lists the fault codes and messages that appear on the display. The table also explains the meaning of each message and a possible cause of the fault. Return to Normal Operation Always return the positioner to NORMAL operating mode to resume contral by the input signal, Use this procedure to return to NORMAL mode from any menu. 1. Press + or repeatedly until MANUAL or NORMAL appears, 2. Press 1) * to return to NORMAL operating mode, if NORMAL appears. 1] * to return to MANUAL Made menu, if MANUAL appears. 3. Press + repeatedly until -» NORMAL appears. © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstaletion and Maintenance Mans | 7?4, Press * to return to NORMAL mode and normal operation Note When entered from NORMAL mode the valve still responds to changes in set point input signal and the values displayed change in accordance with changes in the input signal. When entered from MANUAL mode the valve is in locked position, Hand Held Communicator For communication to a HART device, there is a Device Description Language. & Device Description, 0D, is published by registration with the HART Communication Foundation. When the DD is installed in a host communication device then the host can readily access all the information in the smart field device. The SvI II AP registered DD will be available from HART Communication Foundation when it next publishes the HART DO. The SVI II AP DD can be obtained from the website or by contacting your local representative. CAUTION Do not connect a HART modem and PC to a control circuit unless the controller is HART compatible or has @ HART filter, Loss of control or a process upset may occur if the controller output circuit is not compatible with MART signal WARNING Do not Connect a PC or HART modem to an intrinsically safe circuit except an the safe area side of the barrier. Do not operate a PC in a hazardous area without compliance to local and plant regulations. 78] ceovaces © 2014 Genero levie Company Alrghts reservedValVue The third digital interface avilable for the SVI II AP is Masoneilan’s ValVue software, ValVue provides a user friendly interface that facilitates set up and operation of the positioner. ValVue is used to configure, calibrate and perform valve diagnostics with the SVI II AP utilizing HART communications protocol Installation of ValVue Software, and Registration For assistance contact the nearest sales office, your local representative or email svisupport@ge.com. Visit our web page at http//www.ge-mes.com/en/download html, ValVue Lite and @ 60-day trial version of ValVue are included with the SVI II AP. Contact the factory to purchase a registered upgrade to ValVue, or to request ValVue on a CD-ROM, ValVue Software The SVI II AP is shipped with a free version of ValVue Lite and o trial version of ValVue Valvue Lite Valvue Lite softwere is shipped with each SVIII AP for positioner calibration and configuration, Value Lite software is offered without registration. It provides sufficient functionality to fully commission, configure, and start up ¢ positioner on @ control valve. Full Trial Version The SvI II AP comes with a copy of ValVue Trial Version software that can be used for sixty days without a license. After the 60-day trial period, ValVue does not execute and you must register. ValVue. full version, provides advanced diagnostic, maintenance capabilities and basic calibration and configuration for the SVI II AP. The SVI II AP performs valve diagnostics and in Valvue displays stroking speed, step response, cumulative travel, cycles, and operation in near-closed position, The software stores test results for comparison with future results for predictive maintenance. Password protected access to remote instruments is set up with administration features. The fully licensed Value software is available as an upgrade. © 2016 Genero electric Comaary Al rghts reserved. lon SV APinstalation and Maintenance anual |79System Requirements ValVue Lite runs on IBM compatible computers. Minimum requirements for all versions of ValVue software are [1 Windows XP, Windows Server 2003, Windows Server 2008 and Windows 7 Ul 64™MB RAM | Hard drive available space 35 MB (1 ACD ROM drive 1 An available Serial or USB port [1 AHART modem and appropriate cables Install the ValVue software in the PC in accordance with the instructions on the CD-ROM jacket. After installation select Valvue fram the program group, and double click to begin. Figure 35 shows the screen for setting the Value options. Be sure to set the COM port to the serial output connection attached to your PC modem. Checking the Allow Multidrop option fas shown], and not configuring selections to perform a tight scan of addresses, slows down the search for active devices on single drop current loops. Itis recommended only for split range ‘and multiplexor applications. one — ln Fea) etenacy |p| =r) © tel Tol | cow @ sp [aris © Parmay Master Mater Mode ni strand & Secanay Naser | Lose eee adtesses to Fle 1 Use Mutipser [WIL Corersiono_ =] Baud Fale — Nodes Seach @ 900 © Scanal nakes © 19200 © Sckected nader © e000 Figure 35 Value Options 80] Groves © 2014 Genero levie Company Alrghts reservedHART 6 Squawk Command For HART 6 units, use the squawk command |HART Command 721 to assist technicians to find specific devices in an installation, Send this command using ValVue ond a specific device will audibly indicate the reception of the command. 4 i El | El fie? Od fps 9 Of Non-squawked displays HART Command 72 from Valvue Figure 36 HART Command 72 Squawk Function © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstalotion and Maintenance Manso | 81Configuration and Calibration Using Pushbuttons Configuration and Calibration This section provides procedures to: View configuration data and status messages for the SVII| AP Configure the SVI II AP Calibrate and tune the SVII| AP Observe all warnings as the valve moves during these procedures. These procedures can cause the valve to move. Before proceeding be sure the valves isolated from the process. Keep hands clear from moving parts. NoTE All configuration and calibration procedures are described using an SVI Il AP with pushbuttons and display and Valvue software. Configuration with Pushbutton Display Prior to changing the SVIII AP configuration, check the existing configuration Verify that the mounting has not been damaged in shipment for a premounted VIII AP. Record the following information for the configuration checkout Valve Air to Open (ATO) or Air to Close [ATC] Actuator pressure rating Actuator bench range inherent trim characteristic of the control valve; linear, equal percentage, or other Refer to valve data sheet or model number of control valve. 2 2014 Genero le vic Company. llrightsreserved Masonelon Sv AP Instellaton ond Maintenance Manval [83Viewing Configuration Data 84 To view SVI II AP configuration data Access the VIEW DATA menu from the MANUAL menu by pressing the + button 2, Inthe VIEW DATA menu, press * to examine the configuration Press + to scroll through and observe the factory configuration 4, Press * to exit VIEW DATA Press + until YMANUAL appears. Press * to enter MANUAL mode Press ony key to make MAN POS appear. When the adjustment screen appears stroke the volve open by holding + down, Notice that the rate of set point change is slow to begin, but increases speed while the + is pressed 9. Stroke the valve to several values. Verify the action is os desired Press * to exit MAN POS mode. 12. Press + to move to the SETUP menu. 13. In the SETUP menu press the * button to access the CONFiGuration menu. in the CONFIG menu set the configuration parameters. 15. When in CONFIGure or CALIBrate, pressing * changes values. 16. Return to NORMAL mode. The valve moves to the Value set by the current calibrator, 17. Stroke the valve through its rang} verify that the movement is as desired ceovaces © 2014 Genero levie Company Alrghts reservedVIEW DATA Settings Table 10 VIEW DATA Settings Typical Setting Optional Setting SINGLE bouate ato ATC LINEAR, €9% 301 9% 501 9% CAMFX Quick so custom Psi BAR KPA 0.00 200 TS. OFF ISON 4.00 400 SIG LO SIG LO 20.00 12.00 SIG HI SIG HI ENGLISH FRENCH © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstaletion and Maintenance ons | 85CONFIGuration Menu ' yee Arte [* | charect pressure |_*.| tight shutott Language |_* Menu [P] Menu Units Menu) > Men Menu ‘Setup “urn tight shutoff on or off Press" to select option to provide maximum actuator Press vor=to.accept and force at o%6 proceed tonext menuitem. — charact Pressure Units Tight Shutoff Language Menu Menu Menu Menu Arto ..Menu #0 LINEAR Pst TS. OFF ENGLISH f c9%301 om VALUES mewn are ¥ ori TecloeiaT Hust €9% 50:1 KPA. Select display language. renee ae i. Y [Ts.ON EQ CAMP | Select display Units for pressure, Displays tight shutoff ¥ value f turned an Press" to change TS. ON/OFF status. Press sors tocnter new value uicxso Press te accept new value and proceed fonext menu item, custom Figure 37 Configuration Pushbutton Guide 86] ceovaces © 2014 Genero levie Company Alrghts reservedCalibration NOTE Always perform configuration before running calibration Y functions. CAUTION Pilot Trim Valve Applications require the use of the Monual Stop calibration procedure, Do not run Find Stops or the ValVue Setup Wizard on valves with Pilot Trim or damage to the valve will occur. Calibrating the SVIII AP Unit Using Pushbuttons To colibrate the SVI Il AP [see Figure 38 on page 90} 1. Observe the display following power-up. The SV! |i AP powers up in the previously active mode either MANUAL or NORMAL (operating) mode Ifin NORMAL mode, the display alternates between POS and SIGNAL indicating Normal mode Ifin MANUAL, the display alternates between POS -M and SIG indicating MANUAL, mode. 2. With MANUAL mode displayed, press * to select the MANUAL mode. Press any key to enter MANUAL menu, 4. Press + to display SETUP. 5. Press * to enter SETUP mode. 6. In SETUP mode press * again; YCONFIG appears. Pressing + again brings JCALIB. 7. Select CALIB by pressing *. STOPS appears. 8 Press * to perform FIND STOPS, The valve moves full open and back to full closed 9. Observe all warnings. 10, Press * and the valve strokes and automatically colibrates valve travel. 1. After the STOPS procedure finishes, press + twice until TUNE appears. © 2016 Genero electric Comaary Al rghts reserved. Masoneilon Sv APInstalation and Maintenance Manual |?Calibration using Auto Tune To auto tune the Svi Il AP: 1. Press * to begin the Autotune procedure. This takes 3 to 10 minutes ond strokes the valve in large and small steos to set the PID parameters for best positioning response. When Autotune proceeds, numerical messages display, indicating the procedure is working. When Autotune is complete, TUNE oppears. 2. Press + repeatedly until SETUP appears. 3, Press* to return to SETUP menu VCALIB appears. WARNING D0 NOT perform STOPS while the valve is controlling the process. DO NOT perform Auto Tune while the vaive is controlling the Correct for Over Travel WARNING — During Calibration and Configuration the valve moves. Keep hands clear. isolate the valve from the process. Calibration Lv functions stroke the valve over is full range 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, Use this procedure to make a correction. From CALIB press * to display Stops. Press + to display STOP OP. Press * to move valve to the 100% position Use the + and - buttons to position the valve to the nominal full open position. 5. Press * to accept this position as the new 100% position, 88 ceovaces © 2014 Genero levie Company Alrghts reservedAdjust Input Signal Range SIG LO displays the input signal that corresponds to the full closed [ATO) or full open (ATC) position of the valve. 1. Ifthe displayed value is: Correct, press + to advance to the next item Not correct, press * to display value of SIG LO. 2. Use + ond - bul Ins to change the value. 3. Press * to return to menu and move to next item. SIG LO must be between 3.8 and 14.0 mA, SIG HI displays the input signal that corresponds to the full open, ATO, or full closed, ATC position 4, ifthe displayed value is: Correct, press + to advance to the next item Not correct, press * to display value of SIG HI 5. Use + ond - buttons to change the value. 6. Press * to return to menu and move to next item. SIG HI must be between 10.0 and 20.2 MA. SIG Hi must be larger than SIG LO by at least $ mA. Colibration of the positioner is now complete. 7. At-> MAN, press * to return to the MANUAL mode. MAN POS appears. Note SIG HI and SIG LO allow adjustment of the input current range that corresponds to full valve travel. Normally they are set to 4 and 20 mA, Adjustment is normally required only for split range applications and provides flexibility for unusual applications. A separate Valve calibration procedure enables adjustment of the current sensing circuit to a precision current reference standard. © 2016 Genero electric Comaary Al rghts reserved. lon Sv APInstalation and Maintenance anual |89CALIBration Menu CAUTION: These functions stroke the valve over its full range. Do not perform while the valve is controlling the process ipa] + “une waLueS sors >| Tune jo} sto? oP sis ow SiG HiGH RUNNING “. Scroll down to S read status. 9, Read message, 10. Press OK. 11, Repeat OK to read all messages until the display returns to read status, Scroll down to 6 clear status, press ->. 13. clear fault codes not completed appears, press OK and read the message [Position Error, for example 14, Correct the problem (is the air supply on?], and then go to clear status until Clear Fault codes Completed appears. 15, Press OK. ceovaces © 2014 Genero levie Company Alrghts reservedConfiguring and Calibrating with ValVue Value Lite is the most complete and easiest to use configuration tool, ValVue Lite is provided with each SVII1 AP. ValVue or ValVue Lite provides a personal computer interface for configuring and calibrating SVI II AP. Use of these tools is recommended, See the ValVue Instruction Manual on the CO-ROM included with the SVIII AP In this section, we recommend a few ValVue Lite steps to checkout and configure a pre-instolled SVI II AP on a control valve. Read and Set Configuration Parameters Change to MANUAL mode Run Find Stops Run AutoTUNE View Calibration Parameters View Diagnostics Read and Clear Status Return to NORMAL mode NOTE Setting the input current span is unnecessary except for applications such as split range. Calibration of the input current sensor requires the use of high accuracy current standards. The factory settings should only be changed ifa calibration laboratory detects errors, Never connect ValVue to an SVI1I AP that is in Configuration or Calibration using pushbuttons. Installation of Cover The cover of the SVI Il AP is @ critical component for safety in Hazardous Areas, To ensure safe ‘operation the flat surfaces of the cover and the housing must be clean and absolutely free of particles or dents. The O-ring must be securely located in its groove. Install the cover and lighten all four screws, There must be no gap between the housing and cover. © 2016 Genero electric Comaary Al rghts reserved. lon SV 1 APinstalation and Maintenance anual | 95Wiring an SVI II AP Overview The SVIII AP is used as @ current loop device drawing power and analog input signal from a precision current source. This section describes wiring configurations using HART digital ‘communications operating in the 4 - 20 mA current mode. System Connections Al system connections must comply with the HART Communications Protocol Specifications. For ‘complete technical information refer to the HART Communications Foundations Document Number HCF-SPEC-11 and the references. The SVIII APs a HART compliant device of type Actuator Its therefore a receiver of 4 - 20 mA, and cannot have « voltage source applied to its input terminals. When installing the SVIII AP in a 4 - 20 mA current loop, the engineer designing the loop must consider a set of conflicting electrical requirements. The control signal to the positioner is a 4 - 20 mA current generated by the controller ar DCS and transmitted to the positioner located remotely in the field. The electrical characteristics of a current loop sending a signal to the field device are different from the apparently similar loop bring a signal to a controller from @ transmitter in the field The positioner receives its power from the current signal. It receives its control setpoint from the value of the current and it must be able to communicate bi-directionally by superimposing signal tones upon the current signal without distorting the current signal, without the tones. being affected by the electrical characteristics of the current signaling device. All these conflicting requirements must be met with equipment manufactured by various manufacturers, ‘ond work with long cables, in « noisy hostile plant environment. Energy levels are often limited for sete installation in explosive environments. Special engineering may be required to meet the signaling requirements at low energy levels. The following will not cover all the details for a successful installation, in all cases. That is beyond the scope of this instruction. twill suffice to explain the requirements as a guide use to obtain necessary components from many sources for a successful installation company. Al ght reserved Masonelan Sv AP Instelevon and Maintenence Monval | 95CAUTION Do not connect a HART modem and PC to a control circuit unless the controller is HART compatible or has @ HART filter. Loss of control or a process upset may occur if the controller output circuit isnot compatible with HART signals. Install in compliance with Hazardous Area rules in accordance with local electrical codes and plant standards by trained specialists Do not connect a PC or HART madem to an intrinsically safe circuit except on the safe area side of the barrier. Do not operate a PC in a hazardous area without compliance with local and plant regulations. Note A control circuit must be HART compatible or have o HART filter installed. Contact the manufacturers of the controller or DCS. See HART Filter Requirements” on page 115 Comply with current national and locol regulations for electrical installation work ©. Comply with national and local explosive atmosphere regulations. Before carrying out any work on the device, power off instrument or make sure that the locale conditions for potentially explosive atmosphere permit the safe opening of the cover. Wiring Guidelines 96. This list contains eight tion of DC curre! juidelines for a successful implement Signal, DC power, and HART communication to the SVI I AP: Compliance voltage at the SV AP must be 9 V at the maximum current of 20 mA, Signol to the VI AP must be a well-regulated current in the range 3.8 to 22 mA, Controller output circuit must be unaffected by the HART tones which are in the frequency range between 1200 and 2200 Hz. Frequency range of the HART tones must have a circuit impedance of more than 220 (Ohms, typically 250 Ohms, HART tones may be imposed by the positioner and a communication device located ‘anywhere on the signaling circuit. Copacitance of the signaling circuit may not exceed about 0.26 microforads or with high series resistance 0.10 microfarads Cabling must be shielded to prevent electrical noise that would interfere with the HART tones, with the shield grounded at only one location Signal must be properly grounded in only one place. © 2014 Genero levie Company Alrghts reservedNOTE For details and calculation methods for wiring resistance, and copacitance and for calculation of cable characteristics please refer to the HART FSK Physical Layer Specification SVIILAP Setups Control Systems using Explosion Proof or Conventional /0 Systems must have a compliance voltage greater than 9 V at 20 mA including wiring losses, Typical Control Systems using Intrinsic Sofety methods must have « compliance voltage greater than 17.64 V. Typical system setups are shown in Figure 40 on page 98, for General Purpose ond Explosion Proof IEEx d) Installation Schematic and Figure 41 on page 99, for intrinsically Safe Instollation ‘Schematic. The SVI 1 AP digital valve positioner can be located in a general-purpose or hozardous area protected by Exalosion Proof |EEx dl methods. Wiring diagrams are generalized, actual wiring must adhere to Electrical installation section of manual and local electrical codes. The use of a Handheld Communicator or a HART modem is not permitted in the Hazardous Area protected by Explosion Proof (EEx dl methods. In Figure 41 on page 99 the SVIIIAP digital valve positioner is located ino hazardous area that is protected by intrinsically Safe wiring proctices ‘The SVIIIAP requires an electrical input from a 4 - 20 mA current source. The SVII1 AP input signal can carry a HART communication protocol signal from Value software and @ HART modem, or from @ HART Hand Held Communicator. Since the process contral system, the source of the input signal, is located in ¢ non-hazardous location, setup requires an intrinsic safety borrier be placed between the process control system and the SVI II AP If the SVIII AP is, located in a hazardous area with intrinsically Safe protection a barrier is not required for a flameproof installation. Alternatively the system can be installed as Explosion Proof/ flameproof. The SVIIIAP can communicate with a remote PC running ValVue software via a modem connected to the PC's serial port, The PC, which is not intrinsically safe, must be connected to the circuit on the sofe area side of the intrinsic safety barrier if the valve is located in a hazardous area, The SVIIIAP can be operated, calibrated, configured, and interrogated either by using local pushbutton and display, or by using @ remote PC running ValVue software or with the HART handheld communicator. The SVIII AP is polarity sensitive so the positive lead must be connected to the positive [+] terminal and the negative lead to the negative (1 terminal Reversol of input will not couse damage but the unit will not function © 2016 Genero electric Comaary Al rghts reserved. lon SV 1 APinstalation and Maintenance Manual |97Hazardous Area Non-Hazardous Area SMIILAP Power supply 220 ohms HART compliant control system output card Figure 40 General Purpose and Explosion Proof Installation 98) ceovaces © 2014 Genero levie Company Alrghts reservedSingle Channel svi ap Zener Barrier 220 0hms HART Compliant {Control System ‘Output Card Ge 0P1620, Figure 41 _Intrinsically Safe installation © 2014 General Electric Comoany lights reserved Masoneilon Sv aPnstalotion and Maintenance Monel [99Grounding Practices To ensure proper grounding make sure that case, signal, and ground connections are made in compliance with the plants normal grounding practices. Any point in the loop can be referenced to ground, but there must never be more than one ground point. Normally ground is connected at the controller or at the intrinsic safety barrier. The case grounding screws are located on the outside of the case at the lower right of the display cover and inside the cover, The case is isolated from all circuitry ond can be grounded locally in accordance with applicable codes. If noise or instability is present set the positioner to MANUAL mode of operation and manually Position the valve over its entire range. If the valve is stable in MANUAL made then the problem can be noise in the control system, Recheck all wiring connections and ground points. Compliance Voltage in Single Drop Current Mode The SVIII AP requires 9.0 V at 20 mA and 11.0 V at 4 mA. Typical smart devices require MORE Voltage at higher current. The controller supplying the current has LESS Voltage available at higher current. The SVI II AP is noteworthy in that it requires LESS Voltage at higher current that complements the characteristic of the source requiring only 9 V at 20 mA. NoTe Improperly or inadequately grounded installations can cause noise or instability in the control foop. The internal electronics are isolated from ground. Grounding the case is unnecessary for functional purposes but grounding the case may be necessary to conform to local codes. Table 11 through Table 13 on page 101 provide examples of several SVIII AP installations and calculating the compliance voltage necessary to supply 9 V at 20 mA, Table 11 Compliance Voltage for Single Channel Zener with 22 AWG Cable Voltage at Sv! I! AP at 20 ma 90V Drop in single channel zener barrier with 342 Ohms end to endresistance | 6.84 Drop in 22 AWG cable, 3000 ft. long (30 Ohms per 10001 1aVv Drop in passive HART Fikter* ov Voltage required at controller 1764 * Such as MTL HCUL6A0 Conclusion: The control system must have a compliance voltage equal to or great 17.64 V; contact the DCS vendor to verify compliance, 100] ceowecas © 2014 Genero levie Company Alrghts reservedTable 12 Compliance Voltage for Galvanic Isolator with 22 AWG Cable Voltage at Sv 11 AP at 20 mA gov Orop in 22 AWG cable, 3000 ft, long [30 Ohms per 10007) 18V Required voltage at isolator 108 Voltage available from isolator rated to drive 22 mainto 7000hms* | 132V Voltage required at controller Not apalcable - isolator supplies the power * Such as R, Stahl Model 9318/16-22-10. Consult R. Stahl Conclusion: The compliance voltage issue is not present because the Isolator provides all the necessary voltage. Table 13 Compliance Voltage for No Barrier with HART Filter and Resistor and 18 AWG Cable Voltage ot $11 AP at 20 mA 90v Drop in 220 Ohm resistor aay Drop in 18 AWG cable, 6000 ft. lang [12 Ohms per 10007 ov Drop in passive HART Filter® 23V Voltage required at contrller 163 Conclusion: The control system must have a compliance voltage equal to or greater than 16.3, V; contact the DCS vendor to verify compliance Wire Size and Conduit Electrical connections are made to the electronics module terminal board as shown in Figure 28 on page $6. The terminals accept wire sizes up to AWG 14. The SVI I AP is supplied with two 1/2" NPT conduit entries. M20 adapters are available. Internal and external ground terminals ore provided for use if grounding is required. NOTE When an intrinsic safety barrier separates the SVI1I AP from the modem or handheld a HART compliant barrier must be used. © 2016 Genero electric Comaary Al rghts reserved. lon Sv APInetalation and Maintenance anual [101HART Physical Layer Compliance of the Control System Communications to 0 SVI I AP requires a HART-compliant communications loop. The HART protocol specifies the noise level, impedance requirements, and configuration of the loop. The controller or output card of the control system must comply with the Physical Layer Specification. Impedance Constraints HART communication is based on the talking device generating an AC current superimposed on the 4 - 20 mA control signal. Two frequencies are generated: 1200 Hz representing the digital value 1 and 2200 H2 representing the digital value 0. The listening device responds to the voltage generated when the AC current flows through the loop impedance. In order to generate a voltage from a current there must be impedance, HART Protocol requires that impedance be at least 220 Ohms at the tone signaling frequencies his HART compliant current sources are supplied with the correct Impedance Versus Frequency Characteristic. In Non-Compliant Current Sources there may be a noise reduction capacitor across the output that lowers the impedance at higher frequencies ond thus lowers the signaling voltage. To be certain that at least 220 Ohms of impedance is presented by the current source a resistor can be added in series with the current source. This reduces the effective compliance voltage of the current source by 20 mA times the value of the series resistor. An added resistor is unnecessary during tests with high impedance current calibrators such as the Altek Model 334 Loop Calibrator. Noise Constraints HART Communication depends on converting two frequencies (1200 and 2200 Ha) into digital values 1 and 0. Noise can cause errors in the conversion. Conventional good wiring practice, such os use of twisted shielded pair cable with the shield and signal loop grounded at only one point, minimizes the effects of noise 102] ceow cas © 2014 Genero levie Company Alrghts reservedCabling and Interconnection Requirements Interconnections are made using shielded twisted pair cables, The shield is connected to ground at one point only. The signal loop is grounded at only one point in accordance with plont electrical standards. is customary to ground the signal at the controller or intrinsic safety barrier. The SVIII AP is supplied with two 1/2" NPT conduit entries. M20 adapters are available, internal and external ground terminals are provided for case grounding requirements. WARNING Install the SVI!I AP in accordance with local and national code in both general and hazardous area locations. Substitution of ZN components can impair suitability for use m hazardous locations NOTE The internal electronic components are isolated for ground. Grounding the case is unnecessary for functional purposes. Grounding the case may be necessary to conform to local codes. Capacitance vs. Length of Cable for HART The HART Communications Foundations specifies cable capacitance requirements to preserve signal strength. Refer to the standards for detailed calculation methods, CAUTION Do not connect @ HART modem and a PC to a control circuit unless the controller is HART compatible or has @ HART filter. Loss of control or a process upset can occur if the controller output circuit is not compatible with HART signals. HART Filter Required for Certain Control System Output Circuits The SVIIIAP is intended for use with all control systems. However, output circuits of several mojor DCS systems are incompatible with the tones used for HART signals, You must verily that the DCS or controller works reliably with the HART protocol. When the DCS is compatible an external HART filter must be installed between the field wiring ond the output cord. MTL manufactures the HART filter HCU16AO. It is @ 16 channel DIN rail mounted device composed of passive circuitry that introduces negligible voltage drop. For additional information, contact MTL. NOTE A control circuit must be HART compatible or have a HART filter installed. Contact the manufacturer of the controller or DCS. See “HART Filter Requirements” on page 115. of this manual for more information. © 2016 Genero electric Comaary Al rghts reserved. lon SV APinstalation and Maintenance Manual | 103Split Range Applications The SVIIAP is designed to operate in split range configurations supporting up to three control valves connected to a single controller output. Minimum input current span for each VIII AP is S mA. For each positioner the upper range value is between 8 and 20 mA and the lower range value is between 4 and 14 mA. For example, three devices might be configured with input current ranges of 4 -9 mA;9- 14 mA, and 14- 20 mA. Split range operation with SvI I AP requires special consideration of the compliance voltage. The SVI II AP requires at least 9.0 V. Two SUI IIAP in series requires at least 18.0 V in addition to the voltage drops in wiring and other series devices. Typical controller output current sources rarely deliver 24 V, so the system can become voltage starved. Itis possible to boost the compliance voltage of the DCS using a series wired voltage source power supply, as shown in Figure 46 on page 111. The total loop voltage must not exceed the rating for the controller output current source. Contact the DCS vendor to validate this approach. NoTe The internal electronic components are isolated from ground. Grounding the case is unnecessary for functional purposes. Grounding the case may be necessary to conform to local codes. 104] ceotecas © 2014 Genero levie Company Alrghts reservedSetting Loop Addresses for Split Range Systems When more than one positioner is installed in a single current loop, the HART loop address of each device must be set to 1, 2, or 3 (or other non-zero values) to ollow a HART master to recognize each SV! Il AP when connected to all three devices on a single current loop. Do not use 0 for any of the positioners. A 0 may cause HART masters to stop searching for additional positioners. Both the ValVue software or a HART handheld communicator con be used to set non-zero addresses. ValVue must be configured to allow multidrop mode, by selecting the Set Options function in the Tools menu on the Select Device screen as shown in Figure 42 on page 105. The Select Device screen oppears on successful logging into ValVue. Figure 42 ValVue Activate Set Options on Device Screen © 2014 General Electric Comoany lights reserved Masoneilon Sv AP nstalotion and Maintenance Manu! | 105Multiple Output Circuit Control System Valvue supports HART devices including, the SVI II AP with non-zero polling addresses and supports for multiple SVIII AP on the same loop, for split ranging. To enable this support, check the Multidrop box as shown in Figure 43. If unchecked, ValVue looks for devices only at polling address 0, Click Allow Multidrop and click either: 1 From and choose on address range from 0 to 63. Choosing a range limits scan time. 11. Specific and enter an address or addresses, where you enter one or multiple addresses separated by commas. This also limits scan time. OCS systems offer multiple independent analg outputs driven by the same control signal to solve the voltage problem with split ranged positioners. Use of such systems is recommended for split range applications. The HART address of each SVI Il AP are 0. Het ton Fata orn © Fem 6 Specie [I a © Panay Waser F Use Han sent © S2eonday Matter I Lond Devoe Addecee fom Fle SC 17 Use Mutpeace [WTLComarione =] BeudFlale Nodes Search @ 600 © Sean al nodes © 19200 © Selected nodes © sean Figure 43 ValVue Setup Options for Multi-Drop 106 | Geos Gas © 2014 Genero levie Company Alrghts reservedFigure 44 shows the dialog when PF-WHA-GW for a wireless gateway is selected. In this case you need to configure the IP Address ond Port Eek ken Fea! Pate © tel Tol | cen 6 Susie Heer © Pinay Master Secondsy Naver Use HRT sere F Load Dovoo Adesso Flo PN W Use Mulipes [ERIE] [0.40 180.4 Por [ae Figure 44 ValVue Options for Wireless © 2014 General Electric Comoany lights reserved Masoneilon Sv AP nstlotion and Maintenance Manu! | 107Isolators ‘Another solution is to use an intrinsic Safety Isolator for each loop as shown in Figure 45 on. page 109. A number of manufacturers moke suitable isolators designed for use with HART output circuits. Using an IS Isolator ollows up to three SVI II AP to be operated from a single 4 - 20 mA OCS output. Each isolator has a low compliance voltage input requirement and a high voltage output capacity. Up to three isolators can be connected in series to a single controller output and each of them can drive a positioner. Isolators are used to provide compliance voltage and isolation even in installations not requiring intrinsic safely. An example of an isolator can be obtained from R Stahl, (Model 9318/26-22-10). Consult the manufacturer for detoiled installation instructions. The HART loop address of each device must be set to 2, 2, and 3 or other non-zero values) to allow a HART moster to recognize each SV! II AP when connected to all three devices on the safe area side of the multiple isolators, Do not use 0 for ony of the positioners. AO causes. HART masters to stop searching for additional positioners, 108] ceoiscas © 2014 Genero levie Company Alrghts reservedHazardous Area Non-Hazardous Area Power Supply Power Supply | 1.5. Galvanic HART Address = 1 Isolator T I I Control system Output Card HART Address = 2 LS. Galvanic Isolator Figure 45 Split Range with Isolator © 2014 General Electric Comoany lights reserved asoneilon Sv AP nstlotion and Maintenance Manual | 108Supplemental Power Supply ‘Another approach is to boost the compliance voltage of the DCS using « supplemental power supply [see Figure 46 on page 111) with the split ranged SVII\ AP connected in series with the supply. Its not proctical to use supplemental supplies when Intrinsic Safety is required. The barriers do not permit adequate voltage. Contact the DCS vendor to verify that the output. circuit is compatible with the added voltage. The supplemental voltage must equal 9.0 V for each additional SVIII AP. Exceeding the values in Table 14 will cause damage if the signal wires are short-circuited Table 14 Supplemental Voltage for Split Range Number of SVIII APs on a Current Loop. ‘Maximum Allowable Supplemental Voltage 1 0 2 9.0 voc 3 180voC Verify Wiring and Connections For split range installations there are additional constraints on the split range system: the minimum span must be § mA; the upper range value must be 8 mA to 20 mA; the lower range values must be 4 mA to 14 mA, Use the following procedure to ensure that the SVI II AP split range system is properly powered Connect a DC voltmeter across the input terminals. For an input current value between 4 and 20 mA the voltage varies between 11 Vand 9 Vrespective Current is read from the local display or with a milliampmeter installed in series the SVI LAP, When voltage exceeds 11 V check that polarity is correct f voltage is less than 9 V ond polarity is correct, voltage compliance of current source is inadequate. Connect a miliampmeter in series with the current signal. Verify that source can supply 20 mA to SVIIIAP input If 20 mais not inable, see troubleshooting. NOTE Improperly or inadequately grounded installations can cause noise or instability in the control foop. The internal electronic components are isolated from ground. Grounding the case is unnecessary for functional purposes but grounding the case may be necessary to conform to local codes. 110] ceowecas © 2014 Genero levie Company Alrghts reservedNon-Hazardous Area Power supply ‘Supplemental (Woltage) Power bane apply Filter HART Modem = HART Address = Figure 46 Split Range with Supplemental Power Supply - Non-Hazardous © 2016 Genero electric Comaary Al rghts reserved. Masonellon Sv aP instalation and Maintenance Manel [111Required Practices for Explosion Proof Installations The SVI I AP is provided with two threaded conduit entries. All wiring must be installed with approved conduit and approved seals or with approved cable and cable glands according to local codes. The unused conduit entry is plugged with a % NPT pipe plug. Thread engagement must comply with local electrical codes. The cover must always be secured before apalication of power, Do not connect a HART communication device in the hazardous area, Use of the SVI II AP local display with pushbuttons is recommended when Explosion Proof methods are in effect, Clarification of Terminology In Factory Mutual Research and Canadian Standards Association codes, Explosion Proof meons use of approved enclosures and conduit enclosed cobles, but in ATEX countries, this method is called Flameproof In ATEX countries, Explosion Proof means both Flameproof and Intrinsically Safe. Recommended Practice for Severe or Humid Environments The circuitry of SVIII AP is encapsulated for protection from corrosive atmospheres. To prevent moisture from damaging the electronics of the SVI 11 AP use a sealed junction box in high humidity or tropical enviranments. The wiring from the junction box to the SVI Il AP is sealed by flexible cable with a cable gland or with a potted nipple ond pigtail, where applicable codes permit. 12] ceowecas © 2014 Genero levie Company Alrghts reservedHART Communications with Intrinsic Safety Overview When an SVI1 APs installed in a hazardous area in accordance with the applicable codes and standards for intrinsic Safety there are wiring considerations for successful operation in addition to the requirements for safety. The choice and application of intrinsic safety barriers requires special training. For additional information, consult MTL Instruments PLC Measurement Technology Limited: wwwmtl-inst.com or R.Stahl, Inc. wwwrstahi.com Al installations must comply with plant standards and local and international electrical codes. There are three basic barrier types: Single channel zener diode barriers Dual channel zener diode barriers Active galvanic isolators To determine if the installation will perform successfully with HART communications you must consider HART filter requirements and HART barrier compliance, company. Al ght reserved Masonelon Sut AP installation and Meintenance Manual |113HART Barrier Compliance The intrinsic safety barrier must be designed to transmit the HART signals in both directions. Both passive zener diode barriers and active galvanic isolators are offered with HART compliance. Consuit the manufacturer or refer to the documents listed at the end of this instruction manual Hazardous Area Non-hazardous Area SVINAP Single Channel Zener Bartier Figure 47 _Intrinsically Safe Installation with Zener Barrier and HART Filter 114 Geoue Gas © 2014 Genero levie Company Alrghts reservedOutput Channel Isolation The designer of the signaling circuit where the SVI II AP is to be installed must consider the 8 design rules in Wiring Guidelines [see "Wiring Guidelines” on page 96 of this manual). In porticular, the control system output interface has analog output channels that are golvanically isolated and share @ common ground or are separated from ground by the current control transistor or sense resistor, If the outputs ore isolated a single channel zener diode barrier con be used If the outputs share a common ground a single channel zener diode barrier can be used Ifthe outputs are separated from ground « dual channel zener barrier is required. Controller outputs are seporated internally from ground by a current sense resistor or a control transistor Oual channel borriers apply excessive oop resistance and cause compliance voltage problems. An intrinsically Safe galvanic isolator operates with all three types of output channels, isolated, grounded or separated from ground, and provides sufficient compliance voltage. The galvanic isolator must be certified by the manufacturer to bbe HART compliant if the HART connections are supported on the sofe area side of the isolator. See Figure 47 on page 114. Consult barrier and isolator manufacturer for devices rated for use with the SVI I APS. entity parameters in Hazardous Area Approvals. HART Filter Requirements The control system output interface must allow the HART frequencies to coexist with the precision 4 - 20 mA DC signal. Circuits that are not designed for HART may need a HART filter. Consult the controller or DCS manufacturer for interfacing to a particular system. The HART communications can cause a non-HART compliant outout circuit to malfunction, in some coses. In other cases the HART communications tones are disabled by the contral circuit. emote The SVIIIAP can be used with non-HART compliant output circuits b communications functionality are not enabled. Use pushbuttons for oll operation and maintenance. If remote maintenance is desired always isolate the control valve from the process and disconnect the non-compliant controller before connecting a current source for power and a HART master device. Ifo HART filter is required, then its voltage drop must be considered in calculating the compliance voltage. © 2016 Genero electric Comaary Al rghts reserved. lon SV APinstalation and Maintenance Manual |115Hazardous Area SVIIIAP, Figure 48 ‘CAUTION NoTE 116] ceotecas Non-hazardous Area LS. Galvanic Isolator Intrinsically Safe Installation with Galvanic Isolator Do not connect a HART modem and a PC to @ cantrol circuit unless the controller is HART compatible or has a HART filter. Loss of control or a process upset can occur if the controller output circuit is not compatible with HART signals A control circuit must be HART compatible or have a HART filter installed. Contact the manufacturer of the controller or DCS. See HART Filter Required for Certain Controls System Output Circuits © 2014 Genero levie Company Alrghts reservedModem and Computer Use in Intrinsically Safe Circuits Many HART modems that are in use today are not approved for connections to intrinsically Safe control circuits. Most portable computers are NOT approved for use in hazardous areas, Modems can be safely connected to the safe area side of barriers, and isolators. Observe requirements for the HART filter. MACTek intrinsically Safe modem, Model 010005 The VIATOR RS232 HART Interface (Eex ia] IIC complies with the Essential Health and Safety Requirements relating to the design and construction of equipment and protective systems intended for use in potentially explosive atmospheres. Requirements given in Annex Il of the Directive 94/9/6C (ATEX Directive] of the European Parliament and the Council of 23 March 1994, Consult MACTek Corporation, http://wwmmactekcorp.com/company.html for detailed requirements for sofe use. MACTek Warning This product has not been tested by any certification agency such os Factory Mutual with jurisdiction outside the European Union for intrinsic sofety. The product can be used outside the European Union (e.g. in the USAl on the sole authority of the buyer, MACTek makes no cloims of suitability and offers no warranties regarding the use of this product for connection of PCs to circuits extending into hazardous areos in countries outside the European Union. Do not connect a PC or HART madem to an intrinsically safe circuit except on the safe area side of a barrier, Do not operate ¢ PC in « hazardous area without compliance with local and plant regulations, Use of Handheld Communicators In Intrinsically Safe Circuits WARNING Ensure that any handheld communicator in use is approved for use in hazardous areas that use explosion proof safety practices Do not use unapproved handheld communicators unless the area hhas been declared safe (Hot Work Permit. Ifo HART communicator is opproved to communicate with intrinsically safe control circuits in hazardous areas. Read the product manual before use and observe all warnings. The intrinsic safety entity parameters must be added to the SVI IIAP entity parameters to determine suitability for use in any intrinsically safe Circuit. Observe the labels on the handheld communicator or consult the manufacturer. © 2016 Genero electric Comaary Al rghts reserved. lon SV APInstalation and Maintenance Manual |117