Spirax Sarco EP5 Series Installation And Maintenance Instructions Manual
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Spirax Sarco EP5 Series Installation And Maintenance Instructions Manual

Electropneumatic positioners
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IM-P343-16
3.568.5275.226
CH Issue 7 - 2016
EP5 and ISP5 Series
Electropneumatic Positioners
Installation and Maintenance Instructions
Attention: Additional instructions are required when a ATEX
intrisically safety instrument ISP5 is used in an explosion risk area.
1. Safety information
2. Introduction
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
© Copyright 2016
E X P E R T I S E
S O L U T I O N S
S U S T A I N A B I L I T Y

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Summary of Contents for Spirax Sarco EP5 Series

  • Page 1 IM-P343-16 3.568.5275.226 CH Issue 7 - 2016 EP5 and ISP5 Series Electropneumatic Positioners Installation and Maintenance Instructions Attention: Additional instructions are required when a ATEX intrisically safety instrument ISP5 is used in an explosion risk area. 1. Safety information 2. Introduction 3.

  • Page 2: Safety Information

    Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery. 1.6 The system Consider the effect on the complete system of the work proposed. Will any proposed action (e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel at risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks. 1.7 Pressure systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero. 1.8 Temperature Allow time for temperature to normalise after isolation to avoid danger of burns. 1.9 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. 3.568.5275.226...

  • Page 3: Protective Clothing

    1.10 Protective clothing Consider whether you and/or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and dangers to eyes and face. 1.11 Permits to work All work must be carried out or be supervised by a suitably competent person. Installation and operating personnel should be trained in the correct use of the product according to the Installation and Maintenance Instructions. Where a formal 'permit to work' system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know what work is going on and, where necessary, arrange to have an assistant whose primary responsibility is safety. Post 'warning notices' if necessary. 1.12 Handling Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised...

  • Page 4: Operating Principle

    2. Introduction Introduction The EP5 is a 2 wire loop powered positioner requiring a 4-20 mA control signal, and is designed for use with linear pneumatic valve actuators. The positioner compares the electrical signal from a controller with the actual valve position and varies a pneumatic output signal to the actuator accordingly. The desired valve position is therefore maintained for any control signal and the effects of varying differential pressure, stem friction and hysterisis are overcome. A mounting kit is supplied to suit all NAMUR standard columns or yokes. Note: A 0-10 Vdc input signal and an intrinsically safe version ISP5 are also available. Operating principle The EP5 operates on a force balance principle by means of a nozzle/flapper mechanism and a feedback spring (refer to Figure 1). The electrical control signal (A) is converted into a proportional air pressure (I). This pressure is applied to the flapper (5) via the receiver (1), causing a deflection of the flapper relative to the nozzles U1/U2.

  • Page 5: Installation

    Step 1 Identify actuator type For correct operation it is important to know two factors which will affect optimum movement of the positioner feedback mechanism: The distance between the axes of the valve/actuator stem and the positioner slide pin. The travel of the valve actuator. To ensure these are set correctly, please note the following: When attaching an EP5 to any Spirax Sarco valve actuator, ignore Step 3. For non-Spirax Sarco actuators, ignore Step 2. 3.568.5275.226...
  • Page 6 Step 2 For attachment to Spirax Sarco actuators Using the 2 off M6 pan head screws, securely attach the 'T' shaped sliding pin holder to the valve actuator coupling block (Figure 2). Apply Loctite to the sliding pin and screw into hole 'Y' (as shown) on the sliding pin holder and tighten. Valve actuator coupling block 'T' shaped sliding pin holder Fig. 2 Close-up of sliding pin holder fitted to valve coupling. Using the 2 off M8 x 15 hex head screws and 8 mm spring washers, attach the mounting plate to the back of the positioner, utilising holes No. 2 in the bracket (Figure 3). Take care not to over-tighten these screws and strip the threads. Positioner Mounting plate Fig.
  • Page 7 Actuator pillar Actuator or yoke spindle 100% Fig. 4 Pillar/yoke spacing, showing 50 % travel. Table 2 Hole to be used Up to 125 mm 125 to 150 mm 150 to 175 mm above 175 mm Step 4 Temporarily apply adequate air pressure directly into the actuator so that the valve is at 50% of travel (Figure 5).
  • Page 8 Step 6 Fit the angled protection plate to the rear of the positioner using the 2 off captive M3 pan head screws. Access to these captive screws is from inside the positioner. Step 7 Adjust the air supply pressure to stroke the actuator from 0% to 100% and ensure the positioner lever rotates freely. Remove the temporary air supply from the actuator. Step 8 Fitting a gauge block (optional) To aid commissioning it is recommended to fit a gauge block and pressure gauges to all EP5s. Please note that gauges and gauge block can be supplied as spare parts if required. Fit gauges to the block before attaching the block to the EP5. Use thread sealant to ensure air tight connections. The upper gauge displays the output of the I/P converter, and is normally 0 - 2 bar g. The lower gauge displays the positioner output pressure, so the gauge range will depend on the actuator.

  • Page 9: Electrical Connections

    3.3.2 Electrical connections Cabling should be installed in accordance with BS 6739 - Instrumentation in Process Control Sy- stems: Installation design and practice or local equivalent. The EP5 only requires a 4 - 20 mA (standard) or 2 - 10 Vdc (if requested) signal. Remove the front cover and locate the terminal block and earth terminal post (Figure 6). Note: Ensure resistance from earth post to local earth (e.g. pipework) is less than 1 Ω. Connection to the unit is through the Pg 13.5 cable gland (as supplied), which when used with suitable cable will ensure the IP54 protection rating. Appropriate conduit connections may be used instead. Connect conductors (0.5 to 2 mm²) to the terminal block and earth post (3 mm²) noting the polarity +/- shown in Figure 6. In hazardous areas use model ISP5 with intrinsic protection (type EEx ia llC T6, T5,T4) ensuring the power supply from adjoining equipment is certified in accordance with EN 50.014 and EN 50.020 standards, in respect of the limits of electric features shown at approval stage. Refer to approval certificate supplied with each ISP5 product. Earth terminal Cable post gland Terminal block Fig. 6 3.568.5275.226...
  • Page 10 4. Commissioning Once the positioner has been mounted and connected up, proceeed as follows. Step 1 Set the valve action Establishing the correct action of the valve is done by: a. Connection to either U1 or U2 nozzles (see Figure 7) and b. Setting the slider in the upper or lower portion of the crescent shaped sector lever (Figure 8). Connection to nozzle U2 Connection to nozzle U1 Fig. 7 U1 = Increase action = With increasing electrical control signal the air pressure to the actuator will increase. U2 = Decrease action = With increasing electrical control signal the air pressure to the actuator will decrease.
  • Page 11 To change the slider location: Refer to Figure 8 to determine the correct portion. To change the slider slacken the screw and slide it into the correct portion of the arm. Fig. 8a Increase action and spring extend Upper sector U1 nozzle Fig. 8b Increase action and spring retract U1 nozzle Lower sector Fig. 8c Decrease action and spring extend U2 nozzle Lower sector...
  • Page 12 Step 2 Set sensitivity The positioner sensitivity is adjusted using the sensitivity screw (Xp %, see Figure 10). It is set de- pending on air supply pressure. Before the commissioning stage it is essential to set the sensitivity within a proportional band of (3% to 6%). Use Figure 10 to adjust the sensitivity screw by firstly fully closing the screw (clockwise), then reopen the screw:- ¾ Supply pressure (S) 1.4 bar - Screw open of a turn ¼ 4.0 bar - Screw open of a turn 6.0 bar - Screw open of a turn 1.4 bar...
  • Page 13 Step 3 Set damping The final adjustment of damping screw should be performed with plant in operation, in order to limit, if necessary, the actuation speed. During the commissioning set the damp screw flush with the body see Figure 11. Damp screw Fig. 11 The reduction of air flowrate capacity to the actuator will slow down the valve movement to limit the effect of cycling hunting. Closing the screw (clockwise) increases damping, and vice versa. Step 4 Set zero point Check all air and electrical connections are in place. Check air supply pressure (S) is correct (see Section 3.3.2). Check electrical control signal (A) (see Section 3.3.3) is at the minimum required (normally 4 mA or 0 V), but the application may require a different setting. It may also be advisable to increase the minimum by 0.5 mA or 0. 25 V to ensure the valve is completely closed. For 3-port...

  • Page 14: Split Range Operation

    Step 5 Set travel Increase the electrical control signal to the upper value (normally 20 mA or 10 V, but this depends on the application) and now check the travel of the valve. If required, slacken the central locking screw (see Figure 12) and adjust the slider up or down the upper or lower portion of the crescent shaped sector lever. Moving the slider away from the pivot will reduce the travel, and vice versa. Normally, except with 3-port valves, the fully open position is achieved before the valve plug hits the upper mechanical stop of the valve/actuator. Avoid settings of the positioner that allow contact with this mechanical stop. Vary the electrical control signal around the upper value to verify the travel setting, and if necessary repeat the adjustment of the slider until the required travel occurs at the upper value. Important: Zero and travel settings on EP5 are not independent of each other, so re-check the zero setting as described in Step 4. It may prove necessary to repeat Steps 4 and 5 several times until acceptable zero and travel settings are achieved. For fine adjustment of the travel, the potentiometer shown in Figure 13 can be used. This should only be used for final adjustment of +/- 5%. When complete, lock both zero and travel adjustments. Travel adjustment potentiometer Fig. 13 Split range operation EP5 may be split ranged to sequentially actuate two valves from one control signal (For example: valve 1 set to 4 - 12 mA and valve 2 set to 12 - 20 mA). Split ranging is achieved by adjustment of the zero and travel settings refer to Steps 4 and 5.

  • Page 15: Regular Maintenance

    5. Maintenance Regular maintenance 1. Drain any build-up within the air supply filter set as impurities such as oil, water and dirt will cause inconsistent operation. 2. Ensure air supply is at the correct pressure (see Section 3.3.2 and refer to actuator TI). 3. Make visual checks to ensure the valve is operating correctly. Corrective maintenance 5.2.1 Removal and cleaning of sensitivity adjuster (see Figure 14): Loosen and remove lock. Note setting then remove sensitivity screw. Wash adjuster with solvent, checking condition of the cone and ensuring 0.35 mm side hole is clear. Dry with clean compressed air to ensure no remaining contaminants. Refit the cleaned adjuster and unscrew it 1 turn from its stop. Fig.
  • Page 16 5.2.2 Removal and cleaning of capillary orifice (see Figure 15): Loosen locking plate screw. Rotate locking plate to expose capillary orifice. Using supplied extractor/cleaner pull the orifice from the body. Clean the small orifice and cross drilling using only the special cleaning wire supplied. Reassemble the orifice ensuring both 'O' rings are in place and the lock plate covers the orifice. Extractor/cleaner Spare 'O' ring Extracting Cleaning wire thread Capillary orifice Fig. 15 Damping faces Locking plate Capillary orifice Fig. 16 Capillary extractor / cleaner 5.2.3 Check damping grease: Ensure gap of 1 mm exists between faces of damper. Adjust if necessary. Verify grease is present between faces. Replace grease if necessary (contact Spirax Sarco for details). 3.568.5275.226...

  • Page 17: Spare Parts

    1. Your name, Company name, address and telephone number, order number and invoice and return delivery address. 2. Description of equipment being returned. 3. Description of the fault. 4. If the equipment is being returned under warranty, please indicate: i. Date of purchase ii. Original order number Please return all items to: Returns Investigations Department Runnings Road, Kingsditch Trading Estate Cheltenham Glos, GL51 9NX United Kingdom Alternatively, please return any items to your local Spirax Sarco branch. Please ensure all items are suitably packed for transit (preferably in the original cartons). 3.568.5275.226...

  • Page 18: Fault Finding

    7. Fault finding Output pressure too low or zero Cause Remedy a. No control signal a. Restore mA signal b. Low air supply pressure b. Verify actuator air pressure requirement c. Clogged or dirty sensitivity adjuster c. Clean adjuster see Section 5.2.1 d. Clogged or dirty capillary orifice d. Clean orifice see Section 5.2.2 e. Incorrect set-up e. Recalibrate see Section 4, Steps 1 to 5 f. Damaged pneumatic actuator or piping f. Verify replace as necessary g.
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  • Page 24 SERVICE For technical support, please contact our local Sales Engineer or our Head Office directly: Spirax Sarco S.r.l. - Technical Assistance Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Italy Tel.: (+39) 0362 4917 257 - (+39) 0362 4917 211 - Fax: (+39) 0362 4917 315 E-mail: support@it.spiraxsarco.com LOSS OF GUARANTEE Total or partial disregard of above instructions involves loss of any rights to guarantee. Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307 3.568.5275.226...

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