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SMAR HART FY500 Installation Operation & Maintenance

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Summary of Contents for SMAR HART FY500

  • Page 3 UNPACKING AND STORAGE Although Smar takes steps to prevent damage in transport, such damage is possible and must be discovered and reported before installing the FY500. Do not install the positioner that has been damaged in transport or during storage.
  • Page 4 Smar provides specific training to instruct and qualify such professionals. However, each country must comply with the local safety procedures,...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1 - INSTALLATION ........................1.1 SAFETY INSTRUCTIONS ............................1.1 MOUNTING .................................. 1.1 QUARTER TURN ROTARY ACTUATORS ......................... 1.2 LINEAR ACTUATOR ................................1.7 PNEUMATIC CONNECTIONS ..........................1.13 DIMENSIONAL DRAWINGS ............................1.15 ELECTRICAL WIRING ............................... 1.16 4 – 20 MA LOOP CONNECTIONS ............................ 1.16 TEST CONNECTIONS ..............................
  • Page 6 FY500 HART – Operation, Maintenance, and Installation Manual TRANSDUCER MODULE ............................6.5 CONNECTION MODULE ..............................6.5 I/P CONVERTER MODULE ..............................6.6 DIAPHRAGM MODULE ..............................6.8 PNEUMATIC MODULE ............................... 6.8 FEEDBACK MODULE ............................... 6.10 PACKAGE CONTENT ............................... 6.10 ACCESSORIES ................................. 6.10 EXPLODED VIEW ..............................

  • Page 7: Section 1 - Installation

    Section 1 INSTALLATION Safety Instructions This entire section should be read before proceeding with the installation. • Operating limits are stated in section 3, Technical Characteristics, on this manual. • The positioner must only be installed, operated, and maintained by qualified personnel with fully trained in field equipment installation.

  • Page 8: Quarter Turn Rotary Actuators

    FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.1 – Linear and rotary assemblies WARNING Modifying this product, substituting non-factory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties. On loss of instrument signal, valve will open or close.
  • Page 9 Section 1 - Installation Figure 1.2 – Quarter turn actuator sizes WARNING In case of a pneumatic or electrical failure, it is important to know the behavior of the actuator. Before mounting the positioner on an actuator, the failsafe position and direction of rotation of the actuator drive shaft should be verified.
  • Page 10 FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.3 – Rotary mounting bracket configuration 4. Before attaching the mounting bracket, determine the orientation of the FY500. It is ‘’IN-LINE’’ to actuator mounting when the pneumatic connections are in the same direction as the longitudinal drive axis of the actuator, or ‘’ACROSS”...
  • Page 11 Section 1 - Installation Figure 1.4 – Positioner assembly orientation relative to actuator axis 6. Fit the rotary adaptor onto the feedback shaft of the FY500 and adjust its position on the actuator shaft so that the arrow on the actuator lines up with the arrow mark on the back of the FY500 housing.
  • Page 12 FY500 HART – Operation, Maintenance, and Installation Manual is fully inserted into the actuator shaft and that the mounting bracket conforms to the configuration shown in figure 1.3. 10. Tighten the mounting bracket screws securely, both those that make it up and those that secure it to the actuator.

  • Page 13: Linear Actuator

    Section 1 - Installation Linear Actuator The FY500 can be mounted in any orientation. The mounting parts kit for the linear actuator contains a mounting bracket with NAMUR/IEC 60534-6-1 standard mounting patterns. Applicable to actuators with cast yoke (with rib or plane surface design), or pillar yoke for U-bolt application. WARNING In case of a pneumatic or electrical failure, it is important to know the behavior of the actuator.
  • Page 14 FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.9 – Feedback assembly mounted on mounting adaptor WARNING In some cases, attach the slotted bracket to the actuactor stem may not be possible, and an mounting adaptor to actuator stem is required. This adaptor will be shipped to the customers according to their purchase order.
  • Page 15 Section 1 - Installation 5. Attach the feedback arm to the end of the feedback shaft with M6x1 screw, M6 hex nuts, lock washers, and flat washers. The markings on the feedback arm must be visible to the operator/installer. Install the compensating spring on the feedback arm. See figure 1.11. Figure 1.11 –...
  • Page 16 FY500 HART – Operation, Maintenance, and Installation Manual Secure the mounting bracket to the actuator yoke using the follow procedures: - For actuators with cast yoke with rib surface application, using the M8x1.25 screw, lock washer, and flat washer. See figure 1.13. Figure 1.13 –...
  • Page 17 Section 1 - Installation - For actuator with pillar yoke for U-bolt application, using two U-bolt, four lock washers, and four flat washers, as shown in figure 1.15. Figure 1.15 – Attachment to pillar yoke for U-bolt 10. Slide the adjustment feedback pin in the slot of the slotted bracket until the pin is in line with the desired actuator travel marking on the feedback arm.
  • Page 18 FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.17 – Admissible range – linear mounting bracket WARNING When test cycling the actuator and valve assembly by applying pressure to the pneumatic port, be aware that there are moving parts can cause serious injuries. The Alternate Method The feedback pin is fixed in the feedback arm and have it ride freely inside the slotted bracket.

  • Page 19: Pneumatic Connections

    Section 1 - Installation Pneumatic Connections The FY500 requires instrument air quality, following the best practices for pneumatic installations. Consult the American National Standard “Quality Standard for Instrument Air” (ANSI/ISA S7.0.01 – 1996) for detailed information. Instrument air shall the following characteristics: Dew point 10ºC below minimum instrument temperature.
  • Page 20 FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.18 – Pneumatic connections 1.14...

  • Page 21: Dimensional Drawings

    Section 1 - Installation Dimensional Drawings Figure 1.19 – Dimensional drawings 1.15...

  • Page 22: Electrical Wiring

    Conduit threads should be sealed by means of code-approved sealing methods. The FY500 is designed to withstand explosion proof, non-incendive, and intrinsic safety. For a complete list of available certificates, please consult http://www.smar.com. Figure 1.20 – Plug Mounting 4 – 20 mA Loop Connections The FY500 is normally powered by a control system output card (PLC).

  • Page 23: Test Connections

    Section 1 - Installation Figure 1.21 – Cover Locking Screw 2. Connect the positive wire to the (+) screw terminal and the negative wire to the (–) screw terminal, As shown in figure 1.22. 3. Two ground terminals are available on electronic housing: one internal and one external. Both are grounded in the housing itself.

  • Page 24: Communication Connections

    FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.23 – Terminal Block 3. Measure the loop current. 5. Remove test cable. Replace and hand tighten the terminal cover. To secure the terminal block cover engage the locking screw. Communication Connections The HART communication interface can be connected to the 4 to 20 mA loop wiring or directly to the appropriate terminals on the FY500 terminal block.

  • Page 25: Electronic Housing Rotation

    Section 1 - Installation Figure 1.24 – Feedback connections Electronic Housing Rotation The electronic housing can be rotated to offer a better display position and/or better access to the field cables. WARNING To avoid damage do not rotate the electronic housing more than 270º starting from the fully threaded without disconnecting the electronic circuit from the printed circuit board and from the power supply.

  • Page 26: Changing The Display Position

    FY500 HART – Operation, Maintenance, and Installation Manual Figure 1.26– Electronic housing rotation Changing the Display Position There are four ways to position the display on the housing. 1. Loose the cover locking screw and remove the cover, as shown in figure 1.21. 2.
  • Page 27 Section 1 - Installation Typical Applications The FY500 connection should be done accordingly following applications, as shown in figures 1.28 and 1.29. Figure 1.28 – Connecting FY500 to the controller Figure 1.29 – Connecting the FY500 to the pressure transmitter WARNING Connect the FY500 to a 4 to 20 mA current source, the positioner will not operate when connected to a voltage source.

  • Page 28: Split-Range Operation

    FY500 HART – Operation, Maintenance, and Installation Manual Split-Range Operation The FY500 can be used for split range operation, when a single current output from a control system is used to operate two actuator/valve assemblies. One of the sets will move its entire course between 4 and 12 mA, for example, while the other will do the same from 12 to 20 mA.

  • Page 29: Installation In Hazardous Areas

    As the positioner is non-ignition capable under normal conditions, the statement “Seal not Required” could be applied for Explosion Proof Version. The standard plugs provided by Smar are certified according to international standards. If the plug needs to be replaced, a certified plug must be used.
  • Page 30 FY500 HART – Operation, Maintenance, and Installation Manual 1.24...

  • Page 31: Section 2 - Operation

    Section 2 OPERATION Principle of Operation Figure 2.1 – FY500 Digital Valve Positioner (Exploded View) The FY500 receives a setpoint signal from a controller or other device through a twisted pair of wires. It compares this input signal to the actual valve position, which is measured with a position sensor, in this case, Hall Effect sensor.

  • Page 32: Display

    FY500 HART – Operation, Maintenance, and Installation Manual Figure 2.2 – FY500 Block Diagram Display The digital display LCD is necessary to show the information, such as measured variable and its unit, and to perform the local adjustment. During the normal operation, the FY500 stay in the monitoring mode and the display shows the valve position in percentage.
  • Page 33 Section 2 - Operation INDICATES TABLE INDICATES MULTIDROP FUNCTION ACTIVATED MODE ACTIVATED INDICATES ACTIVATED CONSTANT OUTPUT MODE F (x) INDICATES ACTUATION ON AUTOMATIC VARIABLE FIELD INDICATES ACTUATION UNIT IN PERCENT ON MANUAL INDICATES ADJUSTMENT/ CHANGE VARIABLE/ MODE POSSIBLE UNIT AND FUNCTION FIELD INDICATES VALVE POSITION INDICATES SETPOINT DISPLAYED CURRENTLY SHOWN...
  • Page 34 FY500 HART – Operation, Maintenance, and Installation Manual...

  • Page 35: Section 3 - Technical Characteristics

    Through HART digital communication over 4-20mA signal. The FY500 can be configured either via FDT/DTM tools or via DD-based Configuration configurators. It can also be configured through local adjustment using Smar's magnetic tool. Hazardous Area Intrinsically safe and explosion proof. Certifications FY500 is in compliance with the directive.

  • Page 36: Performance Specifications

    FY500 HART – Operation, Maintenance, and Installation Manual Performance Specifications Independent ±0.5% of output span (1,2) Linearity Air Consumption 0.31 scfm (0.49 normal m3/hr) @ 60 psig (4.1 bar) supply pressure) Output Capacity 11 scfm (20.5 normal m3/hr) @ 60 psig (4.1 bar) supply pressure) Vibration Effect Tested per ANSI/ISA-75.13.01 Section 5.3.5.

  • Page 37: Ordering Code

    CEPEL Housing Material Aluminum (IP/TYPE) 316 SST (IP/TYPE) Aluminum for saline atmosphere (IPW/TYPE X) (1) 316 SST for saline atmosphere (IPW/TYPE X) (1) Manufacturing Standard SMAR Painting Gray Munsell N 6.5 Polyester Without painting Tag Plate With tag Blank According to user´s notes...
  • Page 38 FY500 HART – Operation, Maintenance, and Installation Manual...

  • Page 39: Section 4 - Local Programming

    Section 4 LOCAL PROGRAMMING Local Adjustment The local adjustment is available for FY500. The interface consists of a liquid crystal display and magnetic tool. The positioner must be powered with at least 9.6V and 3.8 mA to operate the display. Certain procedures require up to 20 mA of current.

  • Page 40: Jumpers Selection

    FY500 HART – Operation, Maintenance, and Installation Manual Jumpers Selection Two jumpers are located on the main board to select the local adjustment (W1 jumper) and write protection (W2 jumper). Change the action jumper by setting both jumpers according to Figure 4.2. Local Adjustment –...

  • Page 41: Local Programming Tree

    Section 4 - Local Programming Local Programming Tree Figure 4.3 – Local Programming Tree...

  • Page 42: Configurable Parameters

    FY500 HART – Operation, Maintenance, and Installation Manual Table 4.1 lists the values that are preconfigured at the factory. Setup Parameter Default Setting AIRTO - Air to Open or Air to Close Air to Open ACT – Setpoint action DIRECT CHAR - Characterization Curve LINEAR MODE - Mode...
  • Page 43 Section 4 - Local Programming Step 3: After adjusting the position reading gain, the set will be moved to the 0% position again. When the set has stopped at position 0%, the user must place the magnetic tool in (S). Step 4: Adjusts the other end of valve travel.

  • Page 44: Restore Factory Settings

    FY500 HART – Operation, Maintenance, and Installation Manual TIME - SETPOINT VARIATION TIME (Time) Determine the time, in seconds, required to move the valve from its fully open position to fully closed, or vice versa based on response parameters measured during the last AUTOTUNING or FULLSETUP procedures.

  • Page 45: Section 5 - Configuration Via Hart

    (See in the Section 4, Local Programming). NOTE The operation and use characteristics of each one of the configurators are in their specific manual. Consult the configurator updates and their respective manuals on http://www.smar.com or at their manufacturer. Configuration Resources By means of the HART ®...

  • Page 46: Identification And Manufacturing Data

    FY500 HART – Operation, Maintenance, and Installation Manual Identification and Manufacturing Data The following information about the FY500 manufacturing and identification data is available: 8-character alphanumeric field for identification of the positioner. DESCRIPTION 16-character alphanumeric field for additional identification of the positioner. May be used to identify service or location.

  • Page 47: Advanced Configuration

    Section 5 – HART ® Configuration LINEAR UNALTERED Equal percentage 1:25 Equal percentage 1:33 Equal percentage 1:50 Quick opening 1:25 (Hyperbolic) Quick opening 1:33 (Hyperbolic) Quick opening 1:50 (Hyperbolic) Table 16 pairs (X, Y) DISPLAY The FY500 digital display has three well-defined fields: information field with icons informing the active status of the configuration, 4 ½...

  • Page 48: Trim

    FY500 HART – Operation, Maintenance, and Installation Manual Trim There are two trim operations: current trim and temperature trim which can be performed by standard HART configurators. − CURRENT TRIM allows to check the positioner input current reading. There are two types of current trims available: 4 mA TRIM: is used to adjust the input current reading correspondent to 0%.

  • Page 49: Section 6 - Maintenance

    It is recommended that the end user do not try to repair printed circuit boards. Instead, replace the pieces and, for this, the user should have spare circuit boards, which may be ordered from Smar whenever necessary.
  • Page 50 FY500 HART – Operation, Maintenance, and Installation Manual Transducer Module topic for further information. To troubleshoot the FY500, refer to Table 6.1. SYMPTOM SOURCE / SOLUTION Use a 4 to 20 mA current source to apply power to the positioner Check input signal current.

  • Page 51: Diagnostics With Hart Interface

    Section 6 - Maintenance Diagnostics with HART Interface For diagnostic with HART interface, perform the following steps. Connect a variable 4-20 mA source to the positioner. Communicates with HART interface. The current signal is the signal to the I/P Converter Module from the analog board. It is the percentage of the microprocessor signal needed to drive the valve fully open.

  • Page 52: Electronic Housing Module

    FY500 HART – Operation, Maintenance, and Installation Manual Electronic Housing Module The main electronic board contains the circuit board that perform control functions of the positioner. The main board is to be replaced as a unit. None of its components can be repaired. WARNING Observe precautions for handling electrostatically sensitive devices.

  • Page 53: Transducer Module

    Section 6 - Maintenance Transducer Module The transducer module contains the following submodules: Connection, I/P Converter, Diaphragm, Pneumatic and Feedback. As shown in Figure 6.2. Figure 6.2 – Transducer Module Connection Module The Connection Module contains the analog board and the sensor board. The input signal from the main board arrives to the analog board through a flat cable.

  • Page 54: I/P Converter Module

    FY500 HART – Operation, Maintenance, and Installation Manual electrical wires enter the I/P converter guides. These guides route the wires to the analog board. 2. Tighten the four M4 x 0.7 hex head screws. I/P Converter Module The I/P Converter Module receives a current signal from analog board and converts it to pneumatic signal to the Diaphragm Module.
  • Page 55 Section 6 - Maintenance Adjusting Nozzle-Flapper with Coil To adjust the Nozzle-Flapper with Coil, perform the following steps. 1. Install the I/P Converter Module into the FYCAL base. 2. Install the four screws and evenly tighten. 3. Regulate the supply pressure to the I/P Converter. Regulated pressure should be between 23 to 25 psi.

  • Page 56: Diaphragm Module

    FY500 HART – Operation, Maintenance, and Installation Manual Diaphragm Module The Diaphragm Module receives the signal pressure from nozzle-flapper. To check the Diaphragm, perform steps, refer to figure 6.2. Remove the Diaphragm Module. Ensure the Diaphragm Module is in good condition. Do not reuse a damage or worn Diaphragm Module.
  • Page 57 Section 6 - Maintenance Pressure Regulator To disassemble the Pressure Regulator, perform the following steps, refer to Figure 6.5. Using a flat screwdriver, remove the regulator cover. Remove the regulator spring button and the regulator spring. Remove the regulator plug and its o-ring. Using a flat screwdriver, remove the poppet guide, its O-ring, the regulator poppet, and the regulator spring.

  • Page 58: Feedback Module

    FY500 HART – Operation, Maintenance, and Installation Manual Feedback Module The Feedback Module transmits valve position to analog board. This is accomplished by means of a Hall sensor that connects to the valve stem through a feedback linkage. To check the Feedback Module, perform the following steps, refer to Figure 6.2. 1.

  • Page 59: Exploded View

    Section 6 - Maintenance Exploded View Figure 6.6 – Exploded View 6.11...

  • Page 60: Spare Parts List

    FY500 HART – Operation, Maintenance, and Installation Manual Spare Parts SPARE PARTS LIST CATEGORY PARTS DESCRIPTION POSITION CODE (NOTE 4) HOUSING (NOTE 1) 400-1314-8 (NOTE 6) COVER WITH WINDOW (INCLUDES O-RING) 400-0822 (NOTE 6) COVER WITHOUT WINDOW (INCLUDES O-RING) 400-1257 (NOTE 6) Cover Locking Bolt 204-0120 Sensor Locking Bolt (M6 Set Screw)
  • Page 61 Section 6 - Maintenance SPARE PARTS LIST CATEGORY PARTS DESCRIPTION POSITION CODE (NOTE 4) POSITIONER MOUNTING BRACKET Linear (contains screws and washers (packaged with 12 units) 400-1517 Rotary (contains screws and washers (packaged with 12 units) 400-1518 NOTES 1) Includes terminal isolator, bolts (cover locking, ground, and terminal isolator) and identification plate without certification. 2) O-rings are packaged with 12 units.

  • Page 62: Detailed Code For Ordering Spare Parts

    FY500 HART – Operation, Maintenance, and Installation Manual Detailed Code for Ordering Spare Parts CODE DESCRIPTION 400-1314-8 Housing; FY500 Option Communication Protocol HART & 4-20 mA Option Electrical Connection ½ NPT M20 X 1.5 PG13.5 Option Material Aluminum (IP/Type) Stainless Steel (IP/Type) Aluminum - for saline atmospheres (IPW/Type X) Aluminum Copper Free (IPW/Type X) Option...
  • Page 63 Section 6 - Maintenance DESCRIPTION CODE 400-1506 Transducer Set; FY500 Option Indication Gauge Without gauge 01 Gauge - Input 01 Gauge – Output 1 02 Gauge – Input and Output 1 02 Gauge – Output 1 and 2 03 Gauge Option Action of Positioner Single Action Double Action...
  • Page 64 FY500 HART – Operation, Maintenance, and Installation Manual CODE DESCRIPTION 400-1508 Connection cover; FY500 Option Material Aluminum (IP/Type) Stainless Steel (IP/Type) Option Painting Gray Munsell N6.5 Without Painting 400-1508 TYPICAL ORDERING CODE CODE DESCRIPTION 400-1509 Feedback Module; FY500 Option Material Aluminum (IP/Type) Stainless Steel (IP/Type) Option...

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