Intelligent Valve Positioner

S1500 Series User’s Manual

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1 Overview
1.1. Product structure

Protective cover

Main body casing

Electrical connection

Pneumatic connection

Actuator connection

Figure 1. Positioner structure

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NOTE！
Error connection of the electrical pin may cause the positioner damage.

Connection Description
P Air supply enter (built-in filter, filter size 5 μm)
R Air exhaust
C Check valve
A1 Pilot air outlet 1
A2 Pilot air outlet 2
Table 4. Pneumatic connection description

NOTE！
The air source pressure bigger than 7 bar may cause positioner damage.

4. Technical data
4.1. Working data

Ambient temperature: 0~70°C

Protection class: IP66
Vibration resistance parameter: 100Hz

4.2. Electrical data

Connections: cable gland

Supply voltage:
24 V DC ± 10 %, ≥1A. Recommend switching-mode power supply.
Power input: <5W
Input resistance for set-point signal: 120Ω

4.3. Mechanical data

Cover material: Polycarbonate (PC)

Sealing material: Silicone rubber (SI)
Main body material: Polyamide Resin (PA6-GF30)
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Control stroke range: 5-50 mm

4.4. Pneumatic data

Air pressure range: 3~7 bar, specific values depending on the actuator
Connections: Plug-in hose connector G1/4
Air quality:
Clean dry air, according to ISO 8573-1;
maximum particle density 10 mg/ m³,
maximum particle size 40 μm;
maximum oil content 25 mg/m³;
maximum pressure dew point -20 °C or minimum 10 °C below the lowest
operating temperature.
Air flow rate:
17L/min (input pressure of 0.6Mpa)
58L/min (input pressure of 0.6Mpa, only single-acting)

5. Operation
5.1. Interface description

The positioner has a 4-key and 12-led control panel. User can set parameters
and functions by pressing the four keys. 10 blue led lights are used to indicate
the position percent zone of the displacement sensor or the position percent
zone of the valve. They indicate the percent zones of 0-10%, 10-20%, 20-30%,
30-40%, 40-50%, 50-60%, 60-70%, 70-80%, 80-90%, 90-100%. The
“MANUAL” led is used to indicate the operating mode. Led off indicates
automatic mode. Led on indicates manual mode. Led flash indicates initial
mode. “STATUS” led is used to indicate some system running states, such as
system error alarms.
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Value light

Mode light Status light

Key 1 Key 4

Key 2 Key 3

Figure 12. Operating interface

5.2. Operating mode

5.2.1. Initial mode

The positioner is default in the initial mode when it starts up after leaving
factory. In the initial mode, the “MANUAL” led is flash, 10 blue led lights
indicate the position percent zone of the displacement sensor effective stroke.
User can operate keys to open and close the valve. Press key
continuously, the actuator is aerated. Press key continuously, the actuator
is deaerated. Check out and make sure that valve position can move in the
effective range of the displacement sensor and the whole valve stroke range is
in the effective range of the displacement sensor according to 10 blue led and
“STATUS” led.
If the whole valve stroke range is out of the effective range of the displacement
sensor, the actuator is fully deaerated. If the minimum value of the whole valve
stroke range is smaller than the minimum value of the effective range of the
displacement sensor, the “STATUS” led is flash quickly. If the maximum value
of the whole valve stroke range is larger than the maximum value of the
effective range of the displacement sensor, the “STATUS” led is flash slowly.
After system reporting the error, user can’t operate keys.
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5.2.2. Automatic mode

After finishing the automatic adjustment function, system is in the automatic

mode by pressing key to exit. And if the positioner restarts up, system is
default in the automatic mode. In this mode, the positioner accepts the input
signal for set-point value and adjusts the valve stroke automatically, “MANUAL”
led is turned off, 10 blue led lights are used to indicate the valve position
percent zone. The valve is fully close when the percent of set-point value ≤ 1%,
and is fully open when the percent of set-point value ≥ 99%.

5.2.3. Manual mode

Press key to switch between the automatic mode and the manual mode.
In the manual mode, “MANUAL” led is turned on, 10 blue led lights are used to
indicate the valve position percent zone. User can operate keys to
open and close the valve manually. User also can operate combination keys to
increase the adjustment speed. If after pressing key continuously first,
press key continuously, the valve is quickly open. If after pressing key
continuously first, press key continuously, the valve is quickly close. When
system switches from automatic mode to manual mode or user finishes
adjusting the valve position manually, the percent of current position value is
as the percent of set-point value in the manual mode. The valve is fully close
when the percent of set-point value ≤ 1%, and is fully open when the percent of
set-point value ≥ 99%.

5.3. Function instruction

5.3.1. Automatic adjustment

The automatic adjustment function can test the related control parameters in-
cluding the direction between the aeration state of the actuator and the actual
position, the total valve scale, PWM parameters etc.
Under the any operating mode interface, press key for about 3 seconds to
run the function. During the process of the function running, blue led lights are
scrolling to display the step of the automatic adjustment.
After finishing the automatic adjustment, all 10 blue led lights are flash. If error
appears during the automatic adjustment, “STATUS” led is turned on, and the
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actuator is fully deaerated.

System will check whether the whole valve stroke range is in the effective
range of the displacement sensor during the automatic adjustment process. If
the whole valve stroke range is out of the effective range of the displacement
sensor, the actuator is fully deaerated. If the minimum value of the whole valve
stroke range is smaller than the minimum value of the effective range of the
displacement sensor, the “STATUS” led is flash quickly. If the maximum value
of the whole valve stroke range is larger than the maximum value of the
effective range of the displacement sensor, the “STATUS” led is flash slowly.
Before finishing the automatic adjustment, user can press key to exit and
turn back to the previous operating mode.
After finishing the automatic adjustment, press key to exit and turn to the
specific operating mode according to the previous operating mode. If the
previous operating mode is automatic mode or manual mode, system turns
back to the previous operating mode. If the previous operating mode is initial
mode, system turns to the automatic mode.

NOTE！
 Although the positioner has ran the automatic adjustment function in
the factory. In order to get the control parameters of the actual work
environment, the positioner must run the function again in the actual
work environment.
 Make sure that the air supply pressure is in the working range of the
actuator and has no big wave. Otherwise the automatic adjustment
may fail or the test parameters may be error.

5.3.2. Dead band setting

The function is used to adjust the valve position control accuracy. The system
does not adjust the valve position when the gap between the current position
value and the position set-point value is not bigger than the dead band value.
The minimum value of the dead band is 0.2%, and the maximum value of the
dead band is 5%. Nine blue led lights separately indicate nine dead band
values of 0.2%, 0.4%, 0.6%, 0.8%, 1%, 2%, 3%, 4%, 5% from left to right. In
the automatic mode, press key for about 3 seconds to enter the dead
band setting interface. One led light is flash in order to display the current dead
band value. Press keys to change the dead band value. And the value
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is displayed by the blue led flashing. Press key to confirm and exit back to
automatic mode interface. Press key to exit back to automatic mode
interface without change.

NOTE！
The smaller the dead band setting, the higher the control accuracy getting.
Please set the dead band value in reason. Because the too small value
may cause the solenoid valve in the body to act frequently and lead to long
adjustment time and unstable working state.

5.3.3. Factory setting

The function is used to recovery the system to factory state. Under the factory
state, the positioner is in the initial mode after starting up, and the dead band
value is the default value 1%. In the automatic mode, press key for about
3 seconds to run the function. After finishing the function, system is in the initial
mode. Before matching between the positioner and the actuator, please make
sure that the positioner is in the initial mode after starting up.

5.3.4. Input signal error detection

The function is used to detect the error of 4-20mA input signal. The error
condition is the value of 4-20mA input signal ≤ 3.5mA. Once detecting the error
signal, “STATUS” led is flash. The single-acting power-off safe positioner will
exhaust the actuator cylinder’s air and the single-acting power-off freeze
positioner will keep the valve position and the double-acting positioner will
leave the valve position in a free state.

5.3.5. Analogue signal output (optional)

The positioner outputs 4-20mA analogue signal in the automatic mode and the
manual mode, and dose not output in the initial mode and the running state of
the automatic adjustment.
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6. Trouble shooting
1. LED does not light after the positioner starting up.
Make sure that the 24V DC power supply is normal.
Make sure that the power cables are connected correctly.
2. The positioner is unable to locate position. The valve cannot be fully
opened or fully closed for a long time.
Make sure that the pressure of air supply meets the requirement.
Make sure that the dead band value meets the situation that the valve
position adjustment is stable and has no fluctuation.
Make sure that the pneumatic connections of the positioner and actuator
are not leaking.

7. Attention
1. The power supply voltage of the positioner is 24V DC ±10%. Please check
the power supply before connecting the power cable to the electrical
terminal. Make sure that the power supply is cut off before connecting the
power cable. If the product is damaged by high voltage, it will lose
warranty.
2. Air supply use specification
1> The air pressure should be less than 0.7MPa.
2> Install the filter pressure reducer (5 um filtration accuracy) in front of
the air supply inlet of the positioner to prevent moisture or oil from
infiltrating. In the situation of much oil in the air, it is suggested to
additionally install the oil separator (3 um filtration accuracy) in front of
the air supply inlet of the positioner. It is suggested to use the
combination of SMC brand filter pressure reducer and SMC brand oil
separator. Its model is AC20D-01CG-A. If the product is damaged due
to the oil entering the product without oil separator or filter pressure
reducer being installed, it will lose warranty.
3. After adjustment, the protective cover must be rotated tightly to ensure
IP66 protection class. If the product is damaged by losing the protective
cover or not rotating the protective cover tightly, it will lose warranty.