IM-P343-35 CH Issue 1 1
SP500
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-35
CH Issue 1
3.568.5275.300
1. Index
2. Safetyinformation
3. Technical information
4. Options
5. Installation
6. Electricalconnections
7. Quickstartprocedure
8. Programming
flowchart
9. Programmingand
commissioning
10. Maintenance
11. Defaultvaluesand
programsettings
12. Glossaryof
displaydata
Printed in the UK
© Copyright 2010
IM-P343-35 CH Issue 12
1. Index
Section Sub-section
2.1 General requirements
2. Safety
2.2 Electrical safety requirements
information
2.3 Electromagnetic compatibility
3.1 Description
3. Technical 3.2 Technical data
information 3.3 Materials
3.4 Programmable functions
4. Options
4.1 Pressure gauge block
4.2 Retransmission and travel switches option board
4.3 External power supply option board
5.1 Mounting the SP500 positioner -
General informaton
5.2 Sequence for mounting an SP500 positioner to
5. Installation a linear actuator
5.3 Sequence for mounting an SP500 positioner to
a rotary actuator
5.4 Air supply and connections
6.
Electrical
6.1 Guidance notes
connections 6.2 Wiring diagrams
7.
Quick start
7.1 2-port valves
procedure 7.2 3-port valves
8. Programming flow chart
9.1 SET-UP NOW
9.2 SP500 MENU
9.3 MANOP
9.
Programming and
9.4 AUTOS - automatic autostroke commissioning
commissioning 9.5 SET - setting of valve functions
9.6 TUNE - setting of valve tune functions
9.7 RUN - automatic operation
9.8 STRVL and RTIME - valve diagnostics
9.9 RETRN - return to SP500 MENU in main menu
10.
Maintenance and
10.1 Air supply quality
troubleshooting 10.2 Fitting replacement filter plug kit
11. Default values and program settings
12.
Glossary of
12.1 Main menu display functions
display data 12.2 Sub-menu display functions
IM-P343-35 CH Issue 1 3
2. Safety information
2.1 General requirements
The flawless and safe operation of the SP500 positioners is reliant on proper
transportation, storage, installation and commissioning by qualified personnel, proper
use and careful maintenance.
Prior to installing, using or maintaining the positioner, consideration should be given to:
- The working environment.
- Safe access.
- Lighting.
- Pipeline fluid hazards.
- Temperature.
- System isolation.
- Location.
The SP500 positioner should be mounted with sufficient space to allow opening of
the hinged cover and to provide access for electrical and air connections. When
fitting to an actuator, ensure that the positioner will not be exposed to an ambient
temperature outside the range of -10°C to +80°C. The positioner enclosure is rated
to IP65 (see BS EN 60534-1 1998).
2.2 Electrical safety requirements
The SP500 is a class III product which must only be powered from Safe Extra Low
Voltage (SELV) sources whether by virtue of a 4 - 20 mA control signal or from a
separate power supply. Similarly all signal circuits connected to an options board must
operate within the confines of SELV systems. All associated wiring must be separated
from other wiring containing hazardous voltages.
2.3 Electromagnetic compatibility
The product complies with the Electromagnetic Compatibility Directive 2004 / 108 / EC
according to:
- EN 61326-1: 2006
- EN 61326-2-3: 2006
- EN 55011: 1998 + A1: 1999 + A2: 2002
- EN 61000-4-2: 1995 + A1: 1998 + A2: 2001
- EN 61000-4-3: 2006
- EN 61000-4-4: 2004
- EN 61000-4-5: 2006
- EN 61000-4-6: 2007
- EN 61000-4-11: 2004
This product may be affected by interference if:
- The product or its wiring is located near a radio transmitter. The actual separation
necessary will vary according to the power of the transmitter.
- Cellular telephones or mobile radios are used within approximately one metre of
the product or its wiring.
- The wiring is routed alongside power cables subject to high voltage transients or
current surges.
IM-P343-35 CH Issue 14
3. Technical information
3.1 Description
The SP500 smart valve positioner is loop powered from a 4 - 20 mA input signal to provide
accurate adaptive positional control of pneumatic actuated linear and quarter turn valves.
Precise control is maintained through valve position feedback that automatically varies the
pneumatic output pressure to overcome the effects of stem friction and flow forces to maintain
desired valve position. Indication of valve position is provided through a continuous digital
display of % travel. Valve position feedback is retrieved by means of a non contact technology
based on Hall effect. The pneumatics are based on piezovalve technology - Therefore, high
resolution, high reliability, vibration insensitivity and extremely low air consumption is
guaranteed at steady state.
The SP500 includes many smart functions that can be fully programmed through menu driven
software using an integral keypad and LCD alphanumeric data. Valve commissioning is
simplified through an autostroke routine and display of programming status, software travel
switch status, mA input signal and valve diagnostics data. Moreover, the absence of
mechanical linkages between valve stem and positioner, drastically simplifies the mounting
procedure and reduces the time required. The SP500 is supplied with a NAMUR standard
mounting kit for attachment to yoke or pillar mounted actuators. For quarter turn valves, a
mounting kit compliant to VDI / VDE 3845 is supplied.
Fig. 1
12
No. Part
1. LCD display
2. Main menu functions with LCD flag indication
3. Signal pressure to activator
4. Gland connection for wiring M20
5. Terminal block
6. Increase value or toggle value key
7. Decrease value or toggle value key
8. Enter key
9. Supply pressure to positioner
10. Optional pressure gauge block with gauges
11. Spare M20 gland connection for wiring a 4-20 mA retransmission or software switches
12. External earth
13. Internal earth
4
11
10
9
3
21
13 5 6 7 8
IM-P343-35 CH Issue 1 5
No. Features
1. indicates all is OK
2. ! Indicates a delay in positioning, this
disappears when the position is reached
3. Indicates that the value displayed is a
percentage
4. Indicates that the value displayed is the
input current measured in mA
5. Indicates that the value displayed is a
time measured in seconds
6. Indicates that you're accessing the main
programming menus
7. Indicates that the positioner is in manual
mode
8. Indicates that the positioner is running
the autocalibration
9. Indicates that you're accessing the SET
menu
10. Indic a tes that the positioner is i n
automatic mode
11. Indicates that you're accessing the
TUNE menu
10 11
6 7 8 9 5
Fig. 2
3.2 Technical data
Input signal range 4 - 20 mA nominal
Minimum input signal (loop powered) 3.6 mA
Minimum air supply pressure 1.0 bar g above maximum spring range pressure
(Note: For the PN5120 actuator, the supply air pressure should be set at 1.5 bar g)
Maximum air supply pressure 6.0 bar g
Air quality Air supply must be dry, oil and dust free to ISO 8573-1 class 2:3:1
Output pressure 0 to 100% supply pressure
Stroke range
Linear valves 10 mm to 100 mm
Quarter turn valves 5° to 120°
Action Single action / fail vent
Operating temperature -10°C to +80°C
Maximum air flow 4.2 normal m
3
/h at 1.4 bar g or 8.5 normal m3/h at 6 bar g
Steady state air consumption Less than 0.016 normal m
3
/h
Air connections Screwed ¼" NPT
Cable gland M20
Electrical connections Spring clamp terminals for 0.2 to 1.5 mm² wire
Enclosure rating IP65
Characteristic Linear, Equal % (ratio 1:50) or Fast opening (ratio 50:1)
Resolution (maximum) 0.1% F.S.
4 - 20 mA retransmit (optional) 4 - 20 mA retransmission of valve position
Software travel switches (optional)
Two software configured
1 x normally closed
travel switches
1 x normally open
Shipping weight 2.2 kg
2
1 4
3
IM-P343-35 CH Issue 16
3.3 Materials
Part Material Finish
Case and cover Die cast aluminium Anti-corrosive paint to RAL5010
Magnet bracket Die cast aluminium
3.4 Programmable functions
Autostroke Automatic commissioning routine
Valve type 2-port or 3-port
% travel
Selectable 0 to 100% or 100% to 0%
depending on valve / actuator configuration
Control action Direct or reverse action (4 - 20 or 20 - 4 mA)
Travel limits (optional)
Setting of minimum and maximum travel limits
(valve open and valve close % travel)
Displayed travel %
0 - 100% displayed over mechanical travel limits or
MIN-T / MAX-T adjusted settings
Signal span 4 - 20 mA or split ranged (minimum span 4 mA)
Dead-band Positional accuracy (minimum 0.2% to max. 10% of valve travel)
Tight shut-off Fully vent or inflate at preset input signals
Characteristic Linear, = % or fast opening input signal to valve travel relationship
Travel time Slows down valve opening or closing
Travel switches Software travel switch setting (range 0 - 100%)
Reset Resets all programmed values to default settings
Calibrate Centering
Input signal Visualisation of input mA signal
Auto operation / vent
Option of automatic operation or
vent (actuator) whilst reprogramming
Data logging
Diagnostic record of total number of valve strokes
and completed hours run time
IM-P343-35 CH Issue 1 7
4. Options
4.1 Pressure gauge block
An optional pressure gauge block (Figure 3) can be fitted onto the SP500 positioner which
includes two pressure gauges indicating air supply pressure and output air signal pressure to
the actuator. The pressure gauge block can be retrospectively fitted using 2 off M5 socket
head screws. Ensure that the gauge block air connection 'O' rings are correctly located
before tightening.
Fig. 3
IM-P343-35 CH Issue 18
4.2 Retransmission and travel switches option board
An option board can be fitted in the positioner to add valve position retransmission
functionality and software travel switches functionality.
The board generates a 4-20 mA current signal which represents the actual valve position.
Moreover 2 output terminals are available to be configured as software travel switches.
The threshold can be adjusted via software.
Refer to Section 6, 'Electrical connections' for wirings.
Refer to Section 9.6.7 for travel switching configuration.
An option board is optionally available and can be mounted in situ. In this case please refer
to the mounting instruction below:
- Open the positioner (Figure 4).
- Switch off the power supply.
- Switch off the air supply.
- Unscrew the board as shown in Figure 5.
Fig. 4
Fig. 5
IM-P343-35 CH Issue 1 9
- Rotate the mainboard and insert the option board (as shown in Figures 6, 7, 8 and 9).
- Rotate the mainboard to the initial position, fix it with the 4 screws, close the positioner and
switch on the power supply and air supply.
Fig. 6
Fig. 7
Fig. 8
Fig. 9
IM-P343-35 CH Issue 110
4.3 External power supply option board
The SP500 can host an option board for 24 V power supply.
It's a 4 wiring diagram: 2 wires for current loop and 2 wires for power supply through a
24 V external voltage. This reduces dramatically the voltage drop on the current loop. The
drop is 7 V when the unit is powered by the loop (2 wires), it falls to 1 V when the 4 wires
configuration is used.
This board can be useful when you have many instruments connected on the same current
loop. The fact is that in this case, the total voltage drop on the loop could be higher than the
maximum voltage drop that the controller (PLC) can handle.
Refer to Section 6, 'Electrical connections' for wirings.
An option board is optionally available and can be mounted in situ. In this case please refer
to the mounting instruction below:
- Open the positioner (Figure 10).
- Switch off the power supply.
- Switch off the air supply.
- Unscrew the board as shown in Figure 11.
Fig. 11
Fig. 10
IM-P343-35 CH Issue 1 11
- Rotate the mainboard and insert the option board (as shown in Figures 12 and 13).
- Remove the Jumper J4 (Figure 14).
Fig. 12
Fig. 13
Fig. 14
IM-P343-35 CH Issue 112
- Insert the power supply option board.
Collocate Jumper J4 as shown in
Figures 15 and 16.
- Rotate the mainboard to the initial position, fix it with the 4 screws, close the positioner
and switch on the power supply and air supply.
Once the option board is mounted, the positioner shall be powered according to the 4 wires
connection diagram, refer to Section 6.2.3, '4 wires electrical connection'. The positioner won't
work if powered according to the standard 2 wires connection.
Fig. 15
Fig. 16
IM-P343-35 CH Issue 1 13
5. Installation
5.1 Mounting the SP500 positioner - General information
Preliminary check of valve and actuator assembly - A preliminary check should be carried
out on the valve and actuator assembly prior to mounting and commissioning the SP500
positioner to confirm smooth movement of the stem. This can be performed by providing an
air supply directly from a filter/regulator to the actuator. The air supply pressure should be
gradually increased to progressively move the stem through its full travel. Any friction or
jerky movement of the stem should be investigated prior to commissioning the SP500.
5.1.1 The SP500 is supplied with a NAMUR standard fixing kit for linear actuators (yoke
or pillar) or with a VDI / VDE 3845 compliant mounting kit for rotary actuators.
5.1.2 The SP500 has an enclosure rating of IP65 and should be installed in a location that
will not exceed its ambient temperature limits of -10°C minimum and +80°C maximum.
5.1.3 Before fitting and commissioning the SP500 positioner ensure that the valve and
actuator are correctly assembled. Refer to the valve and actuator Installation and
Maintenance Instructions for details.
IM-P343-35 CH Issue 114
5.2.1 Loosely attach the magnet bracket (2) to the valve / actuator connector (refer to Figures
17 and 18). Be sure it is positioned horizontally (as shown in Figure 18).
Fig. 17 Pillar mounting kit for a linear actuator
Fig. 18
Yoke mounting assembly
for a linear actuator
5.2 Sequence for mounting an SP500 positioner to a
linear actuator
2
2
IM-P343-35 CH Issue 1 15
5.2.2 Slide the bracket (2) to the left or to the right (Figure 19) till the correct position is
achieved. If you’re using a Spirax Sarco actuator the correct position is impressed
on the magnet bracket (Figure 20).
5.2.3 If you’re not using a Spirax Sarco actuator, slide the bracket till the distance 'A'
between the center of the magnet and the inner side of the mounting plate is 25 mm
(Figure 21).
Fig. 21
A
Distance between the mounting plate and magnet
Fig. 20 Bracket markings
Fig. 19
Assembled
2
Mounting plate
Bracket
Center
of the
magnet
PN1000PN9000
IM-P343-35 CH Issue 116
5.2.4 Loosely attach the positioner mounting plate to the actuator as shown in the following
pictures: for the pillar actuator (Figure 22), and for the yoke actuator (Figure 23).
Fig. 22 Pillar actuator assembly
Pillar actuatorMounting plate
Fig.23 Yoke actuator assembly
Yoke actuator
Mounting plate
5.2.5 Locate the protection plate onto the back of the SP500 positioner housing and fix in
place (Figures 24 and 25).
Protection
plate
Fig. 24
Assembled
Assembled
Assembled
Fig. 25
IM-P343-35 CH Issue 1 17
5.2.6
Attach the positioner mounting plate to the
positioner as shown in Figures 26 and 27.
Protection
plate
5
Fig. 26
Attach
t he
mounting
plate
Assembled
Fig. 27
5.2.7
Adjust the ver tical position of the SP500
positioner and mounting plate assembly, by
sliding it up or down on the pillar style actuators,
ensuring that the positioner is roughly centred
on the actuator / valve stroke (Figure 23).
Even if this is the ideal condition, it’s not
mandatory. In fact, as shown in Figure 28, the
only necessary condition for correct operation
is that the stroke of the magnet (dimension B)
lay inside the sensor operating linear range
(dimension A), i.e. the vertical dimension marked
on the case of the positioner.
B
A
Fig. 28
SP500 positoner
5.2.8
When the SP500 positioner and mounting
plate as s em b ly is co rr e ct l y posit i on e d,
tighten the hexagon headed screw (5) on
the yoke mounted actuator (Figure 26) to
10 - 12 N m and tighten the 'U'bolt nuts (6) on the
pillar mounted actuators (Figure 29) to 10 - 12 N m.
6
Fig. 29
IM-P343-35 CH Issue 118
5.3 Sequence for mounting an SP500 positioner to a
rotary actuator
5.3.1 Assembly for fitting an SP500 on to a ¼ turn valve.
Fig. 30 Mounting kit
IM-P343-35 CH Issue 1 19
Fig. 31
Fig. 33
Fig. 32
IM-P343-35 CH Issue 120
Fig. 34
Fig. 35
Assembled
IM-P343-35 CH Issue 1 21
5.3.2 Adjust the magnet orientation as illustrated in Figures 36 and 37 and tighten the bolt to
fix the magnet into position. There should be a distance of between 5 and 14 mm between
the magnet and the positioner.
Refer to Figure 36 for actuator with clockwise rotation.
Refer to Figure 37 for actuator with anti-clockwise rotation.
In fact, in this way the magnet movements will always be comprised in the sector between
the directions C and D which delimit the operating area of the Hall sensor.
Fig. 36 View from the bottom of the positioner - Magnet orientation for clockwise
actuator.
Fig. 37 View from bottom of the positioner - Magnet orientation for anti-clockwise
actuator.
D
B
A
C
15°
90°
120°
15°
D
B
A
C
15°
90°
120°
15°
IM-P343-35 CH Issue 122
Fig. 38
¼" NPT air supply (supply)
¼" NPT air signal to
actuator (output 1)
5.4 Air supply and connections
WARNING: Supply air pressure must not exceed the maximum allowable air pressure of
the actuator. Air connections should be ¼" NPT for air supply (supply) and output signal to
actuator (Figure 38).
The supply air should be between 1.4 bar g minimum and 6 bar g maximum and be oil and
dust free to IEC 60770. Mains air supply may sometimes contain traces of dirt, rust, water, oil
and other deposits with the potential for contaminating the internals of the positioner. It is
therefore essential that a filter / regulator is fitted in the mains air supply to the positioner.
The filter / regulator should have a coalescing filter such as a Spirax Sarco type MPC2, or
suitable compressed air pipework is used.
IM-P343-35 CH Issue 1 23
6. Electrical connections
6.1 Guidance notes on wiring installation
For heavy industrial applications it is recommended to use screened cables or signal cables
run in metal conduit. Failure to do so could result in positional errors of up to ±5% in an
RF field excess of 10 V/m. If screened cables are used, ensure that the screen is connected to
the local earth at one end with a connection resistance of less than 1 ohm.
For light industrial applications where RF fields do not exceed 3 V/m unscreened cables
may be used.
Cabling should be installed in accordance with BS 6739 - Instrumentation in Process Control
Systems: Installation design and practice or local equivalent.
6.2 Wiring diagrams
6.2.1 Terminal block
No. Pole Description
1 +
24 V external power supply
24 V power supply option board
(PWS)
2 -
3 +
4-20 mA current signal input Mainboard
4 -
5 +
Travel switch 1
Retransmission and travel
switches option board (RTX)
6 -
7 +
Travel switch 2
8 -
9 +
4-20 mA retransmission of valve position
10 -
Fig. 39
SP500
AUTOMATIC
TUNE
50
%
SET
AUTOS
MANUAL
MENU
- +
RTX
- +
SW2
- +
SW1
- +
4-20mA
- +
24V
1
2
3
4
5
6
7
8
9
10
▲
▲
IM-P343-35 CH Issue 124
6.2.3 Multi-loop applications
Loop powered multi-positioner connections
4 - 20 mA signal
+
@ 14 V minimum
-
In a loop powered application, the 4-20 mA signal must be capable of supplying a
minimum of 7 V per positioner at 20 mA. In a split range application the signal source
must be capable of supplying sufficient voltage, i.e. 14 V is enough to power 2 positioners.
4 wires electrical connection
If the controller cannot supply the voltage needed, it is possible to power one or more
positioner through an external 24 V power supply connected to terminals 1 and 2.
In this way the voltage drop is about 1 V per positioner with an impedance of 50 Ohm.
Fig. 40
4 - 20 mA signal
3 4
+ -
3 4
Positioner 1
3 4
Positioner 2
Fig. 41
6.2.2 Single loop applications
The SP500 is loop powered using the 4 - 20 mA input signal source providing a
minimum signal of 3.6 mA can be maintained.
Minimum current 3.6 mA
Maximum current 30 mA
Maximum voltage drop < 7 V
Overvoltage protection Up to 30 Vdc
Protection against polarity inversion Up to 30 Vdc
1
Positioner 1
24 V
+
-
+
-
2 3 4 5 6 7 8 9 10
Current loop @ 8 V - (1 V + 7 V)
1
Positioner 2
2 3 4 5 6 7 8 9 10
Please note that for this configuration the PWS option board must be fitted. The PWS
option board can be specified when the product is ordered or bought later and fitted
in situ - In this case reference Section 4.3 for mounting instructions.
Fig. 42 Split range with 2 positioners
IM-P343-35 CH Issue 1 25
6.2.4 Travel switches-
and 4-20 mA retransmission wiring digrams
Fig. 43 Software switches
2 k
Travel switches 1
Table 1
Ratings Supply Impedance On current Off current
TS1 travel switch 18 - 30 Vdc 1.8 k 13 mA 1 mA @ 24 V
TS2 travel switch 18 - 30 Vdc 1.8 k 13 mA 1 mA @ 24 V
4 - 20 mA 8 - 30 Vdc - - -
Fig. 44 4 - 20 mA retransmit
4 - 20 mA
retransmit
-
Example of customers external application wiring.
22 k
5
6
2 k
Travel switches 2
22 k
7
8
9
10
IM-P343-35 CH Issue 126
7. Quick start procedure
7.1 2-port valves
The following applies to positioners fitted to 2-port valves having plug above the seat and
fitted to pneumatic actuators having a direct acting (DIR) 4 - 20 mA input signal and excludes
the setting of any additional program functions (i.e. default value only).
Note: For PN5100 and PN6100 series actuators an additional programming step is required.
(Refer to Section 9.5.2).
7.1.1 The positioner should be correctly assembled as described in Section 5 and Section 6
and supplied with mains air and signal pipework as described in Section 5.4.
7.1.2 Provide a minimum input signal of 3.6 mA to the positioner.
SET-UP NOW should be displayed.
7.1.3 Ensure that upstream isolation valves are closed.
Press and hold key for 3 seconds to advance to SP500 MENU.
The display will count down the 3 seconds.
7.1.4 Press to advance to MANOP.
7.1.5 Press and hold key for 3 seconds to enter manual control mode MCTL.
7.1.6 In manual control press and hold or keys to drive the valve stem up or down.
Check for any obstructions of valve movement.
The display will indicate FILL or VENT as appropriate.
Any obstruction should be investigated before proceeding to Section 7.1.7.
7.1.7 Press key to return to MANOP in main menu.
7.1.8 Press key to advance to AUTOS autostroke mode.
7.1.9 Press and hold key for 3 seconds to start the autostroke routine.
This will take approximately 2 minutes to complete.
! displayed indicates an incomplete or unsuccessful autostroke.
The routine can be aborted at any time by pressing key once.
If autostroke is aborted during operation ABORT will be displayed and ! to indicate
incomplete autostroke.
On completion the program will automatically return to AUTOS in main menu.
A will be displayed if successful autostroke has been completed. It is now
possible to advance to RUN in main menu.
7.1.10 Press key three times to advance to RUN in main menu.
7.1.11 Press and hold key for 3 seconds to commence automatic operation.
The valve will move to a control position related to the input control signal.
The percentage valve travel will be displayed %.
The positioner cover can now be closed and cover screws tightened.
IM-P343-35 CH Issue 1 27
7.2 3-port valves (with travel setting (TRAVL) 0 - 100%, refer to Figures 27 and 28)
Proceed as above up to Section 7.1.9.
7.2.1 On completion of a successful autostroke press the key once to advance to SET
in main menu.
7.2.2 Press key once to advance to VALVE TYPE.
Press key to indicate VALVE 3-PORT.
7.2.3 Press key to select VALVE 3-PORT. Continue to press key to return to SET in
main menu.
7.2.4 Press key twice to advance to RUN in main menu. Proceed as described in
Section 7.1.11.
IM-P343-35 CH Issue 128
8. Programming flow chart
Fig. 45
Software
version
(Ver X.XX)
MANOP
AUTOS
SET
TUNE
RUN
SET-UP
NOW
SP500
MENU
% Travel
(TRAVL
0-100% /
100-0%)
Manual operation
(MCTL)
Autostroke activate
(AUTOS)
Mounting position
check
(CALIB)
Valve type
(VALVE 2-PORT /
VALVE 3-PORT)
Dead-band
(dBand)
AUTO
OPERATION
(% TRAVEL)
Shut-off minimum
(S-MIN)
Return to SP500
menu
(RETRN AUTO /
RETRN VENT)
RETURN
(To SP500 MENU)
Note: SET, TUNE,
and RUN can
only be accessed
on completion
of a successful
autostroke
(AUTOS)
(RETAIN)
(RESET)
From RETRN
(To SP500 MENU)
Actuator type
(ACT)
C-CAL
IM-P343-35 CH Issue 1 29
Clear stored
values
(RESET)
Recall stored
values
(RETRN)
Retain temporary
values
(RTAIN)
AUTO
OPERATION
(mA Input signal)
Shut-off maximum
(S-MAX)
Characterisation
(LIN / FAST /
EQUAL)
Time to open
(T-UP)
Time to close
(T-dWN)
Travel switch 2 (NC)
(TS2)
Travel switch 1 (NO)
(TS1)
Stem travel
(STRVL)
Key
3 seconds enter
Enter
Auto return
Run time
(RTIME)
(RETAIN)
(RESET)
† Only if MIN-T / MAX-T not 0 / 100%
Maximum
travel
(MAX-T)
Minimum
range
(MIN-R)
Maximum
range
(MAX-R)
Displayed %
travel
(DTRVL)†
Minimum
travel
(MIN-T)
Control action
(CTRLA)
IM-P343-35 CH Issue 130
9. Programming and commissioning
9.1 Set-up now
Programming notes
The positioner fitted to this control valve requires programming. A minimum input
signal of 3.6 mA is required to power the positioner. To program the positioner it
is necessary to enter SP500 MENU and carry out an autostroke commissioning
routine (AUTOS) prior to putting the control valve into automatic operation.
A flow chart is included in Section 8 to guide you through the procedure. The
display provides a flag indication of the active main menu function.
To enter SP500 MENU press and hold key for 3 seconds. The display will
count down the 3 seconds.
Commissioning notes
Main menu functions include:
SP500 MENU View software version, mounting position check, reset default values.
MANOP Manual control of valve movement (Actuator inflation / deflation).
AUTOS Automatic valve commissioning. Provides selection of % travel display.
SET Setting of valve type, control action, travel limits and input signal span.
TUNE Setting of deadband, tight shut-off, lift characterisation, travel time and
software switches.
RUN Activates automatic operation plus input signal, total valve strokes and
total run time. Also provides route for returning to SP500 MENU.
Note: SET, TUNE and RUN functions are restricted and can only be accessed on
completion of a successful autostroke routine (AUTOS).
IM-P343-35 CH Issue 1 31
Clear stored
values
(RESET)
Recall stored
values
(RETRN)
Retain temporary
values
(RTAIN)
Mounting position
check
(CALIB)
➤
Fig. 46
Software
version
(Ver X.XX)
SET-UP
NOW
From RETRN
SP500
MENU
3 seconds enter
3 seconds enter
9.2 SP500 MENU
Programming notes
You are now in SP500 MENU.
SP500 functions include:
1. Visualisation of the embedded software version (VER--).
2. Positional setting (CALIB).
3. Resetting of programmed values to default settings (RESET).
4. To retain settings in the temporary memory (RTAIN).
5. Returning to previously stored settings (RETRN).
To check the setting (CALIB) press and hold
key for 3 seconds. The display will
count down the 3 seconds. CALIB also provides access to RESET / RTAIN / RETRN
functions.
To view the embedded version of software (VER-.--) press
key. To advance to manual
operation (MANOP) press key.
9.2.1 VER -.-- software version
Programming notes
To view the version of the embedded software (VER-.--) press key.
Press key to return to SP500 MENU. The display will automatically return to
SP500 MENU after 10 seconds.
IM-P343-35 CH Issue 132
9.2.2 CALIB - mounting position calibration
Programming notes
To access CALIB press and hold
key for 3 seconds. The display will count
down the 3 seconds. You are now in calibrate mode. The LCD shows in % the
magnet position in respect to the sensor board of the positioner, without any
offset or scale up or down.
When the LCD shows 0% the magnet is positioned near the bottom of the
positioner’s case.
At 50% the magnet will be in front of the cross impressed on the back of the
positioner.
At 100% the magnet will be roughly aligned with the top of the positioner’s
case.
Desired setting is 50% with the valve at half stroke. The and keys can be
used to manipulate the actuator inflation. In this way it is possible to check the
mounting position and if necessary change it and then check again to get the
positioner well centred.
Press
key advance to RESET / RTAIN / RETRN.
IM-P343-35 CH Issue 1 33
9.2.3 RETRN - RTAIN - RESET
Programming notes
Provides the facility to restore previous permanently stored values (RETRN),
to retain values stored in the temporary memory (RTAIN) or to reset all values
to factory default settings (RESET). Press and keys to select RETRN,
RTAIN or RESET. To advance proceed as follows:
RETRN
To cancel any temporary changes to programmed values select RETRN and
press key to return to SP500 MENU.
RTAIN
To retain temporary changes to programmed values select RTAIN and
press key to return to SP500 MENU.
RESET
Provides the facility to reset all values to factory default settings and return to
SET UP NOW. Press and hold key for 3 seconds. The display will count down
the 3 seconds.
Commissioning notes
RETRN
If changes have been made to program values they will be held in the temporary memory.
To retain changes in the permanent memory it is necessary to advance to RUN in the main
menu and press and hold key for 3 seconds. The display will count down the 3 seconds.
If you do not wish to retain temporary changes select RETRN and press key to return
to SP500 MENU.
RTAIN
If changes have been made to programmed values they will be held in the temporary memory.
If you wish to retain these changes select RTAIN and press key to return to SP500 MENU.
To retain temporary changes in the permanent memory advance to RUN in the main
menu and press and hold key for 3 seconds. The display will count down the 3 seconds.
RESET
Resetting to default values (refer to Section 9 for default values) should be used if it is intended
to use the positioner on a different control valve. If the SP500 positioner has been moved
on its mounting or is to be fitted on a different control valve it will be necessary to undertake
a new autostroke (AUTOS).
RESET to factory default settings can also be used if it is required to recommission the valve.
To reset to factory default values select RESET and press and hold key for 3 seconds.
The display will count down the 3 seconds.
IM-P343-35 CH Issue 134
9.3 MANOP
Fig. 47
Programming notes
Press and hold key for 3 seconds to enter manual control mode (MCTL).
The display will count down the 3 seconds.
Press the key to enter the current calibration mode (C-CAL). Press to
return to MANOP.
In MANOP press key to advance to autostroke (AUTOS).
Commissioning notes
Before initiating an autostroke commissioning (AUTOS) use manual control (MCTL) to
manually fully inflate and deflate the actuator to ensure there are no obstructions to the
full valve travel movement.
Manual control is also useful during normal operation to manually control the valve position
as a commissioning aid or in the event of input signal failure.
9.3.1 MCTL - manual control
Programming notes
Manual control enables the actuator to be manually inflated or deflated.
Press
key to inflate actuator and key to deflate the actuator. Press and
hold
or key to accelerate action.
Prior to undertaking an AUTOS the display will indicate FILL or VENT.
On completion of AUTOS the display will indicate
% valve travel.
Manual control (MCTRL) - Tight shut-off function
Press and hold the
key to drive the valve to its closed position. At 0% travel the
! will flash to indicate limit of travel. To initiate tight shut-off release the key and
press
again. The actuator will be vented of air to provide dead tight shut-off.
This also applies to the 100% valve position by pressing and releasing the
key and pressing
again to inflate the actuator to provide dead tight shut-off.
Manual control (MCTRL) - Travel limits
When operating in manual control any travel limit settings will be overridden
therefore it is possible to manual position the valve through its full 0 to 100%
travel as measured in autostroke (AUTOS).
Commissioning notes
Before initiating an autostroke commissioning routine (AUTOS) the actuator should be
manually fully inflated and deflated to ensure there are no obstructions to the full valve
travel movement.
Manual control is also useful during normal operation to manually control the valve position
as a commissioning aid or in the event of input signal failure.
MANOP
Manual operation
(MCTL)
3 second enter
C-CAL
IM-P343-35 CH Issue 1 35
9.3.2 C-CAL - current calibration
Programming notes
C-Cal provides a simple way to make a fine calibration of the input current signal
(4 - 20 mA).
To perform the calibration:
1. Enter C-CAL and press the key, then press the key.
2. Generate a 4 mA input signal and press
3. Generate a 12 mA input signal and press
4. Generate a 20 mA input signal and press
If 'ERROR' is displayed the calibration routine is aborted. The value of the
generated signal is too far from the expected one. Be sure that a 4 mA, 12 mA or
20 mA signal is generated as required. Press to return to C-CAL.
If 'OK' is displayed the calibration has succeeded. Press to return to C-CAL.
Where possible current calibration should be overtaken, to guarantee a perfect
match between the input current generated and the reading of the SP500.
Let’s assume that the table below show the input signal generated by a PLC or
DCS versus the input signal read by the SP500.
Setpoint Input current from PLC Current read from SP500
0% 3.6 mA 3.8 mA
50% 12 mA 12.2 mA
100% 20 mA 20.2 mA
Hence when the setpoint is 0% the PLC generates a 3.6 mA instead of 4 mA.
After C-CAL is executed the SP500 recalibrates the current read to compensate
the error.
Setpoint Input current from PLC Current read from SP500
0% 3.6 mA 4 mA
50% 12 mA 12 mA
100% 20 mA 20 mA
In this way a perfect match is achieved between the setpoint of the PLC and the
setpoint of the of the SP500 (i.e. the input current read by the SP500).
IM-P343-35 CH Issue 136
9.4 AUTOS - automatic autostroke commissioning
AUTOS
% Travel
(TRAVL
0-100% /
100-0%)
Autostroke activate
(AUTOS)
3 second
enter
Fig. 48
Programming notes
AUTOS provides access to:
1. Autostroke commissioning (AUTOS). 2. % travel display (TRAVL).
AUTOS
Autostroke provides an automatic commissioning routine which will take
approximately 1 to 3 minutes to complete.
Press and hold
key for 3 seconds to start autostroke. The display will count
down the 3 seconds. When autostroke is active a flashing AUTOS message
will be displayed.
On completion of a successful autostroke the programme will automatically
return to AUTOS in the main menu and a
will be displayed. In the event of
an unsuccessful autostroke routine a flashing
! will be displayed.
If during AUTOS inconsistent data is obtained due to mechanical problems, the
autostroke procedure will be terminated and ABORT will be displayed.
It is also possible to immediately abort during an autostroke routine by pressing
the
key. ABORT will be displayed together with a flashing !.
Error messages:
ERROR 1 Indicates a wrong mechanical coupling between positioner and
actuator. Check the mounting is correct.
ERROR 2 Indicates that there is insufficient air pressure to achieve valve
movement. Check that the air supply is adequate to overcome the actuator
spring force. Fitting of a gauge block will aid the commissioning procedure.
ERROR 3 Indicates that the actuator will not deflate. Check that there is
no obstruction preventing the stem travel or air venting from the actuator.
ERROR 4 indicates that the stroke measured is less than the minimum
stroke allowed - 10 mm for linear valves, and 5° for quarter turn valves
(output 1 and output 2 for double action applications).
ABORT indicates mechanical problems have occurred during the Autostroke
procedure or the
key has been pressed during Autostroke to abort the
procedure.
On completion of a successful autostroke it will be possible to advance to
SET, TUNE and RUN functions in the main menu. Press the key to advance
to these functions.
Commissioning notes
Prior to undertaking an autostroke routine, manual operation should be used to fully
inflate and deflate the actuator to ensure there are no obstructions to the full valve
movement. Autostroke is an automatic commissioning routine that checks for maximum
valve travel, signal response, valve characteristics, inflation / deflation times etc. Data
gathered will be automatically download into the embedded software to ensure optimum
performance of the valve / actuator combination.
Autostroke commissioning will take approximately 1 to 3 minutes to complete
depending on air pressure and actuator size etc.
Autostroke commissioning must be carried out on start-up or at any other time if the
valve performance is not satisfactory.
IM-P343-35 CH Issue 1 37
9.4.1 TRAVL - % travel display
Programming notes
Press key to access TRAVL.
Provides selection of % valve travel display with option of 0 - 100% or 100 - 0%.
Default is 0 - 100%.
Use and keys to toggle selection.
Press key to return to AUTOS.
Commissioning notes
The selection of % valve travel display depends on the valve and actuator configuration.
Figures 49 to 52 (pages 37 and 38), and Figures 53 and 54 (page 39) provide guidance on
selection. After completion of AUTOS if a change is made to TRAVL it will be necessary to
initiate an AUTOS routine once again.
Display = 0%
Display = 100%
Display = 0%
Display = 100%
Fig. 49 2-port valve normally closed - TRAVL setting = 0 to 100%
Fig. 50 2-port valve normally open - TRAVL setting = 0 to 100%
IM-P343-35 CH Issue 138
Display = 100%
Display = 0%
Display = 100%
Display = 0%
Fig. 51 2-port valve normally open - TRAVL setting = 100% to 0%
Fig. 52 2-port valve normally closed - TRAVL setting = 100% to 0%
IM-P343-35 CH Issue 1 39
TRAVEL setting = 0 to 100%
DISPLAY = 0%
TRAVL setting = 100 to 0%
DISPLAY = 100%
TRAVEL setting = 0 to 100%
DISPLAY = 100%
TRAVL setting = 100 to 0%
DISPLAY = 0%
TRAVEL setting = 0 to 100%
DISPLAY = 0%
TRAVL setting = 100 to 0%
DISPLAY = 100%
TRAVEL setting = 0 to 100%
DISPLAY = 100%
TRAVL setting = 100 to 0%
DISPLAY = 0%
100%
0%
100%
0%
100%
0%
100%
0%
Fig. 53 3-port valve and spring extend actuator
Fig. 54 3-port valve and spring retract actuator
IM-P343-35 CH Issue 140
9.5 SET - setting of valve functions
Fig. 55
Programming notes
Provides access to basic valve set up functions. Press key to scroll round all
SET functions.
Functions include:
- Valve type (2-port or 3-port) (VALVE)
- Actuator type (on /off) (ACT)
- Control action (direct or reverse) (CTRLA)
- Minimum travel setting (0 to 66.66%) (MIN-T)
- Maximum travel setting (33.3 to 100%) (MAX–T)
- Displayed % travel (on / off) (DTRVL)
- Minimum span range (input mA signal) (MIN-R)
- Maximum span range (input mA signal) (MAX-R)
Press
key to advance to valve type (VALVE). Repeat pressing of key will
scroll round all SET functions.
Press key to advance to TUNE in the main menu.
Commissioning notes
Each SET function has a default value as listed in the Installation and Maintenance
Instructions. Default values are based on a 2-port normally closed valve having maximum
95% lift and an input signal span range 4 - 20 mA.
SET values should be adjusted to suit the valve type (2-port or 3-port) and application.
Functions include the facility to change the control action, limit the full travel of the valve
plug (minimum and maximum) and to split range the input signal.
More detailed information is provided for each SET function.
Valve type
(VALVE 2-PORT /
VALVE 3-PORT)
Control action
(CTRLA)
Minimum range
(MIN-R)
Maximum range
(MAX-R)
SET
Displayed %
travel
(DTRVL)†
† Only if MIN-T / MAX-T not 0 / 100%
Maximum travel
(MAX-T)
Minimum travel
(MIN-T)
Actuator type
(ACT)
IM-P343-35 CH Issue 1 41
9.5.1 VALVE - valve type
Programming notes
Provides selection between 2-port and 3-port valves. Default is 2-port valve.
Default values for travel limit settings (MIN-T and MAX-T) and early vent /
inflate settings (S-MIN and S-MAX) will depend on the valve type (2-port or
3-port) and control action (direct or reverse) as follows:
Valve type
2-port 3-port
Display Direct Reverse Direct Reverse
MIN-T 0% 0% 0% 0%
MAX-T 95% 95% 100 100%
S-MIN 0.1% OFF 0.1% 0.1%
S-MAX OFF 0.1% 0.1% 0.1%
Use and keys to select type. Press key to accept displayed type and
advance to actuator type (ACT).
Commissioning notes
Selection of 2-port or 3-port valves will automatically alter the maximum travel default
value (MAX-T) to 95% for 2-port and 100% for 3-port valves. Advance to MAX-T to change
these values if required.
9.5.2 ACT - actuator type
Programming notes
ACT selection makes the positioner control more fluid and reactive, improving
feedback to the control signal. Selection is: 'ON' or 'OFF'. Default value is 'OFF'.
Use the and keys to toggle selection. Press key to accept displayed value and
advance to Control action (CTRLA).
Commissioning notes
If the actuator or the valve have high hysteresis or high friction it is suggested to set ACT
to 'OFF'.
If hunting is present set ACT to 'OFF'.
IM-P343-35 CH Issue 142
9.5.3 CTRLA - direct or reverse control action
Programming notes
Provides selection of direct (dIRCT) (4 - 20 mA) or reversed (REV) (20 - 4 mA)
valve positioning control action. Press and keys to select desired action.
Default action is dIRCT.
Default values for travel limit settings (MIN-T and MAX-T) and early shut-off
vent / inflate settings (S-MIN and S-MAX) will depend on the valve type (2-port
or 3-port) and control action (direct or reverse) as follows:
DIR - direct action
Display 2-port 3-port
MIN-T 0% 0%
MAX-T 95% 100%
S-MIN 0.1% 0.1%
S-MAX OFF 0.1%
REV - reverse action
Display 2-port 3-port
MIN-T 0% 0%
MAX-T 95% 100%
S-MIN OFF 0.1%
S-MAX 0.1% 0.1%
Press key to accept the displayed action and advance to minimum travel
setting (MIN–T).
Commissioning notes
Selection of direct or reverse action changes the direct of valve plug movement
relative to the input signal. Refer to Figures 56 and 57, and the table shown in
Figure 58 for further guidance.
Valve plug position
Valve stem lifting
mA
Increasing input signal
Valve plug position
Valve stem falling
mA
Increasing input signal
Fig. 56 Direct action (DIR) Fig. 57 Reverse action (REV)
IM-P343-35 CH Issue 1 43
Installed orientation At-rest position Control action
Manual Selection
of required % travel
(TRAVL)
Automatic determintation
Spring action only affects
the rest or fail-safe position
Manual Selection of required
Control Action
(CTRLA)
(TRAVL)
0 - 100%
(TRAVL)
100 - 0%
0%
100%
0%
100%
Fig. 58 CTRL Control Action dIRCT or REV setting guidance
IM-P343-35 CH Issue 144
9.5.4 MIN-T - minimum travel setting
Programming notes
Enables the minimum valve travel to be set as a percentage of the maximum
travel obtained during autostroke. Maximum setting is MAX-T less 33.3%.
Default value is 0%.
Use and keys to alter the displayed value. Press key to accept the
displayed value and advance to the maximum travel setting (MAX-T).
Commissioning notes
Minimum travel should be used where a minimum flowrate is required to be maintained
through the valve, (i.e. a cooling water application). Setting a minimum travel % value will
prevent the valve fully closing.
The input signal span range set (MIN-R) and (MAX-R) will operate over the travel limits
set. If a value for MIN–T is set it will exclude the setting of shut-off minimum (S-MIN) for
control action direct (DIR) and shut-off maximum (S-MAX) for control action reverse (REV).
9.5.5 MAX-T - maximum travel setting
Programming notes
Enables the maximum valve travel to be set as a percentage of the maximum
travel measured during autostroke. Minimum setting is MIN-T plus 33.3%.
Default values will depend on the selection of valve type (2-port or 3-port) and
control action (direct or reverse) as follows:
Valve type Direct Reverse
2-port 95% 95%
3-port 100% 100%
Use and keys to adjust the displayed value. Press key to accept displayed
value and advance to the next function.
Commissioning notes
The maximum valve travel percentage should be used to prevent a control valve fully
opening. This is useful for applications where the valve is oversized or to restrict the
maximum flowrate through the valve.
On 2-port valves the default value is 95% to prevent the back of the plug hitting the bonnet.
On 3-port valves to ensure shut-off on both seats a 100% setting is required.
The input signal span range set (MIN-R) and (MAX-R) will operate over the travel limits set.
If a value for MAX-T is set it will exclude the setting of shut-off maximum (S-MAX) for
direct action (DIR) and shut-off minimum control action (S-MIN) for reverse action (REV).
IM-P343-35 CH Issue 1 45
9.5.6 DTRVL - displayed travel percentage
Programming notes
The full mechanical limits of valve travel (0 to 100%) are measured during
autostroke (AUTOS).
It is possible to limit the minimum and maximum valve travel by programming
MIN-T and MAX-T values, i.e. MAX-T maximum travel limit of 95% (Autostroke
default value for 2-port valves).
DTRVL (0 to 100% displayed travel value) can be displayed over the actual
mechanical travel limits (as measured during Autostroke), or adjusted MIN-T
and MAX-T travel settings.
DTRVL programming options
DTRVL - ON will display 0 to 100% over the MIN-T and MAX-T travel settings,
or,
DTRVL - OFF will display 0 to 100% over the actual mechanical limits of travel.
Default value is DTRVL - ON. Use and keys to toggle selection.
Press key to accept displayed 'ON' or 'OFF' option and advance to minimum
range setting (MIN-R).
Examples
Example 1 Example 2
MAX-T = 95%
MIN-T = 0%
MAX-T = 95%
MIN-T = 5%
Display values
DTRVL - ON DTRVL - OFF
100% 95%
0% 0%
Commissioning notes
DTRVL provides the choice of travel display. For 2-port valves you can adjust the MAX-T
setting to achieve the actual desired valve lift (i.e. 20 mm or 30 mm, etc). Using DTRVL you
can then choose to display the MAX-T valve travel you have set as 100%.
Display values
DTRVL - ON DTRVL - OFF
100% 95%
0% 5%
IM-P343-35 CH Issue 146
9.5.7 MIN-R - minimum signal span range
Programming notes
Enables the minimum mA input signal span range to be set. The value set will
correspond to the minimum travel setting. Default value is 4 mA.
Use and keys to alter the displayed value. Minimum difference between
MIN-R and MAX-R is 4 mA.
Press key to accept the displayed value and advance to the maximum mA
input span range (MAX-R).
Commissioning notes
This function can be used to set split range applications i.e. 4 - 12 mA or 12 - 20 mA.
To ensure tight shut-off refer to Section 9.6.2 S-MIN, page 48.
9.5.8 MAX-R - maximum signal span range
Programming notes
Enables the maximum mA input signal span range to be set. The value set will
correspond to the maximum travel setting. Default value is 20 mA.
Use and keys to alter the displayed value. Minimum difference between
MIN-R and MAX-R is 4 mA.
Press key to accept the displayed value and return to SET in the main
menu.
Commissioning notes
This function can be used to easily set split range applications i.e. 4 - 12 mA or 12 - 20 mA.
To ensure tight shut-off refer to Section 9.6.3 S-MAX, page 49.
IM-P343-35 CH Issue 1 47
Fig. 59
Provides access to more advanced valve tuning functions including:
- Dead-band (valve positioning sensitivity) (dBANd)
- Shut-off minimum (ensures tight closure) (S-MIN)
- Shut-off maximum (ensures tight closure) (S-MAX)
- Characterisation (signal / lift relationship) (CHAR)
- Time open (slows down valve opening) (T-UP)
- Time close (slows down valve closure) (T-dWN)
- Travel switch 1 normally open (sets software travel switch) (TS1)
- Travel switch 2 normally closed (sets software travel switch) (TS2)
Programming notes
Press
key to advance to deadband (dBANd). Repeated pressing of key
will scroll round all TUNE functions. If you do not wish to alter TUNE default
values press
key to advance to RUN in the main menu.
Commissioning notes
Each TUNE function has a default value as listed in the Installation and Maintenance
Instructions. Default values are based on a 2-port normally closed valve having maximum
95% lift and an input signal span range 4 - 20 mA.
TUNE values should be adjusted to suit the valve type and application. Functions include:
1. The facility to alter deadband positioning sensitivity (to dampen out signal fluctuations).
2. Setting input signal to achieve tight shut-off (inflation and deflation of actuator).
3. Relationship between valve lift to input signal.
4. Slowing down the valve open or closing time duration.
5. Setting the switching position for the software travel switches.
More detailed information is provided for each TUNE function.
9.6 TUNE - setting of valve tune functions
Dead-band
(dBand)
Shut-off maximum
(S-MAX)
Characterisation
(LIN / FAST /
EQUAL)
Time to open
(T-UP)
Time to close
(T-dWN)
Travel switch 2
(TS2)
Normally closed
Travel switch 1
(TS1)
Normally open
Shut-off minimum
(S-MIN)
TUNE
IM-P343-35 CH Issue 148
9.6.1 dbANd - deadband setting (positional sensitivity)
Programming notes
Dead-band provides adjustment of the valve positioning sensitivity relative to
the input signal and is expressed as a % of the input signal span.
Default value based on a 4 - 20 mA input signal span is 0.5% with a minimum
setting of 0.2%. Note: 3% may be displayed if ACT is set to 'ON'. Refer to
Section 9.5.2, page 41.
These values may change if the input signal span is reduced i.e. for a 4 mA input
signal span the default and minimum setting is 0.8%.
The maximum setting is 10% of the input signal span.
To alter the displayed value press and keys. Press
key to accept the
displayed value and advance to the shut-off minimum (S-MIN).
Commissioning notes
Setting a narrow deadband may induce oscillations of valve movement caused by fluctuations
in the input signal, high stem friction or operating at low ambient temperatures below 0°C.
Setting a wider deadband will dampen out oscillations but may cause an inaccuracy in actual
valve position. This effect will increase if valve travel is limited. It is normally recommended
that the default value is used. If necessary gradually increase the % value to dampen out any
oscillations in valve movement. This may be necessary for valves having graphite packed stem
seals or smaller size actuators where typically a deadband of 4% may be required.
9.6.2 S-MIN - valve shut-off - minimum travel
Programming notes
Provides the facility to fully vent the actuator at a predetermined input signal.
The value set is a percentage of the input signal span range, i.e. setting a
value of 10% with an input span range of 4 - 20 mA (span 16 mA), will cause
the valve to close with an input signal of 5.6 mA i.e. 4 mA + 1.6 mA (10% of
16 mA). Maximum setting is 20%.
Default values will depend on the selection of valve type (2-port or 3-port)
and control action (direct or reverse) as follows:
Valve type Direct Reverse
2-port 0.1% Off%
3-port 0.1% 0.1%
For direct control action (dIRCT) can only be set if MIN-T = 0% (will vent the
actuator at set value). For reverse action (REV) can only be set if MAX-T = 100%
(will inflate the actuator at set value).
Press and keys to alter the displayed value. Press key to accept the
displayed value and advance to shut-off maximum (S-MAX).
Commissioning notes
With an actual input signal equivalent to minimum input signal span range (MIN-R) it
may cause the valve plug to hover over the seat preventing tight closure with the possibility
of erosion damage to the plug and seat faces. Setting a shut-off value can help prevent
this by providing early closure of the valve.
IM-P343-35 CH Issue 1 49
9.6.3 S-MAX - valve shut-off maximum
Programming notes
Provides the facility to fully inflate the actuator at a pre-determined input signal.
The value set is a percentage of the input signal span range, i.e. setting a value
of 10% with an input span range of 4 - 20 mA (16 mA), will cause the valve
to close with an input signal of 18.4 mA i.e. 20 mA - 1.6 mA (10% of 16 mA).
Maximum setting is 20%.
Default values will depend on the selection of valve type (2-port or 3-port) and
control action (direct or reverse) as follows:
Valve type Direct Reverse
2-port Off 0.1%
3-port 0.1% 0.1%
For direct action (dIRCT) can only be set if MAX-T = 100% (will inflate the
actuator at set value). For reverse action (REV) can only be set if MIN-T = 0%
(will vent the actuator at set value).
Press and keys to alter displayed value. Press key to accept the
displayed value and advance to the characterisation (CHAR).
Commissioning notes
With an actual input signal of 20 mA and a maximum span range setting (MAX-R) of
20 mA may cause the valve plug to hover over the seat preventing tight closure with the
possibility of erosion damage to the plug and seat. Setting a shut-off value can help prevent
this by providing early closure of the valve.
9.6.4 CHAR - valve characterisation
Programming notes
Provides selection of linear (LIN), equal percentage (EQUAL) or fast opening
(FAST) characterisation. Characterisation is the relationship between input
signal and valve lift. Default value is Linear (LIN).
Use and keys to select the desired action. Press key to accept the
displayed characterisation and advance to time open (T-UP).
Commissioning notes
The standard characterisation for 2-port and 3-port valves is linear (LIN). For special
applications using 2-port valves an equal percentage (EQUAL) or fast opening (FAST)
characteristic can be selected. With equal percentage the valve will start to open slowly
and gradually accelerate opening related to input signal. With fast opening characteristic
the valve will commence to open quickly and gradually slow down opening related to
the input signal. This action is in addition to the valve trim flow characterisation (refer to
Figure 60 for guidance).
Fig. 60
Valve lift
Signal (mA)
Ratio 1:50
Ratio 50:1
Valve lift
Signal (mA)
Valve lift
Signal (mA)
Ratio 1:1
IM-P343-35 CH Issue 150
9.6.5 T-UP - valve slow opening action
Programming notes
This function slows down the time taken for the valve to travel from 0 to 100%
lift. The time displayed is the fastest travel time measured during autostroke
(AUTOS). 4 seconds may be displayed if ACT is set to 'ON' (refer to Section
9.5.2, page 41).
Default value is the fastest time measured during autostroke.
Press and keys to alter the displayed value. Press key to accept the
displayed value and advance to time down (T-dWN).
Commissioning notes
The time displayed on start-up is the fastest time measured during autostroke
commissioning (AUTOS). A time cannot be set less than the minimum recorded during
autostroke. The value set will be the time taken for the valve to travel from 0 to 100% lift.
The time set will apply at all times and not just at start-up. This function is useful to prevent
the effects of system waterhammer, thermal shocks or slow down over-reactive systems
or the effects of oversized valves. Default is the fastest time measured during autostroke.
Maximum setting is 180 seconds.
9.6.6 T-dWN - valve slow closing action
Programming notes
This function slows down the time taken for the valve to travel from 100 to 0%
lift. The time displayed on start-up is the fastest travel time measured during
autostroke (AUTOS). 4 seconds may be displayed if ACT is set to 'ON' (refer
to Section 9.5.2, page 41). Default value is the fastest time measured during
autostroke.
Press and keys to alter the displayed value. Press key to accept the
displayed value and advance to travel switch 1 (TS1).
Commissioning notes
During autostroke routine the quickest time taken for the valve to fully close will be
measured and displayed. A time cannot be set less than the minimum recorded during
autostroke. The value set will be the time taken for the valve to travel from 100 to 0% lift.
This action will apply at all times and not just at start-up. This function is useful to prevent
the effects of system waterhammer, or to slow down over-reactive systems or the effects
of oversized valves. Default is the minimum time measured during autostroke. Maximum
setting is 180 seconds.
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Fig. 61 TS1 Travel switch 1 (normally open)
Switch
closed
Signal
Switch
open
Travel
100%
0%
Note:
Software configured travel
switches can be set within
the range 0% to 100% of
full travel irrespective of any
travel limit settings.
9.6.7 TS1 and TS2 software travel switches
Two switches are available TS1 and TS2.
TS1 is normally open and TS2 is normally closed. Switching action is set as
a % of valve travel (refer to Figures 61 and 62).
TS1 - software configured travel switch 1 (normally open)
Programming notes
The switching point can be set as a percentage of the valve travel between 0
to100%. A value can be set outside the limits of the travel settings (MIN-T)
and (MAX-T).
Initially OFF will be displayed indicating that the switch is not set. To set a
switching point press and keys to alter the displayed value.
Press
key to accept the displayed value and advance to travel switch 2
normally closed (TS2).
Commissioning notes
Travel switch 1 (TS1) is normally open. External wiring should be made between terminals
1 (+) and 2 (-). The value set is a % of valve travel. At the set value the switch will close.
The status of the switch will be shown on the LCD (refer to Figure 61).
Software configured travel switches can be used to remotely indicate valve position or
to operate warning devices, fans, stirrers, motors or other process equipment via a
secondary switching device.
50%
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TS2 - software configured travel switch 2 (normally closed)
Programming notes
The switching point can be set as a percentage of the valve travel between 0
to 100%. A value can be set outside the limits of the travel settings (MIN-T)
and (MAX-T). Initially OFF will be displayed indicating that the switch is
not set. To set a switching point press and keys to alter the displayed
value.
Press key to accept the displayed value and return to TUNE in the
main menu.
Commissioning notes
Travel switch 2 (TS2) is normally closed. External wiring should be made between terminals
3 (+) and 4 (-). The value set is a % of valve travel. At the set value the switch will open. The
status of the switch will be shown on the LCD (refer to Figure 62).
Software configured travel switches can be used to remotely indicate valve position or
to operate warning devices, fans, stirrers, motors or other process equipment via a
secondary switching device.
Note: If the switch is in its 'off' status it will be an open circuit.
Fig. 62 TS2 Travel switch 2 (normally closed)
Switch
open
Switch
closed
Travel
100%
0%
50%
Signal
Note:
Software configured travel
switches can be set within
the range 0% to 100% of
full travel irrespective of any
travel limit settings.
IM-P343-35 CH Issue 1 53
9.7 RUN - automatic operation
Fig. 63
AUTO OPERATION
( % TRAVEL)
Return to
SP500 menu
(RETRN AUTO /
RETRN VENT)
Run time
(RTIME)
Return to
SP500 MENU
RUN
mA
(mA input signal)
Stem travel
(STRVL)
Programming notes
Provides the facility to put the valve into automatic operation. Press and
hold key for 3 seconds to start automatic operation. The display will count
down the 3 seconds.
The valve will move to a position in response to the input control signal.
All values stored in the temporary memory will be transferred to the permanent
memory.
Commissioning notes
By pressing and holding the key for 3 seconds all values previously set will be entered
into the permanent memory. The valve will move to a position as dictated by the input
control signal.
To alter or check SET or TUNE values it is necessary to return to SP500 MENU. Press and
hold key for 3 seconds to return to SP500 MENU. The display will count down the 3 seconds.
There are two options for returning to SP500 MENU:
Option 1 is to stay in automatic control (AUTO) where the valve will continue to position
itself relative to the input control signal.
Option 2 is to vent the actuator (VENT) where the valve will travel to its fail-safe position.
(RETAIN)
(RESET)
(RETAIN)
(RESET)
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9.7.1 Automatic operation - % travel
Programming notes
During normal automatic operation the % valve travel will be continuously
displayed together with the switch status of the software travel switches (if fitted).
Additionally, a
will be displayed indicating that the valve is operating
satisfactorily. At any time during automatic operation the mA input signal
can be displayed by pressing
key.
To return to SP500 MENU press and hold
key for 3 seconds. The display will
count down the 3 seconds. You will advance to RETRN with the option of AUTO
(automatic operation) or VENT (venting air from actuator). Use
and keys to
select the desired option. Press
key to accept the displayed option and return
to SP500 MENU.
Commissioning notes
During normal operation the % valve travel will be continually displayed. A indicates
that the valve is performing satisfactorily. Causes of fluctuations in valve movement can
be related to input signal. Press key to view actual mA input signal.
9.7.2 Input signal - mA signal display
Programming notes
The mA input signal will be displayed. Press key to return to displaying
% travel. The programme will automatically return to displaying % travel after
5 minutes.
It is possible to advance to view valve diagnostics data STRVL (total valve strokes)
and RTIME (total run time).
To advance to STRVL press and hold key for 3 seconds. The display will count
the 3 seconds.
Commissioning notes
This function is of assistance to visualise and check input signal relative to valve position
and to investigate causes of fluctuations in valve movement. The mA input signal will be
displayed for 5 minutes. Press key to return to displaying % travel. The programme will
automatically return to displaying % travel after 5 minutes.
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9.8.2 RTIME - total valve run time in hours
Programming notes
The number displayed is the total valve run time in hours. Run time is defined
as the total time the positioner is receiving a control signal.
The number displayed can be retained (RTAIN) or reset to zero (RESET). Press
the key to advance to RTAIN / RESET. Press and keys to toggle selection.
Press key to accept the displayed selection and return to displaying % travel.
Commissioning notes
Information displayed should be used in conjunction with total valve strokes (STRVL)
to assess the valve usage and evaluate the need for routine maintenance, replacement
of stem seals etc. To retain the displayed value press key and select RTAIN. If the
valve is dismantled for maintenance inspection etc. The value can be reset to zero if
required by selecting RESET.
9.8 STRVL and RTIME - valve diagnostics
Provides visibility of total number of valve strokes (STRVL) and total valve
run time in hours (RTIME).
9.8.1 STRVL - total stem travel
Programming notes
The number displayed should be multiplied by a factor of 10 to obtain the total
number of complete valve strokes. A complete valve stroke is as measured
in autostroke AUTOS.
The number displayed can be retained (RTAIN) or reset to zero (RESET).
Press the
key to advance to RTAIN / RESET. Press and keys to toggle
selection.
Press key to accept the displayed selection and advance to run time RTIME.
Commissioning notes
Information displayed should be used in conjunction with total runtime RTIME to assess
the valve usage and evaluate the need for routine maintenance, replacement of stem seals
etc. The number displayed should be multiplyed by a factor of 10 to obtain the local total
number of complete valve strokes. (A complete valve stroke is as measured in autostroke
(AUTOS)). The maximum possible display value is 99999. If this value is exceeded, the
display will roll over to zero and an ! will be displayed. To retain the displayed value press
the enter key and select RTAIN. If the valve is dismantled for maintenance inspection etc.
The value can be reset if required by selecting RESET.
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9.9 RETRN - return to SP500 MENU in main menu
Fig. 64
Programming notes
Press and hold key for 3 seconds. The display will count down the 3 seconds.
This provides the facility to return to SP500 MENU with the option of staying in
automatic operation (AUTO) or venting the actuator (VENT). Use and keys
to toggle selection. Press key to select and return to SP500 MENU.
Commissioning notes
To alter any SET or TUNE values, go into manual control (MCTL) it is then necessary to
return to the SP500 MENU.
Any values altered will be recorded in the temporary memory and activated immediately.
To store in the permanent memory it will be necessary to advance to RUN and press
and hold key for 3 seconds. The display will count down the 3 seconds.
To return to the main menu but stay in automatic control select AUTO. The valve will
continue in automatic operation and respond to changes in input control signal. With the
exception of CALIB and MCTL functions, main menu and subroutines will timeout after
5 minutes if no key is pressed and revert to displaying % TRAVEL in automatic control
mode. Any temporary changes made will not be recorded in the permanent memory.
To return to main menu in a fail-safe position select VENT. The actuator will be fully vented
of air and the valve will return to its fail-safe position.
To return to manual control (MCTL) advance to MANOP in the main menu and advance
to manual control (MCTL). The valve can now be manually controlled using the and
keys to inflate or deflate the actuator. The desired % TRAVEL will be displayed.
To return to automatic control advance to RUN and press key for 3 seconds. The
display will count down the 3 seconds. The valve will revert to automatic control and
position itself relative to the input control signal. Any SET or TUNE values altered will be
recorded in the permanent memory.
AUTO OPERATION
(% TRAVEL)
Return to
SP500 menu
(RETRN AUTO /
RETRN VENT)
Return to SP500 MENU
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10. Maintenance
10.1 Air supply quality
As stated in Section 5.4, it is important for correct operation of the SP500
positioner that good quality air is supplied.
It is therefore recommended that a Spirax Sarco MPC2 filter regulator or
equivalent is fitted on the air supply to the positioner. In addition the
SP500 positioner has an internal filter. In normal operation it is recommended
that this filter is replaced every 6 to 12 months depending on the air quality and
valve usage. A spare filter plug kit can be obtained from Spirax Sarco that
includes: filter plug, plus 3 off 'O' rings and filter.
10.2 Fitting replacement filter plug kit
To change the filter proceed as follows:
- Ensure that the air supply to the positioner is isolated.
- Unscrew the filter plug (1) from the SP500 housing using a 5 mm hex. head
socket key (refer to Figure 65).
The replacement filter plug can now be fitted:
- Fit the 'O' ring (4) and filter (3) onto the filter plug (1) (refer to Figure 49).
- Finally fit the retaining screw (2).
The filter plug can now be replaced into the SP500 housing, checking that the
'O' ring (4) is correctly located.
The pnuematic air supply can now be restored to the positioner and checks
made to ensure that the filter plug 'O' ring has provided the neccesary air tight
seal.
Fig. 66
Fig. 65
Filter plug (1)
2
3
4
1
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11. Default values and
program settings
Main menu Sub-menu Setting options Default value
Programmed
value
SET
Valve type 2-PORT
(VALVE) 3-PORT
(2-PORT)
SET
Actuator type ON
(ACT) OFF
OFF
SET
Control action Direct (dIRCT)
(CTRLA) Reverse (REV)
(dIRCT)
SET
Minimum travel
(MIN-T)
0 to 66% 0%
SET
Maximum travel 33 to 100% 95% for 2-port
(MAX-T) 100% for 3-port
SET
Displayed % travel ON
(DTRVL) OFF
ON
SET
Minimum input signal
(MIN-R)
4 to 16 mA 4 mA
SET
Maximum input signal
(MAX-R)
8 to 20 mA 20 mA
Dead-band
0.2 to 10% 0.5%
TUNE
(dBAND)
(% of (3% if
input signal span) ACT is 'ON')
TUNE
Minimum shut-off OFF,
(S-MIN) 0 to 20%
0.1%
TUNE
Maximum shut-off OFF, OFF for 2-port
(S-MAX) 0 to 20% 0.1% for 3-port
Characteristic
Linear (LIN),
TUNE
(CHAR)
Equal (EQUAL), (LIN)
Fast (FAST)
Autostroke time
Time-up Autostroke time – (seconds)
TUNE
(T-UP) 180 seconds
4 seconds
if ACT is 'ON'
Autostroke time
Time-down Autostroke time – (seconds)
TUNE
(T-dWN) 180 seconds
4 seconds
if ACT is 'ON'
TUNE
Travel switch 1 OFF,
(TS1) 0 to 100%
(TS1 OFF)
TUNE
Travel switch 2 OFF,
(TS2) 0 to 100%
(TS2 OFF)
RUN Return to menu
Auto (RETRN AUTO)
(RETRN AUTO)
Vent (RETRN VENT)
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12. Glossary of display data
12.1 Main menu display functions
Display Description
SET UP Indicates that the SP500 positioner fitted to the valve has not been
NOW programmed or commissioned.
Indicates that you have now entered the SP500 main menu.
Provides access to:
SP500 • View the version of the embedded software.
MENU • Facility to centre the mounting position (CALIB).
• Retain temporary changes to menu values (RETRN).
• Recall previously stored menu values (RTAIN).
• Reset to default values (RESET).
MAN OP Provides access to manual control (MCTL) and current calibration (C-CAL).
Provides access to:
• Autostroke commissioning routine.
AUTOS Note: SET, TUNE and RUN functions can only be accessed after
a successful AUTOSTROKE routine has been completed.
• Selection of percentage travel display % (TRAVL).
Provides access to valve set up functions as follows:
• Valve type (VALVE).
• Actuator type (ACT).
• Control action (CTRLA).
SET • Minimum valve travel (MIN-T).
• Maximum valve travel (MAX-T).
• Displayed % travel (DTRVL).
• Minimum signal range (MIN-R).
• Maximum signal range (MAX-R).
Provides access to additional valve characterisation functions as follows:
• Dead-band sensitivity (dbANd).
• Valve shut-off minimum setting (S-MIN).
• Valve shut-off maximum setting (S-MAX).
TUNE • Valve signal – lift characterisation (CHAR).
• Valve slow opening time (T-UP).
• Valve slow closing time (T-dWN).
• Setting software travel switch 1 (normally open) (TS1).
• Setting software travel switch 2 (normally closed) (TS2).
Provides access to:
• Commencing automatic operation.
• Displaying percentage valve travel (%).
RUN • Visualisation of input mA input signal (mA).
• Total stem strokes (STRVL).
• Total running time (RTIME).
• Return to SP500 menu (RETRN).
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12.2 Sub-menu display functions
Display Description
VER x.xx Indicates the version of software embedded within the SP500 positioner.
CALIb Provides facility for mounting position adjustment.
RETRN Enables previously stored function values to be recalled.
RTAIN Enables temporary changes made to function values to be retained.
RESET
Enables all function values to be reset to default settings.
Refer to Section 11 for default settings.
MCTL
Provides manual control of the valve.
Use and keys to fill or vent the actuator.
C-CAL Calibration of the current input.
TRAVL
Selection of percentage of travel display - 0 to 100% or 100 to 0%
depending on valve and actuator configuration.
AUTOS Initiates the autostroke automatic commissioning routine.
AbORT Indicates that the AUTOS commissioning routine has been aborted.
VALVE Selection of 2-port or 3-port valve.
ACT Improve action and speed.
CTRLA Selection of input signal control action 4 - 20 mA or 20 - 4 mA.
MIN-T Setting of minimum valve travel % to prevent the valve fully closing.
MAX-T Selection of maximum valve travel % to prevent the valve fully opening.
DTRVL
Selection of displaying 0 - 100% travel over the mechanical travel limits or
adjusted MIN-T / MAX-T settings.
MIN-R Selection of the input signal related to the minimum valve travel (MIN-T).
MAX-R Selection of the maximum input signal related to maximum valve travel (MAX-T)
dbANd Selection of % valve position dead-band sensitivity.
S-MIN
Facility to select pre-determined input signal to fully close the valve at
the minimum travel position.
S-MAX
Facility to select a pre-determined input signal to fully close the valve at
the maximum travel position.
Selection of input signal to valve lift characterisation. Options include:
CHAR
• Linear (LIN)
• Equal percentage (EQUAL)
• Fast opening (FAST)
LIN Indicates a linear relationship between the input signal and the valve travel.
IM-P343-35 CH Issue 1 61
Display Description
EQUAL
Indicates an equal percentage relationship between the input signal and the
valve travel.
FAST
Indicates a fast opening relationship between the input signal and the valve travel.
T-UP
Facility to slow down the valve opening movement.
T-dWN
Facility to slow down the valve closing movement.
TS1
Setting of % travel for software travel switch 1 (normally open).
TS2
Setting of % travel for software travel switch 2 (normally closed).
%
Indicates percentage of valve travel in automatic operation or
manual control (MCTL).
mA
Indicates the input signal in mA.
AUTOC
Return to SP500 MENU remaining in automatic control operation.
FILL
Indicates the actuator is being filled with air (manual control before AUTOS).
Indicates that there are no problems with the positioner.
!
An error or warning indication.
ERROR 1
(AUTOS)
Indicates a problem with the mounting position.
ERROR 2
(AUTOS)
Indicates that there is insufficient air pressure to position the valve.
ERROR 3
(AUTOS)
Indicates that the air cannot be vented from the actuator.
ERROR 4
(AUTOS)
Detected stroke too short.
— Software travel switch (TS1 and TS2) - closed.
/ Software travel switch (TS1) - open.
\ Software travel switch (TS2) - open.
STRVL
Indicates the total number of valve strokes (x10).
Value can be retained (RTAIN) or reset (RESET).
RTIME
Indicates the total run time of the SP500 in hours.
Value can be retained (RTAIN) or reset (RESET)
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IM-P343-35 CH Issue 1 63
IM-P343-35 CH Issue 164
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