w Installation & Operating Instructions for …

1 Rev G 04/20/01tech-251/DWO11819 Page 1 of 33w ANALOG POSITIONERSI nstallation & Operating Instructionsfor smartcal Valve PositionerRev G 04/20/01tech-251/DWO11819 Page 2 of 33 Table of ContentsSection 1 - Description of Principal of 2 - Initial Mounting positioner on a Rotary Mounting Remote positioner on a Rotary Wiring the Remote Sencor to the Pneumatic Electrical 3 - Enter Configure The Positioners Automatic Advanced Calibration (Optional).. Exit Description of Menu Description of Manually Control Valve 4 - Trouble Preliminary Common 5 - 6 - Error 7 - Exploded Parts 8 - Product 9 - Procedure to Adjust Err 3 Procedure to Remove Display Board & Electronic Procedure to Check transducer Grounding Pneumatic Manifold Control Schematic for Wiring of Intrinsically Safe Procedure to Reset the EEprom to Factory Hart Communicator Menu Flow G 04/20/01tech-251/DWO11819 Page 3 of 33 Section 1- Description of smartcal PositionerThe smartcal Valve positioner is anelectro-pneumatic servo system thatcontinuously controls the position of avalve based on a 4 to 20 mA input sig-nal.

2 The smartcal is an instrument thatderives its power directly from a controlsystems current loop. The instrumentsenses valve position via a non-contactHall effect sensor and controls valveposition through a current to of the smartcal can transpireby two means. Non-Hart calibration isthrough an on-board keypad. Communi-cation using Hart protocol allows calibra-tion and access to on-line diagnostics viaa Rosemount 275 hand-held terminal orthrough positioner has a local liquid crystaldisplay which indicates valve positionand set-point in percentage open. It alsoindicates whether the positioner is in cal-ibration smartcal has the capability to monitor operation. If a failure condition occurs,an error message is displayed on the local liquid crystal G 04/20/01tech-251/DWO11819 Page 4 of Principal of OperationUnlike conventional positioners, the smartcal positioner feeds back valve position withoutthe need for linkages, levers, or rotary and linear seals.

3 Position sensing is performed totallyby non-contacting means, permitting use of advanced control strategies where knowledge ofvalve position is used in predictive and other algorithms. By the integration of multiple compo-nents into a singular, cost efficient unit, microprocessor-based intelligence can now be usedto implement advanced functions such as early warning diagnostics and fugitive smartcal positioner provides intelligence for the control valve through a microprocessor-based diagnostic system utilizing the HART protocol. Accurate measurement of valve stemposition, input signal, actuator pressure and travel time can be recorded during normal oper-ation, thereby providing information for control valve signature Position FeedbackTo provide consistently accurate performance information, all linkages, levers and connect-ing rods, from the positioner to the control valve have been eliminated from the design.

4 Valveposition sensing is performed totally by non-contacting means based upon characterizationof flux strength as a function of Position ControlSince valve position feedback to the SmartCalpositioner is accomplished by non-contactingmeans, the smartcal has the unique ability tobe mounted remotely (up to a distance of 50feet) from the device it is controlling. In the eventthe control valve is located in either a high vibra-tion or extremely corrosive environment, thenon-contact position feedback feature allows forisolated placement of the KeypadAll smartcal positioners are provided with a 3button membrane keypad is pro-vided for zero and span adjustments, as well asvalve characterization and gain Calibration (HART Protocol)The smartcal positioner responds to HART commands for seeking the valve closed positionand assigns an instrument signal of 4 mA to this position.

5 The counterpart of the operation for afull open state is implemented next by setting the span value. Action reversal is also , provisions are made for altering internal servo loop tuning via the HART link. In thismanner, positioner performance may be optimized with a wide combination of valves and G 04/20/01tech-251/DWO11819 Page 5 of 33 Section 2 - Initial Mounting positioner on a Rotary ActuatorPort 1 Port 2 SupplyActuator(In Fail Position)TURNSSemi-Circle FacesThe Front of the PositionerModMountCOUNTER-CLOCKWISE(From Fail Position)Drive Insert*Port 1 Port 2 SupplyActuator(In Fail Position)Triangle Faces theFront of the PositionerModMountTURNS CLOCKWISE(From Fail Position)Drive Insert*Figure 2-1 Condition 1:Actuator fails in a clockwise direction(Turns counter clockwise from fail position).Spring ReturnOutput Port 2 is Port 1 is piped to turn the actuator ActingOutput Port 2 is piped to turn the actuator Port 1 is piped to turn the actuator 2:Actuator fails in a counter clockwise direction(Turns clockwise from fail position).

6 Spring ReturnOutput Port 2 is Port 1 is piped to turn the actuator ActingOutput Port 2 is piped to turn the actuator counter Port 1 is piped to turn the actuator : actuators for ModMount installations. 1. Drive insert must be provided with Keystone/Tyco*90 to allow for proper mounting. 2. Drive insert may need to be disengaged and rotatedRev G 04/20/01tech-251/DWO11819 Page 6 of Mounting Remote positioner on a Rotary ActuatorFigure 2-2 Actuator(In Fail Position)TURNSSemi-Circle FacesSide With TheConduit EntryMountingAssemblyCOUNTER-CLOCKWISEC onduit EntryPositionerSensor(From Fail Position)Drive Insert*Actuator(In Fail Position)TURNS CLOCKWISET riangle Faces theSide With TheConduit EntryMountingAssemblyConduit EntryPositionerSensor(From Fail Position)Drive Insert*Condition 1:Actuator fails in a clockwise direction(Turns counter clockwise from fail position).

7 Spring ReturnOutput Port 2 is Port 1 is piped to turn the actuator ActingOutput Port 2 is piped to turn the actuator Port 1 is piped to turn the actuator 2:Actuator fails in a counter clockwise direction(Turns clockwise from fail position).Spring ReturnOutput Port 2 is Port 1 is piped to turn the actuator ActingOutput Port 2 is piped to turn the actuator counter clockwiseOutput Port 1 is piped to turn the actuator clock-wiseNote: actuators for ModMount installations. 1. Drive insert must be provided with Keystone/Tyco*90 to allow for proper mounting. 2. Drive insert may need to be disengaged and rotatedRev G 04/20/01tech-251/DWO11819 Page 7 of Wiring the Remote Sensor to the PositionerMount positioner at a remote location, wire the positioner sensor back to the positioner using the cable provided (See Figure 2-3).1/2 NPTA ctuator(Top View) positioner (Mounted Remote fromActuator at Users Discretion)3/4 NPT(F)Position Sensor(Mounted on Actuatoras Described in Section ) (F)(4) Conductor Cable(Cut to Required Lengthand Run Through Conduit)OUT 2 SUPPLYJ1J4AJ4 BCALLCD1TP1J5TP2J6 TRANSDUCEROUT 1J3123456-+4-20mAFigure 2-3 Pin Connector(To Display Boardof positioner )PositionerSensor(4) Conductor ShieldedCableWiring SchematicBLACKGREENREDWHITE8 SHIELD (YELLOW)7654321 HALLEFFECTSENSORRev G 04/20/01tech-251/DWO11819 Page 8 of 33 MOUNTING Pneumatic ConnectionSingle Acting Actuator (Spring Return):For single acting actuators Outlet Port 2 is to be plugged.

8 Outlet Port 1 is to be piped to the actuator inlet port that acts against the spring. (Increasing signal causes pressure to increase in Outlet Port 1 of the positioner ).Double Acting Actuator (Double Return):For double acting actuators Outlet Port 2 is piped to drive the actuator towards the fail position. Outlet Port 1 is piped to drive theactuator away from the fail position. (Increas-ing signal causes pressure to increase in Outlet Port 1 of the positioner and pressure to decrease in Outlet Port 2 of the positioner ).Note: Air supply to the positioner must be clean, dry, oil free instrument air per Maximum supply pressure is 120 psi. All pneumatic connections are 1/4 Port 1 GageOutlet Port 1 Outlet Port 2 Inlet PortOutlet Port 2 GageInlet PortGage1. Single Acting/Spring Return (Plug Outlet Port 2) increas-ing signal causes pressure to increase in Outlet Port Double Acting/Double Return (Pipe Outlet Port 2 to drive actuator towards the desired failure direction) increasing signal causes pressure to decrease in Outlet Port 2 and pressure to increase in Outlet Port :1.

9 On loss of power pressure fails to Outlet Port 2-4 Rev G 04/20/01tech-251/DWO11819 Page 9 of Electrical Connection1. Remove positioner Locate terminal strip and carefully disconnect (slide off).3. Connect the 4 to 20 mA loop signal to termi-nal points marked (+) and (-). See figure 2-5 for a wiring If using the analog transmitter, connect out-put wiring to terminal points 5 & 6, (Polari-ties Shown Below). The 4 to 20mA analog output requires an external 24 volt DC power After all connections have been made recon-nect the terminal strip and replace positioner Off Terminal Stripfrom Keypad assemblyANALOGINPUTANALOGOUTPUTDISPLAY BOARD5-+-+}}12346-+Figure 2-5 Rev G 04/20/01tech-251/DWO11819 Page 10 of 33 Section 3 - CalibrationIf during the calibration routine you need more information describing any of the menus or functions refer to Sec-tions and The smartcal positioners also has an on-board help menu that can be accessed by pressing the Cal button and either arrow button simultaneously, anytime during Enter Calibration (Menu Level)Enter the calibration routine by pressing and holding the CAL button.

10 Continue to hold the CAL button until ACAL appears on the LCD. ACAL (Auto Cal Menu) is the first of four menus. By pressing the down arrow button you can cycle through the four menus. The remaining three menus are MCAL (Manual Cal Menu), Cofg (Configuration Menu), Stro (Manual Position Override Menu). The menu level is shown Configure the Positioners ParametersFrom the menu level press the down arrow button until the Cofg (Configuration Menu) is shown on the dis-play (Configuration Routine Shown Below). Enter this menu and change any of the parameters, if other than the factory settings are needed. The factory settings are OperationPress & Hold CALkey until ACAL appears on displayACALMCALDownArrowCofgUpArrowStro( OK Displayed on LCD)UpArrowDownArrow(See Section )(See Section )(See Section )UpArrowDownArrowUpArrowCofgDown Arrow(From Previous Menu)FlowUp ArrowTypeCALUp ArrowFLOPUp ArrowOPSPUp ArrowCLSPUp ArrowLin LinearFlowCALOPn QuickOpeningEP EqualPercentageDownDownCALCALDownCALLin LinearValveCALrot RotaryValveDownCALCALDownOFF FailClosedCALOn FailOpenDownCALCALDownCALCALUse UP& DownCALA rrowsto SelectCloseSpeed01=Slow05=FastCALDown Arrow(To Next Menu)Up Arrow(Exit Calibration)Use UP& DownArrowsto SelectOpenSpeed01=Slow05=FastEDbUp ArrowDownArrowOFF Deadbandat.