SP1 Smart Positioner Installation and Maintenance Instructions

Transcription

1 /1 IM-P CH Issue 1 SP1 Smart Positioner Installation and Maintenance Instructions Operating elements Safety instructions Operating instructions in brief 1.Technical description 2. Mounting 3. Electrical connection 4. Manual operation 5. Special SP1 features 6. Maintenance 7. Appendix Printed IM-P in the CH UK Issue 1 Copyright 19971

2 SP1 operating elements SP1 terminal assignment 2 IM-P CH Issue 1

3 Closed case with position (angle) indicator IM-P CH Issue 1 3

4 Safety instructions Flawless and safe operation of SP1 and SP1 Ex positioners requires proper transportation and storage, installation and commissioning by qualified personnel, proper use, and careful maintenance. Only qualified personnel who are familiar with the installation, commissioning, operation and maintenance of this signal converter or similar devices are authorized to work with it. Observe The present operating instructions The relevant safety regulations and standards for the installation and operation of electrical systems, The regulations and standards governing explosion protection, when using intrinsically safe devices. The regulations, standards and directives referred to in these operating instructions are applicable in the Federal Republic of Germany. When using this signal converter outside the German Federal jurisdiction, the relevant regulations, standards and directives applicable in the country where the device is used must be observed. The SP1 positioner - as far as the device itself is concerned - has been designed in accordance with DIN VDE 0411, Part 1 (based on IEC Publication 348), Safety Requirements for Electronic Measuring Apparatus, and has been supplied in a safe condition. The present operating instructions contain warnings and cautions marked with a warning sign which have to be followed by the user to retain the device in a safe condition and to ensure safe operation. Otherwise, persons may be injured or the device itself or other devices or installations may be damaged or fail. If you should need any information which is not contained in the present operating instructions please contact Spirax Sarco. 4 IM-P CH Issue 1

5 Table of contents Chapter SP1 operating instructions in brief 1 Technical description 1.1 Applications and features 1.2 Functional principle 1.3 Configurable parameters 2 Mounting 2.1 Linear actuators 2.2 Pneumatic connections 2.3 Check for correct mounting 2.4 Optional pressure gauge block 2.5 Optional position feedback modules 3 Electrical connection 4 Manual operation 4.1 Factory setting 4.2 Operating elements and display 4.3 Local operation 4.4 Operating modes 4.5 Mechanical limit switches 5 Special SP1 features 5.1 Range of the positioner 5.2 Configurable parameters 6 Maintenance 6.1 Filter of the pneumatic output unit 6.2 Replacing the pneumatic output unit 7 Appendix 7.1 Autostroke 7.2 Ex-certificate of the PTB 7.3 Ex-certificate for approach switches 7.4 Technical data 7.5 Dimensional drawings 7.6 Error codes List of figures Figure Fig. 1 Schematic diagram of the SP1 Fig. 2 Position sensing with inductive sensor Fig. 3 Functional principle of pneumatic output unit Fig. 4 Schematic diagram of the electronic unit Fig. 5 Mounting kit for linear actuators Fig. 6 Actuators with cast iron yoke Fig. 7 Actuators with columnar yoke Fig. 8 Minimum operating range Fig. 9 Optimum SP1 operating range Fig. 10 Maximum operating range Fig. 11 Link bolt adjustment Fig. 12 Pneumatic connections Fig. 13 Optional pressure gauge block Fig. 14 SP1 terminal block Fig. 15 SP1 terminal assignment Fig. 16 SP1 connection diagram Fig. 17 SP1 operator panel Fig. 18 Symbols shown by the display Fig. 19 Range of the positioner Fig. 20 Valve action Fig. 21 Shut-off value Fig. 22 Action of actuator spring Fig. 23 Air filter, sectional drawing Fig. 24 Replacing the pneumatic output unit Fig. 25 Linear actuator, front view Fig. 26 Linear actuator, rear view Fig. 27 Linear actuator, top view Fig. 28 Linear actuator, side view (right) IM-P CH Issue 1 5

6 Operating instructions in brief Mount the device (see also section 2) Linear actuators, special information: Position the link bolt on the lever according to the stroke length of the valve. The scale on the lever indicates the link points for different stroke lengths. The lever should be in a more or less horizontal position when the scale is used. Shifting the link point outwards increases the stroke length, shifting it inwards decreases the stroke length. Determine the position (height) of the positioner at the valve yoke (not necessary for actuators with cast iron yokes). Open/close valve until reaching central position; adjust actuator height until position indicator is in center of angular scale. or Set valve to lower stop; adjust actuator height in such a way that position indicator is at 55- degree mark. The positioner for linear actuators has an operating range of 60 degrees. A deviation of 20 degrees for full valve stroke already provides for correct functioning. The position of the selected 20-degree segment is negligible. The figure above shows two examples of correct deviation. However, it can be advantageous to adjust an operating range which is as big as possible. Make sure that the levers can move freely. Deviations of more than 100 degrees may cause damage to the mechanical parts of the device. 6 IM-P CH Issue 1

7 Start Autostroke function; proceed as follows: To change over to operating mode level 2: Press Up and Down buttons at the same time and hold. Briefly press Reset button. Wait until displayed countdown from 3 to 0 is finished. Release Up and Down buttons. Set rotary switch to position 0, display indicates 2.0 (operating mode followed by switch position, eg. 1.0 or 1.1 is shown briefly when the rotary switch is actuated.) Start Autostroke function: Press Up and Down buttons at the same time and hold. Wait until displayed countdown from 3 to 0 is finished. Release Up and Down buttons. Wait for about 2-5 minutes until the Autostroke is complete; for details on the display refer to the Appendix. As soon as the Autostroke function is finished, the stroke in percent and a flashing colon are shown on the display. Press Reset button for 3 seconds to save the measured values in a non-volatile memory (EEPROM) (EEP is shown on display). Let the device return to operating mode level 1. Make sure that the rotary switch is in position 0 or 1 ("Controlling adaptive" or "Controlling fixed") The Autostroke function determines the valve stops and adjusts the control parameters. After this function has been run successfully, the positioner changes over to control mode. If the Autostroke function is aborted; check the pressure of the supplied air, check the positioner for correct operating range by manual actuation, increase the dead band if the valve tends to oscillate. Recommended values: 0.5 % % For details on dead band adjustment refer to section 4.4. For details on further error sources refer to section 7.5. IM-P CH Issue 1 7

8 1.1 Applications and features The SP1 intelligent positioner is used for controlling the position of pneumatic actuators: Set point: current 4-20 ma 1. Technical description Single (double acting to order only) actuators Mounting to standard linear actuators in accordance with DIN IEC 534 (NAMUR). Process value: position (stroke or angle of rotation) Output : compressed air Action of the control loop: Set point adjustment by input current 4-20 ma Position feedback via non-contact, wear-free electrical position sensor Comparison of set point and process value, output signal calculation through microprocessor Electropneumatic conversion of output signal Digital interface with HART protocol for configuration monitoring while operation is running remote control of all functions Applications Two-wire applications Use in hazardous areas, intrinsically safe to DIN EN Options Supplementary module for position feedback, switching (two limits, one alarm) Supplementary module for analog position feedback, electrically isolated 4-20 ma signal Two Pepperl & Fuchs proximity switches as limit switches, redundancy option for electronic unit Pressure gauge block, filter regulator Special features: Constant control accuracy due to electronic control loop, no variations result from air pressure variations, vibrations, etc. Practically no air consumption after the setpoint is achieved Also available as fail-freeze option which locks the pneumatic output in case of power failure. Fig. 1 Schematic diagram of the SP1 8 IM-P CH Issue 1

9 1.2 Functional principle SP1 has a rugged aluminium case and a separated terminal box. The individual modules are shown in the fig. 1. Position sensor The actuator movement is transmitted to the rotating shaft of the positioner. The cam attached to the shaft is scanned by an inductive non-contact sensor. The angle of rotation is then converted to an electrical signal, as seen in the diagram below. Fig. 2 Position sensing with inductive sensor The position sensor also contains a temperature sensor for measuring the temperature inside the case. The cam is not user-replaceable. The position sensor, the cam, and the CPU form a factory-adjusted unit which can only by replaced by the manufacturer. The SP1 model designed for linear actuators is linearized for linear movement. Linearization is only possible if the positioner is mounted symmetrically. Pneumatic output module The pneumatic output module consists of a pilot stage and an analog 3/3-way valve as a main stage. The pilot stage converts the electrical signal to a pressure. This is done by a system made up of a coil/magnet and a nozzle/flapper group. A special technique patented for SENSYCON is used here. The resulting pressure controls the main stage. Besides the two positions air in and air out there is a neutral position. After the setpoint is achieved the valve switches over to this neutral position, so that no air loss occurs in the main stage. Two main stages are available for double action output. Fig. 3 Functional principle of pneumatic output unit Electronic unit The electronic unit reads in the set point of the 4-20 ma loop and the process value of the position sensor via the A/D converter. The microprocessor calculates the control deviation and outputs the appropriate correction signals to the pneumatic unit. Valve parameters like actuator spring action (lever shaft / actuator turning counterclockwise or lever shaft / actuator turning clockwise) are determined by Autostroke. Parameters like set point range / characteristic curve etc. can be entered from a PC. This data is saved in a non-volatile memory (EEPROM). The basic SP1 model already provides an RS232 interface for connecting the device directly to a PC via an LKS adapter (LKS = local communication interface). The optionally available ASIC for HART communication has to be ordered for communication via two-wire link. Options for the electronic unit Supplementary module for analog position feedback The actual position of the controlled valve is transmitted via a second, electrically isolated 4-20 ma signal loop. Supplementary module for digital position feedback Two programmable limit switches and an alarm output. The signal level is in accordance with DIN (NAMUR switches). Mechanical kit for digital position feedback Two safe Pepperl & Fuchs SJ2-SN slot-type proximity switches, signal level to DIN This kit is a redundancy option for the microprocessor electronic. The optionally available parts listed above have to be mounted in factory. Note that only one supplementary module can be used at the same time. IM-P CH Issue 1 9

10 Fig. 4 Schematic diagram of the electronic unit Electrical function SP1 is a classical two-wire unit. The supply voltage is generated from the 4-20 ma signal. No external power supply is needed. When working with the factory-setting the positioner can be used without any digital communication. If communication is desired, this is possible through the RS232 interface and the LKS adapter or by using a modem and modulating the communication on the 4-20 ma signal. 1.3 Configurable parameters The SP1 positioner parameters can be configured electronically. The following parameters are automatically determined by the integrated microprocessor during the Autostroke: Positioning travel of the valve Valve action (direct or reverse) Parameters for the internal PD controller The following parameters can be set by keyboard entries: Controlling / manual control Alarm limits for optional position feedback Dead band The following settings can be made on a PC via the IBIS user interface: 1. Set point range (input current) 2. Characteristic curve (linear, equal percentage, user-configurable) 3. Valve action (direct/reverse) 4. Dead band 5. Stroke range 6. Shut-off value 7. Adjusted speed 8. Dead band time limit 9. Alarm limits 10. Spring action of the actuator 11. Control parameters 12 Lever zero position For details on the individual parameters refer to section 5.2. The following output values are accessible from a PC with the user interface IBIS: Stroke time (valve stroke time determined by Autostroke) Manufacturer s information e.g. device type, hardware revision, position sensor, pneumatic output module, software revision Used position sensor range All settings made Parameters for the internal PD controller 10 IM-P CH Issue 1

11 The mounting position is arbitrary. 2.1 Mounting to actuators Mount the kit as seen in the following diagrams 2. Mounting Pos. Qty Description 1 1 Right-angle mounting plate 2 5 Spring washer B8 3 5 Screw M8 x Lever short, incl. in scope of delivery Lever long, incl. in scope of delivery 5 1 Screw M4 x Spring washer B4 7 1 Plain washer A4,3 8 1 Angular slide rod 9 2 Spring washer B Screw M6 x Bolt 13 1 Nut M Spring clip 15 1 Spring washer B Plain washer A6, Fastening bow 18 4 Nut M Spring washer B Plain washer A4 Position the link bolt on the lever according to the stroke length of the valve. Fig. 5 Mounting kit Fig. 6 Actuators with cast iron yoke The scale on the lever indicates the link points for different stroke lengths. The lever should be in a more or less horizontal position when the scale is used. Shifting the link point outwards increases the stroke length, shifting it inwards decreases the stroke length. Fig. 7 Actuators with columnar yoke Fig. 8 Minimum operating range IM-P CH Issue 1 11

12 The positioner has an operating range of 60 degrees. A rotation of 20 minimum is required to enable accurate positioning. The location of this 20 rotation within 60 maximum range is not critical. Fig. 11 Link bolt adjustment Fig. 9 Optimum SP1 operating range For systems which are difficult to control (e. g. due to high friction or short stroke time) it is advantageous to adjust an operating range which is as big as possible. 2.2 Pneumatic connections Connect pneumatic connections for air supply (supply) and actuator supply (Y1/Y2) as shown in the following diagram. The supply air should be oil and dust free to IEC 770. Fig. 10 Maximum operating range Make sure that the levers can move freely. Deviations of more than 100 degrees may cause damage to the mechanical parts of the device. Valve stroke versus distance between link bolt and rotating shaft Stroke Distance (mm) at angle of (mm) Fig. 13 Pneumatic connections 12 IM-P CH Issue 1

13 2.3 Check for correct mounting When the SP1 has been electrically connected, it can be checked in operating mode 2.2 for correct mounting to a valve. 2.4 Optional pressure gauge block Set selector switch to position 2 Switch on power and air supply Change over to operating mode level 2; proceed as follows: Press Up and Down buttons at the same time and hold Briefly press Reset button Wait until displayed countdown from 3 to 0 is finished Release Up/Down buttons Manually open/close the valve until reaching the stops. Make sure that the levers can move freely. Proceed as follows: Open/close valve by pressing the Up/Down buttons Slow action: Press one button Fast action: Press and hold one button; additionally press second button. Check the display The stops should be within the range > 2 % and < 98 % Fig. 14 Optional pressure gauge block 2.5 Optional position feedback modules The optional modules and the mechanical kit are mounted in factory. They can be combined as described below: Module for analog position feedback, electrically isolated, via 4-20 ma loop Module for digital feedback to DIN (NAMUR), 2 switches for position feedback, 1 output for alarms Pepperl & Fuchs mechanical kit, SN J2, 2 switches Combined analog position feedback module and Pepperl & Fuchs mechanical kit The difference between the stops should be at least 30 % If the difference is less than 10 %, the positioner is blocked. Comments: In mode 2.2 the display shows the operating range of the position sensor as a percentage. This enables the user to check how the mechanical valve stroke matches the range of the position sensor. IM-P CH Issue 1 13

14 3. Electrical connection When making the electrical installation observe the relevant VDE standards or equivalent standards applicable in the country where SP1 is installed, and the regulations for the prevention of accidents of the employer s liability insurance association. SP1 input terminals 11 and 12 Always connect a current source, e.g. a controller output. Connecting a voltage source, e.g. a 24 V power supply, will damage the input. Load voltage The SP1 model for nonhazardous areas applies a load voltage of 9.8 volts corresponding to a resistance of 490 ohms at 20 ma to the current source, the intrinsically safe model applies 10.8 volts corresponding to 540 ohms. SP1 Fig. 17 SP1 connection diagram Fig. 15 SP1 terminal block When making the electrical installation (e.g. electrical connection or grounding/ potential equalization) of intrinsically safe devices, observe the regulations, standards, directives, specifications and requirements governing explosion protection applicable in the country where SP1 is used, and notice the Ex certificate of the device. In Germany, VDE standard 0165 is applicable. Intrinsic safety is indicated by the type label. A copy of the German Ex certificate confirming intrinsic safety is seen in the Appendix. Fig. 16 SP1 terminal assignment 14 IM-P CH Issue 1

15 4.1 Factory setting Set point range: 4-20 ma Characteristic curve: linear Valve action: direct Dead band: 0.5% Stroke range % Shut-off value: OFF Adjusted speed: OFF Dead band time limit: OFF Alarm limit, low: 0% Alarm limit, high: 100% Inhibit Autostroke: OFF Spring action actuator: Lever shaft / actuator turning clockwise Valve range Start of range: % End of range: 100 % This factory setting can be restored at any time using the IBIS user interface on a PC. Menu items: Device data Specialist Device Factory setting 4.2 Operating elements and display 4. Manual operation Symbols shown by the display Fig. 19 Symbols shown by the display Flashing arrow: Operating mode level 2.x Flashing colon: Data was modified by Autostroke or manual entry and has not yet been saved in the nonvolatile memory. At temperatures below - 10 C and above+ 50 C the display is switched off. 4.3 Local operation The SP1 provides 2 operating mode levels with 4 selectable operating modes, each: Level 1: 1.0 Controlling adaptive 1.1 Controlling fixed 1.2 Manual control up/down 1.3 Setting of switches (if optional position feedback module, switching, has been installed) Level 2: 2.0 Autostroke 2.1 Man. dead band adjustment 2.2 Position sensor span 2.3 Zero adjustment Fig. 18 SP1 operator panel Push-buttons and switch 1 rotary switch, 4 positions - Select operating mode 1 Reset push-button (red) - Reset, save in non-volatile memory, change operating mode level 2 push-buttons (black) - Up/Down buttons Selecting another operating mode at the same level: Selection by setting the rotary switch to the appropriate position. The selected operating mode is briefly indicated each time when the switch is actuated. After this, the standard display is shown. Example The SP1 is working at operating mode level 1 in control mode and is to be set to manual control. This is done by setting the rotary switch from position 0 to 2. The display briefly indicates 1.2 (manual control) and then changes over to the valve position in percent. Changing the operating level: Changing over from level 1 to 2 Press Up and Down buttons at the same time and hold Briefly press Reset button Wait until displayed countdown from 3 to 0 is finished Release Up/Down buttons The device is operating at level 2 then. This is indicated by an arrow shown on the display. IM-P CH Issue 1 15

16 Changing over from level 2 to 1 Briefly press the Reset button All parameters modified by the operator are overwritten with the values stored in the EEPROM. or Press Reset for 3 sec. (countdown shown on display) All parameters modified by the operator - e.g. dead band or alarm limits - are stored in the non-volatile EEPROM. The display briefly shows the message EEP. Example: After mounting, the device is to perform an Autostroke and then start up in control mode. Switch on power supply; device is at operating mode level 1; operating mode is according to position of rotary switch Set rotary switch to position 2, manual control. First press the Up, then the Down button. Visually check the mechanical deviation to see if it is all right. Change over to level 2: Press Up and Down buttons at the same time and hold. Briefly press Reset button Wait until displayed countdown from 3 to 0 is finished. Release Up/Down buttons Set rotary switch to position 0, display shows 2.0 Start the Autostroke function: Press Up and Down at the same time and hold Wait until displayed countdown from 3 to 0 is finished Release Up/Down button Wait for about 2-5 minutes until the Autostroke is complete; for details on the display refer to the appendix. As soon as the Autostroke function is finished, the stroke (%) and a flashing colon are shown on the display. Press Reset button for 3 seconds to save the determined values in non-volatile EEPROM let the device return to operating mode level 1 Make sure that the rotary switch is in position 0 or 1 (Controlling adaptive or Controlling fixed) If no further user actions are made for 10 minutes, the SP1 automatically switches over to level 1 and saves all data in the non-volatile memory. Load factory setting (Rev. 4.5 and higher) How to proceed:- Set selector switch to position 2 Press Reset button for 3 seconds Display is switched off, after 3 seconds 0 is displayed Release Reset button Flashing colon ( : ) appears on the display Press Reset button for 10 seconds Countdown from 10 to 0 is displayed Release Reset button Effect Factory setting is loaded and saved in the non-volatile memory Recommendation Autostroke should be run Applications after special error codes (see error code list in the Appendix) restore the factory setting after unwanted user entries 4.4 Operating modes Controlling adaptive Control mode with automatic adaptation of the control parameters. Control mode, the internal control parameters are tracked adaptively. Recommended use: controlled systems with changing parameters. Example: changing ambient temperature, changing supply air pressure. Display: valve position as a percentage of the stroke range Controlling fixed Control mode with fixed control parameters Display: valve position as a percentage of the stroke range Manual control up/down Manual valve actuation by pressing Up and Down buttons 16 IM-P CH Issue 1

17 Slow action: Press one button Fast action: Press one button and hold, additionally press 2nd button Display: valve position as a percentage of the stroke range Setting of switches (alarm limits) Display high limit as a percentage of the stroke range: briefly press Up button. Display low limit as a percentage of the stroke range: briefly press Down button. Save current position as high limit: Press Up button for 3 seconds P22 is briefly displayed Save current position as low limit Press Down button for 3 seconds P21 is briefly displayed Display: valve position as a percentage of the stroke range 2.0 Autostroke The Autostroke function should be run after mounting, after changes of the mechanical link, or when the controlled system has been modified. It will take about 2 to 5 minutes. After Autostroke the SP1 is working in normal control mode. The parameters determined by Autostroke can be ignored by pressing the Reset button briefly or saved in the non-volatile memory by holding Reset for 3 seconds. Start the Autostroke function, proceed as follows: Press Up and Down buttons at the same time and hold Wait until displayed countdown from 3 to 0 is finished Release Up and Down buttons Wait for about 2 to 5 minutes until the Autostroke is complete. The Autostroke function determines the valve range (by opening/closing the valve until reaching the stops; corresponds to zero and span adjustment of conventional positioners) controller setting (offset values, derivative gain) Display: shows individual steps of Autostroke (see Section 7.1) If an actuator of big volume is used, the Autostroke function should not be started when the actuator is at the stop. 2.1 Man. dead band adjusment Expand dead band Press Up button Reduce dead band Press Down button SP1 is in control mode. The effect of dead band adjustment on the controller action can be seen immediately. Display: shows adjusted dead band as a percentage of the stroke range. 2.2 Position sensor span Open/close valve by pressing Up or Down button. This operating mode serves for verifying the effective range of the position sensor (lever range). If the valve is opened by pressing the Up/Down buttons until reaching the valve stops, the operator can see on the display if the permissible lever range is observed (displayed value must be > 2 % and < 98 %) at least 30 % of the lever range are used. For critical control action the effective range should be bigger. Example: The display shows 3 % for the lower and 35 % for the upper valve stop. This indicates that mounting has been done properly as the permissible lever range is not exceeded (3 % > 2 %) 32 % (35 % - 3 % = 32 %) of the lever range are used. Slow action: press one button Fast action: press one button and hold, additionally press 2nd button Display: shows valve position as a percentage of the lever range. 2.4 Zero adjustment The adjusted valve range can be shifted up or down by pressing the Up/Down buttons. The percentage shown on the display increases (decreases) correspondingly. No control takes place. Pressing the Reset button for 3 seconds takes over a new value for the valve range. The valve will be opened/ closed as soon as control is restarted. Display: shows valve position as a percentage of the stroke range. Note This function corresponds to adjusting the zero adjustment screw of a conventional positioner. It should be used only if the Autostroke function cannot be run. It enables the operator to compensate mounting inaccuracies leading to mismatching parts. For details refer to the definitions of the terms stroke range and valve range ins section Mechanical limit switches The limit switches can be adjusted by using the two adjustment screws shown in figure 1. Push in and turn the appropriate adjustment screw. IM-P CH Issue 1 17

18 5. Special SP1 features 5.1 Range of the positioner The positioner for linear actuators can detect an angle of rotation of 60 at its drive shaft. The following terms have to be distinguished: Lever range Valve range Stroke range Application: Example 1: A mimimum flow must be ensured for a valve. A stroke range of 10% - 100% must be entered. Example 2: The Kvs value of a valve is too big and has to be limited. A stroke range of 0-60% must be entered. The positioner display shows : Stroke movement as a percentage of the stroke range in operating modes 1.0, 1.1, 1.2 and 1.3, and in 2.0 after Autostroke Stroke movement as a percentage of the stroke range: 2.2 Fig. 20 Range of the positioner Lever range The maximum range within which the movement of the rotating shaft can be measured. Valve range The preset range within which the positioner can open/close an attached valve. The limits of the valve range depend upon the valve and the mounting method and are determined by: Autostroke The positioner opens/closes the valve until reaching the upper and the lower mechanical stop, which are then stored as the limits of the valve range. or Loading a data set from a floppy disk using the IBIS user interface. or Manual adjustment of the limits under IBIS, menu item Adjustment. Stroke range Programmed range within the valve range which limits the stroke movement of the valve. The range is user-definable via the IBIS user interface. The stroke range is always indicated as a percentage of the valve range. If the valve range is re-determined (e.g. by Autostroke), the stroke range is recalculated for the new valve range. The percentage set for the stroke range remains unchanged. The set point range of the current (example: 4-20 ma) always refer to the stroke range. Note: Mode 2.2 serves for checking if the SP1 has been mounted properly to a valve. For details see section 2.4. If the valve lever is outside the lever range, error code E18 is displayed. 5.2 Configurable parameters The SP1 positioner can be configured electronically via the IBIS user interface and the communication interface. The settings can be saved in a non-volatile memory. The following parameters are configurable: Set point range The input current range corresponding to a valve stroke movement of 100 % is to be set here. The current values for both the starting value and the end value are entered with one digit to the right of the point. Any value between 4 and 20 ma can be entered. Example Example Example Split range : starting value 4.0mA, end value 12.0 ma Split range, overlapping: Starting value 4.0 ma, End value 13 ma Starting value 8.3 ma, End value 15.6 ma Characteristic curve Selection of the characteristic curve, 6 choices: - linear - exponential 1:25 (equal percentage) - exponential 1:50 (equal percentage) - exponential 25:1 (equal percentage) - exponential 50:1 (equal percentage) - user-configurable The user-configurable characteristic curve can be defined by the operator using 20 reference points, provided that the characteristic curve is monotonously rising or falling. A current value and a value for the valve stroke movement in percent are to be entered for each reference point. The values are freely selectable. It is recommended to define the reference points. 18 IM-P CH Issue 1

19 5.2.3 Valve action Selection of the valve action, 2 choices - direct (4-20 ma) - reverse (20-4 ma) Shut-off value Input in % : % The shut-off value is a certain percentage of the input current from which on the valve is set to its zero position, i.e. the characteristic defined by the Set point range is cut off in a step without modifying the rest of the characteristic. Example: Inputting 5 % has the effect the valve is set to zero at a current below 4.8 ma (4 ma + 5 % of 16 ma), while the valve follows the normal characteristic at a current above 4.8 ma. Fig. 21 Valve action The valve action parameter represents the relation between the input current and the moving direction of the valve. If the valve action is direct, the valve opens with increasing input current. This relation is independent of the spring action of the actuator, i.e. the relation between air supply and moving direction of the valve Dead band Input value 0.0 to 10.0 % The dead band defines the accuracy with which the valve position is corrected to reach the set point. If the control deviation is smaller than the value defined by the dead band, no further correction occurs, and the air output is set to the neutral position. Recommended setting 0.5 % Stroke range Input value (between 0 and 100 %) for the start and the end of the stroke range. The stroke range enables the user to further reduce the valve range given by the valve stops. Example: If the flow rate of a linear valve used in a plant is to be halved, the start of the stroke range is set to 0%, the end to 50 %. Example: If the minimum flow should always be 10 % of the maximum value, the start of the stroke range is set to 10 %, the end to 100 %. Note: The display (LC display at the SP1 or PC screen display when using IBIS) always refers to the configured stroke range. The position is shown as a percentage. Fig. 22 Shut-off value Adjusted speed: Input in seconds: s, 0 = OFF Separate inputs for opening and closing the valve. This function provides for electronic damping of the valve stroke movement. The stroke speed is limited to the value set here In case of an error the valve is set to the fail-safe position at max. speed. With adjusted speed, only. Does not apply to manual control Dead band time limit Input in seconds: s, 0 = OFF This function serves for monitoring the control deviation. If the SP1 is not able to position the valve properly (i.e. drive it into the dead band) within the set time, an alarm is generated and output to the IBIS user interface the SP1 local LC display the alarm contacts of the optional module for digital position feedback. IM-P CH Issue 1 19

20 5.2.9 Alarm limits Input in %, value between 0.0 % and %, separate inputs for low and high alarm limit. If the measured value exceeds or falls below the alarm limits, the appropriate output is set. This is indicated by the IBIS user interface. The appropriate limit switch of the optional module (if available) is set Lever zero position Indicates whether the zero position of the valve is allocated to the lever shaft stop turning counterclockwise or turning clockwise. This parameter is not determined by the Autostroke function and must be set by the user Spring action actuator (Y1 = evacuating air) Selection of the spring action of the actuator, 2 choices: Lever shaft/actuator turning counterclockwise Lever shaft/actuator turning clockwise Parameter spring action actuator defines the position of the lever after air evacuation through pneumatic output Y1. Usually, this parameter is determined by the Autostroke function. If this parameter is set to turning clockwise, the spring acts in such a way when pressure is relieved (Y1) that the valve stem moves the lever to the right stop. For double acting actuators the spring action is as follows: pneumatic output Y2 fills with air, Y 1 evacuates air Control parameters The following parameters of the internal PD controller are configurable Minimum threshold response, increasing Minimum threshold response, decreasing Kp value Tv value Adaptation time Noise These parameters are set during the Autostroke and should not be modified by the user. Any changes of these parameters indicate changes of the controlled system, i.e. of the attached actuator Additional output values The following output values can be accessed via the IBIS user interface: Measured stroke time: Travel time of the valve between the valve stops in seconds, measured during the Autostroke. The values for the two directions of action are measured separately. Manufacturer s specifications (device type, hardware revision, position sensor, pneumatic module, software revision). Fig. 23 Action of actuator spring This parameter is determined by the Autostroke function and need not be set by the user. This parameter is independent of the valve action 20 IM-P CH Issue 1

21 The electronic unit does not contain any adjustable components. - Do not replace the electronic unit or the position sensor. Any userreplacements of these units will affect the balancing done in factory. - Do not open/manipulate the electronic unit in any way. This is forbidden for intrinsically safe devices and not necessary for positioners used in non-hazardous areas. 6. Maintenance 6.2 Replacing the pneumatic output unit The pneumatic output unit can be taken out of the case from the top after disconnecting the plug of the electrical control (two-wire cable, red and black) and unscrewing the three fastening screws (Torx head). - Do not dismount the electronic unit or the position sensor. Otherwise, the warranty will expire. 6.1 Filter of the pneumatic output unit The positioner is maintenance-free. This is also valid for the built-in air filter of the pneumatic output unit. The filter retains any air pollution that might occur occasionally, e.g. during commissioning. Note that this filter does not relieve you of proper supply air cleaning. If the filter is choked up with dirt due to impermissible air pollution, the filter element must be replaced (see Fig. 24). Unscrew the screw plug and take out the filter element using tweezers. Spare filters can be ordered from Spirax Sarco. After filter element replacement the SP1 will immediately be operational and does not require any further steps (e.g. cleaning). Fig. 25 Replacing the pneumatic output unit Do not damage or lose the gasket between output unit and case bottom. Notice the position of the gasket when mounting the pneumatic output unit. The punch holes for the fastening screws must be centred right over the drilled holes for the screws in the case bottom to avoid the gasket being drawn towards the air inlet and outlet when fastening the screws. Fasten the screws with a torque of 350 Ncm. When attaching the electrical control unit make sure that the plug snaps in. The connector is protected against polarity reversal. When ordering a pneumatic output unit note the error function of the unit i.e. fail safe, fail freeze, etc. Fig. 24 Air filter, sectional drawing Switch off air supply before replacing the filter element. Otherwise, the full air pressure is applied to the screw plug. IM-P CH Issue 1 21

22 7.1 Autostroking 7.2 Ex-certificate of the PTB (certificate of the Federal German Institute of Determine lower valve stop, actuator stops for ca. 10 s. Save lower valve stop 7. Appendix Physics and Technology, confirming intrinsic safety) Determine noise band of the A/D converter, actuator stops Determine upper valve stop Save upper valve stop Prepare stroke time measurement Measure valve closing time Measure valve opening time Measure natural frequency of actuator Determine slow motion speed of valve. Direction: up. Perform a maximum of 8 strokes at different speeds. Determine slow motion speed of the valve. Direction: down. Perform a maximum of 8 strokes at different speeds. Determine adaptation time of the valve. 22 IM-P CH Issue 1

23 7.3 Ex-certificate for approach switches IM-P CH Issue 1 23

24 7.4 Technical data Input Signal range 4-20 ma, two-wire Supply voltage Interface Output Control pressure Air capacity Actuator Stroke movement Linear actuators Air supply Instrument air Supply pressure Own consumption about 9.8 Vdc 10.8Vdc for EEx ia protected against polarity reversal, overload protection up to 0.5 A (from March 95) RS 232 (as a standard) via LKS (local communication interface) adapter 0-6 bar 5.5 kg/h at 1.4 bar supply 9.5kg/h at 3 bar supply 13 kg/h at 6 bar supply single (standard device) double (optional) 10-85/ mm or rotation angle oil, water, and dust free bar < kg/h at 1.4 bar supply General and technical safety data Characteristic curves linear or equal percentage 1 : 25, 1 : 50, 25 : 1, 50 : 1 or with 22 freely selectable reference points Deviation < 0.5 % Resolution Sample rate 8,000 steps 20 msec. 24 IM-P CH Issue 1

25 Influences Ambient temperature < 0.5 %/10 K Vibration < 1% up to 10 g, frequency Hz and an amplitude of max. 0.5 mm EMC increased, in accord. with NAMUR 7.5 Dimension drawings [inches (mm)] Mounting position any recommended: air outlets downward Environmental capabilities Climate class GPF to DIN Ambient and storage temperature C Fig. 25 Linear displacement actuator, front view Explosion protection CENELEC PTB No.: EExia IIC T4/T5/T6 Ex 94.C.2133X Values for intrinsically safe connection Input signal Signal and power supply circuit (11, 12) Max. values Vi = 30 V Ii = 150 ma Pi = 1.1 W Fig. 26 Linear displacement actuator, rear view Internal capacitance 1,2 nf Internal inductance 50 H Case Case material aluminium (Al Si 12) Mounting kit material stainless steel Class of equipment IP 65 (NEMA ratio) (NEMA 4X) Electrical connection Pneumatic connection Weight 1 screw terminals, internal, for 2.5 mm² and 2 cable connectors Pg 13.5 or NPT 1/2 1/4 NPT threads or G 1/4 3.2 kg Fig. 27 Linear displacement actuator, top view Observe the temperature limits specified in the Ex certificate FSK modem for HART communication Protocol for two-wire link (set point current) LKS adapter for RS-232 interface Fig. 28 Linear displacement actuator, lateral view (right) IM-P CH Issue 1 25

26 7.6 Error codes E01 Fatal error in boot phase User action Load standard configuration (see section 4.3). Consequence All control modes are set to manual control. E02 No valid configuration data available in EEPROM User action Load standard configuration (see section 4.3). Consequence All control modes are set to manual control. E03 - E17 Internal data error User action Press Reset button; load standard configuration if reset fails (see section 4.3). Consequence SP1 output is set to safe state. E18 E19 E20 E21 E22 E23 E27 User action Consequence User action Consequence User action User action Consequence User action Consequence User action Consequence User action Consequence Positioner out of range Check in mode 2.2 if positioner was mounted properly, align until range is matched (see section 2.4). Autostroking is aborted. Set point not reached within time set under IBIS for parameter time-out monitoring Check mechanical link and pressure of supply air. No consequence; SP1 attempts to reach the set position; alarm output is set. Autostroking inhibited under IBIS Press Reset to acknowledge or re-enable autostroking under IBIS. Autostroking took more than about 2 minutes and was timed out Check mechanical link and air supply. Check if valve is blocked. Check input signal for EMI. Trouble-shoot, then restart autostroking. Autostroking is aborted. Positioner out of range during autostroking Check in mode 2.2 if positioner was mounted properly, align until range is matched (see section 2.4). Autostroking is aborted Autostroking, valve range < 10% of lever range (positioner range, see section 5.1) or with big-volume actuators, valve at stop when autostroking is started. Check in mode 2.2 if positioner was mounted properly, align until range is matched (see section 2.4). Restart autostroking with valve in its central position. Autostroking is aborted. Autostroking manually aborted via Reset button or rotary switch Press reset to acknowledge. Autostroking is aborted. 26 IM-P CH Issue 1

27 E28 Internal data error User action Reset; load standard configuration if reset fails (see section 4.3). Consequence SP1 output is set to safe state. E30/31 Range limits exceeded by % after manual dead band adjustment User action none Consequence Limited to range limits. E32/33 Out of range in mode 2.3, zero adjustment (see section 5.1) User action none Consequence Limited to range limit. E92 E93 User action Consequence User action Consequence Power down, short interruption of 3.6 ma set point current (> about. 20 ms) Check set point current for interruption. Reset, then normal operation. Watchdog reacts Eliminate EMI source in the near vicinity. Reset, then normal operation. Parameter P21/22 Configure switching point for digital position feedback module in mode 1.3 Consequence Valve position is saved as upper/lower switching point. IM-P CH Issue 1 27

28 28 IM-P CH Issue 1