SMAR FY302 Manuel

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.

Waiver of responsibility

The contents of this manual abides by the hardware and software used on the current equipment

version. Eventually there may occur divergencies between this manual and the equipment. The

information from this document are periodically reviewed and the necessary or identified corrections

will be included in the following editions. Suggestions for their improvement are welcome.

Warning

For more objectivity and clarity, this manual does not contain all the detailed information on the

product and, in addition, it does not cover every possible mounting, operation or maintenance

cases.

Before installing and utilizing the equipment, check if the model of the acquired equipment complies

with the technical requirements for the application. This checking is the user’s responsibility.

If the user needs more information, or on the event of specific problems not specified or treated in

this manual, the information should be sought from Smar. Furthermore, the user recognizes that the

contents of this manual by no means modify past or present agreements, confirmation or judicial

relationship, in whole or in part.

All of Smar’s obligation result from the purchasing agreement signed between the parties, which

includes the complete and sole valid warranty term. Contractual clauses related to the warranty are

not limited nor extended by virtue of the technical information contained in this manual.

Only qualified personnel are allowed to participate in the activities of mounting, electrical connection,

startup and maintenance of the equipment. Qualified personnel are understood to be the persons

familiar with the mounting, electrical connection, startup and operation of the equipment or other

similar apparatus that are technically fit for their work. Smar provides specific training to instruct and

qualify such professionals. However, each country must comply with the local safety procedures,

legal provisions and regulations for the mounting and operation of electrical installations, as well as

with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased

safety and instrumented safety systems, among others.

The user is responsible for the incorrect or inadequate handling of equipments run with pneumatic

or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since their

utilization may cause severe bodily harm and/or material damages.

The field equipment referred to in this manual, when acquired for classified or hazardous areas, has

its certification void when having its parts replaced or interchanged without functional and approval

tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying

that the equipment in its entirety meets the applicable standards and regulations. The same is true

when converting the equipment of a communication protocol to another. In this case, it is necessary

sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are

different and the user is responsible for their correct use.

Always respect the instructions provided in the Manual. Smar is not responsible for any losses

and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to

know and apply the safety practices in his country.

Table of Contents

TABLE OF CONTENTS

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

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

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

PNEUMATIC CONNECTIONS .............................................................................................................................1.4

DIMENSIONAL DRAWINGS ................................................................................................................................1.6

ELECTRONIC HOUSING ROTATING ................................................................................................................. 1.7

ELECTRIC WIRING.............................................................................................................................................. 1.8

TOPOLOGY AND NETWORK CONFIGURATION...............................................................................................1.9

INTRINSIC SAFETY BARRIER..........................................................................................................................1.11

JUMPER CONFIGURATION..............................................................................................................................1.11

POWER SUPPLY ............................................................................................................................................... 1.11

AIR SUPPLY REQUIREMENTS......................................................................................................................... 1.11

RECOMMENDATIONS FOR AN INSTRUMENT AIR SYSTEM.........................................................................1.11

ROTARY AND LINEAR MAGNET ......................................................................................................................1.12

MAGNET CENTRALIZER DEVICE .................................................................................................................... 1.12

REMOTE HALL SENSOR .................................................................................................................................. 1.13

INSTALLATION IN HAZARDOUS AREAS......................................................................................................... 1.14

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

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

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

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

TRANSDUCER..................................................................................................................................................... 3.2

TRANSDUCER BLOCK PARAMETERS -DEFAULT VALUES AND UNITS .......................................................3.2

TRANSDUCER BLOCK PARAMETERS -DESCRIPTION .................................................................................. 3.5

TRANSDUCER BLOCK PARAMETERS -ATTRIBUTES .................................................................................... 3.8

HOW TO CONFIGURE ATRANSDUCER BLOCK ............................................................................................ 3.10

AUTO-SETUP .................................................................................................................................................... 3.10

CALIBRATION.................................................................................................................................................... 3.12

POSITION TRIM.................................................................................................................................................3.12

VIA SYSCON..................................................................................................................................................................3.12

SENSOR PRESSURE........................................................................................................................................ 3.15

FLOW CHARACTERIZATION............................................................................................................................3.16

TEMPERATURE CALIBRATION .......................................................................................................................3.18

DISPLAY TRANSDUCER BLOCK ..................................................................................................................... 3.18

DEFINITION OF PARAMETERS AND VALUES ................................................................................................3.19

CALIBRATING USINGLOCAL ADJUSTMENT..................................................................................................3.21

PROGRAMMING USING LOCAL ADJUSTMENT ............................................................................................. 3.21

BLOCK TYPE AVAILABILITY AND INITIAL BLOCK SET ..................................................................................3.25

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

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

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

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

RESTRICTION CLEANING PROCEDURE ..........................................................................................................4.3

CHANGEOF THE FILTER ELEMENTS............................................................................................................... 4.4

ELECTRONIC CIRCUIT ....................................................................................................................................... 4.4

INTERCHANGEABILITY...................................................................................................................................... 4.5

FY302 – Operation, Maintenance, and Instructions Manual

PACKAGE CONTENT ..........................................................................................................................................4.5

EXPLODED VIEW ................................................................................................................................................ 4.6

SPARE PARTS LIST ............................................................................................................................................4.7

DETAILED CODE WHEN ORDERING OF SPARE PARTS.................................................................................4.9

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

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

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

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

ORDERING CODE ...............................................................................................................................................5.3

APPENDIX A – CERTIFICATIONS INFORMATION...............................................................................A.1

EUROPEAN DIRECTIVE INFORMATION ...........................................................................................................A.1

HAZARDOUS LOCATIONS GENERAL INFORMATION .....................................................................................A.1

HAZARDOUS LOCATIONS APPROVALS...........................................................................................................A.2

CSA (CANADIAN STANDARDS ASSOCIATION) ........................................................................................................... A.2

FM APPROVALS (FACTORY MUTUAL)......................................................................................................................... A.2

NEMKO (NORGES ELEKTRISKE MATERIELKONTROLL)............................................................................................ A.3

EXAM (BBG PRÜF - UND ZERTIFIZIER GMBH)............................................................................................................ A.3

CEPEL (CENTRO DE PESQUISA DE ENERGIA ELÉTRICA)........................................................................................ A.3

IDENTIFICATION PLATE.....................................................................................................................................A.5

CONTROL DRAWING..........................................................................................................................................A.7

APPENDIX B – SRF – SERVICE REQUEST FORM ..............................................................................B.1

RETURNING MATERIALS...................................................................................................................................B.2

APPENDIX BFY......................................................................................................................................... 1

Installation Flowchart

VII

Installation Flowchart

FY302 – Operation, Maintenance, and Instructions Manual

VIII

Section 1

1.1

INSTALLATION

General

NOTE

The installation carried out in hazardous areas should follow the recommendations of the IEC60079-14 standard.

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.

IMPORTANT

Avoid the use of thread sealing tape in the air inputs and outputs, as this type of material can release small

residues and clog the inputs and outputs, thus compromising the efficiency of the equipment.

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

other vibrating equipment should be avoided. If these vibrations cannot be avoided, is

recommended to install the positioner with remote position sensor.

Mounting

The mounting of positioner 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 positioner itself. Smar may supply them both since they are

specified in the order code. (See Table 5.2).

Additionally, a wide variety of customized mounting brackets are available, covering a variety of

control valve models and manufacturers.

Check availability and select the mounting bracket that meets the needs of your process. Visit the

product page on the Smar website https://www.smar.com/brasil/produto/fy300series-posicionador-

inteligente-de-valvulas.

Rotary Movement

Install the magnet on the valve stem using the magnet support (See Figure 1.1).

FY302 – Operation, Maintenance, and Instructions Manual

1.2

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

VDI/VDE 5845, thus 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 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".

LOCK

ROTATY

MAGNET

POSITIONER

VALVE STEM

ROTATY

MAGNETY

BRACKET

POSITIONER

BRACKET

M6x1 SCREWS

(4 PLACES)

Figure 1.1 - Positioner on Rotary Actuator

OUT1 IN OUT2

REMOTE

EXTENSION

REMOTE EXTENSION

BRACKT

“L” BRACKT WITH “U” CLAMP

FOR REMOTE POSITION

M6x1 SCREWS

(2 PLACES)

REMOTE POSITION

Figure 1.2 - Positioner on Rotary Actuator with Remote Position Sensor

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