SMAR FY302 Handbuch

FY302ME

MAR / 05

web: www.smar.com

smar

Specifications and information are subject to change without notice.

For the latest updates, please visit the SMAR website above.

BRAZIL

Smar Equipamentos Ind. Ltda.

Rua Dr. Antonio Furlan Jr., 1028

Sertãozinho SP 14170-480

Tel.: +55 16 3946-3510

Fax: +55 16 3946-3554

e-mail: insales@smar.com.br

CHINA

Smar China Corp.

3 Baishiqiao Road, Suite 30233

Beijing 100873, P.R.C.

Tel.: +86 10 6849-8643

Fax: +86-10-6894-0898

e-mail: [email protected].cn

FRANCE

Smar France S. A. R. L.

42, rue du Pavé des Gardes

F-92370 Chaville

Tel.: +33 1 41 15-0220

Fax: +33 1 41 15-0219

e-mail: smar.am@wanadoo.fr

NETHERLANDS

Smar Nederland

De Oude Wereld 116

2408TM Alphen aan den Rijn

Tel: +31 172 494 922

Fax: +31 172 479 888

e -mail : info@smarnederland.nl

GERMANY

Smar GmbH

Rheingaustrasse 9

55545 Bad Kreuznach

Germany

Tel: + 49 671-794680

Fax: + 49 671-7946829

e-mail: [email protected]

MEXICO

Smar Mexico

Cerro de las Campanas #3 desp 119

Col. San Andrés Atenco

Tlalnepantla Edo. Del Méx - C.P. 54040

Tel.: +53 78 46 00 al 02

Fax: +53 78 46 03

e-mail: [email protected]

SINGAPORE

SmarSingapore Pte. Ltd.

315 Outram Road

#06-07, Tan Boon Liat Building

Singapore 169074

Tel.: +65 6324-0182

Fax: +65 6324-0183

e-mail: info@smar.com.sg

UNITED KINGDOM

SmarUK Ltd

3, Overhill Road - Cirencester

Gloucestershire -

GL7 2LG

Tel: +44 (0)797 0094138

Fax: +44 (0)797 4747502

e-mail: info@smarUK.co.uk

USA

Smar International Corporation

6001 Stonington Street, Suite 100

Houston, TX 77040

Tel.: +1 713 849-2021

Fax: +1 713 849-2022

e-mail: sales@smar.com

Smar Laboratories Corporation

6001 Stonington Street, Suite 100

Houston, TX 77040

Tel.: +1 713 849-2021

Fax: +1 713 849-2022

e-mail: sales@smar.com

Smar Research Corporation

4250 Veterans Memorial Hwy. Suite 156

Holbrook , NY 11741

Tel: +1-631-737-3111

Fax: +1-631-737-3892

e-mail: sales@smarresearch.com

Introduction

III

INTRODUCTION

The FY302 is a Fieldbus valve positioner for Single (spring return) or Double acting Linear motion

type control valves e. g. Globe, Gate, Diaphragm, Pinch or Clamp and Rotary motion type control

valves e. g. Ball, Butterfly or Plug with pneumatic type actuators e. g. Diaphragm, Piston, Vane, or

Bellows. It is based on a field-proven piezo flapper and non-contacting Hall-effect position sensor

that provides reliable operation and high performance. The digital technology used in the FY302

enabled the choice of several types of flow characterizations, an easy interface between the field

and the control room and several interesting features that considerably reduce the installation,

operating and maintenance costs.

The FY302 is part of Smar's complete 302 line of Fieldbus devices.

Fieldbus is not only a replacement for 4-20 mA, or intelligent/smart transmitter protocols, it contains

much more. Fieldbus is a complete system enabling distribution of the control function to equipment

in the field.

Some of the advantages of bi-directional digital communications are known from existing smart

transmitter protocols: Higher accuracy, multi-variable access, remote configuration and diagnostics,

and multi-dropping of several devices on a single pair of wires.

The main requirements for Fieldbus were to overcome these problems. Closed loop control with

performance like a 4-20 mA system requires higher speed. Since higher speed means higher power

consumption, this clashes with the need for intrinsic safety. Therefore a moderately high

communication speed was selected, and the system was designed to have a minimum of

communication overhead. Using scheduling the system controls variable sampling, algorithm

execution and communication so as to optimize the usage of the network, not loosing time. Thus,

high closed loop performance is achieved.

Using Fieldbus technology, with its capability to interconnect several devices, very large control

schemes can be constructed. In order to be user friendly the function block concept was introduced

(users of SMAR CD600 should be familiar with this, since it was implemented there years ago). The

user may now easily build and overview complex control strategies. Another advantage is added

flexibility; the control strategy may be edited without having to rewire or change any hardware.

The FY302, like the rest of the 302 family, has several Function Blocks built in, like PID controller,

Input Selector and Splitter/Output Selector, eliminating the need for separate device. This takes to

reduced communication and thereby less dead-time and tighter control, not to mention the reduction

in cost.

The need for implementation of Fieldbus in small as well as large systems was considered when

developing the entire 302 line of Fieldbus devices. They have the common features of being able to

act as a master on the network and be configured locally using a magnetic tool, eliminating the need

for a configurator or console in many basic applications.

Get the best result of the FY302 by carefully reading these instructions.

WARNING

Throughout the operation of the positioner, including self-setup, do not touch the moving parts of

valve/actuator/positioner assembly as they may unexpectedly move automatically. Make sure to

disconnect supply air before touching any moving parts.

FY302 – Operation, Maintenance and Instructions Manual

NOTE

This manual is compatible with version 3XX, where 3 denotes software version and XX software

release. The indication 3.XX means that this manual is compatible with any release of software

version 3.

Table of Contents

TABLE OF CONTENTS

SECTION 1 - INSTALLATION.................................................................................................1.1

GENERAL..............................................................................................................................1.1

MOUNTING............................................................................................................................1.1

ROTARY MOVEMENT..............................................................................................................1.1

LINEAR MOVEMENT ...............................................................................................................1.2

PNEUMATIC CONNECTIONS....................................................................................................1.2

ELECTRONIC HOUSING ROTATING..........................................................................................1.5

ELECTRIC WIRING .................................................................................................................1.5

TOPOLOGY AND NETWORK CONFIGURATION...........................................................................1.6

INTRINSIC SAFETY BARRIER...................................................................................................1.8

JUMPER CONFIGURATION ......................................................................................................1.8

POWER SUPPLY ....................................................................................................................1.8

RECOMMENDATIONS FOR AN INSTRUMENT AIR SYSTEM...........................................................1.8

SECTION 2 - OPERATION......................................................................................................2.1

FUNCTIONAL DESCRIPTION -OUTPUT MODULE.......................................................................2.1

FUNCTIONAL DESCRIPTION-ELECTRONICS..............................................................................2.2

INTRODUCTION TO FIELDBUS APPLICATION .............................................................................2.4

FUNCTION BLOCKS................................................................................................................2.4

TRANSDUCER BLOCKS...........................................................................................................2.4

RESOURCE BLOCK ................................................................................................................2.4

THE LOCAL INDICATOR ..........................................................................................................2.5

FOUR DIFFERENT POSITIONS TO THE LCD DISPLAY................................................................2.6

SECTION 3 - CONFIGURATION.............................................................................................3.1

TRANSDUCER BLOCK.............................................................................................................3.1

TRANSDUCER BLOCK DIAGRAM..............................................................................................3.1

FIELDBUS POSITIONER TRANSDUCER .....................................................................................3.2

TRANSDUCER BLOCK PARAMETER DESCRIPTION ....................................................................3.7

TRANSDUCER BLOCK PARAMETER ATTRIBUTES......................................................................3.9

HOW TO CONFIGURE A TRANSDUCER BLOCK........................................................................3.11

AUTO-SETUP ......................................................................................................................3.11

CALIBRATION ......................................................................................................................3.13

POSITION TRIM....................................................................................................................3.14

Via SYSCON....................................................................................................................................3.14

SENSOR PRESSURE ............................................................................................................3.18

FLOW CHARACTERIZATION...................................................................................................3.19

TEMPERATURE CALIBRATION ...............................................................................................3.21

DISPLAY TRANSDUCER BLOCK.............................................................................................3.21

DEFINITION OF PARAMETERS AND VALUES............................................................................3.22

CALIBRATING VIA LOCAL ADJUSTMENT.................................................................................3.24

PROGRAMMING USING LOCAL ADJUSTMENT .........................................................................3.25

SECTION 4 - MAINTENANCE PROCEDURES ......................................................................4.1

GENERAL..............................................................................................................................4.1

DISASSEMBLY PROCEDURE ...................................................................................................4.2

REASSEMBLY PROCEDURE ....................................................................................................4.3

SECTION 5 - TECHNICAL CHARACTERISTICS...................................................................5.1

FUNCTIONAL SPECIFICATIONS................................................................................................5.1

PERFORMANCE SPECIFICATIONS............................................................................................5.2

PHYSICAL SPECIFICATIONS....................................................................................................5.2

SMAR -GENERAL TERMS OF WARRANTY ..............................................................................5.5

FY302 – Operation, Maintenance and Instructions Manual

Section 1

1.1

INSTALLATION

General The overall accuracy of measurement and control depends on several variables. Although the

converter has an outstanding performance, proper installation is essential, in order to maximize its

performance.

Among all factors, which may affect converter accuracy environmental conditions are the most

difficult to control. There are, however, ways to reduce the effects of temperature, humidity and

vibration.

The FY302 has a built-in temperature sensor to compensate for temperature variations. At the field,

this feature minimizes the temperature variation effect.

Locating the positioner in areas protected from extreme environmental changes can minimize

temperature fluctuation effects.

In warm environments, the positioner should be installed to avoid, as much as possible, direct

exposure to the sun. Installation close to lines and vessels subjected to high temperatures should

also be avoided.

Use of sunshades or heat shields to protect the positioner from external heat sources should be

considered, if necessary.

Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the O-rings for the

electronics cover must be correctly placed. Removal of the electronics cover in the field should be

reduced to the minimum necessary, since each time it is removed; the circuits are exposed to

humidity. The electronic circuit is protected by a humidity proof coating, but frequent exposures to

humidity may affect the provided protection. It is also important to keep the covers tightened in

place. Every time they are removed, the threads are exposed to corrosion, since painting cannot

protect these parts. Code approved sealing methods on conduit entering the positioner should be

employed.

Although the positioner is virtually insensitive to vibration, installation close to pumps, turbines or

other vibrating equipment should be avoided.

Mounting The mounting of positioner FY302 will depend on actuator type, single (spring return) action or

double action and on actuator movement, if it is linear or rotary. Two supports are required for

mounting, one for the magnet and the other for the positoner itself. Smar may supply them both

since they are specified in the order code. (See Table 5.2 – Bracket Ordering Code).

Rotary Movement

Install the magnet on the valve stem using the magnet support (See Figure 1.2 - Positioner on

Rotary Actuator).

Install the positioner support on the actuator. The actuator should be in accordance with standard

VDI/VDE 5845, all you have to do is tighten the four screws with the lock washers on the standard

support.

For special supports, refer to specify instructions. After installing the support on the actuator, it is

possible to mount the positioner FY302 on the support by means of the four screws with lock

washers.

Make sure that the arrow engraved on the magnet coincides with the arrow engraved on the

positioner when the valve is in mid travel.

If the installation of the positioner or magnet should be altered, or if there should be any other

modification, the positioner will require a recalibration.

As to the type of valve action, refer to paragraph "Pneumatic Connections".

FY302 – Operation, Maintenance and Instructions Manual

1.2

Linear Movement

Install the magnet on the valve stem using the magnet support (See Figure 1.3 - Positioner on

Linear Actuator).

Install the positioner support on the actuator. The actuator support may be secured in place as per

standard NAMUR/IEC 536-4 or in accordance with user specified boring. Install the positioner on the

support and tighten the four screws in the threaded bores located on the side opposite to the

pressure gages (See Figure 1.3 - Positioner on Linear Actuator). Use lock washers in order to

prevent screw slackening.

Make sure that the support is not obstructing the exhaustion outlets.

NOTE

Make sure that arrow engraved on the magnet coincides with the arrow engraved on the positioner when the

valve is in mid travel. The magnet mounting in relation to the hall sensor:

1 . Must not have attrict between the internal magnet face and the hall sensor salience during the travel

(rotary or linear), through the magnet.

2. The magnet and the salience of hall sensor must not be distant.

A minimum distance of 2mm and a maximum distance of 4mm is recommended between the magnet external

face and the positioner face. For that, a centralizer device (linear or rotary) must be used. The centralizer

device is in the positioner packing.

If the installation of the positioner or magnet should be altered, or if there should be any other

modification, the positioner will require a recalibration.

Pneumatic Connections

Air supplied to the positioner FY302 shall be quality instrument air, i. e., dry, clean and non-

corrosive. Refer to the American National Standard. “Quality Standard for Instrument Air” (ANSI/ISA

S7.0.01 - 1996).

The FY302 is supplied with input and outputs air filters; but these filters do not substitute a

preliminary instrumentation air treatment. We recommend a periodic cleaning of such filters each 6

months or less, case the air instrument quality is not good.

Air supply pressure to the FY302 shall be between 1.4 bar (20 psi) and 7 bar (100 psi). In case such

requirements can not be fulfilled, the use of an air pressure regulator is acceptable.

Use sealant on threads. Sealants like PTFE (Teflon) tape shall be avoided because they may

fragment and eventually obstruct internal parts.

The positioner FY302 may be supplied with pressure gages. There are taps available for IN, OUT1

and OUT2. Before connecting the pressure gages, make sure that all lines be completely purged.

Valve positioner FY302 has two pneumatic outputs. They work on opposite directions to open or

close the valve.

WARNING

The FY302 should fail, for example, because of a power failure. The output identified as OUT1 (output 1)

goes to nearly zero; while the output identified as OUT2 (output 2) goes to nearly the air supply pressure.

Pneumatic connections are identified as IN (input) for the air supply, and OUT1 and OUT2 for

Output 1 and Output 2 respectively (See Figure 1.1 - FY302 Dimensional Drawing). Use 1/4 NPT

connections. Sealant may be used NPT threads. Connect the air supply tubing to the connection

identified as IN. Make sure that the air supply pressure does not exceed the maximum rating

accepted by the positioner or actuator. The tubing used to connect the positioner FY302 to the

actuator shall be as short as possible. The manometer supply is optional.

NOTE

When ordering the positioner in stainless steel 316, combined with the local pressure gauges, the gauge

case is in SS 316. For wet parts and threads in SS 316, please, consult Smar.

ATTENTION

Make sure that sealant does not enter the positioner.

Installation

1.3

There are six exhaust outputs in the FY302, all of them fitted with filters (See Figure 1.1 - FY302

Dimensional Drawing).

It is very important that such outputs are neither blocked nor obstructed, because the air must

circulate freely.

All filters shall be inspected to make sure they will not obstruct the outputs (Refer to Section 4 -

Maintenance Procedures).

Double Action - Air to Open (Fail Close)

Connect Output 1 (OUT1) of the positioner to the input identified as OPEN in the actuator, and

connect Output 2 (OUT2) of the positioner to the input CLOSE in the actuator (See Figure 1.1 -

FY302 Dimensional Drawing).

Double Action - Air to Close (Fail Open)

Connect Output 2 (OUT2) of the positoner to the input identified as OPEN in the actuator, and

connect Output 1 (OUT 1) of the positioner to the input CLOSE of the actuator.

Single Action

Connect Output 1 (OUT1) of the positioner to the input of the actuator. Use a plug to block Output 2

(OUT2). (The Figure 1.2 - Positioner on Rotary Actuator and Figure 1.3 - Positioner on Linear

Actuator show the positioner in rotary and linear actuators).

OUTPUT 1

1/8 - 27 NPT

(

1,97

)

(0,954)

(0,83)

(2,72)

(0,94)

113

(4,45)

(1,83)

39 45 45 260

22,5

HOLE 6,3 (0,25)

(2 PLACES)

(0,59)

(0,89)

(1,30)

(2,10)

53,3

49,5 56

(2,17)

(1,95)

24 24

EXHAUST ORIFICIES

(0,94) (0,94)

(1,54) (1,77)

6,5

MOUNTING ROLES FOR M6x1

SCREWS (2 PLACES)

Up to 15 mm (0,59)

TRAVEL DIMENSION A

Up to 50 mm (1,97)

43 mm (1,7)

105 mm (4,13)

181 mm (7,12)

Up to 100 mm (3,94)

(0,25)

22 22

(

1,54

)

(0,87) (0,87)

(1,77) (10,24)

(3,27)

OUTPUT 1

1’/4 - 18NPT OUTPUT 2

1’/4 - 18NPT

(2,16)

(3,27)

64,5

(2,54)

(0,71)

AIR SUPPLY

1/8 - 27 NPT

AIR

SUPPLY

1/8 - 27 NPT

OUTPUT 2

1/8 - 27 NPT

VALVE POSITIONER

ROTARY MAGNET

LINEAR MAGNET

ll dimensions are in mm

(

)

Up to 30 mm (1,18) 67 mm (2,64)

Figure 1.1 - FY302 Dimensional Drawing

FY302 – Operation, Maintenance and Instructions Manual

1.4

ROTATING

MAGNET BASE

ROTARY

MAGNET

POSITIONER

BASE

POSITIONER

VALVE STEM

Figure 1.2 - Positioner on Rotary Actuator

LINEAR MAGNET

BRACKET

VALVE YOKE

VALVE STEM

LINEAR MAGNET

CENTRALIZER

DEVICE

POSITIONER

BRACKET

Figure 1.3 - Positioner on Linear Actuator

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