Pneumatic Cylinder Actuator: Operation, Maintenance and Instruction Manual

OPERATION, MAINTENANCE AND
INSTRUCTION MANUAL
Pneumatic Cylinder
Actuator
ACP301
A C P 3 0 1 ME
smar
www.smar.com
Specifications and information are subject to change without notice.

Up-to-date address information is available on our website.
web: www.smar.com/contactus.asp
Introduction
INTRODUCTION
The ACP301 - Pneumatic Cylinder Actuator, was designed by Smar to fit the growing demand from
the industries, mainly to what concerns the control applications for pneumatic cylinders.
The ACP301 - Pneumatic Cylinder Actuator allies the power of pneumatic cylinders to the FY301
microprocessed positioner capabilities, allowing the cylinder to be applied for modulating control.
The ACP301 modularity design is suitable for a wide range of cylinders through a unique solution
for mounting brackets for an unnumbered variety of applications.
The ACP301 - Pneumatic Cylinder Actuator is presented in different sizes, being selected
according to the application and required travel. There are two available models: Linear and Rotary.
By using the FY301 valve positioner assembled to a double action pneumatic cylinder, with a non-
contact linear or rotary magnet via Hall effect, it is possible to overcome the natural difficulties of a
pneumatic cylinder to stop between the ends of his travel, promoting the modulating control on the
final element.
The final control elements could be dampers (for furnace draft), sluices and huge control valves,
besides other applications requiring torque and powered controlled movement.
The ACP301 receives a 4-20 mA from a controller to drive the cylinder for an accurate required
position, as per the control loop strategy and tuning. They bring the intelligence to the cylinder, the
ACP allows to the user to configure the final element opening characteristic. For more sophisticated
applications, the user can configure a customized curve for up to 16 points.
Additionally, the communication benefits on Hart®, Fieldbus, and Profibus™ open wide possibilities
to link the field installations to the control room, with direct impact on installation cost reduction and
lower operation and maintenance cost.
Ø Modular and compact design;

Ø Easy installation;
Ø Position sensor, with no mechanical contact, via Hall effect;
Ø For pneumatic double action actuators, for both rotary and linear models;
Ø Easy parameters tuning through local adjustment and remote with handheld configurators or
software for desk and palm top;
Ø Explosion proof and intrinsically safe positioner;
Ø Opening characteristic changeable via local and/or remote configuration;
Ø Auto Setup in few minutes;
Ø Self lubricated, no need for external lubrication;
Ø Optional Limit switch for the cylinder;
Ø Filter regulator incorporated.
Get the best results of the ACP301 by carefully reading the instructions of this manual.
III
ACP301 – Operation, Maintenance and Instructions Manual
NOTE
This manual is compatible with version 3.XX, where 3 indicates 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.
IV
Table of Contents
TABLE OF CONTENTS
SECTION 1 - INSTALLATION .................................................................................................................. 1.1
ACP - GENERAL CHARATERISTICS........................................................................................................................ 1.1
ACP LINEAR MODEL (ACP301L/302L/303L) ............................................................................................................ 1.2
ACP ROTARY MODEL (ACP301R / 302R / 303R) .................................................................................................... 1.3
ACP – DIMENSIONAL DRAWINGS ........................................................................................................................... 1.4
LINEAR ACP MAIN DIMENSIONS TABLE ................................................................................................................................ 1.6
INSTALLATION .......................................................................................................................................................... 1.9
LINEAR ACP ............................................................................................................................................................................. 1.9
ASSEMBLING PROCEDURE .................................................................................................................................................... 1.9
ROTARY ACP.......................................................................................................................................................................... 1.11
INSTALLATION PROCEDURE................................................................................................................................................ 1.11
FY301 POSITIONER GENERAL CHARACTERISTICS ........................................................................................... 1.16
ELECTRONIC HOUSING ROTATING ..................................................................................................................... 1.16
ELECTRIC WIRING ................................................................................................................................................. 1.17
AIR SUPPLY REQUIREMENTS ............................................................................................................................... 1.20
RECOMMENDATIONS FOR AN INSTRUMENT AIR SUPPLY SYSTEM ............................................................... 1.20
ACTUATOR SECURITY POSITION ........................................................................................................................ 1.21
SECTION 2 - OPERATION ....................................................................................................................... 2.1

TRANSDUCER FUNCTIONAL DESCRIPTION ......................................................................................................... 2.1
ELECTRONICS FUNCTIONAL DESCRIPTION ........................................................................................................ 2.2
THE LOCAL INDICATOR ........................................................................................................................................... 2.4
SECTION 3 - CONFIGURATION .............................................................................................................. 3.1

CONFIGURATION RESOURCES .............................................................................................................................. 3.3
IDENTIFICATION AND MANUFACTURING DATA ................................................................................................... 3.3
MONITORING ............................................................................................................................................................ 3.3
DEVICE CONFIGURATION ....................................................................................................................................... 3.3
ADVANCED CONFIGURATION................................................................................................................................. 3.4
DEVICE MAINTENANCE ........................................................................................................................................... 3.4
TRIM ........................................................................................................................................................................... 3.4
SETUP ........................................................................................................................................................................ 3.4
MULTIDROP CONFIGURATION ............................................................................................................................... 3.5
DIAGNOSTIC ............................................................................................................................................................. 3.5
BACKUP ..................................................................................................................................................................... 3.5
PRESSURE SENSOR ................................................................................................................................................ 3.5
FACTORY ................................................................................................................................................................... 3.5
SECTION 4 - LOCAL ADJUSTMENT PROGRAMMING .......................................................................... 4.1

W1 AND W2 JUMPERS CONNECTION.................................................................................................................... 4.1
LOCAL PROGRAMMING TREE ................................................................................................................................ 4.2
ADJUSTABLE PARAMETERS ................................................................................................................................... 4.3
PROCEDURE FOR VALVE CALIBRATION............................................................................................................... 4.4
SECTION 5 - MAINTENANCE PROCEDURES ........................................................................................ 5.1

LINEAR MODEL ......................................................................................................................................................... 5.1
DISASSEMBLING PROCEDURE - LINEAR ACP ...................................................................................................... 5.1
ROTARY MODEL ....................................................................................................................................................... 5.4
ACP POSITIONER ..................................................................................................................................................... 5.5
CORRECTIVE MAINTENANCE FOR THE ACP301 POSITIONER .......................................................................... 5.5
ACP301 POSITIONER DIAGNOSTICS WITHOUT CONFIGURATOR ..................................................................... 5.5
ACP301 POSITIONER DIAGNOSTICS WITH CONFIGURATOR ............................................................................ 5.6
ACP301 POSITIONER DISASSEMBLY PROCEDURE FOR MAINTENANCE ......................................................... 5.7
POSITIONER ELECTRONIC CIRCUIT ...................................................................................................................... 5.7
PREVENTIVE MAINTENANCE FOR THE ACP301 POSITIONER ........................................................................... 5.8
ACP301 POSITIONER DISASSEMBLY PROCEDURE ............................................................................................. 5.8
V
ACP301 POSITIONER ASSEMBLY PROCEDURE ................................................................................................... 5.9

RESTRICTION CLEANING PROCEDURE .............................................................................................................. 5.10
CHANGE OF THE FILTER ELEMENTS OF ACP301 POSITIONER....................................................................... 5.11
ACP301 POSITIONER EXHAUSTS PORTS ........................................................................................................... 5.11
ELECTRONIC CIRCUIT ........................................................................................................................................... 5.12
PNEUMATIC CYLINDER MAINTENANCE .............................................................................................................. 5.12
PACKAGE CONTENT .............................................................................................................................................. 5.13
ACP301 POSITIONER EXPLODED VIEW .............................................................................................................. 5.14
ACCESSORIES ........................................................................................................................................................ 5.15
SPARE PARTS LIST FOR ACP301 POSITIONER .................................................................................................. 5.15
ROTARY ACP EXPLODED VIEW ........................................................................................................................... 5.18
SPARE PARTS LIST FOR ROTARY ACP301 (ACP301LN).................................................................................... 5.19
LINEAR ACP EXPLODED VIEW.............................................................................................................................. 5.20
SPARE PARTS LIST FOR LINEAR ACP301 (ACP301LN)...................................................................................... 5.21
SECTION 6 - TECHNICAL CHARACTERISTICS ..................................................................................... 6.1

CYLINDER SPECIFICATIONS ................................................................................................................................... 6.1
LIMIT SWITCH CHARACTERISTICS ........................................................................................................................ 6.1
MOUNTING BRACKET CHARACTERISTICS ........................................................................................................... 6.1
ISO6431 ...................................................................................................................................................................... 6.2
FY301 POSITIONER FUNCTIONAL SPECIFICATIONS ........................................................................................... 6.2
FY301 POSITIONER PERFORMANCE SPECIFICATIONS ...................................................................................... 6.2
FY301 POSITIONER PHYSICAL SPECIFICATIONS ................................................................................................ 6.3
WEIGHT ANALYSIS FOR LINEAR ACP .................................................................................................................... 6.4
ORDERING CODE ..................................................................................................................................................... 6.5
APPENDIX A – SRF – SERVICE REQUEST FORM ................................................................................ A.1

RETURNING MATERIALS ......................................................................................................................................... A.2
APPENDIX B - SMAR WARRANTY CERTIFICATE ................................................................................. B.1
VI
Section 1
INSTALLATION
ACP - General Charateristics
The ACP is available for Hart® (301 line) Foundation Fieldbus (302), and Profibus™ (303)
communications protocols. For both linear (ACP301L / 302L / 303L) and rotary (ACP301R / 302R /
303R) applications.
The ACP basic features are:
LINEAR Model
The main parts are the pneumatic double action cylinder, brackets for the cylinder, linear magnet
and the FY positioner. The linear model uses a conic rule to change the linear pneumatic cylinder
movement into a perpendicular movement related to the magnet.
Figure 1.1 - ACP Linear Model ACP301L / 302L / 303L
ROTARY Model
The main parts are the pneumatic double action cylinder, a jointed structure with a rotary lever, a
rotary magnet and a FY positioner, promoting an angular movement.
Figure 1.2 - ACP Rotary Model ACP301R / 302R / 303R
1.1
ACP301 - Operation, Maintenance and Instructions Manual
ACP Linear Model (ACP301L/302L/303L)

The ACP modular design – Linear Model, allows the user to apply it in a wide variety of cylinder
strokes and different sizes with just one design of mounting brackets.
The working strokes for ACP301L / 302L / 303L are:
100 mm.
125 mm.
160 mm.
200 mm.
250 mm.
320 mm.
400 mm.
500 mm.
630 mm.
800 mm.
1000 mm.
The internal cylinder diameters are:
63 mm.
80 mm.
100 mm.
125 mm.
160 mm.
The following chart shows the available stem force according to the working pressure and to the
cylinder diameter:
LINEAR ACP - Force x Pressure
1400
Força (Diam 160mm) (Kgf)
1300 The chart represents the force and
Força (Diam 125mm) (Kgf) considering 10% loss due to the
1200 attriction.
Força (Diam.100mm) (Kgf)
1100
Força (Diam.80mm) (Kgf)
1000
Força (Diam. 63mm) (Kgf)
900
Force (Kgf)
800
700
600
500
400
300
200
100
0
20 30 40 50 60 70 80 90 100
Pressure (psi)
Figure 1.3 - ACP Linear Model – Stem Force x Working Pressure
The chart represents the force and considering 10% loss due to the attrition.
1.2
Installation
ACP Rotary Model (ACP301R / 302R / 303R)

The ACP Rotary Model is suitable for different strokes using the same structure. This structure
allows selecting wider movements, using only one cylinder.
The standard cylinder for the Rotary Model has a 100 mm diameter, and 400 mm stroke.
Combining the pre-defined holes at the ACP lever it is possible to get the following strokes:
100 mm.
150 mm.
200 mm.
250 mm.
300 mm.
350 mm.
400 mm.
450 mm.
500 mm.
The actuating force is directly proportional to the working pressure, and also proportional to the
hole position. The forces available for the ACP301R / 302R / 303R are on the following chart.
Rotary ACP - Force x Actuation Travel
2000
Pressão 100 psi
1900 The graphics shows the force against the Pressão 90 psi
1800 cylinder stroke, considering 10% loss due Pressão 80 psi
1700 to attrition.
Pressão 70 psi
1600 Pressão 60 psi
Force (Kgf)
1100
1000
900
800
700
600
500
400
300
200
100
0
100 150 200 250 300 350 400 450 500
Actuation Travel (mm)
Figure 1.4 - Force x Actuation Travel Graphic - ACP - Rotary Model
The graphics shows the force against the cylinder stroke, considering 10% loss due to attrition.
1.3
ACP – Dimensional Drawings

293,5 (11.555)
260,0 (9.843)
NA MONTAGEM DO
EQUIPAMENTO VERIFICAR
MANUAL DE INSTRUCÇOES
1496,0 (58.898)
1135,0 (44.685)
P
1196,0 (47.087)
794,0 (31.260)
856,5 (33.720)
125,0 (4.921)
570,0 (22.441)
540,0 (21.260)
150,0 (5.906)
194,5 (7.657)
Figure 1.5 - Dimensional – Rotary ACP
1.4
Installation
D
C
H
G
E
F
A
B
REGULATOR
LINEAR MAGNET
Figure 1.6 - Dimensional – Linear ACP
1.5
Linear ACP Main Dimensions Table

63, 80, 100, 125 and 160 mm Diameters
A Dimension = Backwarded cylinder
Cylinder Diameter (mm)

Cylinder 63 80 100 125 160
Travel/Rule
(mm) A (mm)
100 466 530.8 558.8 679 797
125 491 562.05 590.05 709 827
160 526 605.8 633.8 751 869
200 566 655.8 683.8 799 917
250 616 718.3 746.3 859 977
320 686 805.8 833.8 943 1061
400 766 905.8 933.8 1039 1157
500 866 1030.8 1058.8 1159 1277
630 996 1193.3 1221.3 1315 1433
800 1166 1405.8 1433.8 1519 1637
1000 1366 1655.8 1683.8 1759 1877
B Dimension = Advanced cylinder

Cylinder 63 80 100 125 160
Travel/Rule
(mm) B (mm)
100 566 630.8 658.8 779 897
125 616 687.05 715.05 834 952
160 686 765.8 793.8 911 1029
200 766 855.8 883.8 999 1117
250 866 968.3 996.3 1109 1227
320 1006 1125.8 1153.8 1263 1381
400 1166 1305.8 1333.8 1439 1557
500 1366 1530.8 1558.8 1659 1777
630 1626 1823.3 1851.3 1945 2063
800 1966 2205.8 2233.8 2319 2437
1000 2366 2655.8 2683.8 2759 2877
C Dimension = Cylinder header height until the FY fixation plate

D Dimension = Cylinder header height until the FY

Dimension 63 80 100 125 160
C (mm) 162.75 183 200 228.5 265
D (mm) 243.75 264 281 309.5 346
1.6
Installation
E Dimension = Backwarded cylinder until the center of the pin hole (of clevis)
Cylinder
Travel/Rule
(mm) Cylinder Diameter (mm)
63 80 100 125 160
A (mm)
100 443.4 503.6 531.6 633.4 739.6
125 468.4 534.85 562.85 663.4 769.6
160 503.4 578.6 606.6 705.4 811.6
200 543.4 628.6 656.6 753.4 859.6
250 593.4 691.1 719.1 813.4 919.6
320 663.4 778.6 806.6 897.4 1003.6
400 743.4 878.6 906.6 993.4 1099.6
500 843.4 1003.6 1031.6 1113.4 1219.6
630 973.4 1166.1 1194.1 1269.4 1375.6
800 1143.4 1378.6 1406.6 1473.4 1579.6
1000 1343.4 1628.6 1656.6 1713.4 1819.6
F Dimension = Advanced cylinder until the center of the pin hole (of clevis)
Cylinder
Travel/Rule
(mm) Cylinder Diameter (mm)
63 80 100 125 160
B (mm)
100 543.4 603.6 631.6 733.4 839.6
125 593.4 659.85 687.85 788.4 894.6
160 663.4 738.6 766.6 865.4 971.6
200 743.4 828.6 856.6 953.4 1059.6
250 843.4 941.1 969.1 1063.4 1169.6
320 983.4 1098.6 1126.6 1217.4 1323.6
400 1143.4 1278.6 1306.6 1393.4 1499.6
500 1343.4 1503.6 1531.6 1613.4 1719.6
630 1603.4 1796.1 1824.1 1899.4 2005.6
800 1943.4 2178.6 2206.6 2273.4 2379.6
1000 2343.4 2628.6 2656.6 2713.4 2819.6
Dimensional – Female back joint bracket (mm)

Dimensio
n 63 80 100 125 160
G (mm) 35 40 50 60 88
J (mm) 52 66 76 94 118
I (mm) 9 11 11 12 14
Center of the cylinder holes (mm)

Dimensio
n 63 80 100 125 160
H (mm) 56.5 72 89 110 140
Reference values for pneumatic cylinders from usual manufacturers line, ISO series.
The values for A, B, E, F were considered with clevis totally threaded.
1.7
12.7 LEVER THICKNESS

(0.5)
POSITIONER MOUNTED IN BOTH ENDS Dimensions in mm (in).

AND IN ANY POSITION.
500 (19.68)
450 (17.72)
400 (15.75)
350 (13.78)
300 (11.81)
250 (9.84)
200 (7.87)
150 (5.91)
100 (3.94)
50
0
60º
(19
.68
(1.95)
49.6
45 )
0(
(1.
45 7)
17
7
.72
Force Chart 40
0( )
15
.75
35 )
0(
13
.78
)
(58.9)
30
1496
0(
11
9 Orifices 13 .81
25 )
(0.51) 0(
(47.09)
1196
9.8
F9A
20 4)
F8A
0(
F7A
7.8
F6A
FORWARD POSITION 15 7)
F5A
(31.26)
0(
F4A
794
5.9
F3A
(3.94) 10 1)
F2A
100 0(
F1A
3. 9
400 mm Travel 4)
(15.75)
60º
(0.37)
9.5
766
F1R
(30.16)
F2R
F3R
F4R
F5R
F6R
F7R
150 (5.9)
F8R
(4.92)
F9R
125
BACKWARD POSITION
540 (21.3) 4 ORIFICES 10.5 (0.41)
570 (22.44)
(FIXING BASE)
RESULTING FORCES IN (Kgf)

FORCES - BACKWARD POSITION FORCES - FORWARD POSITION (A)
20 psi 100 psi 20 psi 100 psi
(1.4 Kgf/ cm 2 ) (7.0 Kgf/ cm 2 ) (1.4 Kgf/ cm 2 ) (7.0 Kgf/ cm 2 )
F1R 377 1888 F1A 397 1987
F2R 251 1259 F2A 265 1325
F3R 188 944 F3A 198 993
F4R 151 755 F4A 159 795
F5R 125 629 F5A 132 662
F6R 107 539 F6A 113 568
F7R 94 472 F7A 99 497
F8R 83 419 F8A 88 441
F9R 75 377 F9A 79 397
Figure 1.7 – Forces Table – Rotary ACP
1.8
Installation
Installation
The installation must consider the facilities for connection to the final control element, having
enough space to allow smooth operation and further maintenance on the actuator and final control
element.
Linear ACP
When necessary assembling in the field, position + ACP set, follow the installation procedures.
Assembling Procedure
The following instructions show the procedure for the ACP301LN - Linear Pneumatic Cylinder
Actuator:
Place the fixing plate on the positioner and tight it with an Allen key size 5.
Figure 1.8 – Fixing Plate on the FY301 Positioner
When assembling the positioner, remember not to tight the screws, since it will necessary to align
the magnet and positioner according to the cylinder stroke length. We suggest, if possible,
assemble the positioner such as its air connections be at the same side of the cylinder air
connections. Next, place the positioner on the cylinder and its bracket.
Figure 1.9 – Assembling the Positioner on the Cylinder
To align the magnet properly, first full close the cylinder and use a mark pen to set the close
position on the rule.
1.9
Figure 1.10 – Magnet Alignment
Full open the cylinder (use air pressure if necessary) and mark the open position on the rule. With a
measuring tape, find the 50% stroke and mark with the proper pen.
Important: first, disconnect the pipes to facilitate the cylinder motion.
Figure 1.11 – Marking Full Open Position Figure 1.12 – Marking 50% Position
Ensure that the magnet groove (with an arrow) is aligned with the Hall sensor.
Figure 1.13 – Magnet Alignment with the Hall Sensor
1.10
Installation
Adjust the magnet position taking the rule up to 50% stroke, aligning the magnet and Hall sensor
arrows. Tight now the plate on the positioner using an Allen key size 10. Full open and full close the
cylinder some times to be sure the assembly is correct. Check if the rule is running parallel to the
cylinder and if the magnet arrow is assembled properly (arrows match). The Hall sensor does not
scrape the magnet internal walls.
Figure 1.14 – Adjusting the Magnet Position
The limit switches (optional) are available and must be specified on the ordering code. They are
reed switches and they are not for use in classified areas.
Rotary ACP
The Rotary ACP has four holes on the base for fixing and fastening on the ground. After pre-
assembling it, place the washers and nuts. Tight them gradually preventing tensions or warping the
structure. It follows the detailed installing procedure.
Installation Procedure
The following instructions cover the installing and assembling procedure for the ACPR – Rotary
Pneumatic Cylinder Actuator.
To transport the ACP is packed with the lever loose. Use the other set of bolts and nuts to
assemble the cylinder to the ACP lever.
Figure 1.15 – Rotary ACP Base with the Cylinder Installed
Notice in the next two pictures the details where to place the rotary magnet. Also notice the groove
on the horizontal axis, for fixing the rotary magnet. Note that, if necessary, the positioner can be
mounted on the opposite side.
1.11
Fix the rotary magnet to the base axis as shown in the picture guided by the groove. Use an Allen
key size 5 mm just to place the magnet but do not tight it yet.
Figure 1.18 - Placing the Magnet Figure 1.19 – Fixing the Screw (Do not tight
it)
Next assemble the positioner bracket using the Allen key 5mm to tight the positioner to the bracket.
Figure 1.20 - Rotary ACP Mounting Bracket Figure 1.21 - Assembling the Bracket and
Positioner
Fix the set “positioner + bracket” to the ACP base and tight it with the Allen key 5mm.
Figure 1.22 - Positioner and Bracket Installed into the ACP Base
1.12
Installation
Ensure a 2 to 4 mm distance between the magnet face and the positioner face and check if there is
no physical contact between the pieces, including the Hall sensor.
Figure 1.23 – Details of the Assembled Magnet
Displace manually the ACP lever to check the upper and lower limits. Place the lever at 50% stroke
and use the auxiliary small lever to sustain the lever at that position. See the picture for details on
how to use the auxiliary lever.
Figure 1.24 - Auxiliary Lever for 50% Stroke Figure 1.25 - Rotary ACP on 50% Stroke
Place the magnet in such way that the 50% position matches with positioner arrow. On this position
tight the two screws on the rotary magnet.
Figure 1.26 – Details of the Fixing Screws on the Rotary Magnet
1.13
Return the lever for its initial position and test. Place the ACP in upper and lower position.
Figure 1.27 - Lower Position Figure 1.28 - Upper Position
Now, install the instrument air pipe on the positioner output 1 and output 2. Note that there are two
fixing device on the ACP base for the pipe, preventing the pipe to move during the actuator
displacement.
Figure 1.29 - Detail of the Pipe Installed on the Rotary ACP for Air Supply
Next, connect the pipe to the regulator filter, which can be installed at both sides of the rotary ACP.
Clear regularly the filter for a better ACP performance.
NOTE
Cleaning will be much more frequent when the installation does not according the specification of the impurities
amount or moisture in the air instrumentation. In this section, refer to item "Air Supply" for proper installation.
1.14
Installation
Figure 1.30 - Installing the Air Filter Figure 1.31 – Air Filter Detail
Next the views of final ACP assembly. One can install the positioner at both ACP sides as per the
field needs.
Figure 1.32 – Final Assembly – Up View Figure 1.33 – Final Assembly
1.15
FY301 Positioner General Characteristics

The overall accuracy of measuring and control depends on several factors. In spite of the excellent
performance, the positioner must be adequately installed so that it may work well.
Among all factors that may affect the positioner accuracy, environmental conditions are the most
difficult to control. But there are ways to reduce the effects of temperature, humidity and vibration.
Installing 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. If not possible to avoid it, consider using the remote
position sensor version.
Use thermal isolation to protect the positioner from external heart sources, if necessary.
Humidity is fatal to electronic circuits. In areas subjected to high relative humidity, the O-rings for
the electronic housing covers must be correctly placed and the covers must be completely closed
by tighten them by hand until you feel the O-rings being compressed. Do not use tools to tight the
covers. 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 the humidity.
The electronic circuit is protected by a humidity proof coating, but frequent exposures to humidity
may affect the protection provided. 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. Sealing methods should be employed on conduit entering of the positioner.
IMPORTANT
Avoid to use thread sealant tapes on the air input and outputs connections, since small pieces of this type
of sealant may block the air flow inside the positioner, affecting the overall equipment performance.
Although the positioner is practically vibration resistant, it is not recommended to install it near
pumps, turbines or other equipment producing too much vibration. If not possible to avoid it,
consider using of remote position sensor version.
Electronic Housing Rotating

The electronic housing can be rotated in order to offer a better to position the digital display and/or
better access to the field wires. To rotate it, release the housing rotation set screw. The local
indicator itself can also be rotated.
Figure 1.34 - Housing Rotation Set Screw
Reach the wiring block by removing the electrical connection cover. This cover can be locked
closed by the cover locking screw. To release the cover, rotate the locking screw clockwise.
1.16
Installation
Figure 1.35 – Cover Locking Screw
Electric Wiring
The access to the signal cables to the terminal wiring can be done through of one of the housing
passes and can be connected to a conduit. The wiring block has screws on which fork or ring-type
terminals can be fastened. Use a plug to block the electrical connection not used. Tight it well and
use thread sealing tape.
NOTE
If the user choose protection against noise induced by atmospheric discharges, overloads, weld
machines and machines in general, it will be necessary to install a transient protector (protector
acquired separately).
Test and communication terminals allow, respectively, to measure the current in the 4 - 20 mA loop,
without opening it, and to communicate with the transmitter. To measure it, connect a multimeter in
the mA scale in the "0" and "É" terminals, and to communicate, use a Hart® configurator in the
"COMM" and "0" terminals. For convenience, there are three ground terminals: one inside the
cover and two externals, located close to the conduit entries.
Attention to prevent the accidental feeding of the test terminals. This occurrence will cause
damages in the equipment.
Figure 1.36 – Wiring Block
HAZARDOUS AREAS
In hazardous areas with explosion proof requirements, the covers must be tightened with at
least 8 turns. In order to avoid the penetration of humidity or corrosive gases, tighten the o-ring
until feeling the o-ring touching the housing. Then, tighten more 1/3 turn (120°) to guarantee
the sealing. Lock the covers using the locking bolts.
Conduit threads should be sealed by means of code-approved sealing methods.
Explosion proof, non-incendive and intrinsic safety certification are standards for ACP301
controlled by FY301 positioner.
For a complete list of available certificates, please consult http://www.smar.com
1.17
The conduit installation diagram shows the correct installation of the conduit, in order to avoid
penetration of water or other substance, which may cause malfunctioning of the equipment.
WIRES
CORRECT INCORRECT
Figure 1.37 - Conduit Installation Diagram
Use of twisted pair (22 AWG or greater than) cables is recommended.
Avoid routing signal wiring close to power cables or switching equipment.
IMPORTANT
The FY301 positioner is protected against reverse polarity, and can withstand up to 50 mA and power supply
of ± 60 Vdc without damage.
The FY301 positioner connection could be done according to the figures below. It is also
recommended to ground the shield of shielded cables at one end only. The non-grounded end must
be carefully isolated.
The configurator can be connected to the communication terminals of the positioner or at any point
of the signal line by using the interface HPI311-M5P with “alligator” clips.
CD600
GROUND THE SIGNAL LOOP AT ONE

END OR LEFT IT
UNGROUNDED
CONFIGURATOR
Figure 1.38 – FY301 Positioner Wiring Diagram
1.18
Installation
CURRENT SUPPLY
OUTPUT
GROUND THE SIGNAL LOOP AT ONE

END OR LEFT IT
UNGROUNDED
CONFIGURATOR
Figure 1.39 - FY301 Positioner Wiring Diagram Connected in the Transmitter
The FY301 has an equivalent impedance of 550 Ohms. Make sure that the current supply or analog
output of DCS, CLP or single loop controller powering the positioner is capable to handle a voltage
drop of 11 V for each positioner (550 x 0,02 = 11 Volts).
NOTE
If you are using two positioners in series as e. g., working in split range, the resulting impedance
will be 1.100 Ohms. Therefore, the analog output should be capable to handle a voltage drop of
22 Volts.
Connection of the FY301 in multidrop configuration should be done as in figure 1.40. Note that a
maximum of two positioners can be connected on the same line and that they should be connected
in series.
CD600
CONFIGURATOR
Figure 1.40 - FY301 Positioner Wiring Diagram for Multidrop Configuration (Split Ranges)
1.19
Air Supply Requirements

Before the air supply is connected to the positioner, we recommend the hose is opened freely for 2
to 3 minutes to allow any contamination to be blown out. Direct the air jet into a large paper towel to
trap any water, oil, or other foreign materials. If this indicates that the air system is contaminated, it
should be properly cleaned.
As soon as the positioner is connected and powered, internal air leakage will provide protection
against corrosion and prevent moisture inside. For this reason, it is strongly recommended to keep
the positioner pressurized as much as possible.
Recommendations for an Instrument Air Supply System
Instrument air quality shall be superior to that of industrial compressed air. Humidity, suspended
particles and oil may impair the instrument operation, either temporarily or permanently in case of
internal parts wearing.
As per standard ANSI/ISA S7.0.01 - 1996 - Quality Standard for Instrument Air, instrument air shall
have the following characteristics:
Dew point 10°C below minimum instrument temperature
Size of particles (airborne) 40 µm (maximum)
Oil content 1 ppm w/w (maximum)
Contaminants free from corrosive flammable gases
This standard recommends that the compressor intake be located in an area free from process
spills and fitted with and adequate filter. It also recommends the use of non-lubricated type
compressors, in order to prevent air contamination by lubricating oil. Where lubricated type
compressors are adopted, there shall be used means to make the air oil free.
Figure 1.41 and 1.42 shows a typical system for air supply and air quality conditioning.
COMPRESSOR
INTAKE
CONDENSATE
AIR RECEIVER
AFTERCOOLER SEPARATOR
WITH DRAIN
WITH DRAIN
COMPRESSOR
Figure 1.41 - Air Supply System
OIL AND WATER

AIR DRY AIR
MIST PREFILTER
DRYER AFTERFILTER
WITH DRAIN
Figure 1.42 - Air Quality Conditioning System
1.20
Installation
Actuator Security Position

Important: If the FY301 positioner fails, 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.
Double Action - Air to Open (Fail Close/ Return on Fail)

Connect Output 1 (OUT1) of the positioner to the input identified as OPEN in the pneumatic
cylinder, and connect Output 2 (OUT2) of the positioner to the input CLOSE of the pneumatic
cylinder.
Double Action - Air to Close (Fail Open/ Go on Fail)

Connect Output 2 (OUT2) of the positioner to the input identified as OPEN in the pneumatic
cylinder, and connect Output 1 (OUT 1) of the positioner to the input CLOSE of the pneumatic
cylinder.
There are five exhaust outputs in the FY301 positioner, all of them fitted with filters. It is very
important that such outputs are neither blocked nor obstructed, because the air must circulate
freely.
Connection of positioner air supply to the pneumatic cylinder should be accomplished with flexible
pipe, due to oscillation of the equipment when in progress operation or return of the pneumatic
cylinder.
Depending on the specifications, rigid or flexible air connections can be used for regulator filter
supply. When possible, the pipe length must be minimum, with the objective of avoiding the delay
in control signs.
1.21
1.22
Section 2
OPERATION
Transducer Functional Description
The main parts of the output module are the pilot, servo, Hall effect position sensor and the output
control circuit.
The control circuit receives a digital setpoint signal from the CPU and a feedback signal from the
position sensor.
The pneumatic circuit is based on a well-known and widely adopted technology, which is described on
item baffle and nozzle and Spool Valve.
PIEZO VANE
RESTRICTION
NOZZLE
PILOT
DIAPHRAGM
PILOT PILOT CHAMBER
SPOOL
DIAPHRAGM
VENT 2
OUTPUT 2
AIR SUPPLY
OUTPUT 1
VENT 1
SPOOL
SPRING
Figure 2.1 - Schematic Pneumatic Transducer
A piezoelectric disk is the flapper in the pilot stage. The flapper is deflected when the control circuit
applies a voltage. A small stream of air flowing through the nozzle is obstructed causing an increase in
pressure in the pilot chamber; this is called the pilot pressure.
The pilot pressure is too low, with a small flowing capacity, and for this reason, it must be amplified in
the servo section. The servo section includes a diaphragm in the pilot chamber and a smaller one in the
spool chamber. The pilot pressure applies a force at the pilot chamber’s diaphragm, which, in the
equilibrium state, will be equal to the force applied by the spool valve at the smaller diaphragm, which
is in the spool chamber.
Upon every position change caused by the positioner, the pilot pressure increases or decreases, as
explained in the pilot stage section. Such change in pilot pressure causes an upward or downward
valve travel, which alters the pressure at Output 1 and Output 2, until a new balance is reached (new
valve position).
2.1
Electronics Functional Description

Refer to the block diagram (Figure 2.2). The function of each block is described below.
A/D
Receives the 4 - 20 mA signal and converts it in the digital format for the CPU.
D/A
Receives the signal from the CPU and converts it to an analog voltage proportional to the desired
position, used by the control.
Control
Controls the valve position according to data received from the CPU and t he Hall effect sensor
feedback.
Position Sensor
Measures the actual position and feedback to the control and CPU.
Temperature Sensor
Measures the temperature of the Transducer Circuit.
Isolation
Isolates the 4 - 20 mA signal from the piezoelectric signal.
EEPROM
A non-volatile memory that stores configuration data as a backup if the FY301 main board be replaced.
Central Processing Unit (CPU), RAM, PROM and EEPROM

The CPU is the intelligent portion of the positioner, being responsible for the management and
operation of block execution, self-diagnostics and communication. The program is stored in PROM. For
temporary storage of data there is a RAM. The data in the RAM is lost if the power is switched off,
however the device also has a nonv olatile EEPROM where data that must be r etained is stored.
Examples of such data are calibration and valve configuration.
HART Modem
The function of this system is to make possible the information exchange between Smar programmer
®
and the positioner, over digital communication using Hart protocol. Modulates and demodulates digital
information transmitted by Smar programmer on the current line. A “1” is represented by 1200 Hz and
“0” by 2200 Hz. The frequency signal is symmetrical and does not affect the DC-level of the 4 - 20 mA
signal.
Power Supply
The positioner circuit receives supply from a 4 - 20 mA power supply or takes power of Loop Line to
power the positioner circuit that is limited to 3.8 mA to work properly.
Display Controller
Receives data from the CPU and controls the (LCD) Liquid Crystal Display.
Local Adjustment
Local adjustment is provided by means of two magnetically actuated switches with no external electric
or mechanical contact, by using a magnetic screwdriver.
Piezo Flapper Nozzle
The unit flapper nozzle converts the movement of piezoelectric into a pneum atic signal to control
pressure in the pilot chamber.
Restriction
The restriction and the nozzle form a pressure-divided circuit. Air is supplied to the nozzle through a
restriction.
Spool
The spool ensures a quick valve positioning by providing a greater airflow than one provided by the
restriction.
Pressure Sensors
®
Measure the pressures of air pressure supply, pressure at Output 1 and Output 2. Available for Hart
reading.
2.2
Operation
NOTE
The pressure sensor’s circuit board is optional. (See request code, session 6, K1 option).
Pressure Sensor Selector

Selects the sensor to be read from.
Sensor IN: Measures air supply pressure.
Sensor OUT1: Changes the pressure in output 1.
Sensor OUT2: Changes the pressure in output 2.
Figure 2.2 - Positioner Block Diagram
2.3
The Local Indicator

The LCD-Local Indicator is required for signaling and for operation in local adjustment.
Normal Indicator
During normal operation, the positioner remains in the monitoring mode and the display indicates the
valve position, either as a percentage or as a current readout. The magnetic tool activates the local
programming mode, by inserting it in orifice “Z” on the housing.
The possible configuration and monitoring operation are shown on figure 2.3.
Upon receiving power, the positioner initializes the position indication on the display, by showing
model positioner and its software version (X.XX).
MD INDICATES ACTIVE MULTIDROP MODE
FIX
INDICATES THAT THE CONSTANT
OUTPUT MODE IS ACTIVE
VARIABLE FIELD % READOUT IN PERCENTAGE
INDICATES THE POSSIBILITY

TO CHANGE / ADJUST
VARIABLE / MODE
UNIT AND FUNCTION FIELD
Figure 2.3 - Local Indicator
Monitoring
During normal operation, positioner remains in the monitoring mode. Figure 2.4 shows the positioning
in percentage.
The display simultaneously shows readout and some other information.
Normal displaying is interrupted when the magnetic tool is placed in orifice “Z” (Local Adjustment),
entering the programming mode local adjustment.
The above mentioned figure shows the result of tool insertion in orifices Z and S , which inform,
respectively, movement and actuation of the selected options.
Figure 2.4 - Typical Indicator
2.4
Section 3
CONFIGURATION
The FY301 Smart Positioner in the ACP301 – Pneumatic Cylinder Actuator is a digital instrument with
the most up-to-date features a measurement device can possibly have. The digital communication
®
protocol (Hart ) enables the instrument to be connected to a computer, in order to be configured in a
very simple and c omplete way. Such computers connected to the positioners, are called host
®
computers. They can be either primary or secondary masters. Even though Hart is a master-slave type
of protocol, it is possible to work with up to two masters in a bus. Usually, the primary host plays the
supervisory role and the secondary host plays the configurator role.
The positioners may be connected in a point-to-point or multidrop type network. In a point-to-point

connection, the equipment’s address must be "0". In a multidrop network, if the devices are recognized
by their addresses, the positioners should be configured with a network address between "1" and "15”.
In this case, the positioners’ output current is kept constant, at 4 mA each if the acknowledgement is
via tag, the positioners addresses may be "0", and even in a multidrop configuration.
NOTE
In case of a multidrop network configuration for classified areas, the entity parameters allowed for the area shall be
strictly observed. Therefore, the following shall be checked:
Ca ≥ Σ Cij + Cc La ≥ Σ Lij + Lc
Voc ≤ min [Vmaxj] Isc ≤ min [Imaxj]
Where:
Ca, La = Allowed Capacitance and Inductance on the bus
Cij, Lij = Non protected internal Capacitance/Inductance of positioner j (j = up to 15)
Cc, Lc = Cable capacitance and Inductance
Voc = Barrier open circuit voltage
Isc = Barrier short circuit current
Vmaxj = Maximum allowable voltage to be applied to the instrument j

Imaxj = Maximum allowable current to be applied to the instrument j
®
The FY301 positioner includes a very encompassing set of Hart Command functions that make it
possible to access the functionality of what has been implemented. Such commands according to the
®
Hart protocol specifications, and are grouped as Universal Commands, Common Practice Controls
Commands and Specific Commands. A detailed description of such commands may be found in the
®
manual entitled Hart Command Specification - FY301 Smart Valve Positioner.
®
Smar developed two types of Configurators for its Hart devices: CONF401 Configurator and HPC401
Configurator. CONF401 supports Windows platform (95, 98, 2000, XP and NT) and UNIX. It provides a
simple configuration, field device monitoring, and ability to analyze data and m odify field device
performance. The HPC401 is the most up-to-date technology in Palm Handheld portable computers.
The operation and use characteristics of each one of the configurators are in their specific manuals.
3.1
Figure 3.1 and 3.2 show Palm and CONF401 screen with active advanced configuration.
CONTRAST
ON/OFF
HPC
APPLICATIONS 301
BUTTON
GRAY
KEYBOARD
Figure 3.1 – Smar Configurator
Figure 3.2 - CONF401 Screen - Active Advanced Configuration
3.2
Configuration
Configuration Resources
®
By means of Hart configurator, the FY301 firmware allows the following configuration features to be
accessed:
• Positioner’s Identification and Manufacturing Data;
• Remote movement;
• Monitoring of all device variables: input, setpoint, deviation and modulated output temperature;
• Diagnostic (Preventive Maintenance);
• Positioner diagnostic and fail determination;
• PID Controller Configuration;
• Device Configuration;
• Device Maintenance.
The operations between the configurator and t he positioner, do not interrupt the cylinder position
measurement, and do not disturb the output signal. The configurator can be connected to the same pair
of wires as the 4-20 mA signal, up to 2 kilometers away from the positioner.
Identification and Manufacturing Data

The following information about the FY301 positioner manufacturing and identification data is available:
 TAG - 8-character alphanumeric field for identification of the positioner.
 DESCRIPTION - 16-character alphanumeric field for additional identification of the positioner. May
be used to identify service or location.
 MESSAGE - 32-character alphanumeric field for any other information, such as the name of the
person who made the last calibration, some special care to be taken, or if a ladder is needed for
physical access to the positioner.
 DATE - The date may be used to identify a relevant date, such as the last calibration, the next
calibration or the installation. The date is presented in the American standard e.g. (Example: Oct 30,
2003) is automatically assumed after the choice of these items.
 UNIQUE ID - Used to identify the device and in construction of Hart® long address.
 DEVICE INFORMATION - This button allows to read device identification and data recorded in the
factory.
NOTE
These information items cannot be modified. They are read directly from the circuit memory.
Monitoring
This function allows remote monitoring of positioner variables. The time to start the reading is around 5
seconds. The values are always updated. Altogether, 20 items could be monitored. These items are:
cylinder actual position in percentage, input in percentage of adjusted current range, input current in
mA or %, device temperature in Celsius and in Fahrenheit degrees, etc.
Device Configuration
Besides the configuration services for equipment operation, the FY301 positioner allows self-
configuration. Services from this group are related to: write protection, and local indication.
 WRITE PROTECTION: The configurator only shows that the writing is authorized if the W2 jumper
from main board is connected to the pins under the word DOWN.
3.3
LOCAL INDICATION - The FY301 local indicator has three well-defined fields: information field with
icons informing the active status of the configuration, 4 ½ numerical digit fields to value indication and
alphanumeric field with 5-digit for status information and units.
The FY301 accepts up to two local indicator configurations, showed with a 2 seconds pause between
each one. The parameters that can be selected to visualization are showed below in table.
PARAMETERS DESCRIPTION
PV % Process variable in percentage.
PV (mm) Process variable in mm.
SP % Setpoint in percentage.
SP(mm) Setpoint in mm.
Advanced Configuration
This function affects actuator advanced configurations. With advanced configuration is possible to
configure if it is air-to-open or air-to-close, cylinder action, setpoint limits and split-range.
Device Maintenance
This group includes maintenance services, related to obtainment of necessary information to the device
maintenance and performance test. Some of the available services are: position adjustment and
performance test, general information about the actuator, operations count, password level, code
number model and performance.
Trim
There are two trim operations: current trim and temperature trim. Current trim allows to calibrate the
positioner input current reading and temperature trim is the temperature reference to the positioner
temperature sensor.
There are two current trims available:

4 mA TRIM: is used to adjust the input current reading correspondent to 0%.
20 mA TRIM: is used to adjust the input current reading correspondent to 100%.
Setup
This function allows to calibrate the cylinder travel automatically (Auto Setup), the points of the totally
opened or totally closed travel with higher precision (lower and higher position), to adjust the opening
and closing times and the proportional and integral actions of PI control, the state of air supply, the
magnet, the sensor Hall, setup and the piezo voltage conditions.
During the setup process, the FY301 positioner takes the following steps:
10% - It opens or closes the cylinder, depending on the initial value of the piezo voltage;
20% - The positioner checks if the flat cable is connected, or if the Hall sensor is working properly. In
case of error, the message “HALL” will appear at local indicator;
30% - The positioner checks whether the magnet is used;
40% - At this point, the positioner opens or closes the cylinder, depending on the initial position. Case
the spool is obstructed or if the positioner has no air supply, the message “FAIL MOVE” will appear in
the local indicator.
50% - At this moment, the positioner checks if the magnet is connected. If not, the message “MGNT”
will appear in the local indicator;
60% - The positioner places the cylinder to 50%. The setup process could remain at this step if the Kp
value is low;
70% - At this moment, the cylinder is close to 50%. The setup process could remain at this step, if the
Kp value is high;
3.4
Configuration
80% - The positioner adjusts its internal references to place the valve in 50%. The setup process could
remain at this step, if the Kp value is high;
90% - The positioner checks if the magnet is correctly mounted (arrow in arrow). If not, the message
“MGNT” will appear in the local indicator;
100% - End of setup;
Multidrop Configuration
ADDRESSING - FY301 contains a variable that define the device address in a HART network. HART
addresses assume values from "0" to "15", the addresses "1" to "15" are specific addresses to
multidrop connection. When FY301 is configured to multidrop, it means that the local indicator is
showing “MD” and the address is a value from "1" to "15". FY301 is factory configured with address "0".
Diagnostic
This function allows engineering unit configuration, the parameters to diagnostic purposes and shows
positioner general conditions.
Backup
Data transference from transducer to main board must be done immediately after the assembly when
there is a transducer or main board substitution.
This process is automatically done when the positioner is powered. If necessary, the user could force
transference using the option read from sensor.
The option write on sensor could be used to record changes previously made, for example, in Kp, Tr,
etc., in transducer memory. The previous values for Kp, Tr, etc. will be lost.
Pressure Sensor
This function allows pressure trim adjustment, to view applied pressure status and to configure
positioner input pressure in order to activate the alarm via HART communication, in case the applied
input pressures are not in accordance with configured values.
Factory
This option is used only in the factory, and the user cannot access it.
3.5
3.6
Section 4
LOCAL ADJUSTMENT PROGRAMMING
To enable local adjustment, move the W1 jumper to “ON”. This jumper is located on top of the main
electronic circuit board.
There are two orifices on the positioner, under the nameplate, identified by “S” and “Z” respectively,
which provide access to two magnetic switches actuated by means of a magnetic tool (Refer to
figure 4.1).
NOTE
In this section, the “Magnetic Tool” will be referred to as “TOOL”, and the orifices identified by “S” and “Z”
will be “ORIFICE S” and “ORIFICE Z”, respectively.
Figure 4.1 - Local Adjustment Orifices
The table indicates the results for the actions on orifices “Z” and “S” in FY301.
ORIFICE ACTION
Z Function browsing.
S Selects the displayed function.
The digital display is required in order to show the programming performed via local adjustment.
W1 and W2 Jumpers Connection

W1 jumper connected in ON (See figure 4.2):
If W1 jumper is connected in ON, adjustment local enabled, the parameters of the programming
tree can be modified.
W2 jumper connected in DOWN (See figure 4.2):

With W2 jumper connected in this mode, write protected, the positioner protects the configuration
against improper modifications.
4.1
UP - Enable Writing
DOWN - Disable Writing
OFF - Disable Local Adjustment
ON - Enable Local Adjustment
Jumpers
Figure 4.2 - W1 and W2 Jumpers

Local Programming Tree
The programming tree is a tree shaped structure with a menu of all available software functions, as
shown on figure 4.3.
While in local adjustment, it is possible to browse through all configuration options by keeping the
magnetic tool in orifice “Z”. Upon choosing the option as described, place the tool in orifice “S” in
order to actuate.
By keeping the tool in orifice “S” it is possible to continuously actuate the selected parameter, since
this is a numeric value. Actions by increment are performed by repeatedly placing and removing the
magnetic tool until reaching the desired valve.
DISPLAY
Z Z Z Z Z Z Z
SP% MODE CHAR TYPE AIR_T SETUP TR TR
S S S S
Op Auto Lin Lind
Man EP50 Linr
HY50 Rotd
Tab Rotr
Z Z
Z Z Z Z Z Z Z Z
SP% LOPOS LOPOS UPPOS UPPOS TIME TIME KP KP
S ACTION
(*)The CHAR function is available for
valve positioner applications.
Z ROTATION
Figure 4.3 - Local Programming Tree

NOTE
The user shall perform every parameter actuation judiciously, since actuation writes configuration
parameters on a permanent basis and does not require confirmation. Once an actuation is performed it is
assumed to be the desired configuration.
4.2
Local Adjustment Programming
Adjustable Parameters
TYPE - Act Type
This parameter enables the user to configure action type. These are the options:
For Linear ACP:
 Lind: Linear and Direct;
 Linr: Linear and Reverse;
For Rotary ACP:
 Rotd: Rotary and Direct;
 Rotr: Rotary and Reverse.
Setup - Auto Positioning

After configuring the action type by means of parameter TYPE, the AUTO SETUP parameter shall
be actuated. During the adjustment procedure the positioner will be i n a s tate of auto positioning
and the message "SETUP” will be flashing on the display.
During this process the control parameters are determined and the 0% and 100% trim is performed.
This operation lasts approximately 4 minutes. While configuring the action type as described above,
the user shall browse up to parameter SETUP (tool in orifice Z) and pl ace the tool in orifice S in
order to initiate the previous auto positioning of the cylinder.
NOTE
Not for ACP
CHAR - Valve Characterization Curve
This parameter allows the user to configure the type of valve characterization curve. Options are as follows:
Lin: Linear;
EP50: Equal Percentage 50%;
HY: Hyperbolic.
MODE - Operation Mode

This parameter allows the user to choose operation mode. Upon turning the positioner on, it will
always be in automatic mode, but it is possible to choose the operation mode. During operation
there are the following options:
Auto - Automatic Mode
During automatic mode the positions is set in accordance with the input 4 to 20 mA current
signal. While in automatic mode, local actuation in the SP% parameter is not allowed.
Man - Manual Mode
During manual mode the position is set in accordance with the SP% parameter value,
independently from the input current. This is the only mode in which the SP% parameter can be
actuated.
SP % - Set Point
This parameter represents the desired position value. While in "Manual" mode, it is possible to
actuate this parameter remotely, independently from the input current. While in automatic, it is
calculated from the input current level.
LOPOS - Lower Position
This parameter allows the lower position calibration as per the input current, usually 4 mA unless it
is in split range operation. During calibration, notice if the control becomes saturated, that is, if the
cylinder no longer moves in the desired direction. Should such a s ituation occur, the user shall
actuate in the opposite direction to the cylinder movement. Calibration is performed in terms of
percentage.
UPPOS - Upper Position
This parameter allows the upper position calibration as per the input current, usually 20 mA unless
it is in split range operation. During calibration, notice if the control becomes saturated, that is, if the
cylinder no longer moves in the desired direction. If such a situation occur, the user shall actuate in
the opposite direction to the cylinder movement. Calibration is performed in terms of percentage.
TIME - Setpoint Variation Time

This allows the configuration of the setpoint variation rate. The unit is expressed in seconds. It is
adjustable in the following range: 1 to 60.
4.3
KP - Proportional Gain
This parameter makes it possible to adjust the servo control proportional gain. It is adjustable within
the following range: 0.5 to 45.
TR - Integral Time
This parameter makes possible to adjust the servo control integral time. It is adjustable within the
following range: 0 to 999 minutes/repetition.
Procedure for Valve Calibration

STEP 1
Select action type by means of the menu TYPE, browsing at least once through the options (Lind,
Linr, Rotd, and Rotr).
STEP 2
Setup
In order to start self-calibration, browse up to the parameter SETUP and insert the tool in S.
NOTE
In most cases, steps 1 and 2 are sufficient to provide a good calibration.
STEP 3
Set the KP to lower the value overshoot (the overshoot will require adjustment after the TIME as
adjusted). The lower the KP is, the lower the overshoot will be, but cylinder positioning will be
slower. Set TR in a value where the position does not oscillate and c ontrol is capable of quickly
reaching the final position.
STEP 4
Time Adjustment (TIME)
Perform TIME adjustment for quick open.
STEP 5
Zero Adjustment by means of LOPOS (Lower Position)
At this moment, current shall be i n the position that corresponds to 0% as, for example, 4 mA. A
more practical way of performing this adjustment is to place the tool in orifice S, thus allowing the
parameter to be continually actuated (increased or decreased). Upon noticing the valve action
around the desired point, remove the tool from orifice S and slowly alter its value on an increment-
by-increment basis, that is, by repeatedly placing and removing the tool in orifice S until reaching
the desired point. At a c ertain point, it is more convenient to perform the adjustment on an
increment-by-increment basis to avoid the risk of passing beyond the desired value.
STEP 6
Span Adjustment by means of UPPOS (Upper Position).
At this moment, current shall be in the position that corresponds to 100% as, for example, 20 mA.
The procedure is similar to the one described for zero adjustment.
STEP 7
Air to Close / Air to Open (AIR_T)
This option configures the air pressure effect on the positioner.
If the positioner operates in “direct action”:
• It should be configured for AIR_OPEN, if the air is to open
• It should be configured for AIR_CLOSED, if the air is to close
In case the positioner is operating in “reverse action”:
• It should be configured for AIR_OPEN, if the air is to close
• It should be configured for AIR_CLOSED, if the air is to open
4.4
Section 5
MAINTENANCE PROCEDURES
Linear Model
In the maintenance of ACP301 Linear, the state of conservation of the components should be
observed below mentioned, and the substitution of each one of them is recommended to each
1.000.000 cycles, or in case of waste very accentuated excessively due to the work atmosphere
aggressive (dust excessive, or abrasive). The components that need periodic visual inspection are:
• rotary bush
• rule
• rod with protection below
• bush support
• bush column
• column
• stem prolongation protection of the cylinder
• pneumatic cylinder
After the maintenance or repair of any item, it is recommended to setup the equipment.
Figure 5.1 - Linear ACP
Disassembling Procedure - Linear ACP

Installation Procedure - Linear ACP
The instructions below indicate the procedure of ACP301L assembly - Linear Pneumatic Cylinder
Actuator:
1. Remove the FY301 positioner air connections of the ACP301 and of the cylinder. To
disassemble the FY301 positioner of ACP301 of cylinder and bracket, remove with an appropriate
key - the screws that fix the support of the FY301 positioner to the cylinder.
5.1
Figure 5.2 - Disassembling the Positioner of the Cylinder
2. Disassemble the magnet of the bracket installed in the cylinder. Detail of the unfastening of the
Allen screw. The other figure shows how to loosen the screws with Allen key.
Figure 5.3 - Disassembling the bracket Figure 5.4 - Loosening the Screws with
magnet Allen key
3. Loosen the nuts of the U clamp with a 13 mm key, to loosen it of the actuator, offering mobility
to the cylinder tip. Disconnect the clevis, uninstall the fixing plate ring, that has the function of
facilitating fixation and alignment of rule/roller system. Disassemble the set removing the rule of the
cylinder tip.
Figure 5.5 - Unfasten the “U” Clamp Figure 5.6 - Disconnecting the Clevis
Screws
4. Remove the FY301 positioner bracket loosening the Allen screws with an appropriate key. The
bracket disassembling is showed below.
5.2
Maintenance Procedures
Figure 5.7 - Disassembling the FY301 Figure 5.8 - Unfasten the Allen Screws
Positioner Bracket
5. Disassemble the fixed roller. Loosen it with help of a key number 10.
Figure 5.9 - Disassembling the Fixed Roller
6. Disassemble the rule. The disassembling should be made using the side of rule internal
contour. The rollers function as a support and your material was chosen to minimum attrition with
the rule. The rollers were also covered with a layer to avoid dust accumulation and to difficult
locking with the rule.
Figure 5.10 - Rule Disassembling
5.3
7. Disassemble the mobile base subset.
Figure 5.11 - Mobile Base Sub Set before Figure 5.12 - Disassembling the Mobile
Disassemble Base Sub Set
8. Loosen the mobile roller of the mobile base, remove the allen (without head) type screw, with
help of a 2.5 mm allen key. Disassemble the mobile roller with rolling of the bracket.
Figure 5.13 - Loosening the mobile roller of Figure 5.14 - Disassembling the mobile
the mobile base roller
9. Disassemble the bush removing spring and bellow set.
Figure 5.15 - Disassembling Spring and Below Set

Rotary Model
In the maintenance of Rotary ACP301 the conservation state of the components should be
observed, being recommended the substitution of each one of them to each 1.000.000 cycles, or in
case of excessively waste due to work in aggressive conditions (excessive or abrasive dust). The
components that need inspection are:
• joint;
• spacing washer;
• stem prolongation protection of the cylinder.
After the maintenance or repair of any item, it is recommended to setup the equipment.
5.4
ACP Positioner
FY301 Valve Positioners of ACP301 are extensively tested and inspected before delivered to the
end user. Nevertheless, during their design and development, consideration was given to the
possibility of repairs by the end user, if necessary.
In general, it is recommended that the end user do not try to repair printed circuit boards. Instead,
he should have spare circuit boards, which may be ordered from Smar whenever necessary.
The maintenance procedure is a set of techniques with the purpose to keep the positioners of
ACP301 with higher time of use (useful life), to operate in safe conditions and to promote costs
reduction. The different maintenance types are described during this section.
Corrective Maintenance for the ACP301 Positioner

Maintenance not planned, with the purpose to locate and to repair problems in the of ACP301
positioners operating in continuous work, or either, specifically to suppress defects already
presented by the equipment.
The diagnostic are a set of methods to detect, to locate and eventually to correct errors and
problems or even verify fail effects in the ACP301 positioner.
ACP301 Positioner Diagnostics without Configurator

In order to carry out the diagnostics, refer to table below.
DIAGNOSTICS
SYMPTOM PROBABLE ERROR SOURCE

Positioner Connections
Check wiring polarity and continuity.
POSITION Power Supply must be a current source
SHOWN ON DISPLAY Check signal input current. Minimum current for positioner operation is 3.8 mA.
Electronics Failure
Check circuit boards for bad connections and replace them for spare boards.
Pressure Output Connections
Check up on air leaks.
Air Supply Pressure

Check the air supply pressure. The input pressure to positioner shall be between 20 psi and
NO RESPONSE 100 psi.
TO INPUT SIGNAL
Calibration
Check the positioner calibration points.
Obstructed Restriction and/or Blocked Output

Observe the following procedures described in this Manual: Output Connections and
Restriction Cleaning.
OSCILLATING Calibration
Adjust parameter Kp.
ACTUATOR
Adjust parameter Tr.
SLOW ACTUATOR Adjustment Parameters are Too Low
RESPONSE Adjust parameter Kp or Time to Open or Time to Close.
TOO FAST ACTUATOR Adjustment Parameters are Too High
RESPONSE Adjust parameter Kp or Time to Open or Time to Close.
Table 5.1 - FY301 Diagnostics without the Configurator
5.5
ACP301 Positioner Diagnostics with Configurator

If the ACP301 positioner is on and with the communication circuit and the processing unit working,
the configurator can be used for diagnostic, in case of problems with the ACP301 positioner. The
configurator should be connected to the ACP301 positioner according to the wiring diagrams show
on Section 1.
Error Messages
The error messages inform the diagnostic through the self diagnostic of errors and malfunctioning.
When the configurator is communicating with the ACP301 positioner, the user is informed on any
problem found, through the self diagnostic. At the ACP301 positioner, the error messages always
alternate with the information on the top line of the configurator’s display. Table 5.2 lists the error
messages and more details on corrective action.
ERROR MESSAGES POTENTIAL SOURCE OF PROBLEM

PARITY ERROR - The line resistance is not according to the technical characteristics.
OVERRUN ERROR - Excessive noise or ripple.
CHECK SUM ERROR - Low level signal.
- Interface damaged.
FRAMING ERROR
- Power supply or battery voltage of the configurator lower than 9 V.
- Positioner line resistance is not according to technical characteristics.
- Positioner not powered.
- Positioner not connected or damaged.
NO RESPONSE - Positioner configured in multidrop mode being accessed by ON LINE SINGLE UNIT.
- Positioner reversibly powered (polarity is reversed).
- Interface damaged.
- Power supply or battery voltage of the configurator lower than 9 V.
LINE BUSY - Other device using the line.
CMD NOT IMPLEMENTED - Software version not compatible between configurator and positioner.
DEVICE BUSY - Positioner carrying out an important task, e.g., local adjustment.
- Voltage to pressure transducer disconnected.
POSITIONER MALFUNCTION
- Voltage to pressure transducer failure.
COLD START - Start-up or reset due to power supply failure.
- Operating in local mode with fix position.
OUTPUT FIXED
- Connected in burnout.
OUTPUT SATURATED - Position out of calibrated span or in fail-safe (Output current in 3.9 or 21 mA).
- Temperature out of operating limits.
2 OUT OF LIMITS
- Temperature sensor damaged.
- Position out of operation valve range.
1 OUT OF LIMITS - Voltage to pressure transducer damaged or not connected.
- Positioner with error configuration.
LOWER RANGE VALUE TOO HIGH - The lower range value > (Upper limit of minimum span range).
LOWER RANGE VALUE TOO LOW - The lower range value < (Upper limit of range).
UPPER RANGE VALUE TOO HIGH - The upper range value > 110 % x (Upper limit of range).
UPPER RANGE VALUE TOO LOW - The upper range value < - 10 % (Lower limit of range).
UPPER AND LOWER RANGE VALUES
- Both the upper and lower points are outside the positioner range limit.
OUT OF LIMITS
- The difference, between the upper and lower points, is less than the allowed by the
SPAN TOO SMALL
positioner.
ACTUAL POSITION - The actual valve position was above of the upper range limit.
ACTUAL POSITION - The actual valve position was below of the lower range limit.
PASSED PARAMETER TOO LARGE - Parameter above operating limits.
PASSED PARAMETER TOO SMALL - Parameter below operating limits.
CONTROL LOOP SHOULD BE IN
- Indicates that the operation could affect the output.
MANUAL
CONTROL LOOP MAY BE RETURNED - After the operation is complete, you are reminded to return the loop to automatic
TO AUTO control.
Table 5.2 – FY301 Diagnostics with the Configurator
5.6
ACP301 Positioner Disassembly Procedure for Maintenance

1. Insert air pressure in the ACP301 positioner input, without applying power supply. Verify if
occurs air pressure leakage in output 1 (OUT1). In case of pressure leakage in output 1,
an analysis of the mechanical parts is indicated.
2. Remove the restriction. Verify if the restriction is not obstructed. (See restriction cleaning
procedure).
3. Disassemble the equipment as shown:
Figure 5.1 - ACP301 Positioner Disassembled
Maintenance – Mechanical Parts
1. Verify if the spool is moving freely.
2. Verify if the spool is not obstructed with dirty.
3. Verify if does not have obstructed way in the FY pneumatic block and in the exhaustion ways.
4. Verify if the diaphragm is not damaged.
5. Verify if the piezo isolating cover has holes.
6. Verify if the nozzle is with dirty.
Maintenance – Electronic Parts
Positioner Electronic Circuit

NOTE
The numbers indicated between parentheses refer to ACP301 positioner exploded view.
To remove the plate of the circuit (5) and the indicator (4), first release the cover locking bolt (6)
from the side not marked "Field Terminals", and after that release the cover (1).
ATTENTION
The circuit boards have CMOS components that can be damaged by electrostatic discharges. Verify the correct
procedures to manipulate CMOS components. Also it is recommended to store the circuit boards in packs with
electrostatic load proof.
Release the two screws (3) that fix the main board circuit and of the indicator. Pull out the indicator,
after the main board (5).
Verify the firmware version; must be version 2.12, 2.13 or higher. Mount the equipment; apply
pressure supply of 30 psi and power on the equipment. When the equipment do not initializes, the
display does not light on, proceed with the following procedures:
5.7
1. Disconnect the analog board from the digital board;
2. Case the equipment initializes, change the GLL1012, if it does not change the GLL1011.
Proceed with the setup. After the setup, verify if the ACP301 positioner is working properly. For that,
apply 12mA and be sure that the valve goes to the position correspondent to the 50% of the valve
travel. If it does not occur, do the following:
1. In case you do not have the software, use a GLL1011;
2. Apply 4 mA and verify through the configurator if SP% is equal to 0%;
3. Apply 20 mA and verify through the configurator if SP% is equal to 100%;
4. If the values above were different, execute the 4 mA and 20 mA current trim;
5. Verify the Hall reading through the configurator. Apply pressure directly to the valve actuator
and verify if there is modification in the Hall reading (65000 means that the Hall is not being
read) and the defect can be the GLL1012 or GLL1019;
6. Verify the piezo voltage in the configurator;
7. The piezo voltage value must be between 30 and 70 Volts.
To verify the Hall value and the piezo voltage, do the following:
• Set the valve in 50% of the opening or closing travel;
• With the configurator, go to the “monitoring” mode and choose two parameters: Hall value and
piezo voltage;
• The piezo voltage values must be the most closed possible to 26000 to 38000;
• The piezo voltage values must be between 30 and 70 Volts. If the voltage is not between these
values, proceed with the piezo calibration.
Preventive Maintenance for the ACP301 Positioner

Planned Maintenance, consists in the set of procedures and anticipated actions to keep the device
functioning, is effectuate with the special objective to prevent the occurrence of fail. Through
adjustments, proves and measures according to the specified values, made before the appearing of
defects. The preventive maintenance is recommended in the maximum period of one (1) year, or
when the process stops.
ACP301 Positioner Disassembly Procedure

Transducer
To remove the transducer from the electronic housing, the electrical connections (in the field
terminal side) and the main board connector must be disconnected.
Loosen the hex screw (6) and carefully unscrew the electronic housing from the transducer,
observing that the flat cable is not excessively twisted.
CAUTION
Do not rotate the electronic housing more than 270° without disconnecting the electronic circuit from the power
supply.
5.8
Figure 5.2 – Transducer Rotation
NOTE
The numbers indicated between parentheses refer to Figure 5.25 – Exploded View.
Figure 5.17 - Transducer Rotation Stopper
1. Remove the cover Allen fixing screw of the flat cable. (This part can not be washed);
2. Remove the flat cable cover. When removing this cover, take care to do not damage the internal
boards, disassembly with care. (This part can not be washed);
3. Remove the analog board GLL1012 ;
4. Remove the electric piezo base (This part can not be washed);
5. Remove the piezo restriction for cleaning;
6. Remove the diaphragm for analysis and cleaning with water and neutral detergent; after that,
wash with alcohol, dry before mounting;
7. Remove the spool valve; the cleaning is made with water and neutral detergent; after that, wash
with alcohol, dry before mounting. This part must be mounted without lubrication;
8. The pneumatic block can be completely washed with water and neutral detergent, after that,
wash with alcohol and verify if it is completely clean, without dust. For that, apply compressed
air in all positioner orifices;
9. Verify if the Hall cover does not have indication of water infiltration. (This part can not be
washed);
10. Verify if the GLL1019 (Hall flat cable) is damaged, curved, cut or oxidate.
ACP301 Positioner Assembly Procedure

To assembly the positioner:
1. Mount the piezoelectric sensor in the jig;
2. Apply 20 PSI in the air pressure input;
3. Apply 0 Volts, after that 100 Volts DC and after 0 Volts again (to avoid hysteretic error);
4. Apply 50 Volts DC to the piezoelectric sensor;
5. Verify the pilot chamber pressure measured in the correspondent manometer. The pressure
must be between 5.8 and 6.2 PSI. In case it is different, made the adjustment rotating the
superior disc of piezoelectric sensor set;
5.9
6. Once reached the previous adjustment, apply 0 Volts again and verify that the pressure in the
pilot chamber must be between 2 PSI. After that, apply 100 Volts and verify that the pressure
must be between 12 and 13 PSI;
7. Apply 50 Volts AC to the piezoelectric sensor. Verify the pilot chamber pressure measured in
manometer, it must be between 5.8 and 6.2 PSI. In case it is different, made the adjustment
again and rotating the superior disc of piezoelectric sensor set and repeating the procedure, to
reach the specified values.
8. When these values are reached, the piezoelectric sensor is already calibrated;
9. After the piezoelectric sensor calibration, proceed with the final verification of the positioner;
10. Mount all positioner set with the calibrated piezoelectric sensor;
11. Made a setup in the positioner;
12. If the piezoelectric sensor voltage is not at indicated range, means that the piezoelectric
sensor needs a new calibration or it needs to be changed.
Restriction Cleaning Procedure

The air flows to the nozzle through a restriction. Verify from time to time the restriction cleaning to
assure a positioner good performance.
1. Be sure that the air supply of the equipment is blocked.
Figure 5.18 – ACP Positioner

2. With an appropriate tool, remove the transducer serial number plate. (New models have
the plate placed on the opposite side of the transducer).
Figure 5.19 - Remove the Transducer Figure 5.20 - Transducer Serial

Serial Number Plate Number Plate Removed
3. Remove the restriction screw using an adequate tool;
5.10
Figure 5.21 - Removing Restriction Screw
4. Remove the o-ring’s with an appropriate tool;
5. Dive the part in petroleum base solvent and dry it with compressed air (apply the
compressed air directly in the smaller orifice for the air to get out through the bigger
orifice).
6. Introduce the appropriate tool (PN 400-0726) into the restriction orifice to prevent any
possible obstruction;
Figure 5.22 – Needle Cleaning Device for Figure 5.23 – Needle in the Restriction
the Restriction and Restriction Orifice (Restriction Cleaning Procedure)
7. Mount the o-rings again and screw the restriction in the positioner.
8. The equipment can be supplied with air again.
Change of the Filter Elements of ACP301 Positioner

Change the ACP301 positioner filter elements with a minimum stated period of 1 (one) year.
The instrumentation air supply must be clean, dry and non-corrosive, following standards indicated
for the American National Standard “Quality Standard for Instrument Air" - (ANSI/ISA S7.0.01 -
1996).
If the instrumentation air does not comply with the above mentioned standards, the user has to
consider changing the ACP301 positioner filter elements more frequently.
ACP301 Positioner Exhausts Ports

Air is vented to the atmosphere through the two exhausts ports located behind the transducer
nameplate and 4 output of the opposite side from gage. A foreign object interfering or blocking
exhaust port provides a way to increase the output. Cleaning by spraying it with a solvent.
ATTENTION
Never use oil or grease in the spool; otherwise the positioner performance will be impaired.
5.11
Electronic Circuit
Plug transducer connector and power supply connector to main board (5). Attach the display to the
main board. Observe the four possible mounting positions. The 5 mark indicates up position.
Anchor the main board and indicator with their screws (3). After tightening the protective cover (1),
mounting procedure is complete. The ACP301 positioner is ready to be energized and tested.
ELECTRICAL CONNECTIONS
The plug must obligatorily be installed in the electric connection that will not be used, preventing the
humidity accumulation. We suggested you to use a sealant on the thread closed by a firm squeeze.
It is also certified if the two housing covers are firmly tight.
NOTE
The plug with sealant from factory is not certified for use in explosion proof installations.
Figure 5.24 - Possible Positions for the Display
Pneumatic Cylinder Maintenance

The maintenance of the pneumatic cylinder should not be made with the equipment in the field. It is
recommended to proceed with maintenance in a clean workbench and provided of compressed air.
The cylinder is auto-lubricated and doesn't need additional lubrication. In case the user decides for
lubricating the cylinder, it will lose the warranty coverings of the product besides the decrease of
useful life of FY301 positioner and of the cylinder.
The table below represents a basic orientation about the problems, probable causes and solutions
for maintenance of the pneumatic cylinder.
Basic orientation of problems, probable causes and solutions

Problem Probable causes Solutions
- change sealings
Leak for the opposite orifice - piston sealings damaged
- change cover
to the air input - striped cylinder cover
- verify air filter
- change sealings
- damaged sealings
Leak for the stem sealing - change stem
- striped stem
- protection below of the rod
Leak for the screw of
- damaged sealings - change sealings
damping adjustment
Leak for the cover junction
- damaged sealings - change sealings
with the heads
5.12
In the case of third part cylinders, Smar is not responsible in case the equipment doesn't offer stem
prolongation protection of the cylinder, because there is not how to guarantee the attrition
prevention and subsequent waste of the stem.
Package Content
When receiving the equipment, verify the package content. The number for items marked with (*)
must be in accordance with the number of positioners.
• ACP301 Positioner Set / Cylinder

• Magnetic tool for local adjustment (*)
• Centralizer transmitter device (*)
• Cleaning device for the restriction (*)
• Operation, maintenance and instructions manual (*)
5.13
ACP301 Positioner Exploded View
Figure 5.25 – ACP301 Positioner Exploded View
5.14
Accessories
ACCESSORIES
ORDERING CODE DESCRIPTION
SD-1 Magnetic tool for local adjustment.
Hart® HPI311-M5P for the PalmOS platform, including the configuration package for the Smar and generic
HPC401* transmitters.
HPI311-M5P* Just the Hart® interface.
400-0726 Needle cleaning device for the restriction.
* For equipment updates and HPC401 software, just check: http://www.smarresearch.com .
Spare Parts List for ACP301 Positioner
SPARE PARTS LIST

CATEGORY
PARTS DESCRIPTION POSITION CÓDE
(NOTE 4)
HOUSING, Aluminum (NOTE 1)
. 1/2 - 14 NPT 8 301-0340 -
. M20 x 1.5 8 301-0341 -
. PG 13.5 DIN 8 301-0342 -
HOUSING, 316 SS (NOTE 1)
. 1/2 - 14 NPT 8 301-0343 -
. M20 x 1.5 8 301-0344 -
. PG 13.5 DIN 8 301-0345 -
COVER (INCLUDES O-RING)
. Aluminum 1 e 13 204-0102 -
. 316 SS 1 e 13 204-0105 -
COVER WITH WINDOW FOR DISPLAY (INCLUDES O-RING)
. Aluminum 1 204-0103 -
. 316 SS 1 204-0106 -
COVER LOCKING BOLT 6 204-0120 -
SENSOR LOCKING BOLT
. M6 Without Head Screw 7 400-1121 -
EXTERNAL GROUND BOLT 14 204-0124 -
IDENTIFICATION PLATE FIXING BOLT 9 204-0116 -
-
DIGITAL INDICATOR 4 214-0108 A
TERMINAL INSULATOR 11 400-0058 A
MAIN ELECTRONIC CIRCUIT BOARD 5 209-0230 A
O-RINGS COVER (NOTE 2)
. Buna-N 2 204-0122 B
TERMINAL HOLDING BOLT HOUSING
. Housing in 316 Aluminum 12 304-0119 B
. Housing in 316 Stainless Steel 12 204-0119 B
MAIN BOARD BOLT HOUSING IN ALUMINUM 3 304-0118 B
. Units with indicator 3 304-0117 B
. Units without indicator
MAIN BOARD BOLT HOUSING IN 316 STAINLESS STEEL 3 204-0118 B
. Units with indicator 3 204-0117 B
. Units without indicator
ALUMINUM CONNECTION COVER 15,16,17 and 18 400-0643 A
316 STAINLESS STEEL CONNECTION COVER 15,16,17 and 18 400-0644 A
. Connection Cover Bolt 15 400-0073 -

. Buna-N Neck O-ring 16 204-0113 B
. Assembled Connection Cover - Aluminum 17 400-0074 -
. Assembled Connection Cover - 316 Stainless Steel 17 400-0391 -
. Analog Board without Pressure Sensor GLL1012 18 400-0060 -
. Analog Board for Pressure Sensor GLL1204 18 400-0840 -
5.15
SPARE PARTS LIST

CATEGORY
(NOTE 4)
PIEZO BASE SET – ALUMINUM 19,20,21,22, 23,24 and 25 400-0645 A
PIEZO BASE SET – 316 STAINLESS STEEL 19,20,21,22, 23,24 and 25 400-0646 A
. Base and Block O-ring 19 400-0085 B
. Restriction 20 344-0165 B
. Restriction External O-ring 21 344-0155 B
. Restriction Internal O-ring 22 344-0150 B
. Syntherized Bushing 23 400-0033 B
. Assembled Base – Aluminum 24 400-0075 A
. Assembled Base – 316 Stainless Steel 24 400-0392 A
. Analog indicator (Gage - 316 Stainless Steel and Brass) (NOTE 6) 25 400-1120 B
. Identification tag bolt 26 344-0160 -

. Assembled diaphragm – Aluminum 27 400-0649 B
. Assembled diaphragm – 316 Stainless Steel 27 400-0650 B
A
ALUMINUM BLOCK SET 19,23,25,28,29,30,31 and 32 400-0651 A
316 STAINLESS STEEL BLOCK SET 19,23,25,28,29,30,31 and 32 400-0652
A
ALUMINUM BLOCK SET WITH PRESSURE SENSOR 19,23,25,28,29,30,31 and 32 400-1072
400-1073 A
316 STAINLESS STEEL BLOCK SET WITH PRESSURE SENSOR 19,23,25,28,29,30,31 and 32
400-0085 -
. Base & Block O-ring 19
400-0033 -
. Syntherized Bushing 23
400-1120 -
. Analog indicator (Gage - 316 Stainless Steel and Brass) (NOTE 6) 25
400-0655 -
. Filtering Element 28
400-0653 A
. Spool valve 29
400-0787 -
. Spool valve Spring 40
. 304 Stainless steel Filter- 1/4" NPT - includes filtering element 30 101B3403
400-0082 B
. Assembled Block– Aluminum 31
400-0394 -
. Assembled Block – 316 Stainless Steel 31
400-0654 -
. Vent Plug - 316 Stainless Steel 32
-
ALUMINUM HALL COVER SET 33,34 and 35 400-0656 A
316 STAINLESS STEEL HALL COVER SET 33,34 and 35 400-0657 A
. Aluminum Hall Cover Set 33 400-0089 -
. 316 Stainless Steel Hall Cover Set 33 400-0396 -
. Hall Cover Bolt 34 400-0092 -
. Hall Support + Hall Sensor + Flat cable 35 400-0090 B
ALUMINUM REMOTE HALL COVER SET (NOTE 5) 36 400-0853 -
316 STAINLESS STEEL REMOTE HALL COVER SET (NOTE 5) 36 400-0854 -
ALUMINUM REMOTE EXTENSION SET 38 400-0855 -
316 STAINLESS STEEL REMOTE EXTENSION SET 38 400-0856 -
CABLE SET + CONNECTOR, 5M 37 400-0857 -
1/2" NPT (Ex d) INTERNAL SOCKET SET PLUG IN BICHROMATIZED 39 400-0808 -
CARBON STEEL
1/2" NPT (Ex d) INTERNAL SOCKET SET PLUG IN 304 SST 39 400-0809
-
1/2" NPT INTERNAL SOCKET SET PLUG IN BICHROMATIZED CARBON
39 400-0583-11
STEEL -
39 400-0583-12
1/2" NPT INTERNAL SOCKET SET PLUG IN 304 SST -
M20 X 1.5 (Ex d) EXTERNAL SOCKET SET PLUG IN 316 SST 39 400-0810 -
PG13.5 (Ex d) EXTERNAL SOCKET SET PLUG IN 316 SST 39 400-0811 -
3/4" NPT (Ex d) ADAPTER IN 316 SST 39 400-0812 -

ALUMINUM TRANSDUCER SET 209-0180 A
NOTE 3
316 STAINLESS STEEL TRANSDUCER SET 400-0399 A
LOCAL ADJUSTMENT PROTECTION COVER 10 204-0114 -
5.16
SPARE PARTS LIST

CATEGORY
(NOTE 4)
MAGNETS
. Linear magnet 15mm - 400-0034 -
. Rotary magnet - 400-0037 -
MOUNTING BRACKET SCREW FOR POSITIONER ASSEMBLY (packaged
- 400-1190 -
with 12 units)
Note
1) Includes terminal isolator, bolts (cover locking, ground and terminal isolator) and identification plate without certification.
2) O-rings are packaged with 12 units.
3) Includes all transducer’s spare parts.
4) For category A it is recommended to keep in stock 25 parts installed for each set and 50 for category B.
5) This code includes the cover, the cable and the connector for the extension cable.
6) The pressure gauges for supply pressure, output 1 or output 2, will be supplied with the wet parts in brass.
5.17
Rotary ACP Exploded View

4
3 11
14
16
15
10
Figure 5.26 - Rotary ACP Exploded View
5.18
Spare Parts List For Rotary ACP301 (ACP301LN)

SPARE PARTS LIST FOR ROTARY ACP301 (ACP301LN)
PARTS DESCRIPTION POSITION CODE CATEGORY

LEVER SUB SET 1 400-0785 A
JOINT BOLT 2 400-0772 A
CLEVIS SPACING WASHER 3 400-0791 B
JOINT BASE 4 400-0774 A
FY301 POSITIONER BRACKET (FOR ROTARY ACP) 5 400-0781 A
FY301 POSITIONER (See positioner exploded view) 6 (FY code) A
PNEUMATIC KIT
(cylinder + protection below + clevis + clevis bolt + air connections) 7 400-0790 A
FIXATION BOLT (OF THE BACK JOINT) 8 400-0786 A
MALE BACK JOINT 9 400-0796 A
FEMALE BACK JOINT 10 400-0797 A
ROTARY MAGNET SET 11 400-0037 A
AIR FILTER REGULATOR FOR ACPRT 12 400-0784 A
MAGNETIC LIMIT SWITCH

Magnetic Limit Switch 100 mm diameter cylinder 13 400-0771 B
CLEVIS 14 400-0800 A
CYLINDER 15 400-0798 A
A – Contains 1 unit.
B – Contains 2 units.
C – Contains 12 units.
5.19
Linear ACP Exploded View
1
2
7
20
5
4
18
13
19
17
10
12
11
21
14
15 16
Figure 5.27 - Linear ACP Exploded View
5.20
Spare Parts List for Linear ACP301 (ACP301LN)

SPARE PARTS LIST FOR LINEAR ACP301 (ACP301LN)
PARTS DESCRIPTION POSITION CODE CATEGORY

FIXED ROLLER 1 400-0758 A
MOBILE ROLLER 2 400-0757 A
FY301 POSITIONER (See positioner exploded view) 3 (FY code) A
MOBILE BASE SUB SET

(mobile base + 2 bushes + 2 stainless steel columns) 4 400-0751 A
SYNTHERIZED SUB SET 5 400-0752 B
RULER IN CARBON STEEL

100mm Ruler 6 400-0760 A
125mm Ruler 6 400-0761 A
160mm Ruler 6 400-0762 A
200mm Ruler 6 400-0763 A
250mm Ruler 6 400-0764 A
320mm Ruler 6 400-0765 A
400mm Ruler 6 400-0766 A
500mm Ruler 6 400-0767 A
630mm Ruler 6 400-0768 A
800mm Ruler 6 400-0769 A
1000mm Ruler 6 400-0770 A
RULER FIXATION PLATE 8 400-0773 A
RULE FIXING PLATE RING

Rule Fixing Plate Ring - 63 mm diameter 9 400-0835 A
Rule Fixing Plate Ring - 80 and 100 mm diameters 9 400-0801 A
RULE FIXING PLATE SET

(rule fixing plate + fixing screws + “U” fixation clamp) 10 400-0759 A
MAGNETIC LIMIT SWITCH

Magnetic Limit Switch for 63/80/100 mm diameters cylinders 11 400-0771 B
Magnetic Limit Switch for 125 mm diameter cylinder 11 400-0802 B
Magnetic Limit Switch for 160 mm diameter cylinder 11 400-0803 B
AIR FILTER REGULATOR FOR ACPLN 12 400-0784 A
CYLINDER 13 400-0798 A
PROTECTION BELLOW 14 400-0799 A
CLEVIS 15 400-0800 A
JOINT BOLT 16 400-0772 A
BRACKET SCREW SET 17 400-0755 C
FY301 POSITIONER BRACKET

FY Bracket for 63/100/160 mm diameters cylinders 18 400-0782 A
FY bracket for 80/125 mm diameters cylinders 18 400-0783 A
SET WITH SPRING AND BELOW 19 400-0753 B
MAGNET SET
50 mm Linear Magnet 20 400-0035 A
PNEUMATIC KIT
(cylinder + protection below + clevis + clevis bolt + air connections) 21 400-0790 A
A – Contains 1 unit. B – Contains 2 units. C – Contains 12 units.
5.21
5.22
Section 6
TECHNICAL CHARACTERISTICS
Cylinder Specifications
ISO Pneumatic Cylinder
The pneumatic cylinder has the following characteristics:
• ISO 6431, VDMA 24562, NFE 49-003-1, BS and CETOP standards.

• Double action
• Double dampening
• Magnetic piston
• Anodized aluminum cover
• Injected aluminum heads
• Piston and rod closing in polyurethane
• Stainless steel rod with protection below and extended rod
• Maximum work pressure for the pneumatic cylinder must be 10 bar
• Work temperature: -20 ºC to 80 ºC
• With female back articulation
• With male bracket for back articulation and pin
• Rod fork with pin
• Diameters of 100 and 125 mm
• Available travels: 100, 200, 400, 500, 800 and 1000 mm.
ACP301 working pressure has to attempt the maximum positioner pressure: 7 bar.
Limit Switch Characteristics

Options
• Magnetic sensor:
- Voltage: 10 to 220 Vac/dc;
Current: 100 mA (maximum).
• External fixing through appropriate bracket
• Protection grade of IP65 sensor
• Independent of FY301 operation must be used only as an indicative system of cylinder position at
end of travels.
Mounting Bracket Characteristics

• The bracket is according to the diameters of ISO6431 cylinders series.
• Materials: Cast aluminum with low magnesium contents, stainless steel, carbon steel with
superficial treatment, bronze and Technyl.
NOTE
Consult Smar for customized applications.
6.1
ISO6431
ISO 6431 norm: “Pneumatic fluid power - Single rod cylinders, 1000 kPa (10 bar) series, with
detachable mountains, bores from 32 mm to 320 mm - Mounting dimensions”.
This norm defines a metric series of assembly dimensions requested for interchangeability of the
pneumatic cylinders for a maximum pressure of work of 1000 kPa (10 bar ≈ 145 psi).
FY301 Positioner Functional Specifications

Input Signal
4 - 20 mA, 2 wire.
Power
Supplied by the 4-20 mA current loop. No external supply required.
Input Impedance
550 Ω.
Minimum Current
3.8 mA.
Communication Protocol
Hart® Communication Protocol (is superimposed on the current signal).
Protection against Reverse Polarity

No damage occurs from reversal of normal supply current (4 - 20 mA) or from misapplication of up
to 50 mA.
Output
Output to actuator 0 -100% supply air pressure. Single or double-action.
Pressure Supply
1.4 - 7 bar (20-100 psi). Free of oil, dust and water.
Indication
4 ½ numerical digits and 5 alphanumerical digits (Liquid Cristal Display).
Hazardous Location Certification

Explosion proof, weather proof and intrinsically safe from CEPEL, FM, CSA, NEMKO and DMT
(pending).
Temperature Limits
Operation: -40 to 85°C (-40 to 185°F).
Storage: -40 to 90°C (-40 to 194°F).
Display: -10 to 75°C (14 to 167°F) operation.
-40 to 85°C (-40 to 185°F) without damage.
Humidity Limits
0 to 100% RH.
Gain
Through software. Locally adjustable.
Actual Position Sensing

Magnet (Non-contact), via Hall effect.
FY301 Positioner Performance Specifications

Resolution
≤ 0.1% F.S.
Repeatability
≤ 0.1% F.S.
6.2
Technical Characteristics
Hysteresis
≤ 0.1% F.S.
Consumption
3
0.35 Nm /h (0.20 SCFM) at 1.4 bar (20 psi) supply.
3
1.10 Nm /h (1.65 SCFM) at 5.6 bar (80 psi) supply.
Output Capacity
3
13.6 Nm /h (8 SCFM) at 5.6 bar (80 psi) supply.
Ambient Temperature Effect

0.8%/20°C do span
Supply Pressure Effect

Negligible
Vibration Effect
±0.3%/g of span during the following conditions:
• 5 - 15 Hz at 4 mm constant displacement.
• 15 - 150 Hz at 2g.
• 150 - 2000 HZ at 1g.
Reference SAMA PMC 31.1 - 1980, Sec. 5.3, Condition 3, Steady State.
Electro-Magnetic Interference Effect

Designed to comply with IEC 801 and European Standards EN50081 and EN50082.
FY301 Positioner Physical Specifications

Electrical Connection
½ - 14 NPT, Pg 13.5 or M20 x 1.5.
Pneumatic Connections
Supply and output: ¼ - 18 NPT
Gage: 1/8 - 27 NPT
Material of Construction
Injected low copper aluminum with polyester painting or 316 Stainless Steel housing, with Buna-N
o-rings on covers (NEMA 4X, IP66).
Weight
Without display and mounting bracket: 2.7 kg. (Aluminum)
5.8 Kg. (Stainless Steel)
Add for digital display: 0.1 kg.
6.3
Weight Analysis for Linear ACP

PNEUMATIC KIT WEIGHT (Weigh in grams)
Pneumatic Kit
Weight Diameters
Travel (mm) 63 mm 80 mm 100 mm 125 mm 160 mm
100 2,860 4,470 5,775 9,120 16,180

125 2,985 4,650 5,995 9,460 16,560
160 3,165 4,920 6,300 9,950 16,870
200 3,360 5,220 6,650 10,470 1,850
250 3,620 5,590 7,090 11,150 19,650
320 3,970 6,120 7,700 12,090 21,250
400 4,370 6,720 8,400 13,170 23,100
500 4,875 7,470 8,965 14,520 25,400
630 5,530 8,440 9,275 16,275 28,380
800 6,385 9,720 11,900 18,570 32,300
1000 7,390 11,215 13,650 21,270 36,900
Positioner Weight FY: 2,700 grams (without display e mounting bracket)
BFY Weight (Bracket): 4,500 grams
(Aluminium as Base Material)
RULE WEIGHT CARBON STEEL
Travel (mm) Weigh (grams)

100 530
125 570
160 650
200 710
250 830
320 950
400 1140
500 1190
630 1510
800 1730
1000 2060
TOTAL WEIGHT (Weigh in grams)
Diameters
Travel (mm) 63 mm 80 mm 100 mm 125 mm 160 mm
100 10,590 12,200 13,505 16,850 23,910
125 10,755 12,420 13,765 17,230 24,330
160 11,015 12,770 14,150 17,800 24,720
200 11,270 13,130 14,560 18,380 9,760
250 11,650 13,620 15,120 19,180 27,680
320 12,120 14,270 15,850 20,240 29,400
400 12,710 15,060 16,740 21,510 31,440
500 13,265 15,860 17,355 22,910 33,790
630 14,240 17,150 17,985 24,985 37,090
800 15,315 18,650 20,830 27,500 41,230
1000 16,650 20,475 22,910 30,530 46,160
6.4
Ordering Code
ACP301L
Hart® Linear Pneumatic Cylindric Actuator
Model
CODE Cylinder Diameter
1 63 mm
2 80mm
3 100 mm
4 125 mm
5 160 mm
CODE Cylinder and Ruler Travel
1 100 mm (3.94 in)
2 125 mm (4.92 in)
3 160 mm (6.30 in)
4 200 mm (7.87 in)
5 250 mm (9.84 in)
6 320 mm (12.60 in)
7 400 mm (15.75 in)
8 500 mm (19.68 in)
9 630 mm (24.80 in)
A 800 mm (31.50 in)
B 1000 mm (39.37 in)
CODE Bracket Material
C Carbon Steel Bracket
I Stainless Steel Bracket
CODE Magnetic Limit Switch
0 Without Limit Switch
1 One Limit Switch
2 Two Magnetic Limit Switch
CODE Local Indicator
0 Without local indicator
1 With local indicator
CODE Electrical Connection
0 ½ – 14 NPT
A M20 X 1.5
B PG 13.5 DIN
SPECIAL OPTIONS
CODE Identification Plate
I1 FM: XP, IS, NI, DI
I3 CSA: XP, IS, NI, DI
I4 EXAM (DMT): Ex-ia; NEMKO: Ex-d
I5 CEPEL: Ex-d, Ex-ia
I6 Without certification
IM BDSR – GOST: Ex-d, Ex-ia
CODE TAG Plate
J0 With tag plate
J1 Tag plate without inscription
J2 Plate according to notes
ZZ With special characteristics
ACP301L 1 1 C 1 0 0 * *
* Leave it blank for no optional items.

Note: All the options for the actuator are only for cylinder in agreement with ISO norm. In case the cylinder is not normatized (ISO
Cylinder) the special cylinder should necessarily be assembled in Smar. (Note: the cylinder assembly, freight and other costs are
customer's responsibility).
6.5
ACP301R
Hart® Rotary Pneumatic Cylinder Actuator
Model
CODE Cylinder Diameter
1 100 mm (3.94 in)
CODE Bracket Material
C Carbon Steel
CODE Magnetic Limit Switch
0 Without Magnetic Limit Switch
1 One Magnetic Limit Switch
2 Two Magnetic Limit Switches
CODE Local Indicator
0 Without Local Indicator
1 With Local Indicator
CODE Electrical Connections
0 ½” – 14 NPT
A M20 X 1.5
B PG 13.5 DIN
SPECIAL OPTIONS
CODE Identification Plate
I1 FM: XP, IS, NI, DI
I3 CSA: XP, IS, NI, DI
I5 CEPEL: Ex-d, Ex-ia
I6 Without certification
IM BDSR – GOST: Ex-d, Ex-ia
CODE TAG Plate
J0 With tag plate
J1 Tag plate without inscription
J2 Plate according to notes
ZZ With special characteristics
ACP301R 1 C 0 1 0 * *
* Leave it blank for no optional items.
6.6
NON HAZARDOUS OR DIVISION 2 AREA HAZARDOUS AREA
REQUIREMENTS:
1 - INSTALLATION TO BE IN ACCORDANCE WITH ANSI/ISA RP12-6.
SAFE AREA APPARATUS
2 - TRANSMITTER SPECIFICATION MUST BE IN ACCORDANCE TO FM
UNSPECIFIED, EXCEPT THAT IT MUST NOT APPROVAL LISTING.
BE SUPPLIED FROM, NOR CONTAIN UNDER 3 - ASSOCIATED APPARATUS GROUND BUS TO BE INSULATED FROM PANELS
NORMAL OR ABNORMAL CONDITIONS, A AND MOUNTING ENCLOSURES.
SOURCE OF POTENTIAL IN RELATION TO 4 - ASSOCIATED APPARATUS GROUND BUS RESISTANCE TO EARTH MUST BE
SMALLER THAN 1(ONE) OHM.
EARTH IN EXCESS OF 250VAC OR 250VDC.
5 - OBSERVE TRANSMITTER POWER SUPPLY LOAD CURVE.
6 - WIRES: TWISTED PAIR, 22AWG OR LARGER.
ASSOCIATED APPARATUS 7 - SHIELD IS OPTIONAL IF USED, BE SURE TO INSULATE THE END NOT
GROUNDED.
8 - CABLE CAPACITANCE AND INDUTANCE PLUS Ci AND Li MUST BE
POWER SUPPLY
SMALLER THAN Ca AND La OF THE ASSOCIATED APPARATUS.
INTRINSICALLY SAFE APPARATUS

OPTIONAL ENTITY VALUES: Ci = 8nF Li = 12uH
SHIELDING Vmax = 30VDC
Rmin
SIGNAL
250 Imax = 110mA
BARRIER
COMPONENTS CAN NOT

BE SUBSTITUTED WITHOUT
PREVIOUS MANUFACTURER
+ - APPROVAL.
GROUND BUS
ENTITY PARAMETERS FOR ASSOCIATED APPARATUS

CLASS I,II,III DIV.1, GROUPS A,B,C,D,E,F & G MODEL FY290 & FY301 - SERIES
Ca >= CABLE CAPACITANCE + Ci CLASS I,II,III DIV.1, GROUPS A,B,C,D,E,F & G
La >= CABLE INDUCTANCE + Li ENTITY VALUES:
Po <= 0.825W 4-20 mA
4-20mA Ci = 8 nF Li = 12 uF
Voc <= 30V Vmax <= 30V
Isc <=110mA Imax <= 110mA
6.7
6.8
Appendix A
SRF – Service Request Form
FY Positioner
GENERAL DATA
Model: FY290 ( ) Firmware Version: ______________________ FY301 ( ) Firmware Version: ______________________
FY302 ( ) Firmware Version: ______________________ FY303 ( ) Firmware Version: ______________________
FY400 ( ) Firmware Version: ______________________
Serial Number: _______________________________________ Sensor Number: ________________________________________
TAG: _______________________________________________________________________________________________
Remote
Position Yes ( ) No ( )
Sensor?
Pressure
Yes ( ) No ( )
Sensor?
Action: Rotary ( ) Linear ( )
Travel: 15 mm ( ) 30 mm ( ) 50 mm ( ) 100 mm ( ) Other: ________ mm
Configuration: Magnetic Tool ( ) Palm ( ) Psion ( ) PC ( ) Software: _________ Version: __________
FINAL CONTROL ELEMENT DATA

Type: Valve + Actuator ( ) Pneumatic Cylinder (ACP) ( ) Other:________________________
Size: _______________________________________________________________________________________________
Travel: _______________________________________________________________________________________________
Manufacturer: _______________________________________________________________________________________________
Model: _______________________________________________________________________________________________
AIR SUPPLY
Conditions: Dry and Clean ( ) Oil ( ) Water ( ) Other: ____________________________________
Work Pressure: 20 PSI ( ) 60 PSI ( ) 100 PSI ( ) Other: ________ PSI
PROCESS DATA
Hazardous Area
Non-Classified ( ) Chemical ( ) Explosive ( ) Other: ________________________________
Calssification
Interference
Vibration ( ) Temperature ( ) Eletromagnetic ( ) Others: _______________________________
Types
SITUATION DESCRIPTION
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
SERVICE SUGGESTION
Adjustment ( ) Cleaning ( ) Preventive Maintenance ( ) Update / Up-grade ( )
Other: _________________________________________________________________________________________________________
USER INFORMATION
Company: _____________________________________________________________________________________________________
Contact: ______________________________________________________________________________________________________
Title: _________________________________________________________________________________________________________
Section: ______________________________________________________________________________________________________
Phone: __________ _________________________ __________ _________________________ Extension:____________________
E-mail: _________________________________________________________________________ Date: ______/ ______/ __________
For warranty or non-warranty repair, please contact your representative.

Further information about address and contacts can be found on www.smar.com/contactus.asp.
A.1
Returning Materials
Should it become necessary to return the ACP with positioner and/or configurator to SMAR, simply
contact our office, informing the defective instrument serial number, and return it to our factory.
In order to speed up anal ysis and s olution of the problem, the defective item should be returned
with a des cription of the failure observed, with as much details as possible. Other information
concerning the instrument operation, such as service and process conditions, is also helpful.
Instruments returned or to be revised outside the guarantee term should be accompanied by a

purchase order or a quote request.
A.2
Appendix B
SMAR WARRANTY CERTIFICATE
1. SMAR guarantees its products for a period of 24 (twenty four) months, starting on the day of
issuance of the invoice. The guarantee is valid regardless of the day that the product was
installed.
2. SMAR products are guaranteed against any defect originating from manufacturing, mounting,
whether of a material or manpower nature, provided that the technical analysis reveals the
existence of a quality failure liable to be classified under the meaning of the word, duly verified
by the technical team within the warranty terms.
3. Exceptions are proven cases of inappropriate use, wrong handling or lack of basic
maintenance compliant to the equipment manual provisions. SMAR does not guarantee any
defect or damage caused by an uncontrolled situation, including but not limited to negligence,
user imprudence or negligence, natural forces, wars or civil unrest, accidents, inadequate
transportation or packaging due to the user’s responsibility, defects caused by fire, theft or
stray shipment, improper electric voltage or power source connection, electric surges,
violations, modifications not described on the instructions manual, and/or if the serial number
was altered or removed, substitution of parts, adjustments or repairs carried out by non-
authorized personnel; inappropriate product use and/or application that cause corrosion, risks
or deformation on the product, damages on parts or components, inadequate cleaning with
incompatible chemical products, solvent and abrasive products incompatible with construction
materials, chemical or electrolytic influences, parts and components susceptible to decay from
regular use, use of equipment beyond operational limits (temperature, humidity, etc.) according
to the instructions manual. In addition, this Warranty Certificate excludes expenses with
transportation, freight, insurance, all of which are the customer’s responsibility.
4. For warranty or non-warranty repair, please contact your representative.
Further information about address and contacts can be found on

www.smar.com/contactus.asp
5. In cases needing technical assistance at the customer’s facilities during the warranty period,
the hours effectively worked will not be billed, although SMAR shall be reimbursed from the
service technician’s transportation, meals and lodging expenses, as well dismounting/mounting
costs, if any.
6. The repair and/or substitution of defective parts do not extend, under any circumstance, the
original warranty term, unless this extension is granted and communicated in writing by SMAR.
7. No Collaborator, Representative or any third party has the right, on SMAR’s behalf, to grant
warranty or assume some responsibility for SMAR products. If any warranty would be granted
or assumed without SMAR’s written consent, it will be declared void beforehand.
8. Cases of Extended Warranty acquisition must be negotiated with and documented by SMAR.
9. If necessary to return the equipment or product for repair or analysis, contact us.
See item 4.
10. In cases of repair or analysis, the customer must fill out the Revision Requisition Form (FSR)
included in the instructions manual, which contains details on the failure observed on the field,
the circumstances it occurred, in addition to information on the installation site and process
conditions. Equipments and products excluded from the warranty clauses must be approved by
the client prior to the service execution.
11. In cases of repairs, the client shall be responsible for the proper product packaging and SMAR
will not cover any damage occurred in shipment.
B.1
12. In cases of repairs under warranty, recall or outside warranty, the client is responsible for the
correct packaging and packing and SMAR shall not cover any damage caused during
transportation. Service expenses or any costs related to installing and uninstalling the product
are the client´s sole responsibility and SMAR does not assume any accountability before the
buyer.
13. It is the customer’s responsibility to clean and decontaminate products and accessories prior
to shipping them for repair, and SMAR and its dealer reserve themselves the right to refuse the
service in cases not compliant to those conditions. It is the customer’s responsibility to tell
SMAR and its dealer when the product was utilized in applications that contaminate the
equipment with harmful products during its handling and repair. Any other damages,
consequences, indemnity claims, expenses and other costs caused by the lack of
decontamination will be attributed to the client. Kindly, fill out the Declaration of
Decontamination prior to shipping products to SMAR or its dealers, which can be accessed at
www.smar.com/doc/declarationofcontamination.pdf and include in the packaging.
14. This warranty certificate is valid only when accompanying the purchase invoice.
B.2

Pneumatic Cylinder Actuator: Operation, Maintenance and Instruction Manual

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Pneumatic Cylinder Actuator: Operation, Maintenance and Instruction Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pneumatic Cylinder Actuator: Operation, Maintenance and Instruction Manual

Uploaded by

Copyright:

Available Formats

OPERATION, MAINTENANCE AND

Specifications and information are subject to change without notice.

Ø Modular and compact design;

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

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

SECTION 4 - LOCAL ADJUSTMENT PROGRAMMING .......................................................................... 4.1

SECTION 5 - MAINTENANCE PROCEDURES ........................................................................................ 5.1

ACP301 POSITIONER ASSEMBLY PROCEDURE ................................................................................................... 5.9

SECTION 6 - TECHNICAL CHARACTERISTICS ..................................................................................... 6.1

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

APPENDIX B - SMAR WARRANTY CERTIFICATE ................................................................................. B.1

The ACP basic features are:

Figure 1.1 - ACP Linear Model ACP301L / 302L / 303L

Figure 1.2 - ACP Rotary Model ACP301R / 302R / 303R

ACP Linear Model (ACP301L/302L/303L)

The working strokes for ACP301L / 302L / 303L are:

The internal cylinder diameters are:

LINEAR ACP - Force x Pressure

ACP Rotary Model (ACP301R / 302R / 303R)

ACP – Dimensional Drawings

Figure 1.5 - Dimensional – Rotary ACP

Figure 1.6 - Dimensional – Linear ACP

Linear ACP Main Dimensions Table

A Dimension = Backwarded cylinder

Cylinder Diameter (mm)

B Dimension = Advanced cylinder

Cylinder Diameter (mm)

C Dimension = Cylinder header height until the FY fixation plate

Cylinder Diameter (mm)

Dimensional – Female back joint bracket (mm)

Center of the cylinder holes (mm)

The values for A, B, E, F were considered with clevis totally threaded.

12.7 LEVER THICKNESS

POSITIONER MOUNTED IN BOTH ENDS Dimensions in mm (in).

540 (21.3) 4 ORIFICES 10.5 (0.41)

RESULTING FORCES IN (Kgf)

Figure 1.7 – Forces Table – Rotary ACP

Figure 1.8 – Fixing Plate on the FY301 Positioner

Figure 1.9 – Assembling the Positioner on the Cylinder

Figure 1.10 – Magnet Alignment

Important: first, disconnect the pipes to facilitate the cylinder motion.

Figure 1.13 – Magnet Alignment with the Hall Sensor

Figure 1.14 – Adjusting the Magnet Position

Figure 1.15 – Rotary ACP Base with the Cylinder Installed

Figure 1.23 – Details of the Assembled Magnet

Figure 1.26 – Details of the Fixing Screws on the Rotary Magnet

Figure 1.27 - Lower Position Figure 1.28 - Upper Position

Figure 1.32 – Final Assembly – Up View Figure 1.33 – Final Assembly

FY301 Positioner General Characteristics

Electronic Housing Rotating

Figure 1.34 - Housing Rotation Set Screw

Figure 1.35 – Cover Locking Screw

Figure 1.36 – Wiring Block

Figure 1.37 - Conduit Installation Diagram

Use of twisted pair (22 AWG or greater than) cables is recommended.

Avoid routing signal wiring close to power cables or switching equipment.

GROUND THE SIGNAL LOOP AT ONE