Spirax Sarco SP200 User manual

IM-P343-29 CH Issue 5 1
SP200
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-29
CH Issue 5
3439650/5
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
13. Certification
Printed in the UK © Copyright 2009

IM-P343-29 CH Issue 52

IM-P343-29 CH Issue 5 3
1. Index
Section Sub-section
2.1 General requirements
2. Safety 2.2 Electrical safety requirements
information 2.3 Electromagnetic compatibility
2.4 Installation for hazardous areas and certification
3.1 Description
3. Technical 3.2 Technical data
information 3.3 Materials
3.4 Programmable functions
4. Options 4.1 Pressure gauge block
5.1 Mounting the SP200 positioner -
General informaton
5.2 Sequence for mounting an SP200 positioner to
5. Installation a linear actuator
5.3 Sequence for mounting an SP200 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 SP200 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 SP200 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
13. Certification

IM-P343-29 CH Issue 54
2. Safety information
2.1 General requirements
The flawless and safe operation of the SP200 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 SP200 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 SP200 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 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.

IM-P343-29 CH Issue 5 5
2.4 Installation for hazardous areas and certification
- General information
SP200 Smart Positioner is available for Intrinsic Safety applications, model identification
is SP200is.
In case of use in hazardous areas with danger of explosion, it must be verified that the
identified type of positioner fits for the classification of the zone and for the presence of
flammable substances in the plant.
Model SP200is is certified by EC-type Examination Certificate N. IMQ 07 ATEX 011- EC
Directive ATEX 94/9/CE with following classification:
II 2GD
and protective system:
Ex ia IIC T6 / Ex iaD 21 T85°C (Tamb –20/+40°C)
Ex ia IIC T5 / Ex iaD 21 T100°C (Tamb –20/+65°C)
Ex ia IIC T4 / Ex iaD 21 T135°C (Tamb –20/+80°C)
2.4.1 Safety data definitions
Group II: surface plants
Category 2: fit for zone 1 Gases – zone 21 Dusts: an area in which an explosive mixture is
likely to occur in normal operation
G (Gas): fit for explosive gases
D (Dust): fit for flammable dusts
Protection system (Intrinsic Safety): Ex ia for Gases
Ex iaD for Dusts
IIC : gas group IIC including Hydrogen and Acetylene
Temperature classification T6 (Maximum surface temperature = 85°C)
Temperature classification T5 (Maximum surface temperature = 100°C)
Temperature classification T4 (Maximum surface temperature = 135°C)

IM-P343-29 CH Issue 56
2.4.2 Electrical connections for IS.
For installation in classified areas it is necessary to foresee the use of certified associated
apparatuses (e.g. safety barriers), with output electrical characteristics compatible with
the maximum input parameters (ref. to Name-plate) of the certified SP200is positioner:
Electrical input parameter of SP200is
Circuit Ui(V) Ii (mA) Pi(mW) Ci(nF) Li(mH)
Supply 30 100 650 2 -
Switch 1&2 15 25 65 12 -
Retransmit 30 100 650 15 -
Evaluation of the system constituted by the associated apparatus, SP200is positioner
and connection cables must be done by experienced personnel only and must match the
requisite of the standard EN 60079-25 for intrinsically safe systems.
In Section 6 there is an example drawing of electrical connections for Intrinsically Safe
applications.
A drawing of the Name-plate is shown below
A copy of EC-Type ATEX Certificate is in 'Section 13 - Certification'.

IM-P343-29 CH Issue 5 7
3. Technical information
No. Part
1. indicating all OK. (! indicates an error)
2. Main menu functions with LCD flag indication
3. Signal pressure to actuator
4. Gland connection for wiring Pg 13.5
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 -
2 gauges for single action, 3 gauges for double action version
11. Display of programming data, mA input signal and % travel
12. Spare Pg 13.5 gland connection for wiring 4-20 mA retransmission or software switches
13. Status of software configured travel switches.
4 5 6 7 8 9
3.1 Description
The SP200 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. Therefore, high resolution, high reliability and vibration insensitivity are
guaranteed.
The SP200 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 SP200 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
1 13 2 11 10
3

IM-P343-29 CH Issue 58
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
Double action / fail vent output 1, fill output 2
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 0.035 normal m3/h
Air connections Screwed ¼" NPT
Cable gland Pg 13.5
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.
Shipping weight 3.2 kg
3.3 Materials
Part Material Finish
Case and cover Die cast aluminium Anti-corrosive paint to RAL5010
Magnet bracket Die cast aluminium
3.4 Model SP200is – ATEX certification
EC-type Certificate N. . IMQ 07 ATEX 011
Classification II 2GD
Ex ia IIC T6 / Ex iaD 21 T85°C (Tamb -20 to +40°C)
Ex ia IIC T5 / Ex iaD 21 T100°C (Tamb -20 to +65°C)
Ex ia IIC T4 / Ex iaD 21 T135°C (Tamb -20 to +80°C)

IM-P343-29 CH Issue 5 9
3.5 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 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

IM-P343-29 CH Issue 510
4. Options
4.1 Pressure gauge block
An optional pressure gauge block (Figure 2) can be fitted onto the SP200 positioner
which includes two pressure gauges indicating air supply pressure and output air signal
pressure to the actuator. For double action valves the gauge block includes 3 pressure gauges
indicating: air supply pressure, output 1 air signal and output 2 air signal. The pressure gauge
block can be retrospectively fitted using 2 off M5 Allen screws. Ensure that the gauge block
air connection 'O' rings are correctly located before tightening.
Fig. 2
Optional
pressure gauge block

IM-P343-29 CH Issue 5 11
5. Installation
5.1 Mounting the SP200 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 SP200
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 SP200.
5.1.1 The SP200 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 Permitted and forbidden mounting positions
The SP200 will not work if mounted on its side or upside down. The positions marked
with an “X” are not allowed. In case this cannot be avoided, please contact Spirax Sarco.
It is possible to ask for a special calibration when you place the order. In this case the
positioner shall be mounted only in the chosen position..
Fig. 3 SP200 mounting
5.1.3 The SP200 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.
5.1.4 Before fitting and commissioning the SP200 positioner ensure that the valve and actuator
are correctly assembled. Refer to the valve and actuator Installation and Maintenance
Instructions for details.

IM-P343-29 CH Issue 512
5.2.1 Loosely attach the magnet bracket (2) to the valve / actuator connector (refer to
Figures 4 and 5). Be sure it is positioned horizontally (as shown in Figure 5).
Fig. 4 Pillar mounting kit for a linear actuator
Fig. 5
Yoke mounting
assembly for a
linear actuator
5.2 Sequence for mounting an SP200 positioner to a
linear actuator
2
2

IM-P343-29 CH Issue 5 13
5.2.2 Slide the bracket (2) to the left or to the right (Figure 6) till the correct position is
achieved. If you’re using a Spirax Sarco actuator the correct position is impressed
on the magnet bracket (Figure 7).
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 8).
Fig. 8 ADistance between the mounting plate and magnet
Fig. 7 Bracket markings
Fig. 6
Assembled
2
Mounting plate
Bracket
Center
of the
magnet
PN1000PN9000

IM-P343-29 CH Issue 514
5.2.4 Loosely attach the positioner mounting plate to the actuator as shown in the following
pictures: for the pillar actuator (Figure 9), and for the yoke actuator (Figure 10).
Fig. 9 Pillar actuator assembly
Pillar actuatorMounting plate
Fig.10 Yoke actuator assembly
Yoke actuator
Mounting plate
5.2.5 Locate the protection plate onto the back of the SP200 positioner housing and fix in
place (Figure 11).
Protection plate
Fig. 11
Assembled
Assembled
Assembled

IM-P343-29 CH Issue 5 15
5.2.6 Attach the positioner mounting plate to the positioner as shown in Figure 12.
Protection plate
Attach
the
mounting
plate
5.2.8
When the SP200 positioner and mounting
plate assembly is correctly positioned,
tighten the hexagon headed screw (5) on
the yoke mounted actuator (Figure 12) to
10 - 12 N m and tighten the 'U'bolt nuts (6)
on the pillar mounted actuators (Figure 14)
to 10 - 12 N m.
5.2.7
Adjust the vertical position of the SP200 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 10).
Even if this is the ideal condition, it’s not mandatory. In
fact, as shown in Figure 13, 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.
6
5
Fig. 14
Fig. 12
B
A
Fig. 13
Assembled
SP200 positoner

IM-P343-29 CH Issue 516
5.3 Sequence for mounting an SP200 positioner to a
rotary actuator
5.3.1 Assembly for fitting an SP200 on to a ¼ turn valve.
Fig. 15 Mounting kit

IM-P343-29 CH Issue 5 17
Fig. 16
Fig. 17
Fig. 18

IM-P343-29 CH Issue 518
Fig. 19
Fig. 20
Assembled

IM-P343-29 CH Issue 5 19
5.3.2 Adjust the magnet orientation as illustrated in Figures 21 and 22 and tighten the bolt to
fix the magnet into position. There should be a distance of between 5 and 14 mm between
the magnet and the positioner.
Refer to Figure 21 for actuator with clockwise rotation.
Refer to Figure 22 for actuator with anti-clockwise rotation.
In fact, in this way the magnet movements will always be comprised in the sector between
the directions C and D which delimit the operating area of the Hall sensor.
Fig. 21 View from the bottom of the positioner - Magnet orientation for clockwise
actuator.
Fig. 22 View from bottom of the positioner - Magnet orientation for anti-clockwise
actuator.
DB
A
C
15°
90°
120°
15°
DB
A
C
15°
90°
120°
15°

IM-P343-29 CH Issue 520
Fig. 23 ¼" NPT air supply (supply)
¼" NPT air signal to
actuator (output 1)
5.4 Air supply and connections
WARNING: Supply air pressure must not exceed the maximum allowable air pressure of
the actuator. Air connections should be ¼" NPT for air supply (supply) and output signal to
actuator (output 1 and output 2 for double action applications) as shown in Figure 23. The
supply air should be between 1.4 bar g minimum and 6 bar g maximum and be oil and dust
free to IEC 60770. Mains air supply may sometimes contain traces of dirt, rust, water, oil
and other deposits with the potential for contaminating the internals of the positioner. It is
therefore essential that a filter / regulator is fitted in the mains air supply to the positioner.
The filter / regulator should have a coalescing filter such as a Spirax Sarco type MPC2, or
suitable compressed air pipework is used.