Spirax Sarco Sp500 203o2d

3.568.5275.300

IM-P343-35

CH Issue 3

SP500 Electropneumatic Smart Positioner Installation and Maintenance Instructions

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

IM-P343-35 Printed in ItalyCH Issue 3

Index Safety information Technical information Options Installation Electrical connections Quick start procedure Programming flow chart Programming and commissioning Maintenance Default values and program settings Glossary of display data

1 © Copyright 2012

2

IM-P343-35 CH Issue 3

1. Index Section

Sub-section

2. Safety information

2.1 General requirements 2.2 Electrical safety requirements 2.3 Electromagnetic compatibility

3. Technical information

3.1 3.2 3.3 3.4

Description Technical data Materials Programmable functions

4.1 4.2 4.3 4.4

Pressure gauge block Retransmission and travel switches option board External power supply option board HART® communication protocol option board

4. Options

5.1 5.2 5. Installation 5.3

Electrical 6. connections Quick start procedure

7.

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

5.4 Air supply and connections 6.1 Guidance notes 6.2 Wiring diagrams 7.1 2-port valves 7.2 3-port valves

8. Programming flow chart

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9

10. Maintenance and troubleshooting

10.1 Air supply quality 10.2 Fitting replacement filter plug kit

9. Programming and commissioning

SET-UP NOW SP500 MENU MANOP AUTOS - automatic autostroke commissioning 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

11. Default values and program settings 12. Glossary of display data


12.1 Main menu display functions 12.2 Sub-menu display functions

3

2. Safety information 2.1 General requirements The flawless and safe operation of the SP500 positioners is reliant on proper transportation, storage, installation and commissioning by qualified personnel, proper use and careful maintenance. Prior to installing, using or maintaining the positioner, consideration should be given to:

- - - - - - -

The working environment. Safe access. Lighting. Pipeline fluid hazards. Temperature. System isolation. Location.

The SP500 positioner should be mounted with sufficient space to allow opening of the hinged cover and to provide access for electrical and air connections. When fitting to an actuator, ensure that the positioner will not be exposed to an ambient temperature outside the range of -10°C to +80°C. The positioner enclosure is rated to IP65 (see BS EN 60534-1 1998).

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. All associated wiring must be separated from other wiring containing hazardous voltages.

2.3 Electromagnetic compatibility The product complies with the Electromagnetic Compatibility Directive 2004 / 108 / EC according to: - EN 61326-1: 2006 - EN 61326-2-3: 2006 - EN 55011: 1998 + A1: 1999 + A2: 2002 - EN 61000-4-2: 1995 + A1: 1998 + A2: 2001 - EN 61000-4-3: 2006 - EN 61000-4-4: 2004 - EN 61000-4-5: 2006 - EN 61000-4-6: 2007 - EN 61000-4-11: 2004 This product may be affected by interference if:

-

The product or its wiring is located near a radio transmitter. The actual separation necessary will vary according to the power of the transmitter.

-

Cellular telephones or mobile radios are used within approximately one metre of the product or its wiring.

-

The wiring is routed alongside power cables subject to high voltage transients or current surges.

4


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 that automatically varies the pneumatic output pressure to overcome the effects of stem friction and flow forces to maintain desired valve position. Indication of valve position is provided through a continuous digital display of % travel. Valve position is retrieved by means of a non technology based on Hall effect. The pneumatics are based on piezovalve technology - Therefore, high resolution, high reliability, vibration insensitivity and extremely low air consumption is guaranteed at steady state. The SP500 includes many smart functions that can be fully programmed through menu driven software using an integral keypad and LCD alphanumeric data. Valve commissioning is simplified through an autostroke routine and display of programming status, software travel switch status, mA input signal and valve diagnostics data. Moreover, the absence of mechanical linkages between valve stem and positioner, drastically simplifies the mounting procedure and reduces the time required. The SP500 is supplied with a NAMUR standard mounting kit for attachment to yoke or pillar mounted actuators. For quarter turn valves, a mounting kit compliant to VDI / VDE 3845 is supplied. The SP500 smart valve positioner s optional expansion to include the HART ® communication protocol, enabling complete configuration using a PC or handheld device. 1

2

4

3

12

10

11

9

Fig. 1

13

5

6

7

8

No. Part

No. Part

1. LCD display

8. Enter key

2. Main menu functions with LCD flag indication

9. Supply pressure to positioner

3. Signal pressure to activator 4. Gland connection for wiring M20 5. Terminal block 6. Increase value or toggle value key 7. Decrease value or toggle value key


10. Optional pressure gauge block with gauges 11. Spare M20 gland connection for wiring a 4-20 mA retransmission or software switches 12. External earth 13. Internal earth

5

2

6

7

8

9

5

3

1

10

11

Fig. 2

3.2 Technical data

4

No. Features 1. indicates all is OK 2. ! Indicates a delay in positioning, this disappears when the position is reached 3. Indicates that the value displayed is a percentage 4. Indicates that the value displayed is the input current measured in mA 5. Indicates that the value displayed is a time measured in seconds 6. Indicates that you're accessing the main programming menus 7. Indicates that the positioner is in manual mode 8. Indicates that the positioner is running the autocalibration 9. Indicates that you're accessing the SET menu 10. Indicates that the positioner is in automatic mode 11. Indicates that you're accessing the TUNE menu

Input signal range 4 - 20 mA nominal Minimum input signal (loop powered) 3.6 mA HART® communication protocol Communication protocol superimposed over dc current signal 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 quality Air supply must be dry, oil and dust free to ISO 8573-1 class 2:3:1 Output pressure 0 to 100% supply pressure Linear valves 10 mm to 100 mm Stroke range Quarter turn valves 5° to 120° Action Single action / fail vent Operating temperature -10°C to +80°C Maximum air flow 4.2 normal m3/h at 1.4 bar g or 8.5 normal m3/h at 6 bar g Steady state air consumption Less than 0.016 normal m3/h Air connections Screwed ¼" NPT Cable gland M20 Electrical connections Spring clamp terminals for 0.2 to 1.5 mm² wire Enclosure rating IP65 Characteristic Linear, Equal % (ratio 1:50) or Fast opening (ratio 50:1) Resolution (maximum) 0.1% F.S. 4 - 20 mA retransmit (optional) 4 - 20 mA retransmission of valve position 1 x normally closed Software travel switches (optional) Two software configured travel switches 1 x normally open Shipping weight 2.2 kg 6


3.3 Materials Part Case and cover Magnet bracket

Material Die cast aluminium Die cast aluminium

Finish Anti-corrosive paint to RAL5010

3.4 Programmable functions Autostroke Valve type % travel Control action Travel limits (optional) Displayed travel % Signal span Dead-band Tight shut-off Characteristic Travel time Travel switches Reset Calibrate Input signal Auto operation / vent Data logging

Automatic commissioning routine 2-port or 3-port Selectable 0 to 100% or 100% to 0% depending on valve / actuator configuration Direct or reverse action (4 - 20 or 20 - 4 mA) Setting of minimum and maximum travel limits (valve open and valve close % travel) 0 - 100% displayed over mechanical travel limits or MIN-T / MAX-T adjusted settings 4 - 20 mA or split ranged (minimum span 4 mA) Positional accuracy (minimum 0.2% to max. 10% of valve travel) Fully vent or inflate at preset input signals Linear, = % or fast opening input signal to valve travel relationship Slows down valve opening or closing Software travel switch setting (range 0 - 100%) Resets all programmed values to default settings Centering Visualisation of input mA signal Option of automatic operation or vent (actuator) whilst reprogramming Diagnostic record of total number of valve strokes and completed hours run time


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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.

Fig. 3

8


4.2 Retransmission and travel switches option board

An option board can be fitted in the positioner to add valve position retransmission functionality and software travel switches functionality. The board generates a 4-20 mA current signal which represents the actual valve position. Moreover 2 output terminals are available to be configured as software travel switches. The threshold can be adjusted via software. Refer to Section 6, 'Electrical connections' for wirings. Refer to Section 9.6.7 for travel switching configuration. 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).

Fig. 4

- - -

Switch off the power supply. Switch off the air supply. Unscrew the board as shown in Figure 5.

Fig. 5


9

-

Rotate the mainboard and insert the option board (as shown in Figures 6, 7, 8 and 9). 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. 6

Fig. 7

Fig. 8

Fig. 9

10


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. This reduces dramatically the voltage drop on the current loop. The drop is 7 V when the unit is powered by the loop (2 wires), it falls to 1 V when the 4 wires configuration is used. This board can be useful when you have many instruments connected on the same current loop. The fact is that in this case, the total voltage drop on the loop could be higher than the maximum voltage drop that the controller (PLC) can handle. Refer to Section 6, 'Electrical connections' for wirings. An option board is optionally available and can be mounted in situ. In this case please refer to the mounting instruction below:

-


Fig. 10

- - -


Fig. 11


11

-

Rotate the mainboard and insert the option board (as shown in Figures 12 and 13).

Fig. 12

Fig. 13

-

Remove the Jumper J4 (Figure 14).

Fig. 14

12


Fig. 15

-

Insert the power supply option board. Collocate Jumper J4 as shown in Figures 15 and 16.

Fig. 16

-

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.

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.


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4.4 HART® option board

An option board can be fitted into the positioner to enable communication using the HART® protocol. 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:

-


Fig. 17

- - -


Fig. 18

14


-

Rotate the mainboard and insert the option board (as shown in Figures 19 and 20).

Fig. 19

Fig. 20

-

Remove the Jumper J14 (Figure 21).

Fig. 21

Jumper J14 IM-P343-35 CH Issue 3

15

-

Insert the HART® option board as shown in Figure 22.

Fig. 22

-

Collocate the Jumper J14 as shown in Figure 23.

Fig. 23

- 16

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. IM-P343-35 CH Issue 3

5. Installation 5.1 Mounting the SP500 positioner - General information Preliminary check of valve and actuator assembly - A preliminary check should be carried out on the valve and actuator assembly prior to mounting and commissioning the SP500 positioner to confirm smooth movement of the stem. This can be performed by providing an air supply directly from a filter/regulator to the actuator. The air supply pressure should be gradually increased to progressively move the stem through its full travel. Any friction or jerky movement of the stem should be investigated prior to commissioning the SP500.

5.1.1 The SP500 is supplied with a NAMUR standard fixing kit for linear actuators (yoke

or pillar) or with a 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.

5.1.3 Before fitting and commissioning the SP500 positioner ensure that the valve and

actuator are correctly assembled. Refer to the valve and actuator Installation and Maintenance Instructions for details.


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5.2 Sequence for mounting an SP500 positioner to a linear actuator

2 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 Figures 24 and 25). Be sure it is positioned horizontally (as shown in Figure 25).

Fig. 25 Yoke mounting assembly for a linear actuator

2

18


Assembled

2

Fig. 26

5.2.2 Slide the bracket (2) to the left or to the right (Figure 26) till the correct position is

achieved. If you’re using a Spirax Sarco actuator the correct position is impressed on the magnet bracket (Figure 27). PN9000

PN1000

Fig. 27 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 28). Mounting plate

Bracket

Fig. 28

A

Distance between the mounting plate and magnet

Center of the magnet IM-P343-35 CH Issue 3

19

5.2.4 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). Mounting plate

Pillar actuator Assembled

Fig. 29 Pillar actuator assembly

Mounting plate

Assembled

Yoke actuator Fig. 30 Yoke actuator assembly 5.2.5 Locate the protection plate onto the back of the SP500 positioner housing and fix in place (Figures 31 and 32).

Protection plate Assembled Fig. 31 20

Fig. 32 IM-P343-35 CH Issue 3

5.2.6 Attach the positioner mounting plate to the positioner as shown in Figures 33 and 34. Protection plate

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). Even if this is the ideal condition, it’s not mandatory. In fact, as shown in Figure 35, the only necessary condition for correct operation is that the stroke of the magnet (dimension B) lay inside the sensor operating linear range (dimension A), i.e. the vertical dimension marked on the case of the positioner.

5 SP500 positoner

B A Fig. 33 Assembled

Fig. 35

5.2.8

Fig. 34

Attach the mounting plate

When the SP500 positioner and mounting plate assembly is correctly positioned, tighten the hexagon headed screw (5) on the yoke mounted actuator (Fig. 33) to 10 - 12 N m and tighten the 'U'bolt nuts (6) on the pillar mounted actuators (Figure 36) to 10 - 12 N m.

6 Fig. 36


21

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

22


Fig. 39

Fig. 38

Fig. 40 IM-P343-35 CH Issue 3

23

Fig. 41

Assembled

Fig. 42 24


5.3.2 Adjust the magnet orientation as illustrated in Figures 43 and 44 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 43 for actuator with clockwise rotation. Refer to Figure 44 for actuator with anti-clockwise rotation. In fact, in this way the magnet movements will always be comprised in the sector between the directions C and D which delimit the operating area of the Hall sensor. B

D 15°

90° 120°

A 15° C

Fig. 43 View from the bottom of the positioner - Magnet orientation for clockwise actuator. B D 15° 90° 120°

A 15° C

Fig. 44 View from bottom of the positioner - Magnet orientation for anti-clockwise actuator. IM-P343-35 CH Issue 3

25

5.4 Air supply and connections Warning: Supply air pressure must not exceed the maximum allowable air pressure of the actuator. Air connections should be ¼" NPT for air supply (supply) and output signal to actuator (Figure 45). The supply air should be between 1.4 bar g minimum and 6 bar g maximum and be oil and dust free to IEC 60770. Mains air supply may sometimes contain traces of dirt, rust, water, oil and other deposits with the potential for contaminating the internals of the positioner. It is therefore essential that a filter / 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.

¼" NPT air signal to actuator (output 1)

¼" NPT air supply (supply)

Fig. 45

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6. Electrical connections 6.1 Guidance notes on wiring installation For heavy industrial applications it is recommended to use screened cables or signal cables run in metal conduit. Failure to do so could result in positional errors of up to ±5% in an RF field excess of 10 V/m. If screened cables are used, ensure that the screen is connected to the local earth at one end with a connection resistance of less than 1 ohm. For light industrial applications where RF fields do not exceed 3 V/m unscreened cables may be used. Cabling should be installed in accordance with BS 6739 - Instrumentation in Process Control Systems: Installation design and practice or local equivalent.

6.2 Wiring diagrams

4

-

7

10

TUNE

▲

+ RTX

9

AUTOMATIC

-

8

-

6

+ SW2

5

50 %

MENU MANUAL AUTOS SET

+ 4-20mA

3

+ SW1

2

▲

1

+ 24V

6.2.1 Terminal block

SP500 Fig. 46

No.

Pole

1

+

2

-

3

+

4

-

5

+

6

-

7

+

8

-

9

+

10

-

Description 24 V external power supply 4-20 mA current signal input

24 V power supply option board (PWS) Mainboard

Travel switch 1 Travel switch 2

Retransmission and travel switches option board (RTX)

4-20 mA retransmission of valve position


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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 Maximum current without HART® option board Maximum voltage drop with HART® option board Overvoltage protection Protection against polarity inversion

Fig. 47

3

4

+

-

3.6 mA 30 mA <7V < 7.4 V Up to 30 Vdc Up to 30 Vdc

4 - 20 mA signal

6.2.3 Multi-loop applications Loop powered multi-positioner connections Positioner 1

Fig. 48

3

4

3

4

Positioner 2

4 - 20 mA signal + @ 14 V minimum In a loop powered application, the 4-20 mA signal must be capable of supplying a minimum of 7 V per positioner at 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 positioner is 7.4 V instead of 7.0 V. 4 wires electrical connection If the controller cannot supply the voltage needed, it is possible to power one or more positioner through an external 24 V power supply connected to terminals 1 and 2. In this way the voltage drop is about 1 V per positioner with an impedance of 50 Ohm. Positioner 2

Positioner 1 1

2

3

4

5

6 7

8

9 10

1

2

3

4

5

6 7

8

9 10

+ +

24 V

Current loop @ 8 V - (1 V + 7 V) Fig. 49 Split range with 2 positioners Please note that for this configuration the PWS option board must be fitted. The PWS option board can be specified when the product is ordered or bought later and fitted in situ - In this case reference Section 4.3 for mounting instructions. 28


6.2.4 Travel switches

and 4-20 mA retransmission wiring digrams

2 k

5 22 k

Travel switches 1 6

2 k

7 22 k

Travel switches 2 8

Fig. 50 Software switches

Example of customers external application wiring. 9 4 - 20 mA retransmit

10

-

Fig. 51 4 - 20 mA retransmit

Table 1 Ratings TS1 travel switch TS2 travel switch 4 - 20 mA

Supply 18 - 30 Vdc 18 - 30 Vdc 8 - 30 Vdc


Impedance 1.8 k 1.8 k -

On current 13 mA 13 mA -

Off current 1 mA @ 24 V 1 mA @ 24 V 29

7. Quick start procedure 7.1 2-port valves The following applies to positioners fitted to 2-port valves having plug above the seat and fitted to pneumatic actuators having a direct acting (DIR) 4 - 20 mA input signal and excludes the setting of any additional program functions (i.e. default value only). Note: For PN5100 and PN6100 series actuators an additional programming step is required. (Refer to Section 9.5.2).

7.1.1 The positioner should be correctly assembled as described in Section 5 and Section 6

and supplied with mains air and signal pipework as described in Section 5.4.

7.1.2 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.

7.1.5 Press and hold

key for 3 seconds to enter manual control mode MCTL.

7.1.6 In manual control press and hold

or keys to drive the valve stem up or down. Check for any obstructions of valve movement. The display will indicate FILL or VENT as appropriate. Any obstruction should be investigated before proceeding to Section 7.1.7.

7.1.7 Press

key to return to MANOP in main menu.

7.1.8 Press

key to advance to AUTOS autostroke mode.


key for 3 seconds to start the autostroke routine. This will take approximately 2 minutes to complete.

! displayed indicates an incomplete or unsuccessful autostroke.

The routine can be aborted at any time by pressing key once. If autostroke is aborted during operation ABORT will be displayed and incomplete autostroke.

On completion the program will automatically return to AUTOS in main menu.

will be displayed if successful autostroke has been completed. It is now A possible to advance to RUN in main menu.

7.1.10 Press

! to indicate

key three times to advance to RUN in main menu.


30

key for 3 seconds to commence automatic operation. The valve will move to a control position related to the input control signal. The percentage valve travel will be displayed %. The positioner cover can now be closed and cover screws tightened. IM-P343-35 CH Issue 3

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 On completion of a successful autostroke press the

7.2.2 Press

Press

key once to advance to valve type. key to indicate VALVE 3-PORT.

7.2.3 Press

key once to advance to SET

in main menu.

key to select VALVE 3-PORT. Continue to press main menu.

key to return to SET in

7.2.4 Press

key twice to advance to RUN in main menu. Proceed as described in Section 7.1.11.


31

8. Programming flow chart Fig. 52 SET-UP NOW

Software version (Ver X.XX)

From RETRN (To SP500 MENU)

% Travel (TRAVL 0-100% / 100-0%) Note: SET, TUNE, and RUN can only be accessed on completion of a successful autostroke (AUTOS)

RETURN (To SP500 MENU)

Mounting position check (CALIB)

SP500 MENU

MANOP

Manual operation (MCTL)

Autostroke activate (AUTOS)

AUTOS

Valve type (VALVE 2-PORT / VALVE 3-PORT)

Actuator type (ACT)

Dead-band (dBand)

Shut-off minimum (S-MIN)

SET

TUNE

RUN

AUTO OPERATION (% TRAVEL)

Return to SP500 menu (RETRN AUTO / RETRN VENT)

32

C-CAL

(RETAIN) (RESET)


Key 3 seconds enter Enter

Clear stored values (RESET)

Auto return

Recall stored values (RETRN) Retain temporary values (RTAIN)

Minimum travel (MIN-T)

Maximum travel (MAX-T)

Displayed % travel (DTRVL)†

Minimum range (MIN-R)

Maximum range (MAX-R)

† Only if MIN-T / MAX-T not 0 / 100% Control action (CTRLA)

Shut-off maximum (S-MAX)

Characterisation (LIN / FAST / EQUAL)

Time to open (T-UP)

Time to close (T-dWN)

AUTO OPERATION (mA Input signal)

Stem travel (STRVL)

Travel switch 2 (NC) (TS2)

Travel switch 1 (NO) (TS1)

Run time (RTIME)

(RETAIN) (RESET)


33

9. Programming and commissioning 9.1 Set-up now Programming notes

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. A flow chart is included in Section 8 to guide you through the procedure. The display provides a flag indication of the active main menu function. To enter SP500 MENU press and hold key for 3 seconds. The display will count down the 3 seconds.

Commissioning notes

Main menu functions include:

SP500 MENU View software version, mounting position check, reset default values. MANOP

Manual control of valve movement (Actuator inflation / deflation).

AUTOS

Automatic valve commissioning. Provides selection of % travel display.

SET

Setting of valve type, control action, travel limits and input signal span.

TUNE

Setting of deadband, tight shut-off, lift characterisation, travel time and software switches.

RUN

Activates automatic operation plus input signal, total valve strokes and total run time. Also provides route for returning to SP500 MENU.

Note: SET, TUNE and RUN functions are restricted and can only be accessed on completion of a successful autostroke routine (AUTOS).

34


9.2 SP500 MENU ➤ SET-UP NOW

3 seconds enter

Clear stored values (RESET)

3 seconds enter

Software version (Ver X.XX)

SP500 MENU

Mounting position check (CALIB)

Recall stored values (RETRN) Retain temporary values (RTAIN)

From RETRN Fig. 53

Programming notes

You are now in SP500 MENU. SP500 functions include: 1. Visualisation of the embedded software version (VER--). 2. Positional setting (CALIB). 3. Resetting of programmed values to default settings (RESET). 4. To retain settings in the temporary memory (RTAIN). 5. Returning to previously stored settings (RETRN). key for 3 seconds. The display will To check the setting (CALIB) press and hold count down the 3 seconds. CALIB also provides access to RESET / RTAIN / RETRN functions. To view the embedded version of software (VER-.--) press key. To advance to manual operation (MANOP) press key.

9.2.1 VER -.-- software version

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.


35

9.2.2 CALIB - mounting position calibration Programming notes

36

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. When the LCD shows 0% the magnet is positioned near the bottom of the positioner’s case. At 50% the magnet will be in front of the cross impressed on the back of the positioner. At 100% the magnet will be roughly aligned with the top of the positioner’s case. Desired setting is 50% with the valve at half stroke. The and keys can be used to manipulate the actuator inflation. In this way it is possible to check the mounting position and if necessary change it and then check again to get the positioner well centred. Press key advance to RESET / RTAIN / RETRN.


9.2.3 RETRN - RTAIN - RESET Programming notes

Provides the facility to restore previous permanently stored values (RETRN), to retain values stored in the temporary memory (RTAIN) or to reset all values to factory default settings (RESET). Press and keys to select RETRN, RTAIN or RESET. To advance proceed as follows: RETRN To cancel any temporary changes to programmed values select RETRN and press key to return to SP500 MENU. RTAIN To retain temporary changes to programmed values select RTAIN and press key to return to SP500 MENU. RESET Provides the facility to reset all values to factory default settings and return to SET UP NOW. Press and hold key for 3 seconds. The display will count down the 3 seconds.

Commissioning notes

RETRN If changes have been made to program values they will be held in the temporary memory. To retain changes in the permanent memory it is necessary to advance to RUN in the main menu and press and hold key for 3 seconds. The display will count down the 3 seconds. If you do not wish to retain temporary changes select RETRN and press key to return to SP500 MENU. RTAIN If changes have been made to programmed values they will be held in the temporary memory. If you wish to retain these changes select RTAIN and press key to return to SP500 MENU. To retain temporary changes in the permanent memory advance to RUN in the main menu and press and hold key for 3 seconds. The display will count down the 3 seconds. RESET 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). RESET to factory default settings can also be used if it is required to recommission the valve. To reset to factory default values select RESET and press and hold The display will count down the 3 seconds.


key for 3 seconds.

37

9.3 MANOP 3 second enter MANOP

Manual operation (MCTL)

C-CAL

Fig. 54

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. In MANOP press

to

key to advance to autostroke (AUTOS).

Commissioning notes

Before initiating an autostroke commissioning (AUTOS) use manual control (MCTL) to manually fully inflate and deflate the actuator to ensure there are no obstructions to the full valve travel movement. 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.

9.3.1 MCTL - manual control Programming notes

Manual control enables the actuator to be manually inflated or deflated. Press key to inflate actuator and key to deflate the actuator. Press and hold or key to accelerate action. Prior to undertaking an AUTOS the display will indicate FILL or VENT. On completion of AUTOS the display will indicate % valve travel.

Manual control (MCTRL) - Tight shut-off function Press and hold the key to drive the valve to its closed position. At 0% travel the ! will flash to indicate limit of travel. To initiate tight shut-off release the key and press again. The actuator will be vented of air to provide dead tight shut-off. This also applies to the 100% valve position by pressing and releasing the key and pressing again to inflate the actuator to provide dead tight shut-off. Manual control (MCTRL) - Travel limits When operating in manual control any travel limit settings will be overridden therefore it is possible to manual position the valve through its full 0 to 100% travel as measured in autostroke (AUTOS).

Commissioning notes

Before initiating an autostroke commissioning routine (AUTOS) the actuator should be manually fully inflated and deflated to ensure there are no obstructions to the full valve travel movement. 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.

38


9.3.2 C-CAL - current calibration Programming notes

C-Cal provides a simple way to make a fine calibration of the input current signal (4 - 20 mA). To perform the calibration: 1. Enter C-CAL and press the key, then press the 2. Generate a 4 mA input signal and press 3. Generate a 12 mA input signal and press 4. Generate a 20 mA input signal and press

key.

If 'ERROR' is displayed the calibration routine is aborted. The value of the generated signal is too far from the expected one. Be sure that a 4 mA, 12 mA or 20 mA signal is generated as required. Press to return to C-CAL. If 'OK' is displayed the calibration has succeeded. Press

to return to C-CAL.

Where possible current calibration should be overtaken, to guarantee a perfect match between the input current generated and the reading of the SP500. Let’s assume that the table below show the input signal generated by a PLC or DCS versus the input signal read by the SP500.

Setpoint

0%

Input current from PLC Current read from SP500 3.6 mA

3.8 mA

50%

12 mA

12.2 mA

100%

20 mA

20.2 mA

Hence when the setpoint is 0% the PLC generates a 3.6 mA instead of 4 mA. After C-CAL is executed the SP500 recalibrates the current read to compensate the error.

Setpoint

0%

Input current from PLC Current read from SP500 3.6 mA

4 mA

50%

12 mA

12 mA

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).


39

9.4

AUTOS

- automatic autostroke commissioning

% Travel (TRAVL 0-100% / 100-0%)

AUTOS

3 second Autostroke activate enter (AUTOS)

Fig. 55

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. Press and hold key for 3 seconds to start autostroke. The display will count down the 3 seconds. When autostroke is active a flashing AUTOS message will be displayed. On completion of a successful autostroke the programme will automatically return to AUTOS in the main menu and a will be displayed. In the event of an unsuccessful autostroke routine a flashing ! will be displayed. If during AUTOS inconsistent data is obtained due to mechanical problems, the autostroke procedure will be terminated and ABORT will be displayed. It is also possible to immediately abort during an autostroke routine by pressing the key. ABORT will be displayed together with a flashing !.

Error messages:

ERROR 1 Indicates a wrong mechanical coupling between positioner and actuator. Check the mounting is correct. ERROR 2 Indicates that there is insufficient air pressure to achieve valve movement. Check that the air supply is adequate to overcome the actuator spring force. Fitting of a gauge block will aid the commissioning procedure. ERROR 3 Indicates that the actuator will not deflate. Check that there is no obstruction preventing the stem travel or air venting from the actuator. Error 4 indicates that the stroke measured is less than the minimum stroke allowed - 10 mm for linear valves, and 5° for quarter turn valves (output 1 and output 2 for double action applications).

ABORT indicates mechanical problems have occurred during the Autostroke procedure or the key has been pressed during Autostroke to abort the procedure. On completion of a successful autostroke it will be possible to advance to SET, TUNE and RUN functions in the main menu. Press the key to advance to these functions.

Commissioning notes

Prior to undertaking an autostroke routine, manual operation should be used to fully inflate and deflate the actuator to ensure there are no obstructions to the full valve movement. Autostroke is an automatic commissioning routine that checks for maximum valve travel, signal response, valve characteristics, inflation / deflation times etc. Data gathered will be automatically into the embedded software to ensure optimum performance of the valve / actuator combination. 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. 40


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%. Use and keys to toggle selection. Press key to return to AUTOS.

Commissioning notes

The selection of % valve travel display depends on the valve and actuator configuration. Figures 56 to 59 (pages 41 and 42), and Figures 60 and 61 (page 43) provide guidance on selection. After completion of AUTOS if a change is made to TRAVL it will be necessary to initiate an AUTOS routine once again.

Display = 0%

Display = 100%

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%


41

Display = 100%

Display = 0%

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%

42


100%

100%

0%

0%

TRAVEL setting = 0 to 100% DISPLAY = 0%


TRAVL setting = 100 to 0% DISPLAY = 100%


Fig. 60 3-port valve and spring extend actuator

100%

100%

0%

0%





Fig. 61 3-port valve and spring retract actuator


43

9.5

SET - setting of valve functions

SET

Valve type (VALVE 2-PORT / VALVE 3-PORT)

Actuator type (ACT)

Maximum range (MAX-R)

Control action (CTRLA)

Minimum range (MIN-R)

Minimum travel (MIN-T)

Displayed % travel (DTRVL)†

Maximum travel (MAX-T)

† Only if MIN-T / MAX-T not 0 / 100%

Fig. 62

Programming notes

Provides access to basic valve set up functions. Press SET functions. Functions include: - Valve type (2-port or 3-port) - Actuator type (on / off) - Control action (direct or reverse) - Minimum travel setting (0 to 66.66%) - Maximum travel setting (33.3 to 100%) - Displayed % travel (on / off) - Minimum span range (input mA signal) - Maximum span range (input mA signal)

key to scroll round all

(VALVE) (ACT) (CTRLA) (MIN-T) (MAX–T) (DTRVL) (MIN-R) (MAX-R)

Press key to advance to valve type (VALVE). Repeat pressing of scroll round all SET functions. Press

key will

key to advance to TUNE in the main menu.

Commissioning notes

Each SET function has a default value as listed in the Installation and Maintenance Instructions. Default values are based on a 2-port normally closed valve having maximum 95% lift and an input signal span range 4 - 20 mA. SET values should be adjusted to suit the valve type (2-port or 3-port) and application. Functions include the facility to change the control action, limit the full travel of the valve plug (minimum and maximum) and to split range the input signal. More detailed information is provided for each SET function.

44


9.5.1 VALVE - valve type Programming notes

Provides selection between 2-port and 3-port valves. Default is 2-port valve. Default values for travel limit settings (MIN-T and MAX-T) and early 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: Valve type Display MIN-T MAX-T S-MIN S-MAX

2-port Direct 0% 95% 0.1% OFF

Reverse 0% 95% OFF 0.1%

Use and keys to select type. Press advance to actuator type (ACT).

3-port Direct 0% 100 0.1% 0.1%

Reverse 0% 100% 0.1% 0.1%

key to accept displayed type and

Commissioning notes

Selection of 2-port or 3-port valves will automatically alter the maximum travel default value (MAX-T) to 95% for 2-port and 100% for 3-port valves. Advance to MAX-T to change these values if required.

9.5.2 ACT - actuator type Programming notes

ACT selection makes the positioner control more fluid and reactive, improving to the control signal. Selection is: 'ON' or 'OFF'. Default value is 'OFF'. Use the and keys to toggle selection. Press key to accept displayed value and advance to Control action (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'.


45

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 and 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:

DIR - direct action

REV - reverse action

Display MIN-T MAX-T S-MIN S-MAX

2-port 0% 95% 0.1% OFF

Display MIN-T MAX-T S-MIN S-MAX

3-port 0% 100% 0.1% 0.1%

2-port 0% 95% OFF 0.1%

3-port 0% 100% 0.1% 0.1%

Press key to accept the displayed action and advance to minimum travel setting (MIN–T).

Commissioning notes

g

tin g lif st em e

Valve plug position

llin

fa

lv

em st

Va

e

lv

46

Va

Valve plug position

Selection of direct or reverse action changes the direct of valve plug movement relative to the input signal. Refer to Figures 63 and 64, and the table shown in Figure 65 for further guidance.

mA Increasing input signal

mA Increasing input signal

Fig. 63 Direct action (DIR)

Fig. 64 Reverse action (REV) IM-P343-35 CH Issue 3

Fig. 65 CTRL Control Action dIRCT or REV setting guidance

Installed orientation

At-rest position

Control action

0%

100% (TRAVL) 0 - 100%

0%

(TRAVL) 100 - 0% Manual Selection of required % travel (TRAVL) IM-P343-35 CH Issue 3

100% Automatic determintation Spring action only affects the rest or fail-safe position

Manual Selection of required Control Action (CTRLA) 47

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%. Use and keys to alter the displayed value. Press key to accept the displayed value and advance to the maximum travel setting (MAX-T).

Commissioning notes

Minimum travel should be used where a minimum flowrate is required to be maintained through the valve, (i.e. a cooling water application). Setting a minimum travel % value will prevent the valve fully closing. The input signal span range set (MIN-R) and (MAX-R) will operate over the travel limits set. If a value for MIN–T is set it will exclude the setting of shut-off minimum (S-MIN) for control action direct (DIR) and shut-off maximum (S-MAX) for control action reverse (REV).

9.5.5 MAX-T - maximum travel setting Programming notes

Enables the maximum valve travel to be set as a percentage of the maximum travel measured during autostroke. Minimum setting is MIN-T plus 33.3%. Default values will depend on the selection of valve type (2-port or 3-port) and control action (direct or reverse) as follows:

Valve type

2-port

Direct 95%

95%

3-port

100%

100%

Use and keys to adjust the displayed value. Press value and advance to the next function.

Reverse

key to accept displayed

Commissioning notes

The maximum valve travel percentage should be used to prevent a control valve fully opening. This is useful for applications where the valve is oversized or to restrict the maximum flowrate through the valve. On 2-port valves the default value is 95% to prevent the back of the plug hitting the bonnet. On 3-port valves to ensure shut-off on both seats a 100% setting is required. 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).

48


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). DTRVL (0 to 100% displayed travel value) can be displayed over the actual mechanical travel limits (as measured during Autostroke), or adjusted MIN-T and MAX-T travel settings.

DTRVL programming options DTRVL - ON will display 0 to 100% over the MIN-T and MAX-T travel settings, or, DTRVL - OFF will display 0 to 100% over the actual mechanical limits of travel. Default value is DTRVL - ON. Use

and

keys to toggle selection.

Press key to accept displayed 'ON' or 'OFF' option and advance to minimum range setting (MIN-R). Examples

Example 1

Example 2

MAX-T = 95% MAX-T = 95%

MIN-T = 5%

MIN-T = 0%

Display values DTRVL - ON

Display values

DTRVL - OFF

DTRVL - ON

DTRVL - OFF

100%

95%

100%

95%

0%

0%

0%

5%

Commissioning notes

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%.


49

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. Use and keys to alter the displayed value. Minimum difference between MIN-R and MAX-R is 4 mA. Press key to accept the displayed value and advance to the maximum mA input span range (MAX-R).

Commissioning notes

This function can be used to set split range applications i.e. 4 - 12 mA or 12 - 20 mA. To ensure tight shut-off refer to Section 9.6.2 S-MIN, page 48.

9.5.8 MAX-R - maximum signal span range Programming notes

Enables the maximum mA input signal span range to be set. The value set will correspond to the maximum travel setting. Default value is 20 mA. Use and keys to alter the displayed value. Minimum difference between MIN-R and MAX-R is 4 mA. Press key to accept the displayed value and return to SET in the main menu.

Commissioning notes

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.

50


9.6 TUNE - setting of valve tune functions

TUNE

Dead-band (dBand)

Shut-off minimum (S-MIN)

Travel switch 2 (TS2) Normally closed

Shut-off maximum (S-MAX)

Travel switch 1 (TS1) Normally open

Characterisation (LIN / FAST / EQUAL)

Time to close (T-dWN)

Time to open (T-UP)

Fig. 66 Provides access to more advanced valve tuning functions including: - Dead-band (valve positioning sensitivity) (dBANd) - Shut-off minimum (ensures tight closure) (S-MIN) - Shut-off maximum (ensures tight closure) (S-MAX) - Characterisation (signal / lift relationship) (CHAR) - Time open (slows down valve opening) (T-UP) - Time close (slows down valve closure) (T-dWN) - Travel switch 1 normally open (sets software travel switch) (TS1) - Travel switch 2 normally closed (sets software travel switch) (TS2)

Programming notes

Press key to advance to deadband (dBANd). Repeated pressing of key will scroll round all TUNE functions. If you do not wish to alter TUNE default values press key to advance to RUN in the main menu.

Commissioning notes

Each TUNE function has a default value as listed in the Installation and Maintenance Instructions. Default values are based on a 2-port normally closed valve having maximum 95% lift and an input signal span range 4 - 20 mA. TUNE values should be adjusted to suit the valve type and application. Functions include: 1. The facility to alter deadband positioning sensitivity (to dampen out signal fluctuations). 2. Setting input signal to achieve tight shut-off (inflation and deflation of actuator). 3. Relationship between valve lift to input signal. 4. Slowing down the valve open or closing time duration. 5. Setting the switching position for the software travel switches. More detailed information is provided for each TUNE function.


51

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%. Note: 3% may be displayed if ACT is set to 'ON'. Refer to Section 9.5.2, page 45. These values may change if the input signal span is reduced i.e. for a 4 mA input signal span the default and minimum setting is 0.8%. The maximum setting is 10% of the input signal span. To alter the displayed value press and keys. Press key to accept the displayed value and advance to the shut-off minimum (S-MIN).

Commissioning notes

Setting a narrow deadband may induce oscillations of valve movement caused by fluctuations in the input signal, high stem friction or operating at low ambient temperatures below 0°C. Setting a wider deadband will dampen out oscillations but may cause an inaccuracy in actual valve position. This effect will increase if valve travel is limited. It is normally recommended that the default value is used. If necessary gradually increase the % value to dampen out any oscillations in valve movement. This may be necessary for valves having graphite packed stem seals or smaller size actuators where typically a deadband of 4% may be required.

9.6.2 S-MIN - valve shut-off - minimum travel Programming notes

Provides the facility to fully vent the actuator at a predetermined 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 (span 16 mA), will cause the valve to close with an input signal of 5.6 mA i.e. 4 mA + 1.6 mA (10% of 16 mA). Maximum setting is 20%. Default values will depend on the selection of valve type (2-port or 3-port) and control action (direct or reverse) as follows:

Valve type

Direct

Reverse

2-port

0.1%

Off%

3-port

0.1%

0.1%

For direct control action (dIRCT) can only be set if MIN-T = 0% (will vent the actuator at set value). For reverse action (REV) can only be set if MAX-T = 100% (will inflate the actuator at set value). Press and keys to alter the displayed value. Press key to accept the displayed value and advance to shut-off maximum (S-MAX).

Commissioning notes

With an actual input signal equivalent to minimum input signal span range (MIN-R) it may cause the valve plug to hover over the seat preventing tight closure with the possibility of erosion damage to the plug and seat faces. Setting a shut-off value can help prevent this by providing early closure of the valve.

52


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. 20 mA - 1.6 mA (10% of 16 mA). Maximum setting is 20%. Default values will depend on the selection of valve type (2-port or 3-port) and control action (direct or reverse) as follows:

Valve type

Direct

Reverse

2-port

Off

0.1%

3-port

0.1%

0.1%

For direct action (dIRCT) can only be set if MAX-T = 100% (will inflate the actuator at set value). For reverse action (REV) can only be set if MIN-T = 0% (will vent the actuator at set value). Press and keys to alter displayed value. Press key to accept the displayed value and advance to the characterisation (CHAR).

Commissioning notes

With an actual input signal of 20 mA and a maximum span range setting (MAX-R) of 20 mA may cause the valve plug to hover over the seat preventing tight closure with the possibility of erosion damage to the plug and seat. Setting a shut-off value can help prevent this by providing early closure of the valve.

9.6.4 CHAR - valve characterisation Programming notes

Provides selection of linear (LIN), equal percentage (EQUAL) or fast opening (FAST) characterisation. Characterisation is the relationship between input signal and valve lift. Default value is Linear (LIN). Use and keys to select the desired action. Press key to accept the displayed characterisation and advance to time open (T-UP).

Commissioning notes

The standard characterisation for 2-port and 3-port valves is linear (LIN). For special applications using 2-port valves an equal percentage (EQUAL) or fast opening (FAST) characteristic can be selected. With equal percentage the valve will start to open slowly and gradually accelerate opening related to input signal. With fast opening characteristic the valve will commence to open quickly and gradually slow down opening related to the input signal. This action is in addition to the valve trim flow characterisation (refer to Figure 67 for guidance). Ratio 1:50

Fig. 67

Valve lift

Valve lift

Signal (mA)


Signal (mA)

Ratio 50:1 Valve lift

Ratio 1:1

Signal (mA) 53

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 45). Default value is the fastest time measured during autostroke. Press and keys to alter the displayed value. Press key to accept the displayed value and advance to time down (T-dWN).

Commissioning notes

The time displayed on start-up is the fastest time measured during autostroke commissioning (AUTOS). A time cannot be set less than the minimum recorded during autostroke. The value set will be the time taken for the valve to travel from 0 to 100% lift. The time set will apply at all times and not just at start-up. This function is useful to prevent the effects of system waterhammer, thermal shocks or slow down over-reactive systems or the effects of oversized valves. Default is the fastest time measured during autostroke. Maximum setting is 180 seconds.

9.6.6 T-dWN - valve slow closing action Programming notes

This function slows down the time taken for the valve to travel from 100 to 0% lift. The time displayed on start-up 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 45). Default value is the fastest time measured during autostroke. Press and keys to alter the displayed value. Press key to accept the displayed value and advance to travel switch 1 (TS1).

Commissioning notes

During autostroke routine the quickest time taken for the valve to fully close will be measured and displayed. A time cannot be set less than the minimum recorded during autostroke. The value set will be the time taken for the valve to travel from 100 to 0% lift. This action will apply at all times and not just at start-up. 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.

54


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 68 and 69).

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%. A value can be set outside the limits of the travel settings (MIN-T) and (MAX-T). Initially OFF will be displayed indicating that the switch is not set. To set a switching point press and keys to alter the displayed value. Press key to accept the displayed value and advance to travel switch 2 normally closed (TS2).

Commissioning notes

Travel switch 1 (TS1) is normally open. External wiring should be made between terminals 1 (+) and 2 (-). The value set is a % of valve travel. At the set value the switch will close. The status of the switch will be shown on the LCD (refer to Figure 68). Software configured travel switches can be used to remotely indicate valve position or to operate warning devices, fans, stirrers, motors or other process equipment via a secondary switching device.

Travel 100% Switch closed 50% Switch open 0%

Note: Software configured travel switches can be set within the range 0% to 100% of full travel irrespective of any travel limit settings. Signal

Fig. 68 TS1 Travel switch 1 (normally open)


55

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). Initially OFF will be displayed indicating that the switch is not set. To set a switching point press and keys to alter the displayed value. Press key to accept the displayed value and return to TUNE in the main menu.

Commissioning notes

Travel switch 2 (TS2) is normally closed. External wiring should be made between terminals 3 (+) and 4 (-). The value set is a % of valve travel. At the set value the switch will open. The status of the switch will be shown on the LCD (refer to Figure 69). Software configured travel switches can be used to remotely indicate valve position or to operate warning devices, fans, stirrers, motors or other process equipment via a secondary switching device. Note: If the switch is in its 'off' status it will be an open circuit.

Travel 100% Switch open 50% Switch closed 0%

Note: Software configured travel switches can be set within the range 0% to 100% of full travel irrespective of any travel limit settings. Signal

Fig. 69 TS2 Travel switch 2 (normally closed)

56


9.7

RUN - automatic operation

RUN

Return to SP500 menu (RETRN AUTO / RETRN VENT) Return to SP500 MENU

AUTO OPERATION ( % TRAVEL)

mA (mA input signal)

(RETAIN) (RESET)

Stem travel (STRVL)

Run time (RTIME)

(RETAIN) (RESET)

Fig. 70

Programming notes

Provides the facility to put the valve into automatic operation. Press and hold key for 3 seconds to start automatic operation. The display will count down the 3 seconds. The valve will move to a position in response to the input control signal. All values stored in the temporary memory will be transferred to the permanent memory.

Commissioning notes

By pressing and holding the key for 3 seconds all values previously set will be entered into the permanent memory. 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 key for 3 seconds to return to SP500 MENU. The display will count down the 3 seconds. There are two options for returning to SP500 MENU: Option 1 is to stay in automatic control (AUTO) where the valve will continue to position itself relative to the input control signal. Option 2 is to vent the actuator (VENT) where the valve will travel to its fail-safe position.


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9.7.1 Automatic operation - % travel Programming notes

During normal automatic operation the % valve travel will be continuously displayed together with the switch status of the software travel switches (if fitted). Additionally, a will be displayed indicating that the valve is operating satisfactorily. At any time during automatic operation the mA input signal can be displayed by pressing key. 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). Use and keys to select the desired option. Press key to accept the displayed option and return to SP500 MENU.

Commissioning notes During normal operation the % valve travel will be continually displayed. A indicates that the valve is performing satisfactorily. Causes of fluctuations in valve movement can be related to input signal. Press key to view actual mA input signal.

9.7.2 Input signal - mA signal display Programming notes

The mA input signal will be displayed. Press key to return to displaying % travel. The programme will automatically return to displaying % travel after 5 minutes. It is possible to advance to view valve diagnostics data STRVL (total valve strokes) and RTIME (total run time). To advance to STRVL press and hold key for 3 seconds. The display will count the 3 seconds.

Commissioning notes

This function is of assistance to visualise and check input signal relative to valve position and to investigate causes of fluctuations in valve movement. The mA input signal will be displayed for 5 minutes. Press key to return to displaying % travel. The programme will automatically return to displaying % travel after 5 minutes.

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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. A complete valve stroke is as measured in autostroke AUTOS. The number displayed can be retained (RTAIN) or reset to zero (RESET). Press the key to advance to RTAIN / RESET. Press and keys to toggle selection. Press key to accept the displayed selection and advance to run time RTIME.

Commissioning notes

Information displayed should be used in conjunction with total runtime RTIME to assess the valve usage and evaluate the need for routine maintenance, replacement of stem seals etc. The number displayed should be multiplyed by a factor of 10 to obtain the local total number of complete valve strokes. (A complete valve stroke is as measured in autostroke (AUTOS)). The maximum possible display value is 99999. If this value is exceeded, the display will roll over to zero and an ! will be displayed. To retain the displayed value press the enter key and select RTAIN. If the valve is dismantled for maintenance inspection etc. The value can be reset if required by selecting RESET.

9.8.2 RTIME - total valve run time in hours Programming notes

The number displayed is the total valve run time in hours. Run time is defined as the total time the positioner is receiving a control signal. The number displayed can be retained (RTAIN) or reset to zero (RESET). Press the key to advance to RTAIN / RESET. Press and keys to toggle selection. Press key to accept the displayed selection and return to displaying % travel.

Commissioning notes

Information displayed should be used in conjunction with total valve strokes (STRVL) to assess the valve usage and evaluate the need for routine maintenance, replacement of stem seals etc. To retain the displayed value press key and select RTAIN. If the valve is dismantled for maintenance inspection etc. The value can be reset to zero if required by selecting RESET.


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9.9 RETRN - return to SP500 MENU in main menu Return to SP500 MENU

Return to SP500 menu (RETRN AUTO / RETRN VENT)

AUTO OPERATION (% TRAVEL)

Fig. 71

Programming notes

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

Commissioning notes

To alter any SET or TUNE values, go into manual control (MCTL) it is then necessary to return to the SP500 MENU. Any values altered will be recorded in the temporary memory and activated immediately. To store in the permanent memory it will be necessary to advance to RUN and press and hold key for 3 seconds. The display will count down the 3 seconds. To return to the main menu but stay in automatic control select AUTO. The valve will continue in automatic operation and respond to changes in input control signal. With the exception of CALIB and MCTL functions, main menu and subroutines will timeout after 5 minutes if no key is pressed and revert to displaying % TRAVEL in automatic control mode. Any temporary changes made will not be recorded in the permanent memory. To return to main menu in a fail-safe position select VENT. The actuator will be fully vented of air and the valve will return to its fail-safe position. To return to manual control (MCTL) advance to MANOP in the main menu and advance to manual control (MCTL). The valve can now be manually controlled using the and keys to inflate or deflate the actuator. The desired % TRAVEL will be displayed. To return to automatic control advance to RUN and press key for 3 seconds. The display will count down the 3 seconds. The valve will revert to automatic control and position itself relative to the input control signal. Any SET or TUNE values altered will be recorded in the permanent memory.

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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. In addition the SP500 positioner has an internal filter. In normal operation it is recommended that this filter is replaced every 6 to 12 months depending on the air quality and valve usage. A spare filter plug kit can be obtained from Spirax Sarco that includes: filter plug, plus 3 off 'O' rings and filter.

10.2 Fitting replacement filter plug kit To change the filter proceed as follows: - Ensure that the air supply to the positioner is isolated. - Unscrew the filter plug (1) from the SP500 housing using a 5 mm hex. head socket key (refer to Figure 72). The replacement filter plug can now be fitted: - Fit the 'O' ring (4) and filter (3) onto the filter plug (1) (refer to Figure 56). - Finally fit the retaining screw (2). The filter plug can now be replaced into the SP500 housing, checking that the 'O' ring (4) is correctly located. The pnuematic air supply can now be restored to the positioner and checks made to ensure that the filter plug 'O' ring has provided the neccesary air tight seal.

Fig. 72

Filter plug (1)

2 3

4 Fig. 73 IM-P343-35 CH Issue 3

1

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11. Default values and program settings Main menu Sub-menu Setting options Default value Programmed value Valve type 2-port SET (2-port) (VALVE) 3-port SET Actuator type ON OFF (ACT) OFF Control action Direct (dIRCT) SET (dIRCT) (CTRLA) Reverse (REV) Minimum travel SET 0 to 66% 0% (MIN-T) Maximum travel 33 to 100% 95% for 2-port SET (MAX-T) 100% for 3-port Displayed % travel ON SET ON (DTRVL) OFF SET Minimum input signal 4 to 16 mA 4 mA (MIN-R) Maximum input signal SET 8 to 20 mA 20 mA (MAX-R) 0.2 to 10% 0.5% Dead-band TUNE (% of (3% if (dBAND) input signal span) ACT is 'ON') TUNE Minimum shut-off OFF, 0.1% (S-MIN) 0 to 20% TUNE Maximum shut-off OFF, OFF for 2-port (S-MAX) 0 to 20% 0.1% for 3-port Linear (LIN), Characteristic TUNE Equal (EQUAL), (LIN) (CHAR) Fast (FAST) Autostroke time Time-up Autostroke time – (seconds) 4 seconds TUNE (T-UP) 180 seconds if ACT is 'ON' Autostroke time Time-down Autostroke time – (seconds) 4 seconds TUNE (T-dWN) 180 seconds if ACT is 'ON' TUNE Travel switch 1 OFF, (TS1 OFF) (TS1) 0 to 100% TUNE Travel switch 2 OFF, (TS2 OFF) (TS2) 0 to 100% Auto (RETRN AUTO) RUN Return to menu (RETRN AUTO) Vent (RETRN VENT)

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12. Glossary of display data 12.1 Main menu display functions Display

SET UP NOW SP500 MENU

MAN OP AUTOS SET TUNE RUN

Description

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: • View the version of the embedded software. • Facility to centre the mounting position (CALIB). • Retain temporary changes to menu values (RETRN). • Recall previously stored menu values (RTAIN). • Reset to default values (RESET). Provides access to manual control (MCTL) and current calibration (C-CAL). Provides access to: • Autostroke commissioning routine. Note: SET, TUNE and RUN functions can only be accessed after a successful AUTOSTROKE routine has been completed. • Selection of percentage travel display % (TRAVL). Provides access to valve set up functions as follows: • Valve type (VALVE). • Actuator type (ACT). • Control action (CTRLA). • Minimum valve travel (MIN-T). • Maximum valve travel (MAX-T). • Displayed % travel (DTRVL). • Minimum signal range (MIN-R). • Maximum signal range (MAX-R). Provides access to additional valve characterisation functions as follows: • Dead-band sensitivity (dbANd). • Valve shut-off minimum setting (S-MIN). • Valve shut-off maximum setting (S-MAX). • Valve signal – lift characterisation (CHAR). • Valve slow opening time (T-UP). • Valve slow closing time (T-dWN). • Setting software travel switch 1 (normally open) (TS1). • Setting software travel switch 2 (normally closed) (TS2). Provides access to: • 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).


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12.2 Sub-menu display functions Display VER

Indicates the version of software embedded within the SP500 positioner.

Provides facility for mounting position adjustment.

x.xx CALIb RETRN RTAIN

Description

Enables previously stored function values to be recalled. Enables temporary changes made to function values to be retained.

RESET

Enables all function values to be reset to default settings. Refer to Section 11 for default settings.

MCTL

Provides manual control of the valve. Use and keys to fill or vent the actuator.

C-CAL

Calibration of the current input.

TRAVL

Selection of percentage of travel display - 0 to 100% or 100 to 0% depending on valve and actuator configuration.

AUTOS AbORT VALVE ACT CTRLA MIN-T MAX-T

Initiates the autostroke automatic commissioning routine.

Indicates that the AUTOS commissioning routine has been aborted.

Selection of 2-port or 3-port valve. Improve action and speed. Selection of input signal control action 4 - 20 mA or 20 - 4 mA. Setting of minimum valve travel % to prevent the valve fully closing. Selection of maximum valve travel % to prevent the valve fully opening.

DTRVL

Selection of displaying 0 - 100% travel over the mechanical travel limits or adjusted MIN-T / MAX-T settings.

MIN-R MAX-R dbANd

Selection of the input signal related to the minimum valve travel (MIN-T). Selection of % valve position dead-band sensitivity.

S-MIN

Facility to select pre-determined input signal to fully close the valve at the minimum travel position.

S-MAX

Facility to select a pre-determined input signal to fully close the valve at the maximum travel position.

Selection of input signal to valve lift characterisation. Options include: • Linear (LIN) • Equal percentage (EQUAL) • Fast opening (FAST)

CHAR

LIN

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Selection of the maximum input signal related to maximum valve travel (MAX-T)

Indicates a linear relationship between the input signal and the valve travel.


Display

Description

EQUAL

Indicates an equal percentage relationship between the input signal and the valve travel.

FAST T-UP T-dWN TS1 TS2

Indicates a fast opening relationship between the input signal and the valve travel.

Facility to slow down the valve opening movement. Facility to slow down the valve closing movement. Setting of % travel for software travel switch 1 (normally open). Setting of % travel for software travel switch 2 (normally closed).

%

Indicates percentage of valve travel in automatic operation or manual control (MCTL).

Indicates the input signal in mA.

mA AUTOC

FILL

 !

Return to SP500 menu remaining in automatic control operation. Indicates the actuator is being filled with air (manual control before AUTOS).

Indicates that there are no problems with the positioner. An error or warning indication.

ERROR 1 (AUTOS) ERROR 2 (AUTOS) ERROR 3 (AUTOS) ERROR 4 (AUTOS) — / \

STRVL

Indicates a problem with the mounting position. Indicates that there is insufficient air pressure to position the valve. Indicates that the air cannot be vented from the actuator. Detected stroke too short. Software travel switch (TS1 and TS2) - closed. Software travel switch (TS1) - open. Software travel switch (TS2) - open. Indicates the total number of valve strokes (x10).

Value can be retained (RTAIN) or reset (RESET).

RTIME

Indicates the total run time of the SP500 in hours. Value can be retained (RTAIN) or reset (RESET)


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