Spirax Sarco SP500 Installation And Maintenance Instructions Manual
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Spirax Sarco SP500 Installation And Maintenance Instructions Manual

Electropneumatic smart valve positioner
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3.568.5275.300
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-35 CH Issue 1
Printed in the UK
SP500
5. Installation
8. Programming
flow chart
9. Programming and
commissioning
11. Default values and
program settings
12. Glossary of
display data
IM-P343-35
CH Issue 1
© Copyright 2010
1

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Summary of Contents for Spirax Sarco SP500

  • Page 1 3.568.5275.300 IM-P343-35 CH Issue 1 SP500 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...

  • Page 2: Table Of Contents

    - setting of valve functions TUNE - setting of valve tune functions - automatic operation STRVL and RTIME - valve diagnostics RETRN - return to SP500 MENU in main menu 10. Maintenance and 10.1 Air supply quality troubleshooting 10.2 Fitting replacement filter plug kit 11.

  • Page 3: Safety Information

    IP65 (see BS EN 60534-1 1998). 2.2 Electrical safety requirements The SP500 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.

  • Page 4: Technical Information

    3. Technical information 3.1 Description The SP500 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.

  • Page 5: Options

    No. Features indicates all is OK ! Indicates a delay in positioning, this disappears when the position is reached Indicates that the value displayed is a percentage Indicates that the value displayed is the input current measured in mA Indicates that the value displayed is a time measured in seconds Indicates that you're accessing the main programming menus...
  • Page 6 3.3 Materials Part Material Finish Case and cover Die cast aluminium Anti-corrosive paint to RAL5010 Magnet bracket Die cast aluminium 3.4 Programmable functions Autostroke Automatic commissioning routine Valve type 2-port or 3-port Selectable 0 to 100% or 100% to 0% % travel depending on valve / actuator configuration Control action...
  • Page 7 4. Options 4.1 Pressure gauge block An optional pressure gauge block (Figure 3) can be fitted onto the SP500 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.

  • Page 8: Electrical Connections

    4.2 Retransmission and travel switches option board An option board can be fitted in the positioner to add valve position retransmission functionality and software travel switches functionality. The board generates a 4-20 mA current signal which represents the actual valve position. Moreover 2 output terminals are available to be configured as software travel switches.
  • Page 9 Rotate the mainboard and insert the option board (as shown in Figures 6, 7, 8 and 9). Rotate the mainboard to the initial position, fix it with the 4 screws, close the positioner and switch on the power supply and air supply. Fig.
  • Page 10 4.3 External power supply option board The SP500 can host an option board for 24 V power supply. It's a 4 wiring diagram: 2 wires for current loop and 2 wires for power supply through a 24 V external voltage. This reduces dramatically the voltage drop on the current loop. The drop is 7 V when the unit is powered by the loop (2 wires), it falls to 1 V when the 4 wires configuration is used.
  • Page 11 Rotate the mainboard and insert the option board (as shown in Figures 12 and 13). Fig. 12 Fig. 13 Remove the Jumper J4 (Figure 14). Fig. 14 IM-P343-35 CH Issue 1...
  • Page 12 Fig. 15 Insert the power supply option board. Collocate Jumper J4 as shown in Figures 15 and 16. Fig. 16 Rotate the mainboard to the initial position, fix it with the 4 screws, close the positioner and switch on the power supply and air supply. Once the option board is mounted, the positioner shall be powered according to the 4 wires connection diagram, refer to Section 6.2.3, '4 wires electrical connection'.

  • Page 13: Maintenance

    VDI / VDE 3845 compliant mounting kit for rotary actuators. 5.1.2 The SP500 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.
  • Page 14 5.2 Sequence for mounting an SP500 positioner to a linear actuator Fig. 17 Pillar mounting kit for a linear actuator 5.2.1 Loosely attach the magnet bracket (2) to the valve / actuator connector (refer to Figures 17 and 18). Be sure it is positioned horizontally (as shown in Figure 18).
  • Page 15 PN1000 Fig. 20 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 21).
  • Page 16 Fig. 22 Pillar actuator assembly Mounting plate Assembled Yoke actuator Fig.23 Yoke actuator assembly 5.2.5 Locate the protection plate onto the back of the SP500 positioner housing and fix in place (Figures 24 and 25). Protection plate Assembled Fig. 24 Fig.
  • Page 17 5.2.6 5.2.7 Attach the positioner mounting plate to the Adjust the vertical position of the SP500 positioner as shown in Figures 26 and 27. positioner and mounting plate assembly, by sliding it up or down on the pillar style actuators,...
  • Page 18 5.3 Sequence for mounting an SP500 positioner to a rotary actuator 5.3.1 Assembly for fitting an SP500 on to a ¼ turn valve. Fig. 30 Mounting kit IM-P343-35 CH Issue 1...
  • Page 19 Fig. 32 Fig. 31 Fig. 33 IM-P343-35 CH Issue 1...
  • Page 20 Fig. 34 Assembled Fig. 35 IM-P343-35 CH Issue 1...
  • Page 21 5.3.2 Adjust the magnet orientation as illustrated in Figures 36 and 37 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 36 for actuator with clockwise rotation. Refer to Figure 37 for actuator with anti-clockwise rotation.
  • Page 22 / 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.
  • Page 23 Systems: Installation design and practice or local equivalent. 6.2 Wiring diagrams 6.2.1 Terminal block MENU MANUAL AUTOS AUTOMATIC TUNE SP500 Fig. 39 Pole Description 24 V power supply option board 24 V external power supply (PWS) 4-20 mA current signal input...
  • Page 24 6.2.2 Single loop applications The SP500 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 Maximum current 30 mA Maximum voltage drop < 7 V...
  • Page 25 6.2.4 Travel switches- and 4-20 mA retransmission wiring digrams 2 k 22 k Travel switches 1 2 k 22 k Travel switches 2 Fig. 43 Software switches Example of customers external application wiring. 4 - 20 mA retransmit Fig. 44 4 - 20 mA retransmit Table 1 Ratings Supply...

  • Page 26: Quick Start Procedure

    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. key for 3 seconds to advance to SP500 MENU. Press and hold The display will count down the 3 seconds. 7.1.4 Press to advance to MANOP.
  • Page 27 7.2 3-port valves (with travel setting (TRAVL) 0 - 100%, refer to Figures 27 and 28) Proceed as above up to Section 7.1.9. 7.2.1 key once to advance to SET On completion of a successful autostroke press the in main menu. 7.2.2 key once to advance to VALVE TYPE.

  • Page 28: Programming Flow Chart

    Mounting position check Software SP500 (CALIB) version MENU (Ver X.XX) Manual operation From RETRN C-CAL (MCTL) (To SP500 MENU) MANOP % Travel (TRAVL Autostroke activate AUTOS 0-100% / (AUTOS) 100-0%) Note: SET, TUNE, and RUN can Valve type Actuator type...
  • Page 29 3 seconds enter Enter Clear stored values (RESET) Auto return Recall stored values (RETRN) Retain temporary values (RTAIN) Minimum Maximum Displayed % Minimum Maximum travel travel travel range range (MIN-T) (MAX-T) (DTRVL)† (MIN-R) (MAX-R) † Only if MIN-T / MAX-T not 0 / 100% Control action (CTRLA) Characterisation...

  • Page 30: Programming And Commissioning

    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 SP500 MENU and carry out an autostroke commissioning routine (AUTOS) prior to putting the control valve into automatic operation.
  • Page 31 9.2.1 VER -.-- software version Programming notes To view the version of the embedded software (VER-.--) press key. key to return to SP500 MENU. The display will automatically return to Press SP500 MENU after 10 seconds. IM-P343-35 CH Issue 1...
  • Page 32 9.2.2 CALIB - mounting position calibration Programming notes To access CALIB press and hold key for 3 seconds. The display will count down the 3 seconds. You are now in calibrate mode. The LCD shows in % the magnet position in respect to the sensor board of the positioner, without any offset or scale up or down.
  • Page 33 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 SP500 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).
  • Page 34 9.3 MANOP 3 second enter Manual operation C-CAL MANOP (MCTL) Fig. 47 Programming notes Press and hold key for 3 seconds to enter manual control mode (MCTL). The display will count down the 3 seconds. Press the key to enter the current calibration mode (C-CAL). Press return to MANOP.
  • Page 35 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 SP500 (i.e. the input current read by the SP500). IM-P343-35 CH Issue 1...
  • Page 36 AUTOS - automatic autostroke commissioning % Travel 3 second (TRAVL Autostroke activate enter AUTOS 0-100% / (AUTOS) 100-0%) Fig. 48 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.
  • Page 37 9.4.1 TRAVL - % travel display Programming notes Press key to access TRAVL. Provides selection of valve travel display with option of 0 - 100% or 100 - 0%. Default is 0 - 100%. keys to toggle selection. key to return to AUTOS. Press Commissioning notes The selection of...
  • Page 38 Display = 0% Display = 100% Fig. 51 2-port valve normally open - TRAVL setting = 100% to 0% Display = 100% Display = 0% Fig. 52 2-port valve normally closed - TRAVL setting = 100% to 0% IM-P343-35 CH Issue 1...
  • Page 39 100% 100% TRAVEL setting = 0 to 100% TRAVEL setting = 0 to 100% DISPLAY = 0% DISPLAY = 100% TRAVL setting = 100 to 0% TRAVL setting = 100 to 0% DISPLAY = 100% DISPLAY = 0% Fig. 53 3-port valve and spring extend actuator 100% 100% TRAVEL setting = 0 to 100%...
  • Page 40 SET - setting of valve functions Valve type Actuator type (VALVE 2-PORT / (ACT) VALVE 3-PORT) Maximum range Control action (MAX-R) (CTRLA) Minimum travel Minimum range (MIN-R) (MIN-T) Displayed % Maximum travel travel (MAX-T) (DTRVL)† † Only if MIN-T / MAX-T not 0 / 100% Fig.
  • Page 41 9.5.1 VALVE - valve type Programming notes Provides selection between 2-port and 3-port valves. Default is 2-port valve. Default values for travel limit settings (MIN-T and MAX-T) and early vent / inflate settings (S-MIN and S-MAX) will depend on the valve type (2-port or 3-port) and control action (direct or reverse) as follows: 2-port 3-port...
  • Page 42 9.5.3 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 keys to select desired action. Default action is dIRCT. Default values for travel limit settings (MIN-T and MAX-T) and early shut-off vent / inflate settings (S-MIN and S-MAX) will depend on the valve type (2-port or 3-port) and control action (direct or reverse) as follows:...
  • Page 43 Fig. 58 CTRL Control Action dIRCT or REV setting guidance Installed orientation At-rest position Control action 100% dIRCT 4 mA 20 mA 100% 100% 4 mA 20 mA 100% dIRCT 4 mA 20 mA 100% 100% (TRAVL) 0 - 100% 4 mA 20 mA 4 mA...
  • Page 44 9.5.4 MIN-T - minimum travel setting Programming notes Enables the minimum valve travel to be set as a percentage of the maximum travel obtained during autostroke. Maximum setting is MAX-T less 33.3%. Default value is 0%. keys to alter the displayed value. Press key to accept the displayed value and advance to the maximum travel setting (MAX-T).
  • Page 45 9.5.6 DTRVL - displayed travel percentage Programming notes The full mechanical limits of valve travel (0 to 100%) are measured during autostroke (AUTOS). It is possible to limit the minimum and maximum valve travel by programming MIN-T and MAX-T values, i.e. MAX-T maximum travel limit of 95% (Autostroke default value for 2-port valves).
  • Page 46 9.5.7 MIN-R - minimum signal span range Programming notes Enables the minimum mA input signal span range to be set. The value set will correspond to the minimum travel setting. Default value is 4 mA. keys to alter the displayed value. Minimum difference between MIN-R and MAX-R is 4 mA.
  • Page 47 9.6 TUNE - setting of valve tune functions Shut-off minimum Dead-band (S-MIN) (dBand) TUNE Travel switch 2 Shut-off maximum (TS2) (S-MAX) Normally closed Travel switch 1 Characterisation (TS1) (LIN / FAST / Normally open EQUAL) Time to close Time to open (T-dWN) (T-UP) Fig.
  • Page 48 9.6.1 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% with a minimum setting of 0.2%.
  • Page 49 9.6.3 S-MAX - valve shut-off maximum Programming notes Provides the facility to fully inflate the actuator at a pre-determined input signal. The value set is a percentage of the input signal span range, i.e. setting a value of 10% with an input span range of 4 - 20 mA (16 mA), will cause the valve to close with an input signal of 18.4 mA i.e.
  • Page 50 9.6.5 T-UP - valve slow opening action Programming notes This function slows down the time taken for the valve to travel from 0 to 100% lift. The time displayed is the fastest travel time measured during autostroke (AUTOS). 4 seconds may be displayed if ACT is set to 'ON' (refer to Section 9.5.2, page 41).
  • Page 51 9.6.7 TS1 and TS2 software travel switches Two switches are available TS1 and TS2. TS1 is normally open and TS2 is normally closed. Switching action is set as a % of valve travel (refer to Figures 61 and 62). TS1 - software configured travel switch 1 (normally open) Programming notes The switching point can be set as a percentage of the valve travel between 0 to100%.
  • Page 52 TS2 - software configured travel switch 2 (normally closed) Programming notes The switching point can be set as a percentage of the valve travel between 0 to 100%. A value can be set outside the limits of the travel settings (MIN-T) and (MAX-T).
  • Page 53 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 SP500 MENU. Press and key for 3 seconds to return to SP500 MENU. The display will count down the 3 seconds.
  • Page 54 At any time during automatic operation the mA input signal can be displayed by pressing key. To return to SP500 MENU press and hold key for 3 seconds. The display will count down the 3 seconds. You will advance to RETRN with the option of AUTO (automatic operation) or VENT (venting air from actuator).
  • Page 55 9.8 STRVL and RTIME - valve diagnostics Provides visibility of total number of valve strokes (STRVL) and total valve run time in hours (RTIME). 9.8.1 STRVL - total stem travel Programming notes The number displayed should be multiplied by a factor of 10 to obtain the total number of complete valve strokes.
  • Page 56 Press and hold key for 3 seconds. The display will count down the 3 seconds. This provides the facility to return to SP500 MENU with the option of staying in automatic operation (AUTO) or venting the actuator (VENT). Use keys key to select and return to SP500 MENU.
  • Page 57 To change the filter proceed as follows: Ensure that the air supply to the positioner is isolated. Unscrew the filter plug (1) from the SP500 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).
  • Page 58 11. Default values and program settings Programmed Main menu Sub-menu Setting options Default value value 2-PORT Valve type (2-PORT) 3-PORT (VALVE) Actuator type (ACT) Control action Direct (dIRCT) (dIRCT) (CTRLA) Reverse (REV) Minimum travel 0 to 66% (MIN-T) Maximum travel 33 to 100% 95% for 2-port (MAX-T)

  • Page 59: Description

    12. Glossary of display data 12.1 Main menu display functions Display Description SET UP Indicates that the SP500 positioner fitted to the valve has not been programmed or commissioned. Indicates that you have now entered the SP500 main menu. Provides access to: SP500 •...

  • Page 60: Port Valves

    12.2 Sub-menu display functions Display Description VER x.xx Indicates the version of software embedded within the SP500 positioner. CALIb Provides facility for mounting position adjustment. RETRN Enables previously stored function values to be recalled. RTAIN Enables temporary changes made to function values to be retained.

  • Page 61: Sp500 Menu

    Indicates the total number of valve strokes (x10). STRVL Value can be retained (RTAIN) or reset (RESET). Indicates the total run time of the SP500 in hours. RTIME Value can be retained (RTAIN) or reset (RESET) IM-P343-35 CH Issue 1...
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