SMAR FY400 Owner's Operation And Maintenance Manual

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Smart Valve Positioner

OPERATION, MAINTENANCE AND INSTRUCTION MANUAL

FY400

F Y 4 0 0 M E

smar

Specifi cations and inf or m ation are subject to change withou t notice.

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

web: www.sm ar.com/contactus.asp

www.smar.com

FY400 Hart – Operation, Maintenance and Instructions Manual

This instructions manual includes information about specification, in stallation, operation and maintenance for the Smart Valve Positioner FY400 Series. The manual describes all FY400 Smar Valve Positioner Series functionalities.

Only qualified personnel should install, operate and perform FY400 maintenance.

Any doubt involving these instructions or (for) information not included in this manual, please contact the Smar Marketing Department for clarifications or more information.

SMAR - MARKETING DEPARTAMENT: +55 16 3946-3519

III

FY400 Hart – Operation, Maintenance and Instructions Manual

THIS MANUAL CONTAINS:

This manual contains the sections listed below. Each section has it own index. Consult the index of each section for a complete list of subsections.

INTRODUCTION Informs the manual content and describes the FY400 in short.

Section 1 - INSTALLATION

Shows information about insta llation on actuators and the FY400 electric and pneumatic connections.

Section 2 - OPERATION Clarifies details on the operation, how the FY400 works.

Section 3 - SPECIFICATIONS Describes the FY400 specifications and other related information.

Section 4 - LOCAL ADJUSTMENT Shows the FY400 local programming instructions.

Section 5 - CONFIGURATION Details the FY400 configuration instructions.

Section 6 - MAINTENANCE Describes troubleshooting and their solutions, and FY400 maintenance procedures.

Section 7 - SPARE PARTS FY400 spare parts and materials.

Introduction

INTRODUCTION

The FY400 is a smart positioner for linear or rota ry control valves, which may use single action (spring return) pneumatic actuators or double action actuators.

It is based on a field-proven piezo flapper and non-c ontacting Hall-effect pos ition sensor that provides reliable operation and safe performance. The digital technology used in the FY400 enables the choice of several types of flow characterizations of the final control element. In addition, it has an easy interface betw een the field and the control room among severa l interesting features that considerably reduce installation, operation and maintenance costs.

The FY400, besides the normal functions offered by other conventional posit ioners, offers the following functions:

Table – through a 16-point table, t he user may configure his ow n characterization curve, in addition to the regular valve characterization functions, such as linear, same percentage and quick hyperbolic opening.

Local Adjustment - not only for travel adjustment, but also flow characterization, tuning, operation mode, indication, set point and PID (proportional, integral, and derivative) parameters.

Password - three levels for different functions.

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

Auto Tuning - Automatic tuning of valve travel and PID parameters.

Auto Setup - It is an automatic procedure t hat allows the positioner to check the valve stroke

limits, giving, at the end of the procedure, a diagnosis indicating possible assembling problems.

Diagnostic - Permanent valve monitoring condition for preventive or predictive maintenance.

Get best results of the FY400 by carefully reading this instruction manual.

WARNING

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

FY400 Hart – Operation, Maintenance and Instructions Manual

This manual is compatible w ith version 2. XX, where 2 indicates softw are version and XX software release. The indication 2.XX means that this manual is co mpatible with any release of software version 2.

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 ma nual 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 obj ectivity and clarity, this man ual does not contain all the d etailed information on th e product and, i n addition, it does not cover every possible mounting, operation or m aintenance 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 Sm ar’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 a nd 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 safet y 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 respons ible for the inc orrect or inadequate handling of equipments run with pneumatic or hydraulic pressure or, still, subject to corrosi ve, 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 necessar y sending the equipment to Smar or any of its aut horized dealer. Moreover, the certificates are different and the user is responsible for their correct use.

Always respect the instructio ns provided in the Manual. Smar is not respons ible for an y 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

Table of Contents

TABLE OF CONTENTS

SECTION 1 - INSTALLATION ..................................................................................................................... 1.1

GENERAL .................................................................................................................................................................... 1.1

MOUNTING .................................................................................................................................................................. 1.1

PNEUMATIC CONNECTIONS .................................................................................................................................... 1.5

DIMENSIONAL DRAWING .......................................................................................................................................... 1.7

ELECTRONIC HOUSING ROTATION ........................................................................................................................ 1.8

ELECTRICAL WIRING ................................................................................................................................................. 1.9

OPTIONS OF DISPLAY ASSEMBLY ........................................................................................................................ 1.10

AIR SUPPLY .............................................................................................................................................................. 1.14

RECOMMENDATIONS FOR INSTRUMENT AIR SUPPLY SYSTEM ...................................................................... 1.14

ROTARY AND LINEAR MAGNET ............................................................................................................................. 1.15

MAGNET CENTRALIZER DEVICE ........................................................................................................................... 1.16

REMOTE SENSOR POSITION ................................................................................................................................. 1.17

INSTALLATION IN HAZARDOUS AREAS ................................................................................................................ 1.18

EXPLOSION/FLAME PROOF .............................................................................................................................................. 1.18

INTRINSICALLY SAFE ........................................................................................................................................................ 1.19

SECTION 2 - OPERATIONAL ..................................................................................................................... 2.1

POSITIONER FUNCTIONAL DESCRIPTION ............................................................................................................. 2.1

CIRCUIT FUNCTIONAL DESCRIPTION ..................................................................................................................... 2.2

DISPLAY ...................................................................................................................................................................... 2.4

SECTION 3 - TECHNICAL CHARACTERISTICS ....................................................................................... 3.1

FUNCTIONAL SPECIFICATIONS ............................................................................................................................... 3.1

PERFORMANCE SPECIFICATIONS .......................................................................................................................... 3.2

PHYSICAL SPECIFICATIONS .................................................................................................................................... 3.2

DIAGNOSTICS ............................................................................................................................................................ 3.3

STROKE LIMIT & REVERSALS ............................................................................................................................................. 3.4

MILEAGE ............................................................................................................................................................................... 3.5

SUPPLY PRESSURE ............................................................................................................................................................. 3.6

PST (PARTIAL STROKE TEST) & LOAD FACTOR .............................................................................................................. 3.6

DEVIATION ............................................................................................................................................................................ 3.7

ALARMS ................................................................................................................................................................................. 3.8

GRAPHS ................................................................................................................................................................................ 3.8

SECTION 4 - LOCAL PROGRAMMING ...................................................................................................... 4.1

LOCAL ADJUSTMENT ................................................................................................................................................ 4.1

MAGNETIC TOOL ....................................................................................................................................................... 4.1

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

LOCAL PROGRAMMING TREE .................................................................................................................................. 4.3

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

SECTION 5 - CONFIGURATION VIA HART® .............................................................................................. 5.1

CONFIGURATION RESOURCES ............................................................................................................................... 5.3

IDENTIFICATION AND MANUFACTURING DATA .................................................................................................... 5.3

MONITORING .............................................................................................................................................................. 5.4

DEVICE CONFIGURATION ........................................................................................................................................ 5.4

ADVANCED CONFIGURATION .................................................................................................................................. 5.5

DEVICE MAINTENANCE ............................................................................................................................................. 5.5

TRIM ............................................................................................................................................................................. 5.5

AUTOMATIC CONFIGURATION ................................................................................................................................. 5.5

MULTIDROP CONFIGURATION ................................................................................................................................. 5.6

DIAGNOSTIC ............................................................................................................................................................... 5.6

PRESSURE SENSOR ................................................................................................................................................. 5.6

FACTORY .................................................................................................................................................................... 5.6

VII

FY400 Hart – Operation, Maintenance and Instructions Manual

SECTION 6 - MAINTENANCE ..................................................................................................................... 6.1

GENERAL INFORMATION .......................................................................................................................................... 6.1

FY400 CORRECTIVE MAINTENANCE ....................................................................................................................... 6.1

FY400 DIAGNOSTICS WITHOUT CONFIGURATOR ................................................................................................ 6.1

FY400 DIAGNOSTICS WITH CONFIGURATOR ........................................................................................................ 6.2

DISASSEMBLY PROCEDURE FOR MAINTENANCE ................................................................................................ 6.2

REMOVAL OF THE ELECTRONIC HOUSING TRANSDUCER ............................................................................................ 6.2

DISASSEMBLED TRANSDUCER .......................................................................................................................................... 6.5

CHECKING THE PIEZO BASE SET CALIBRATION ............................................................................................................. 6.8

MAINTENANCE - MECHANICAL PARTS ................................................................................................................. 6.10

MAINTENANCE – ELECTRONIC PARTS ................................................................................................................. 6.11

FY400 PREVENTIVE MAINTENANCE ..................................................................................................................... 6.12

RESTRICTION CLEANING PROCEDURE ............................................................................................................... 6.12

CHANGE OF THE FILTERS ELEMENTS ................................................................................................................. 6.13

SECTION 7 - SPARE PARTS AND MATERIALS ....................................................................................... 7.1

PACKAGE CONTENT ................................................................................................................................................. 7.1

EXPLODED VIEW ....................................................................................................................................................... 7.2

ACCESSORIES ........................................................................................................................................................... 7.3

SPARE PARTS LIST ................................................................................................................................................... 7.3

ORDERING CODE ...................................................................................................................................................... 7.5

APPENDIX A - CERTIFICATIONS INFORMATION .................................................................................... A.1

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

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

CEPEL (CENTRO DE PESQUISA DE ENERGIA ELÉTRICA) .............................................................................................. A.2

IDENTIFICATION PLATE ........................................................................................................................................... A.3

APPENDIX B – SRF – SERVICE REQUEST FORM ................................................................................... B.1

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

APPENDIX C – SMAR WARRANTY CERTIFICATE ................................................................................... C.1

APPENDIX - BFY ............................................................................................................................................ 1

VIII

Installation Flowchart

Start

Check the package content before

installation. (Section 7)

Proceed with the field installation. (Section 1)

Install the valve and the actuator. (Section 1)

ATTENTION

Do not touch the moving parts of the

valve/positioner/actuator, because they

can unexpectedly move.

Check valve conditions: Apply pressure on

the actuator and check if the valve stem

travels from 0 to 100%.

Be sure there is no additional friction or

any possibility of blocking the valve stem

movement. (Section 1)

Is the positioner pre-configured?

YES

Check if there is no leakage in the

connections or the actuator.

Depressurize all the equipments

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 in 50% of opening. The

arrow of the magnet and the arrow of the

positioner should be aligned.

Check the distance between the magnet

and the positioner surface that should

be from 2 to 4 mm. (Section 1)

Choose the most suitable position for

the Display. (Section 1)

Check if the cover is correctly closed.

Install the pneumatic parts of the positioner

(Section 1)

Verify the classification area and

its practices.

Purge the air supply line before

connecting the positioner.

in the actuator. (Section 5)

YES

Define the

current

range.

Define the type of action.

(Direct/Reverse) (Section 4)

Define the valve type . (Air to

Open/Air to Close) (Section 4)

Is the

Positioner in Split Range?

(Section 1 and 4)

Execute a Full Setup in the

positioner. (Section 4)

Is the valve working correctly?

YES

Consult Section 6

Maintenance.

Use sealant on the threads and check if the

bracket is not obstructing the positioner

exhaustion outlets.

ATTENTION

Do not touch the moving parts of the

valve/positioner/actuator, because they

can unexpectedly move.

Apply pressure in the positioner.

(Between 1.4 bar (20 psi)

and 7 bar (100 psi)). (Section 1 and 3)

Power up the positioner.

FY400 Hart – Manual de Instruções, Operação e Manutenção

Section 1

General

Mounting

INSTALLATION

NOTE

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

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 effectsof temperature, humidity and vibration.

Installing the positioner in ar eas 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 avoided. 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 correctly placed and the covers must be completely closed by tighten them by hand until y ou 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 protect ed by a humidity proof coating, but frequent ex posures to humidity may affect the protection provided. It is also important to keep t he covers tightened in place. Every time they are removed, the th reads are exposed to corrosion, si nce 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 practica lly vibration resistant, it is not recommended to install it near pumps, turbines or other equipament producing too much vibration. If not possible to avoid it, consider using of remote position sensor version.

The FY400 mounting depends on the type of actuator, its actions, si ngle (with spring return) or double, and the movement characteristic (linear or rotary). It requires two mounting brackets: one for the magnet and another for t he positioner. Smar supplies both acco rding to the specified ordering code (see Page 7.6 for mounting bracket ordering code).

Additionally, a great variety of customized mounting brackets is ava ilable, 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 y our login and password, click on the Bracket for FY link and choose the most appropriate mounting bracket to your application.

1.1

FY400 Hart – Operation, Maintenance and Instructions Manual

LINEAR MAGNET

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

ROTARY MAGNET

OUT 2OUT 1

PG 13.5

Figure 1.1 – Positioner and Linear Magnet

M20x1.5

1/2 NPT

Figure 1.2 – Positioner and Rotary Magnet

OUT 1OUT 2

PG 13.5

1/2 NPT

M20x1.5

IMPORTANT

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

Rotary Movement

ROTARY MAGNET BRACKET

ROTARY MAGNET

POSITIONER BRACKET

1.2

VALVE STEM

M6x1 SCREWS (4 PLACES)

Figure 1.3 – Positioner with Rotary Actuator

NOTE

Included in the package content the centralizer device of rotary magnet. See figure 1.21-B.

POSITIONER

Section 1 - Installation

REMOTE POSITIONER

1/2 NPT M20x1.5 PG 13.5

M6 x 1 SCREWS (2 PLACES)

OUT 2

“L” BRACKET WITH “U” CLAMP FOR REMOTE POSITIONER

OUT 1

REMOTE EXTENSION

REMOTE EXTENSION BRA

KET

Figure 1.4 – Positioner in Rotary Actuator with Remote Position Sensor

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

Then, install the positioner bracket on the actuator. Usually , the actuador is designed according to the VDI/VDE 3845 standard, and, in this case, tight en the four screw s with their lock washeers on the proper bracket.

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 betw een 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 betw een the magnet external face and the positioner face. For that, a cent ralizer device (linear or rotary ) must be used. 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 5 for Auto-Setup procedure.

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

1.3

FY400 Hart – Operation, Maintenance and Instructions Manual

Linear Movement

Install the magnet on the valve stem using its proper bracket, according to Figure 1.5.

Install the positioner bracket on t he actuator. The fastening of the actuator br acket may follow the NAMUR/IEC 60534-6-1 standard or be in accordance w ith 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 orthogonal in relation to t he 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 1.5.

LINEAR MAGNET BRACKET

VALV E YOKE

POSITIONER

VALV E STEM

LINEAR MAGNET

CENTRALIZER DEVICE

POSITIONER

OUT 1OUT 2

BRACKET

M6 x 1 SCREWS (4 PLACES)

M20x1.5

PG 13.5

1 2NPT

Figure 1.5 – Positioner in Linear Actuator

NOTE

Included in the package content the centralizer device of linear magnet. See figure 1.21-A.

1.4

VALVE YOKE

VALVE STEM

LINEAR MAGNET

CENTRALIZER DEVICE

REMOTE EXTENSION

LINEAR MAGNET BRACKET

POSITIONER BRACKET

M6 x 1 SCREWS

(2 PLACES)

REMOTE POSITIONER

M6 x 1 SCREWS

(2 PLACES)

“L” BRACKET WITH “U” CLAMP FOR REMOTE POSITIONER

Section 1 - Installation

1/2 NPT M20x1.5 PG 13.5

OUT 2

OUT 1

Figure 1.6 – Positioner in Linear Actuator with Remote Position Sensor

Make sure the bracket does not obstruct the exhaust outputs.

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 betw een the internal magnet face and the position sensor salience during the

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

Case the positioner installation or magnet change or if any other modification is done, the positioner will require a re-calibration. See Section 5 for Auto-Setup procedure.

Pneumatic Connections

The FY400 requires instrument air quality , following the best practices for pneumatic installations. Consult the American National St andard "Quality Standard for Instrum ent Air" (ANSI/ISA S7.0.01 -

1996) for detailed information. The FY400 comes with input and output stainless steel air filters, but these filters do not exclude the

preliminary instrument air treatment. Periodical f ilter 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 FY400 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 posit ioner 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.

NOTE

travel (rotary or linear), through the magnet.

1.5

FY400 Hart – Operation, Maintenance and Instructions Manual

If a failure occurs on the FY400, 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.

The positioner can have pressure gages (see the ordering code tabl e) 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 w ith IN for the air supply and OUT1 and OUT2 for Output1 and Output2, respectively . Use 1/4 NPT connections w ith sealing material for the NPT screw threads. Connect the air supply on the connection marked IN. Be sure the air supply does not exceed the maximum allowed pressure of the positioner or the actuator.

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

The FY400 has five protected exhaust orif ices 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 beign obs tructed by paint. The orifices must be inspected on a regular basis to ensure they not blocked, granting the air to flow smothly.

Double Action – Air to open (Close on failure) Connect the positioner OUT 1 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 OUT 2 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 nece ssary, 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.

IMPORTANT

1.6

(

)

(

1.95

)

Dimensional Drawing

(3.74)

OUTPUT 1 1/8-27NPT

268

(10.55)

OUTPUT 2 1/8-27NPT

OUTPUT 3 1/8-27NPT

(2.17)

REMOTE SENSOR POTION

TERMINAL

WIRING

39 45

(1.53) (1.77) (1.77)

POSITIONER

125

(4.92)

SOCKET SET PLUG

OUTPUT 2 1/4-18NPT

INPUT PRESSURE 1/4-18NPT

OUTPUT 1 1/4-18NPT

(0.35)

46.5

(1.83)

DIMMENSIONS IN mm (in)

Leave, at least, a 150mm (5.8in) spa ce, for lower and upper position ad with the magnetic tool.

ELECTRICAL

(3.27)

CONNECTION

EXHAUST

ORIFICIES

THREADS FOR

24 24

(0.94) (0.94)

53,3

(2.10)

M6x1

SCREWS

4 PLACES

ustments

Section 1 - Installation

(0.94)

(2.17)

49.5

Figure 1.7 – FY400 Dimensional Drawing

1.7

FY400 Hart – Operation, Maintenance and Instructions Manual

(1.97)

)

LINEAR MAGNE

HOLE 6.3 (0.25)Ø

(2 PLACES)

64.5

(2.54)

(0.71)

ROTARY MAGNET

MOUNTING HOLES FOR M6x1

SCREWS (2 PLACES)

6.5

(0.25)

22.5

(0.89)

(1.30)

TRAVEL DIMENSION A

UP TO 15 mm (0.59) UP TO 30 mm (1.18) UP TO 50 mm (1.97) UP TO 100 mm (3.94)

43 mm (1.7)

67 mm (2.64) 105 mm (4.13) 181 mm (7.12)

*ONLY FOR 50 AND 100 mm TRAVELS.

(0.59)

Figure 1.8 – Magnet Dimensional Drawing

Electronic Housing Rotation

The electronic housing can be rotated to offer a be tter Display position and/or better access to the field cables. To rotate it loose the Housing Locking Screw as shown on Figure 1.9 below.

(2.72)

15 *

(0.59)

(0.83)

(0.87)13(0.51)

(1.54)

Dimensions in mm (in

(0.954)

1.8

HOUSING ROTATION

ADJUSTING SCREW

Figure 1.9 – Housing Rotation Adjusting Screw

Electrical Wiring

Section 1 - Installation

To access the terminals block loosen the cover locking screw to release the cover as show n in Figure 1.10.

COVER LOCKING SCREW

Figure 1.10 – Cover Locking Screw

The wiring block has screws is suitable for fork or eye terminals.

COMMUNICATION TERMINALS

GROUND TERMINALS

TEST TERMINALS

Figure 1.11 – Terminal Block

The FY400 terminal block was developed to allow signal connections regardless their polarity.

Test and Communication terminals allow, respectively, to measure the current in the 4 - 20 mA loop, without opening the circuit, and also to communicate with the Positioner via HART protocol. T he “Test Terminals” is used to measure the current. T he “COMM” terminal is used for HART communication. The terminal block has screws where fork or ring-type terminals can be fastened.

1.9

FY400 Hart – Operation, Maintenance and Instructions Manual

For convenience, the positioner has two ground terminals: one internal and one external, both located near the conduit inlet.

Figure 1.11-A - Conduit Installation Diagram

Use of twisted pair cables (22 AW G or greater) is recommended. F or environments with high EMI interference levels, the use of shielded cables should be observed.

Avoid routing signal wiring near to power cables or switching equipment.

The duct threads must be sealed according to the hazardous area standards.

The unused cable entries should be plugged and sealed accordingly to avoid humidity entering, which can cause the loss of the product’s warranty (see figure 1.12).

Options of Display Assembly

It is possible to turn the Display in four different positions, making easie r the reading. The mark , enrolled on the top of Display indicates the reading position. See figure 1.13 below.

After opening the electronic housing cover, release the four screw s of Display. Choose the most appropriate position and re-assembly the whole set.

1.10

Figure 1.12 – Plug Mounting

Section 1 - Installation

Figure 1.13 – Positions four of Display

Put back the Main Electronic Circuit Board and the Display with your screws.

Typical Installation fot the Hart® Protocol

The FY400 connection should be made accordingly follwing examples.

Conect the hand held configurator to the communication terminals of positioner or at any point of the cable.

The Hand-Held Terminal can be connected to the co mmunication terminals of the transmitter or at any point of the signal line by using the alligator clips. It is also recommended to ground the shield of shielded cables at only one end. The ungrounded end must be carefully isolated. On multi-drop connections, the circuit loop integrity must be assur ed, with special care to prevent short-circuit between the circuit loop and the housing.

CD600

THE LOOP SIGNAL CAN BE GROUNDED

(OR NOT) AT ANY POINT.

Figure 1.14 – Hart FY400 Wiring Diagram, wiht the CD600

CONFIGURATOR

1.11

FY400 Hart – Operation, Maintenance and Instructions Manual

LC700 / M501

THE LOOP SIGNAL CAN BE GROUNDED

(OR NOT) AT ANY POINT.

Figure 1.15 - Hart FY400 Wiring Diagram, wiht LC700/M501

CONFIGURATOR

OUTPUT

POWER SUPPLY

THE LOOP SIGNAL CAN BE GROUNDED

(OR NOT) AT ANY POINT.

CONFIGURATOR

Figure 1.16 - Connected FY400 the a Transmitter Smar working as Controller

The FY400 has an equivalent impedance of 550 Ohms. T herefore, check if t he power supply, the DCS, CLP analog output, or single loop controller powering the positioner is capable to handle a voltage drop of 11 V for the positioner.

1.12

Section 1 - Installation

IMPORTANT

When having tw o positioners working in the Split Range mode, connected to only one 4 to 20 mA current source, their impedances are added, resulting 1100 Ohms (in the case of 2 Posicionadores). The maximum voltage drop for the two positioner is 22 Volts. Be sure that the current source is able to drive the 4 o 20 mA for both positioners.

What is a Split Range control?

That type of control involves tw o positioners c onnected in series into just one analogical output, each one controlling its own valve. For instance:

- Positioner 1: 4 - 12 mA = 0 - 100%;

- Positioner 2: 12 - 20 mA = 0 - 100%;

The examples on Figure 1.17 and 1.18 shows a typical installation of a device driving an output of 4 to 20 mA in combination with a power distributor isolator IS400P, granting power both positioners to work in a Split Range application.

OUTPUT A

OUTPUT B

CONFIGURATOR

IS400P - Power Distributor and Isolator

INPUT

POWER SUPPLY 24VDC

OFF

FUSE

0.2A

CONFIGURATOR

smar

Figure 1.17 – Potitioners Wiring Diagram with CD600, in Split Range.

1.13

FY400 Hart – Operation, Maintenance and Instructions Manual

OUTPUT A

OUTPUT B

CONFIGURATOR

IS400P - Power Distributor and Isolator

INPUT

POWER SUPPLY 24VDC

OFF

FUSE

0.2A

smar

Figure 1.18 - Wiring Diagram of Positioners with LC700/M501, in Split Range.

Air Supply

The FY400 is designed and manufacture to work with good quality instrumentation air. The following issues are some recommendations based on field practices w hich will increase the FY400 performance and lifetime.

Before connecting the instrument air supply to the positioner, it is strongly recommended to open the tubing freely for 2 to 3 minutes to blow out any possible contamination present inside the installation.

Use a white paper towel direct into the instrument air flow and check visually if there is any water, oil, or any other undesirable material. Case the ins pection shows the presence of contaminants and/or humidity please refers to the “Recommendations for Instrument Air Supply System” below.

Once the positioner is pressuri zed and powered, an internal air fl ow will improve protection against corrosion and prevent the moisture getting inside it. For this reason, the air supply should always pressurize the equipment, even when the process is not operating.

Recommendations for Instrument Air Supply System

To get the best F Y400 performance and to increase its lifetime, the instrum ent air quality shall be superior to that of industrial compressed air. Humidity, suspended particles and oil contamination, even lubricating oil, may impair the instrument operation, either temporarily or permanently in case of internal parts wearing.

As per the ANSI/ISA Standard S7.0. 01 - 1996 - Quality Standard for Instrument Air, instrument air shall the following characteristics:

Dew point Size of particles Oil content Contaminants

10ºC below minimum instrument temperature. 40 µm (maximum). 1 ppm w/w (maximum). Free of corrosive contaminants and hazardous gases.

CONFIGURATOR

1.14

COMPRESSOR

INTAKE

Section 1 - Installation

The mentioned standard recommends to place the compressor intake in an environment free from process spills, contaminants, and to use adequate filters. Also, t he compressors must be of nonlubricated type to prevent the pres ent of lubrificants. When using lubricated compressors, the plant must have resources to remove the lubricant from the instrument air supplied.

The Figure 1.19 shows a typical for air supply and air quality adequacy:

AFTERCOOLER

CONDESANTE

SEPARATOR WITH DRAIN

AIR RECEIVER

WITH DRAIN

COMPRESSOR

OIL AND WATER

MIST PREFILTER

WITH DRAIN

Figure 1.20 – Air Quality Conditioning System

Rotary and Linear Magnet

The Magnet models are linear (up to 30 mm, 50 mm and 100 mm) and rotary (30º - 120º), for utilization on linear and rotary actuators, respectively. The white bars on the linear magnet indicate the limit for using the magnet.

Linear Magnet

Figure 1.19 – Air Supply System

AIR

DRYER

DRY AIR

AFTERFILTER

Figure 1.21 – Linear and Rotary Models

Rotary Magnet

1.15

FY400 Hart – Operation, Maintenance and Instructions Manual

Magnet Centralizer Device

NOTE

Centralizer device of linear magnet is used for all type of linear bracket.

NOTE

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

Figure 1.21-A – Centralizer device of linear magnet Figure 1.21-B - Centralizer device of rotary magnet

1.16

Remote Sensor Position

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

For an appropriate installation of the sensor, c heck if the engraved arro w on the magnet matches the positioner arrow when the valve is at half way course.

The magnet mounting in relation to the position sensor should follow procedure below:

1. There is no friction betw een the magnet internal face, linear of rotary , and the remote

2. The magnet and the remote sensor bulge are not too far.

It is recommended to keep a minimum 2 mm space and maximum 4 mm distance betw een the magnet external face and the remote sensor face. There is a centralizing device, for both linear and rotary installations, inside the positioner packing which will help you to correctly install the positioner and remote sensor.

Section 1 - Installation

position sensor bulge when excursioning for opening or closing the valve.

Positione

Extension Cable

Remote Position Senso

Figure 1.22 – Remote Position Sensor

The electric signals in the remote sensor cable are of low intensity. Therefore, when installing the remote sensor cable inside the conduit (maximum limit 20 meters length), w e recommend to avoid the proximity of possible inducti on sources and/or magnetic interf erence. The supplied cable is shielded for protection against electromagnetic interference, but despite this protection avoid the cable sharing the same conduit with other cables. See the figure 1.6.

The connector for remote position sensor is easy handle and simple installation. See the installation procedure as per Figures 1.23 and 1.24:

1.17

FY400 Hart – Operation, Maintenance and Instructions Manual

Figure 1.23 – Connecting the Cable to the Remote Position

Sensor

Installation in Hazardous Areas

Explosions could result in death or serious injury, besides financial damage. Installation of this positioner in explosive areas must be carried out in accordance with the local standards and the protection ty pe adopted. Before continuing the installation make sure the certificate parameters are in accordance with the classified area where the equipment will be installed.

The instrument modification or parts replacement supplied by other than authorized representative of Smar is prohibited and will void the certification.

The positioners are marked with options of the protection type. The certification is valid only when the protection type is indicated by the user. Once a particular ty pe of protection is selected, any other type of protection can not be used.

The electronic housing and the position sensor installed in hazardous areas must have a minimum of 6 fully engaged threads. Lock the housing using the locking screw (Figure 1.10).

The cover must be tighten with at least 8 turns to av oid the penetration of humidity or corrosive gases. The cover must be tighten until it touches the housing. Then, tighten more 1/3 turn (120) to guarantee the sealing. Lock the covers using the locking screw (Figure 1.10).

Consult the Appendix A for further information about certification.

Explosion/Flame Proof

In Explosion-Proof installations the cable entries must be connected or closed using metal cable gland and metal blanking plug, both with at least IP66 and Ex-d certification.

As the positioner is non-ignition c apable under normal conditions, the statement “Seal not Required” could be applied for Explosion Proof Version.

The standard plugs provided by Smar are certified according to the standards at FM, CSA and CEPEL. If the plug needs to be replaced, a certified plug must be used.

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

Do not remove the positioner covers when power is ON.

1.18

Figure 1.24 – Connecting Cable to the Positioner

WARNING

Section 1 - Installation

Intrinsically Safe

WARNING

In hazardous zones w ith intrinsically safe or non-incendive requirement s, the circuit entity parameters and applicable installation procedures must be observed.

To protect the application the positioner must be connected to a barrier. Match the parameters betw een barrier and the equipment (Consider the cable par ameters). Associated apparatus ground bus shall be insulated from panels and mounting enclosures. Shield is optional. If used, 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 w iring practices. Use only Ex Hart communicator approved according to the type of protection Ex-i (IS) or Ex-n (NI).

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

NOTE

To obtain all the available certifications consult www.smar.com.

1.19

FY400 Hart – Operation, Maintenance and Instructions Manual

1.20

Section 2

RESTRICTION

PILOT

DIAPHRAGM

SPOOL

DIAPHRAGM

AIR SUPPLY

NOZZLE

PIEZO VAN E

SPOOL

PILOT CHAMBER

VENT 2

OUTPUT 2

OUTPUT 1

VENT 1

SPRING

PRESSURE TRANSDUCER

OPERATIONAL

Positioner Functional Description

The FY400 Hart® senses the actual stem valve position and takes the corrective action according to a fully user configurable strategy. The “non-contact” position sensor (Hall effect based) prevents the inadequacy of links and levers.

Figure 2.1 – Pneumatic Transducer

The 4 to 20 mA signal (from the controller) is processed at the main digital circuit board. The analog board gets the information from the main circuit board and generates a low power voltage signal to a piezo electric disc in the pressure transducer. It results in a inflection in such disc, moving it nearer or further away from a noz zle in the pressure transducer. This inflection provides a (pilot) pressure variation proportional to the loop controller.

The diaphragm block amplifies the force related to the pilot pressure and pushes down the spool valve, allowing the supply pressure into the valve actuator. On the other hand, the spool valve movement reliefs the pressure from the valve actuator to the atmosphere.

The valve stem will move in response to spool valve movement up to the correct position. The magnet sensor reads the actual valve position (Hall effect) and feed it back to the main circuit board. With the position information (readback signal), the microprocessor will drive a signal to the analog circuit, correcting the valve position.

2.1

FY400 Hart – Operation, Maintenance and Instructions Manual

Circuit Functiona l Description

To understand the electronic operation of the FY400 positioner, refer to the blocks as per Figure

2.2.

DISPLAY

MAIN CIRCUIT BOARD

SUPPLY

LOCAL AJUST

POWER SUPPLY

4-20mA

INPUT SUPPLY

TRANSDUCER

ANALOG CIRCUIT BOARD

TEMPERATURE

19K2

PWM

4-20 mA

SENSOR

DISPLAY

CONTROLLER

HART

MODEM

D/A

FRAM

A/D

CONVERTER

P_OUT2

P_OUT1

PWM

ISOLATION

P_IN

19K2

0-100 Vdc

POSITION SENSOR

CIRCUIT

CPU

PID

FLASH

RAM

A/D

RESTRICTION

PRESSURE SENSOR CIRCUIT BOARD

P_IN

P_OUT1

P_OUT2

2.2

PIEZZO

FLAPPER

NOZZLE

SPOOL VALVE

POSITION SENSOR

SENSOR

OUT1

SENSOR

OUT2

* Optional

Figure 2.2 – FY400 Block Diagram

VALVE

ACTUATOR

STEM

MAGNET

VALVE

Section 2 - Operation

Current Power Supply

To power the positioner circuit , it is used a current source of 4-20 mA, in general supplied by a controller or through a transmission line of the sign (two-cable system). It needs at least of 3,8 mA to work properly and to drive a necessary power to maintain the current through a load of 550 ohms.

A/D

It is a digital 16-bits converter used for reading of the following signs: 4-20 mA input, position sensor, input pressure signal, the output 1 pressure and output 2 pressure and converts them into a digital format for the CPU.

FRAM (Ferroelectric Crystal Memory)

It is a non-volatile memory where the configuration data are stored. Examples of such data are: calibration, diagnosis and configuration of the valve.

HART

Modem

The function of this component is to make possible to exchange information between the Smar hand-held programmer and the positioner though the frequency modulation HART

protocol digital communication. Thus, the positioner demodulates the digital information from the current line transmitted by the Smar hand-held programmer and, after processing it, modulates the result on the line again. The “1” represents 1200 Hz and t he “0” represents 2200 Hz, according to the NAMUR NE-43 standard. The frequency signal is symmetrical and so does not affect the DC level on the 4-20 mA current. The display controller and D/A are embodied in this component.

D/A

It communicates with the CPU and applies a voltage output on the piezoelectric disk, proportional to the position desirable by the controller. The signal is sent via modulation by pulse (PWM) based on a reference frequency (19K2).

Display Controller

It receives data from CPU and manages the information to the liquid crystal display (LCD).

Central Processing Unit ( CP U) , RAM, FLASH e PID

The central processing unit (CPU) is the intelligent part of the positioner, which is responsible for its management, operation, control, self-diagnostic and communications. The firmware is stored in the FLASH memory. For temporary data storage, the CPU has an internal RAM. The PID controls the valve desired position.

Local Adjustment Two keys are activated magnetically without any external contact, electric or mechanical, through a magnetic tool.

Temperature Sensor It measures the temperature of the transducer circuit.

Isolation

Its function is to isolate the control signal of the piezoelectric disc voltage.

Position Sensor by Hall Effect

It measures the valve real position, conditioning the signal and sending it to the CPU for the PID control execution.

Restriction The restriction and the nozzle form a pressure division circuit. The air is supplied for the nozzle through a restriction.

Baffle-Nozzle

The baffle-nozzle unit converts the piezoelectric disc movement in one sign of control pressure in the pilot chamber.

Spool Valve

The spool valve assures the fast valve positioning amplifying the air flow.

Pressure Sensors (optional)

They make the readings of the positioner input and outputs pressures for diagnostic purposes.

2.3

FY400 Hart – Operation, Maintenance and Instructions Manual

NOTE

INDICATES TABLE

INDICATES MULTIDROP

INDICATES VALVE POSITION CURRENTLY SHOWN

Pressure Sensor Circuit Board

Sensor IN: Measures the Input pressure. Sensor OUT1: Measures the Output 1 pressure. Sensor OUT2: Measures the Output 2 pressure.

The Pressure Sensor Circuit Board is optional (in the ordering code, K1 option).

Display

The digital display LCD is necessary to show the information and for operation in the local adjustment mode.

During the normal operation, the FY400 stay in the monitoring mode and the display shows the valve position in percentage. During the configuration process, there is an option to show the setpoint on the display. The local programming mode is activated by approximating the magnetic tool to the hole marked by the letter "Z", on the top of the electronic housing.

The Figures 2.3 and 2.4 show the possible configuration indications and monitoring information. When powering the FY400, the display shows the FY400 model and the firmware version (X.XX).

Monitoring During normal operation, the FY400 remains in the monitoring mode. The display on F igure 2.3 shows the valve position percentage.

This indication changes when approaching the magnetic tool near to the hole marked with "Z" (Local Adjustment), and shows the programming mode through local adjustment.

On the indicator, one can see the result of inserting the magnetic tool in holes marked with “Z” and “S”, which allows, respectively, browse through the programming tree and select option. (More details in the Section 4).

2.4

INDICATES

CONSTANT OUTPUT MODE

INDICATES ADJUSTMENT/

INDICATES SETPOINT DISPLAYED

ACTIVATED

INDICATES ACTUATION

ON AUTOMATIC

INDICATES

ACTUATION

ON MANUAL

CHANGE VARIABLE/

MODE POSSIBLE

Figure 2.3 – Typical Display

FUNCTION ACTIVATED

Fix

F (x)

SP PV

Figure 2.4 – Local Display

MODE ACTIVATED

VARIABLE FIELD

UNIT IN PERCENT

UNIT AND FUNCTION FIELD

Section 3

TECHNICAL CHARACTERISTICS

Functional Specifications

Travel

Linear Motion: 3 - 100 mm. Rotary Motion: 30° - 120° rotation angle.

Input and Communication Protocol

Two-wires, 4-20 mA, accordi ng to NAMUR NE43 specification, with super-imposed digital Hart® Protocol.

Power Supply

4 to 20 mA Loop-powered. No external supply required. Built-in circuit protection against overvoltage up to 60 Vdc. Built-in circuit protection against overcurrent up to 25 mA. Context saving in case of power failure. The critical variables used in the positioner are saved in the memory, avoiding the startup being affected by missing data in the registers and positioner variables.

Input Impedance

550 .

Minimum Current

3.8 mA.

Configuration

Local Adjustment (partially) with magnetic tool. No need to open the cover. Remotely through:

- CONF401 Windows Based configuration software;

- HPC401 PalmOS Based Configurator;

- FDT/DTM Applications (Field Device Tool/Device Type Manager)

- Asset Management Applications (AssetView);

- Other configurations tools based on EDD.

Protection against Reverse Polarity

Electrical connection without polarity.

Built-in transient protection

Supports the instantaneous maximum v oltage of 65 V components.

Output

Output from 0% to 100% pressure supply to the actuator. Single or double action.

Pressure Supply

1,4 - 7 bar (20 - 100 psi). Free of greas e, dust and water, according to ANSI/ISA S7.0.01 – 1996 standard.

Indication

4½ - numeric al digits and 5-character alphanumerical digits Liquid Crystal Display indicator. Function and status icon.

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 105°C (-40 to 221°F)

without damage to the electronic

peak

3.1

FY400 Hart – Operation, Maintenance and Instructions Manual

Humidity Limits

0 to 100% RH (Relative Humidity).

Flow Characterization

Linear, equal percentage, quick opening and 16 freely selectable points by operator.

Auto Setup

It is an autom atic adjustment of the positioner to the va lve and actuator set, in others words, an auto-calibration procedure of the equipment. During this procedure, the positioner checks the 0% and 100% of the valve stroke related to the magnet and also calculates the converter A/D gain for position readings.

Proportional Gain, Integral and Derivative Rates

Adjustable locally or by communication. Adjusted automatically during the Auto Tuning or Full Setup procedure.

Travel Time

Adjustable locally or by communication.

Position Sensor

Non-contact Sensor by Hall effect. It is also available for the integral or remote assembling version. Optional 4 to 20 mA for position measurement.

Pressure Sensor (optional request in the ordering code)

0 to 100 psi range.

Performance Specifications

Resolution

0.1 % F.S.

Repeatability

0.1 % F.S.

Hysteresis

0.1 % F.S.

Consumption

0.35 Nm³/h (0.20 SCFM) to 1.4 bar @ 20 psi air supply.

1.10 Nm³/h (0.65 SCFM) to 5.6 bar @ 80 psi air supply.

Output Capacity

13.6 Nm³/h (8 SCFM) to 5.6 bar @ 80 psi air supply.

Ambient Temperature Effect

0.8%/20 °C F.S.

Pressure Supply Effect

Negligible.

Vibration Effect

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

5-15 Hz to 4 mm constant displacement. 15-150 Hz to 2g. 150-2000 Hz to 1g. as per the IEC60770-1 Standard.

Electromagnetic Interference Effect

Designed to comply with the IEC801 Standards and European EN50081 and EN50082 directives.

Physical Specifications

Electrical connections

½ -14 NPT, Pg 13.5 or M20 x 1.5.

Certified Hazardous Locations (CEPEL). See Appendix “A”.

3.2

Diagnostics

Section 3 - Technical Characteristics

Pneumatic Connections

Air Supply and output: 1/4 - 18 NPT. Gage: 1/8 - 27 NPT.

NOTE

The pressure gages for input, output 1 or output 2 pressures will be supplied with the external housing in SS316 and the wet parts in brass.

Construction Material

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

Equipment Weight

Without display and mounting bracket:

- 5.8 kg (Stainless Steel);

- 2.7 kg (Aluminum).

Add for the digital display: 0.1 kg. Add for the remote position sensor: 550 g. Add for the c able and connectors of the remote sensor: 100 g (c able) and 45 g/m (for eac h connector).

- What is diagnostic?

Diagnostic is a group of methods to detect, locate and eventually indicate the corrective actions for problems or failures in the actuator-valve set.

- What’s this for?

Using the diagnostics functions, it is pos sible to monitor permanently the actu ator-valve set condition and to configure the parameters aiming at predictiv e and proactive maintenances. Besides, it shows the equipment general conditions, allowing preventive actions to be taken on time. The predictive maintenance prevents malfunctions in the actuator-valve set for continuous working equipment, in other words, the diagnostic makes the actuator-valve set more reliable, improving the process stability and keeping it safer.

- When should I configure the diagnostic? The diagnostics configuration can be made only once, and the positioner will run the diagnostic procedure continually. The user can change diagnostic configuration whenever necessary, since each diagnostic can be enabled separately.

- What tool is necessary for the diagnostic? The diagnostic is automatically performed by the positioner and the user can enable, configure and visualize the diagnostic parameters through a configurator such as CONF401 or HPC401, or additionally with asset management applications existing in the market that support EDD structure.

- Is it possible to configure the diagn ostic WITH or WI THOUT configurator?

The diagnostic will only be configured via a configurator that supports the positioner. The HPC401 enables and configures the simplest diagnostics, while the CONF401 makes possible the use of the most advanced functions, besides, with through diagnostics graphs. The diagnostics functions and configurations can also be accessed via application software based on the FDT/DTM standard.

3.3

FY400 Hart – Operation, Maintenance and Instructions Manual

STROKE LIMIT & REVERSALS

Stroke Limit - Characterizes the situation which the valve (or actuator) reaches an upper or lower

position, to the maximum or minimum limits, respectively, configured by the user, ge nerating an alarm.

Related parameters:

Parameters Description

Stroke Limit High Stroke Limit Low

Stroke Limit Deadband Stroke Limit Counter

Stroke Limit Counter Limit

Stroke Limit Counter Alarm Stroke Limit Counter First

Activation Stroke Limit Counter Last

Activation Stroke Limit Alarm Time L imit

Stroke Limit Alarm Stroke Limit Operation Time

Stroke Limit Measured Time

Configuration example:

Parameters

Stroke Limit High Stroke Limit Low Stroke Limit Deadband Stroke Limit Counter Limit Stroke Limit Alarm Time L imit

Following the example, when the valve position value goes smaller than 2% (Stroke Limit Low) the equipment will consider Stroke Limit reached and it will increment by 1 (one) the counter. While the valve position value does not arise again for an upper value to 3% (Stroke Limit Low + Stroke Limit Deadband) the equipment will continue understanding as one Stroke only, and it won't increment the counter. If the valve position value increases to a larger value than 3% and goes down again to 2%, the pr ocess is repe ated and Strok e Limit counters are incremented again by 1 (one). In a similar way, when the valve position goes up to 98% (Stroke Limit High), the Stroke Limit is reached, and also the counter is incremented by 1 (one).

Still according to the exampl e, when the value of the Stroke Lim it counter reaches 10 (ten), the equipment will generate an alarm (Stroke Limit Counter Alarm). Similarly, when the valve set stays in Stroke Limit for a time ove r to 60.0 seco nds, an alarm of the e xceeded time will be generated (Stroke Limit Alarm).

Maximum limit value for the valve travel, before being considered Stroke Limit. Minimum limit value for the valve travel, before being considered Stroke Limit. Dead zone on the Stroke Limit High and Low values. Counter of the number of times in that the Stroke Limit was reached.

Maximum value allowed to the Stroke Limit counter, before generating an alarm.

Generated alarm when the counter of Stroke Limit exceeds the Counter Limit.

Time when the first occurrence of Stroke Limit happened.

Time when the last occurrence of Stroke Limit happened.

Maximum value of time in Stroke Limit allowed, before generating an alarm.

Alarm generated when the time in Stroke Limit exceeds the Alarm Time Limit value.

Total operation time of the Stroke Limit diagnostic. Total time the valve set was in Stroke Limit.

alue (%)

98%

2% 1%

60.0 second

3.4

Section 3 - Technical Characteristics

Reversals - Characterizes the situation when the valve movement direction (opening - closing).

Related parameters:

Parameters Description

Dead zone of the reversal. If the change in direction is larger

Reversal Deadband

than the value of the dead zone, the equipment will assume it as reversion.

Actuator ou Valve Reversal Counters

Actuator ou Valve Reversal Counter Limits

Actuator ou Valve Reversal Counter Alarm Actuator ou Valve Reversal Counter First Activation Actuator ou Valve Reversal Counter Last Activation Actuator ou Valve Reversal Operation Time

Configuration example:

Parameters

Reversal Deadband Actuator Reversal Counter Limit Valve Reversal Counter Limit

Counter that shows the number of reversals of the equipment, for valve or actuator, separately. Maximum value of reversals allowed to the counter before generating an alarm. Configuration for valve or actuator, separately. Alarm generated when the counter of Reversals exceeds the respective Reversal Counter Limit value.

Time when the first Reversal happened.

Time in that the last occurrence of Reversal happened.

Total operation time of the Reversal diagnostic.

alue (%)

1% 5 5

For every change in direction when the displacement is larger than 1% (Reversal Deadband), the positioner will consider it a reversal and it will increment the respective counters by 1 (one).

When the val ue of the cou nters (Reversal Counter Limit) reaches 5 (five), the positio ner will generate the respective alarm (Reversal Counter Alarm) for the act uator and the va lve, given that the reversal counters of th e actuator and that of the valve are independent. The reason for th e counters to be independent, in spite of be ing increased together is that when maintenance is done in just one of the set of elements, the respective counter can be zeroed by the user, independently of the other.

MILEAGE

Valve Mileage - mileage or total travel of the valve and actuator. It can adopt percentage values, of

length units or angular units. It also has a limit value for an alarm to be generated (Mileage Limit Alarm) when its value is exceeded.

Related parameters:

Parameters Description

Dead zone inside which a displacement is not considered as

Mileage Deadband

movement in the Mileage count. This value is always configured in percentage. Actuator or valve mileage. It is the sum of the displacements

Actuator ou Valve Mileage

larger than the dead zone, executed by the respective equipment.

Actuator ou Valve Mileage Limit Actuator ou Valve Mileage Limit Alarm

Maximum value allowed to Mileage, before generating an alarm. Alarm generated when the respective Mileage exceeds the Mileage Limit value. Travel measurement of the valve-actuator set, in other words,

Travel Range

total travel in engineering units. The Mileage values of the actuator are converted into engineering units starting from this value.

Eng. Unit

Engineering Unit in which Travel Range and Mileage will be visualized.

3.5

FY400 Hart – Operation, Maintenance and Instructions Manual

SUPPLY PRESSURE

The pressure diagnostic checks if the p ower supply pressure of the positioner is between the limits configured by the user. This diagnostic have two limits, one lower and another upper limit that make possible to check if the pressure is good or generate alarms of too l ow or too high pressure in the positioner status (Supply Pressure Status).

For this diagnostic to work correctly it is necessary to use a positioner model that has pressure sensors installed.

Related parameters:

Parameters Description

Supply Pressure High Limit Supply Pressure Low Limit

Supply Pressure Status Supply Pressure Alarm Time

Limit Supply Pressure Alarm Supply Pressure Problem

Counter Supply Pressure Problem First Activation Time Supply Pressure Problem Last Activation Time Supply Pressure Problem Accumulated Time Supply Pressure Problem Operation Time

PST (Partial Stroke Test) & LOAD FACTOR

PST (Partial Stroke Test) - This diagnostics executes a test to ver ify if the va lve is not locked,

besides measuring the necessary pressure for the valve to move. Durin g its exec ution, the Load Factor is calculated.

Related parameters:

Parameters Description

PST Mode PST Type

PST Offset PST Pause PST Timeout PST Timeout Alarm PST Breakout Value PST Breakout Limit PST Breakout Alarm PST Cycle Time PST SP Change Alarm PST Aborted Alarm Valve Spring Range

3.6

Upper value limit for the supply pressure. Lower Value limits for the supply pressure. Indicates the actual state of the supply pressure: too low, good or too high. Allowed time maximum value, for the power supply pressure to be outside the limits before generating an alarm. Alarm generated when the time when the pressure is out of the limits exceed the value of the Alarm Time Limit.

Total (problems in the power supply pressure. Time of the first occurrence of a problem in the supply

pressure. Time of the last occurrence of a problem in the supply pressure. Accumulated time in which the supply pressure was out of the limits: too low or too high.

Total time of operation of the diagnostic of Supply Pressure.

It configures the valve to be tested: safety or control type. It configures the test as valve opening or closing, in the case of a safety valve. Percentage displacement value of the valve position for the test. Time awaited by the test, after the valve starts moving, to return to the original position. Maximum time a waited for the test to be executed entirely, before generating an alarm. Alarm generated when the test time exceeds the value of PST Timeout. Time elapsed for the valve to leave the inertia and begin its movement. Maximum time allowed for the PST Breakout Value, before generating an alarm. Alarm generated when the Breakout Value exceeds the PST Breakout Limit value. Period when the equipment will execute the PST automatically (for manual PST, this parameter should be zero). Alarm that indicates if the Setpoint was changed during the PST execution. The result invalidates the test. Alarm that indicates an error in the valve positioning before beginning the PST. The result invalidates the test. Spring range, for simple action valves. It can be calculated automatically by the equipment or configured by the user.

Section 3 - Technical Characteristics

When the PST Mode is configured as safety valves, the PST should be executed starting from the position 0%, in the case of a PST Type configured to open. Or then, 100%. If the PST Type was configured to close.

Some checks are made during the test and can generate its cancellation and a respective alarm:

 time of the test exceeds PST Timeout;  PST Breakout Value exceeds PST Breakout Limit;  the initial valve position doesn't correspond to the initial position configured for the test

to begin (for safety valves);

 The Setpoint is altered during the test.

Load Factor - This diagnostics attributes the percentage of the press ure used to move the va lve from one point to another, indicating a diagnostics related to the attrition of the valve. It is calculated during the PST.

Related parameters:

Parameters Description

Load Factor Value Load Factor Limit

Load Factor Alarm Load Factor First Calculation

Time Load Factor Last Calculation Time Load Factor OperationTime

Value calculated for the Load Factor. Maximum value allowed for the Load Factor, before generating an alarm. Alarm generated when the Load Factor Value exceeds the value of the Load Factor Limit.

Time of the first Load Factor calculation.

Time of the last Load Factor calculation. Total operation time of the Load Factor diagnostics.

DEVIATION

This diagnostics indicate if the pos ition error, in relation to the Setpoi nt is above th e maximum defined by the user.

Related parameters:

Parameters Description

Deviation Value Deviation Deadband

Deviation Time Deviation Counter Deviation Counter Limit

Deviation Counter Alarm Deviation Counter First

Activation Time Deviation Counter Last Activation Time Deviation Counter Accumulated Time

Deviation Alarm Time Limit Deviation Alarm

Deviation Operation Time Deviation Measured Value Deviation Measured Time

Maximum deviation value allowed by the user. Dead Zone in relation to the deviation value, used to avoid

that the same deviation is counted more than once. Necessary time for a position error to be considered as a deviation provided that it is above the Deviation Value.

Counter of the number of times when a Deviation occurred. Maximum value allowed to the Deviation counter, before

generating an alarm. Alarm generated when the Deviation Counter exceeds the Counter Limit value.

Time when the first Deviation occurred.

Time when the last Deviation occurred.

Total time when the set was in Deviation. Maximum time value allowed in Deviation, before generating

an alarm. Alarm generated when the time in Deviation exceeds the Alarm Time Limit value.

Total operation time of the Deviation diagnostics. Deviation value when the time alarm is generated. Deviation time when the time alarm is generated.

3.7

FY400 Hart – Operation, Maintenance and Instructions Manual

ALARMS

Besides the specific alarms of each diagnostics already mentioned, some additional alarms are also present in status format, even after the setup or during the control process. They are:

Parameters Description

Temperature out of range No movement or low air supply Fail Hall SP out of limits Magnet not centralized

Piezo voltage out of range

Low current supply

GRAPHS

DEVIATION GRAPH

The travel deviation indicates the difference between the Setpoint and the valve position. The user then can configure the tolerance of acceptable deviations for his process. The Deviation Graph shows the deviation values along the time.

Related parameters:

Parameters Description

Graph Operation Time Device Total Operation Time

PST GRAPH

The Partial Stroke Test verifies the valve response to a certain course, together with the necessary pressure to execute the movement. The PST Graph illustrates the valve opening and closing test process to the positions configured by the user.

LOAD FACTOR GRAPH

The Load Factor indicates the total valve inherent attrition. The Load Factor Graph shows the Load Factor values calculated along the time.

Related parameters:

Graph Operation Time Device Total Operation Time

HISTOGRAM

The Histogram indicates the amount of tim e the valve stayed in a c ertain position. It shows the positions in intervals of 5% and the time the valve stayed in each position when the diagnostic was enabled.

Related parameters:

Histogram Operation Time Device Total Operation Time

VALVE SIGNATURE

The Valve Signature is a graph that shows the equipment performance curve, in relation to the used pressure, for the whole valve course, in the valve opening and closing. Therefore, in time the user can analyze if the system is being degraded, as well as diagnose some problem with the actuatorvalve system.

Parameters Description

Indicates that the temperature is out of the acceptable e equipment limits. Indicates that the valve is locked or that the air supply is insufficient. Indicates no-reading or a reading problem with the Hall-magnet sensor set. Indicates that the Setpoint is out of the range specified as useful for the user. Indicates that the magnet is not centralized with the valve travel. Indicates Piezo base voltage out of calibrated range, required for the control. Refer to section 6, in item: Checking the Calibration of the Piezo Base Set, in this manual. Indicates insufficient electric current to supply the equipment circuits.

Indicates the graph operation time. Indicates the total graph operation time.

Indicates the graph operation time. Indicates the total positioner operation time.

Indicates the total Histogram operation time. Indicates the total positioner operation time.

3.8

Section 4

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

Local Adjustment

LOCAL PROGRAM M ING

The FY400 positioner has under the identification plate two shallow holes, where the magnetic tool is placed to execute the local adjustment.

Figure 4.1 – Shallow holes for Local Adjustment/Configuration and Magnetic Tool

The holes identified with Z (Zero) and S (Span) will be indicated by (Z) and (S). The table shows the action accomplished by the magnetic tool when inserted in (Z) and (S) according to the adjustment selected.

ORIFICE ACTION

The digital display is necessary to visualize the programming tree via local adjustment.

Moves between the functions. Selects the display function.

Magnetic Tool

With the magnetic tool, it is possible to configure FY400 locally, eliminating the need of additional configurators in many basic applications.

W1 and W2 Jumpers Connection

Write Protection

- W1 Jumper connected in OFF

If the W1 jumper is connected in OFF, the write protection is disabled.

- W1 Jumper connected in ON

If the W1 jumper is connected in ON, the write protection is enabled.

NOTE

4.1

FY400 Hart – Operation, Maintenance and Instructions Manual

Local Adjustment

LOCAL ADJUSTMENT

Disabled

Enabled

WRITE PROTECTION

Enabled

Disabled

Local Adjustment

- W2 Jumper connected in OFF

If the W2 jumper is connected in OFF and the local adjustment is disabled, the programming tree parameters cannot be modified.

- W2 Jumper connected in ON

If the W2 jumper in ON and the local adjustment is enabled, the programming tree parameters can be modified.

Write Protection

Figure 4.2 – Main Board

To configure the local adjustment, place the main board jumpers as indicated in the Figures 4.3 and

4.4.

Figure 4.3 and 4.4 – Local Adjustment Options

To configure the write protection, place the main board jumpers as indicated in the Figures 4.5 and

4.6.

4.2

Figure 4.5 and 4.6 – Write Protection Options

ACTION

ROTATIONZ

ManSETUP

DISPLAY

TuneSETUP

AutoSETUP FullSETUP

AirTo

CHAR

TYPE

TIME

SP %

MODE

Z Z Z

ZZZ

Sind, Sinr, Doud, Dour

Linear, EP25, EP33, EP50 HY25, HY33, HY50, Tab

Auto, Man

Open, Close

LOPOS

UPPOS

Local Programming Tree

The programming tree is structured with menus of the main software functions.

Section 4 - Local Programming

With local adjustment enabled, it is possible to travel through all the configuration options maintaining the magnetic tool in the hole marked with "Z". To select the option, after choosing the option by the previous way, place the tool in the hole marked with "S".

By keeping the tool in “S” hole it is possible to continuously operate the selected parameter, since this is a numeric value. Incrementing actions are performed by repeatedly placing and removing the magnetic tool until reaching the desired value.

Do all changes and c onfigurations very carefully since all modifications in the parameters are recorded automatically and do not need user confirmation to save the configuration.

Adjustable Parameters

FULL SETUP

Executes the AUTO SETUP and the AUTOTUNING for full valve adjustment, including the PID control parameters.

SETUP

AUTO

During this adjustment, the positioner checks the 0% and 100% valve travel in relation to the magnet and then calculates the AD converter gain for position readings.

AUTOTUNING

Performs the PID control tuning through automatic selection of the Kp, Tr and Td values.

MANUAL SETUP

Executes the AUTO SETUP steps but it needs user confirmation between steps.

Figure 4.7 – Local Programming Tree

NOTE

4.3

FY400 Hart – Operation, Maintenance and Instructions Manual

ner/actuator, because they may unexpectedly move

The user must confirm the current step conclusion only when the valve is not active. The steps are described below:

Step 1: Valve closing to check the 0% position. Step 2: Valve opening to check the 100% position. Step 3: Valve closing to begin calculating the AD converter gain. Step 4: Valve opening to end the calculation of the AD converter gain

The M ANUAL SETUP is recommended in cases where it is not possible to activate the AUTO SETUP due to very unstable environment.

Do not touch the moving parts of the valve/positio automatically.

TYPE – Valve Type

Through this parameter, the user configures the valve type and t he type of action associated to valve. See valve type options:

- Sind: Single action and Direct;

- Sinr: Single action and Reverse;

- Doud: Double action and Direct;

- Dour: Double action and Reverse.

CHAR - Characterization Curves

Through this parameter, the user configures the characterization curve of the valve. See the existing options:

- Linear: linear

- EP25; EP33; EP50: equal percentage

- QO25; QO33; QO50: hyperbolic (quick opening)

- Tab: table of 16 points (configurable)

Allows choosing the mode in operation. When activating the positioner, it will be al ways in automatic mode. Operation Mode options:

- Auto - Automatic Mode

In the automatic mode, the position is adjusted according to the 4 to 20 mA current signal input. This mode does not allow the local access to the SP% parameter.

- Man - Manual Mode

In the manual mode, the position is adjusted according to the SP% parameter value, independently of the input current. Only this mode allows the operation in the SP% parameter.

SP % - Set Point

This parameter represents the desired position value. In the “Manual” mode, this parameter may be operated remotely, independently from the input current. The desired value from the input current level is calculated in the “Auto” mode.

LOPOS - Lower Position adjustment

This parameter allows the user to calibrate the desired lower position, associated to the input current. This is also useful to calibrate the lower Split Range position.

UPPOS - Upper Position Adjustment

This parameter allows the user to calibrate the desired upper position, associated to the input current. This is also useful to calibrate the upper Split Range position..

TIME - Setpoint Variation Time

Allows to configure the Setpoint variation rate by selecting the desired time for the valve open or close. The unit is shown in seconds.

Kp - Proportional Gain Allows to adjust the proportional gain of the digital PID control.

Tr - Integral Time

Allows to adjust the integral time of the digital PID control.

NOTE

4.4

Section 4 - Local Programming

Td - Derivative Time

Allows to adjust the derivative time of the digital PID control.

AIRTO - Air to Open or Air to Close

This option allows to adjust the positioner according to the valve actuation. If the actuator works with "air to open" or "air to close", the positioner should be c onfigured for AirTo OPEN or AirTo CLOSE, respectively.

4.5

FY400 Hart – Operation, Maintenance and Instructions Manual

4.6

Section 5

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

NOTE

CONFIGURATION VIA HART

The positioners may be connected in a point-to-point type or multidrop network. In a point-to-point connection, the equipment must be on "0". In a multidrop network, once the devices are recognized by their addresses, the positioners should be configured with a network address between "1" and "15”. If the acknowledgement is via tag, the positioners addresses may be on "0" and keep controlling the valve, even in a multidrop configuration.

NOTE

must be strictly observed. Therefore, the following should be checked:

Ca Voc

Where:

Ca, La = Allowed Capacitance and Inductance on the bus;

Cc, Lc = Cable capacitance and Inductance;

Vmax

Imax

The FY400 Smart Valve Positioner includes a wide variety of Hart it possible to access whatever functionality implemented on it. These commands work according to the Hart Commands and Specific Commands.

Smar developed configurators for its Hart Windows or HPC401 for Palms. It provides a simple configuration, field device monitoring, and ability to analyze data and modify field device performance.

For the user's safety the FY400 has two kinds of write protection in its memory, one hardware and the other a software mechanism. The hardware is selected by a H-H switch with priority over the software (See in the Section 4, Local Programming).

≥ Σ

Cij + Cc La ≥ Σ Lij + Lc

≤

min [Vmaxj] Isc ≤ min [Imaxj]

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

= open circuit tension of the intrinsic safety barrier

= short circuit current of the intrinsic safety barrier

= Maximum allowable voltage to be applied to the positioner j;

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

protocol specifications and are grouped as Universal Commands, Common Practice

devices: CONF401 configurator or DDCON100 for

command functions that makes

The operation and use characteristics of each one of the configurators are in their specific manual. Consult the configurator updates and their manuals, on http://www.smar.com.

Figures below show the front of the Palm and the CONF401 screen with active advanced configuration.

5.1

FY400 Hart – Operation, Maintenance and Instructions Manual

Figure 5.1 - Smar Configurator

Figure 5.2 - CONF401 Screen - Advanced Configuration

5.2

Section 5 – Hart® Configuration

DDCON 100 - DDL Based HART Configurator

See the manual in the site http://www.smarresearch.com to configure.

Figure 5.3 – DDCON 100 - DDL Based HART Configurator

Configuration Resource s

By means of the Hart® configurator, the FY400 firmware allows the following configuration features to be accessed; see below:

- Positioner Identification and Manufacturing Data;

- Remote Setpoint;

- Special valve characterization function according to a 16-point configurable curve;

- Flow characterization (Linear, Equal percentage and Quick opening);

- Monitoring of all device variables: position, setpoint, deviation and temperature;

- Positioner diagnostic, preventive maintenance and failure determination;

- PID Controller Configuration;

- Device Configuration;

- Device Maintenance.

The configurator can be connected to the same pair of wires as the 4-20 mA signal, up t o 2 kilometers away from the positioner.

Identification and Manufact uring Data

The following information about the FY400 manufacturing and identification data is available: TAG

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

16-character alphanumeric field for additional identification of the positioner. May be used to identify service or location.

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.

5.3

FY400 Hart – Operation, Maintenance and Instructions Manual

NOTE

WRITE PROTECTION

W1 jumper

main board is connected to the pins over the word ON or if the protection is enabled by software.

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 stored in the American standard e.g.: Oct 16, 2007) and is automatically assumed after the choice of these items.

UNIQUE ID Used to identify the device and in the construction of the Hart® long form address.

DEVICE INFORMATION Allows to read the equipment identification data recorded in the factory.

These items related to EQUIPMENT INFORMATION, engraved in the factory cannot be modified. They are read directly from the circuit memory.

Monitoring

This function allows remote monitoring of positioner variables. The time to start the reading is around 5 seconds. The values are always updated. Among others, some of the variables that can be monitored are: valve actual position in percentage, input in percentage of the adjusted current range (before the flow limits and linearization), input current in mA or %, device temperature in Celsius and in Fahrenheit degrees, etc.

Device Configuration

– The configurator only shows that the writing is authorized if the

NOTE

from

Besides the equipment configuration and operation services, the FY400 allows Auto Setup (Calibration) and Auto Tuning. See below the configuration options:

- CHARACTERIZATION FUNCTION

This function can change valve flow characteristics. For example, if an 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 flow characterization are:

LINEAR UNALTERED

Equal percentage 1:25 Equal percentage 1:33 Equal percentage 1:50 Quick opening 1:25 (Hyperbolic) Quick opening 1:33 (Hyperbolic) Quick opening 1:50 (Hyperbolic) Table 16 pairs (X, Y)

- DISPLAY

The FY400 digital display has three well-defined fields: information field with icons informing the active status of the configuration, 4 ½ numerical digit fields for value indication and alphanumeric field with 5-digit for status information and units. The parameters that can be selected for visualization are showed below:

PARAMETERS DESCRIPTION

PV % Process variable in percentage. SP % Setpoint in percentage.

- TABLE CONFIGURATION

Through this 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.

5.4

Section 5 – Hart® Configuration

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

OPENING

100

80 60 40 20

100 20

40 50 60 70 80 90 100

Advanced Configurati on

This function affects valve advanced configurations. With advanced configuration it 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 obtaining necessary information for the device maintenance and performance test. Some of the available services are: position adjustment and valve performance test, general information about the actuator and t he valve, operations count, password level, code number model, performance and others.

Trim

There are two trim operations: current trim and temperature trim. They are configured via HPC401 for Palms or Advanced Configuration via CONF401.

− CURRENT TRIM allows to check the positioner input current reading. There are two types of

current trims available:

− TEMPERATURE TRIM is the temperature reference for the positioner temperature sensor.

Automatic Configuration

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

Setup Stages for FY400

(Full Setup, Auto Setup, Auto Tuning)

HALL

Sends the valve to the end of travel, open or closed, depending on mounting. (0%, 0%, - )

GAIN

Verifies if the valve movements up to the other extremity and finds the A/D gain. (5%, 25%, - )

Table 5.1 - Valve Characteristic Curve

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%.

5.5

FY400 Hart – Operation, Maintenance and Instructions Manual

SPAN

Calibrates the valve travel, with limit values for the position sensor. (10%, 50%, - )

SAVE

Saves calibration data in FRAM memory. (15%, 75%, -)

TIME

Finds opening and closing times for the valve. (20%, 100%, -)

CNTRL

Starts Auto tuning in 50% position. (25%, - , 0%)

TUNE1

Oscillates the system for PID parameters calculation. (55%, - , 30%)

TUNE2

Oscillation values acquisition.

(60%, - , 35%)

WAIT

Beginning of PID parameters calculation. (65%, - , 40%)

PARAM

Saves the calculated parameters and returns to the control at the setup end (calibration). (100%, - , 98%)

Multidrop Configuration

ADDRESSING FY400 contains a variable that defines the device address in a Hart® network. Hart® addresses assume values from "0" to "15", the addresses "1" to "15" being specific addresses to multidrop connection. When the FY400 is configured for multidrop, it means that the display is showing “MD” and the address is a value from "1" to "15". FY400 is factory-configured with address "0".

Diagnostic

This function allows engineering unit configuration, the parameters for diagnostic purposes and shows the positioner general conditions. Consult the “Section 3” for more details about the available functions for the diagnostic.

Pressure Sensor

This function allows pressure trim adjustment for the positioners that have optional pressure sensor. Besides visualize the status of the applied pressure and to configure the positioner input pressure in order to activate the alarm via Hart® communication, if the applied input pressures are not in accordance with the configured values.

Factory

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

5.6

Section 6

MAINTENANCE

General Information

Equipment installed in hazardou s atmospheres must be inspected in compliance with the IEC6 0079-17 standard.

As a guarantee of quality, the FY400 Valve Positioners are extensively tested and inspected before delivery to the end user. Nevertheless, they were designed to provide an easy periodic cleaning and repair, when necessary.

In general, it is recommended that the end user do not tr y to repair printed circuit boards. Instead, replace the pieces and, for this, he sh ould have spare circuit boards, which may be ordered from Smar whenever necessary. See list of recommended spare parts on page 7.3.

The maintenance procedure is a set of tech niques with the purpose of keeping the positioners with higher useful life, to operate in safe conditions and to promote costs reduction. The different types of maintenance are described during this section.

The positioner should be disassembled and undergo cleaning procedures, every time the fina l element of control is subject to maintenance.

FY400 Corrective Maintenance

Unplanned maintenance intends to locate and repair malfunction in the positioners or final elements of control operating in continuous work, or, specifically to suppress already existing defects.

Diagnostics are a set of methods to det ect, to locate and eventually to correct errors and problems or even verify failures in the final element of control and in the positioner.

FY400 Diagnostics without Configurator

In order to carry out the diagnostics, refer to Table 6.1.

SYMPTOM SOURCE / SOLUTION

Power Supply must be a current source

Check input signal current. Minimum current for positioner operation is 3.8

POSITION NOT ON DISPLAY

NO RESPONSE FOR THE INPUT SIGNAL

OSCILLATING ACTUATOR SLOW ACTUATOR

RESPONSE ACTUATOR RESPONDS TOO FAST

mA.

Electronic Circuit Failure Check the boar ds for malfunctions and replace faulty boards for spare

ones. Pressure Output Connections Check for air leakeage.

Air Supply Pressure Check the air supply pressure. Input pressure to the FY400 must be

between 20 and 100 psi.

Calibration

Check the positioner calibration points.

Obstructed Restriction and/or Blocked Output Connection

Refer to t he procedures described in this Manual: OUTP UT CONNECTION and RESTRICTION CLEANING.

Calibration

Adjust tuning parameters.

Adjustment Parameters are Too Low

Adjust tuning parameters.

Adjustment Parameters are too High

Adjust tuning parameters.

Table 6.1 - FY400 Diagnostics Without Configurator

NOTE

6.1

FY400 Hart – Operation, Maintenance and Instructions Manual



FY400 Diagnostics with Configurator

If the position er is on and with the com munication circuit and the p rocessing unit working, the configurator can be use d for dia gnostics. The configurator should be co nnected to the positio ner according to the wiring diagram showed on page 1.8.

Error Messages

The error messages inform which diagnostics were found through errors and m alfunctioning selfdiagnosing. When the configurator is communicating with the positioner, the user is informed on any problem found, through the self-diagnosis. At t he FY400 positioner, the error messages always alternate with the information on the top li ne of t he configurator display. The table list s the error messages and more details on the corrective action.

STATUS POTENTIAL SOURCE

PARITY ERROR OVERRUN ERROR CHECK SUM ERROR

FRAMING ERROR BUSY LINE

CMD NOT IMPLEMENTED BUSY DEVICE

POSITIONER MALFUNCTION

COLD START-UP FIXED OUTPUT

NO RESPONSE

Excessive noise or ripple in the line.

 Low level signal.

 damaged Interface

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

Other device using the line. Software version not compatible between configurator and positioner. Positioner carrying out an important task, e.g., local adjustment. Disconnected Transducer.

 Transducer with damage.  Stuck valve.

Start-up or power supply failure. Operating in local mode with fixed position. Positioner line resistance is not according to technical characteristics.

 Positioner without power supply.  Interface disconnected or damaged.  Positioner configured in multidrop mode being accessed by

 Interface damaged.  Power supply or battery voltage of the configurator lower than 9 V.

Table 6.2 – FY400 Diagnostics with the Configurator

Disassembly Procedure for Maintenance

1. Apply air pressure in the positioner inlet, without applying power supply. Verify if there is any air

leakage in output 1 (OUT1). In case of air leakage in outlet 1, remove power supply and check the mechanical parts.

2. Remove the base restriction, without disassembling the transducer. Verify if the restriction is not

obstructed. (See Restriction Cleaning Procedure, page 6.11).

Have the following tools at hands:

- Allen Key

- Screwdriver

Disassemble the equipment as shown:

Removal of the Electronic Housing Transducer

Follow correctly the disassemble steps, avoiding damaged parts or equipment.

1. Disconnect the electrical connections (on the side marked: FIELD TERMINALS);

2. Remove the cover. It has a cover locking screw that needs to be rotated in a cl ockwise

direction to be loosened. By reversing the process the cover will be locked. See figure 6.1.

6.2

ON_LINE_ÚNICO_INSTR.

IMPORTANT

Section 6 - Maintenance

COVER LOCKING SCREW

Figure 6.1 – Cover locking screw

3. Release the two screws that tighten the main board, to remove the main board and the housing

display.

4. Disconnect the power supply cable a nd the main board flat cable (It ha s two lockers, release

them to disconnect both cables easily).

Figure 6.2 – Disconnecting the main board cables

6.3

FY400 Hart – Operation, Maintenance and Instructions Manual

5. Loosen the housing rotation locking screw (rotating in a counterclockwise direction).

Not rotate the housing without loosening the rotary locking screw, because that can damage the housing thread and consequently it will need to be changed.

IMPORTANT

HOUSING ROTATION

ADJUSTING SCREW

Figure 6.3 – Housing rotary locking screw

IMPORTANT

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

Figure 6.4 – Transducer rotation

Loosen carefully the electronic cover of the transduc er without twisting the flat cabl e. Remove the housing transducer, rotating them in opposite directions and loosening the housing internal lock at each turn.

6.4

Section 6 - Maintenance

Figure 6.5 – Disassembled housing with disconnected transducer

Disassembled Transducer

1. Remove anticlockwise the Allen screws that fix th e assembled connection cover (this part

cannot be washed).

IMPORTANT

Before loosening the assembled connection cover, remove the position sensor cover, at the other positioner end. See the indicated parts in the figure below or in the drawing exploded view.

ssembled Bloc

Assembled Connection Cover

nalog Board

2. Remove, with care, the asse mbled connection cover not to damage the main electronic circuit

board with the flat cable, because it is fragile (this part cannot be washed); See figures below:

Assembled Base

Figure 6.6 – Disassembled connection cover

Restriction

Position Sensor Cover

6.5

FY400 Hart – Operation, Maintenance and Instructions Manual

Figure 6.7 – Loosening the Assembled Base Connection

Cover

3. Remove, with care, the main electronic circuit board, which is firmly fitted. Remove and inspect

it for damages (oxidation, etc); See figures below:

Figure 6.8 – Loosened Connection Cover

Figure 6.9 – Removing the connection cover main board Figure 6.10 – Main board loosened from the assembled base

4. Remove the flat cable from the main board. Pull the lock that fixes the position sensor to the

main circuit board, and this will loose easily. Check if the p osition sensor flat ca ble is no t twisted, broken or oxidized, etc; See figures below:

6.6

Section 6 - Maintenance

Figure 6.11 – Pulling, with the nail, the lock that fixes the

flat cable to the main board

5. Remove the transd ucer. This part cann ot be washed It is calibrated from the factor y and is

protected with a sealing wax to avoid inadequate handling. The re-calibration can be made by the user, see the item: Check the calibration of the piezo base set.

6. Remove the t ransducer restriction. Check if it is not blocked, see: Restriction Cleaning

Procedure.

7. Remove the diaphragm set. Check visually if the diaphragm is not damaged, with small holes or

sealing failures. Wash the parts of the diaphragm set carefully with water and neutral detergent; then wash it with alcohol and dry well before assembling.

8. Remove the spool valve. T his spool va lve moves against a spring l ocated in the s pool valve

conditioning hole; take care when handling the block so that the spool valve spring isn’t lost during the cleaning procedure, it is very small. Wash the spool valve with water and neutral detergent and then with alcohol and dry the part well before re-assembling it in the pneumatic block. This part should be set up without any lubrication.

9. Remove the position sensor cover (or trans ducer) carefully not to damage the flat ca ble (the

four screws must be rem oved when disassembling the transducer block). Inspect the part visually, for in dications of h umidity infiltration or other fo reign element. This part cannot b e washed.

10. Remove the hall effect position sensor with the flat cable.

11. The pneumatic block can be washed in water and neutral detergent, and then with alcohol. Be

careful not to lose the small spool valve. Blow dry compressed air in all hoses to clean any dirt.

Figure 6.12 - Flat Cable loosened from the connector

6.7

FY400 Hart – Operation, Maintenance and Instructions Manual

Figure 6.13 – Disassembled FY400

Checking the Piezo Base Set Calibration

A good FY400 performing depends on the Piezo Base calibration integrity. Due to its continuous use is expected a small variation on the piezo work voltage. If the piezo work voltage is close to 30 V or 70 V, this may be an indication the Piezo Base needs to be recalibrated soon.

Using the Hand-Held configurator, its possible re ad the pi ezo work voltage. This should be do ne periodically. Additionally, the FY400 monitors the piezo work voltage at intervals defined by user. By using the CONF401 application the user can observe a graph (see Figure 6.13a) which shows the calibration deviation trend.

Figure 6.13a – Characteristic – Piezo Voltage Trend Graph

More information on the Calibration Procedure, r efers to the F YCAL manual (Calibration Device f or Pressure Transducer) by visiting our web page on the Internet: http://www.smar.com.

6.8

ATTENTION

1. Assemble the base in the FYCAL according to the figure 6.14:

Section 6 - Maintenance

Figure 6.14 – FYCAL – Piezoelectric calibration

6.9

FY400 Hart – Operation, Maintenance and Instructions Manual

2. Assemble the piezoelectric sensor on the jig, by tightening the four screws to ensure good

sealing.

CALIBRATION TABLE FOR FYCAL

A B C

Input Pressure (psi) Power Supply (Vdc) Pilot Pressure (psi)

20 40 7.5 to 8.5 40 40 12 to 13 60 40 16 to 17 80 40 20 to 21

100 40 24 to 25

Table 6.3 – FYCAL Calibration Table

3. Apply the appropriate (psi) input pressure – As column A;

4. According to the calibration table above, apply 40 DC Volts to th e piezoelectric sensor

(independently from the input pressure applied). With the calibration tool, turn carefully the piezo position on the base, to get the corresponding pilot pressure on the gauge. The pilot pressure measured on the gauge corresponds to the pilot pressure values (psi) indicated in column C in the FYCAL calibration table.

Example: When applying 40 DC volts to the piezoelectric sensor, for an input pressure of 60 psi, result must be a pressure between 16 to 17 psi in the pilot chamber.

5. In case the value for the pilot pressure is not a value defined in the FYCAL calibration table (as

per the Column C), adjust th e upper disk o f the piezoelectric sensor set by turning it with the appropriate tool. Repeat the calibration procedure to obtain the v alues for the pilot p ressure defined in Table 6.3, as expected for the required range.

After calibrating the pi ezoelectric sensor, c heck the p ositioner. Then assemble and setup th e positioner.

If the positioner is checked while assembled with all its electronic components, the FYCAL 4 to 20 mA output may be used to power the positioner.

The FYCAL may also be used as power supply for any Smar Hart line product, as it generates a 4 to 20 mA current.

Maintenance - Mechanical Parts

1. Verify if the spool valve (28) is moving freely.

2. Verify if the spool valve is not obstructed with dirty (28).

Never use oil or grease to lubricate the spool valve; otherwise the positioner performance will be impaired.

3. Verify if there is any obstruction inside the FY pneumatic block (19 to 35) and at the exhausts.

4. Verify the diaphragm (26) integrity.

5. Verify if the transducer block (base) (24) is dirty with oil, water, etc.

6. Verify if the restriction (20) is dirty. See Restriction Cleaning Procedure.

ATTENTION

6.10

Maintenance – Electronic Parts

Electronic Circuit

The numbers indicated between parentheses refer to exploded view figure.

To remove the main board (5) and the display (4) of the circuit, first release the cover locking screw (6) from the side not marked "Field Terminals", and after that release the cover (1).

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 packings with electrostatic load proof.

Release the two screws (3) that fix the main board and display.

Assembly the device in a valve to test it i nside a laboratory. Apply power pressure according to the pressure of t he actuator that is being used and power on the equipment with a v ariable power supply from 4 to 20 mA. If the device does not initialize, i.e., the display does not light on, proceed with the following procedures:

1. Disconnect the main board from the m ain electronic circuit board, disconnecting the flat cable

connector in the housing;

2. Case the equipment initializes, change the main electronic circuit board (GLL1315) (18 - part

number 400-0914). If it does not, change the main board (GLL1314) (5 - part number 400-0909).

Proceed with full setup. After the s etup, verify if the positioner is working properly. For that, apply 12mA and be sure that the valve goes to the position correspondent to the 50% of the valve travel. If it does not occur, do the following:

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

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

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

Via software HPC401 for Palms or CONF401 it is possible to execute the CURRENT TRIM that allows to calibrate the positioner input current reading. There are two types of current trims available:

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

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

4. Verify the Hall-effect position sensor reading through the configurator. Apply pressure directly to

the valve actuator and check the Ha ll reading (65000 means that the hall is not being read). Case there is no cha nge at the Hal l reading or th e value is 6 5000, the d efect can be the GLL1314 (5 - part number 400-0909), GLL1315 (18 - part number 400-0914), GLL1316; or Hall flat cable (GLL1019);

5. Verify the piezo base/transducer voltage in the configurator;

6. The piezo base/transducer voltage value must be between 30 and 70 Volts.

To verify the hall value and the piezo base/transducer voltage, do the following:

1. Set the valve in 50% of the opening or closing travel;

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

piezo voltage;

3. The hall values must be between 28000 a 37000;

Section 6 - Maintenance

NOTE

ATTENTION

NOTE

6.11

FY400 Hart – Operation, Maintenance and Instructions Manual

4. The Voltage values of the base or piezo transducer should be between 30 and 70 Volts. If the

tension is not among those values, to proceed to the piezo calibration using the FYCAL checking and calibration device for Sm ar valve positioner, see item: Calibration Checking of th e Piezo Base Set.

FY400 Preventive Maintenance

Planned Maintenance consists of a set of p rocedures and anticipated actions to keep t he device functioning, in other words, mainly to prevent failures, through adjustments, proves and measures according to previously specified values. The preventive maintenance is rec ommended in t he maximum period of one (1) year, or when the process stops.

Restriction Cleaning Procedure

The instrument air flows to the nozzle through a restriction. From time to time the restriction must be cleaned to assure good performance to the positioner.

1. Disable the positioner power supply and disconnect the instrument air pressure;

2. With an appropriate screwdriver remove the restriction screw;

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

4. Wash the part with water and neutral detergent and dry it with compressed air (apply the

compressed air directly to the smaller orifice for the air to get out through the bigger hole).

5. Insert the cl eaning needle (PN 400-0726) into the restriction hole to prevent any possible

obstructions;

6.12

Figure 6.15 – Removing the Restriction Screw

Figure 6.16 - Restriction and Restriction

Cleaning Needle

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

7. The equipment can be supplied with air again.

Change of the Filters Elements

Change the positioner filter elements with a minimum stated period of 1 (one) year (See exploded view figure (27)). The air supply must be clean, dry and non-corrosive, according standards set by the American National Standard “Quality Standard for Instrument Air" - ANSI/ISA S7.0.01 - 1996. If the instrumentation air does not c omply with the above mentioned standards, the user should consider changing the positioner filter elements more frequently.

The Filtering Element has two threaded Stainless Steel mechanical parts. Inside them is the Filter Element with an o-ring.

How to disassemble the Filtering Element?

Firstly, remove the air filter set of the positioner (See exploded view figure (30)) and then unthread the two mechanical parts. Refer to the drawing exploded view (27) to identify the Filtering Element that is between the two mechanical parts of the dismounted air filter.

EXHAUST OUTLETS Air is vented to the atmosphere through an outlet located beside the restriction and 4 outlets on the opposite side to the gauge. A foreign object interfering or blocking exhaust port provides a way to increase the output. Cleaning by spraying it with a solvent.

Never use oil or grease to lubricate the spool valve, otherwise the positioner performance will be impaired.

Section 6 - Maintenance

Figure 6.17 - Cleaning Procedure

ATTENTION

6.13

FY400 Hart – Operation, Maintenance and Instructions Manual

6.14

Section 7

Package Content

SPARE PARTS AND MATERIALS

Verify the package content. The items marked with (*) must be in accordance with the number of positioners supplied.

 Positioner  Positioner Mounting Screws  Magnet  Magnetic Tool (*)  Magnet Centralizer device (*)  Restriction Cleaning device (*)  Instructions Manual (*)

7.1

FY400 Hart – Operation, Maintenance and Instructions Manual

Exploded View

7.2

Figure 7.1 – Exploded View

Section 7 – Spare Parts and Materials

Accessories

ACCESSORIES

ORDERING CODE DESCRIPTIONS

SD-1 Magnetic tool for configuration via local adjustment. HPC401* PalmOS Platform, including the HPC401.installation and initialization software. HPI311 Hart® Interface. 400-0726 Restriction Cleaning needle. 400-1176 Teflon guide for linear magnet. 400-1177 Teflon guide for rotary magnet.

* For updates of the HPC401 equipment and software, visit: http://www.smarresearch.com.

Spare Parts List

SPARE PARTS LIST

PARTS DESCRIPTION POSITION CODE

Cover with Display (O-ring included) Cover o-ring (with and without display) NOTE 1

Main Board screw

Digital Display - includes fixation screws Main Board Cover locking screw Housing Rotation Locking Screw, 316 Stainless Steel Identification Plate screw

Housing, Aluminum (NOTE 2)

Housing, 316 Stainless Steel (NOTE 2)

Toothed Communication Terminal and Terminal Screw Internal ground screw and square washer

External ground screw

Cover without display (included O-ring)

1/2" NPT (Ex d) Six-sided internal plug

1/2" NPT Six-sided internal plug M20x1.5 (Ex d) Six-sided external plug

PG13.5 (Ex d) Six-sided external plug 3/4" NPT (Ex d) Retention Bushing Connection cover screw Neck O-RING

Assembled Connection Cover

Connection Cover Set Main Electronic Circuit Board

Base and Block O-ring Piezo Base Set Restriction

O-ring

Aluminum 316 Stainless Steel Buna-N Carbon Steel – for Aluminum housing

316 Stainless Steel

316 Stainless Steel M6 - Without Head

316 Stainless Steel 1/2 - 14 NPT

M20 x 1,5 PG 13,5 DIN 1/2 - 14 NPT M20 x 1,5 PG 13,5 DIN

316 Stainless Steel

Self-cutting stainless steel for

Aluminum housing 316 Stainless Steel Aluminum 316 Stainless Steel Bichromatized Carbon Steel

304 Stainless Steel Bichromatized Carbon Steel 304 Stainless Steel

316 Stainless Steel 316 Stainless Steel 316 Stainless Steel

Buna-N

Aluminum 316 Stainless Steel Aluminum 316 Stainless Steel

Aluminum

316 Stainless Steel

Restriction External

10 400-0827 B 11 400-0833 -

12 400-0904 - 12 400-0826 -

13 400-0822 - 13 400-0823 - 14 400-0808

14 400-0809 14 400-0583-11 - 14 400-0583-12

14 400-0810 14 400-0811 14 400-0812 - 15 400-0073 -

16 204-0113 B 17 400-0910 -

17 400-0911 - 15 a 18 400-0912 A 15 a 18 400-0913 A

18 400-0914 -

19 400-0915 B 19 a 25 400-0916 A

19 a 25 400-0917 A

20 344-0165 B

21 344-0155 B

SMAR FY400 Owner's Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual