Spirax Sarco EP6 User manual

IM-P703-04 CTLS Issue 3 1
EP6 ATEX Electro-pneumatic Positioner
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Fault finding
8. Approvals
© Copyright 2021
EP6
ATEX Electro-pneumatic Positioner
Installation and Maintenance Instructions
IM-P703-04
CTLS Issue 3

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EP6 ATEX Electro-pneumatic Positioner
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.13) in compliance with
the operating instructions. General installation and safety instructions for pipeline and plant
construction, as well as the proper use of tools and safety equipment must also be complied with.
WARNING: The maximum process fluid temperature must be suitable for use if the
unit is to be used in any potential explosive atmosphere. For the device maintenance
in a potentially explosive atmosphere, we recommend the usage of tools which do
not produce and / or propagate sparks.
1.1 Explosion Proof Warning
Please ensure the unit is being used and installed in conformity with local, regional, and national
explosion proof regulations.
-Refer to “8. Approvals”
-Explosion proof type of cables and gaskets should be used, when explosive gases
are present at the installation site.
-Power should be turned off completely when opening the product’s cover. When
opening the cover, ensure that there is no power remaining in any electrical parts
nearby.
-Flameproof enclosure type positioner has 2 ports for power connection. Explosion
proof type wires and packing should be used. A blanking plug is required for any
port that is not being used.
-Ring terminal with surface area of more than 1.25 mm2with M4 spring washer should
be used to connect the power.
-For external ground terminal, ring terminal with surface area of more than 5.5 mm2
should be used.
-There is risk of explosion due to static electricity charge. Static electricity charge
may develop when cleaning the product with a dry cloth. It is imperative to avoid
static electricity charge in the hazardous environment. A damp cloth must be used,
when cleaning the surface of the product.
-To meet explosion-proof marking information and ingress protection of IP66, use
certified Ex-cable glands and Ex-plugs.
-If you need additional information about the values of the flameproof joints, contact
Spirax Sarco directly.
-The electric valve positioner must be connected in series with a fuse with a rated
current not higher than 62mA, a breaking capacity above 1500A, and a rated voltage
not less than the working voltage of the product.
-The cable entry must be equipped with a cable entry device, which must be an Ex
cable entry device approved by the explosion-proof inspection agency (For NEPSI
- according to the requirements of GB3836.1-2010 and GB3836.2-2010) and meet
the requirements of the product explosion-proof mark, and the installation of the
cable entry device Use must follow its instructions.
1. Safety information

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EP6 ATEX Electro-pneumatic Positioner
1.2 Wiring
Every effort has been made during the design of the positioner to ensure the safety of the user,
but the following precautions must be followed:
i) Ensure correct installation. Safety may be compromised if the installation of the product is
not carried out as specified in this manual.
ii) Wiring should be carried out in accordance with IEC 60364 or equivalent.
iii) Fuses should not be installed in the protective earth conductor. The integrity of the installation
protective earth system must not be compromised by the disconnection or removal of other
equipment.
1.3 Intended use
Referring to the Installation and Maintenance Instructions, product markings and Technical
Information Sheet, check that the product is suitable for the intended use / application. These
products comply with the requirements of the Directive 2014/34/EU (ATEX) for the use of equipments
in potentially explosive atmospheres.
1.4 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)before attempting
to work on the product. Arrange suitable lifting gear if required.
1.5 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.6 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.7 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
The positioner is suitable for installation in Zone 1 or Zone 2 ( Gas ). The positioner shall not
be used in zone 0.
1.8 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel
at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms. Ensure isolation valves are opened and closed progressively to avoid system
shocks.
1.9 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.

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EP6 ATEX Electro-pneumatic Positioner
1.10 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns.
1.11 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.12 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high / low temperature, radiation, noise, falling objects,
and dangers to eyes and face.
1.13 Permits to work
All work must be carried out or be supervised by a suitably competent person.Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and, where
necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.
1.14 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being carried out.
1.15 Residual hazards
In normal use the external surface of the product may be hot. Many products are not self-draining.
Take due care when dismantling or removing the product from an installation (refer to 'Maintenance
instructions').
1.16 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.17 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
1.18 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present a
health, safety or environmental risk. This information must be provided in writing including Health
and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.

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EP6 ATEX Electro-pneumatic Positioner
Product return procedure
Please provide the following information with any equipment being returned:
1. Your name, Company name, address and telephone number, order number and invoice and return
delivery address.
2. Description of equipment being returned.
3. Description of the fault.
4. If the equipment is being returned under warranty, please indicate:
i. Date of purchase
ii. Original order number
iii. Serial number
Please return all items to your local Spirax Sarco branch.
Please ensure all items are suitably packed for transit (preferably in the original cartons).

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EP6 ATEX Electro-pneumatic Positioner
2.1 Introduction
The EP6 is a 2 wire loop powered positioner requiring a 4-20 mA control signal, and is designed for use with
linear and rotary pneumatic valve actuators. The positioner compares the electrical signal from a controller
with the actual valve position and varies a pneumatic output signal to the actuator accordingly. The mounting
kit is suitable for all pneumatic actuators compliant with the NAMUR standard.
2.2 Label description
-Model Indicates the model number and additional symbols.
-Explosion proof Indicates certified explosion proof grade.
-Ingress protection Indicates enclosure protection grade.
-Input signal Indicates input signal range.
-Operating temperature Indicates the allowable operating temperature.
-Ambient temperature Indicates the allowable ambient temperature for explosion proof.
-Supply pressure Indicates the supply pressure range.
-Serial number Indicates unique serial number.
-Year. Month Indicates manufactured year and month.
2. General product information

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EP6 ATEX Electro-pneumatic Positioner
Fig. 1
ATEX / IECEx / KCs
INMETRO
CCC / NEPSI / ATEX / IECEx

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EP6 ATEX Electro-pneumatic Positioner
2.3 Operating principle
2.3.1 Linear positioner
When INPUT SIGNAL is supplied to the positioner to open the valve, power is generated from the torque
motor (1) and pushes the flapper (2) to the opposite side of the nozzle (3).
The gap between the nozzle (3) and the flapper (2) becomes wider and from inner part of the pilot (4), air
inside the chamber (9) is exhausted through the nozzle (3).
Due to this effect, the spool (5) moves to the right.
Then chamber’s (10) pressure will increase and when there is enough pressure inside the chamber to push
the actuator’s spring (11), actuator’s stem (12) will start to go down and through the feedback lever, stem’s
linear motion will be converted to span lever’s rotary motion (14).
Then chamber’s pressure will increase and when there is enough pressure inside the chamber to push the
actuator’s spring, actuator’s stem will start to go down and through the feedback lever, stem’s linear motion
will be converted to span lever’s rotary motion.
This 14 span lever’s rotary motion will then once again rotate the span (15) and pulls the span spring. (16)
When the valve’s position reaches to given input signal, span spring’s (16) pulling force and torque motor’s (1)
power will be balanced and move the flapper (2) back its original position to reduce the gap with the nozzle.(3)
The amount of air being exhausted through the nozzle (3) will reduce and the chamber (9) pressure will
increase again.
The spool (5) will move back to its original position on the left and the poppet (8) will also move in same
direction blocking the seat (7) to stop the air coming into the chamber (10) through the SUPPLY.
As a result, the actuator will stop operating and the positioner will return to its normal condition.

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EP6 ATEX Electro-pneumatic Positioner
Fig. 2 Linear positioner with an actuator
1Torque motor
2Flapper
3Nozzle
4Pilot
5Spool
6Supply chamber
7Seat
8Poppet
9Chamber
Supply
Input signal
4-20 mA
Out 1
Out 2
17
10 Chamber of the actuator
11 Actuator spring
12 Actuator stem
13 Feedback Lever
14 Span lever (rotary motion)
15 Span adjuster
16 Span spring
17 Zero adjuster

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EP6 ATEX Electro-pneumatic Positioner
2.3.2 Rotary positioner
When INPUT SIGNAL is supplied to the positioner to open the valve, power is generated from the torque
motor (1) and pushes the flapper (2) to the opposite side of the nozzle (3).
The gap between the nozzle (3) and the flapper (2) becomes wider and from inner part of the pilot (4), air
inside the chamber (9) is exhausted through the nozzle (3).
Due to this effect, the spool (5) moves to the right.
Then the spool pushes the poppet (8) away from the seat (7) which was blocked by the poppet and the
supplied pressure (air) goes through the seat (7) and OUT1 Port and enters into the chamber (10) of the
actuator through OUT1.
Then chamber’s (10) OUT1 pressure will increase and 11 the actuator’s stem will rotate and through the
feedback shaft (12), actuator’s rotating motion will be transferred to the cam (13).
This motion will then rotate the span lever (14) and pull the span’s spring (15).
Once it reaches to given input signal, span spring’s (15) pulling force and torque motor’s (1) power will be
balanced and move the flapper (2) back its original position to reduce the gap with the nozzle (3).
The amount of air being exhausted through the nozzle (3) will reduce and chamber pressure (9) will increase
again.
The spool (5) will move back to its original position on the left and the poppet (8) will also move in same
direction blocking the seat (7) to stop the air coming into the chamber (10) through the SUPPLY.
As a result, the actuator will stop operating and the positioner will return to its normal condition.

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EP6 ATEX Electro-pneumatic Positioner
Fig. 3 Rotary positioner with an actuator
1Torque motor
2Flapper
3Nozzle
4Pilot
5Spool
6Supply chamber
7Seat
8Poppet
9Chamber
Supply
Input signal
4-20 mA
Out 1
Out 2 Out 2
Out 1
Out 1Out 2
16
10 Chamber of the actuator
11 Actuator spring
12 Actuator stem
13 Cam
14 Span lever
15 Span spring
16 Zero adjuster

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EP6 ATEX Electro-pneumatic Positioner
3. Installation
Note: Before starting any installation observe the 'Safety information' in Section 1.
This document is provided as a guide and it is recommended that it is read thoroughly prior to
installation. Also refer to the separate Installation and Maintenance Instructions for the control
valve and actuator.
3.1 Safety
When installing a positioner, please ensure to read and follow safety instructions.
-Any input or supply pressures to valve, actuator, and / or to other related devices must be
turned off.
-Use bypass valve or other supportive equipment to avoid entire system “shut down”.
-Ensure there is no remaining pressure in the actuator.
-The positioner has a vent cover to exhaust internal air and drain internal condensation
water.
When installing the positioner, make sure the vent cover is facing downwards. Otherwise, the
condensation water could cause corrosion and damage to internal parts.
Fig. 4 The correct positions of a vent cover
3.2 Location
The positioner should be mounted in sufficient space to allow opening of the cover and provide access
to connections. When fitting to an actuator, ensure the positioner will not be exposed to an ambient
temperature outside the range -20 °C to +60 °C. The positioner enclosure is rated to IP66. Connection of
air supply pressure (1.4 to 7 bar g) and control signal (4 - 20 mA) should be considered prior to choice of
location.
Vent cover
Vent cover
Vent cover
Vent cover

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EP6 ATEX Electro-pneumatic Positioner
3.3 Tools for installation
-Hex key set for hex socket cap bolts
-(+) & (-) Screw drivers
-Spanners for hexagonal-head bolts
3.4 Linear positioner Installation
Linear positioner should be installed on linear motion valves such as globe or gate type which uses spring
return type diaphragm or piston actuators.
Fig. 5 Installation example
Before proceeding with the installation, ensure following components are available.
-Positioner
-Mounting kit
-Air supply pipe and couplings
-Signal pipe and couplings to actuator
-Conduit gland connector
Mounting
Positions
Pin
Locator
Marking
Valve
stroke
MTG
kit
Feedback
pin locator
direction
Central N/A
20
EY1
30
50
EY2
70
Left hand
side
D20
UY3
A30
B50
UY1
E70

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EP6 ATEX Electro-pneumatic Positioner
3.5 Installation Steps
3.5.1 Central mount
1. Assemble feedback lever to positioner, retaining with screw & M6 nut.
2. Assemble mounting bracket onto back of positioner, by feeding feedback lever through opening in bracket,
retain using 4 off M8 screws and washers.
3. Assemble feedback pin to feedback pin locator
and secure with nut. Secure feedback pin
locator to actuator coupling with M6 cap screws,
ensuring feedback pin is to the left of actuator
centre line.
4. Connect air supply to actuator to position valve
to mid travel, see Fig. 9
5. Assemble positioner onto actuator, ensuring
feedback pin engages with feedback lever and
tensioning spring is the correct side of feedback
pin, see Fig. 8. Move positioner up or down, so
that feedback lever is horizontal.
Secure mounting bracket to actuator yoke using M8
screw & spring washer (or 'U' bolts if applicable).
Hardware identification
ABracket
CLever 20-30 EY1/PY1 only
DLever 50-80 EY2/PY2 only
HLocator 20-30 EY1/PY1 only
KLocator 50-80 EY2/PY2 only
MPin
PSpring
OSpacer PY1/PY2 only
RU-bolt UBC only
SM8 cap head screw
TM8 hex head screw
UM8 spring washer
VM8 plain washer
WM8 nut
XM6 cap head screw
YM5 nut
ZNut, spring washer and screw supplied with
EP6/PP6 positioner
Discard when fitting UBC
UBC only
Actuator
coupling

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EP6 ATEX Electro-pneumatic Positioner
Fig. 6 Exploded view of central mount assembly
(PP6 positioner shown, for EP6 spacers are not required)
Positioner
(PP6 shown)
UBC only
PP6 positioners only
Actuator yoke or pillar
Fit pin into relevant hole according to stroke 20, 30, 50 or 70 (observe markings on front face)

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EP6 ATEX Electro-pneumatic Positioner
3.5.2 Side mount
1. Assemble feedback lever to positioner, retaining
with screw & M6 nut.
2. Assemble mounting bracket onto back of
positioner, retain using 4 off M8 screws and
washers.
3. Assemble feedback pin to feedback pin locator,
and secure with nut. Secure feedback pin
locator to actuator coupling with M6 cap screws,
ensuring feedback pin locator is positioned
according to feedback pin locator table.
4. Connect air supply to actuator to position valve
to mid travel, see Fig. X
5. Assemble positioner onto actuator, ensuring
feedback pin engages with feedback lever and
tensioning spring is the correct side of feedback
pin, see Fig. X. Move positioner up or down, so
that feedback lever is horizontal.
Secure mounting bracket to actuator yoke using M8
screw & spring washer (or 'U' bolts if applicable).
Hardware identification
BBracket
ELever 10-40 UY3 only
FLever 30-70 UY1 only
GLever 60-100 UY2/UY4 only
JLocator 65-70-75 UY2 only
LLocator - slotted UY1/UY3/UY4
NPin
PSpring
RU-bolt UBC only
SM8 cap head screw
TM8 hex head screw
UM8 spring washer
VM8 plain washer
WM8 nut
XM6 cap head screw UY1/UY3/UY4
YM5 nut
ZNut, spring washer and screw supplied with
EP6/PP6 positioner
UBC only
Actuator yoke or pillar
Fig. 7.1
Mounting position for feedback pin
locator
Actuator
coupling
Pin left
e.g D - L
Pin right
e.g C - R
Capscrew
markers

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EP6 ATEX Electro-pneumatic Positioner
Fig. 7.2 Exploded view of side mount assembly (PP6 positioner shown)
Fit pin into relevant hole
according to stroke
65, 70 or 75 (observe
markings on front face)
UY1/UY3/UY4
must be fitted
and adjusted
to application
- see table on
previous page
and Figure xx
for details
Actuator
coupling
Positioner
(PP6 shown)
UBC only
Discard when
fitting UBC

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EP6 ATEX Electro-pneumatic Positioner
Fig. 8 Proper way to insert feedback pin between feedback lever and lever spring
Fig. 9
Feedback lever and
valve stem
Feedback pin
Lever spring
Fig. 10 Feedback lever and location of the feedback pin
Stroke : 30 mm
Stroke : 70 mm

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EP6 ATEX Electro-pneumatic Positioner
Fig. 11
Linear lever stopper should not touch stopping bosses of positioner on 0% ~ 100% valve stroke.
Full stroke
gap clearance
Stopping bosses
Linear lever stopper
Fig. 12 Namur type
3.6 Rotary positioner Installation
Rotary positioner should be installed on rotary motion valve such as ball or butterfly type which uses rack
and pinion, scotch yoke or other type of actuators which its stem rotates 90 degrees. Before proceeding
with the installation, ensure following components are available.
Components
-Positioner
-Rotary bracket set
(2 pieces)
-Mounting kit
-Air supply pipe and
couplings
-Signal pipe and couplings
to actuator
-Conduit gland connector

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EP6 ATEX Electro-pneumatic Positioner
Fig. 13 Positioner and mounting kit
J
J
B
H = 50
H = 30
H = 20
30 (H)
K
L
LK
L
K
L
K
D
C
C
D
C
D
C
D
F
G
E
E
F
G
E
F
G
E
F
G
J
J
J
J
B
A
3.7 Rotary Bracket Information
The rotary bracket set(included with the positioner) contains two components. The bracket is designed to
fit onto the actuator with 20 mm, 30 mm and 50 mm stem height (H) according to VDI/VDE 3845 standard.
Please refer to below figures how to adjust the height of the bracket.
EP6
positoner
Ball valve actuator
Choose correct holes according to actuator stem height (H) See Figure 14 (both ends)