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

Electropneumatic smart positioner
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3.568.5275.300
IM-P343-35
CTLS Issue 5
SP500
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
© Copyright 2020
1
IM-P343-35 CTLS Issue 5
Printed in Italy

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  • Page 1 3.568.5275.300 IM-P343-35 CTLS Issue 5 SP500 Electropneumatic Smart Positioner Installation and Maintenance Instructions © Copyright 2020 IM-P343-35 CTLS Issue 5 Printed in Italy...
  • Page 2 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 3: Table Of Contents

    ® 5. Installation Mounting the SP500 positioner - General informaton Sequence for mounting an SP500 positioner to a linear actuator Sequence for mounting an SP500 positioner to a rotary actuator Air supply and connections 6. Electrical connections...
  • Page 4 SET - setting of valve functions TUNE - setting of valve tune functions RUN - automatic operation STRVL and RTIME - valve diagnostics RETRN - return to SP500 MENU in main menu 10. Maintenance and troubleshooting 10.1 Air supply quality 10.2...

  • Page 5: Safety Information

    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. Similarly all signal circuits connected to an options board must operate within the confines of SELV systems.

  • Page 6: 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 7 Indicates that the positioner is in manual mode Indicates that the positioner is running the autocalibration Indicates that you're accessing the SET menu Indicates that the positioner is in automatic mode Indicates that you're accessing the TUNE menu SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 8: Technical Data

    Software travel travel switches 1 x normally open Shipping weight 2.2 kg 3.3 Materials Part Material Finish Case and cover Die cast aluminium Anti-corrosive paint to RAL5010 Magnet bracket Die cast aluminium SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 9: Programmable Functions

    Input signal Visualisation of input mA signal Auto operation/vent Option of automatic operation or vent (actuator) whilst reprogramming Data logging Diagnostic record of total number of valve strokes and completed hours run time SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 10: Options

    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. Ensure that the gauge block air connection 'O' rings are correctly located before tightening.

  • Page 11: Retransmission And Travel Switches Option Board

    An option board is optionally available and can be mounted in situ. In this case please refer to the mounting instruction below: Open the positioner (Figure 4). Switch off the power supply. Switch off the air supply. Unscrew the board as shown in Figure 5. Fig. 4 Fig. 5 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 12 Rotate the mainboard to the initial position, fi x it with the 4 screws, close the positioner and switch on the power supply and air supply. Fig. 6 Fig. 7 Fig. 8 Fig. 9 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 13: External Power Supply Option Board

    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.
  • Page 14 Rotate the mainboard and insert the option board (as shown in Figures 12 and 13). Remove the Jumper J4 (Figure 14). Fig. 12 Fig. 13 Fig. 14 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 15 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'. The positioner won't work if powered according to the standard 2 wires connection. Fig. 15 Fig. 16 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 16: Hart

    In this ® case it is possible to configure and drive the positioner remotely using a PC or handheld device. For further details refer to the specific literature about SP500 HART available on the Spirax Sarco website. ® An option board is optionally available and can be mounted in situ. In this case please refer to the mounting instruction below: Open the positioner (Figure 17).
  • Page 17 Rotate the mainboard and insert the option board (as shown in Figures 19 and 20). Remove the Jumper J14 (Figure 21). Fig. 19 Fig. 20 Fig. 21 Jumper J14 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 18 Collocate the Jumper J14 as shown in Figure 23. 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. 22 Fig. 23 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 19: Installation

    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 20: Sequence For Mounting An Sp500 Positioner To A Linear Actuator

    5.2 Sequence for mounting an SP500 positioner to a linear actuator Fig. 24 Pillar mounting kit for a linear actuator 5.2.1 Loosely attach the magnet bracket (2) to the valve/actuator connector (refer to Fi gure s 24 and 25). B e sure it is positioned horizontally (as shown in Figure 25).
  • Page 21 Spirax Sarco actuator the correct position is impressed on the magnet bracket (Figure 27). 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 28).
  • Page 22 Loosely attach the positioner mounting plate to the actuator as shown in the following pictures: for the pillar actuator (Figure 29), and for the yoke actuator (Figure 30). 5.2.5 Locate the protection plate onto the back of the SP500 positioner housing and fix in place (Figures 31 and 32). Mounting plate...
  • Page 23 Attach the positioner mounting plate to the positioner as shown in Figures 33 and 34. 5.2.7 Adjust the vertical position of the SP500 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 30).

  • Page 24: Sequence For Mounting An Sp500 Positioner To A Rotary Actuator

    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. 37 Mounting kit SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 25 Fig. 39 Fig. 38 Fig. 40 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 26 Assembled Fig. 41 Fig. 42 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 27 View from the bottom of the positioner - Magnet orientation for 15° clockwise actuator. 15° 90° 120° Fig. 44 View from bottom of the positioner - Magnet orientation 15° for anti-clockwise actuator. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 28: Air Supply And Connections

    The filter/regulator should have a coalescing filter or suitable compressed air pipework is used. ¼" NPT air signal to actuator (output 1) ¼" NPT air supply (supply) Fig. 45 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 29: Electrical Connections

    24 V power supply option board 24 V external power supply (PWS) 4-20 mA current signal input Mainboard Travel switch 1 Retransmission and travel switches Travel switch 2 option board (RTX) 4-20 mA retransmission of valve position SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 30 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 without HART option board <...
  • Page 31 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. In case the SP500 smart valve positioner is equipped with the HART board the voltage drop for each ®...
  • Page 32 1 mA @ 24 V 1.8 k Ω TS2 travel switch 18 - 30 Vdc 13 mA 1 mA @ 24 V 1.8 k 4 - 20 mA 8 - 30 Vdc SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 33: 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. Press and hold key for 3 seconds to advance to SP500 MENU. The display will count down the 3 seconds. 7.1.4 Press to advance to MANOP.

  • Page 34: Programming Flow Chart

    VALVE 3-PORT) successful autostroke (AUTOS) Shut-off minimum Dead-band (S-MIN) (dBand) RETURN TUNE (To SP500 MENU) AUTO OPERATION (% TRAVEL) Return to SP500 menu (RETAIN) (RETRN AUTO/ (RESET) RETRN VENT) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 35 Time to close Characterisation Shut-off maximum (T-UP) (T-dWN) (LIN/FAST/EQUAL) (S-MAX) AUTO Travel switch 2 (NC) Travel switch 1 (NO) Stem travel OPERATION (TS2) (TS1) (STRVL) (mA Input signal) Run time (RETAIN) (RTIME) (RESET) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 36: 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 37: Sp500 Menu

    • Programming notes To view the version of the embedded software (VER-.--) press key. Press key to return to SP500 MENU. The display will automatically return to SP500 MENU after 10 seconds. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 38 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 39: Manop

    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. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 40 100% 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). SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 41: Autos - Automatic Autostroke Commissioning

    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. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 42 Fig. 56 2-port valve normally closed - TRAVL setting = 0 to 100% Display = 0% Display = 100% Fig. 57 2-port valve normally open - TRAVL setting = 0 to 100% SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 43 Fig. 58 2-port valve normally open - TRAVL setting = 100% to 0% Display = 100% Display = 0% Fig. 59 2-port valve normally closed - TRAVL setting = 100% to 0% SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 44 DISPLAY = 0% DISPLAY = 100% TRAVL setting = 100 to 0% TRAVL setting = 100 to 0% DISPLAY = 100% DISPLAY = 0% Fig. 61 3-port valve and spring retract actuator SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 45: Set - Setting Of Valve Functions

    (minimum and maximum) and to split range the input signal. More detailed information is provided for each SET function. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 46 (CTRLA). Commissioning notes If the actuator or the valve have high hysteresis or high friction it is suggested to set ACT to 'OFF'. If hunting is present set ACT to 'OFF'. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 47 Refer to Figures 63 and 64, and the table shown in Figure 65 for further guidance. Increasing input signal Increasing input signal Fig. 63 Fig. 64 Direct action (DIR) Reverse action (REV) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 48 20 mA 100% (TRAVL) 100% 100 - 0% Manual Selection Automatic determintation Manual Selection of required of required % travel Control Action Spring action only affects (TRAVL) (CTRLA) the rest or fail-safe position SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 49 The input signal span range set (MIN-R) and (MAX-R) will operate over the travel limits set. If a value for MAX-T is set it will exclude the setting of shut-off maximum (S-MAX) for direct action (DIR) and shut-off minimum control action (S-MIN) for reverse action (REV). SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 50 DTRVL provides the choice of travel display. For 2-port valves you can adjust the MAX-T setting to achieve the actual desired valve lift (i.e. 20 mm or 30 mm, etc). Using DTRVL you can then choose to display the MAX-T valve travel you have set as 100%. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 51 This function can be used to easily set split range applications i.e. 4 - 12 mA or 12 - 20 mA. To ensure tight shut-off refer to Section 9.6.3 S-MAX, page 53. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 52: Tune - Setting Of Valve Tune Functions

    Relationship between valve lift to input signal. Slowing down the valve open or closing time duration. Setting the switching position for the software travel switches. More detailed information is provided for each TUNE function. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 53 Setting a shut-off value can help prevent this by providing early closure of the valve. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 54 (refer to Figure 67 for guidance). Ratio 1:1 Ratio 1:50 Ratio 50:1 Linear Linear Linear Equal Equal Equal Fast Fast Fast percentage percentage percentage opening opening opening Signal (mA) Signal (mA) Signal (mA) Fig. 67 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 55 This function is useful to prevent the effects of system waterhammer, or to slow down over-reactive systems or the effects of oversized valves. Default is the minimum time measured during autostroke. Maximum setting is 180 seconds. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 56 Software configured travel switches can be set within the range 0% to 100% of full travel irrespective of any travel limit Switch settings. open Signal Fig. 68 TS1 Travel switch 1 (normally open) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...
  • Page 57 Software configured travel switches can be set within the range 0% to 100% of full travel irrespective of any travel limit Switch settings. closed Signal Fig. 69 TS2 Travel switch 2 (normally closed) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 58: Run - Automatic Operation

    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 hold for 3 seconds to return to SP500 MENU. The display will count down the 3 seconds.
  • Page 59 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 60: Strvl And Rtime - Valve Diagnostics

    To retain key and select RTAIN. If the valve is dismantled for maintenance inspection the displayed value press etc. The value can be reset to zero if required by selecting RESET. SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 61: Retrn - Return To Sp500 Menu In Main Menu

    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 to toggle selection. Press key to select and return to SP500 MENU.

  • Page 62: Air Supply Quality

    10. Maintenance 10.1 Air supply quality As stated in Section 5.4, it is important for correct operation of the SP500 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.

  • Page 63: Default Values And Program Settings

    Travel switch 1 OFF, TUNE (TS1 OFF) (TS1) 0 to 100% Travel switch 2 OFF, TUNE (TS2 OFF) (TS2) 0 to 100% Auto (RETRN AUTO) Return to menu (RETRN AUTO) Vent (RETRN VENT) SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 64: Glossary Of Display Data

    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: •...
  • Page 65 Commencing automatic operation. • Displaying percentage valve travel ( • Visualisation of input mA input signal (mA). • Total stem strokes (STRVL). • Total running time (RTIME). • Return to SP500 menu (RETRN). SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

  • Page 66: Sub-Menu Display Functions

    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 67 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) SP500 Electropneumatic Smart Positioner...
  • Page 68 SP500 Electropneumatic Smart Positioner IM-P343-35 CTLS Issue 5...

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