Spirax Sarco SX25 Series User manual

IM-P323-25 CH Issue 3 1
SX25 Series Process Controller
Installation and Maintenance Instructions
IM-P323-25
CH Issue 3
3231450/3
1. Safety Information
2. Installation
3. Electrical connections
4. Configuration
5. Operations
6. Commissioning examples
7. utomatic tuning
8. Technical specifications
Printed in the UK © Copyright 2003

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IM-P323-25 CH Issue 3 3
1. Safety Information
1.1 General
1.2 Wiring Notes
1.3 Safety requirements and electromagnetic
compatibility
2. Installation
2.1 General description
2.2 Dimensional details
2.3 Panel cut-out
2.4 Environmental ratings
2.5 Panel mounting
3. Electrical connections
3.1 Termination
3.2 Precautions and advised conductor course
3.3 Wiring details
3.4 Wiring examples
3.5 Auxiliary relays for Valve Motor Drive actuators
4. Configuration
4.1 Configuration coding
5. Operations
5.1 Keys and display overview
5.2 Display
5.3 Parameter setting
5.4 Parameter menu
5.5 Parameter description
5.6 Configuration menu
6. Commissioning examples
6.1 Example of pressure control for SX25-mA
6.2 Example of temperature control for SX25-VMD
7. Automatic tuning
8. Technical specification
General Index

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1.1 General
Please carefully read through the following before proceeding with the installation of the controller.
Your attention is drawn to Safety Information leaflet IM-GCM-10.
If the controller is handled improperly or not used as specified, the resultant may:
cause danger of the life and limb of the third party,
damage the controller and other assets belonging to the owner,
hinder the performance of the controller and control system.
1.2 Wiring notes
Every effort has been made during the design of the controller to ensure the safety of the user, but the following
precautions must be followed:-
i) Maintenance personnel must be suitably qualified in working with equipment containing hazardous live voltages.
ii) Ensure correct installation. Safety may be compromised if the installation of the product is not carried out as
specified in this manual.
iii) Isolate the controller from the mains supply before opening the unit.
iv) The controller is designed as an installation category II product, and is reliant on the building installation for over-
current protection and primary isolation.
v) Wiring should be carried out in accordance with IEC 60364 or equivalent. For installations in the US and Canada,
the controller must be wired in accordance with the Local and National Electrical Code (NEC) or the Canadian
Electrical Code (CEC).
vi) Fuses should be fitted in all phases. The instrument is protected with an internal fuse PTC, thermal protective
device. To protect the instruments internal circuits use 2A T fuses for Relay outputs and 1A T fuses for Triac
outputs. The Relay contacts are already protected with varistors. Fuses should not be fitted in the protective
earth conductor. The disconnection or removal of other equipment must not compromise the integrity of the
installation protective earth system.
vii) The mains cable connection at the rear of the controller must be retained in position (by tie wrapping Etc.) This will
prevent the high voltage cables at the rear of the controller from touching the SELV (Safe Extra Low Voltage)
connections, in the unlikely event of the terminals coming loose.
1. Safety Information

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viii) A disconnecting device (switch or circuit breaker) must be included in the building installation. This must be
in close proximity to the equipment and within easy reach of the operator.
There must be a 3 mm contact separation in all poles.
It must be marked as the disconnecting device for the controller.
It must not interrupt the protective earth conductor.
It must not be incorporated into a mains supply cord.
The requirements for the disconnecting device are specified in IEC 60947-1 and IEC 60947-3 or equivalent.
ix) The controller must not be located in such a way that the disconnecting device is made difficult to operate.
1.3 Safety requirements and electromagnetic compatibility
This product is CE marked. It complies with the requirements of 73/23/EEC as ammended by 93/68/EEC on the
harmonisation of the law of Member States relating to electrical equipment designed for use within certain voltage
limits, by meeting the standard EN 61010-1 (IEC 601010-1):90 +A1:92 + A2:95
This product complies with the requirement of 89 / 336/ EEC as amended by 92/ 31/ EEC on the approximation of
laws of the Member States relating to Electromagnetic Compatibility, by meeting the standards of :
EN 50081-2 (Industrial Emissions)
EN 61000-6-2 (Industrial immunity)
The product may be exposed to interference above the limits of EN 61000-6-2 if:
The product or its wiring is located near to a radio transmitter.
Excessive electrical noise occurs on the mains supply.
Cellular telephones and mobile radios may cause interference if used within approximately one metre of the
product or its wiring. The actual separation necessary will vary according to the power of the transmitter.
Power line protectors (ac) should be installed if mains supply noise is likely.
Protectors can combine filtering, suppression, surge and spike arrestors.

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2. Installation
2.1 General description
Installation must only be carried
out by qualified personnel.
Before proceeding with the installation
of this controller, follow the instructions
illustrated in this manual and,
particularly the installation precautions
marked with the symbol, related
to the European Community directive
on electrical safety and electromagnetic
compatibility.
To prevent hands or metal touching
parts that may be electrically live, the
controllers must be installed in an
enclosure and/or in a cubicle.

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2.2 Dimensional details 2.3 Panel cut-out

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2.4 Environmental ratings
Operating conditions
Altitude up to 2 000 m (6 561 ft)
Temperature 0...50°C (32...122°F)
Relative humidity 5...95% non-condensing
Special conditions Suggestions
Temperature >50°C
Humidity > 95%
Conducting atmosphere Use filter
Warm up
Use forced air ventilation
Forbidden conditions
Corrosive atmosphere
Explosive atmosphere
%Rh
%Rh

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2.5 Panel mounting
1Prepare panel cut-out
2Check front panel gasket position
3Insert the instrument through
the cut-out
1Fit the mounting clamps
2Push the mounting clamps towards
the panel surface to secure the
instrument
1Push and
2pull to remove the instrument
Electrostatic discharges can damage
the instrument
Before removing the
instrument the operator must
discharge himself to ground
1Insert the screwdriver in the
clips of the clamps
2Rotate the screwdriver
2.5.1 Insert the instrument 2.5.2 Installation securing 2.5.3 Clamps removing
2.5.4 Instrument unplugging
UL note:
For use on a flat surface
of a Type 2 and Type 3
'raintight' enclosure.

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3. Electrical connections
3.1 Termination Unit
SX25-VMD
Output onOP1:
OP3:
SX25-mA
Output on OP4: mA
Pt 100
VMD
t
VMD
OP4 mA
(SX25 mA ONLY)
t
t
t
Terminals
Pin connector
q 1.4 mm
0.055 in max
Fork-shape
AMP 165004
Ø5.5 mm - 0.21 in
Stripped wire
L 5.5 mm - 0.21 in
18 screw terminals
Option terminals
Holding screw
0.5 N m
Positive screw
driver PH1
Negative screw
driver 0.8 x 4 mm
UL note:
Use 60/70°C (140/158°F)
copper (cu) conductor only.

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3.2 Precautions and advised
conductor course
Despite the fact that the instrument
has been designed to work in an harsh
and noisy environmental (level IV of the
industrial standard IEC 60801-4), it is
recommended to use the following
suggestions.
All the wiring must comply with the
local regulations.
The supply wiring should be routed
away from the power cables.
Avoid to use electromagnetic
contactors, power Relays and high
power motors nearby.
Avoid power units nearby, especially if
controlled in phase angle
Keep the low level sensor input wires
away from the power lines and the
output cables.
If this is not achievable, use shielded
cables on the sensor input, with the
shield connected to earth.

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3.3 Wiring details
3.3.1 Power supply
Please read the safety information
and the wiring notes before
proceeding with the installation of
the controller.
The controller provides switching
power supply with multiple isolation
and internal PTC
• Nominal voltage 100 - 240V~
(-15% +10%) Frequency 50/60Hz
• Power consumption 1.6 W max
3.3.2 PV control unit
A For L-J-K-S-T thermocouple type
• Connect the wires with the polarity as
shown
• Always use compensation cable of the
correct type for the thermocouple used
• The shield, if present, must be
connected to a proper earth
B For Pt100 temperature sensor
• If a 3 wire system is used, always use
cables of the same diameter (1 mm2min.)
(line 20 W/lead maximum resistance)
• when using a 2 wire system, always use
cables of the same diameter 1mm2
(AWG 18) and link terminals 5 and 6
C For DT (2xRTD Pt100) Special
When the distance between the
controller and the sensor and the sensor
is 15 m, using a cable of 1mm2
(AWG 18) diameter, produces an
error on the measure of 1°C
R1 + R2 must be <320W
Wire
resistance
150Wmax
For 3 wires
only 20W/lead
maximum
resistance
Use wires of same
length and 1mm²
(AWG 18) size.
20W/lead
maximum

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3.3.2 PV control unit
D For mA, mV D1 With 2 wire transducer
(SX25 mA only) D2 With 3 wire transducer (SX25 mA only)
Rj >10MW
[1] Auxiliary power supply for external
transmitter 18 V ±20%/30 mA max.
without short circuit protection
Note:
The auxiliary power supply is not
available on the VMD controller.

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The functionality associated to each of the outputs is defined during the
configuration of the instrument, index L(see section 4.1).
The suggested combinations are:
3.3.5 Output configuration
Note: With heat or cool control AL2 and AL3 share the same output.
Output Alarms
Primary Secondary AL2 AL3
ASingle Action Heat or Cool OP4 none none OP2 OP3
BSingle Action Heat or Cool OP4 none none OP1 OP3
CDouble Action Heat OP4 Cool OP3 OP2 -
DDouble Action Heat OP4 Cool OP2 - OP3
EDouble Action Heat OP1 Cool OP4 OP2 OP3
FDouble Action Heat OP2 Cool OP4 OP1 OP3
GValve Motor Drive Open OP1 Close OP3 OP2 OP2
HSingle Action Heat or Cool OP1 none none OP2 OP3
ISingle Action Heat or Cool OP2 none none OP1 OP3
JDouble Action Heat OP1 Cool OP3 OP2 -
KDouble Action Heat OP1 Cool OP2 - OP3
LDouble Action Heat OP2 Cool OP3 OP1 -
SX25 mASX25 VMD
Relay output
Relay output
Logic output
OP1 - OP3
OP2 - R
OP2 - L
OP2 output can be Relay or logic.
The 'jumper' on the auxiliary
board selects the output type:
Link Pins 1-2 for OP2-Relay
(Factory set)
Link Pins 2-3 for OP2-Logic
Auxiliary
board
Jumper

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load
coil
16
15
2
load
coil
16
15
2
load
coil
SX25 mA Output combination
3.3.5 – A, B
OP4 Analogue mA control output
Galvanic isolation 500V~/1 min
0/4...20mA, (750Wor 15Vmax)
Relay output
SPST Relay N.O., 2A/250 V~
for resistive load, fuse 2A ~ T
Logic output not isolated
0...5V, ±20%, 30 mA max
OP2, use Relay (terminals 15,16) or
Logic (terminals 10,11)
3.3.5 – D Double action analogue mA/relay control output
3.3.5 – E Double action relay/analogue mA control output
3.3.5 – F Double action relay/analogue mA control output
3.3.5 – C Double action analogue mA/relay control output
load
coil

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SX25 VMD Output combination
3.3.5 – G Valve Motor Drive
Relay/Relay Control Output 3.3.5 – H Single Action Relay Control Output 3.3.5 – I Single Action Logic Control Output
3.3.5 – J Double Action Relay/Relay Control Output
3.3.5 – K Double Action Relay/Logic Control Output
Relay output
SPST Relay N.O., 2A/250 V~
for resistive load, fuse 2A ~ T
Logic output not isolated
0...5 V, ±20%, 30 mA max
Valve drive PID without
potentiometer (open,close,stop).
Coil of the heat
load contactor
Coil of the heat
load contactor
Coil of the heat
load contactor
Coil of the cool
load contactor

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Coil of the load
alarm contactor
3.3.5 – L Double Action
Logic/Relay Control Output
Fuse
Load
alarm
LogicRelay
Relay
Relay
The outputs OP1, OP2 and OP3,
can be used as alarm outputs
only if they are not configured
as control outputs.
3.3.6 Alarms outputs
Relay output
SPST Relay N.O., 2A/250 V~
for resistive load, fuse 2A ~ T
Logic output not isolated
0...5 V, ±20%, 30 mA max
Coil of the cool
load contactor
16
15
2
Coil of the load
alarm contactor Coil of the load
alarm contactor

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3.4 Wiring examples 3.5 Auxiliary Relays for Valve Motor
Drive actuators
When using SX25 controllers to directly drive VMD
electric actuators, damage to the controllers internal
relays might occur due to switching the relatively
heavy electrical loads.
Auxiliary relays should therefore always be installed
between the controller and the valve drive actuator.
This will protect the controller from switching the
actuators high current loads, avoid introducing high
current loops within the proximity of the controller, and
provide an easily replaceable switching element
outside of the controller.
This advice is in line with that given by other
manufacturers of similar equipment and is considered
to be good working practice.
SX25 VMD
Example2. SX25-VMD for Temperature control:
Using Pt100 temperature sensor and a control
valve with a Valve Motor Drive Elctric Actuator.
SX25mA
Example 1. SX25-mA for Pressure control: Using a 4-20mA
pressure transmitter and a control valve with 4-20mA
Electric or Electro-pneumatic positioner.
SX25mA

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4.1 Configuration coding
The configuration code consists of
4 digits that identify the operating
characteristic of the controller, as
chosen by the user.
Refer to section 5.6 configuration
menu and section 6,
commissioning examples for
additional help.
Input type and range I
RTD Pt100 IEC 60751 -99.9...300.0 °C -99.9...572.0 °F0
RTD Pt100 IEC 60751 -200...600 °C -328...1112 °F1
TC L Fe-Const DIN43710 0...600 °C -328...1112 °F2
TC J Fe-Cu45% Ni IEC 60584 0...600 °C 32...1112 °F3
TC T Cu-CuNi -200...400 °C -328...752 °F4
TC K Cromel -Alumel IEC 60584 0...1200 °C 32...2192 °F5
TC S Pt10%Rh-Pt IEC 60584 0...1600 °C 32...2912 °F6
0...20mA/0...50 mV, linear Engineering units 7
4...20mA/»10...50 mV, linear Engineering units 8
Custom input and range [1] 9
[1] For example, other thermocouples types, DT (with 2 PT 100), custom linearisation etc.
Control action type M
Reverse (single action) Linear Cool (Heat/Cool double action) 0
Direct (single action) On-Off Cool (Heat/Cool double action) 1
4. Configuration
The configuration code can be
displayed on the front panel,
following the instructions on page
22 section 5.2.2.
2.5W1% shunt resistor must be fitted
for mA input signal. See section 3.3.2
SX25-VMD SX25-mA L
Control Output Output
mode configuration Alarms configuration Alarms
Control OP1 OP2, OP3 Control OP4 OP2, OP3 0
PID Control OP2 OP1, OP3 Control OP4 OP1, OP3 1
Control OP1 OP2, OP3 Control OP4 OP2, OP3 2
ON - OFF Control OP2 OP1, OP3 Control OP4 OP1, OP3 3
Control OP1-OP3 OP2 Control OP4-OP3 OP2 6
Heat/Cool Control OP1-OP2 OP3 Control OP4-OP2 OP3 7
Action Control OP2-OP3 OP1 Control OP4-OP3 OP1 8
PID VMD Control OP1-OP3 OP2 N/A N/A 9

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When the controller is powered up
for the first time, the display shows
the following message.
This shows that the controller has
not been configured.
Input the first code ILMN , using the
up and down arrow keys, then press
the enter key. The lower display will
show Con2 . Now input code Ofor
alarm 3, then press enter.
The controller will remain in stand-by
until the configuration code is set
correctly (see section 5.6 page 36).
Alarm 2 type and function N
Not active 0
Sensor break alarm/Loop Break Alarm 1
Process active high 2
active low 3
Deviation active high 4
active low 5
Band active out 6
active in 7
Alarm 3 type and function O
Disabled 0
Sensor break alarm/Loop Break Alarm 1
Process active high 2
active low 3
Deviation active high 4
active low 5
Band active out 6
active in 7
For alarm type and function see page 30.
CON2