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3.568.5275.400
IM-P343-37
CH Issue 1
SP400
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
1. Index
2. Safety information
3. Technical information
4. Options
5. Installation
6. Electrical connections
7. Quick start procedure
8. Programming
flow chart
9. Programming and
commissioning
10. Maintenance
11. Default values and
program settings
12. Glossary of
display data
IM-P343-37
Printed in the CH
UK Issue 1
1
© Copyright 2010
1. Index
Section
Sub-section
2. Safety information
2.1 General requirements
2.2 Electrical safety requirements
2.3 Electromagnetic compatibility
3. Technical information
3.1 3.2 3.3 3.4
4. Options
4.1 Pressure gauge block
5.1 5.2
5. Installation
5.3
Electrical
6.
connections
7.
Quick start procedure
Description
Technical data
Materials
Programmable functions
Mounting the SP400 positioner General informaton
Sequence for mounting an SP400 positioner to
a linear actuator
Sequence for mounting an SP400 positioner to
a rotary actuator
5.4 Air supply and connections
6.1 Guidance notes
6.2 Wiring diagrams
7.1 2-port valves
7.2 3-port valves
8. Programming flow chart
9.1 9.2 9.3 9.4 9.5 9.6 10. Maintenance and troubleshooting
10.1 Air supply quality
10.2 Fitting replacement filter plug kit
9. Programming and
commissioning
SET-UP NOW
SP400 MENU
MANOP
AUTOS - automatic autostroke commissioning
SET - setting of valve functions
RUN - automatic operation
11. Default values and program settings
12. Glossary of display data
2
12.1 Main menu display functions
12.2 Sub-menu display functions
IM-P343-37 CH Issue 1
2. Safety information
2.1 General requirements
The flawless and safe operation of the SP400 positioners is reliant on proper
transportation, storage, installation and commissioning by qualified personnel, proper
use and careful maintenance.
Prior to installing, using or maintaining the positioner, consideration should be given to:
-
-
-
-
-
-
-
The working environment.
Safe access.
Lighting.
Pipeline fluid hazards.
Temperature.
System isolation.
Location.
The SP400 positioner should be mounted with sufficient space to allow opening of
the hinged cover and to provide access for electrical and air connections. When
fitting to an actuator, ensure that the positioner will not be exposed to an ambient
temperature outside the range of -10°C to +80°C. The positioner enclosure is rated
to IP65 (see BS EN 60534-1 1998).
2.2 Electrical safety requirements
The SP400 is a class III product which must only be powered from Safe Extra Low
Voltage (SELV) sources whether by virtue of a 4 - 20 mA control signal or from a
separate power supply. Similarly all signal circuits connected to an options board must
operate within the confines of SELV systems. All associated wiring must be separated
from other wiring containing hazardous voltages.
2.3 Electromagnetic compatibility
The product complies with the Electromagnetic Compatibility Directive 2004 / 108 / EC
according to:
- EN 61326-1: 2006
- EN 61326-2-3: 2006
- EN 55011: 1998 + A1: 1999 + A2: 2002
- EN 61000-4-2: 1995 + A1: 1998 + A2: 2001
- EN 61000-4-3: 2006
- EN 61000-4-4: 2004
- EN 61000-4-5: 2006
- EN 61000-4-6: 2007
- EN 61000-4-11: 2004
This product may be affected by interference if:
-
The product or its wiring is located near a radio transmitter. The actual separation
necessary will vary according to the power of the transmitter.
-
Cellular telephones or mobile radios are used within approximately one metre of
the product or its wiring.
-
The wiring is routed alongside power cables subject to high voltage transients or
current surges.
IM-P343-37 CH Issue 1
3
3. Technical information
3.1 Description
The SP400 smart valve positioner is loop powered from a 4 - 20 mA input signal to provide
accurate adaptive positional control of pneumatic actuated linear and quarter turn valves.
Precise control is maintained through valve position feedback that automatically varies the
pneumatic output pressure to overcome the effects of stem friction and flow forces to maintain
desired valve position. Indication of valve position is provided through a continuous digital
display of % travel. Valve position feedback is retrieved by means of a non contact technology
based on Hall effect. The pneumatics are based on piezovalve technology - Therefore, high
resolution, high reliability, vibration insensitivity and extremely low air consumption is
guaranteed at steady state.
The SP400 includes many smart functions that can be fully programmed through menu driven
software using an integral keypad and LCD alphanumeric data. The absence of mechanical
linkages between valve stem and positioner, drastically simplifies the mounting procedure
and reduces the time required. Moreover the software has been designed to simplify
operations as much as possible: commissioning requires just assembling the SP400 to the
valve and pressing one button. The SP400 is supplied with a NAMUR standard mounting kit
for attachment to yoke or pillar mounted actuators. For quarter turn valves, a mounting kit
compliant to VDI / VDE 3845 is supplied.
1
2
4
3
12
10
11
9
Fig. 1
13
5
6
7
8
No. Part
1. LCD display
2. Main menu functions with LCD flag indication
3. Signal pressure to actuator
4. Gland connection for wiring M20
5. Terminal block
6. Increase value or toggle value key
7. Decrease value or toggle value key
8. Enter key
9. Supply pressure to positioner
10. Optional pressure gauge block with gauges
11. Spare M20 gland connection for wiring a 4-20 mA retransmission or software switches
12. External earth
13. Internal earth
4
IM-P343-37 CH Issue 1
2
6
7
8
9
5
3
1
10
4
Fig. 2
No. Features
1. indicates all is OK
2. ! Indicates a delay in positioning, this
disappears when the position is reached
3. Indicates that the value displayed is a
percentage
4. Indicates that the value displayed is the
input current measured in mA
5. Indicates that the value displayed is a
time measured in seconds
6. Indicates that you're accessing the main
programming menus
7. Indicates that the positioner is in manual
mode
8. Indicates that the positioner is running
the autocalibration
9. Indicates that you're accessing the SET
menu
10. Indicates that the positioner is in
automatic mode
3.2 Technical data
Input signal range
4 - 20 mA nominal
Minimum input signal (loop powered)
3.6 mA
Minimum air supply pressure
1.4 bar g
Maximum air supply pressure
7 bar g
Air quality
Air supply must be dry, oil and dust free to ISO 8573-1 class 2:3:1
Output pressure
Stroke range
Action
Operating temperature
Maximum air flow
Steady state air consumption
Air connections
Cable gland
Electrical connections
Enclosure rating
Characteristic
Resolution (maximum)
Shut-off
Shipping weight
IM-P343-37 CH Issue 1
0 to 100% supply pressure
Linear valves 10 mm to 100 mm
Quarter turn valves 5° to 120°
Single action / fail vent
-10°C to +80°C
4.2 normal m3/h at 1.4 bar g or 8.5 normal m3/h at 6 bar g
Less than 0.016 normal m3/h
Screwed ¼" NPT
M20
Spring clamp terminals for 0.2 to 1.5 mm² wire
IP65
Linear
0.1% F.S.
1%
2.2 kg
5
3.3 Materials
Part
Case and cover
Magnet bracket
Material
Die cast aluminium
Die cast aluminium
Finish
Anti-corrosive paint to RAL5010
3.4 Programmable functions
Autostroke
Valve type
% travel
Control action
Split range
Deadband
Reset
Input signal
6
Automatic commissioning routine
2-port or 3-port
Selectable 0 to 100% or 100% to 0%
depending on valve / actuator configuration
Direct or reverse action (4 - 20 or 20 - 4 mA)
OFF
range 4-20 mA
LOW
range 4-13 mA
HIGH range 11-20 mA
0.5%
1.5%
3.0%
5.0%
Resets all programmed values to default settings
Visualisation of input mA signal
IM-P343-37 CH Issue 1
4. Options
4.1 Pressure gauge block
An optional pressure gauge block (Figure 3) can be fitted onto the SP400 positioner which
includes two pressure gauges indicating air supply pressure and output air signal pressure to
the actuator. The pressure gauge block can be retrospectively fitted using 2 off M5 socket
head screws. Ensure that the gauge block air connection 'O' rings are correctly located
before tightening.
Fig. 3
IM-P343-37 CH Issue 1
7
5. Installation
5.1Mounting the SP400 positioner - General information
Preliminary check of valve and actuator assembly - A preliminary check should be carried
out on the valve and actuator assembly prior to mounting and commissioning the SP400
positioner to confirm smooth movement of the stem. This can be performed by providing an
air supply directly from a filter/regulator to the actuator. The air supply pressure should be
gradually increased to progressively move the stem through its full travel. Any friction or
jerky movement of the stem should be investigated prior to commissioning the SP400.
5.1.1The SP400 is supplied with a NAMUR standard fixing kit for linear actuators (yoke
or pillar) or with a VDI / VDE 3845 compliant mounting kit for rotary actuators.
5.1.2The SP400 has an enclosure rating of IP65 and should be installed in a location that
will not exceed its ambient temperature limits of -10°C minimum and +80°C maximum.
5.1.3 Before fitting and commissioning the SP400 positioner ensure that the valve and
actuator are correctly assembled. Refer to the valve and actuator Installation and
Maintenance Instructions for details.
8
IM-P343-37 CH Issue 1
5.2 Sequence for mounting an SP400 positioner to a
linear actuator
2
Fig. 4 Pillar mounting kit for a linear actuator
5.2.1Loosely attach the magnet bracket (2) to the valve / actuator connector (refer to
Figures 4 and 5). Be sure it is positioned horizontally (as shown in Figure 5).
Fig. 5
Yoke mounting assembly
for a linear actuator
2
IM-P343-37 CH Issue 1
9
Assembled
2
Fig. 6
5.2.2 Slide the bracket (2) to the left or to the right (Figure 6) till the correct position is
achieved. If you’re using a Spirax Sarco actuator the correct position is impressed
on the magnet bracket (Figure 7).
PN9000
PN1000
Fig. 7 Bracket markings
5.2.3 If you’re not using a Spirax Sarco actuator, slide the bracket till the distance 'A'
between the center of the magnet and the inner side of the mounting plate is 25 mm
(Figure 8).
Mounting plate
Bracket
Fig. 8
A
Distance between the mounting plate and magnet
Center
of the
magnet
10
IM-P343-37 CH Issue 1
5.2.4 Loosely attach the positioner mounting plate to the actuator as shown in the following
pictures: for the pillar actuator (Figure 9), and for the yoke actuator (Figure 10).
Mounting plate
Pillar actuator
Assembled
Fig. 9 Pillar actuator assembly
Mounting plate
Assembled
Yoke actuator
Fig.10 Yoke actuator assembly
5.2.5 Locate the protection plate onto the back of the SP400 positioner housing and fix in
place (Figures 11 and 12).
Protection
plate
Assembled
Fig. 11
IM-P343-37 CH Issue 1
Fig. 12
11
5.2.6
Attach the positioner mounting plate to the
positioner as shown in Figures 26 and 27.
Protection
plate
5.2.7
Adjust the vertical position of the SP400
positioner and mounting plate assembly, by
sliding it up or down on the pillar style actuators,
ensuring that the positioner is roughly centred
on the actuator / valve stroke (Figure 10).
Even if this is the ideal condition, it’s not
mandatory. In fact, as shown in Figure 15, the
only necessary condition for correct operation
is that the stroke of the magnet (dimension B)
lay inside the sensor operating linear range
(dimension A), i.e. the vertical dimension marked
on the case of the positioner.
5
SP400 positoner
B
A
Fig. 13
Assembled
Fig. 15
5.2.8
Fig. 14
Attach
the
mounting
plate
When the SP400 positioner and mounting
plate assembly is correctly positioned,
tighten the hexagon headed screw (5) on
the yoke mounted actuator (Figure 13) to
10 - 12 N m and tighten the 'U'bolt nuts (6) on the
pillar mounted actuators (Figure 16) to 10 - 12 N m.
6
Fig. 16
12
IM-P343-37 CH Issue 1
5.3 Sequence for mounting an SP400 positioner to a
rotary actuator
5.3.1 Assembly for fitting an SP400 on to a ¼ turn valve.
Fig. 17 Mounting kit
IM-P343-37 CH Issue 1
13
Fig. 19
Fig. 18
Fig. 20
14
IM-P343-37 CH Issue 1
Fig. 21
Assembled
Fig. 22
IM-P343-37 CH Issue 1
15
5.3.2 Adjust the magnet orientation as illustrated in Figures 23 and 24 and tighten the bolt to
fix the magnet into position. There should be a distance of between 5 and 14 mm between
the magnet and the positioner.
Refer to Figure 23 for actuator with clockwise rotation.
Refer to Figure 24 for actuator with anti-clockwise rotation.
In fact, in this way the magnet movements will always be comprised in the sector between
the directions C and D which delimit the operating area of the Hall sensor.
B
D
15°
90°
120°
A
15°
C
Fig. 23 View from the bottom of the positioner - Magnet orientation for clockwise
actuator.
B
D
15°
90°
120°
A
15°
C
Fig. 24 View from bottom of the positioner - Magnet orientation for anti-clockwise
actuator.
16
IM-P343-37 CH Issue 1
5.4 Air supply and connections
Warning: Supply air pressure must not exceed the maximum allowable air pressure of
the actuator. Air connections should be ¼" NPT for air supply (supply) and output signal to
actuator (Figure 25).
The supply air should be between 1.4 bar g minimum and 6 bar g maximum and be oil and
dust free to IEC 60770. Mains air supply may sometimes contain traces of dirt, rust, water, oil
and other deposits with the potential for contaminating the internals of the positioner. It is
therefore essential that a filter / regulator is fitted in the mains air supply to the positioner.
The filter / regulator should have a coalescing filter such as a Spirax Sarco type MPC2, or
suitable compressed air pipework is used.
¼" NPT air signal to
actuator (output 1)
¼" NPT air supply (supply)
Fig. 25
IM-P343-37 CH Issue 1
17
6. Electrical connections
6.1 Guidance notes on wiring installation
For heavy industrial applications it is recommended to use screened cables or signal cables
run in metal conduit. Failure to do so could result in positional errors of up to ±5% in an
RF field excess of 10 V/m. If screened cables are used, ensure that the screen is connected to
the local earth at one end with a connection resistance of less than 1 ohm.
For light industrial applications where RF fields do not exceed 3 V/m unscreened cables
may be used.
Cabling should be installed in accordance with BS 6739 - Instrumentation in Process Control
Systems: Installation design and practice or local equivalent.
6.2 Wiring diagrams
6.2.1 Terminal block
1
4
5
6
+
4-20mA
3
50 %
MENU MANUAL AUTOS SET
2
AUTOMATIC
TUNE
AUTOSTROKE
7
▲
9
▲
8
10
keep pressed
SP400
Fig. 26
No.
Pole
1
+
2
-
3
+
4
-
5
+
6
-
7
+
8
-
9
+
10
-
18
Description
Not used
4-20 mA current signal input
Mainboard
Not used
Not used
Not used
IM-P343-37 CH Issue 1
6.2.2 Single loop applications
The SP400 is loop powered using the 4 - 20 mA input signal source providing a
minimum signal of 3.6 mA can be maintained.
Minimum current
3.6 mA
30 mA
<7V
Up to 30 Vdc
Up to 30 Vdc
Maximum current
Maximum voltage drop
Overvoltage protection
Protection against polarity inversion
Fig. 27
3
4
+
-
4 - 20 mA signal
6.2.3 Multi-loop applications
Loop powered multi-positioner connections
Positioner 1
Fig. 28
3
4
Positioner 2
3
4
4 - 20 mA signal +
@ 14 V minimum In a loop powered application, the 4-20 mA signal must be capable of supplying a
minimum of 7 V per positioner at 20 mA. In a split range application the signal source
must be capable of supplying sufficient voltage, i.e. 14 V is enough to power 2 positioners.
IM-P343-37 CH Issue 1
19
7. Quick start procedure
7.1 2-port valves
The following applies to positioners fitted to 2-port valves having plug above the seat and
fitted to pneumatic actuators having a direct acting (DIR) 4 - 20 mA input signal and excludes
the setting of any additional program functions (i.e. default value only).
Note: For PN5100 and PN6100 series actuators an additional programming step is required.
(Refer to Section 9.5.2).
7.1.1 The positioner should be correctly assembled as described in Section 5 and Section 6
and supplied with mains air and signal pipework as described in Section 5.4.
7.1.2 Provide a minimum input signal of 3.6 mA to the positioner.
SET-UP NOW should be displayed.
7.1.3 Ensure that upstream isolation valves are closed.
Press and hold the key for 3 seconds to advance to the SP400 MENU.
The display will count down the 3 seconds.
7.1.4 Press the
key to advance to manop.
7.1.5 Press and hold the
key for 3 seconds to enter manual control mode MCTL.
7.1.6 In manual control press and hold the
or
key to drive the valve stem up or
down. Check for any obstructions of valve movement.
The display will indicate FILL or VENT as appropriate.
Any obstruction should be investigated before proceeding to Section 7.1.7.
7.1.7 Press the
key to return to MANOP in main menu.
7.1.8 Press and hold the
key for 6 seconds to start the autostroke routine.
This will take approximately 2 minutes to complete.
! displayed indicates an incomplete or unsuccessful autostroke.
The routine can be aborted at any time by pressing the
key once.
If autostroke is aborted during operation ABORT will be displayed and
incomplete autostroke.
On completion the program will automatically return to AUTOS in main menu.
A
! to indicate
will be displayed if successful autostroke has been completed.
7.1.9 The valve will move to a control position related to the input control signal.
20
The percentage valve travel will be displayed %.
The positioner cover can now be closed and cover screws tightened.
IM-P343-37 CH Issue 1
7.2 3-port valves (with travel setting (TRAVL) 0 - 100%, refer to Figures 14 and 15)
Proceed as above up to Section 7.1.8.
7.2.1 On completion of a successful autostroke press and hold the
7.2.2 Press the
key three times to access SET.
7.2.3 Press the
key once to advance to valve type.
key to indicate VALVE 3-PORT.
Press the
7.2.4 Press the
key for 3 seconds
to access the SP400 MENU.
key to select VALVE 3-PORT. Continue to press the
SET in the main menu.
7.2.5 Press the
key to return to
key twice to advance to RUN in the main menu.
7.2.6 Press and hold the
key for 3 seconds to commence automatic operation.
The valve will move to a control position related to the input control signal. The
percentage travel will be displayed %. The positioner cover can now be closed and
the cover screws tightened.
IM-P343-37 CH Issue 1
21
8. Programming flow chart
SET-UP
NOW
Software
version
(Ver X.XX)
PSWRD
SP400
MENU
From
RETRN
MANOP
% Travel
(TRAVL
0-100% /
100-0%)
Note: SET and
RUN can only
be accessed
on completion
of a successful
autostroke
(AUTOS)
AUTOS
Manual operation
(MCTL)
Autostroke activate
(AUTOS)
SET
RUN
Fig. 29
22
IM-P343-37 CH Issue 1
Key
3 seconds enter
Enter
Auto return
Clear stored
values
(RESET)
Recall stored
values
(RETRN)
Retain temporary
values
(RTAIN)
C-CAL
VALVE
AUTO
OPERATION
(% TRAVEL)
CTRLA
DBAND
SPLIT RANGE
mA INPUT
RETURN
(To SP400 MENU)
IM-P343-37 CH Issue 1
23
9. Programming and commissioning
9.1 Set-up now
Programming notes
The positioner fitted to this control valve requires programming. A minimum input
signal of 3.6 mA is required to power the positioner. To program the positioner it is
necessary to enter the SP400 MENU and carry out an autostroke commissioning
routine (AUTOS) prior to putting the control valve into automatic operation.
A flow chart is included in Section 8 to guide you through the procedure. The
display provides a flag indication of the active main menu function.
To enter the SP400 MENU press and hold the key for 3 seconds. The display
will count the 3 seconds.
Commissioning notes
Main menu functions include:
SP400 MENU View software version, mounting position check, reset default values.
MANOP
Manual control of valve movement (Actuator inflation / deflation).
AUTOS
Automatic valve commissioning. Provides selection of % travel display.
SET
Setting of valve type, control action, input signal span and deadband.
RUN
Activates automatic operation plus input signal, total valve strokes and
total run time. Also provides route for returning to the SP400 MENU.
Note: SET and RUN functions are restricted and can only be accessed on completion of
a successful autostroke routine (AUTOS).
In order to make commissioning as fast and simple as possible, you can run
the autocalibration routine directly from the following menus: SETUP NOW,
SP400 MENU, MANOP, SET, RUN. Keep the key pressed for 6 seconds
and the autostroke will start. At the end of the routine the positioner will enter
into automatic mode and move the valve according to the current signal
received. This means that once you have checked the functionality and safety
of the assembly, you can commission the valve by just pressing one button.
24
IM-P343-37 CH Issue 1
9.2 SP400 MENU
SET-UP
NOW
3 seconds enter
Software
version
(Ver X.XX)
PSWRD
SP400
MENU
3 seconds enter
Clear stored
values
(RESET)
Recall stored
values
(RETRN)
Retain temporary
values
(RTAIN)
From
RETRN
Fig. 30
Programming notes
You are now in the SP400 MENU.
SP400 functions include:
1. Visualisation of the embedded software version (VER--).
2. Positional setting (CALIB).
3. Resetting of programmed values to default settings (RESET).
4. To retain settings in the temporary memory (RTAIN).
5. Returning to previously stored settings (RETRN).
Press and hold the key for 3 seconds. The display will count the 3 seconds
and access to RESET / RTAIN / RETRN functions.
To view the embedded version of software (VER-.--) press the
key. To
advance to manual operation (MANOP) press the key.
9.2.1 VER -.-- software version
Programming notes
To view the version of the embedded software (VER-.--) press key.
Press the key to return to the SP400 MENU. The display will automatically
return to the SP400 MENU after 10 seconds.
Press and hold the
IM-P343-37 CH Issue 1
key for 3 seconds to access the PSWRD menu.
25
9.2.2 PSWRD menu
This menu allows the user to upgrade an SP400 to an SP500 smart positioner.
Contact our offices for further details.
9.2.3 RETRN - RTAIN - RESET
Programming notes
Provides the facility to restore previous permanently stored values (RETRN),
to retain values stored in the temporary memory (RTAIN) or to reset all values
to factory default settings (RESET). Press the and keys to select RETRN,
RTAIN or RESET. To advance proceed as follows:
RETRN
To cancel any temporary changes to programmed values select RETRN and
press the key to return to the SP400 MENU.
RTAIN
To retain temporary changes to programmed values select RTAIN and
press the key to return to the SP400 MENU.
RESET
Provides the facility to reset all values to factory default settings and return to
SET UP NOW. Press and hold the key for 3 seconds. The display will count
the 3 seconds.
Commissioning notes
RETRN
If changes have been made to program values they will be held in the temporary memory.
To retain changes in the permanent memory it is necessary to advance to RUN in the main
menu and press and hold the key for 3 seconds. The display will count the 3 seconds.
If you do not wish to retain temporary changes select RETRN and press the key to
return to the SP400 MENU.
RTAIN
If changes have been made to programmed values they will be held in the temporary
memory. If you wish to retain these changes select RTAIN and press the key to return
to the SP400 MENU. To retain temporary changes in the permanent memory
advance to RUN in the main menu and press and hold the key for 3 seconds. The display
will count the 3 seconds.
RESET
Resetting to default values (refer to Section 9 for default values) should be used if it is
intended to use the positioner on a different control valve. If the SP400 positioner has been
moved on its mounting or is to be fitted on a different control valve it will be necessary to
undertake a new autostroke (AUTOS).
RESET to factory default settings can also be used if it is required to recommission the
valve.
To reset to factory default values select RESET and press and hold the
3 seconds. The display will count the 3 seconds.
26
key for
IM-P343-37 CH Issue 1
9.3 MANOP
3 second enter
MANOP
Manual operation
(MCTL)
C-CAL
Fig. 31
Programming notes
Press and hold the key for 3 seconds to enter manual control mode (MCTL).
The display will count the 3 seconds.
Press the key to enter the current calibration mode (C-CAL). Press the
key to return to MANOP.
In MANOP press the
key to advance to autostroke (AUTOS).
Commissioning notes
Before initiating an autostroke commissioning (AUTOS) use manual control (MCTL) to
manually fully inflate and deflate the actuator to ensure there are no obstructions to the
full valve travel movement.
Manual control is also useful during normal operation to manually control the valve
position as a commissioning aid or in the event of input signal failure.
9.3.1 MCTL - manual control
Programming notes
Manual control enables the actuator to be manually inflated or deflated.
Press the key to inflate actuator and the key to deflate the actuator. Press
and hold the or key to accelerate action.
Prior to undertaking an AUTOS the display will indicate FILL or VENT.
On completion of AUTOS the display will indicate % valve travel.
Manual control (MCTRL) - Tight shut-off function
Press and hold the key to drive the valve to its closed position. At 0% travel
the ! will flash to indicate limit of travel. To initiate tight shut-off release
the key and press the again. The actuator will be vented of air to provide
dead tight shut-off. This also applies sto the 100% valve position by pressing
and releasing the key and pressing the again to inflate the actuator to
provide dead tight shut-off.
Manual control (MCTRL) - Travel limits
When operating in manual control any travel limit settings will be overridden
therefore it is possible to manual position the valve through its full 0 to 100%
travel as measured in autostroke (AUTOS).
Commissioning notes
Before initiating an autostroke commissioning routine (AUTOS) the actuator should be
manually fully inflated and deflated to ensure there are no obstructions to the full valve
travel movement.
Manual control is also useful during normal operation to manually control the valve position
as a commissioning aid or in the event of input signal failure.
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9.3.2 C-CAL - current calibration
Programming notes
C-Cal provides a simple way to make a fine calibration of the input current signal
(4 - 20 mA).
To perform the calibration:
1. Enter C-CAL and press the key, then press the
2. Generate a 4 mA input signal and press
3. Generate a 12 mA input signal and press
4. Generate a 20 mA input signal and press
key.
If 'ERROR' is displayed the calibration routine is aborted. The value of the
generated signal is too far from the expected one. Be sure that a 4 mA, 12 mA or
20 mA signal is generated as required. Press the key to return to C-CAL.
If 'OK' is displayed the calibration has succeeded. Press the
to return to C-CAL.
Where possible current calibration should be overtaken, to guarantee a perfect
match between the input current generated and the reading of the SP400.
Let’s assume that the table below show the input signal generated by a PLC or
DCS versus the input signal read by the SP400.
Setpoint
0%
Input current from PLC Current read from SP400
3.6 mA 3.8 mA
50%
12 mA
12.2 mA
100%
20 mA
20.2 mA
Hence when the setpoint is 0% the PLC generates a 3.6 mA instead of 4 mA.
After C-CAL is executed the SP400 recalibrates the current read to compensate
the error.
Setpoint
0%
Input current from PLC Current read from SP400
3.6 mA 4 mA
50%
12 mA
12 mA
100%
20 mA
20 mA
In this way a perfect match is achieved between the setpoint of the PLC and the
setpoint of the of the SP400 (i.e. the input current read by the SP400).
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9.4
AUTOS
- automatic autostroke commissioning
% Travel
(TRAVL
0-100% /
100-0%)
AUTOS
3 second
Autostroke activate
enter
(AUTOS)
Fig. 32
Programming notes
AUTOS provides access to:
1. Autostroke commissioning (AUTOS).
2. % travel display (TRAVL).
AUTOS
Autostroke provides an automatic commissioning routine which will take
approximately 1 to 3 minutes to complete.
Press and hold the key for 3 seconds to start autostroke. The display will
count down the 3 seconds. When autostroke is active a flashing AUTOS
message will be displayed.
On completion of a successful autostroke the programme will automatically
return to AUTOS in the main menu and a
will be displayed. In the event of
an unsuccessful autostroke routine a flashing ! will be displayed.
If during AUTOS inconsistent data is obtained due to mechanical problems, the
autostroke procedure will be terminated and ABORT will be displayed.
It is also possible to immediately abort during an autostroke routine by pressing
the
key. ABORT will be displayed together with a flashing !.
Error messages:
ERROR 1 Indicates a wrong mechanical coupling between positioner and
actuator. Check the mounting is correct.
ERROR 2Indicates that there is insufficient air pressure to achieve valve
movement. Check that the air supply is adequate to overcome the actuator
spring force. Fitting of a gauge block will aid the commissioning procedure.
ERROR 3Indicates that the actuator will not deflate. Check that there is
no obstruction preventing the stem travel or air venting from the actuator.
Error 4 indicates that the stroke measured is less than the minimum
stroke allowed - 10 mm for linear valves, and 5° for quarter turn valves
(output 1 and output 2 for double action applications).
ABORT indicates mechanical problems have occurred during the Autostroke
procedure or the
key has been pressed during Autostroke to abort the
procedure.
On completion of a successful autostroke it will be possible to advance to
SET and RUN functions in the main menu. Press the key to advance to these
functions.
Commissioning notes
Prior to undertaking an autostroke routine, manual operation should be used to fully
inflate and deflate the actuator to ensure there are no obstructions to the full valve
movement. Autostroke is an automatic commissioning routine that checks for maximum
valve travel, signal response, valve characteristics, inflation / deflation times etc. Data
gathered will be automatically download into the embedded software to ensure optimum
performance of the valve / actuator combination.
Autostroke commissioning will take approximately 1 to 3 minutes to complete
depending on air pressure and actuator size etc.
Autostroke commissioning must be carried out on start-up or at any other time if the
valve performance is not satisfactory.
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9.4.1 TRAVL - % travel display
Programming notes
Press the key to access TRAVL.
Provides selection of % valve travel display with option of 0 - 100% or 100 - 0%.
Default is 0 - 100%.
Use the and keys to toggle selection.
Press the key to return to AUTOS.
Commissioning notes
The selection of % valve travel display depends on the valve and actuator configuration.
Figures 33 to 36, and Figures 37 and 38 (page 32) provide guidance on selection. After
completion of AUTOS if a change is made to TRAVL it will be necessary to initiate an AUTOS
routine once again.
Display = 0%
Display = 100%
Fig. 33 2-port valve normally closed - TRAVL setting = 0 to 100%
Display = 0%
Display = 100%
Fig. 34 2-port valve normally open - TRAVL setting = 0 to 100%
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Display = 100%
Display = 0%
Fig. 35 2-port valve normally open - TRAVL setting = 100% to 0%
Display = 100%
Display = 0%
Fig. 36 2-port valve normally closed - TRAVL setting = 100% to 0%
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100%
100%
0%
0%
TRAVEL setting = 0 to 100%
DISPLAY = 0%
TRAVEL setting = 0 to 100%
DISPLAY = 100%
TRAVL setting = 100 to 0%
DISPLAY = 100%
TRAVL setting = 100 to 0%
DISPLAY = 0%
Fig. 37 3-port valve and spring extend actuator
100%
100%
0%
0%
TRAVEL setting = 0 to 100%
DISPLAY = 0%
TRAVL setting = 100 to 0%
DISPLAY = 100%
TRAVEL setting = 0 to 100%
DISPLAY = 100%
TRAVL setting = 100 to 0%
DISPLAY = 0%
Fig. 38 3-port valve and spring retract actuator
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9.5
SET - setting of valve functions
VALVE
CTRLA
DBAND
SET
SPLIT
RANGE
Fig. 39
Programming notes
Provides access to basic valve set up functions. Press the
all SET functions.
Functions include:
- Valve type - Control action - Deadband
- Split range
(2-port or 3-port)
(direct or reverse) (valve positioning sensitivity)
(split range)
key to scroll round
(VALVE)
(CTRLA)
(dBand)
(SPLIT RANGE)
Press the key to advance to valve type (VALVE). Repeat pressing of the
will scroll round all SET functions.
Press the
key
key to advance to TUNE in the main menu.
Commissioning notes
Each SET function has a default value as listed in the Installation and Maintenance
Instructions. Default values are based on a 2-port normally closed valve having maximum
95% lift and an input signal span range 4 - 20 mA.
SET values should be adjusted to suit the valve type (2-port or 3-port) and application.
Functions include the facility to change the control action, limit the full travel of the valve
plug (minimum and maximum) and to split range the input signal.
More detailed information is provided for each SET function.
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9.5.1 VALVE - valve type
Programming notes
2-port
On 2-port valves when the setpoint is 100%, the positioner will open to 95% of
the stroke and display 100%, to prevent the back of the plug hitting the bonnet.
Tight shut-off is set to 1% on 'vent' operation.
3-port
On 3-port valves tight shut-off is set to 1% on 'vent' and 'fill' operations to
ensure shut-off on both seats. When setpoint is 100%, the positioner will open
to 100% of the stroke and display 100%.
Use the
and
keys to select type. Press the
type and advance to control action (CTRLA).
34
key to accept displayed
IM-P343-37 CH Issue 1
9.5.2 CTRLA - direct or reverse control action
Programming notes
Provides selection of direct (dIRCT) (4 - 20 mA) or reversed (REV) (20 - 4 mA)
valve positioning control action. Press the and keys to select desired action.
Default action is dIRCT.
Press the
(DBAND).
key to accept the displayed action and advance to deadband
Commissioning notes
g
lif
tin
m
st
e
Valve plug position
g
llin
fa
e
m
lv
e
st
Va
ve
l
Va
Valve plug position
Selection of direct or reverse action changes the direct of valve plug movement relative
to the input signal. Refer to Figures 40 and 41 for further guidance.
mA
Increasing input signal
mA
Increasing input signal
Fig. 40 Direct action (DIR)
Fig. 41 Reverse action (REV)
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Fig. 42 CTRL Control Action dIRCT or REV setting guidance
Installed orientation
At-rest position
Control action
0%
100%
(TRAVL)
0 - 100%
0%
(TRAVL)
100 - 0%
Manual Selection
of required % travel
(TRAVL)
36
100%
Automatic determintation
Spring action only affects
the rest or fail-safe position
Manual Selection of required
Control Action
(CTRLA)
IM-P343-37 CH Issue 1
9.5.3 dbANd - deadband setting (positional sensitivity)
Programming notes
Dead-band provides adjustment of the valve positioning sensitivity relative to
the input signal and is expressed as a % of the input signal span.
Default value based on a 4 - 20 mA input signal span is 0.5%.
To alter the displayed value press the and keys. Press the key to accept
the displayed value and advance to split range.
Commissioning notes
Setting a narrow deadband may induce oscillations of valve movement caused by
fluctuations in the input signal, high stem friction or operating at low ambient temperatures
below 0°C. Setting a wider deadband will dampen out oscillations but may cause an
inaccuracy in actual valve position. This effect will increase if valve travel is limited. It is
normally recommended that the default value is used. If necessary increase the % value
to dampen out any oscillations in valve movement. This may be necessary for valves
having graphite packed stem seals or smaller size actuators.
9.5.4 Split range
This menu can change the range. 3 values are allowed: OFF, LOW and HIGH.
OFF
(range: 4-20 mA)
4 mA corresponds to the minimum of the stroke 0%
20 mA corresponds to the maximum of the stroke 100%
LOW
(range: 4-13 mA)
4 mA corresponds to the minimum of the stroke 0%
13 mA corresponds to the maximum of the stroke 100%
HIGH (range: 11-20 mA)
11 mA corresponds to the minimum of the stroke 0%
20 mA corresponds to the maximum of the stroke 100%
To alter the displayed value press the
and
accept the displayed value and return to SET.
keys. Press the
key to
Commissioning notes
This function is used when 2 positioners are on the same current loop. One set to LOW,
the other set to HIGH. When the current rises beyond 11 mA, the second valve starts to
open giving its contribution to the overall flow. A single current signal drives 2 valves.
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9.6
RUN - automatic operation
RUN
Fig. 43
AUTO
OPERATION
(% TRAVEL)
mA INPUT
RETURN
(To SP400 MENU)
Programming notes
Provides the facility to put the valve into automatic operation. Press and
hold the key for 3 seconds to start automatic operation. The display will count
the 3 seconds.
The valve will move to a position in response to the input control signal.
All values stored in the temporary memory will be transferred to the permanent
memory.
Commissioning notes
By pressing and holding the key for 3 seconds all values previously set will be entered
into the permanent memory. The valve will move to a position as dictated by the input
control signal.
To alter or check SET or TUNE values it is necessary to return to the SP400 MENU. Press
and hold the key for 3 seconds to return to the SP400 MENU. The display will count the
3 seconds.The positioner will vent the actuator and the valve will travel to its fail safe position.
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9.6.1 Automatic operation - % travel
Programming notes
During normal automatic operation the % valve travel will be continuously
displayed. Additionally, a
will be displayed indicating that the valve is
operating satisfactorily. At any time during automatic operation the mA input
signal can be displayed by pressing the key.
To return to the SP400 MENU press and hold the key for 3 seconds.
Commissioning notes
During normal operation the % valve travel will be continually displayed. A
indicates
that the valve is performing satisfactorily. Causes of fluctuations in valve movement can
be related to input signal. Press the key to view actual mA input signal.
9.6.2 Input signal - mA signal display
Programming notes
The mA input signal will be displayed. Press the key to return to displaying
% travel. The programme will automatically return to displaying % travel after
5 minutes.
Commissioning notes
This function is of assistance to visualise and check input signal relative to valve position
and to investigate causes of fluctuations in valve movement. The mA input signal will be
displayed for 5 minutes. Press the key to return to displaying % travel. The programme
will automatically return to displaying % travel after 5 minutes.
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10. Maintenance
10.1 Air supply quality
It is important for correct operation of the SP400 positioner that good quality air
is supplied.
It is therefore recommended that a Spirax Sarco MPC2 filter regulator or
equivalent is fitted on the air supply to the positioner. In addition the
SP400 positioner has an internal filter. In normal operation it is recommended
that this filter is replaced every 6 to 12 months depending on the air quality and
valve usage. A spare filter plug kit can be obtained from Spirax Sarco that
includes: filter plug, plus 3 off 'O' rings and filter.
10.2 Fitting replacement filter plug kit
To change the filter proceed as follows:
- Ensure that the air supply to the positioner is isolated.
- Unscrew the filter plug (1) from the SP400 housing using a 5 mm hex. head
socket key (refer to Figure 65).
The replacement filter plug can now be fitted:
- Fit the 'O' ring (4) and filter (3) onto the filter plug (1) (refer to Figure 49).
- Finally fit the retaining screw (2).
The filter plug can now be replaced into the SP400 housing, checking that the
'O' ring (4) is correctly located.
The pnuematic air supply can now be restored to the positioner and checks
made to ensure that the filter plug 'O' ring has provided the neccesary air tight
seal.
Fig. 44
Filter plug (1)
2
3
4
Fig. 45
40
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11. Default values and
program settings
Main menu
Sub-menu
Setting options
Valve type
SET
(VALVE)
SET
Control action
(CTRLA)
Deadband
SET
(dBAND)
Split range
SET
(SPLIT)
IM-P343-37 CH Issue 1
Default
value
Programmed
value
2-port
(2-port)
3-port
Direct (dIRCT)
(dIRCT)
Reverse (REV)
0.5%, 1.5%,
0.5%
3.0%, 5.0%
OFF (range 4-20 mA)
LOW (range 4-13 mA)
OFF
HIGH (range 11-20 mA)
41
12. Glossary of display data
12.1 Main menu display functions
Display
SET UP
NOW
SP400 MENU
MAN OP
AUTOS
SET
RUN
42
Description
Indicates that the SP400 positioner fitted to the valve has not been
programmed or commissioned.
Indicates that you have now entered the SP400 main menu.
Provides access to:
• View the version of the embedded software.
• Retain temporary changes to menu values (RETRN).
• Recall previously stored menu values (RTAIN).
• Reset to default values (RESET).
Provides access to manual control (MCTL) and current calibration (C-CAL).
Provides access to:
• Autostroke commissioning routine.
Note: SET and RUN functions can only be accessed after
a successful AUTOSTROKE routine has been completed.
• Selection of percentage travel display % (TRAVL).
Provides access to valve set up functions as follows:
• Valve type (VALVE).
• Control action (CTRLA).
• Deadband (dBAND).
• Split range (SPLIT).
Provides access to:
• Commencing automatic operation.
• Displaying percentage valve travel (%).
• Visualisation of input mA input signal (mA).
• Total stem strokes (STRVL).
• Total running time (RTIME).
• Return to SP400 menu (RETRN).
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12.2 Sub-menu display functions
Display
VER
x.xx
PSWRD
RETRN
RTAIN
Description
Indicates the version of software embedded within the SP400 positioner.
Permits the upgrade from SP400 to SP500.
Enables previously stored function values to be recalled.
Enables temporary changes made to function values to be retained.
RESET
Enables all function values to be reset to default settings.
Refer to Section 11 for default settings.
MCTL
Provides manual control of the valve.
Use the and keys to fill or vent the actuator.
C-CAL
Calibration of the current input.
TRAVL
Selection of percentage of travel display - 0 to 100% or 100 to 0%
depending on valve and actuator configuration.
AUTOS
AbORT
VALVE
CTRLA
dBAND SPLIT Initiates the autostroke automatic commissioning routine.
Indicates that the AUTOS commissioning routine has been aborted.
Selection of the range, used with 2 positioner in the same loop.
%
Indicates percentage of valve travel in automatic operation or
manual control (MCTL).
mA
FILL

!
ERROR 1
(AUTOS)
ERROR 2
(AUTOS)
ERROR 3
(AUTOS)
ERROR 4
(AUTOS)
Selection of 2-port or 3-port valve.
Selection of input signal control action 4 - 20 mA or 20 - 4 mA.
Selection of deadband.
Indicates the input signal in mA.
Indicates the actuator is being filled with air (manual control before AUTOS).
Indicates that there are no problems with the positioner.
An error or warning indication. Indicates a problem with the mounting position.
Indicates that there is insufficient air pressure to position the valve.
Indicates that the air cannot be vented from the actuator.
Detected stroke too short.
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