Spirax Sarco EP5 Series User manual

3.568.5275.226
© Copyright 2016
EXPER
TISE SOLUTIONS SUST
AINABILITY
IM-P343-16
CH Issue 7 - 2016
1. Safety information
2. Introduction
3. Installation
4. Commissioning
5. Maintenance
6. Spare parts
7. Faultnding
EP5 and ISP5 Series
Electropneumatic Positioners
Installation and Maintenance Instructions
Attention: Additional instructions are required when a ATEX
intrisically safety instrument ISP5 is used in an explosion risk area.

3.568.5275.226
2
1. Safety information
Safe operation of these products can only be guaranteed if they are properly installed, commissioned,
usedandmaintainedbyqualiedpersonnel(seeparagraph1.11)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 uid 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 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use / application. The products comply
withtherequirementsoftheEuropeanDirective2014/34/EU(ATEX).
1.2 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.
1.3 Lighting
Ensureadequatelighting,particularlywheredetailedorintricateworkisrequired.
1.4 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:ammablematerials,substanceshazardoustohealth,extremesoftemperature.
1.5 Hazardous environment around the product
Consider:explosion riskareas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature,hotsurfaces,rehazard(e.g.duringwelding),excessivenoise,movingmachinery.
1.6 The system
Considerthee󰀨ect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ine󰀨ectiveofcontrols
oralarms.Ensureisolationvalvesareturnedonando󰀨inagradualwaytoavoidsystemshocks.
1.7 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.
1.8 Temperature
Allowtimefortemperaturetonormaliseafterisolationtoavoiddangerofburns.
1.9 Tools and consumables
Beforestartingworkensurethatyouhavesuitabletoolsand/orconsumablesavailable.Useonly
genuine Spirax Sarco replacement parts.

3.568.5275.226
3
1.10 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.
1.11 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.
1.12 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done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum permitted
operating conditions the surface temperature of some products may reach temperatures of 176°F.
Manyproductsarenotself-draining.Takeduecarewhendismantlingorremovingtheproductfrom
aninstallation(referto'Maintenanceinstructions').
1.14 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.
1.15 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.
1.16 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identiedashazardousorpotentiallyhazardous.

3.568.5275.226
4
2. Introduction
1 =Receiver0.2to1bar(3to15psi)
2 =Amplifierrelay
3 =Adjustableorifice:sensitivitysetting
4 =Damping:outletairflowadjustment
5= Flapper
6= Reaction spring
7 =Zeroscrew
8= Positioner lever
9 =Lock-nut
10 = Slider
11 = Sector lever
A= Control signal
I= I / P converter output
S =Airsupply
O= Positioner output
U1 =Increaseactionnozzle
U2 =Decreaseactionnozzle
8
7
9
6
5
U1 U2
1
S
2
O
I
+
-
11
10
A
4
3
2.1 Introduction
TheEP5isa2wirelooppoweredpositionerrequiringa4-20mAcontrolsignal,andisdesigned
forusewithlinear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desiredvalvepositionisthereforemaintainedforanycontrolsignalandthee󰀨ects
ofvaryingdi󰀨erentialpressure,stemfrictionandhysterisisareovercome.Amountingkitissupplied
tosuitallNAMURstandardcolumnsoryokes.
Note:A0-10VdcinputsignalandanintrinsicallysafeversionISP5arealsoavailable.
2.2 Operating principle
TheEP5operatesonaforcebalanceprinciplebymeansofa nozzle/appermechanismanda
feedbackspring(refertoFigure1).
The electrical control signal (A) is converted into a proportional air pressure (I). This pressure is
appliedtotheapper(5) via the receiver (1),causingadeectionoftheapperrelativetothenozzles
U1/U2. From the air supply (S)areducedbleedofairisfedtotheamplierrelay(2) and into one
ofthenozzlesU1/U2.Astheappermovesthepressuredropthroughthenozzleissensedbythe
amplierrelay.Theamplierrelayoutputsasignal(O)totheactuatorwhichisproportionaltothe
pressuredropthroughthenozzle.
Astheactuatormoves,connectinglever(8) causes a change in tension of the reaction spring (6).
Thistensionisappliedtotheappercausingittomovetoanewpositionatwhichtheforcesapplied
by the spring and the applied pressure (I) balance.
Important:Thisinstrumentbleedsairinnormaloperationatarateofapproximately0.7N
m³ / hour at a supply pressure of 6 bar.
Fig. 1

3.568.5275.226
5
3. Installation
Note: Before starting any installation observe the 'Safety information' in Section 1.
This publication 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 Location
Thepositionershouldbemountedinsu󰀩cientspacetoallowremovalofthecoverandprovide
accesstoconnections.Whenttingtoanactuator,ensurethepositionerwillnotbeexposedtoan
ambient temperature outside the range -15°C to +65°C. The positioner enclosure is rated to IP54
seeBSEN60534-6-11998.
Connectionofairsupplypressure(1.4to6barg)andcontrolsignal(4-20mAor0-10Vdc)should
be considered prior to choice of location.
3.2 Mounting the positioner onto the actuator
TheEP5positionermayhavebeensuppliedalreadyfactoryttedontothevalveactuator.However,
using the mounting kit provided it can be attached retrospectively onto any other type of valve and
actuatorconformingtoNAMURstandards.
Step 1 Identify actuator type
Forcorrectoperationitisimportanttoknowtwofactorswhichwilla󰀨ectoptimummovementofthe
positioner feedback mechanism:
- Thedistancebetweentheaxesofthevalve/actuatorstemandthepositionerslidepin.
-The travel of the valve actuator.
To ensure these are set correctly, please note the following:
- WhenattachinganEP5toanySpiraxSarcovalveactuator,ignoreStep3.
-For non-Spirax Sarco actuators, ignore Step 2.

3.568.5275.226
6
Step 2 For attachment to Spirax Sarco actuators
Usingthe2o󰀨M6panheadscrews,securelyattachthe'T'shapedslidingpinholdertothevalve
actuatorcouplingblock(Figure2).ApplyLoctitetotheslidingpinandscrewintohole'Y'(asshown)
on the sliding pin holder and tighten.
Usingthe2o󰀨M8x15hexheadscrewsand8mmspringwashers,attachthemountingplatetothe
backofthepositioner,utilisingholesNo.2inthebracket(Figure3).Takecarenottoover-tighten
thesescrewsandstripthethreads.
Step 3 For attachment to non-Spirax Sarco actuators
Usingthe2offM6panheadscrews,securelyattachthe'T'shapedslidingpinholdertothevalve
actuatorcouplingblock(Figure2).Dependingonthetravelofthevalveactuator,applyLoctiteto
slidingpinandscrewintothecorrectholeontheslidingpinholderandtighten.UseFigure2and
Table 1 to determine the correct hole to use.
Fig. 2
Close-up of
sliding pin holder
fitted to valve
coupling.
Fig. 3
Valve travel Hole to be used
 8-15mm X
 15-30mm Y
 above30mm Z
Table 1
Usingthe2offM8x15hexheadscrewsand8mmspringwashers,attachthemountingplate
to the back of the positioner. The correct fixing hole may be determined by reference to Figure
3, Table 2 and Figure 4. Take care not to over-tighten these screws and strip the threads.
Z
XY
Valve
actuator
coupling
block
'T'shaped
sliding pin holder
1
3
42
Positioner
Mounting plate

3.568.5275.226
7
Fig. 5
Table 2 D Hole to be used
 Upto125mm 1
 125to150mm 2
150to175mm 3
above 175 mm 4
Fig. 4 Pillar/yoke spacing, showing 50 % travel.
Actuator
spindle
Actuatorpillar
or yoke
100%
50%
0%
D
Valve
position
indicator
Slide pin
Step 4 Temporarily apply adequate air pressure directly into the actuator so that the valve is
at50%oftravel(Figure5).
Step 5Engagetheslidepinintothepositionerlever(seeFigure5,notingthepositionofthe
spring,abovethepin)andlooselyxthepositionertotheactuator.Foryokeactuatorsusethesin-
gleelongatedscrewholewiththeM8x20screwandspringwasher,forpillarsusetheU-clamps.
Important:Slidepositionerverticallyupordowntheyoke/pillarssothepositionerleverishorizontal
at50%travel,andtheindicatoratLHSisaligned(Figure5).Securethetighteningscrews/nuts.

3.568.5275.226
8
Step 6Fittheangledprotectionplatetotherearofthepositionerusingthe2o󰀨captiveM3pan
headscrews.Accesstothesecaptivescrewsisfrominsidethepositioner.
Step 7 Adjusttheairsupplypressuretostroketheactuatorfrom0%to100%andensurethe
positioner lever rotates freely. Remove the temporary air supply from the actuator.
Step 8 Fitting a gauge block (optional)
ToaidcommissioningitisrecommendedtotagaugeblockandpressuregaugestoallEP5s.Please
note that gauges and gauge block can be supplied as spare parts if required.
FitgaugestotheblockbeforeattachingtheblocktotheEP5.Usethreadsealanttoensureairtight
connections.TheuppergaugedisplaystheoutputoftheI/Pconverter,andisnormally0-2barg.The
lowergaugedisplaysthepositioneroutputpressure,sothegaugerangewilldependontheactuator.
RemoveanyairttingsandblankingplugfromtheEP5,thenattachtheassembledblocktotheEP5
usingthe2o󰀨socketheadcapscrewssupplied.Ensurethesealing'O'ringsarecorrectlyttedto
sealthejointsbetweentheEP5bodyandthegaugeblock.Replacethettingsandblankingplug
into the corresponding ports on the gauge block.
3.3 Connecting up
3.3.1 Pneumatic connections (with or without a gauge block)
Warning:Airsupplymustbedry,oilanddustfreetoISO8573-1:class2:3:1.Acoalescinglter
regulatorsuchasaSpiraxSarcoMPC2willremoveoilanddirttomeetthisstandardifpro-
perlyttedandmaintained.Dirtyairsupplymaydamagetheproductandinvalidatewarranty.
The supply air pressure must not exceed the maximum allowable air pressure of the actuator.
Av oi dus eo ff er r ou sp ip ew or ka f te rt heM PC 2.Fo rbe stp er f or ma nc e,s et th eai rs up pl yp res su re
toabout0.5bargabovethepressurerequiredtofullytraveltheactuator.
Ch e c ka llc o n ne c tionsf o rleaks.Pl e a senotehowevert hatt h eEP5bleedsa i rinno r malo p e r at i o n
atarateofapproximately0.7Nm³/hour at 6 bar supply pressure.
PneumaticconnectionsarelocatedattherighthandendofthepositionerandidentiedI, S
and Oasfollows:
I -NotusedonEP5,t¼" NPT plug.
S-Airsupply-1.4bargto6barg,dependinguponrequiredactuatorspringrange.
O-Outputsignaltotheactuator.
Connections are ¼"NPTfemale. Interconnectionbetween positioner andactuator should beat
least6mmODtube.

3.568.5275.226
9
3.3.2 Electrical connections
CablingshouldbeinstalledinaccordancewithBS6739-InstrumentationinProcessControlSy-
stems: Installation design and practice or local equivalent.
TheEP5onlyrequiresa4-20mA(standard)or2-10Vdc(ifrequested)signal.Removethefront
coverandlocatetheterminalblockandearthterminalpost(Figure6).
Note:Ensureresistancefromearthposttolocalearth(e.g.pipework)islessthan1Ω.
ConnectiontotheunitisthroughthePg13.5cablegland(assupplied),whichwhenusedwithsuitable
cablewillensuretheIP54protectionrating.Appropriateconduitconnectionsmaybeusedinstead.
Connectconductors(0.5to2mm²)totheterminalblockandearthpost(3mm²)notingthepolarity
+/-showninFigure6.
InhazardousareasusemodelISP5withintrinsicprotection(typeEExiallCT6,T5,T4)ensuringthe
powersupplyfromadjoiningequipmentiscertiedinaccordancewithEN50.014andEN50.020
standards,inrespectofthelimitsofelectricfeaturesshownatapprovalstage.Refertoapproval
certicatesuppliedwitheachISP5product.
Fig. 6
Cable
gland
Terminal
block
-
+
Earth
terminal
post
I
S
O

3.568.5275.226
10
4. Commissioning
Once the positioner has been mounted and connected up, proceeed as follows.
Step 1 Set the valve action
Establishingthecorrectactionofthevalveisdoneby:
a. ConnectiontoeitherU1orU2nozzles(seeFigure7)and
b. Settingthesliderintheupperorlowerportionofthecrescentshapedsectorlever(Figure8).
U1 = Increase action = Withincreasingelectricalcontrolsignaltheairpressuretotheactuator
willincrease.
U2 =Decreaseaction =Withincreasingelectricalcontrolsignaltheairpressuretotheactuator
willdecrease.
To change the working nozzle connections (U1 or U2):
Disconnecttheairsupply.Loosentheretainingplateandrotateitclearofthetubeholder.Pull
the tube holder clear of its seat and re-insert the tube holder into the alternative seat location.
Lockinplacewithalternativeretainingplate(lockunusedretainingplatetopreventlossofplate).
Reconnect air supply.
Fig. 7
Connection
tonozzleU2
Connection
tonozzleU1