Avid Technology SMARTCAL Installation And Operation Manual
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Avid Technology SMARTCAL Installation And Operation Manual

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VALVE POSITIONER
INSTALLATION AND OPERATION MANUAL
Tech-440
IOM:
Prepared By:
M. Twardowski
Reviewed By: C. Irwin
This IOM contains confidential information and is issued in confidence on the condition that it be returned on demand and not be copied,
reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Crane Co.
280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM 
12/17/12
SMARTCAL
Revision: A
Date:
Drafting Work Order:
12/17/12
23135
Date: 3/14/18
Approved By: T. Paolini
CRANE CO. 
TECH-440/D.W.O. 23135
ECN:
13247
Date:10/18/18
Page 1 of 55

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Summary of Contents for Avid Technology SMARTCAL

  • Page 1 SMARTCAL VALVE POSITIONER INSTALLATION AND OPERATION MANUAL Tech-440 Revision: A IOM: Prepared By: Date: Drafting Work Order: ECN: M. Twardowski 12/17/12 23135 13247 Reviewed By: C. Irwin Date: 3/14/18 Approved By: T. Paolini Date:10/18/18 This IOM contains confidential information and is issued in confidence on the condition that it be returned on demand and not be copied, reproduced, disclosed to others or used in manufacture of the subject matter thereof without the written consent of Crane Co.
  • Page 2 Revision History Revision Sept 3, 2014 Initial release October 24, 2017 Revision A Crane Co. Americas: +1 201 794 7650 Europe, Middle East & Africa: +44 (0) 1892 516 277 Asia Pacific: +65 6869 8909 CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM  12/17/12 TECH-440/D.W.O. 23135 Page 2 of 55...

  • Page 3: Table Of Contents

    Table of Contents Introduction .................. 5     1.1  Product Certification.  ........................ 5  1.2  Description of SmartCal Positioner.  .................... 5  1.3  Principle of Operation  ........................ 6  1.4  Special Features .......................... 7  Ordering  .................. 9     2.1  SmartCal Positioner Ordering Guide  ..................... 9  Initial Setup  ................. 10     3.1  Mounting Positioner on a Rotary Actuator  ................. 10  3.2  Mounting Remote Positioner on a Rotary Actuator .............. 12 ...
  • Page 4 Appendix F ......................... 46   Grounding Schematic  .......................... 46  Appendix G  ......................... 47   Control Schematic for Wiring of Intrinsically safe SmartCal for ATEX & IECEX  ........ 47  Appendix H ......................... 49   Control Schematic for Wiring of Intrinsically safe SmartCal (WD‐10836) for US & CANADA  .... 49  Appendix I  ........................... 53   Procedure to Reset the Non‐Volatile Memory to Factory Settings ............ 53  Appendix J  .......................... 54   ®  HART Communicator Menu Flow Chart  .................... 54  Appendix K ......................... 54   DD and DTM for configuration and control system integration ............. 55 ...

  • Page 5: Introduction

    It also indicates whether the positioner is in calibration mode. The SmartCal has the capability to monitor operation. If a failure condition occurs, an error message is displayed on the local liquid crystal display. There are several accessories that can be integrally supplied with the SmartCal.

  • Page 6: Principle Of Operation

    By the integration of multiple components into a singular, cost efficient unit, microprocessor-based intelligence can now be used to implement advanced functions such as early warning diagnostics. The SmartCal positioner provides intelligence for the control valve through a microprocessor-based diagnostic system utilizing HART ®...

  • Page 7: Special Features

    1.4 Special Features Non-Contact Position Feedback To provide consistently accurate performance information, all linkages, levers and connecting rods, from the positioner to the control valve have been eliminated from the design. Valve position sensing is performed totally by non- contact means based upon characterization of magnetic flux strength as a function of position.
  • Page 8 On-Board Sensors The SmartCal positioner has the capability to monitor its operation. If an error or failure condition occurs, it will be displayed on the local LCD, or if the positioner is supplied with a HART ®...

  • Page 9: Ordering

    2 Ordering The SmartCal positioner is designed to handle a wide range of control valve applications. Please use the following ordering guide to help choose the SmartCal positioner that best suits the application. 2.1 SmartCal Positioner Ordering Guide CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM ...

  • Page 10: Initial Setup

    3 Initial Setup 3.1 Mounting Positioner on a Rotary Actuator Step 1. Figure 1 shows typical direct mounting of positioner to an actuator. Mount the modmount bracket to positioner using positioner mounting screws. Figure 3-1 CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM  12/17/12 TECH-440/D.W.O. 23135 Page 10 of 55...
  • Page 11 Step 2. The visual indicator needs to be properly oriented. Use the symbols on the bottom of the indicator to mount as shown in Condition 1 or Condition 2. (see figure 3-2). Condition 1 and Condition 2 show the placement of the indicator with respect to the positioner housing while the actuator is in the fail position.

  • Page 12: Mounting Remote Positioner On A Rotary Actuator

    3.2 Mounting Remote Positioner on a Rotary Actuator Step 1. Mount bracket and visual indicator to positioner as described in Section 3.1 Step Step 2. The visual indicator needs to be properly oriented. Use the symbols on the bottom of the indicator to mount as shown in Condition 1 or Condition 2. (see figure 3-3). Condition 1 and Condition 2 show the placement of the indicator with respect to the positioner housing while the actuator is in the fail position.
  • Page 13 Step 4. Mount positioner at a remote location. Step 5. Remove the electronic canister cover by unscrewing (2) mounting screws. (Appendix B: Procedure to Remove Electronics Cover and Electronic Canister) Step 6. If necessary cut remote cable to required length, making sure to cut end opposite female connector.

  • Page 14: Mounting Positioner On A Linear Actuator

    3.3 Mounting Positioner on a Linear Actuator Step 1. Mount the magnet assembly to the stem of the actuator. A coupler block normally is needed to extend the magnet assembly outside the yoke area and into the sensing range of the magnetic pick-up unit. Step 2.
  • Page 15 3. Place a third mark on the yoke centered between the upper and lower limit marks. 4. Lastly, mount the positioner to the bracket so that the positioner sensor (nose) of the SmartCal lines up with the midpoint mark. (See Figure 3-6). 3.4 Mounting Remote Positioner on a Linear Actuator CRANE CO. ...
  • Page 16 Step 1. Mount the magnet assembly and bracket to the actuator as described in Section 3.3 Step 1. Step 2. Mount the position sensor housing so that the conduit entry faces away from the diaphragm or cylinder. (See Figure 3-7) Figure 3-7 Note: For Fisher actuators model 657 &...
  • Page 17 Step 4. Remove the electronic canister cover by unscrewing (2) mounting screws. (Appendix B: Procedure to Remove Electronics Cover and Electronic Canister) Step 5. If necessary cut remote cable to required length, making sure to cut end opposite female connector. Wire the positioner sensor back to the positioner using the cable provided and replace cover.

  • Page 18: Pneumatic Connection

    3.5 Pneumatic Connection Single Acting Actuator (Spring Return): For single acting actuators Outlet Port 2 is to be plugged. Outlet Port 1 is to be piped to the actuator inlet port that acts against the spring. (increasing set-point signal causes pressure to increase in Outlet Port 1 of the positioner).

  • Page 19: Electrical Connection

    3.6 Electrical Connection A) The certification applies to equipment without cable glands. When mounting the enclosure in the hazardous areas, only suitably certified cable glands and blanking elements must be used to maintain ingress protection of IP66. B) All unused cable entries must be plugged with suitably certified plugs that can maintain an ingress protection level of IP66.
  • Page 20 Figure3-10 CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM  12/17/12 TECH-440/D.W.O. 23135 Page 20 of 55...

  • Page 21: Calibration

    4 Calibration The SmartCal positioner has an on-board menu structure that can be accessed by pressing the Cal button. Exit any function by pressing both up and down arrow buttons simultaneously, anytime during calibration. 4.1 Enter Calibration (Menu Level) Enter the calibration menu by pushing the CAL button. ACAL (Auto Cal Menu) is the first of four menus.

  • Page 22: Automatic Calibration

    Sensor Calibration. SPECIAL NOTE Flow Capacity: SmartCal standard flow design is suitable for actuator swept volumes of a minimum 40 inch (0.65 liters) to a maximum of 600 inch (9.80 liters) for proper Auto Calibration functionality.

  • Page 23: Proceed To Exiting Calibration Or Perform Advanced Calibration

    4.3 Proceed to Exiting Calibration or Perform Advanced Calibration After the completion of an Automatic Calibration (ACAL) the calibration of the positioner is complete. The Automatic Calibration that was performed in Section 3 is adequate for most applications. If no advanced calibration is required proceed to Section 5 to exit calibration.

  • Page 24: Exiting Calibration

    4.4 Exiting Calibration To exit calibration mode and return to normal operation use the up arrow key as follows:  If the positioner is at Menu level in the calibration, as determined by LCD displaying a Menu name only (MCAL, etc.), press the up arrow key once to exit CAL mode. ...

  • Page 25: Manual Override Of Input Signal (Via On-Board Keypad)

    4.6 Manual Override of Input Signal (Via On-Board Keypad) The positioner has a feature which allows the operator to override the analog set-point signal and change valve position from the keypad. This is done from the Stro (Manual Override- Stroke Menu). Enter calibration as described in section 4.1 and use the down arrow button to cycle to the Stro menu.

  • Page 26: Description Of Functions

    Entering this menu allows you access to the following four calibration functions via the keypad: 1. -Lo- Low (Zero) Calibration 2. -Hi- High (Span) Calibration 3. -PID- Proportional, Integral and Derivative Gain Adjustment 4. -Snsr- Sensor Calibration 5. -Trnd- Transducer Calibration 6.
  • Page 27 energized (full travel) position (hard stop). The user will notice full pressure to Outlet Port 1 and zero pressure to Outlet Port 2. At this point the user has the option to either select the hard stop as the high (span) position, or to select an arbitrary position as the high (span) position.
  • Page 28 positioner is set-up on a new application and only if the ACAL routine is not performed. The purpose of this function is to calibrate the positioner’s pressure transducer. Trnd It should be performed only after a manual sensor calibration. This routine calibrates the positioner’s electronics to recognizing input current. This is done using 4.0 mA and 20.0 mA as reference points.
  • Page 29 OPSP This function allows for the setting of Setting Approx.% Dynamic Speed opening speed 100% actuator/valve. The range is 1 thru 5. Setting 5 is the fastest opening speed and setting 1 is the slowest opening speed. This function allows for the setting of CLSP Setting Approx.% Dynamic Speed...

  • Page 30: Trouble Shooting

    3.5 ≤ I < 3.8 3.8 ≤ I ≤ 20.5 I > 20.5 5.1.2. Electrical Connection Check the polarity of the 4-20 mA loop current loop. The SmartCal terminal strip visually designates positive negative terminal points for connection with a “+” and “-”, respectively.

  • Page 31: Faq's

    The stroke length and failure direction should be printed on the part. On the older SmartCal the magnet assembly is not printed with this information, although there should be a serial number. Contact the factory with the serial number to verify that it is correctly matched to the actuator.
  • Page 32 5.2.3. The positioner is properly set-up, and air is applied to the positioner. When powering up the positioner, the actuator goes into a state of constant oscillation.  Check for air leaks and if assembly is tightly coupled: tubing, actuator, bracket, cables etc.

  • Page 33: Technical Specifications

    6 Technical Specifications Remote Hall sensor: -40 C to 125 C Input (-40 F to 257 F) Set-point: 4-20 mA, two wire, Namur NE43 Normal Operation: 3.8≤ I ≤ 20.5 mA Thermal Coefficient: ± 2% / 100 C Fail Condition: I≤3.6 or I≥21.0 mA Minimum current w/o reset: 3.2mA Air Consumption: 0.08 scfm @ 90 psi Voltage: 9 to 35 VDC...

  • Page 34: Error Codes And Lcd Messages

    7 Error codes and LCD messages 7.1 Error codes that are backward compatible to previous versions of the SmartCal positioner Err 3 (Error 3) Low Input Pressure Err 5 (Error 5) Integrator Overflow – Actual position does not match set-point...

  • Page 35: Lcd Error Messages

    7.2 LCD error messages The SmartCal positioner has built-in diagnostics that allow the user to identify and resolve most of the common installation and operation problems. The following table lists the available messages, their meaning and recommended solutions: Message Meaning...
  • Page 36 Message Meaning Solution Input Pressure was Check:  pressure unstable during Pressure supply stability unstable calibration  Actuator and tubing leaks  Manifold and transducer assembly are tightly coupled to the enclosure and there are no leaks  Check if the cable between the inner canister and the pneumatic transducer assembly is tightly connected ...
  • Page 37 Message Meaning Solution Comp range An unknown Check:  error error has Remove power for at least 1 minute and retry occurred during  Remove power for at least 1 minute, perform a factory default calibration (see Appendix I) and retry a full auto CAL ...
  • Page 38 Message Meaning Solution During Check:  overflow calibration an Hall sensor connector and cable, especially if remote (see error occurred Figure 3-4, connector J8) with the PWM  Magnet assembly is in correct position. signal that For rotary magnets check if it is not rotated 90 control the degrees (see figures 3.2, 3.3 and 3.4).
  • Page 39 Message Meaning Solution Too few An unknown Check:  bytes error has Remove power for at least 1 minute and retry received occurred during  Remove power for at least 1 minute, perform a factory default calibration (see Appendix I) and retry a full auto CAL ...

  • Page 40: Procedure To Adjust The Error 3 Setting (Or Low Input Pressure)

    Appendix A Procedure to Adjust the Error 3 Setting (or Low input pressure) Note: The error 3 message threshold is pre-set from the factory. For a low pressure positioner it is set to 15 psi and for a high pressure positioner it is set at 55 psi.

  • Page 41: Procedure To Remove Electronics Cover And Electronic Canister

    2. Disconnect all connectors from electronics canister; make sure to note connector locations. Remove the screw that secures canister housing and ground cable. Remove the screw that secures ground cable (see figures below). 3. Remove the canister with electronics from SmartCal enclosure. INDICATED SCREW SECURES COVER...

  • Page 42: Setting The Transmitter Output Fail Current

    Appendix C Setting the Transmitter Output Fail current. The SmartCal positioner conforms to Namur NE43 with an operating input current of 3.8 mA to 20.5 mA. Input currents between 3.2mA and 3.6mA and above 21.0 mA are considered outside the control range and are a current input failure.

  • Page 43: Procedure To Check Transducer Operation

    Appendix D Procedure to Check Transducer Operation This procedure should only be used for trouble shooting This procedure requires a 4-20mA current generator. 1. Mount the positioner and connect the pneumatics as described in section 3 of this manual. 2. Remove the cable that connects the inner canister to the pneumatic transducer assembly. The electronic canister does not need to be removed.

  • Page 44: General Maintenance Standard Flow

    Appendix E General Maintenance Standard Flow The positioner’s onboard filter should be replaced regularly or whenever it gets clogged. See diagram below for location of the filter. Note: the following instructions are for Standard Flow. For High Flow please contact the factory. Important: The positioner’s onboard filter is not a substitute for normal instrument air preparation.
  • Page 45 recommended. These items can be obtained from most industrial supply companies or catalogs. Important: do not use an abrasive cleaner on the spool or sleeve. Never buff the spool or sleeve or use crocus cloth, and never attempt to remove the sharp edges from the spool lands.

  • Page 46: Grounding Schematic

    Appendix F Grounding Schematic CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM  12/17/12 TECH-440/D.W.O. 23135 Page 46 of 55...

  • Page 47: Control Schematic For Wiring Of Intrinsically Safe Smartcal For Atex & Iecex

    (Associated Apparatus) ground. 5. Where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting. 6. Installation should be in accordance with EN 60079 and / or the local / national electrical codes of practice.
  • Page 48 4. To maintain intrinsic safety, each field wiring pair (4-20 mA and Analog Output) must be run in separate cables or separate shields connected to intrinsically safe (Associated Apparatus) ground. 5. Where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting.

  • Page 49: Control Schematic For Wiring Of Intrinsically Safe Smartcal (Wd-10836) For Us & Canada

    COMMUNICATOR is NOT FMRC approved for use in Class II and III Hazardous Locations. 7. For Class II and III locations where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting.
  • Page 50 COMMUNICATOR is NOT FMRC approved for use in Class II and III Hazardous Locations. 5. For Class II and III locations where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting.
  • Page 51 COMMUNICATOR is NOT FMRC approved for use in Class II and III Hazardous Locations. 5. For Class II and III locations where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting.
  • Page 52 COMMUNICATOR is NOT FMRC approved for use in Class II and III Hazardous Locations. 6. For Class II and III locations where rigid metal conduit is not used, seal SmartCal cable entries against dust and fibers using an appropriate NRTL listed cable gland fitting.

  • Page 53: Procedure To Reset The Non-Volatile Memory To Factory Settings

    Appendix I Procedure to Reset the Non-Volatile Memory to Factory Settings The SmartCal positioner is a digital device. Its operation relies on data that is stored in the positioner’s non-volatile memory. Calibration and configuration data that has been established during the positioner’s calibration is stored in this memory. Under abnormal conditions this stored information can become corrupted.

  • Page 54: Hart Communicator Menu Flow Chart

    Appendix J ® HART Communicator Menu Flow Chart SmartCal Digital Valve Controller CRANE CO.  280 N. MIDLAND AVE., STE 258, SADDLE BROOK, NJ 07663 WWW.AVIDCONTROLS.COM  12/17/12 TECH-440/D.W.O. 23135 Page 54 of 55...

  • Page 55: Dd And Dtm For Configuration And Control System Integration

    Appendix K DD and DTM for configuration and control system integration The SmartCal positioner can be fully integrated into most of the configuration tools, control systems and asset management systems in the market. Crane Co. provides DD files and DTM for this integration.

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