Spirax Sarco SP2 User manual

IM-P343-22 CH Issue 2 1
SP2 Options
Installation and Maintenance Instructions
IM-P343-22
CH Issue 2
3439152/2
1. General
safety information
2. Options
3. Electrical connections
4. Programming and
commissioning
travel switches
5. Fitting a filter pl g kit
50%
SP2
Printed in the UK © Copyright 2002

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1. General safety information
YourattentionisdrawntoSafetyInformationLeafletIM-GCM-10,aswellastoanyNational
or Regional regulations.
1.1 Electrical safety requirements
The SP2 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 allsignalcircuits connectedtoan optionsboardmust operatewithinthe
confines of SELV systems. All associated wiring must be separated from other wiring
containing hazardous voltages.
1.2 Electromagnetic compatibility
The product complies with the Electromagnetic Compatibility Directive 89/336 EEC by
meeting standards EN 5008-1 (Emissions) and EN 50082-2 (Industrial Immunity). This
product may be affected by interference above the limits within EN 50082-2 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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2. Options
Fig. 1 Options PCB
2.1 Available options
2.1.1 Software travel switches
Two software configured travel switches supplied on a standard options PCB.
The travel switch 1 (TS1) is normally open and the travel switch 2 (TS2) is normally closed.
2.1.2 Pepperl and Fuchs mechanical travel switches
Two mechanical proximity travel switches plus standard options PCB board.
2.1.3 4 - 20 mA retransmit
4 - 20 mA retransmission of actual valve position (as measured in autostroke - AUTOS) plus
standard options board having two software configured travel switches or connections for Pepperl
and Fuchs mechanical proximity travel switches.
Note: Options boards are individually electrically isolated and externally powered.
2.2 Fitting the options board
2.2.1 Firstly set the yellow slide switch as follows (refer to Fig. 1):
If the options PCB is used for software configured travel switches, set all elements of the
yellow slide switch SW1 to position 'A'. Prepare the ribbon cable by ensuring that the
connector is at right angles to the options PCB, ready for insertion into the main PCB
socket (refer to Fig. 1).
SW1 switch set
in position A
Earth
connection
fitted with
4 - 20 mA
option only
Terminal block
Ribbon
cable
connector
2.2.2 To gain easy access for fitting the options board remove the indicator disc domed nut,
washer and travel indicator disc.

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Fig. 3
2.2.4 Locate the edge of the options PCB in the two cast-in location lugs at the base of the
SP2 case (refer to Fig. 3).
2.2.5 Push the connector on the ribbon cable into the socket on the main PCB.
Note: this should be done with light finger pressure only, do not apply force.
Cast in
location
lugs
Fig. 2
Retaining
clamp Retaining
clamp
2.2.3 Loosen the two plastic retaining clamps within the SP2 housing (refer to Fig. 2).

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Fig. 4
Retaining
clips
Earth
connection
(4 - 20 mA
option only)
2.2.6 Secure the options PCB in place by locating the two retaining clips and tighten the fixing
screws. Note: with the retaining clips secured, there will be some float of the PCB
(refer to Fig. 4).
2.2.7 Options boards having 4 - 20 mA retransmit are provided with an earth connection.
Using the M4 screw, secure the earth wire to adjacent pillar removing any excess paint
thatmaybepresent.Thesamepillarshouldbeusedforboththe4 20mAPCBandPepperl
and Fuchs switch earth connections if necessary.
2.2.8 Make electrical connections to terminals as required. Refer to Section 3 'Electrical
connection' for details of wiring connections.
2.2.9 Refit the travel indicator disc, washer and domed nut.

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2.3 FittingPepperlandFuchsmechanicalproximityswitches
2.3.1 Fitting of Pepperl and Fuchs switch assembly. Refer to Fig. 5 for components and
Fig. 6 for general assembly.
Fig. 5 Pepperl and Fuchs switch assembly kit components
No. Description Quantity
1Support plate 1
2Spacer 1
3Spacer 1
4Adjustment
plate 2
5Switch sensor 2
6Switch vane 2
7Fixings 2
8Screws (M4 x 8) 1
9Adjustment
screw 2
10 'O' ring 1
11 Earth adaptor
screw 1
12 Extension
spindle 1
13 Spindle 1
14 Washer 2
15 Domed nut 1
16 Indicator disc 1
17 Washer 2
2.3.2 Prepare the assembly kit by unscrewing the extension spindle (12) and remove the two
switch vanes (6). Remove the spindle (13) ensuring that the 'O' ring (10) remains in place.
16
7
11
1
17
2
13
12
15
14
10
3
8
9
1
PF2
5
6
4
PF1
Fig. 6 General assembly
6
9

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2.3.6 Fit the Pepperl and Fuchs support plate (1) aligning central holes to pass over spindle
(13). Note: the support plate will only locate in one orientation.
2.3.7 Use earth adapter screw (11) and M4 x 8 screw (8) and tighten to locate the support
plate (1) (refer to Fig. 8).
Fig. 7
Spindle (13)
2.3.3 Ensure that the electrical and pneumatic supplies to the positioners are isolated. To fit
the Pepperl and Fuchs switches it is recommended that the SP2 positioner is removed
from the valve / actuator assembly and fitting is carried out on a clean flat surface.
2.3.4 Prepare the SP2 by removing the indicator disc domed nut, washers, indicator disc and
spindle. Remove existing M4 x 8 screw from the SP2 earth pillar.
2.3.5 Screw new spindle (13) onto existing central pin (refer to Fig. 7) using a 7 mm spanner.
Fig. 8
Potentiometer
mounting
bracket
Support
plate (1)
Earth
adaptor
screw (11)
M4 x 8
screw (8)

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2.3.8 It is now necessary to fit the options board. Firstly ensure all elements of the yellow
changeover switch SW1 are set at position 'B'. Prepare the ribbon cable by ensuring
that the connector is at right angles to the options PCB, ready for insertion into the main
PCB socket, (only required with 4 - 20 mA retransmit option). Plug the Pepperl and Fuchs
switch sockets onto the options board connectors. The PF1 socket should be engaged in
the PF1 connector. The PF2 socket should be connected to the PF2 connector (refer to
Fig. 9a).
Fig. 9a
PF1 socket
connection
PF2 socket
connection
SW1 set at position B
Ribbon cable
connector
Potentiometer
mounting
bracket
PF1 switch
sensor
PF2 switch
sensor
Fig. 9b
2.3.9 Secure the PF2 switch connector wire behind the potentiometer mounting bracket
(refer to Fig. 9b).

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Fig. 10
2.3.11 The earth cable should now be reconnected to the earth adaptor (11) and secured using
the original M4 x 8 screw (refer to Fig. 11). When correctly located, the plastic retaining
clamps can be tightened to secure the options board in place. Note: With the retaining
clips secured there will be some float of the PCB.
Fig. 11
Earth
connection Ribbon cable
connector
located on
main PCB
Retaining clips
2.3.10 Loosen the option board plastic retaining clamps. Now locate the options board within
the SP2 enclosure ensuring it is correctly located within the lugs at the bottom of the
housing (refer to Fig. 10). Note: the options board should be located with terminal
connectors at the top. Location lugs
2.3.12 Prepare the ribbon cable by ensuring it is at right angles to the options PCB. Engage
the ribbon connector onto the main PCB socket permanently pushing in place
to locate. This should be done with light finger pressure only (refer to Fig. 11) do
not apply force, (only required with 4 - 20 mA retransmit and software switch options).

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Fig. 13
Fig. 12
2.3.13 Fit switching vanes (6) to the spindle (13) and ensure 'O' ring (10) is correctly located
within the end of the spindle. Now fit the extension spindle (12) and finger tighten to
secure in position.
It is essential that the switching vanes are correctly located within the slots of the PF1
and PF2 switches. The top vane should be positioned within PF1 switch sensor (5)
and the bottom vane positioned within the PF2 switch sensor (5) to ensure they are
positioned evenly within the slots (refer to Fig. 12).
Switching vane (6)
PF1 switch sensor (5)
Switching vane (6)
PF2 switch sensor (5)
2.3.14 It is now necessary to set the switching action. Note, adjustment of the switch vanes
provides coarse setting whilst movement of the adjustment plates (4) provides
fine setting.
For setting the Pepperl and Fuchs switches you must now mount the SP2
positioner onto the valve / actuator assembly and recommission the SP2 positioner
as described in Section 5, 'Installation' of the SP2 Installation and Maintenance
Instructions IM-P343-19.
Please note: if the SP2 positioners are supplied with Pepperl and Fuchs switches
already fitted, they will be supplied unset.
2.4 Setting Pepperl and Fuchs switches
Note: The PF1 or PF2 switch will open when the switching vane is 50% or more within
the switch sensor.
2.4.1 Coarse setting of the PF1 switch
Locate the adjustment plate (4) at its mid position and tighten the adjustment screws (9)
(refer to Fig. 13).
Position the valve at the desired switching position for PF1 switch. The valve can be
positioned using manual control (M-CTL) in conjunction with the digital display of
percentage travel, or alternatively using the valve travel indicators located on the actuator
pillar / yoke. Coarsely set the switching vane within the PF1 switch sensor (5) at the
desired switching position. Fine adjustment will be made later.
Extension spindle (12)
'O' ring (10)
Spindle (13)
Washer and domed nutTravel indicator disc
Adjustment
screw (9)
Adjustment
plate (4)

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Fig. 14
2.4.2 Coarse setting of the PF2 switch
Position the valve at the desired switching position for PF2. Coarsely set the second
switching vane within PF2 switch sensor (5) as previously described whilst maintaining
the previous setting of the PF1 switching vane. Tighten the extension spindle (12).
2.4.3 Fine adjustment of the PF1 and PF2 switch
Toachieve fine adjustmentit is necessaryto have someform of switching indicator device
across terminals 1and 2for PF1 and terminals 3and 4for PF2. Adjust the valve travel
position of PF1 switch sensor (5). If fine adjustment is required it can be achieved
by loosening the adjustment screw (9) and sliding the adjustment plate (4) in either
direction to achieve the desired switching position. Tighten the adjustment screw (9) to
secure the setting. This exercise should be repeated for the PF2 switch whilst
maintaining the previous setting position of switch PF1 (refer to Fig. 6).
2.4.4 On completion of setting PF1 and PF2 switches refit the travel indicator disc, washer and
domed nut (refer to Fig. 14).
Indicator disc

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3. Electrical connections
3.1 Guidance notes on wiring installation
For heavy industrial applications it is recommended to use screened cables or signal cables run
inmetalconduit.Failuretodosocouldresultinpositionalerrorsofupto±5%inanRFfieldexcess
of 10 V/m.
For light industrial applications where RF fields do not exceed 3 V/m unscreened cables may be
used.
Cable connection blanking plug
(Note: a spare Pg 13.5 cable gland is supplied with each options board kit)
Options board terminal block
Fig. 15

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1 +
2 -
3 +
4 -
5 +
6 -
3.2 Options board wiring diagrams
SW1 shown in position 'A'
Socket connections
PF1 and PF2
from Pepperl and
Fuchs switches
EMC earth
to case
Ribbon connection
to main PCB
3.2.1 Options wiring diagrams
Fig. 16
Fig. 17 Software switches
Fig. 18 4 - 20 mA retransmit
PF1
1 kW
Travel switch 1
4 - 20 mA
retransmit
PF2
1 kW
Travel switch 2
Note: Switch is shown in position A
-
-
-

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Table 1
Changeover switch SW1 Terminals 1 and 2 Terminals 3 and 4
ATS1 TS2
(Software travel switches)
PF2
BPF1 (Pepperl and Fuchs
mechanical travel switches)
Table 2 - Software travel switch ratings
Ratings Supply Impedance On current Off current
TS1 travel switch 18 - 30 Vdc 1 kW10 mA < 53 µA @ 24 V
TS2 travel switch 18 - 30 Vdc 1 kW10 mA < 53 µA @ 24 V
4 - 20 mA 8 - 30 Vdc - - -
Isolation between each option and between option boards to main circuit = 50 Vac
Table 3 - Pepperl and Fuchs switch ratings
Switch type Pepperl and Fuchs SJ3, 5-N
Switch characteristic NAMUR constant current
Voltage range 5 - 25 Vdc
Nominal voltage 8 Vdc
Current (sensing face covered) < 1 mA
Current (sensing face free) > 3 mA

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Fig. 19
4.1 Advance to TUNE in the SP2 main menu.
Press key to advance to travel switch 1 (TS1).
Dead-band
(dBand)
ää
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
ä
Shut-off minimum
(S-MIN)
TUNE
ä
ä
ä
ä
ä
ä
4. Programming and commissioning
travel switches

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Fig. 20 TS1 Travel switch 1 (normally open)
Switch
closed
Signal
Switch
open
Travel
100%
0%
Note:
Software configured travel
switches can be set within
therange 0% to 100% of full
travel irrespective of any
travel limit settings.
4.2 TS1 and TS2 software travel switches
Software configured travel switches are optional and provided on a separate
plug in PCB board. They will only appear in the programming menu if the
options PCB is fitted, and switch SW1 set to position A.
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 Figs. 20 and 21).
TS1 - software configured travel switch 1 (normally open)
Programming notes
Software configured travel switches are optional with the SP2 positioner. 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 sand tkeys 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.
If the options PCB is fitted and the slide switch SW1 set to position 'A' the status of the
switch will be shown on the LCD (refer to Fig. 20).
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.
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TS2 - software configured travel switch 2 (normally closed)
Programming notes
Software configured travel switches are optional with the SP2 positioner. 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 sand tkeys 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.If
the options PCB is fitted and the slide switch SW1 set to position 'A' the staus of the
switch will be shown on the LCD (refer to Fig. 21).
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. 21 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.

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To change the filter proceed as follows:
-Ensure that the air supply to the positioner is isolated.
-Unscrew the filter plug (1) from the SP2 housing using a 5 mm allen key
(refer to Fig. 22).
The replacement filter plug can now be fitted:
-Fit the 'O' ring (4) and filter (3) onto the filter plug (1) (refer to Fig. 23).
-Finally fit the retaining screw (2).
The filter plug can now be replaced into the SP2 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. 23
Fig. 22 Filter plug (1)
2
3
4
1
5. Fitting a filter pl g kit

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