Spirax Sarco SP500 User manual

IM-P343-35 CTLS Issue 5 1
3.568.5275.300
SP500
Electropneumatic Smart Positioner
Installation and Maintenance Instructions
IM-P343-35
CTLS Issue 5
© Copyright 2020
Printed in Italy

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SP500 Electropneumatic Smart Positioner

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SP500 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
4.2 Retransmission and travel switches option board 11
4.3 External power supply option board 13
4.4 HART®communication protocol option board 16
5. Installation
5.1 Mounting the SP500 positioner - General informaton 19
5.2 Sequence for mounting an SP500 positioner to a linear actuator 20
5.3 Sequence for mounting an SP500 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
1. Contents
Index continued on page 4

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SP500 Electropneumatic Smart Positioner
7. Quick start procedure
33
7.1 2-port valves
7. 2 3-port valves
8. Programming flow chart 34
9. Programming and commissioning
36
9.1 SET-UP NOW
9.2 SP500 MENU 37
9.3 MANOP 39
9.4 AUTOS - automatic autostroke commissioning 41
9.5 SET - setting of valve functions 45
9.6 TUNE - setting of valve tune functions 53
9.7 RUN - automatic operation 58
9.8 STRVL and RTIME - valve diagnostics 60
9.9 RETRN - return to SP500 MENU in main menu 61
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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SP500 Electropneumatic Smart Positioner
2.1 General requirements
The flawless and safe operation of the SP500 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 SP500 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 SP500 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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SP500 Electropneumatic Smart Positioner
3.1 Description
The SP500 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 SP500 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 SP500 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.
The SP500 smart valve positioner supports optional expansion to include the HART®communication protocol,
enabling complete configuration using a PC or handheld device.
Fig. 1
12
4
11
10
9
3
21
13 5 6 7 8
23 24
19 20 21 22 18
Fig. 2
15
14 17
16
3. Technical information

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SP500 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
24. Indicates that you're accessing the TUNE menu

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SP500 Electropneumatic Smart Positioner
3.2 Technical data
Input signal range 4 - 20 mA nominal
Minimum input signal 3.6 mA
Air supply pressure 1.4 - 7.0 bar (5-10 psi above spring range pressure)
Communication protocol HART®communication protocol superimposed over dc current signal
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
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, Equal % (ratio 1:50) or Fast opening (ratio 50:1)
Resolution (maximum) 0.1% F.S. (Full Scale)
4 - 20 mA retransmit (optional) 4 - 20 mA retransmission of valve position
Tolerance ±0.5% F.S. (Full Scale)
Software travel Two software configured switches (optional)
travel switches
1 x normally closed
1 x normally open
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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SP500 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)
Travel limits Setting of minimum and maximum travel limits
Signal span 4 - 20 mA or split ranged (minimum span 4 mA)
Deadband 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 configured travel switch setting (range 0 - 100%)
Reset Resets all programmed values
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

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SP500 Electropneumatic Smart Positioner
4.1 Pressure gauge block
An optional pressure gauge block (Figure 3) can be fitted onto the SP500 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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SP500 Electropneumatic Smart Positioner
Fig. 4
Fig. 5
4.2 Retransmission and travel switches option board
An option board can be t ted in the posit i oner to add valve positio n retransmi ssion functi o na li t y an d sof twar e
travel switches functionality.
The board generates a 4-20 mA current signal which represents the actual valve position.
Moreover 2 output terminals are available to be congured as software travel switches.
The threshold can be adjusted via software.
Refer to Section 6, 'Electrical connections' for wirings.
Refer to Section 9.6.7 for travel switching conguration.
An option board is optionally available and can be mounted in situ. In this case please refer to the mounting
instruction below:
-Open the positioner (Figure 4).
-Switch o󰀨 the power supply.
-Switch o󰀨 the air supply.
-Unscrew the board as shown in Figure 5.

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Fig. 6
Fig. 7
Fig. 8
Fig. 9
-Rotate the mainboard and insert the option board (as shown in Figures 6, 7, 8 and 9).
-Rotate the mainboard to the initial position,  x it with the 4 screws, close the positioner and switch on
the power supply and air supply.

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SP500 Electropneumatic Smart Positioner
Fig. 11
Fig. 10
4.3 External power supply option board
The SP500 can host an option board for 24 V power supply.
It's a 4 wiring diagram: 2 wires for current loop and 2 wires for power supply through a 24 V external voltage.
This reduces dramatically the voltage drop on the current loop. The drop is 7 V when the unit is powered by
the loop (2 wires), it falls to 1 V when the 4 wires conguration is used.
This board can be useful when you have many instruments connected on the same current loop. The fact is
that in this case, the total voltage drop on the loop could be higher than the maximum voltage drop that the
controller (PLC) can handle.
Refer to Section 6, 'Electrical connections' for wirings.
An option board is optionally available and can be mounted in situ. In this case please refer to the mounting
instruction below:
-Open the positioner (Figure 10).
-Switch o󰀨 the power supply.
-Switch o󰀨 the air supply.
-Unscrew the board as shown in Figure 11.

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Fig. 12
Fig. 13
Fig. 14
-Rotate the mainboard and insert the option board (as shown in Figures 12 and 13).
-Remove the Jumper J4 (Figure 14).

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SP500 Electropneumatic Smart Positioner
-Insert the power supply option board. Collocate Jumper J4 as shown in Figures 15 and 16.
-Rotate the mainboard to the initial position, x it with the 4 screws, close the positioner and switch on
the power supply and air supply.
Once the option board is mounted, the positioner shall be powered according to the 4 wires connection
diagram, refer to Section 6.2.3, '4 wires electrical connection'. The positioner won't work if powered according
to the standard 2 wires connection.
Fig. 15
Fig. 16

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Fig. 18
Fig. 17
4.4 HART®option board
An option board can be tted into the positioner to enable communication using the HART® protocol. In this
case it is possible to congure and drive the positioner remotely using a PC or handheld device. For further
details refer to the specic literature about SP500 HART® available on the Spirax Sarco website.
An option board is optionally available and can be mounted in situ. In this case please refer to the mounting
instruction below:
-Open the positioner (Figure 17).
-Switch o󰀨 the power supply.
-Switch o󰀨 the air supply.
-Unscrew the board as shown in Figure 18.

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SP500 Electropneumatic Smart Positioner
-Rotate the mainboard and insert the option board (as shown in Figures 19 and 20).
-Remove the Jumper J14 (Figure 21).
Fig. 20
Fig. 19
Jumper J14
Fig. 21

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SP500 Electropneumatic Smart Positioner
-Insert the HART®option board as shown in Figure 22.
-Collocate the Jumper J14 as shown in Figure 23.
-Rotate the mainboard to the initial position, x it with the 4 screws, close the positioner and switch on
the power supply and air supply.
Fig. 22
Fig. 23

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SP500 Electropneumatic Smart Positioner
5.1 Mounting the SP500 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 SP500 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 SP500.
5.1.1 The SP500 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 SP500 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 SP500 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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5. 2.1 Loosely attach the magnet bracket (2) to
the valve/actuator connector (refer to
Figures 24 and 25). Be sure it is
positioned horizontally (as shown in
Figure 25).
Fig. 24 Pillar mounting kit for a linear actuator
Fig. 25 Yoke mounting assembly for a linear actuator
5.2 Sequence for mounting an SP500 positioner to a
linear actuator
2
2