Spirax Sarco SP500 User manual

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. Safetyinformation
3. Technical information
4. Options
5. Installation
6. Electricalconnections
7. Quickstartprocedure
8. Programming
 flowchart
9. Programmingand
 commissioning
10. Maintenance
11. Defaultvaluesand
 programsettings
12. Glossaryof
 displaydata
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.

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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

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No. Features
1. indicates all is OK
2. ! Indicates a delay in positioning, this
disappears when the position is reached
3. Indicates that the value displayed is a
percentage
4. Indicates that the value displayed is the
input current measured in mA
5. Indicates that the value displayed is a
time measured in seconds
6. Indicates that you're accessing the main
programming menus
7. Indicates that the positioner is in manual
mode
8. Indicates that the positioner is running
the autocalibration
9. Indicates that you're accessing the SET
menu
10. Indicates that the positioner is in
automatic mode
11. Indicates that you're accessing the
TUNE menu
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 m3/h at 1.4 bar g or 8.5 normal m3/h at 6 bar g
Steady state air consumption Less than 0.016 normal m3/h
Air connections Screwed ¼" NPT
Cable gland M20
Electrical connections Spring clamp terminals for 0.2 to 1.5 mm² wire
Enclosure rating IP65
Characteristic Linear, Equal % (ratio 1:50) or Fast opening (ratio 50:1)
Resolution (maximum) 0.1% F.S.
4 - 20 mA retransmit (optional) 4 - 20 mA retransmission of valve position
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

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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

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4. Options
4.1 Pressure gauge block
An optional pressure gauge block (Figure 3) can be fitted onto the SP500 positioner which
includes two pressure gauges indicating air supply pressure and output air signal pressure to
the actuator. The pressure gauge block can be retrospectively fitted using 2 off M5 socket
head screws. Ensure that the gauge block air connection 'O' rings are correctly located
before tightening.
Fig. 3

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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

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- 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

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- 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 ADistance between the mounting plate and magnet
Fig. 20 Bracket markings
Fig. 19
Assembled
2
Mounting plate
Bracket
Center
of the
magnet
PN1000PN9000

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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

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5.2.6
Attach the positioner mounting plate to the
positioner as shown in Figures 26 and 27.
Protection
plate
5
Fig. 26
Attach
the
mounting
plate
Assembled
Fig. 27
5.2.7
Adjust the vertical position of the SP500
positioner and mounting plate assembly, by
sliding it up or down on the pillar style actuators,
ensuring that the positioner is roughly centred
on the actuator / valve stroke (Figure 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 assembly is correctly positioned,
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