Spirax Sarco SP7-11 User manual

IM-P706-02 CTLS Issue 5 1
SP7-10, SP7-11 and SP7-12 Smart positioner
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Troubleshooting
7. Maintenance
8. Approvals
9. Declaration of conformity
© Copyright 2023
3440750/5
SP7-10, SP7-11 and SP7-12
Smart positioner
Installation and Maintenance Instructions
IM-P706-02
CTLS Issue 5
Throughout the document SP7-1* is written
where the information is relevant to all
versions; the SP7-10, SP7-11 and SP7-12.
Where the information is specific it will be
referenced as the version appropriate.

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SP7-10, SP7-11 and SP7-12 Smart positioner
Copyright © Spirax-Sarco Limited 2022
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.
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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SP7-10, SP7-11 and SP7-12 Smart positioner
1. Safety information 5
2. General product information
8
2.1 Introduction
2.2 Operating principle
2.3 Label description
10
2.4 Principle of operation
3. Installation
12
3.1 Mechanical mounting
3.2 Electrical connections SP7-10 22
3.3 Electrical Connection SP7-11/12 24
3.4 Connection on device 30
3.5 Connection on device - SP7-10 Control Unit with SP7-1 Remote Sensor 32
3.6 Connection on device – SP7-10 Control Unit for remote position sensor 34
3.7 Pneumatic connections 36
4. Commissioning
38
4.1 Commissioning the positioner
4.2 Recommended rotational angle range
4.3 Operating modes 39
4.4 Standard automatic adjustment 40
4.5 Commissioning SP7-11/12 41
4.6 Setting the bus address 42
4.7 Request information 44
4.8 Operating modes 44
4.9 Jumper configuration 45
4.10 Standard automatic adjustment 46
4.11 Sample parameters 47
4.12 Setting the option modules 48
4.13 Setting the mechanical limit switch with proximity switches
49
4.14 Setting the mechanical limit switch with 24 V micro-switches
Contents

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SP7-10, SP7-11 and SP7-12 Smart positioner
5. Operation
50
5.1 Parameterization of the device
5.2 SP7-10 HART Parameter Overview 52
5.3 SP7-11/12 Parameter Overview 57
6. Troubleshooting
60
6.1 Error codes SP7-10
6.2 Error Codes SP7-11/12 62
6.3 Alarm codes 63
6.4 Message codes 64
7. Maintenance 65
8. Approvals 66
9. Declaration of Conformity 67

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SP7-10, SP7-11 and SP7-12 Smart positioner
1. Safety information
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 Explosion proof warning
Please ensure the unit is being used and installed in conformity with local, regional, and national
explosion proof regulations.
- Refer to “8. Approvals”
-The "Local communication interface (LCI)" of the SP7-1* may only be used outside of the
explosion hazardous area with Um ≤ 30 Vdc.
-The positioner type SP7-1* may only be operated as a source of auxiliary energy with gases of
the group IIA and the temperature class T1 in outdoor applications or inside of buildings with
sufficient ventilation.
-The fed gas must be free of air and oxygen insofar as no explosive atmosphere can occur. The
exhaust gas must always let outwards.
-The equipment may only be used as a II 2 D type device in areas where the level of mechanical
hazard is ‘low’.
-Cable entries that meet the requirements of EN 61241-11 for Category II 2 D as well as the
ambient temperature range must be used.
-Prevent electrostatic charging due to propagating brush discharge when the equipment is used
for applications involving combustible dust.
1.2 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.

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SP7-10, SP7-11 and SP7-12 Smart positioner
1.3 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.
1.4 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.
1.5 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.6 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.
1.7 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.
1.8 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.
1.9 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.
1.10 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns.
1.11 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables available. Use only
genuine Spirax Sarco replacement parts.
Operators must wear ear protection when commissioning the positioner

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SP7-10, SP7-11 and SP7-12 Smart positioner
1.12 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.
1.13 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.
1.14 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.
1.15 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').
1.16 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.
1.17 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.

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SP7-10, SP7-11 and SP7-12 Smart positioner
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
2. General product information
Fig. 1 Schematic diagram

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SP7-10, SP7-11 and SP7-12 Smart positioner
Basic device
1 LCI plug *
2 Setpoint signal 4 to 20 mA/bus connection 9 to 32 Vdc
3 Binary input *
4 Binary output *
5 Supply air: 1.4 to 6 bar (20 to 90 psi)
6 Exhaust
7 I/P module with 3/3-way valve
8 Position sensor (optional up to 270° rotation angle)
Optional upgrades
9 Plug-in module analog feedback (4 to 20 mA) *
10 Plug-in module for digital feedback *
11 Installation kit for mechanical position indication
12 Installation kit for digital feedback with proximity switches
13 Installation kit for digital feedback with 24 V microswitches
* Only for devices with HART Communication.
Note : With optional upgrades either, the ‘Installation kit for digital feedback with proximity switches’ m or
the ‘Installation kit for digital feedback with 24 V microswitches’ can be used.
In both cases though, the mechanical position indication l must be installed.

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SP7-10, SP7-11 and SP7-12 Smart positioner
2.3 Label description
- Order-Code
- Serial no.
- HW-Rev.
- SW-Rev.
- DOM
- Special Request
- Supply press.
- Input
- Output
- Safe position
Options:
- Analogue feedback output
- Digital feedback output
- Electr. limits switch
- Mech. limits switch
- Position indicator
- Approvals
2.4 Principle of operation
The SP7-10, SP7-11, SP7-12 is an electronically configurable positioner with communication capabilities
designed for mounting on pneumatic linear or rotary actuators.
Label
example
Safe area

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SP7-10, SP7-11 and SP7-12 Smart positioner
Label
examples
ATEX/IECEx
NEPSI
Fully automatic determination of the control parameters and adaptation to the positioner allow for considerable
time savings as well as optimum control behavior.

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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
Fig. 6
Note
Positioner mounting threaded holes & bracket holes, depend on the actuator type used. Select to suit, to
ensure the follower pin has free movement in the follower guide over entire valve travel.
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 6 fig. 6).
Then tighten mounting bolt (item 4 fig. 7) (lever moves between the arrow marks item 4 fig. 6).
3.1.5 Mounting lever and bracket on the positioner

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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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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SP7-10, SP7-11 and SP7-12 Smart positioner
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