Spirax Sarco SP400 User manual

IM-P343-37 CH Issue 3 1
SP400
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-37
CH Issue 3
3.568.5275.400
1. Index
2. Safety information
3. Technical information
4. Options
5. Installation
6. Electrical connections
7. Gyorsbeállítási folyamat
8. Programozási
folyamatábra
9. Programozás és
beüzemelés
10. Maintenance
11. Default values and
program settings
12. Glossary of
display data
Printed in Italy © Copyright 2011

IM-P343-37 CH Issue 32
1. Index
Section Sub-section
2.1 General requirements
2. Safety 2.2 Electrical safety requirements
information 2.3 Electromagnetic compatibility
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 SP400 positioner -
General informaton
5.2 Sequence for mounting an SP400 positioner to
5. Installation a linear actuator
5.3 Sequence for mounting an SP400 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 SP400 MENU
9.3 MANOP
9. Programming and 9.4 AUTOS - automatic autostroke commissioning
commissioning 9.5 SET - setting of valve functions
9.6 RUN - automatic operation
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

IM-P343-37 CH Issue 3 3
2. Safety information
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.

IM-P343-37 CH Issue 34
3. Technical information
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
No. Part
1. LCD display
2. Main menu functions with LCD flag indication
3. Signal pressure to actuator
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
4
11
10
9
3
21
13 5 6 7 8

IM-P343-37 CH Issue 3 5
No. Features
1. indicates all is OK
2. ! Indicates a delay in positioning, this
disappears when the position is reached
3. Indicates that the value displayed is a
percentage
4. Indicates that the value displayed is the
input current measured in mA
5. Indicates that the value displayed is a
time measured in seconds
6. Indicates that you're accessing the main
programming menus
7. Indicates that the positioner is in manual
mode
8. Indicates that the positioner is running
the autocalibration
9. Indicates that you're accessing the SET
menu
10. Indicates that the positioner is in
automatic mode
10
6 7 8 9 5
Fig. 2
3.2 Technical data
Input signal range 4 - 20 mA nominal
Minimum input signal (loop powered) 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 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
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 0.016 normal m3/h
Air connections Screwed ¼" NPT
Cable gland M20
Electrical connections Spring clamp terminals for 0.2 to 1.5 mm²wire
Enclosure rating IP65
Characteristic Linear
Resolution (maximum) 0.1% F.S.
Shut-off 1%
Shipping weight 2.2 kg
2
1 4
3

IM-P343-37 CH Issue 36
3.3 Materials
Part Material Finish
Case and cover Die cast aluminium Anti-corrosive paint to RAL5010
Magnet bracket Die cast aluminium
3.4 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)
OFF range 4-20 mA
Split range LOW range 4-13 mA
HIGH range 11-20 mA
0.5%
Deadband 1.5%
3.0%
5.0%
Reset Resets all programmed values to default settings
Input signal Visualisation of input mA signal

IM-P343-37 CH Issue 3 7
4. Options
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

IM-P343-37 CH Issue 38
5. Installation
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.

IM-P343-37 CH Issue 3 9
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

IM-P343-37 CH Issue 310
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-P343-37 CH Issue 3 11
Bracket
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 SP400 positioner housing and fix in
place (Figures 11 and 12).
Protection
plate
Fig. 11
Assembled
Assembled
Assembled
Fig. 12

IM-P343-37 CH Issue 312
5.2.6
Attach the positioner mounting plate to the
positioner as shown in Figures 26 and 27.
Protection
plate
5
Fig. 13
Attach
th e
mounting
plate
Assembled
Fig. 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.
B
A
Fig. 15
SP400 positoner
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 (Figure 13) to
10 - 12 N m and tighten the 'U'bolt nuts (6) on the
pillar mounted actuators (Figure 16) to 10 - 12 N m.
6
Fig. 16

IM-P343-37 CH Issue 3 13
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

IM-P343-37 CH Issue 314
Fig. 18
Fig. 20
Fig. 19

IM-P343-37 CH Issue 3 15
Fig. 21
Fig. 22
Assembled

IM-P343-37 CH Issue 316
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°

IM-P343-37 CH Issue 3 17
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 such as a Spirax Sarco type MPC2, or
suitable compressed air pipework is used.

IM-P343-37 CH Issue 318
6. Electrical connections
6.1 Guidance notes on wiring installation
For heavy industrial applications it is recommended to use screened cables or signal cables
run in metal conduit. Failure to do so could result in positional errors of up to ±5% in an
RF field excess of 10 V/m. If screened cables are used, ensure that the screen is connected to
the local earth at one end with a connection resistance of less than 1 ohm.
For light industrial applications where RF fields do not exceed 3 V/m unscreened cables
may be used.
Cabling should be installed in accordance with BS 6739 - Instrumentation in Process Control
Systems: Installation design and practice or local equivalent.
6.2 Wiring diagrams
6.2.1 Terminal block
No. Pole Description
1+Not used
2-
3+4-20 mA current signal input Mainboard
4-
5+Not used
6-
7+Not used
8-
9+Not used
10 -
Fig. 26
SP400
AUTOMATIC TUNE
50
%
SET AUTOS MANUAL MENU
- +
4-20mA
1
2
3
4
5
6
7
8
9
10
▲
▲
AUTOSTROKE
keep pressed

IM-P343-37 CH Issue 3 19
6.2.3 Multi-loop applications
Loop powered multi-positioner connections
4 - 20 mA signal +
@ 14 V minimum -
In a loop powered application, the 4-20 mA signal must be capable of supplying a
minimum of 7 V per positioner at 20 mA. In a split range application the signal source
must be capable of supplying sufficient voltage, i.e. 14 V is enough to power 2 positioners.
Fig. 27
4 - 20 mA signal
3 4
+ -
3 4
Positioner 1
3 4
Positioner 2
Fig. 28
6.2.2 Single loop applications
The SP400 is loop powered using the 4 - 20 mA input signal source providing a
minimum signal of 3.6 mA can be maintained.
Minimum current 3.6 mA
Maximum current 30 mA
Maximum voltage drop < 7 V
Overvoltage protection Up to 30 Vdc
Protection against polarity inversion Up to 30 Vdc

IM-P343-37 CH Issue 320
7. Gyors beállítási funkció
7.1 2-utú szelep
Akövetkező leírás a 2 utú szelepeknél használható melyhez pneumatikus működtetőt szereltek
direct működésú és a vezérlőjele 4-20 mA kivétel ha egyébb különleges beállítást igényel.
Megjegyzés:: A PN5000 és PN6100 sotrozathoz egyéb beállítások is szükségesek.
(lásd a 9.5.2).
7.1.1 A poziciónálót helyesen fel kell szerelni lásd 5 és 6 os fejezet
7.1.2 Minimum 3,6 mA vezérlő jel esetén megjelenik a kijelzőn a SET-UP NOW felírat
7.1.3 Ellenőrizendő hogy a primer elzáró zárva van-e.
Nyod és tratsd az enter gombot lenyomva 3 másodpercre .
A kijelző visszaszámol
7.1.4 nyomd meg lefelé nyilat a kéziműködtetéshez.
.
7.1.5 tarsd lenyova a enter gombot 3 másodperce a funkció aktiváláshoz MCTL.
7.1.6 Kézi módban a le fel nyilakkal mükdtethető a s z e l e p
ellenőrizendő a szabad mozgás.
A kijelző a és kijelzés adja
FILL VENT
Hiba estén a hibát ki kell javítani mielőtt a következő lépést megtennénk
7.1.7 Az enter gomb megnyomásával visszatér a MANOP menűbe.
7.1.8 Nyomd és tarasd az enter gombot lenyomva 6 másodpercre az auto kalibrálkés érdekében
Kb 2 percet vesz igénybe a folyamat.
! a befejezetlen vagy sikertelen kalibrálást jelöli
A folyamat bármikor megszakítható az enter gomb egyszeri megnyomásával.
ABORT felírat fogja jelezni és megjelenik a ! jel.
Sikeres befelyezés után automatikusan visszatér a AUTOS menűbe.
A szimbolum jelzi a sikereséget.
7.1.9 A szelep a vezérlő jelnek megfelelő pozicióba áll. A kilyelzőn pedig megjelenik % a szelep állása.
A poziciónáló fedelét ekkor be lehet zárni.