Spirax Sarco SP7-20 User manual

IM-P706-03 CTLS Issue 1 1
SP7-20 Smart Positioner
© Copyright 2021
3440751/1
SP7-20
Smart Positioner
Installation and Maintenance Instructions
IM-P706-03
CTLS Issue 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Troubleshooting
7. Maintenance
8. Approvals
9. Declaration of conformity

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SP7-20 Smart 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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Contents
1. Safety information 4
2. General product information
82.1 Introduction
2.2 Label description
2.3 Operating principle
10
2.4 Principle of operation
3. Installation
11
3.1 Mechanical mounting
3.2 Electrical connections 22
3.3 Connection on the device 27
4. Commissioning
314.1 Commissioning the positioner
4.2 Recommended rotational angle range
4.3 Operating modes 32
4.4 Standard automatic adjustment 33
4.5 Sample parameters 34
4.6 Setting the option modules 35
4.7 Setting the mechanical limit switch with proximity switches
36
4.8 Setting the mechanical limit switch with 24 V micro-switches
5. Operation
37
5.1 Parameterisation of the device
5.2 SP7-20 HART Parameter Overview 39
5.3 SP7-21/22 Parameter Overview 44
6. Troubleshooting
47
6.1 SP7-20 Error codes
6.2 SP7-21/22 Error codes 49
6.3 Alarm codes 50
6.4 Message codes 51
7. Maintenance 52
8. Approvals 53
9. Declaration of conformity 54

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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”
-Explosion proof type of cables and gaskets should be used, when explosive gases
are present at the installation site.
-Power should be turned off completely when opening the product’s cover. When
opening the cover, ensure that there is no power remaining in any electrical parts
nearby.
-Flameproof enclosure type positioner has 2 ports for power connection. Explosion
proof type wires and packing should be used. A blanking plug is required for any
port that is not being used.
-For external ground terminal, ring terminal with surface area of more than 5.5 mm2
should be used.
-There is risk of explosion due to static electricity charge. Static electricity charge
may develop when cleaning the product with a dry cloth. It is imperative to avoid
static electricity charge in the hazardous environment. A damp cloth must be used,
when cleaning the surface of the product.
-To meet explosion-proof marking information and ingress protection of IP66, use
certified Ex-cable glands and Ex-plugs.
-The cable entry must be equipped with a cable entry device, which must be an Ex
cable entry device approved by the explosion-proof inspection agency (For NEPSI
- according to the requirements of GB3836.1-2010 and GB3836.2-2010) and meet
the requirements of the product explosion-proof mark, and the installation of the
cable entry device Use must follow its instructions.
-The positioner is designed for use at an ambient temperature range of -40 °C up
to 85 °C at maximum.
-If the positioner is used at an ambient temperature above 60 °C or below -20 °C,
cable glands and cables approved for a service temperature corresponding to the
maximum ambient temperature increased by 10 K or corresponding to the minimum
ambient temperature shall be used.
-The dimensions of the flameproof joints are in parts other than the relevant minimum
or maximum values of IEC 60079-1:2014. For information on the dimensions of the
flameproof joints contact the manufacturer.
-Fasteners with a minimum property class of 10.12, A2-70 or A2-80 must be used
for the closing of the flameproof enclosure.

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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.
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: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
The positioner is suitable for installation in Zone 1 or Zone 2 ( Gas ). The positioner shall not
be used in zone 0.
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.

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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.
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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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 is an electronically configurable positioner with communication capabilities designed for mounting on
pneumatic linear or rotary actuators. It features a small and compact design, a modular construction, and an
excellent cost-performance ratio. Fully automatic determination of the control parameters and adaptation to
the positioner allow for considerable time savings as well as optimum control behaviour. The positioner has a
built-in LCD indicator with a multi-line LCD display and 4 operating buttons for commissioning, configuration,
and monitoring during live operation. Alternatively, the appropriate DTM/EDD can be used via the available
communication interface. The positioner supports HART5 and HART7 communication. In addition to its
input for the analogue position set-point, the positioner is equipped with a digital input which can be used to
activate a control system functions in the device.
2.2 Label description
- Order-Code
-Serial no.
- HW-Rev.
- SW-Rev.
- DOM
- Special Request
- Supply press.
- Input
- Output
- Safe position
Label example
2. General product information
Options:
- Analogue feedback output
- Digital feedback output
- Electr. limits switch
- Mech. limits switch
- Position indicator
- Approvals

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2.3 Operating principle
Fig. 1 Schematic diagram
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)
Note : With optional upgrades either, the ‘Installation kit for digital feedback with proximity switches’ (13) or
the ‘Installation kit for digital feedback with 24 V microswitches’ (14) can be used.
In both cases though, the mechanical position indication (12) must be installed.
2.4 Principle of operation
The SP7-20, SP7-21, SP7-22 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.
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.

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Fig. 2
3. Installation
Arrow (1) on the device feedback shaft (position feedback) point must move between the arrow marks (2)
3.1 Mechanical mounting

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Fig. 3
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
3.1.1 Measuring and operating ranges of the positioner

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1Screw
2Washer
3Mounting bracket
4Lever with follower pin
(for mechanical stroke
10 to 35 mm [0.39 to 1.38"]
or
20 to 100 mm [0.79 to 3.94"])
5Washers
6Screws
7U-Bolts
8Washers
9Nuts
10 Screws
11 Spring washers
12 Clamp plates
13 Follower guide
Note:
Items 7, 8 and 9 to be ordered seperately
3.1.2 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:
Fig. 4

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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).
3.1.3 Attaching a follower guide to the actuator
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 Mounting lever and bracket on the positioner

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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. Refer to mounting table fig (tbc)
5. Secure the mount bracket 1 with screws 2 and washers 3 using the relevant tap holes on the
positioner housing. Refer to mounting table fig (tbc)
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. 10) (lever moves between the arrow marks
Item 4 Fig. 9).
3.1.5 Mounting on a cast iron yoke
Fig. 7
1. Attach the mount bracket (2) with screw (4) and washer (3) to the cast iron yoke (1)

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3.1.6 Mounting on a columnar yoke
Fig. 8
1. Hold the mount bracket (3) in the proper position on the columnar yoke (2).
2. Insert the U-bolts (1) from the inside of the columnar yoke (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.
Notes:
- 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.
- Items 1, 4 and 5 to be ordered separately

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(1) Increase linkage
(2) Decrease linkage
3.1.7 Positioner linkage
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.
3.1.8 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 linearisation. The default setting is
actuator bolt on lever

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3.1.9 Actuator bolts on the lever (Rear view)
1Potentiometer lever
2Actuator bolts
3Valve stem
4Valve yoke
5Positioner
Fig. 10
1Potentiometer lever
2Actuator bolts
3Valve stem
4Valve yoke
5Positioner
Fig. 11
3.1.10 Actuator bolts on the Valve (Rear view)
M11032
1 2 3
5 4

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3.1.11 Mounting on rotary actuator
For mounting on part-turn actuators in accordance with VDI/VDE 3845, the following attachment kit is
available.
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

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3.1.12 Mounting the adapter on the 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 XX), 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.