Spirax Sarco SP7-10 User manual

IM-P706-02-US Issue 1 1
SP7-10 Digital positioner
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Troubleshooting
© Copyright 2021
Printed in US
3440750/1
SP7-10
Digital positioner
Installation and Maintenance Instructions
IM-P706-02-US
Issue 1

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SP7-10 Digital positioner
Copyright © Spirax-Sarco Limited 2021
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to
use the Work(s) solely within the scope of the legitimate operation of the product
(or device). No other right is granted under this licence. In particular and without
prejudice to the generality of the foregoing, the Work(s) may not be used, sold,
licensed, transferred, copied or reproduced in whole or in part or in any manner
or form other than as expressly granted here without the prior written consent of
Spirax-Sarco Limited.

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1. Safety information 4
2. General product information
72.1 Introduction
2.2 Operating principle
3. Installation
8
3.1 Mechanical mounting
3.2 Electrical connections 18
3.3 Connection on the device 22
3.4 Connection on device - SP7-1 Control Unit with SP7-1 Remote Sensor 24
3.5 Connection on device – SP7-1 Control Unit for remote position sensor 26
3.6 Pneumatic connections - Air supply 29
4. Commissioning
304.1 Commissioning the positioner
4.2 Recommended rotational angle range
4.3 Operating modes 31
4.4 Standard automatic adjustment 32
4.5 Sample parameters 33
4.6 Setting the option modules 34
4.7 Setting the mechanical limit switch with proximity switches
35
4.8 Setting the mechanical limit switch with 24 V micro-switches
5. Operation
36
5.1 Parameterization of the device
5.2 HART®Parameter Overview 38
6. Troubleshooting
43
6.1 Error codes
6.2 Alarm codes 45
6.3 Message codes 46
Contents

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SP7-10 Digital positioner
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.13) in compliance
with the operating instructions. General installation and safety instructions for pipeline
and plant construction, as well as the proper use of tools and safety equipment must also
be complied with.
WARNING: The maximum process fluid temperature must be suitable for use
if the unit is to be used in any potential explosive atmosphere. For the device
maintenance in a potentially explosive atmosphere, we recommend the usage
of tools which do not produce and / or propagate sparks.
1.1 Wiring
Every effort has been made during the design of the positioner to ensure the safety of the
user, but the following precautions must be followed:
i) Ensure correct installation. Safety may be compromised if the installation of the product
is not carried out as specified in this manual.
ii) Wiring should be carried out in accordance with IEC 60364 or equivalent.
iii) Fuses should not be installed in the protective earth conductor. The integrity of the
installation protective earth system must not be compromised by the disconnection or
removal of other equipment.
1.2 Intended use
Referring to the Installation and Maintenance Instructions, product markings and Technical
Information Sheet, check that the product is suitable for the intended use / application.
1.3 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)before
attempting to work on the product. Arrange suitable lifting gear if required.
1.4 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.5 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.6 Hazardous environment around the product
Consider: lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of temperature, hot
surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1. Safety information

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1.7 The system
Consider the effect on the complete system of the work proposed. Will any proposed action
(e.g. closing isolation valves, electrical isolation) put any other part of the system or any
personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective
of controls or alarms. Ensure isolation valves are opened and closed progressively to avoid
system shocks.
1.8 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider
double isolation (double block and bleed) and the locking or labelling of closed valves. Do
not assume that the system has depressurised even when the pressure gauge indicates zero.
1.9 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns.
1.10 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available. Use
only genuine Spirax Sarco replacement parts.
1.11 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing to protect
against the hazards of, for example, chemicals, high / low temperature, radiation, noise,
falling objects, and dangers to eyes and face.
1.12 Permits to work
All work must be carried out or be supervised by a suitably competent person.Installation
and operating personnel should be trained in the correct use of the product according to
the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no
such system, it is recommended that a responsible person should know what work is going
on and, where necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.
1.13 Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the
back. You are advised to assess the risks taking into account the task, the individual, the
load and the working environment and use the appropriate handling method depending on
the circumstances of the work being done.
1.14 Residual hazards
In normal use the external surface of the product may be hot. Many products are not self-
draining. Take due care when dismantling or removing the product from an installation (refer
to 'Maintenance instructions').

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1.15 Freezing
Provision must be made to protect products which are not self-draining against frost damage
in environments where they may be exposed to temperatures below freezing point.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and
the precautions to be taken due to contamination residues or mechanical damage which may
present a health, safety or environmental risk. This information must be provided in writing
including Health and Safety data sheets relating to any substances identified as hazardous
or potentially hazardous.
Product return procedure
Please provide the following information with any equipment being returned:
1. Your name, Company name, address and telephone number, order number and invoice and
return delivery address.
2. Description of equipment being returned.
3. Description of the fault.
4. If the equipment is being returned under warranty, please indicate:
i. Date of purchase
ii. Original order number
iii. Serial number
Please return all items to your local Spirax Sarco branch.
Please ensure all items are suitably packed for transit (preferably in the original cartons).

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2.1 Introduction
The SP7-1 is an intelligent digital positioner available with communication via HART.®within the
positioner product range. Unsurpassed shock absorption and vibration compensation from 10 g to
80 Hz distinguishes the SP7-1 from other products and guarantees reliable operation in nearly any
area under the harshest ambient conditions.
2.2 Operating principle
1LCI plug
2Setpoint signal 4 to 20 mA
3Binary input
4Binary output
5Supply air: 1.4 to 6 bar
(20 to 90 psi, 0.14 to 0.6 MPa)
6Exhaust
2. General product information
The SP7-1 is an electronically configurable positioner with communication capabilities designed for
mounting on pneumatic linear or rotary actuators.
Fully automatic determination of the control parameters and adaptation to the positioner allow for
considerable time savings as well as optimum control behavior.
Fig. 1
7I/P module with 3/3-way valve
8Position sensor
9Plug-in module analog feedback (4 to 20 mA)
10 Plug-in module digital feedback
11 Installation kit for mechanical position indication
12 Limit value monitor with proximity switches
13 Limit value monitor with 24 V-micro-switches

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Fig. 2
Fig. 3
3. Installation
3.1 Mechanical mounting
3.1.2 Measuring and operating ranges of the positioner
Arrow (1) on the device feedback
shaft (position feedback) point must
move between the arrow marks (2)
Operating range for linear actuators:
The operating range for linear
actuators is ±45° symmetrically
to the longitudinal axis.
The usable span within the
operating range is at least
25° (recommended figure
40°). The usable span
does not necessarily need
to run symmetrically to the
longitudinal axis.
Operating range of rotary
actuators:
The usable span is 90°,
which must be entirely within
the measuring range, but
does not necessarily need
to run symmetrically to the
longitudinal axis.
Note
During installation make sure
that the actuator travel or
rotation angle for position
feedback is implemented
correctly.
(1) Measuring range
(2) Operating range

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Fig. 4
3.1.3 Mounting on linear actuators
For mounting on a linear actuator in accordance
with IEC 534 (lateral mounting as per NAMUR), the
following attachment kit is available:
1Screw
2Washer
3Mounting bracket
4Lever with follower pin
(for mechanical stroke
10 to 35 mm [0.39 to 1.38 in]
or
20 to 100 mm [0.79 to 3.94 in])
5Washers
6Screws
7U-Bolts
8Washers
9Nuts
10 Screws
11 Spring washers
12 Clamp plates
13 Follower guide

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Fig. 5
1. Tighten the screws so that they are hand tight
2. Attach the follower guide (1) and clamp plates (2) with screws (4) and spring washers (3) to the
actuator stem.
3.1.4 Attaching a follower guide to the actuator

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Fig. 6
1. Attach the lever (6) to the feedback shaft (5) of the positioner (can only be mounted in one position
due to the cut shape of the feedback shaft).
2. Using the arrow marks (4), check whether the lever moves within the operating range (between
the arrows).
3. Hand-tighten the screw (7) on the lever.
4. Hold the prepared positioner (with the mount bracket (1) still loose) on the actuator so that the
follower pin for the lever enters the follower guide to determine which tap holes on the positioner
must be used for the mount bracket.
5. Secure the mount bracket (1) with screws (2) and washers (3) using the relevant tap holes on the
positioner housing.
Tighten the screws as evenly as possible to ensure subsequent linearity.
Align the mount bracket in the oblong hole to ensure that the operating range is symmetrical.
Set the valve mid stroke and align the lever horizontal (item 4 fig. 7).
Then tighten mounting bolt (item 4 fig. 7) (lever moves between the arrow marks item 4 fig. 8).
3.1.5 Mounting lever and bracket on the positioner

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3.1.6 Mounting on a yoke
Fig. 7
3.1.7 Mounting on a column
1. Attach the mount bracket (2) with screw (4)
and washer (3) to the yoke (1).
Fig. 8
1. Hold the mount bracket (3) in the proper
position on the column (2).
2. Insert the U-bolts (1) from the inside of the
column (2) through the holes of the mount
bracket.
3. Add the washers (4) and nuts (5).
4. Tighten the nuts so that they are hand-tight.
Note
Adjust the height of the positioner on the cast
iron yoke or columnar yoke until the lever is
horizontal (based on a visual check) at half
stroke of the valve.

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Fig. 9
The scale on the lever indicates the link points for the various stroke ranges of the valve.
Move the bolt with the follower pin in the oblong hole of the lever to adjust the stroke range of the
valve to the working range for the position sensor.
Moving the link point inwards increases the rotation angle of the sensor. Moving the link point outwards
reduces the rotation angle of the sensor.
Adjust the actuator stroke to make use of as large an angle of rotation as possible (symmetrical around
the center position) on the position sensor.
Recommended range for linear actuators: −28 to 28°
Minimum angle: 25°
Note After mounting, check whether the positioner is operating within the measuring range.
3.1.9 Position of the actuator bolt
The actuator bolt for moving the potentiometer lever can be mounted permanently on the lever
itself or on the valve stem. Depending on the mounting method, when the valve moves the actuator
bolt performs either a circular or a linear movement with reference to the center of rotation of the
potentiometer lever. Select the chosen bolt position in the HMI menu in order to ensure optimum
linearization. The default setting is actuator bolt on lever
3.1.8 Positioner linkage
(1) Increase linkage
(2) Decrease linkage

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Fig. 10
Fig. 11
3.1.10 Actuator bolts on the lever (rear view)
3.1.11 Actuator bolts on the Valve (rear view)
1Potentiometer lever
2Actuator bolts
3Valve stem
4Valve yoke
5Positioner
1Potentiometer lever
2Actuator bolts
3Valve stem
4Valve yoke
5Positioner

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Fig. 12 Components of attachment kit
-Adapter 1 with spring (5)
-Four M6 screws each (4), spring washers (3) and washers (2) to fasten the attachment bracket
(6) to the positioner
-Four M5 screws (7), Spring washers (8) and washers (9) to fasten the attachment bracket to
the actuator
Required tools:
-Wrench, size 8/10
-Allen key, size 3
3.1.12 Mounting on rotary actuator
For mounting on part-turn actuators in accordance with VDI/VDE 3845, the following attachment
kit is available:

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Fig. 13
1. Determine the mounting position (parallel to actuator or at 90° angle).
2. Calculate the rotational direction of the actuator (right or left).
3. Move the part-turn actuator into the home position.
4. Pre-adjust feedback shaft.
To make sure that the positioner runs within the operating range (refer to General on page 14), the
mounting position as well as the basic position and rotation direction of the actuator must be considered
when determining the adapter position on axis 1. For this purpose, the feedback shaft can be adjusted
manually so that the adapter (3) can be attached in the correct position.
5. Place the adapter in the proper position on the feedback shaft and fasten with threaded pins (2).
One of the threaded pins must be locked in place on the flat side of the feedback shaft.
3.1.13 Mounting the adapter on the positioner

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Fig. 15
3.1.14 Screwing the attachment bracket onto the positioner
(1) Attachment bracket
Fig. 14
3.1.15 Screwing the positioner onto the actuator
Note
After mounting, check whether the operating range of the
actuator matches the measuring range of the positioner,
refer to General on page 14.

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Fig. 16
ABasic device
BOptions
CConnection SP7-1 Remote Sensor/remote position sensor (only for SP7-1 Control Unit version)
DOptions, limit value monitor with proximity switches or micro-switches (not for SP7-1 Control
Unit version)
Terminal Function/comments
+11/−12 Analog input
+81/−82 Binary input DI
+83/−84 Binary output DO2
+51/−52 Digital feedback SW1 (Option module)
+41/−42 Digital feedback SW2 (Option module)
+31/−32 Analog feedback AO (Option module)
1/2/3 SP7-1 remote sensor (Only for options SP7-1 Remote Sensor or SP7-1 for remote position sensor)
+51/−52 Limit switch Limit 1 with proximity switch (optional)
+41/−42 Limit switch Limit 2 with proximity switch (optional)
41/42/43 Limit switch Limit 1 with micro-switch (optional)
51/52/53 Limit switch Limit 2 with micro-switch (optional)
Note
The SP7-1 can be fitted either with proximity switches or micro-switches as limit switches. It is not
possible to combine both variants. For the version SP7-1 Control Unit with SP7-1 Remote Sensor,
the limit switches are located in the SP7-1 Remote Sensor.
3.2 Electrical connections
3.2.1 Positioner SP7-1 Control Unit Electrical Connection
Limit 2Limit 1
Limit 2Limit 1

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Fig. 17
ABasic device
BOptions
1Position sensor
2Limit monitor with proximity switches (optional)
3Limit monitor with micro-switches (optional)
3.2.3 Connections for inputs and outputs
Terminal Function/comments
1/2/3 SP7-1 control unit
+51/−52 Proximity switches Limit 1 (Option)
+41/−42 Proximity switches Limit 2 (Option)
41/42/43 Micro-switches Limit 1 (Option)
51/52/53 Micro-switches Limit 2 (Option)
3.2.4 Analog input
Terminals +11/−12
Nominal operating range 4 to 20 mA
Split range configuration between 20 to 100 % of the nominal operating range can be
parameterized
Maximum 50 mA
Minimum 3.6 mA
Starting at 3.8 mA
Load voltage 9.7 V at 20 mA
Impedance at 20 mA 485 Ω
Note
The SP7-1 Remote Sensor can be fitted either with proximity switches or micro-switches as limit
switches. It is not possible to combine both variants.
3.2.2 SP7-1 Remote Sensor Electrical Connection

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3.2.5 Digital input
Input for the following functions:
-no function
-move to 0 %
-move to 100 %
-hold previous position
-block local configuration
-block local configuration and operation
-block any access (local or via PC)
3.2.6 Binary input DI
Terminals +81/−82
Supply voltage 24 Vdc (12 to 30 Vdc)
Input ‘logical 0’ 0 to 5 Vdc
Input ‘logical 1’ 11 to 30 Vdc
Input Current Maximum 4 mA
3.2.7 Binary output
Output configurable as alarm output by software
3.2.8 Binary output DO
Terminals +83/−84
Supply voltage 5 to 11 Vdc (Control circuit in accordance with /NAMUR)
Output ‘logical 0’ > 0.35 mA to < 1.2 mA
Output ‘logical 1’ > 2.1 mA
Direction of action Configurable ‘logical 0’ or ‘logical 1’
3.2.9 Option modules
All factory options must be selected at time of ordering.
Module for analog feedback AO*
Without any signal from the positioner (e.g. ‘no power’ or ‘initializing’) the module sets the output to >
20 mA (alarm level).
Terminals +31/−32
Signal range in the event of an error 4 to 20 mA (split ranges can be parameterized)
> 20 mA (alarm level)
Supply voltage, two-wire technology 24 Vdc (11 to 30 Vdc)
Characteristic curve rising or falling (configurable)
Deviation < 1 %