SMAR FY301 Instruction, Operations & Maintenance Manual

A

OPERATION, MAINTENANCE

ND INSTRUCTION MANUAL

Smart Valve Positioner

JUN / 16

FY301

VERSION 3

FY301ME

smar

Specifications and information are subject to change without notice.

Up-to-date address information is available on our website.

web: www.smar.com/contactus.asp

www.smar.com

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INTRODUCTION

The FY301 is a smart valve positioner for Single (spring return) or Double acting Linear motion type
control valves e.g. Globe, Gate, Diaphragm, Pinch or Clamp and Rotary motion type control valves e.g.
Ball, Butterfly or Plug with pneumatic type actuators e.g. Diaphragm, Piston, Vane, or Bellows. It is
based on a field-proven piezo flapper and non-contacting Hall-effect position sensor that provides
reliable operation and high performance. The digital technology used in the FY301 enabled the choice of
several types of flow characterizations, an easy interface between the field and the control room, not to
mention several interesting features that considerably reduce the installation, operation and
maintenance costs.
The FY301, besides the normal functions offered by other smart positioners, offers the following
functions:

* Table - on top of the regular valve characterization curves like linear, equal percentage and quick
opening (hyperbolic), the valve set point signal may be custom linearized according to a 16 point table,
making it possible to achieve flow characterization being a combination of linear and equal percentage
etc.

* Local Adjustment - not only for travel adjustment, but also flow characterization, tuning, operation
mode, indication, set point and PID parameters... as well.

* Password - three levels for different functions.

* Operation Counter - shows the number of changes in each function.

* Auto Setup - automatic calibration of valve travel.

* Diagnostic – permanently valve monitoring condition for preventive maintenance.

Get the best results of the FY301 by carefully reading the instructions of this manual.

WARNING

Throughout the operation of the positioner, including auto setup, do not touch the moving parts of the
valve/actuator/positioner `set as they may unexpectedly move automatically. Make sure to disconnect
air supply before touching any moving parts.

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This manual is compatible with version 3.XX, where 3 indicates software version and XX software
release. The indication 3.XX means that this manual is compatible with any release of software
version 3.

Waiver of responsibility

The contents of this manual abides by the hardware and software used on the current equipment
version. Eventually there may occur divergencies between this manual and the equipment. The
information from this document are periodically reviewed and the necessary or identified corrections
will be included in the following editions. Suggestions for their improvement are welcome.

Warning

For more objectivity and clarity, this manual does not contain all the detailed information on the
product and, in addition, it does not cover every possible mounting, operation or maintenance
cases.

Before installing and utilizing the equipment, check if the model of the acquired equipment complies
with the technical requirements for the application. This checking is the user’s responsibility.

If the user needs more information, or on the event of specific problems not specified or treated in
this manual, the information should be sought from Smar. Furthermore, the user recognizes that the
contents of this manual by no means modify past or present agreements, confirmation or judicial
relationship, in whole or in part.

All of Smar’s obligation result from the purchasing agreement signed between the parties, which
includes the complete and sole valid warranty term. Contractual clauses related to the warranty are
not limited nor extended by virtue of the technical information contained in this manual.

Only qualified personnel are allowed to participate in the activities of mounting, electrical connection,
startup and maintenance of the equipment. Qualified personnel are understood to be the persons
familiar with the mounting, electrical connection, startup and operation of the equipment or othe
similar apparatus that are technically fit for their work. Smar provides specific training to instruct and
qualify such professionals. However, each country must comply with the local safety procedures,
legal provisions and regulations for the mounting and operation of electrical installations, as well as
with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased
safety and instrumented safety systems, among others.

The user is responsible for the incorrect or inadequate handling of equipments run with pneumatic
or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since thei
utilization may cause severe bodily harm and/or material damages.

The field equipment referred to in this manual, when acquired for classified or hazardous areas, has
its certification void when having its parts replaced or interchanged without functional and approval
tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying
that the equipment in its entirety meets the applicable standards and regulations. The same is true
when converting the equipment of a communication protocol to another. In this case, it is necessary
sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are
different and the user is responsible for their correct use.

Always respect the instructions provided in the Manual. Smar is not responsible for any losses
and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to
know and apply the safety practices in his country.

NOTE

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TABLE OF CONTENTS

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GENERAL ..................................................................................................................................................................... 1.1

MOUNTING .................................................................................................................................................................. 1.1

PNEUMATIC CONNECTIONS ..................................................................................................................................... 1.4

DIMENSIONAL DRAWING........................................................................................................................................... 1.6

ELECTRONIC HOUSING ROTATING ......................................................................................................................... 1.7

ELECTRIC WIRING ...................................................................................................................................................... 1.8

AIR SUPPLY REQUIREMENTS ................................................................................................................................ 1.11

RECOMMENDATIONS FOR INSTRUMENT AIR SUPPLY SYSTEM ....................................................................... 1.11

RECOMMENDATIONS FOR MOUNTING APPROVED EQUIPMENTS WITH THE IP 66 W CERTIFICATIONS (USE

IN SALINE ATMOSPHERES) .................................................................................................................................... 1.12

ROTARY AND LINEAR MAGNET .............................................................................................................................. 1.12

MAGNET CENTRALIZER DEVICE ............................................................................................................................ 1.13

REMOTE HALL SENSOR .......................................................................................................................................... 1.13

INSTALLATION IN HAZARDOUS AREAS ................................................................................................................. 1.14

EXPLOSION/FLAME PROOF .................................................................................................................................................. 1.15

INTRINSICALLY SAFE ............................................................................................................................................................. 1.15

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TRANSDUCER FUNCTIONAL DESCRIPTION ........................................................................................................... 2.1

ELECTRONICS FUNCTIONAL DESCRIPTION .......................................................................................................... 2.2

THE LOCAL INDICATOR ............................................................................................................................................. 2.4

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CONFIGURATION RESOURCES ................................................................................................................................ 3.3

IDENTIFICATION AND MANUFACTURING DATA ..................................................................................................... 3.3

MONITORING .............................................................................................................................................................. 3.3

DEVICE CONFIGURATION ......................................................................................................................................... 3.4

ADVANCED CONFIGURATION .................................................................................................................................. 3.5

DEVICE MAINTENANCE ............................................................................................................................................. 3.5

TRIM ............................................................................................................................................................................. 3.5

SETUP .......................................................................................................................................................................... 3.5

MULTIDROP CONFIGURATION ................................................................................................................................. 3.5

DIAGNOSTIC ............................................................................................................................................................... 3.6

BACKUP ....................................................................................................................................................................... 3.6

PRESSURE SENSOR .................................................................................................................................................. 3.6

FACTORY ..................................................................................................................................................................... 3.6

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W1 AND W2 JUMPERS CONNECTION ...................................................................................................................... 4.1

LOCAL PROGRAMMING TREE .................................................................................................................................. 4.2

ADJUSTABLE PARAMETERS ..................................................................................................................................... 4.3

PROCEDURE FOR VALVE CALIBRATION ................................................................................................................ 4.4

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GENERAL INFORMATION .......................................................................................................................................... 5.1

RECOMMENDATIONS FOR MOUNTING APPROVED EQUIPMENTS WITH THE IP66 W CERTIFICATIONS (USE IN

SALINE ATMOSPHERES) ........................................................................................................................................... 5.1

CORRECTIVE MAINTENANCE FOR THE POSITIONER ........................................................................................... 5.1

DIAGNOSTICS WITHOUT CONFIGURATOR ............................................................................................................. 5.1

DIAGNOSTIC WITH CONFIGURATOR ....................................................................................................................... 5.2

DISASSEMBLY PROCEDURE FOR MAINTENANCE ................................................................................................ 5.3

MAINTENANCE – MECHANICAL PARTS ................................................................................................................................. 5.3

MAINTENANCE – ELECTRONIC PARTS .................................................................................................................................. 5.3

PREVENTIVE MAINTENANCE FOR THE POSITIONER ............................................................................................ 5.4

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DISASSEMBLY PROCEDURE .................................................................................................................................... 5.4

RESTRICTION CLEANING PROCEDURE .................................................................................................................. 5.6

CHANGE OF THE FILTER ELEMENTS ...................................................................................................................... 5.7

EXHAUSTS PORTS ..................................................................................................................................................... 5.7

ELECTRONIC CIRCUIT ............................................................................................................................................... 5.8

PACKAGE CONTENT .................................................................................................................................................. 5.8

EXPLODED VIEW ........................................................................................................................................................ 5.9

ACCESSORIES .......................................................................................................................................................... 5.10

SPARE PARTS LIST .................................................................................................................................................. 5.10

DETAILED CODE WHEN ORDERING OF SPARE PARTS ...................................................................................... 5.12

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FUNCTIONAL SPECIFICATIONS ................................................................................................................................ 6.1

PERFORMANCE SPECIFICATIONS ........................................................................................................................... 6.2

PHYSICAL SPECIFICATIONS ..................................................................................................................................... 6.2

ORDERING CODE ....................................................................................................................................................... 6.3

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EUROPEAN DIRECTIVE INFORMATION .................................................................................................................. A.1

HAZARDOUS LOCATIONS GENERAL INFORMATION ........................................................................................................... A.1

HAZARDOUS LOCATIONS APPROVALS ................................................................................................................. A.2

CSA (CANADIAN STANDARDS ASSOCIATION) ...................................................................................................................... A.2

FM APPROVALS (FACTORY MUTUAL) .................................................................................................................................... A.2

NEMKO (NORGES ELEKTRISKE MATERIELKONTROLL) ...................................................................................................... A.3

EXAM (BBG PRÜF - UND ZERTIFIZIER GMBH) ...................................................................................................................... A.3

CEPEL (CENTRO DE PESQUISA DE ENERGIA ELÉTRICA) ................................................................................................... A.3

IDENTIFICATION PLATE ............................................................................................................................................ A.5

CONTROL DRAWING ................................................................................................................................................. A.7

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RETURNING MATERIALS .......................................................................................................................................... B.2

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Start

Verify, before installation, the
package content. (Section 5)

Proceed with field installation. (Section 1)

Install the valve and the actuator. (Section 1)

Check

valve conditions: apply pressure

in the actuator and verify if the valve

stem travels from 0 to 100%.

Be sure there is no additional

between magnet and Hall sensor

or possibility of movement stop.

Check if there is no leakages

at connections or actuator.

friction

(Section 1)

Is the

positioner

pre-configured?

NO

Define action type. (direct / reverse)

(Section 3)

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YES

Install the magnet bracket. (Section 1)

Install the positioner bracket. (Section 1)

Assemble the positioner and

the magnet in the valve. (Section 1)

Place the valve . Make sure that
the arrow engraved on the magnet coincides

with the arrow engraved on the positioner .

Check between the magnet

external face and the positioner face.

(Recommended: (Section 1)

position for local indicator. (Section 5)

Connect the positioner pneumatic

in mid travel

the distance

2 mm to 4 mm)

Verify the most suitable

Install the positioner. (Section 1)

Check if the cover is correctly

closed. (Section 1)

Check area classification and

respective practices.

Purge air supply lines before

connecting the pressure .tubings

parts to the actuator. (Section 5)

YES

Define the

current

range.

Define valve type.

(air to open / air to close)

(Section 3)

Is the

positioner in ?urnkv"tcpig

(Section 1)

NO

Is the

valve working

correctly?

YES

OK

NO

Use sealant on threads. Make sure

that the bracket is not obstructing

the positioner exhausted ports.

Do not touch the moving parts of the

valve/actuator/positioner assembly as they

may unexpectedly move automatically.

(Between 1.4 bar (20 psi) and 7 bar (100 psi))

ATTENTION

Apply pressure in the positioner.

(Section 5)

Power up the positioner.

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Section 1

NOTE

The installation carried out in hazardous areas should follow the recommendations of the IEC60079-14 standard.

General

Mounting

INSTALLATION

The overall accuracy of measuring and control depends on several factors. In spite of the excellent
performance, the positioner must be adequately installed so that it may work well.

Among all factors that may affect the positioner accuracy, environmental conditions are the most
difficult to control. But there are ways to reduce the effects of temperature, humidity and vibration.

Installing the positioner in areas protected from extreme environmental changes can minimize
temperature fluctuation effects. In warm environments, the positioner should be installed to avoid, as
much as possible, direct exposure to the sun. Installation close to lines and vessels subjected to
high temperatures should also be av oided. If not possible to avoid it, consider using the remote
position sensor version.

Use thermal isolation to protect the positioner from external heart sources, if necessary.

Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the O-rings for the
electronic housing covers must be c orrectly placed and the covers must be completely closed by
tighten them by hand until you feel the O-rings being compressed. Do not use tools to tight the
covers. Removal of the electronics cover in the field should be reduced to the minimum necessary,
since each time it is removed; the circuits are exposed to the humidity.

The electronic circuit is protected by a humidity proof coating, but frequent exposures to humidity
may affect the protection provided. It is also important to keep the covers tightened in place. Every
time they are removed, the threads are exposed to corrosion, since painting cannot protect these
parts. Sealing methods should be employed on conduit entering of the positioner.

IMPORTANT

Avoid to use thread sealant tapes on the air input and outputs connections, since small pieces of this type of

sealant may block the air flow inside the positioner, affecting the overall equipment performance.

Although the positioner is practically vibration resistant, it is not recommended to install it near
pumps, turbines or other equipment producing too much vibration. If not possible to avoid it,
consider using of remote position sensor version.

The FY301 mounting depends on the type of actuator, its actions, single (with spring return) or
double, and the movement characteristic (linear or rotary). It requires two mounting brackets: one for
the magnet and another for the positioner. Smar supplies both according to the specified ordering
code (see Page 6.4 for mounting bracket ordering code)

Additionally, a great variety of customized mounting brackets is available, covering several control
valves models from different manufacturers.

Check the availability and select the most adequate mounting bracket to your need, by visiting our
web page on the Internet: http://www.smar.com. Select "Valve Positioner" option to access the
product specific page. After enter your login and password, click on the Bracket for FY link and
choose the most appropriate mounting bracket to your application.

See below an example showing the Positioner with rotary and linear magnets.

IMPORTANT

Smar web site (www.smar.com) has options of mounting brackets available for several actuators of several
manufacturers and models and the related dimensional drawings.

1.1

FY301 – Operation, Maintenance and Instructions Manual

(4 PLACES)

NOTE

EXTENSION

BRACKT

REMOTE POSITION

Rotary Movement

Install the magnet on the valve stem using the its proper bracket, according to the Figure 1.1.

ROTATY
MAGNETY
BRACKET

LOCK

VALVE STEM

ROTATY
MAGNET

M6x1 SCREWS

Figure 1.1 – Positioner with Rotary Actuator

Included in the package content the centralizer device of rotary magnet. See figure 1.17.

POSITIONER
BRACKET

POSITIONER

M6x1 SCREWS
(2 PLACES)

OUT 2

IN

OUT 1

REMOTE

“L” BRACKT WITH “U” CLAMP
FOR REMOTE POSITION

REMOTE EXTENSION

Figure 1.2 – Positioner on Rotary Actuator with Remote Position

Then, install the positioner bracket on the actuator. Usually, the actuator is designed according to
the VDI/VDE 3845 standard, and, in this case, tighten the four screws with their lock washers on the
proper bracket.

1.2

Installation

OUT 2OUT 1

IN

POSITIONER

M6x1 SCREWS

(4 PLACES)

LINEAR MAGNET

VALVE YOKE

VALVE STEM

CENTRALIZER DEVICE

LINEAR MAGNET
BRACKET

POSITIONER
BRACKET

NOTE

NOTE

Make sure that the arrow engraved on the magnet coincides with the arrow engraved on the positioner when
the valve is in mid travel.
When mounting the magnet, be sure that:

1. There is no attrict between the internal magnet face and the position sensor salience during the
travel (rotary or linear), through the magnet.

2. The magnet and the salience of position sensor must not be distant.

A minimum distance of 2 mm and a maximum distance of 4mm are recommended between the magnet
external face and t he positioner face. For that, a centralizer device (linear or rotary) must be u sed. The
centralizer device is in the positioner packing.

Case the positioner installation or magnet change or if any other modification is done, the positioner
will require a re-calibration. See Section 3 (Setup - for Auto Setup procedure).

See item “Pneumatic Connections” as recommended practice to install the positioner to the valve
type.

Linear Movement

Install the magnet on the valve stem using its proper bracket, according to Figure 1.3.

Install the positioner bracket on the actuator. The fastening of the actuator bracket may follow the
NAMUR/IEC 60534-6-1 standard or be in accordance with the user specified boring. Mount the
positioner on the bracket by fastening the four screws in the holes of the pressure gauges opposite
face. Use lock washers to avoid loosening the screws.

The linear magnet movement must be or thogonal in relation to the main axis of the position
positioner. For example, if the linear magnet movement is vertical, the positioner main axis must be
horizontal, as show in Figure 1.3.

Included in the package content the centralizer device of linear magnet. See figure 1.16.

Figure 1.3 - Positioner on the Linear Actuator

1.3

FY301 – Operation, Maintenance and Instructions Manual

OUT 2

IN

OUT 1

REMOTO EXTENSION

LINEAR MAGENT

VALVE YOKE

VALVE
STEM

CENTRALIZER
DEVICE

REMOTE
POSITION

“L” BRACKT WITH “U” CLAMP
FOR REMOTE POSITION

M6x1 SCREWS
(2 PLACES)

LINEAR MAGNET
BRACKET

POSITIONER
BRACKET

M6x1 SCREWS
(2 PLACES)

Pneumatic Connections

1.4

Figure 1.4 – Positioner on Linear Actuator with Remote Position

Make sure the bracket does not obstruct the exhaust outputs.

NOTE

Make sure that the arrow engraved on the magnet coincides with the arrow engraved on the positioner when
the valve is in mid travel.
When mounting the magnet, be sure that:

1. There is no attrict between the internal magnet face and t he position sensor salience during the
travel (rotary or linear), through the magnet.

2. The magnet and the salience of position sensor must not be distant.

A minimum distance of 2 m m and a m aximum distance of 4mm are recommended between the magnet
external face and t he positioner face. For that, a c entralizer device (linear or rotary) must be us ed. The
centralizer device is in the positioner packing.

Case the positioner installation or magnet change or if any other modification is done, the positioner
will require a re-calibration. See Section 3 (Setup - for Auto Setup procedure).

The FY301 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.
The FY301 comes with input and output stainless steel air filters, but these filters do not exclude the

preliminary instrument air treatment. Periodical filter cleaning is recommended at every 6 months or
less, if the air quality is not good. Please, check the maintenance section for clean the filters.

The FY301 supply air pressure varies from 1.4 bar (20 psi) minimum, to 7.0 bar (100 psi) maximum.
The actuator working pressure must follow these limits. Consider the use of boosters, if required.
Pressure below this range shall affect the positioner performance. Pressure above this range may
damage the positioner.

The two pneumatic outputs, marked as “OUT1” and “OUT2”, work in opposite directions to open or
close the valve.

If a failure occurs on the FY301, such as power loss (4-20 mA input signal), the output marked OUT1 goes to
zero pressure and the output marked OUT2 goes to the air supply pressure value.

IMPORTANT

Installation

The positioner can have pressure gages (see the ordering code table) attached to the supply air
input and in each output. The indications on gages are references only and does not have the same
overall positioner accuracy.

The pneumatic connections are marked with IN for the air supply and OUT1 and OUT2 for Output1
and Output2, respectively. Use 1/4 NPT connections with sealing material for the NPT screw
threads. Connect the air supply on t he connection marked IN. Be sure the air supply does not
exceed the maximum allowed pressure of the positioner or the actuator.

IMPORTANT

When using tape sealant type on the thread connections, be sure not spread small residues inside, since they
may clog the air flow inside the positioner and even impair the equipment efficiency.

The FY301 has five protected exhaust orifices with filters. Do not block any of these exhaust, as the
air must circulate freely through them. If painting the positioner block, remove the filters before, to
prevent them from being obstructed by paint. The orifices must be inspected on a r egular basis to
ensure they not blocked, granting the air to flow smoothly.

Double Action – Air to open (Close on failure)

Connect the positioner OUT1 output on the actuator connection marked with “OPEN” and connect
the positioner OUT2 output on the actuator connection marked with “CLOSE”.

Double Action – Air to close (Open on failure)

Connect the positioner OUT2 output on the actuator connection marked with “OPEN” and connect
the positioner OUT1 output on the actuator connection marked with “CLOSE”.

Single Action

Connect the positioner OUT1 output on the actuator input. Use a plug to block OUT2. Pay attention
to the safe logic on the actuator for the specific process. If necessary, invert the connections. Take
into consideration that in case of power failure the output marked OUT1 goes to zero pressure and
the output marked OUT2 goes to the air supply pressure value.

1.5

FY301 – Operation, Maintenance and Instructions Manual

69

21

24

50

(1.97)

(0.954)

(0.83)

(2.72)

6,5

MOUNTING HOLES FOR M6x1

SCREWS (2 PLACES)

(0.25)

22

13

39

(1.54)

(0.87)

(0.51)

ROTARY MAGNET

VALVE POSITIONER

All dimensions are in mm (in)

THREADS FOR SCREWS

M6x1 (4 PLACES)

INPUT
PRESSURE
1/8-27 NPT

OUTPUT
PRESSURE 2
1/8-27 NPT

OUTPUT
PRESSURE 1
1/8-27 NPT

TERMINAL

WIRING

OUTPUT 2

1/4-18 NPT

Leave, at least, a 150mm (5.8 in) space,
for zero and span adjustments with the
magnetic tool.

INPUT

1/4-18 NPT

OUTPUT 1

1/4-18 NPT

EXHAUST
ORIFICES

ELECTRICAL

CONNECTION

SOCKET SET
PLUG

(3.27)

(10.24)

(1.77)(1.77)(1.77)

(1.53)

(2.17) (1.83)

(2.42)

(0.94)

(2.10) (0.94) (0.94)

(4.45)

(1.95) (2.17)

(0.35)

LINEAR MAGNET

TRAVEL DIMENSION A

Note: Dimensions in mm (in)

*ONLY FOR 50 AND 100 mm TRAVELS.

UP TO 100 mm (3.94)

UP TO 50 mm (1.97)

UP TO 15 mm (0.59)
UP TO 30 mm (1.18)

43 mm (1.7)

105 mm (4.13)
181 mm (7.12)

67 mm (2.64)

64.5

(2.54)

(0.71)

18

(0.89)

22.5

(1.30)

33

(0.59)

15

A

(2 PLACES)

15 *

(0.59)

HOLE 6.3 (0.25)Ø

Dimensional Drawing

1.6

REMOTE HALL SENSOR

Installation

Electronic Housing Rotat ing

The electronic housing can be rotated in order to offer a better to position the digital display and/or
better access to the field connections. To rotate it, release the housing rotation set screw. See figure

1.6. The local indicator itself can also be rotated. See section 5, figure 5.2.

Figure 1.5 – FY301 Dimensional Drawing

Figure 1.6 - Housing Rotation Set Bolt

1.7

FY301 – Operation, Maintenance and Instructions Manual

Reach the wiring block by removing the electrical connection cover. This cover can be locked closed
by the cover locking screw. To release the cover, rotate the locking screw clockwise. See figure 1.7.

Electric Wiring

Figure 1.7 - Cover Locking Bolt

The access to the signal cables to the terminal wiring can be done through of one of the electronic
housing orifices and can be connected to a conduit. The wiring block has screws on which fork or
ring-type terminals can be fastened. See figure 1.8. Use a plug to block the electrical connection not
used. Tight it well and use thread sealing tape.

If the user choose protection against noise induced by atmospheric discharges, overloads, weld
machines and machines in general, it will be necessary to install a transient protector (Protector
acquired separately).

Test and communication terminals allow, respectively, to measure the current in the 4 - 20 mA loop,
without opening it, and to communicate with the transmitter. To measure it, connect a multimeter in
the mA scale in the "" and "" terminals, and to communicate, use a Hart® configurator in the
"COMM" and " " terminals. For convenience, there are three ground terminals: one inside the
cover and two externals, located close to the conduit entries.

Attention to prevent the accidental feeding of the test terminals. This occurrence will cause damages
in the equipment.

In hazardous areas with explosion proof requirements, the covers must be tightened with at least 8 turns. In
order to avoid the penetration of humidity or corrosive gases, tighten the o-ring until feeling the o-ring
touching the housing. Then, tighten more 1/3 turn (120°) to guarantee the sealing. Lock the covers using
the locking bolts.

Conduit threads should be sealed by means of code-approved sealing methods.
Explosion proof, non-incendive and intrinsic safety certification are standards for FY301.
For a complete list of available certificates, please consult http://www.smar.com.

1.8

Figure 1.8 - Wiring Block

HAZARDOUS AREAS

Installation

CORRECT

WIRES

INCORRECT

The figure 1.9 - Conduit installation diagram shows the correct installation of the conduit, in order to
avoid penetration of water or other substance, which may cause malfunctioning of the equipment.

Figure 1.9 - Conduit Installation Diagram

Use of twisted pair (22 AWG or greater than) cables is recommended.

Avoid routing signal wiring close to power cables or switching equipment.
The FY301 is protected against reverse polarity, and can withstand up to 50 mA and power supply

of ± 60 Vdc without damage.
The FY301 connection could be done according to the figures 1.10, 1.11 and 1.12.

It is also recommended to ground the shield of shielded cables at one end only. The non-grounded
end must be carefully isolated.

The configurator can be connected to the communication terminals of the positioner or at any point
of the signal line by using the interface HPI311-M5P with “alligator” clips.

CD600

GROUND THE SIGNAL LOOP AT ONE
END OR LEAVE IT
UNGROUNDED

CONFIGURATOR

Figure 1.10 - FY301 Wiring Diagram

1.9

FY301 – Operation, Maintenance and Instructions Manual

CONFIGURATOR

CD600

OUTPUT

CURRENT SUPPLY

GROUND THE SIGNAL LOOP AT ONE
END OR LEAVE IT
UNGROUNDED

CONFIGURATOR

Figure 1.11 - FY301 Wiring Diagram - Connected in the Smar Transmitter

The FY301 has an equivalent impedance of 550 Ohms. Make sure that the current supply or analog
output of DCS, CLP or single loop controller powering the positioner is capable to handle a voltage
drop of 11 V for each positioner (550 x 0.02 = 11 Volts).

NOTE

If you are using two positioners in series as e. g., working in split range, the resulting impedance will be

1.100 Ohms. Therefore, the analog output should be capable to handle a voltage drop of 22 Volts.

Connection of the FY301 in multidrop configuration should be done as in figure 1.12. Note that a
maximum of two positioners can be connected on the same line and that they should be connected
in series.

Figure 1.12 - FY301 Wiring Diagram in Multidrop Configuration (Split Ranges)

1.10

Air Supply Requirements

COMPRESSOR

INTAKE

COMPRESSOR

AFTERCOOLER

CONDENSATE

SEPARATOR
WITH DRAIN

AIR RECEIVER

WITH DRAIN

Before the air supply is connected to the positioner, we recommend the hose is opened freely for 2
to 3 minutes to allow any contamination to be blown out. Direct the air jet into a large paper towel to
trap any water, oil, or other foreign materials. If this indicates that the air system is contaminated, it
should be properly cleaned.

As soon as the positioner is connected and powered, internal air leakage will provide protection
against corrosion and prevent moisture inside. For this reason, it is strongly recommended to keep
the positioner pressurized as much as possible.

Recommendations for I ns tr um e nt Air Supply System

Instrument air quality shall be superior to that of industrial compressed air. Humidity, suspended
particles and oil may impair the instrument operation, either temporarily or permanently in case of
internal parts wearing.

As per standard ANSI/ISA S7.0.01 - 1996 - Quality Standard for Instrument Air, instrument air shall
have the following characteristics:

Dew point
Size of particles (airborne)
Oil content
Contaminants

This standard recommends that the compressor intake be located in an area free from process spills
and fitted with and adequate filter. It also recommends the use of non-lubricated type compressors,
in order to prevent air contamination by lubricating oil. Where lubricated type compressors are
adopted, there shall be used means to make the air oil free.

Figure 1.13 and 1.14 shows a typical system for air supply and air quality conditioning.

10°C below minimum instrument temperature

40 µm (maximum)

1 ppm w/w (maximum)

free from corrosive flammable gases

Installation

OIL AND WATER

MIST PREFILTER

WITH DRAIN

Figure 1.13 - Air Supply System

AIR

DRYER

Figure 1.14 - Air Quality Conditioning System

DRY AIR

AFTERFILTER

1.11

FY301 – Operation, Maintenance and Instructions Manual

approved with the

ent modification or replacement parts supplied by other than authorized

representative of Smar is prohibited and will void the certification.

Recommendations for mounting Approved Equipments wit h t he I P 66 W
certifications (use in saline atmospheres)

NOTE

This certification is valid for stainless steel positioners manufactured,
certification IP 66 W. All positioner external material, such as gauge, plugs, connections etc.,
should be made in stainless steel.
The electrical connection with 1/2” – 14NPT thread must use waterproofing sealant. A non­hardening silicone sealant is recommended.
The instrum

Rotary and Linear Magnet

Magnet models are linear and rotary, for utilization on linear and rotary actuators.

1.12

Figure 1.15 – Linear and Rotary Magnet Models

Magnet Centralizer Devic e

NOTE

linear bracket.

NOTE

Centralizer device of linear magnet is used only for
universal rotary bracket.

Figure 1.16 – Centralizer device of linear magnet

Figure 1.17 - Centralizer device of rotary magnet

Installation

Centralizer device of linear magnet is used for all type of

Remote Hall Sensor

The remote Hall magnetic sensor is an accessory recommended for high temperature and extreme
vibration applications. It prevents excessive wear of the equipment and, consequently, the reduction
of its useful time.

Figure 1.18 - Remote Hall Sensor

1.13

FY301 – Operation, Maintenance and Instructions Manual

Remote Hall Sensor

Positioner

WARNING

Explosions could result in death or serious injury, besides financial damage. Installation of this

according to the local environmental protection method. Before proceeding with the installation

The positioners are marked with options of the protection type. The certification is valid only when

type is indicated by the user. Once a particular type of protection is selected, any

The electronic housing installed in hazardous areas must have a m inimum of 6 f ully engaged

he cover until it touches the housing. Then, tighten more 1/3 turn (120°) to guarantee the

Consult the Appendix A for further information about certification.

The electric signals on the remote sensor’s connection to equipment are of low intensity. Therefore,
when installing the cable inside the conduit (maximum limit 20 m eters length) keep it away from
possible sources of induction and/or magnetic interference. The cable supplied by Smar is shielded
for excellent protection against electromagnetic interference, but despite this protection avoid the
cable sharing the same conduit with other cables.

The connector for remote Hall sensor is easy handling and simple installation.

See the installation procedure:

Figure 1.19 – Connecting the Cable to the

Figure 1.20 – Connecting the Cable to the

Installation in Hazardous Areas

instrument in an explosive environment must be in accordance with the national standards and

check the certificate parameters according to the environmental classification.

The instrument modification or replaced parts supplied by any other supplier than the authorized
representative of Smar Equipamentos Industriais Ltda is prohibited and will void the Certification.

the protection
other type of protection can not be used.

threads. Lock the housing using the locking screw (Figure 1.6).

Tighten the cover with at least 8 turns to avoid the penetration of humidity or corrosive gases.

Tighten t
sealing. Lock the covers using the locking screw (Figure 1.6).

1.14

Installation

WARNING

The electric connection’s entries must be connected or closed using the appropriate Ex-d metal

Do not remove the positioner covers when power is ON.

WARNING

In hazardous zones with intrinsically safe or non-incendive requirements, the circuit entity

ground bus shall be insulated from panels and mounting enclosures. Shield is optional. If used,

It is not recommended to remove the positioner cover when the power is ON.

Explosion/Flame Proof

cable gland and/or metal blanking plug with certified IP66 rating.

The standard plugs provided by Smar do not have an Ex-d/XP certification. For Explosion proof
applications a certified plug must be used. Consult Smar for certified plugs.

The electrical connection with NPT thread must use waterproofing sealant. A non-hardening
silicone sealant is recommended.

Intrinsically Safe

parameters and applicable installation procedures must be observed.
To protect the application, the positioner must be connected to a barrier. Match the parameters

between barrier and the equipment (Consider the cable parameters). Associated apparatus

be sure to insulate the end not grounded. Cable capacitance and inductance plus Ci and Li must
be smaller than Co and Lo of the associated Apparatus (see appendix “A” for Ci and Li values).

For free access to the Hart bus in the explosive environment, ensure the instruments in the loop
are installed in accordance with intrinsically safe or non-incendive field wiring practices. Use only
Ex Hart communicator approved according to the type of protection Ex-i (IS) or Ex-n (NI).

1.15

FY301 – Operation, Maintenance and Instructions Manual

1.16

Section 2

PILOT

RESTRICTION

PILOT

DIAPHRAGM

SPOOL

DIAPHRAGM

AIR SUPPLY

NOZZLE

PIEZO VANE

SPOOL

PILOT CHAMBER

VENT 2

OUTPUT 2

OUTPUT 1

VENT 1

SPRING

OPERATION

Transducer Functional Description

The main parts of the output module are the pilot, servo, Hall effect position sensor and the output
control circuit.

The control circuit receives a digital setpoint signal from the CPU and a feedback signal from the
position sensor.

The pneumatic circuit is based on a well-known and widely adopted technology, which is described on
item baffle and nozzle and Spool Valve.

Figure 2.1 - Schematic Pneumatic Transducer

A piezoelectric disk is the flapper in the pilot stage. The flapper is deflected when the control circuit
applies a voltage. A small stream of air flowing through the nozzle is obstructed causing an increase in
pressure in the pilot chamber; this is called the pilot pressure.

The pilot pressure is too low, with a small flowing capacity, and for this reason, it must be amplified in
the servo section. The servo section includes a diaphragm in the pilot chamber and a smaller one in the
spool chamber. The pilot pressure applies a force at the pilot chamber’s diaphragm, which, in the
equilibrium state, will be equal to the force applied by the spool valve at the smaller diaphragm, which
is in the spool chamber.

Upon every position change caused by the positioner, the pilot pressure increases or decreases, as
explained in the pilot stage section. Such change in pilot pressure causes an upward or downward
valve travel, which alters the pressure at Output 1 and Output 2, until a new balance is reached (new
valve position).

2.1

FY301 - Operation, Maintenance and Instructions Manual

Electronics Functional Description

Refer to the block diagram (Figure 2.2). The function of each block is described below.

A/D

Receives the 4 - 20 mA signal and converts it in the digital format for the CPU.

D/A

Receives the signal from the CPU and converts it to an analog voltage proportional to the desired
position, used by the control.

Control

Controls the valve position according to data received from the CPU and the Hall effect sensor
feedback.

Position Sensor

Measures the actual position and feedback to the control and CPU.

Temperature Sensor

Measures the temperature of the Transducer Circuit.

Isolation

Isolates the 4 - 20 mA signal from the piezoelectric signal.

EEPROM
A non-volatile memory that stores configuration data as a backup if the FY301 main board be replaced.

Central Processing Unit (CPU), RAM, PROM and EEPROM

The CPU is the intelligent portion of the positioner, being responsible for the management and
operation of block execution, self-diagnostics and communication. The program is stored in PROM. F or
temporary storage of data there is a RAM. The data in the RAM is lost if the power is switched off,
however the device also has a nonvolatile EEPROM where data that must be retained is stored.
Examples of such data are calibration and valve configuration.

HART Modem

The function of this system is to make possible the information exchange between Smar programmer
and the positioner, over digital communication using Hart
information transmitted by Smar programmer on the current line. A “1” is represented by 1200 Hz and
“0” by 2200 Hz. The frequency signal is symmetrical and does not affect the DC -level of the 4 - 20 mA
signal.

Power Supply

The positioner circuit receives supply from a 4 - 20 mA power supply or takes power of Loop Line to
power the positioner circuit that is limited to 3.8 mA to work properly.

Display Controller

Receives data from the CPU and controls the (LCD) Liquid Crystal Display.

Local Adjustment

Local adjustment is provided by means of two magnetically actuated switches with no ex ternal electric
or mechanical contact, by using a magnetic screwdriver.

Piezo Flapper Nozzle

The unit flapper nozzle converts the movement of piezoelectric into a pneumatic signal to control
pressure in the pilot chamber.

Restriction

The restriction and the nozzle form a pressure-divided circuit. Air is supplied to the nozzle through a
restriction.

Spool

The spool ensures a quick valve positioning by providing a greater airflow than one provided by the
restriction.

®

protocol. Modulates and demodulates digital

2.2

Operation

Pressure Sensors

Measure the pressures of air pressure supply, pressure at Output 1 and Output 2. Av ailable for Hart®
reading.

NOTE

The pressure sensor’s circuit board is optional. (See request code, session 6, K1 opt ion) .

Pressure Sensor Selector

Selects the sensor to be read from.

Sensor IN: Measures air supply pressure.
Sensor OUT1: Changes the pressure in output 1.
Sensor OUT2: Changes the pressure in output 2.

Figure 2.2 - FY301 Block Diagram

2.3

FY301 - Operation, Maintenance and Instructions Manual

The Local Indicator

The LCD-Local Indicator is required for signaling and for operation in local adjustment.
Normal Indicator

During normal operation, the FY301 remains in the monitoring mode and the display indicates the valve
position, either as a per centage or as a c urrent readout. The magnetic tool activates the local
programming mode, by inserting it in orifice “Z” on the housing.

The possible configuration and monitoring operation are shown on figure 2.3.
Upon receiving power, the FY301 initializes the position indication on the display, by showing model

FY301 and its software version (X.XX).

Figure 2.3 - Local Indicator

Monitoring
During normal operation, FY301 remains in the monitoring mode. Figure 2.4 shows the positioning in
percentage.

The display simultaneously shows readout and some other information.

Normal displaying is interrupted when the magnetic tool is placed in orifice “Z” (Local Adjustment),
entering the programming mode local adjustment.

The above mentioned figure shows the result of tool insertion in orifices Z and S, which inform,
respectively, movement and actuation of the selected options.

2.4

Figure 2.4 - Typical Indicator

Section 3

In case of a multidrop network configuration for classified areas, the entity parameters allowed for the area shall be

Imaxj = Maximum allowable current to be applied to the instrument j

CONFIGURATION

The FY301 Smart Valve Positioner is a digital instrument with the most up-to-date features a controlling
device can possibly have. The Hart
connected to a computer, in order to be configured in a very simple and complete way. Such computers
connected to the positioners, are called host computers. They can be either primary or secondary
masters. Even though Hart

®

masters in a bus. Usually, the primary host, plays the supervisory role and the secondary host plays
the configurator role.

The positioners may be connected in a point-to-point or multidrop type network. In a point-to-point
connection, the equipment’s address must be "0". In a multidrop network, if the devices are recognized
by their addresses, the positioners should be configured with a network address between "1" and "15”.
In this case, the positioners’ output current is kept constant, at 4 mA each if the acknowledgement is
via Tag, the positioners addresses may be "0", and even in a multidrop configuration.

strictly observed. Therefore, the following shall be checked:

≥ Σ

Ca
Voc ≤ min [Vmaxj] Isc ≤ min [Imaxj]

Where:

Ca, La = Allowed capacitance and inductance on the bus

, Lij = Non protected internal capacitance/Inductance of positioner j (j = up to 15)

Ci

j

Cc, Lc = Cable capacitance and inductance

= Barrier open circuit voltage

V

oc

= Barrier short circuit current

I

sc

= Maximum allowable voltage to be applied to the instrument j

Vmax

j

Cij + Cc La ≥ Σ Lij + Lc

®

digital communication protocol enables the instrument to be

is a master-slave type of protocol, it is possible to work with up to two

NOTE

The FY301 Smart Valve Positioner includes a very encompassing set of Hart
make it possible to access the functionality of what has been implemented. Such commands according
to the Hart
controls commands and specific commands. A detailed description of such commands may be found in
the manual entitled Hart

Smar developed two types of configurators for its Hart

®

protocol specifications, and ar e grouped as universal commands, common practice

®

command specification - FY301 Smart Valve Positioner.

®

devices: CONF401 configurator and HPC401
configurator. CONF401 supports Windows platform (95, 98, 2000, XP and NT) and UNIX. It provides a
simple configuration, field device monitoring, and abi lity to analyze data and modify field device
performance. The HPC401, is the most up-to-date technology in Palm platform Handheld portable
computers.

The operation and use characteristics of each one of the configurators are in their specific manual.

The figures below show the front of the Palm based configurator and CONF401 screen with active
advanced configuration.

®

command functions that

3.1

FY301 - Operation, Maintenance and Instructions Manual

LIST

LIST

TO CONNECT TO THE

CONTRAST

APPLICATIONS
BUTTON

GRAY
KEYBOARD

MENU ACTIVE

ALFANUMERICAL
KEYBOARD

HOME

NOTEBOOK

ON/OFF

HPC
301

TASKS

3

2

1

TEXT
EDITOR

a

b

c

ADDRESS

Figure 3.1 - Smar Configurator

ROLLING
BAR

CALCULATOR
SEARCH

NUMERICAL
KEYBOARD

ALLIGAT OR CLAMPS
TRANSMITTER

3.2

Figure 3.2 - CONF 401 Screen - Active Advanced Configuration

The TSO stands for "Tight Shut Off", which assure the valve is totally closed, avoiding leakage on the
valve seat. If the TSO value is 5% the valve will only start moving from the close position (for instance)
on 5% of the controller signal. The TSO D stands for "Tight Shut Off Deadband". When the value is 1%,
the valve will start to move from the close position on 6%. On 4% the valve shall close totally.

Configuration Resources

By means of the Hart
be accessed:

 Positioner’s Identification and Manufacturing Data;
 Remote movement;
 Special characterization function according to a 16-point configurable curve;
 Flow characterization (Linear, equal percentage and quick opening);
 Monitoring of all device variables: input, setpoint, deviation and modulated output temperature;
 Diagnostic (Preventive maintenance);
 Positioner diagnostic and fail determination;
 PID Controller Configuration;
 Device Configuration;
 Device Maintenance.

The operations between the configurator and the positioner, do not interrupt the valve positioning, and
do not disturb the positioner operation. The configurator can be connected to the same pair of wires as
the 4-20 mA signal, up to 2 kilometers away from the positioner.

®

Configurator, the FY301 firmware allows the following configuration features to

Identification and Manufacturing Data

The following information about the FY301 manufacturing and identification data is available:

 TAG - 8-character alphanumeric field for identification of the positioner.
 DESCRIPTION

be used to identify service or location.

 MESSAGE - 32-character alphanumeric field for any other information, such as the name of the

person who made the last calibration, some special care to be taken, or if a ladder is needed for
physical access to the positioner.

 DATE - The date may be used to identify a relevant date, such as the last calibration, the next
calibration or the installation. The date is presented in the American standard e.g. (Example: Oct
30, 2003) is automatically assumed after the choice of these items.

 UNIQUE ID - Used to identify the device and in construction of Hart
 DEVICE INFORMATION - This button allows to read device identification and data recorded in the

factory.

- 16-character alphanumeric field for additional identification of the positioner. May

Configuration

®

long address.

These information items cannot be modified. They are read directly from the circuit memory.

Monitoring

This function allows remote monitoring up to 4 different of positioner variables at the same time. The
time to start the reading is around 5 seconds. The values are always updated. Altogether, 20 items
could be monitored. These items are: valve actual position in percentage, input in percentage of
adjusted current range (before the limits and f low linearization), input current in mA or %, device
temperature in Celsius and in Fahrenheit degrees, etc..

NOTE

3.3

FY301 - Operation, Maintenance and Instructions Manual

7

6

5

Linear
Equal Percentage 1:25

1:33
1:50

Equal Percentage
Equal Percentage

Quick opening 1:25

1:33
1:50

Quick opening
Quick opening

2

1

3

4

OPENING

100

80
60
40
20

0

SP

100 20

30

40 50 60 70 80 90 100

7

6

5

1

2

3

4

Device Configuration

Besides the configuration services for equipment operation, the FY301 allows self-configuration.
Services from this group are related to: write protection, security position, flow characterization function,
local indication and table configuration.

 WRITE PROTECTION: The configurator only shows that the writing is authorized if the W2 jumper

from main board is connected to the pins under the word DOWN.

 CHARACTERIZATION FUNCTION – It changes the valve flow characteristics. For example, if

equal percentage flow characterization is applied to a valve with linear flow characteristics, it will
work as an equal percentage valve. Manufacturer documentation contains the valve inherent
characteristic. The options for applied flow characterization are:

 LOCAL INDICATIONS - The FY301 local indicator has three well-defined fields: information field

with icons informing the active status of the configuration, 4 ½ numerical digit field to value
indication and alphanumeric field with 5-digit for status information and units.

The FY301 accepts up to two local indicator configurations, showed with a 2 second pause between
each one. The parameters that can be selected to visualization are showed below:

PARAMETERS DESCRIPTION

PV % Process variable in percentage.
PV (mm) Process variable in mm.
SP % Setpoint in percentage.
SP(mm) Setpoint in mm.

TABLE CONFIGURATION - Through the Table button, a flow characterization curve with up to 16
points can be configured. This allows the construction of a special flow characterization curve, like
linear combinations and equal percentage or other characterizations.

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)

3.4

Table 3.1 - Valve Characteristic Curve

Advanced Configuration

This function affects valve advanced configurations. With advanced configuration is possible to
configure the valve type, if it is air-to-open or air-to-close, valve action, setpoint limits and split-range.

Device Maintenance

This group includes maintenance services, related to obtainment of necessary information to the device
maintenance and performance test. Some of the available services are: position adjustment and valve
performance test, general information about the actuator and the valve, operations count, password
level, code number model and performance.

Trim

There are two trim operations: Current trim and Temperature trim. Current trim allows to calibrate the
positioner input current reading and Temperature trim is the temperature reference to the positioner
temperature sensor.
There are two current trims available:

• 4 mA TRIM: is used to adjust the input current reading correspondent to 0%.

• 20 mA TRIM: is used to adjust the input current reading correspondent to 100%.

Setup

This function allows to calibrate the value travel automatically (Auto Setup), the points of the totally
opened or totally closed travel with higher precision (lower and higher position), to adjust the opening
and closing times and the proportional and integral actions of PI control, the state of air supply, the
magnet, the sensor Hall, setup and the piezo voltage conditions.

During the setup process, the local display, if installed, will show the setup progress, in which the
positioner takes the following steps:

10% - It opens or closes the valve, depending on the initial value of the piezo voltage;
20% - The positioner checks if the flat cable is connected, or if the position sensor is working properly.

In case of error, the message “HALL” will appear at local indicator;

30% - The positioner checks whether the magnet is used linear or rotary valve;
40% - At this point, the positioner opens or closes the valve, depending on the initial position. Case the

spool is obstructed or if the positioner has no air supply, the message “FAIL MOVE” will appear in the
local indicator.

50% - At this moment, the positioner checks if the magnet is connected to the valve. If not, the
message “MGNT” will appear in the local indicator;

60% - The positioner places the valve to 50%. The setup process could remain at this step if the Kp
value is low;

70% - At this moment, the valve is close to 50%. The setup process could remain at this step, if the Kp
value is high;

80% - The positioner adjusts its internal references to place the valve in 50%. The setup process could
remain at this step, if the Kp value is high;

90% - The positioner checks if the magnet is correctly mounted (arrow in arrow). If not, the message
“MGNT” will appear in the local indicator;

100% - End of setup;

Multidrop Configuration

ADDRESSING - FY301 contains a variable that define the device address in a Hart® network. Hart
addresses assume values from "0" to "15", the addresses "1" to "15" are specific addresses to
multidrop connection. When FY301 is configured to multidrop , it means that the local indicator is
showing “MD” and the address is an value from "1" to "15".

FY301 is factory configured with address "0".

Configuration

®

3.5

FY301 - Operation, Maintenance and Instructions Manual

Diagnostic

This function allows engineering unit configuration, the parameters for diagnostic purposes and shows
positioner general conditions. See parameters:

 Dead zone (0 to 100%)
 Odometer Curse (mm/rad)
 Odometer Value Maximun (mm/rad)
 Engineering Unit (mm/rad or %)
 Dead zone Reversal (%)
 Reversal Limit (uni)

Backup

Data transference from transducer to main board must be done immediately after the assembly when
there is a transducer or main board substitution.

This process is automatically done when the positioner is powered. If necessary, the user could force
transference using the option Read from Sensor.

The option Write on Sensor could be used to record changes previously made, for example, in Kp, Tr,
etc., in transducer memory. The previous values for Kp, Tr, etc. will be lost.

Pressure Sensor

This function allows pressure trim adjustment, to view applied pressure status and to configure
positioner input pressure in order to activate the alarm via Hart
input pressures are not in accordance with configured values.

Factory

This option is used only in the factory, and the user cannot access it.

®

communication, in case the applied

3.6

Section 4

In this section the “Magnetic Tool” will be referred to as “TOOL”, and the orifices identified by “S” and “Z” will be
“ORIFICE S” and “ORIFICE Z”, respectively.

Writing must be enabled during the configuration and after configuration must be disabled again.

PROGRAMMING USING LOCAL
ADJUSTMENT

Move Jumper “W1" to position “ON” to enable the local adjustment. This jumper is located on top of the
main electronic circuit board.

There are two orifices on the positioner, under the nameplate, identified by “S” and “Z” respectively,
which provide access to two magnetic switches actuated by means of a magnetic tool (Refer to Figure

4.1).

NOTE

Table indicates the results for the actions on orifices “Z” and “S” in FY301.

ORIFICE ACTION

Z
S

The digital display is required in order to show the programming performed via local adjustment.

Function browsing.
Selects the displayed function.

W1 and W2 Jumpers Connection

W1 Jumper connected in ON

If W1 Jumper is connected in ON, adjustment local enabled, the parameters of the programming tree
can be modified.

W2 Jumper connected in DOWN

With W2 Jumper connected in this mode, write protected, the positioner protects the configuration
against improper modifications.

Figure 4.1 - Local Adjustment Orifices

NOTE

4.1

FY301 - Operation, Maintenance and Instructions Manual

S

Op

Z

Z Z Z Z Z Z Z

DISPLAY

AIR_T

TYPE

CHAR

MODE

SETUP

TR

SP%

TR

S

Lin

EP50

HY50

Tab

S

Lind

Linr

Rotd

Rotr

Auto
Man

S

Z

ZZZZ

S ACTION

ROTATIONZ

ZZZZ

Z

LOPOS

LOPOS

SP%

KPKPTIME

TIME

UPPOS

UPPOS

Local Programming Tree

The programming tree is a tree shaped structure with a menu of all available software functions, as
shown on figure 4.3.

While in local adjustment, it is possible to browse through all configuration options by keeping the
magnetic tool in orifice “Z”. Upon choosing the option as described, place the tool in orifice “S” in order
to actuate.

By keeping the tool in orifice “S” it is possible to continuously actuate the selected parameter, since this
is a numeric value. Actions by increment are performed by repeatedly placing and removing the
magnetic tool until reaching the desired valve.

Figure 4.2 - Jumpers W1 and W2

The user shall perform every parameter actuation judiciously, since actuation writes configuration parameters
on a permanent basis and does not require confirmation. Once an actuation is performed it is assumed to be
the desired configuration.

4.2

Figure 4.3 - Local Programming Tree

NOTE

Adjustable Parameters

TYPE - Valve Type
This parameter enables the user to configure valve type as well as the type of action associate to the
valve. These are the options:

Lind: Linear and Direct;
Linr: Linear and Reverse;
Rotd: Rotary and Direct;
Rotr: Rotary and Reverse.

CHAR - Valve Characterization Curve

This parameter allows the user to configure the type of valve characterization curve. Options are as
follows:

Lin: Linear;
EP50: Equal Percentage 50%;
HY: Hyperbolic.
Tab: 16 points - table (Configurable).

MODE - Operation Mode

This parameter allows the user to choose operation mode. Upon turning the positioner on, it will always
be in automatic mode, but it is possible to choose the operation mode. During operation there are the
following options:

Auto - Automatic Mode
During automatic mode the positions is set in accordance with the input 4 to 20 mA current signal.
While in automatic mode, local actuation in the SP% parameter is not allowed.
Man - Manual Mode
During manual mode the position is set in accordance with the SP% parameter value,
independently from the input current. This is the only mode in which the SP% parameter can be
actuated.

SP % - Set Point
This parameter represents the desired position value. While in "Manual" mode, it is possible to actuate
this parameter remotely, independently from the input current. While in automatic, it is calculated from
the input current level.

LOPOS - Lower Position
This parameter allows the lower position calibration as per the input current, usually 4 mA unless it is in
split range operation. During calibration, notice if the control becomes saturated, that is, if the valve no
longer moves in the desired direction. Should such a situation occur, the user shall actuate in the
opposite direction to the valves movement. Calibration is performed in terms of percentage.

UPPOS - Upper Position
This parameter allows the upper position calibration as per the input current, usually 20 mA unless it is
in split range operation. During calibration, notice if the control becomes saturated, that is, if the valve
no longer moves in the desired direction. Should such a situation occur, the user shall actuate in the
opposite direction to the valves movement. Calibration is performed in terms of percentage.

TIME - Setpoint Variation Time
This allows the configuration of the setpoint variation rate. The unit is expressed in seconds. It is
adjustable in the following range: 1 to 60.
TIME close to 60 causes the setpoint variation to be slower.
TIME close to 1 causes the setpoint variation to be faster.

KP - Proportional Gain

This parameter makes it possible to adjust the servo control proportional gain. It is adjustable within the
following range: 0.5 to 45.
For linear valves, typical KP values are between 35 and 45.
For rotary valves, typical KP values are around 8.

TR - Integral Time
This parameter makes possible to adjust the servo control integral time. It is adjustable within the
following range: 0 to 999 minutes/repetition.
For linear valves, typical TR values are around 2 minutes/repetition.
For rotary valves, typical TR values are around 8 minutes/repetition.

Programming using Local Adjustment

4.3

FY301 - Operation, Maintenance and Instructions Manual

In most cases, steps 1 and 2 are sufficient to provide a good calibration.

Setup - Auto Positioning
After configuring the valve type by means of parameter TYPE, the AUTO SETUP parameter shall be
actuated. During the adjustment procedure the positioner will be in a state of auto positioning and the
message "SETUP” will be f lashing on t he display. During this process the control parameters are
determined and the 0% and 100% trim is performed. This operation lasts approximately 4 minutes.
While configuring the valve type as described above, the user shall browse up to parameter SETUP
(tool in orifice Z) and place the tool in orifice S in order to initiate the previous auto positioning of the
valve.

Air to Close / Air to Open (AIR_T)

This option configures the air pressure effect on the positioner.
If the positioner operates in “direct action”:

• It should be configured for AIR_OPEN, if the air is to open the valve

• It should be configured for AIR_CLOSED, if the air is to close the valve

In case the positioner is operating in “reverse action”:

• It should be configured for AIR_OPEN, if the air is to close the valve

• It should be configured for AIR_CLOSED, if the air is to open the valve

Procedure for Val ve C alibration

STEP 1
Select valve type by means of the menu TYPE, browsing at least once through the options (Lind, Linr,
Rotd, and Rotr).

STEP 2
Setup

In order to start self-calibration, browse up to the parameter SETUP and insert the tool in S.

NOTE

STEP 3

Set the KP so as to lower the value overshoot (the overshoot will require adjustment after the TIME as
adjusted). The lower the KP is, the lower the overshoot will be, but valve positioning will be slower. Set
TR in a value where the position does not oscillate and control is capable of quickly reaching the final
position.

STEP 4
Time Adjustment (TIME)

Perform TIME adjustment for quick valves in order to increase the time and decrease the overshoot.

STEP 5
Zero Adjustment by means of LOPOS (Lower Position)

At this moment, current shall be in the position which corresponds to 0% as, for example, 4 mA. A more
practical way of performing this adjustment is to place the tool in orifice S, thus allowing the parameter
to be continually actuated (increased or decreased). Upon noticing the valve action around the desired
point, remove the tool from orifice S and slowly change its value on an increment by increment basis,
that is, by repeatedly placing and removing the tool in orifice S until reaching the desired point. At a
certain point, it is more convenient to perform the adjustment on an increment by increment basis so as
to avoid the risk of exceeding beyond the desired value.

STEP 6
Span Adjustment by means of UPPOS (Upper Position)

At this moment, current shall be in the position which corresponds to 100% as, for example, 20 mA.
The procedure is similar to the one described for zero adjustment.

STEP 7
Air to Close / Air to Open (AIR_T)

This option configures the air pressure effect on the positioner.
If the positioner operates in “direct action”:

• It should be configured for AIR_OPEN, if the air is to open the valve.

• It should be configured for AIR_CLOSED, if the air is to close the valve.

In case the positioner is operating in “reverse action”:

• It should be configured for AIR_OPEN, if the air is to close the valve.

• It should be configured for AIR_CLOSED, if the air is to open the valve.

4.4

Section 5

NOTE

Equipment installed in hazardous atmospheres must be inspected in compliance with the IEC60079-17 standard.

MAINTENANCE PROCEDURES

General Information

FY301 Valve Positioners are extensively tested and i nspected before delivered to the end us er.
Nevertheless, during their design and development, consideration was given to the possibility of repairs
by the end user, if necessary.

In general, it is recommended that the end user do not try to repair printed circuit boards. Instead, he
should have spare circuit boards, which may be ordered from Smar whenever necessary.

The maintenance procedure is a set of techniques with the purpose to keep the positioners with higher
time of use (useful life), to operate in safe conditions and to promote costs reduction. The different
maintenance types are described during this section.

Recommendations for mounting Approved Equipments with the IP66 W
certifications (use in saline atmospheres)

This certification is valid for stainless steel positioners manufactured, approved with the certification
IP66 W. All positioner external material, such as gauge, plugs, connections etc., should be made in
stainless steel.
The electrical connection with 1/2” – 14NPT thread must use a sealant. A non-hardening silicone
sealant is recommended.
The instrument modification or replacement parts supplied by other than authorized representative
of Smar is prohibited and will void the certification.

Corrective Main t en ance for the Positioner

Maintenance not planned, with the purpose to locate and to repair problems in the positioners operating
in continuous work, or either, specifically to suppress defects already presented by the equipment.

The diagnostic are a set of methods to detect, to locate and eventually to correct errors and problems
or even verify fail effects in the positioner.

Diagnostics without Configurator

In order to carry out the diagnostics, refer to table 5.1.

DIAGNOSTICS

SYMPTOM PROBABLE ERROR SOURCE

Positioner Connections
Check wiring polarity and continuity.

POSITION

SHOWN ON DISPLAY

Power Supply must be a current source
Check signal input current. Minimum current for positioner operation is 3.8 mA.

Electronics Failure

Check circuit boards for bad connections and replace them for spare boards.

NOTE

Check up on air leaks.

NO RESPONSE

TO INPUT SIGNAL

Air Supply Pressure

Check the air supply pressure. The input pressure to positioner shall be between 20 psi and 100 psi.

Calibration

5.1

FY301 – Operation, Maintenance and Instructions Manual

SLOW ACTUATOR

Obstructed Restriction and/or Blocked Output
Observe the following procedures described in this Manual: Output Connections and Restriction Cleaning.

OSCILLATING

ACTUATOR

Calibration

Adjust parameter Kp.
Adjust parameter Tr.

DIAGNOSTICS

RESPONSE

TOO FAST ACTUATOR

RESPONSE

Adjust parameter Kp or Time to Open or Time to Close.

Adjustment Parameters are Too High

Adjust parameter Kp or Time to Open or Time to Close.

Table 5.1 - FY301 Diagnostics without the Configurator

Diagnostic with Configurator

If the positioner is on and w ith the communication circuit and t he processing unit working, the
configurator can be us ed for diagnostic, in case of problems with the positioner. The configurator
should be connected to the positioner according to the wiring diagrams show on Section 1.

Error Messages

The error messages inform the diagnostic through the self diagnostic of errors and malfunctioning.
When the configurator is communicating with the positioner, the user is informed on any problem
found, through the self diagnostic. At the FY301 positioner, the error messages always alternate with
the information on the top line of the configurator’s display. Table 5.2 lists the error messages and more
details on corrective action.

ERROR MESSAGES POTENTIAL SOURCE OF PROBLEM

PARITY ERROR - The line resistance is not according to the technical characteristics.
OVERRUN ERROR
CHECK SUM ERROR

FRAMING ERROR

NO RESPONSE

LINE BUSY - Other device using the line.
CMD NOT IMPLEMENTED - Software version not compatible between configurator and positioner.
DEVICE BUSY - Positioner carrying out an important task, e.g., local adjustment.

POSITIONER MALFUNCTION

COLD START - Start-up or reset due to power supply failure.

OUTPUT FIXED

OUTPUT SATURATED - Position out of calibrated span or in fail-safe (Output current in 3.9 or 21 mA).

2 OUT OF LIMITS

1 OUT OF LIMITS

LOWER RANGE VALUE TOO HIGH - The lower range value > (Upper limit of minimum span range).
LOWER RANGE VALUE TOO LOW - The lower range value < (Upper limit of range).
UPPER RANGE VALUE TOO HIGH - The upper range value > 110 % x (Upper limit of range).
UPPER RANGE VALUE TOO LOW - The upper range value < - 10 % (Lower limit of range).

- Excessive noise or ripple.

- Low level signal.

- Interface damaged.

- Power supply or battery voltage of the configurator lower than 9 V.

- Positioner line resistance is not according to technical characteristics.

- Positioner not powered.

- Positioner not connected or damaged.

- Positioner configured in multidrop mode being accessed by ON LINE SINGLE UNIT.

- Positioner reversibly powered (polarity is reversed).

- Interface damaged.

- Power supply or battery voltage of the configurator lower than 9 V.

- Voltage to pressure transducer disconnected.

- Voltage to pressure transducer failure.

- Operating in local mode with fix position.

- Connected in burnout.

- Temperature out of operating limits.

- Temperature sensor damaged.

- Position out of operation valve range.

- Voltage to pressure transducer damaged or not connected.

- Positioner with error configuration.

5.2

ERROR MESSAGES POTENTIAL SOURCE OF PROBLEM

The numbers indicated between parentheses refer to Figure 5.4 – Exploded View.

UPPER AND LOWER RANGE VALUES

- Both the upper and lower points are outside the positioner range limit.

OUT OF LIMITS

SPAN TOO SMALL

- The difference, between the upper and lower points, is less than the allowed by the
positioner.

ACTUAL POSITION - The actual valve position was above of the upper range limit.
ACTUAL POSITION - The actual valve position was below of the lower range limit.
PASSED PARAMETER TOO LARGE - Parameter above operating limits.
PASSED PARAMETER TOO SMALL - Parameter below operating limits.
CONTROL LOOP SHOULD BE IN

- Indicates that the operation could affect the output.

MANUAL
CONTROL LOOP MAY BE RETURNED TO

AUTO

- After the operation is complete, you are reminded to return the loop to automatic
control.

Table 5.2 – FY301 Diagnostics with the Configurator

Disassembly Procedur e for Maintenance

1. Apply air pressure in the positioner input, without applying power supply. Verify if there is any
air leakage in output 1 (OUT1). In case of air leakage in output 1, it is necessary to check
mechanical parts.

2. Remove the restriction. Verify if the restriction is not obstructed. (See restriction cleaning
procedure).

3. Disassemble the equipment as shown:

Maintenance Procedures

the

Maintenance – Mechanical Parts

1. Verify if the spool valve is moving freely.

2. Verify if the spool valve is not obstructed with dirty.

3. Verify if there is any obstruction inside the FY pneumatic block and at the exhausts.

4. Verify if the diaphragm integrity.

5. Verify if the nozzle is dirty.

Maintenance – Electronic Parts

Electronic Circuit

To remove the plate of the circuit (5) and the indicator (4), first release the cover locking bolt (6)
from the side not marked "Field Terminals", and after that release the cover (1).

Figure 5.1 – FY301 Disassembled

NOTE

5.3

FY301 – Operation, Maintenance and Instructions Manual

ATTENTION

electrostatic load proof.

The circuit boards have CMOS components that can be damaged by electrostatic discharges. Verify the correct
procedures to manipulate CMOS components. Also it is recommended to store the circuit boards in packs with

Release the two screws (3) that fix the main board circuit and the indicator. Pull out the indicator, then
the main board (5).
Verify the firmware version; must be version 2.12, 2.13 or higher. Mount the equipment; apply pressure
supply of 30 PSI and power on the equipment. If the equipment does not initialize and the display does
not light on, proceed to the following steps:

1. Disconnect the analog board from the digital board (17);

2. Case the equipment initializes, replace the analog circuit board (18 - part number 400-0060)
or the analog circuit board for pressure sensors, if this replacement does not solve the
problem, it is necessary to replace the main circuit board (5 - part number 209-0320).

Perform the auto-setup. After the setup, verify if the positioner is working properly. For that, apply 12mA
input and be sure that the valve goes to the position correspondent to the 50% travel. If it does not
occur, do the following:

1. Connect the Smar configurator to the input electric wires; select "Monitoring" option on the menu
screen;

2. Apply 4 mA and verify through the configurator if SP% is equal to 0%;

3. Apply 20 mA and verify through the configurator if SP% is equal to 100%;

4. If the values above were different, execute the 4 mA and 20 mA current trim;

5. Verify the Hall position sensor reading through the configurator. Apply pressure directly to the valve
actuator and verify if there is change in the Hall position sensor reading (18 - part number 400-

0840), (65000 means that the position sensor is not being read) and the defect can be at the analog
circuit board or analog circuit board for pressure sensors (18 - part number 400-0060) or the
position sensor set (35 - part number 400-0090); replace the boards and perform the step 2 through
step 4 again;

6. Verify the piezo voltage at the configurator;

7. The piezo voltage value must be between 30 and 70 Volts.

To verify the Hall position sensor value and the piezo voltage, do the following:

1. Set the valve in 50% travel;

2. With the configurator, go to the “monitoring” mode and choose two parameters: Hall value and

piezo voltage;

3. The piezo voltage values must be the most closed possible to 26000 to 38000;

4. The piezo voltage values must be between 30 and 70 Volts. If the voltage is not between these

values, proceed with the piezo calibration by using the FYCAL calibration device (check at
www.smar.com for more details on the FYCAL).

Preventive Main t en ance for the Positioner

Planned Maintenance, consists in the set of procedures and anticipated actions to keep the device
functioning, is effectuate with the special objective to prevent the occurrence of fail. Through
adjustments, proves and measures according to the specified values, made before the appearing of
defects. The preventive maintenance is recommended in the maximum period of one year, or when the
process stops.

Disassembly Procedur e

Voltage to Pressure Transducer

To remove the transducer from the electronic housing, the electrical connections (in the field terminal
side) and the main board connector must be disconnected.

Loosen the hex screw (6) and carefully unscrew the electronic housing from the transducer, observing
that the flat cable is not excessively twisted.

5.4

CAUTION

Do not rotate the electronic housing more than 270° without disconnecting the electronic circuit from the power supply.

.

Maintenance Procedures

Figure 5.2 – Transducer Rotation

NOTE

The numbers indicated between parentheses refer to Figure 5.4 – Exploded View

1. Remove the flat cable cover (17) by releasing the Allen screws (15). When removing this cover
(17), take care to do not damage the internal board: disassembly it with care. (This part can not be
washed);

2. Remove the analog board (18);

3. Remove the electric piezo base (24) (This part can not be washed);

4. Remove the restriction (20) for cleaning;

5. Remove the intermediate set (27) and check the diaphragms integrity; if necessary, clean the
diaphragms with water and neut ral detergent; after that, wash them with alcohol, dry before
mounting;

6. Remove the spool valve (29); the cleaning is made with water and neutral detergent; after that,
wash it with alcohol, dry before mounting. Do not use lubricant of any kind in this part;

7. The pneumatic block (31) can be completely washed with water and neutral detergent, after that,
wash it with alcohol and verify if it is completely clean, without dust or any kind of impurity. For that,
apply dry compressed air in all block orifices;

8. Verify if the position sensor cover (33) does not have indication of water or humidity. (This part can
not be washed);

9. Verify if the position sensor flat cable is damaged, twisted, cut or oxidate.

Piezo Electric Calibration - FYCAL

To mount the positioner:

1. Mount the piezoelectric base (24) on the jig;

2. Apply 20 psi at the air pressure input;

3. Apply 0 Volts, then 100 Volts DC and after 0 Volts again (to avoid hysteresys error);

4. Apply 50 Volts DC to the piezoelectric base;

5.5

FY301 – Operation, Maintenance and Instructions Manual

5. Verify the pilot chamber pressure measured in the correspondent FYCAL gauge. The pressure

must be between 5.8 and 6.2 psi. In case it is different, made the adjustment rotating the superior
disc of piezoelectric base set;

6. Once reached the previous adjustment, apply 0 Volts again and verify that the pressure in the

pilot chamber must be between 2 psi. After that, apply 100 Volts and verify that the pressure must
be between 12 and 13 psi;

7. Apply 50 V olts AC to the piezoelectric base. Verify the pilot chamber pressure measured in

manometer, it must be between 5.8 and 6.2 psi. In case it is different, made the adjustment again
and rotating the superior disc of piezoelectric base set and repeating the procedure, to reach the
specified values.

8. When these values are reached, the piezoelectric base calibrated;

9. After the piezoelectric base calibration, proceed with the positioner final checking;

10. Re-assembly all positioner set with the calibrated piezoelectric base;

11. Execute the auto-setup for the positioner;

12. If the piezoelectric base voltage is not at indicated range, it means that the piezoelectric base

needs a new calibration or it needs to be replaced.

Restriction Cleaning Procedure

The air flows to the nozzle through a restriction. Verify the restricti on cleaning from time to time to
assure a positioner good performance.

1. Be sure that the air supply is not pressurizing the equipment.

2. With an appropriate tool, remove the transducer serial number plate. (New models have the
plate placed on the opposite side of the transducer).

3. Remove the restriction screw using an adequate tool;

5.6

Maintenance Procedures

4. Remove the o-ring’s with an appropriate tool;

5. Dive the part in petroleum base solvent and dry it with dry compressed air (apply the
compressed air directly in the smaller orifice for the air to get out through the bigger orifice).

6. Introduce the appropriate tool (PN 400-0726) into the restriction orifice to prevent any possible
obstruction;

7. Mount the o-rings again and screw the restriction in the positioner.

8. Apply instrument air into the equipment and it shall work normally.

Change of the Filter Elements

Replace the positioner filter elements (28 - part number 400-0655) with a minimum stated period of 1
(one) year.

The instrument air supply must be clean, dry and non-corrosive, following standards indicated for the
American National Standard “Quality Standard for Instrument Air" - (ANSI/ISA S7.0.01 - 1996).

If the instrument air does not comply with the above mentioned standards, the user has to consider
replacing the positioner filter elements more frequently.

Exhausts Ports

Air is vented to the atmosphere through the two exhausts ports located behind the transducer
nameplate and 4 output of the opposite side from gage. Any strange object interfering or blocking the
exhaust port may degrade the positioner performance. Clean the exhausts periodically by spraying it
with a solvent.

Never use oil or grease in the spool valve; lubricants may degrade the positioner performance.

ATTENTION

5.7

FY301 – Operation, Maintenance and Instructions Manual

Electronic Circuit

Plug transducer connector and power supply connector to main board (5). Attach the display to the
main board. Observe the four possible mounting positions (Figure 5.2). The  mark on the display
indicates up position.

Package Content

Figure 5.3 – Four Possible Positions for Local Indicator

Anchor the main board and indicator with their screws (3). After tightening the protective cover (1),
mounting procedure is complete. The positioner is ready for powering and testing..

Electrical Connections

The plug must obligatorily be i nstalled in the electric connection not used, preventing the humidity
entrance.

When receiving the equipment, verify the package content. The number for items marked with (*) must
be in accordance with the number of positioners delivered.

Positioner
Adequate mounting brackets

- For the positioner

- For the magnet
Magnetic tool for local adjustment (*)
Centralizer transmitter device (*)
Cleaning device for the restriction (*)
Operation, maintenance and instructions manual (*)

5.8

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1

2

3

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4

5

6

7

8

9

10

6

11

12

13

39

14

15

16

17

"

18

19

20

21

22

23

24

27

28

30

29

40

31

23

32

19

35

33

34

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36

37

38

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ACCESSORIES

ORDERING CODE DESCRIPTION

SD-1

HPC401*

HPI311-M5P*

400-0726

* For equipment updates and HPC401 software, just check: http://www.smarresearch.com .

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PARTS DESCRIPTION POSITION CÓDE

HOUSING (NOTE 1)

COVER (INCLUDES O-RING)

Cover Locking Bolt
Sensor Locking Bolt (M6 Without Head Screw)
External Ground Bolt
Identification Plate Fixing Bolt
Orings Cover (NOTE 2)
Local Adjustment Protection Cover
DIGITAL INDICATOR GLL1438 (for old electronic main board GLL1011)

DIGITAL INDICATOR (for new main boards GLL1443 e 1451)
TERMINAL INSULATOR

TERMINAL INSULATOR FOR 4-20mA POSITION FEEDBACK (packaged
with 6 units) (NOTE 7)

MAIN ELECTRONIC CIRCUIT BOARD (include digital indicator and
mounting kit)

TERMINAL HOLDING BOLT HOUSING

MOUNTING KIT FOR MAIN ELECTRONIC BOARD (new boards GLL1443
and 1451), (2 bolts with spacers and retention washers)

CONNECTION COVER

. Connection Cover Bolt
. Buna-N Neck O-ring (NOTE 2)
ANALOG BOARD without Pressure Sensor GLL1012 (version K0)
ANALOG BOARD for Pressure Sensor GLL1204 (version K1)
ANALOG BOARD for Position Feedback GLL1456 (version K2)
PIEZO BASE SET

. Base and Block O-ring (NOTE 2)
. Restriction
. Restriction External O-ring (NOTE 2)
. Restriction Internal O-ring (NOTE 2)
. Syntherized Bushing
. Analog indicator (Gage - Stainless Steel and Brass) (NOTE 5)
ASSEMBLED DIAPHRAGM (include hall tube, mechanical part and
O-rings)

Magnetic tool for local adjustment.

Hart® HPI311-M5P for the PalmOS platform, including the configuration package for the Smar and generic
transmitters.

Just the Hart® interface.

Needle cleaning device for the restriction.

SPARE PARTS LIST

1 and 13

15,16 and 17

19,20,21,22, 23,24 and 25

CATEGORY

(NOTE 4)

8

6
7

14

9
2

10

4

11

5 400-1334 A

12

3

15
16
18
18
18

19
20
21
22
23
25

27

400-1314-3 (NOTE 6)

400-1307 (NOTE 6)

204-0120
400-1121
204-0124
204-0116
204-0122
204-0114

400-1305
400-1310

400-0058

400-1329

204-0119

400-0560

400-1320 (NOTE 6)

400-0073
204-0113
400-0060
400-0840
400-1341

400-1318 (NOTE 6)

400-0085
344-0165
344-0155
344-0150
400-0033
400-1120

400-1321 (NOTE 6)

-

-

-

-

-

-

B

-

A

A

B

B

A

-

B

-

-

-

A

B
B
B
B
B
B

B

7032"

SPARE PARTS LIST

PARTS DESCRIPTION POSITION CÓDE

PNEUMATIC BLOCK SET

. Base & Block O-ring (NOTE 2)
. Syntherized Bushing
. Analog indicator (Gage - Stainless Steel and Brass) (NOTE 5)
. Filtering Element
. Spool valve
. Spool valve Spring
. Stainless steel Filter- 1/4" NPT - includes filtering element
. Vent Plug - Stainless Steel

HALL COVER SET

. Hall Cover Bolt
. Hall Support + Hall Sensor + Flat cable

REMOTE EXTENSION SET

CABLE SET + CONNECTOR
1/2" NPT (Ex d) INTERNAL SOCKET SET PLUG IN BICHROMATIZED

CARBON STEEL
1/2" NPT (Ex d) INTERNAL SOCKET SET PLUG IN 304 SST

1/2" NPT INTERNAL SOCKET SET PLUG IN BICHROMATIZED CARBON
STEEL
1/2" NPT INTERNAL SOCKET SET PLUG IN 304 SST

M20 X 1.5 (Ex d) EXTERNAL SOCKET SET PLUG IN 316 SST
PG13.5 (Ex d) EXTERNAL SOCKET SET PLUG IN 316 SST

3/4" NPT (Ex d) ADAPTER IN 316 SST
TRANSDUCER SET

MAGNETS
. Linear magnet 30mm
. Linear magnet 50mm
. Linear magnet 100mm
. Rotary magnet
MOUNTING BRACKET SCREW FOR POSITIONER ASSEMBLY (packaged

with 12 units)

19,23,25,28,29,30,31 and

32

19
23
25
28
29
40
30
32

33 (or 36), 34 and 35

34
35

38

37
39

39

39

39

39
39

39

NOTE 3

-

-

-

-

- 400-1190 -

400-1317 (NOTE 6)

400-0085
400-0033
400-1120
400-0655
400-0653
400-0787
400-1383
400-0654

400-1319 (NOTE 6)

400-0092
400-0090

400-1322 (NOTE 6)

400-1325 (NOTE 6)

400-0808

400-0809

400-0583-11

400-0583-12

400-0810
400-0811

400-0812

400-1316 (NOTE 6)

400-0748
400-0035
400-0036
400-0037

1) Includes terminal isolator, bolts (cover locking, ground and terminal isolator) and identification plate without certification.

2) O-rings are packaged with 12 units.

3) Includes all transducer’s spare parts.

4) For category A it is recommended to keep in stock 25 parts installed for each set and 50 for category B.

5) The pressure gauges for supply pressure, output 1 or output 2, will be supplied with the wet parts in brass.

6) For code detailed, use the tables below.

7) Use only with K2 Positioner version.

Note

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CATEGORY

(NOTE 4)

A

-

-

-

-

A

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

A

-

-

-

-

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7033"

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CÓDE DESCRIPTION

400-1314-3 HOUSING; FY301

Option Communication Protocol
H
R
Option Electrical Connection
0
A
B

400-1314-3 * * * * TYPICAL ORDERING CODE

* Choose the desired option

CÓDE DESCRIPTION

400-1307 Cover

0
1

H0
H1

P0
P8
P9

400-1307 * * * TYPICAL ORDERING CODE

* Choose the desired option.

Option Type

Hart & 4-20 mA
Hart & 4-20 mA + Position Feedback

Without window for display
With window for display

Option Material

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

DETAILED CODE WHEN ORDERING OF SPARE PARTS

½ NPT
M20 X 1,5
PG13,5

Option Material

Aluminum (IP/Type)

H0

Stainless Steel (IP/Type)

H1

Aluminum - for saline atmospheres (IPW/Type X)

H2

Aluminum Copper Free (IPW/Type X)

H4

Option Painting

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Gray Munsell N 6,5

P0

Without Painting

P8

Safety Blue Epoxy - Electrostatic Painting

P9

7034"

)

CÓDE DESCRIPTION

400-1316 Transducer Set; FY30X

Option Indication Gage
0
6
7
8
9

A

Without Gage
01 Gage - Input
01 Gage – Output 1
02 Gage – Input and Output 1
02 Gage – Output 1 and 2
03 Gage

Option Action of Positioner
C

D

Single Action
Double Action

Option Material
H0

H1
Option Painting

P0
P8
P9

Option Standard of Manufacture
S0

Option Hall Remote Sensor
R0

R9
Option Special Sensor

K0

K2

400-1316 * * * * * * * TYPICAL ORDERING CODE

* Choose the desired option.

CÓDE DESCRIPTION

400-1317 Pneumatic Block Set; FY30X

0
7
9

C
D

Option Indication Gage

Without Gage
01 Gage – Output 1
02 Gage – Output 1 and 2

Option Action of Positioner

Single Action
Double Action

Option Material

H0
H1

P0
P8
P9

S0

K0

400-1317 * * * * * * TYPICAL ORDERING CODE

* Choose the desired option.

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Smar

Standard Mounting (Without Hall Remote Sensor)
Remote Mounting (adapted for Remote Sensor)

Without Special Sensor (compatible w/ main board until version 4)
With Pressure Sensors for Diagnostic (compatible w/ main board

K1

until version 3)
With 4-20mA Position Feedback (compatible w/ main board version 5

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture

Smar

Option Special Sensor

Without Special Sensor
With Pressure Sensor for Diagnostic (compatible w/ main board version 3,

K1

besides analog board GLL1204)

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"

7035"

H[523"⁄"Qrgtcvkqp."Ockpvgpcpeg"cpf"Kpuvtwevkqpu"Ocpwcn"

CÓDE DESCRIPTION

400-1318 Piezo Base Set; FY30X

0
6

H0
H1

Option Indication Gage

Without Gage
01 Gage – Input

Option Material

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

P0
P8
P9

S0

400-1318 * * * * TYPICAL ORDERING CODE

* Choose the desired option.

CÓDE DESCRIPTION

400-1319 Hall Cover Set; FY30X

H0
H1

P0
P8
P9

Option Material

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture

S0

R0
R9

KA
KB

400-1319 * * * * * TYPICAL ORDERING CODE

* Choose the desired option.

CÓDE DESCRIPTION

400-1320 Connection Cover; FY30X

Option
H0
H1

Material
Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting
P0
P8
P9

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture
S0

400-1320 * * * TYPICAL ORDERING CODE

* Choose the desired option.

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture

Smar

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Smar

Option Hall Remote Sensor

Standard Mounting (Without Hall Remote Sensor)
Remote Mounting (adapted for Remote Sensor)

Option Special Sensor

For Pneumatic Block without Pressure Sensors
For Pneumatic Block with Pressure Sensors

DETAILED CODE WHEN ORDERING OF SPARE PARTS

Smar

7036"

DETAILED CODE WHEN ORDERING OF SPARE PARTS

CÓDE DESCRIPTION

400-1321 Assembled Diaphragm; FY30X

H0
H1

P0
P8
P9

S0

400-1321 * * * TYPICAL ORDERING CODE

Option Material

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture

Smar

* Choose the desired option.

DETAILED CODE WHEN ORDERING OF SPARE PARTS

CÓDE DESCRIPTION

400-1322 Remote Extension Set; FY30X

H0
H1

P0
P8
P9

S0

400-1322 * * * TYPICAL ORDERING CODE

Option Material

Aluminum (IP/TYPE)
Stainless Steel (IP/TYPE)

Option Painting

Gray Munsell N 6,5
Without Painting
Safety Blue Epoxy - Electrostatic Painting

Option Standard of Manufacture

Smar

* Choose the desired option.

DETAILED CODE WHEN ORDERING OF SPARE PARTS

CÓDE DESCRIPTION

400-1325 Cable Set and Connectors for Hall Remote Sensor; FY30X

Option Cable Length

1
2
3
4
Z

400-1325 * TYPICAL ORDERING CODE

5 m
10 m
15 m
20 m
Special

* Choose the desired option.

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"

7037"

H[523"⁄"Qrgtcvkqp."Ockpvgpcpeg"cpf"Kpuvtwevkqpu"Ocpwcn"

7038"

Section 6

TECHNICAL CH A RACT E RISTICS

Functional Specifica t ions

Travel

Linear Motion: 3 - 100 mm
Rotary Motion: 30° - 120°

Input Signal

4 - 20 mA, 2 wires.

Power

Supplied by the 4-20 mA current loop. No external supply required.

Input Impedance

550 Ω.

Minimum Current

3.8 mA.

Communication Protocol

Hart® Communication Protocol (is superimposed on the current signal).

Protection against Reverse Polar ity

No damage occurs from reversal of normal supply current (4 - 20 mA) or from misapplication of up
to 50 mA.

Output

Output to actuator 0 -100% supply air pressure. Single or double-action.

Pressure Supply

1.4 - 7 bar (20-100 psi). Free of oil, dust and water.

Indication

4 ½ numerical digits and 5 alphanumerical digits (Liquid Cristal Display).

Hazardous Area Certifications

See appendix “A”.

European Directive Information

See appendix “A”.

Temperature Limits

Operation: -40 to 85°C (-40 to 185°F).
Storage: -40 to 90°C (-40 to 194°F).
Display: -10 to 75°C ( 14 to 167°F) operation.

-40 to 85°C (-40 to 185°F) without damage.
Remote Sensor: -40 to 105º C (-40 to 221ºF) operation.

Humidity Limits

0 to 100% RH.

Flow Characterization

Linear, Equal Percentage, Quick Opening, 16 freely selectable points.

Gain

Through software. Locally adjustable.

Travel Time

Through software. Locally adjustable.

Actual Position Sensing

Magnet (Non-contact), via Hall Effect.

6.1

FY301 – Operation, Maintenance and Instructions Manual

Performance Specif ic a t ions

Resolution

≤ 0.1% F.S.

Repeatability

≤ 0.1% F.S.

Hysteresis

≤ 0.1% F.S.

Consumption

0.35 Nm

1.10 Nm

3

/h (0.20 SCFM) at 1.4 bar (20 psi) supply.

3

/h (1.65 SCFM) at 5.6 bar (80 psi) supply.

Output Capacity

13.6 Nm

3

/h (8 SCFM) at 5.6 bar (80 psi) supply.

Ambient Temperature Effect

0.8%/20°C of span

Supply Pressure Effect

Negligible

Vibration Effect

±0.3%/g of span during the following conditions:

• 5 - 15 Hz at 4 mm constant displacement.

• 15 - 150 Hz at 2g.

• 150 - 2000 HZ at 1g.

Reference SAMA PMC 31.1 - 1980, Sec. 5.3, Condition 3, Steady State.

Electro-Magnetic Interference Effect

Designed to comply with IEC 801 and European Standards EN50081 and EN50082.

Physical Specifications

Electrical Connection

½ - 14 NPT, Pg 13.5 or M20 x 1.5.

Pneumatic Connections

Supply and output: ¼ - 18 NPT
Gage: 1/8 - 27 NPT

Material of Construction

Injected low copper aluminum with polyester painting or 316 Stainless Steel housing, with Buna-N
O-rings on covers (NEMA 4X, IP66).

Weight

Without display and mounting bracket: 2.7 kg. (Aluminum)

5.8 kg. (Stainless Steel)
Add for digital display: 0.1 kg.

Remote Sensor: 550 g.
Cable: 100 g. (For connectors plus 45 g/m)

6.2

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®

"

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MODEL SMART VALVE POSITIONER

FY301 HART

COD. Local Indicator

COD. Mounting Bracket

COD. Electrical Connections

COD. Type of Actuator

COD. Indication Gage

& 4 to 20 mA

Without Indicator

0
1

With Digital Indicator

0

Without Bracket

1

With Bracket

0
1
2

1/2" - 14 NPT (4)
1/2" - 14 NPT X 3/4 NPT (316 SS) - with adapter (5)
1/2" - 14 NPT X 3/4 BSP (316 SS) - with adapter (3)

1

Rotary - Single Action

2

Rotary - Double Action

3

Linear Stroke Up to 15 mm. - Single Action

4

Linear Stroke Up to 15 mm. - Double Action

5

Linear Stroke Up to 50 mm. - Single Action

6

Linear Stroke Up to 50 mm. - Double Action

7

Linear Stroke Up to 100 mm. - Single Action

Without Gage

0

With 1 Gage (Acrylic, Stainless steel and wetted parts in brass) - Input

6

With 1 Gage (Acrylic, Stainless steel and wetted parts in brass) -

7

Output 1
With 2 Gage (Acrylic, Stainless steel and wetted parts in brass) - Input

8

and Output 1

1/2" - 14 NPT X 1/2 BSP (316 SS) - with adapter (3)

3

A

M20 X 1.5 (6)

B

PG 13.5 DIN (7)

8

Linear Stroke Up to 100 mm. - Double Action

A

Linear Stroke Up to 30 mm. - Single Action

B

Linear Stroke Up to 30 mm. - Double Action

C

Without magnet (for linear actuator ) - Single Action

D

Without magnet (for linear actuator) - Double Action

Z

Others Specify

Whit 2 Gage (Acrylic, Stainless steel and wetted parts in brass)

9

- Output 1 and 2

A

With 3 Gage (Acrylic, Stainless steel and wetted parts in brass)
Others Specify

Z

SPECIAL OPTIONS (Leave it blank for no optional items)

COD. Housing

COD. Identification Plate

COD. Painting

COD. TAG Plate
J0 With TAG J1 Blank J2 According to user’s notes
COD. Sensor Mounting (1)

COD. Special Sensor

COD. Special
ZZ Leave it blank for no optional items

FY301 1 0 0 1 0

(1) Consult Smar for applications in classified areas.
(2) IPW/TYPEX tested for 200 hours according to NBR 8094 / ASTM B 117 standard.
(3) Options not certified for Hazardous Locations.
(4) Certificate for use in Hazardous Locations (CEPEL, NEMKO, EXAM, FM, CSA).

H0

Aluminum (IP/Type)

H1

316 Stainless Steel (IP/Type)

H2

Aluminum for saline atmosphere (IPW/Type X) (2)

I1

FM: XP, IS, NI, DI

I3

CSA: XP, IS, NI, DI

I4

EXAM (DMT): EX-IA, NEMKO: EX-D

I5

CEPEL: EX-D, EX-IA

P0

Gray Munsell N 6.5 Polyester

P8

Without Painting

P9

Blue Safety Epoxy – Electrostatic Painting

PD

Blue smooth diamond RAL5010 - Epoxy

R0

Full Mounting

R1

Remote sensor - 5 m cable

R2

Remote sensor - 10 m cable

R3

Remote sensor - 15 m cable

R4

Remote sensor - 20 m cable

R9

Remote Mounting (adapted for Remote Sensor, without cable and remote extension set)

RZ

Specify (*)

K0

Without special sensor

K1

With pressure sensors for diagnostic

K2

With 4-20 mA Position Feedback (open collector)

* * * * * * *

TYPICAL MODEL NUMBER

NOTES

H3

316 Stainless Steel for saline atmosphere (IPW/Type X) (2)

H4

Copper Free Aluminum (IPW/Type X) (2)

I6IOWithout certification

CEPEL: Ex-tb (explosive dust - Zone 21)

(5) Certificate for use in Hazardous Locations (CEPEL, FM, CSA).
(6) Certificate for use in Hazardous Locations (CEPEL, NEMKO, EXAM, FM).
(7) Certificate for use in Hazardous Locations (CEPEL, NEMKO, EXAM).

805"

H[523"⁄"Qrgtcvkqp."Ockpvgpcpeg"cpf"Kpuvtwevkqpu"Ocpwcn"

"

BFY BRACKET (1)

CODE Positioner Mounting Bracket (2)

CODE Magnet Mounting Bracket

COD. Positioner Mounting Bracket Material

COD. Magnet Bracket Material

COD. Optional Items
ZZ Leave it blank for no optional items

0

Without Bracket

1

Universal Rotary

2

Universal Linear - Yoke and Pillar Type
Linear - Yoke Type

3

Linear - Pillar Type

4

Others - Specify

Z

0

Without Bracket

1

Rotary
Linear up to 15 mm / 30 mm

2

Linear up to 50 mm

3

Linear up to 100 mm

4

Others - Specify

Z

7

Carbon Steel Bracket and Accessories in SST
Carbon Steel Bracket

C

Stainless Steel Bracket

I

Not applicable

N

Others - Specify

Z

C

I
N
Z

Carbon Steel Bracket
Stainless Steel Bracket
Not applicable
Others - Specify

BFY - 1 1 7 I . * TYPICAL MODEL NUMBER

(1) When choosing the remote sensor version, an additional “L” shape bracket is included, for 2” tube mounting.
(2) For customized mounting bracket, for different brands and models, please, consult www.smar.com.

806"

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CERTIFICATIONS INFORMATION

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Consult www.smar.com for the EC declarations of conformity for all applicable European directives
and certificates.

ATEX Directive (94/9/EC) – “Electrical equipment and protective system intended for use in
potential explosive atmospheres”

The EC-Type Examination Certificate had been released by Nemko AS (CE0470) and/or DEKRA
EXAM GmbH (CE0158), according to European Standards.
The certification body for Production Quality Assurance Notification (QAN) and IECEx Quality
Assessment Report (QAR) is Nemko AS (CE0470).

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Ex Standards:

IEC 60079-0 General Requirements
IEC 60079-1 Flameproof Enclosures “d”
IEC 60079-11 Intrinsic Safety “i”
IEC 60079-26 Equipment with equipment protection level (EPL) Ga
IEC 60529 Classification of degrees of protection provided by enclosures (IP Code)

Customer responsibility:

IEC 60079-10 Classification of Hazardous Areas
IEC 60079-14 Electrical installation design, selection and erection
IEC 60079-17 Electrical Installations, Inspections and Maintenance

Warning:

Explosions could result in death or serious injury, besides financial damage.
Installation of this instrument in an explosive environment must be in accordance with the national
standards and according to the local environmental protection method. Before proceeding with the
installation match the certificate parameters according to the environmental classification.

General Notes:
Maintenance and Repair

The instrument modification or replaced parts supplied by any other supplier than authorized
representative of Smar Equipamentos Industriais Ltda is prohibited and will void the Certification.

Marking Label

Once a device labeled with multiple approval types is installed, do not reinstall it using any other
approval types. Scratch off or mark unused approval types on the approval label.

For Ex-i protection application

- Connect the instrument to a proper intrinsically safe barrier.

- Check the intrinsically safe parameters involving the barrier, equipment including the cable and
connections.

- Associated apparatus ground bus shall be insulated from panels and mounting enclosures.

- When using shielded cable, isolate the not grounded cable end.

- Cable capacitance and inductance plus C
Apparatus.

For Ex-d protection application

- Only use Explosion Proof/Flameproof certified Plugs, Adapters and Cable glands.

- In an Explosion-Proof/Flame-Proof installation, do not remove the instrument housing covers when
powered on.

- Electrical Connection

In Explosion-Proof installations the cable entries must be connected through conduit with sealed
unit or closed using metal cable gland or closed using metal blanking plug, all with at least IP66
and Ex-d certification. For enclosure with saline environment protection (W) and ingress protection
(IP) applications, all NPT thread parts must apply a proper water-proof sealant (a non-hardening
silicone group sealant is recommended).

and Li must be smaller than Co and Lo of the Associated

i

C03"

H[523"⁄"Qrgtcvkqp."Ockpvgpcpeg"cpf"Kpuvtwevkqpu"Ocpwcn"

For Ex-d and Ex-i protection application

- The transmitter has a double protection. In this case the transmitter shall be fitted with appropriate
certified cable entries Ex-d and the electric circuit supplied by a certified diode safety barrier as
specified for the protection Ex-ia.

Environmental Protection

- Enclosure Types (Type X): Supplementary letter X meaning special condition defined as default by
Smar the following: Saline Environment approved - salt spray exposed for 200 hours at 35ºC. (Ref:
NEMA 250).

- Ingress protection (IP W): Supplementary letter W meaning special condition defined as default by
Smar the following: Saline Environment approved - salt spray exposed for 200 hours at 35ºC. (Ref:
IEC60529).

- Ingress protection (IP x8): Second numeral meaning continuous immersion in water under special
condition defined as default by Smar the following: 1 Bar pressure during 24hours. (Ref: IEC60529).

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CSA (Canadian Standards Association)

Class 2258 02 – Process Control Equipment – For Hazardous Locations (CSA1078546)

Class I, Division 1, Groups B, C and D
Class II, Division 1, Groups E, F and G
Class III, Division 1
Class I, Division 2, Groups A, B, C and D

Class 2258 04 – Process Control Equipment – Intrinsically Safe Entity – For Hazardous Locations (CSA 1078546)
Class I, Division 1, Groups A, B, C and D
Class II, Division 1, Groups E, F and G
Class III, Division 1

Model FY301 Valve Positioners; input supply 12-42 V dc, 4-20mA; Enclosure Type 4/4X; intrinsically safe with entity parameters:
Vmax = 28 V, Imax = 110 mA, Ci = 5 nF, Li = 12uH,
when connected through CSA Certified Safety Barriers as per Smar Installation Drawing 102A0833; T Code T3C @ Max
Ambient 40 Deg C; MWP 100 psi.
Note: Only models with stainless steel external fittings are Certified as Type 4X.

Special conditions for safe use:
Temperature Class T3C
Maximum Ambient Temperature: 40ºC (-20 to 40 ºC)
Maximum Working Pressure: 100 psi

FM Approvals (Factory Mutual)

Intrinsic Safety (FM 3009955)

IS Class I, Division 1, Groups A, B, C and D
IS Class II, Division 1, Groups E, F and G
IS Class III, Division 1

Explosion Proof (FM 3007267)
XP Class I, Division 1, Groups A, B, C and D

Dust Ignition Proof (FM 3009955)
DIP Class II, Division 1, Groups E, F and G
DIP Class III, Division 1

Non Incendive (FM 3009955)
NI Class I, Division 2, Groups A, B, C and D

Environmental Protection (FM 3009955)
Option: Type 4X or Type 4

Special conditions for safe use:
Entity Parameters:

C04"

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Vmax = 30 Vdc, Imax = 110 mA, Ci = 8 nF, Li = 12 uH

Temperature Class T4
Maximum Ambient Temperature: 60ºC (-20 to 60 ºC)

NEMKO (Norges Elektriske MaterielKontroll)

Explosion Proof (NEMKO 00ATEX305X)

Group II, Category 2 G, Ex d, Group IIC, Temperature Class T6, EPL Gb

Ambient Temperature: -20ºC ≤ Ta ≤ +60ºC
Working Pressure: 20-100 psi

Environmental Protection (NEMKO 00ATEX305X)
Options: IP66W or IP66

Special conditions for safe use:

Repairs of the flameproof joints must be made in compliance with the structural specifications provided by the manufacturer.
Repairs must not be made on the basis of values specified in tables 1 and 2 of EN/IEC 60079-1.

The Essential Health and Safety Requirements are assured by compliance with:

EN 60079-0:2012 General Requirements
EN 60079-1:2007 Flameproof Enclosures “d”

EXAM (BBG Prüf - und Zertifizier GmbH)

Intrinsic Safety (DMT 01 ATEX E 012)

Group II, Category 2 G, Ex d [ia], Group IIC, Temperature Class T6, EPL Gb

Supply and signal circuit for the connection to an intrinsically safe 4-20mA current loop
Ui = 28 Vdc, Ii = 93 mA, Pi = 700 mW, Ci ≤ 5 nF Li = Neg

Ambient Temperature: -20ºC ≤ Ta ≤ +60ºC

The Essential Health and Safety Requirements are assured by compliance with:

EN 60079-0:2012 +A11:2013 General Requirements
EN 60079-1:2007 Flameproof Enclosures “d”
EN 60079-11:2012 Intrinsic Safety “i”

CEPEL (Centro de Pesquisa de Energia Elétrica)

Intrinsic Safety (CEPEL 00.0017)

Ex d ia, Group IIC, Temperature Class T5/T6, EPL Gb

Entity Parameters:
Pi = 0.7 W, Ui = 30 V, Ii = 100 mA, Ci = 6.4 nF, Li = Neg

Ambient Temperature:

-20 to 65 ºC for T5

-20 to 40 ºC for T6

Protection by enclosure (CEPEL 00.0017)
Ex tb, Group IIIC, Temperature Class T100ºC/T85ºC, EPL Db

Ambient Temperature:

-20 to 65 ºC for T100ºC

-20 to 40 ºC for T85ºC

Explosion Proof (CEPEL 98.0008)
Ex d, Group IIC, Temperature Class T6, EPL Gb

Maximum Ambient Temperature: 40ºC (-20 to 40 ºC)

Protection by enclosure (CEPEL 98.0008)
Ex tb, Group IIIC, Temperature Class T85ºC, EPL Db

C05"

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Maximum Ambient Temperature: 40ºC (-20 to 40 ºC)

Environmental Protection (CEPEL 00.0017 AND CEPEL 98.0008)
Options: IP66W or IP66

The Essential Health and Safety Requirements are assured by compliance with:

ABNT NBR IEC 60079-0:2008 General Requirements
ABNT NBR IEC 60079-1:2009 Flameproof Enclosures “d”
ABNT NBR IEC 60079-11:2009 Intrinsic Safety “i”
ABNT NBR IEC 60529:2009 Classification of degrees of protection provided by enclosures (IP Code)
ABNT NBR IEC 60079-31:2011 Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure "t"

C06"

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CSA (Canadian Standards Association)

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FM Approvals (Factory Mutual)

NEMKO (Norges Elektriske MaterielKontroll) / EXAM (BBG Prüf - und Zertifizier GmbH)

C07"

H[523"⁄"Qrgtcvkqp."Ockpvgpcpeg"cpf"Kpuvtwevkqpu"Ocpwcn"

CEPEL (Centro de Pesquisa de Energia Elétrica)

C08"

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FM Approvals (Factory Mutual)

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C09"

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CSA (Canadian Standards Association)

C0:"

Appendix B

GENERAL DATA

Sensor?

Pressure
Sensor?

FINAL CONTROL ELEMENT DATA

AIR SUPPLY

___

PROCESS DATA

Hazardous Area
Calssification

Interference
Types

SITUATION DESCRIPTION

SERVICE SUGGESTION

USER INFORMATION

Further information about address and contacts can be found on www.smar.com/contactus.asp.

SRF – Service Request Form

FY Positioner

Model:

Serial Number:
TAG:

Remote
Position

Action:
Travel:
Configuration:

Type:
Size:
Travel:
Manufacturer:
Model:

Conditions:
Work Pressure:

FY290 ( ) Firmware Version: ______________________
FY302 ( ) Firmware Version: ______________________
FY400 ( ) Firmware Version: ______________________
_______________________________________
_______________________________________________________________________________________________

Yes ( ) No ( )

Yes ( ) No ( )

Rotary ( ) Linear ( )
15 mm ( ) 30 mm ( ) 50 mm ( ) 100 mm ( ) Other: ________ mm
Magnetic Tool ( ) Palm ( ) Psion ( ) PC ( ) Software: _________ Version: __________

Valve + Actuator ( ) Pneumatic Cylinder (ACP) ( ) Other:________________________
_______________________________________________________________________________________________
_______________________________________________________________________________________________
_______________________________________________________________________________________________
_______________________________________________________________________________________________

Dry and Clean ( ) Oil ( ) Water ( ) Other: _________________________________
20 PSI ( ) 60 PSI ( ) 100 PSI ( ) Other: ________ PSI

Sensor Number:

FY301 ( ) Firmware Version: ______________________
FY303 ( ) Firmware Version: ______________________

________________________________________

Non-Classified ( ) Chemical ( ) Explosive ( ) Other: ________________________________

Vibration ( ) Temperature ( ) Eletromagnetic ( ) Others: _______________________________

______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________

Adjustment ( ) Cleaning ( ) Preventive Maintenance ( ) Update / Up-grade ( )
Other: _________________________________________________________________________________________________________

Company: _____________________________________________________________________________________________________
Contact: ______________________________________________________________________________________________________
Title: _________________________________________________________________________________________________________
Section: ______________________________________________________________________________________________________
Phone: __________ _________________________ __________ _________________________ Extension:____________________
E-mail: _________________________________________________________________________ Date: ______/ ______/ __________

For warranty or non-warranty repair, please contact your representative.

B.1

FY301 – Operation, Maintenance and Instructions Manual

Returning Materials

Should it become necessary to return the positioner and/or configurator to SMAR, simply contact
our office, informing the defective instrument serial number, and return it to our factory.

In order to speed up analysis and solution of the problem, the defective item should be returned with
a description of the failure observed, with as much details as possible. Other information concerning
the instrument operation, such as service and process conditions, is also helpful.

Instruments returned or to be revised outside the guarantee term should be ac companied by a
purchase order or a quote request.

B.2

Appendix C

SMAR WARRANTY CER TIF ICATE

1. SMAR guarantees its products for a period of 24 (twenty four) months, starting on the day of
issuance of the invoice. The guarantee is valid regardless of the day that the product was
installed.

2. SMAR products are guaranteed against any defect originating from manufacturing, mounting,
whether of a material or manpower nature, provided that the technical analysis reveals the
existence of a quality failure liable to be classified under the meaning of the word, duly verified
by the technical team within the warranty terms.

3. Exceptions are proven cases of inappropriate use, wrong handling or lack of basic maintenance
compliant to the equipment manual provisions. SMAR does not guarantee any defect or
damage caused by an uncontrolled situation, including but not limited to negligence, user
imprudence or negligence, natural forces, wars or civil unrest, accidents, inadequate
transportation or packaging due to the user’s responsibility, defects caused by fire, theft or stray
shipment, improper electric voltage or power source connection, electric surges, violations,
modifications not described on the instructions manual, and/or if the serial number was altered
or removed, substitution of parts, adjustments or repairs carried out by non-authorized
personnel; inappropriate product use and/or application that cause corrosion, risks or
deformation on the product, damages on parts or components, inadequate cleaning with
incompatible chemical products, solvent and abrasive products incompatible with construction
materials, chemical or electrolytic influences, parts and components susceptible to decay from
regular use, use of equipment beyond operational limits (temperature, humidity, etc.) according
to the instructions manual. In addition, this Warranty Certificate excludes expenses with
transportation, freight, insurance, all of which are the customer’s responsibility.

4. For warranty or non-warranty repair, please contact your representative.
Further information about address and contacts can be found on www.smar.com/contactus.asp

5. In cases needing technical assistance at the customer’s facilities during the warranty period,
the hours effectively worked will not be billed, although SMAR shall be reimbursed from the
service technician’s transportation, meals and lodging expens es, as well dismounting/mounting
costs, if any.

6. The repair and/or substitution of defective parts do not extend, under any circumstance, the
original warranty term, unless this extension is granted and communicated in writing by SMAR.

7. No Collaborator, Representative or any third party has the right, on SMAR’s behalf, to grant
warranty or assume some responsibility for SMAR products. If any warranty would be granted
or assumed without SMAR’s written consent, it will be declared void beforehand.

8. Cases of Extended Warranty acquisition must be negotiated with and documented by SMAR.

9. If necessary to return the equipment or product for repair or analysis, contact us.
See item 4.

10. In cases of repair or analysis, the customer must fill out the Revision Requisition Form (FSR)
included in the instructions manual, which contains details on the failure observed on the field,
the circumstances it occurred, in addition to information on the installation site and process
conditions. Equipments and products excluded from the warranty clauses must be approved by
the client prior to the service execution.

11. In cases of repairs, the client shall be responsible for the proper product packaging and SMAR
will not cover any damage occurred in shipment.

C.1

FY301 – Operation, Maintenance and Instructions Manual

12. In cases of repairs under warranty, recall or outside warranty, the client is responsible for the
correct packaging and packing and SMAR shall not cover any damage caused during
transportation. Service expenses or any costs related to installing and uninstalling the product
are the client´s sole responsibility and SMAR does not assume any accountability before the
buyer.

13. It is the customer’s responsibility to clean and decontaminate products and accessories prior to
shipping them for repair, and SMAR and its dealer reserve themselves the right to refuse the
service in cases not compliant to those conditions. It is the customer’s responsibility to tell
SMAR and its dealer when the product was utilized in applications that contaminate the
equipment with harmful products during its handling and repair. Any other damages,
consequences, indemnity claims, expenses and other costs caused by the lack of
decontamination will be attributed to the client. Kindly, fill out the Declaration of
Decontamination prior to shipping products to SMAR or its dealers, which can be accessed at

www.smar.com/doc/declarationofcontamination.pdf

14. This warranty certificate is valid only when accompanying the purchase invoice.

and include in the packaging.

C.2

MOUNTING BRACKET FOR POSITI ONER – LINEAR STROKE VALVE

MOUNTING INSTRUCTIONS

1 –Attach the magnet to the magnet bracket

support before connect them to the valve
stem.

2 - The stem nuts should be used to fasten
the magnet bracket.

APPENDIX

3 – Mount the magnet assembly using the

nuts of the valve stem. The mounting
bracket has two parts that should be

mounted to the stem.

2 Mounting Instructions

CLAMPS

4 – Tighten the hex screw that join the two

parts of the magnet bracket. It will avoid
sliding of the two parts of the bracket during
the fastening of the stem nuts.

5 – Tighten the stem nuts.

6 – Attach the “clamps” to the positioner

bracket.
If your actuator is pillar type, go to step 15
to see the instructions.

BFY – MOUNTING BRACKET FOR POSITIONER FY 3

9 – Use the plate as a guidance to adjust

7 – Adjust the clamps according to the

width of the yoke and tighten the bolts
finger tight.

8 – Mount the positioner back plate. Tighten
the nuts finger tight.

the position of the positioner so that the
back plate is about 1 mm apart from the
magnet.

BACK PLATE

ADJUST

4 Mounting Instructions

2mm

to

4mm

10 – Fasten the nuts to fix the positioner

bracket to the yoke.
If the actuator is pillar type, fasten the U­clamp nuts.

11 – Mount the positioner to the plate and
tighten the hex screws. You can take the
back plate apart to facilitate the assembling.

12 – Move the positioner as to adjust the

Hall sensor tip in the center of the magnet.

Tighten the nuts after the adjustment.

A minimum distance of 2mm and a maximum

distance of 4mm is recommended between the

magnet external face and the positioner face.
For that, a centralizer device (linear or rotary)
must be used. The centralizer device is in the

positioner packing.

ATTENTION:

BFY – MOUNTING BRACKET FOR POSITIONER FY 5

13 – Put the pressure equivalent to the half
of the stem travel and adjust the height of
the bracket assembly to have the arrows
matching.

14 - Tighten the bolts to fasten the clamps
to the yoke.

If the actuator is pillar type, fasten the U­clamp nuts.

6 Mounting Instructions

MOUNTING DETAILS FOR THE PILLAR TYPE ACTUATOR

15 - This is the mounting bracket using U-

clamps to be mounted on pillar type
actuators.

16 – After assembling the U-clamps, follow
the steps 8 to 13.

ROTARY VALVE POSITIONER BRACKET

Rotary Valve Positioner Bracket Parts.

MOUNTING INSTRUCTIONS

1- Attach the clamps to the threaded

orifices existent on the actuator.
Do not tight them completely.

The bolts are not supplied with the
mounting bracket and they must be in
accordance with size and thread of the
actuator holes.

2- Attach the magnet bracket to the
Actuator extremity (NAMUR).

The end the valve shaft must comply with
Namur Standard.

2 Mounting Instructions

3 – Fasten the hex screw.

4 – Attach the magnet to the NAMUR

adapter.
Do not fasten the bolts completely, allowing
the magnet rotation.

5 – Mounting the positioner bracket
through the threaded rods.

BFY – MOUNTING BRACKET FOR POSITIONER FY 3

6 – Use the centralizer gadget to get the
bracket centralized with the magnet.

7 – Adjust the positioner bracket using the
centralizer gadget and the nuts to get the
height.

8 – Place the nut and washers.
Do not fasten the nuts completely.

4 Mounting Instructions

9 – Tighten the clamp bolts to fasten them
to the actuator.

10 – Fasten the positioner bracket bolts to
the clamps fastening.

11 – Remove the centralizer gadget and
fasten the positioner to the positioner
bracket.

BFY – MOUNTING BRACKET FOR POSITIONER FY 5

12 – Put the pressure equivalent to the half
of the stem and adjust the magnet position
to have the arrows matching.

13 – Tighten the bolts to fasten the magnet
to the magnet bracket.

6 Mounting Instructions