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Spirax Sarco SP200 Installation And Maintenance Instructions Manual
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Spirax Sarco SP200 Installation And Maintenance Instructions Manual

Spirax Sarco SP200 Installation And Maintenance Instructions Manual

Electropneumatic smart positioner
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3439650/5
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-29 CH Issue 5
Printed in the UK
SP200
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
13. Certification
IM-P343-29
CH Issue 5
© Copyright 2009
1

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Summary of Contents for Spirax Sarco SP200

  • Page 1 3439650/5 IM-P343-29 CH Issue 5 SP200 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.
  • Page 2 IM-P343-29 CH Issue 5...
  • Page 3 - setting of valve functions TUNE - setting of valve tune functions - automatic operation STRVL and RTIME - valve diagnostics RETRN - return to SP200 MENU in main menu 10. Maintenance and 10.1 Air supply quality troubleshooting 10.2 Fitting replacement filter plug kit 11.

  • Page 4: Safety Information

    IP65 (see BS EN 60534-1 1998). 2.2 Electrical safety requirements The SP200 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 5 2.4 Installation for hazardous areas and certification - General information SP200 Smart Positioner is available for Intrinsic Safety applications, model identification is SP200is. In case of use in hazardous areas with danger of explosion, it must be verified that the identified type of positioner fits for the classification of the zone and for the presence of flammable substances in the plant.
  • Page 6 2.4.2 Electrical connections for IS. For installation in classified areas it is necessary to foresee the use of certified associated apparatuses (e.g. safety barriers), with output electrical characteristics compatible with the maximum input parameters (ref. to Name-plate) of the certified SP200is positioner: Electrical input parameter of SP200is Circuit Ui(V)

  • Page 7: Technical Information

    3. Technical information 3.1 Description The SP200 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 8 3.2 Technical data Input signal range 4 - 20 mA nominal Minimum input signal (loop powered) 3.6 mA Minimum air supply pressure 1.0 bar g above maximum spring range pressure (Note: For the PN5120 actuator, the supply air pressure should be set at 1.5 bar g) Maximum air supply pressure 6.0 bar g Air supply must be dry, oil and dust free to...
  • Page 9 3.5 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 Direct or reverse action (4 - 20 or 20 - 4 mA) Setting of minimum and maximum travel limits Travel limits (valve open and valve close % travel)
  • Page 10 4. Options 4.1 Pressure gauge block An optional pressure gauge block (Figure 2) can be fitted onto the SP200 positioner which includes two pressure gauges indicating air supply pressure and output air signal pressure to the actuator. For double action valves the gauge block includes 3 pressure gauges indicating: air supply pressure, output 1 air signal and output 2 air signal.

  • Page 11: Installation

    Fig. 3 SP200 mounting 5.1.3 The SP200 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. 5.1.4 Before fitting and commissioning the SP200 positioner ensure that the valve and actuator are correctly assembled.
  • Page 12 5.2 Sequence for mounting an SP200 positioner to a linear actuator Fig. 4 Pillar mounting kit for a linear actuator 5.2.1 Loosely 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).
  • Page 13 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).
  • Page 14 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 SP200 positioner housing and fix in place (Figure 11). Protection plate Assembled Fig. 11 IM-P343-29 CH Issue 5...
  • Page 15 5.2.7 Adjust the vertical position of the SP200 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).
  • Page 16 5.3 Sequence for mounting an SP200 positioner to a rotary actuator 5.3.1 Assembly for fitting an SP200 on to a ¼ turn valve. Fig. 15 Mounting kit IM-P343-29 CH Issue 5...
  • Page 17 Fig. 16 Fig. 17 Fig. 18 IM-P343-29 CH Issue 5...
  • Page 18 Fig. 19 Assembled Fig. 20 IM-P343-29 CH Issue 5...
  • Page 19 5.3.2 Adjust the magnet orientation as illustrated in Figures 21 and 22 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 21 for actuator with clockwise rotation. Refer to Figure 22 for actuator with anti-clockwise rotation.
  • Page 20 / 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 21: Electrical Connections

    In terms of impedance, this means that in split range application, the load in the loop at 20 mA is 1060 Ohm. The impedance of a single SP200 is 530 Ohm at 20 mA. A typical controller might not be able to drive such a impedance load, hence a different approach is required.
  • Page 22 6.2.3 Travel switches- and 4-20 mA retransmission wiring digrams 2 k 22 k Travel switches 1 2 k 22 k Travel switches 2 Fig. 26 Software switches Example of customers external application wiring. � ������ 4 - 20 mA retransmit �...
  • Page 23 6.2.4 Wiring for instrinsic safe applications Safe Hazardous area area Switch 1 and 2 Travel switches Barrier (a) Supply Signal Barrier (b) 4 - 20 mA retransmit Position transmitter Barrier (c) Fig. 28 Example of electrical connections for Intrinsically Safe applications Output parameter for Barrier (b) and (c) Uo 30 V, Io 100 mA, Po...

  • Page 24: 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 SP200 MENU. Press and hold The display will count down the 3 seconds. 7.1.4 Press to advance to MANOP.
  • Page 25 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 26: Programming Flow Chart

    Mounting position check Software SP200 (CALIB) version MENU (Ver X.XX) Manual operation From RETRN C-CAL (MCTL) (To SP200 MENU) MANOP % Travel (TRAVL Autostroke activate AUTOS 0-100% / (AUTOS) 100-0%) Note: SET, TUNE, and RUN can Valve type Actuator type...
  • Page 27 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 28 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 SP200 MENU and carry out an autostroke commissioning routine (AUTOS) prior to putting the control valve into automatic operation.
  • Page 29 9.2.1 VER -.-- software version Programming notes To view the version of the embedded software (VER-.--) press key. key to return to SP200 MENU. The display will automatically return to Press SP200 MENU after 10 seconds. IM-P343-29 CH Issue 5...
  • Page 30 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 31 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 SP200 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 32 9.3 MANOP 3 second enter Manual operation C-CAL MANOP (MCTL) Fig. 31 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 33 100% 20 mA 20.2 mA Hence when the setpoint is 0% the PLC generates a 3.8 mA instead of 4 mA. After C-CAL is executed the SP200 recalibrates the current read to compensate the error. Setpoint Input current from PLC Current read from SP200 3.8 mA...
  • Page 34 AUTOS - automatic autostroke commissioning % Travel 3 second (TRAVL Autostroke activate enter AUTOS 0-100% / (AUTOS) 100-0%) 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.
  • Page 35 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 36 Display = 0% Display = 100% 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% IM-P343-29 CH Issue 5...
  • Page 37 100% 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. 37 3-port valve and spring extend actuator 100% 100% TRAVEL setting = 0 to 100%...
  • Page 38 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 39 When 'ACT' is ON there could be a light speed slow down approaching to the target position. This behaviour doesn’ t influence SP200 performance and guarantee a positioning without hunting. If a residual hunting or oscillation is present it is possible to operate changing Deadband (dBAND), Valve opening time (T-UP), Valve closing time (T-dWN).
  • Page 40 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 41 Fig. 42 CTRL Control Action dIRCT or REV setting guidance Installed orientation At-rest position Control action ���� ����� �� ���� ����� ���� ��� ���� �� ���� ����� �� ���� ����� �� ���� ����� ���� ��� 100% (TRAVL) �� 0 - 100% ����...
  • Page 42 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 43 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 44 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 45 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 46 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 47 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 48 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 39).
  • Page 49 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 44 and 45). 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 50 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 51 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 SP200 MENU. Press and key for 3 seconds to return to SP200 MENU. The display will count down the 3 seconds.
  • Page 52 At any time during automatic operation the mA input signal can be displayed by pressing key. To return to SP200 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 53 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 54 Press and hold key for 3 seconds. The display will count down the 3 seconds. This provides the facility to return to SP200 MENU with the option of staying in automatic operation (AUTO) or venting the actuator (VENT). Use keys key to select and return to SP200 MENU.

  • Page 55: Maintenance

    To change the filter proceed as follows: Ensure that the air supply to the positioner is isolated. Unscrew the filter plug (1) from the SP200 housing using a 5 mm allen key (refer to Figure 48). 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 56 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 57 12. Glossary of display data 12.1 Main menu display functions Display Description SET UP Indicates that the SP200 positioner fitted to the valve has not been programmed or commissioned. Indicates that you have now entered the SP200 main menu. Provides access to: SP200 •...
  • Page 58 12.2 Sub-menu display functions Display Description VER x.xx Indicates the version of software embedded within the SP200 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 59 Indicates the total number of valve strokes (x10). STRVL Value can be retained (RTAIN) or reset (RESET). Indicates the total run time of the SP200 in hours. RTIME Value can be retained (RTAIN) or reset (RESET) IM-P343-29 CH Issue 5...
  • Page 60 13. Certification EC-Type ATEX Certificate (Model SP200is) IM-P343-29 CH Issue 5...
  • Page 61 EC Declaration of conformity (Model SP200is) IM-P343-29 CH Issue 5...
  • Page 62 IM-P343-29 CH Issue 5...
  • Page 63 IM-P343-29 CH Issue 5...
  • Page 64 IM-P343-29 CH Issue 5...