Spirax Sarco SP400 User manual

IM-P343-37 CTLS Issue 4 1
3.568.5275.400
SP400
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-37
CTLS Issue 4
© Copyright 2020
Printed in Italy

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SP400 Electropneumatic Smart Positioner

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SP400 Electropneumatic Smart Positioner
2. Safety information
5
2.1 General requirements
2.2 Electrical safety requirements
2.3 Electromagnetic compatibility
3. Technical information
6
3.1 Description
3.2 Technical data
8
3.3 Materials
3.4 Programmable functions 9
4. Options
10
4.1 Pressure gauge block
5. Installation
5.1 Mounting the SP400 positioner - General informaton 19
5.2 Sequence for mounting an SP400 positioner to a linear actuator 20
5.3 Sequence for mounting an SP400 positioner to a rotary actuator 24
5.4 Air supply and connections 28
6. Electrical connections
29
6.1 Guidance notes
6.2 Wiring diagrams
7. Quick start procedure
33
7.1 2-port valves
7. 2 3-port valves
1. Contents
Index continued on page 4

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SP400 Electropneumatic Smart Positioner
8. Programming flow chart 34
9. Programming and commissioning
36
9.1 SET-UP NOW
9.2 SP400 MENU 37
9.3 MANOP 39
9.4 AUTOS - automatic autostroke commissioning 41
9.5 SET - setting of valve functions 45
9.6 RUN - automatic operation 58
10. Maintenance and troubleshooting
62
10.1 Air supply quality
10.2 Fitting replacement filter plug kit
11. Default values and program settings 63
12. Glossary of display data
64
12.1 Main menu display functions
12.2 Sub-menu display functions 66

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SP400 Electropneumatic Smart Positioner
2.1 General requirements
The flawless and safe operation of the SP400 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 SP400 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 SP400 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 2004/108/EC according to:
- EN 61326-1: 2006
- EN 61326-2-3: 2006
- EN 55011: 1998 + A1: 1999 + A2: 2002
- EN 61000-4-2: 1995 + A1: 1998 + A2: 2001
- EN 61000-4-3: 2006
- EN 61000-4-4: 2004
- EN 61000-4-5: 2006
- EN 61000-4-6: 2007
- EN 61000-4-11: 2004
This product may be affected by interference 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.
2. Safety information

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SP400 Electropneumatic Smart Positioner
3.1 Description
The SP400 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. The pneumatics are based on piezovalve
technology - Therefore, high resolution, high reliability, vibration insensitivity and extremely low air
consumption is guaranteed at steady state.
The SP400 includes many smart functions that can be fully programmed through menu driven software using
an integral keypad and LCD alphanumeric data. The absence of mechanical linkages between valve stem
and positioner, drastically simplifies the mounting procedure and reduces the time required. Moreover the
software has been designed to simplify operations as much as possible: commissioning requires just
assembling the SP400 to the valve and pressing one button. The SP400 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
4
11
10
9
3
21
13 5 6 7 8
23
19 20 21 22 18
Fig. 2
15
14 17
16
3. Technical information

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SP400 Electropneumatic Smart Positioner
No. Part
1. LCD display
2. Main menu functions with LCD flag indication
3. Signal pressure to activator
4. Gland connection for wiring M20
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
11. Spare M20 gland connection for wiring a 4-20 mA retransmission or software switches
12. External earth
13. Internal earth
No. Features
14. indicates all is OK
15. ! Indicates a delay in positioning, this disappears when the position is reached
16. Indicates that the value displayed is a percentage
17. Indicates that the value displayed is the input current measured in mA
18. Indicates that the value displayed is a time measured in seconds
19. Indicates that you're accessing the main programming menus
20. Indicates that the positioner is in manual mode
21. Indicates that the positioner is running the autocalibration
22. Indicates that you're accessing the SET menu
23. Indicates that the positioner is in automatic mode

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3.2 Technical data
Input signal range 4 - 20 mA nominal
Minimum input signal 3.6 mA
Minimum air supply pressure 1.4 bar g
Maximum air supply pressure 7 bar g
Air quality Air supply must be dry, oil and dust free to ISO 8573-1 class 3:3:3
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
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 6.0 bar g
Steady state air consumption Less than 0.016 normal m3/h
Air connections Screwed ¼" NPT
Cable gland M20
Electrical connections Spring clamp terminals for 0.2 to 1.5 mm² wire
Enclosure rating IP65
Characteristics Linear
Resolution (maximum) 0.1% F. S
Shut-off 1%
Shipping weight 2.2 kg
3.3 Materials
Part Material Finish
Case and cover Die cast aluminium Anti-corrosive paint to RAL5010
Magnet bracket Die cast aluminium

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SP400 Electropneumatic Smart Positioner
3.4 Programmable functions
Autostroke Automatic commissioning routine
Valve type 2-port or 3-port
% travel Selectable 0 - 100% or 100% - 0% depending on valve/actuator configuration
Control action Direct or reverse action (4 - 20 or 20 - 4 mA)
Split range
OFF range 4 - 20 mA
LOW range 4 - 13 mA
HIGH range 11 - 20 mA
Deadband
0.5%
1.5%
3.0%
5.0%
Reset Resets all programmed values to default settings
Input signal Visualisation of input mA signal

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SP400 Electropneumatic Smart Positioner
4.1 Pressure gauge block
An optional pressure gauge block (Figure 3) can be fitted onto the SP400 positioner which includes two
pressure gauges indicating air supply pressure and output air signal pressure to the actuator. The pressure
gauge block can be retrospectively fitted using 2 off M5 socket head screws. Ensure that the gauge block
air connection 'O' rings are correctly located before tightening.
Fig. 3
4. Options

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SP400 Electropneumatic Smart Positioner
5.1 Mounting the SP400 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 SP400 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 SP400.
5.1.1 The SP400 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 The SP400 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.
5.1.3 Before fitting and commissioning the SP400 positioner ensure that the valve and actuator are
correctly assembled. Refer to the valve and actuator Installation and Maintenance Instructions
for details.
5. Installation

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SP400 Electropneumatic Smart Positioner
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 SP400 positioner to a
linear actuator
2
2

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SP400 Electropneumatic Smart Positioner
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
Assembled
2
Mounting plate
Bracket
Center of the magnet
PN1000PN9000
Fig. 6

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SP400 Electropneumatic Smart Positioner
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).
5.2.5 Locate the protection plate onto the back of the SP400 positioner housing and x in place (Figures
11 and 12).
Fig. 9 Pillar actuator assembly
Pillar actuatorMounting plate
Fig. 10 Yoke actuator assembly
Yoke actuator
Mounting plate
Protection
plate
Fig. 11
Assembled
Assembled
Assembled
Fig. 12

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SP400 Electropneumatic Smart Positioner
5.2.6 Attach the positioner mounting plate to the positioner as shown in Figures 13 and 14.
5.2.7 Adjust the vertical position of the SP400 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 15, 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.
5.2.8 When the SP400 positioner and mounting plate assembly is correctly positioned, tighten the hexagon
headed screw (5) on the yoke mounted actuator (Fig. 13) to 10 - 12 Nm and tighten the 'U'bolt nuts
(6) on the pillar mounted actuators (Figure 16) to 10 - 12 Nm.
Protection plate
5
Fig. 13
Attach the mounting plate
Assembled
Fig. 14
B
A
Fig. 15
SP400 positoner
6
Fig. 16

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5.3 Sequence for mounting an SP400 positioner to a
rotary actuator
5.3.1 Assembly for fitting an SP400 on to a ¼ turn valve.
Fig. 17 Mounting kit

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SP400 Electropneumatic Smart Positioner
Fig. 18
Fig. 20
Fig. 19

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SP400 Electropneumatic Smart Positioner
Fig. 22
Assembled
Fig. 21

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SP400 Electropneumatic Smart Positioner
5.3.2 Adjust the magnet orientation as illustrated in Figures 23 and 24 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 23 for actuator with clockwise rotation.
Refer to Figure 24 for actuator with anti-clockwise rotation.
In fact, in this way the magnet movements will always be comprised in the sector between the
directions Cand Dwhich delimit the operating area of the Hall sensor.
Fig. 23
View from the bottom
of the positioner -
Magnet orientation for
clockwise actuator.
Fig. 24
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°

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Fig.25
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 (Figure 25).
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 or suitable compressed air pipework is used.