No.

IP80-OM00003-F

PRODUCT NAME

ELECTRO-PNEUMATIC POSITIONER

MODEL / Series / Product Number

IP8000
IP8100
Contents

Safety Instructions 3-4

Introduction 5
1.Specifications 6
2.Operation principle 7-10
2-1 Type IP8000 7-8
2-2 Type IP8100 9-10
3.Attaching 11-13
3-1 Type IP8000 11-12
3-2 Type IP8100 12-13
4.Piping and Attaching of Internal Feedback Unit 14-16
5.Electrical Wiring 16
5-1 Positioner with terminal box 16
5-2 Positioner without terminal box 16
6.Explosion-Protected construction 17
7.Adjustment 18-20
7-1 Zero-point adjustment and span adjustment 19
7-2 Sensitivity adjustment 20
7-3 Manual switching 20
8.Maintenance and Check 21
9.Caution on Handling 22-23
10.Troubleshooting 24-26
11.Option 27-29
11-1 Pilot valve with output throttle 27
11-2 Fork lever type joint (Type IP8100) 27-28
11-3 External feet back lever (Type IP8000) 28
11-4 Resin Cable cramp unit ( Type non-explosion protection) 28
11-4 Scale plate unit 29
13.How to order 30
14.Attached Drawing 31-37
 Safety Instructions
These safety instructions are intended to prevent hazardous situations and/or equipment
damage.
These instructions indicate the level of potential hazard with the labels of “Caution,” “Warning” or
“Danger.”
They are all important notes for safety and must be followed in addition to International Standards
(ISO/IEC)*1) , and other safety regulations.
*1) ISO 4414: Pneumatic fluid power -- General rules relating to systems.
ISO 4413: Hydraulic fluid power -- General rules relating to systems.
IEC 60204-1: Safety of machinery -- Electrical equipment of machines .(Part 1: General requirements)
ISO 10218-1992: Manipulating industrial robots -Safety.
etc.

Caution indicates a hazard with a low level of risk which, if not avoided, could result
Caution in minor or moderate injury.
Warning indicates a hazard with a medium level of risk which, if not avoided, could
Warning result in death or serious injury.
Danger indicates a hazard with a high level of risk which, if not avoided, will result
Danger in death or serious injury.

Warning
1. The compatibility of the product is the responsibility of the person who designs the equipment
or decides its specifications.
Since the product specified here is used under various operating conditions, its compatibility with specific
equipment must be decided by the person who designs the equipment or decides its specifications based on
necessary analysis and test results.
The expected performance and safety assurance of the equipment will be the responsibility of the person who
has determined its compatibility with the product.
This person should also continuously review all specifications of the product referring to its latest catalog
information, with a view to giving due consideration to any possibility of equipment failure when configuring
the equipment.
2. Only personnel with appropriate training should operate machinery and equipment.
The product specified here may become unsafe if handled incorrectly.
The assembly, operation and maintenance of machines or equipment including our products must be
performed by an operator who is appropriately trained and experienced.
3. Do not service or attempt to remove product and machinery/equipment until safety is confirmed.
1.The inspection and maintenance of machinery/equipment should only be performed after measures to
prevent falling or runaway of the driven objects have been confirmed.
2.When the product is to be removed, confirm that the safety measures as mentioned above are
implemented
and the power from any appropriate source is cut, and read and understand the specific product
precautions
of all relevant products carefully.
3. Before machinery/equipment is restarted, take measures to prevent unexpected operation and malfunction.
4. Contact SMC beforehand and take special consideration of safety measures if the product is to
be used in any of the following conditions.
1. Conditions and environments outside of the given specifications, or use outdoors or in a place exposed to
direct sunlight.
2. Installation on equipment in conjunction with atomic energy, railways, air navigation, space, shipping,
vehicles, military, medical treatment, combustion and recreation, or equipment in contact with food and
beverages, emergency stop circuits, clutch and brake circuits in press applications, safety equipment or
other applications unsuitable for the standard specifications described in the product catalog.
3. An application which could have negative effects on people, property, or animals requiring special safety
analysis.
4.Use in an interlock circuit, which requires the provision of double interlock for possible failure by using a
mechanical protective function, and periodical checks to confirm proper operation.

3
 Safety Instructions
Caution
1.The product is provided for use in manufacturing industries.
The product herein described is basically provided for peaceful use in manufacturing industries.
If considering using the product in other industries, consult SMC beforehand and exchange
specifications or a contract if necessary.
If anything is unclear, contact your nearest sales branch.

Limited warranty and Disclaimer/Compliance Requirements

The product used is subject to the following “Limited warranty and Disclaimer” and “Compliance
Requirements”.
Read and accept them before using the product.

Limited warranty and Disclaimer

1.The warranty period of the product is 1 year in service or 1.5 years after the product is
delivered,whichever is first.2)
Also, the product may have specified durability, running distance or replacement parts. Please
consult your nearest sales branch.

2. For any failure or damage reported within the warranty period which is clearly our responsibility,
a replacement product or necessary parts will be provided.
This limited warranty applies only to our product independently, and not to any other damage
incurred due to the failure of the product.

3. Prior to using SMC products, please read and understand the warranty terms and disclaimers
noted in the specified catalog for the particular products.

2) Vacuum pads are excluded from this 1 year warranty.

A vacuum pad is a consumable part, so it is warranted for a year after it is delivered.
Also, even within the warranty period, the wear of a product due to the use of the vacuum
pad or failure due to the deterioration of rubber material are not covered by the limited
warranty.

Compliance Requirements
1. The use of SMC products with production equipment for the manufacture of weapons of mass
destruction(WMD) or any other weapon is strictly prohibited.

2. The exports of SMC products or technology from one country to another are govemed by the
relevant security laws and regulation of the countries involved in the transaction. Prior to the
shipment of a SMC product to another country, assure that all local rules goveming that export
are known and followed.

4
Introduction E

IP8*00 Series Electro-pneumatic positioner controls the motion of actuator by the operation of
pilot valve. This pilot valve is activated by signal current from adjustment unit mounted to air
actuator.
And this product get certification regarding explosion-protection construction from Technology
institution of industrial safety (TIIS) Japan. If the positioner is used as the product with explosion
-protection, use in accordance with “Recommended Practice for Explosion-Protected Electrical
Installations in General Industries” by Technology institution of industrial safety Japan

5
 1.Specifications
Table 1 Specifications

IP8000 IP8100
Type
Lever type lever Rotary type cam
Item
Single action Double action Single action Double action
Input current 4～20mADC (Standard)*1
Input resistance 235±15Ω (4～20mADC)
Supply air pressure 0.14～0.7MPa
Standard stroke 10 ～ 85mm (External lever
60° to 100°*2
allow-able runout angle 10° to 30°)
Sensitivity Within 0.1%F･S Within 0.5%F･S
Linearity Within ±1%F･S Within ±2%F･S
Hysteresis Within 0.75%F･S Within 1%F･S
Repeatability Within ±0.5%F.S
Thermal coefficient Within 0.1%F.S/oC
Output flow rate *3 80L/min (ANR) or more (SUP=0.14MPa)
200L/min(ANR) or more (SUP=0.4MPa)
Air consumption *3 Within 5L/min (ANR) (SUP=0.14MPa)
Within 11L/min (ANR) (SUP=0.4MPa)
Ambient and using fluid -20oC to 80oC (When use in non-hazardous area)
Temperature -20oC to 60oC (When use at flameproof type ExdⅡBT5)
Explosion-protected Flameproof type of explosion-protection (ExdⅡBT5),
Construction Technology institution of industrial safety (TIIS) Japan certified. E
Air connection port / 1/4(Rc,NTP,G) female screw ／ Rc1/8 female screw E
Pressure gauge connection port
Electric wiring connection E
1/2(G,NPT), M20×1.5 female screw
Port
Metal conduit type
Wiring Flameproof packing type
G1/2 connector (option for non-explosion protection type)
Material Die-cast aluminum for the body
Mass Approx. 2.6kg with terminal box
(Approx.2.4kg without terminal box)
Classification of degree of JISF8007 IP65 (conform to IEC Pub.529)
Protection
＊1：1/2 split range is available as standard. When the product is used in 1/2 split range, be D
aware that the linearity range is 1% F.S. wider (+/-1% F.S.) and the hysteresis should be
increased by 1% F.S. to the values shown in the Specification table above.
＊2：The stroke is adjustable in 0 to 60°and 0 to 100°.
＊3：Standard air (JIS B0120):temp.20oC, absolute press.101.3KPa, ratio humidity 65%.

6
2.Operation Principle

2-1 Type IP8000

When the input current increases, armature (13) receives counter-clockwise rotating torque with
leaf-spring (11) of torque motor (12) functioning as the support, counter-weight (4) is pushed
towards left, the space between nozzle (6) and flapper (5) opens and the nozzle back pressure
decreases. As the result, exhaust valve (7) of pilot valve (1) moves to right, the output pressure
of OUT1 increases and diaphragm valve (15) moves downward. The movement of diaphragm
valve (15) acts on feedback spring (10) through feedback lever (8), transmission lever (14) and
span adjusting lever (9) and the actuator is balanced at the position where it is balanced with the
force generated by the input current. Gain suppression spring (2) is used to immediately
feedback the movement of exhaust valve (7) to counter-weight (4) and it increases the loop
stability. For zero-point adjustment, change the tension of zero-adjust spring (3).

SUP
Zero Restrictor
adjusting ) (
spring
Stem stroke
IN current Torque + + Nozzle Exhaust Inlet Driven OUT
○
○

motor - - flapper Diaphragm valve diaphragm

valve

Gain
suppression
spring

Feedback Span Feedback

adjusting
spring lever lever

Fig. 1 Block diagram of Type IP8000

7
 IP8000(lever type feedback)
single action positive operation M

View A

Stopper screw X Automatic/Manual

(Do not move) change-over screw
(Built-in restrictor) (15) Driven diaphragm
SUP OUT2 OUT1 Sensitivity adjusting screw
(1) Pilot valve
X (Adjusts GAIN)
Inlet valve A
Inlet valve B
(8) Feedback lever
Span
(9) adjusting lever
Exhaust
EXH. Diaphragm (7) valve
(4) Counter weight Span adjusting lever shaft
(2) Gain suppression spring (5) Flapper
(6) Nozzle Transmission pin

(3) Zero adjusting spring Lock screw

Zero adjusting screw (14) Transmission lever

(10) Span adjusting screw

E Feedback spring

(11) Leaf spring

(12) Torque motor

Input
current terminal (13) Armature

For reverse position, exchange

the shaft of the span adjusting
lever to the opposite side.
The span adjusting screw faces
upward in this condition.
(See "Piping method")

Fig.2. Drawing for IP8000 operation principle

8
2-2 Type IP8100

When the input current increases, armature (14) receives counter-clockwise rotation torque with
leaf-spring (12) of torque motor (13) functioning as the support, counter-weight (4) is pushed
towards left, the space between nozzle (6) and flapper (5) opens and the nozzle back pressure
decreases. As the result, exhaust valve (7) of pilot valve (1) moves to right, the output pressure
of OUT1 increases and the output pressure of OUT2 decreases, starting the rotation of rocking
actuator (16). The movement of rocking actuator (16) acts on feedback spring (10) through
feedback shaft, cam (8), span adjusting lever (9) and transmission lever (15) and the actuator is
balanced at the position where it balances with the force generated by the input current. Fig.6
shows the case of cam DA structure normal actuation (the main shaft of rocking actuator (16)
turns clockwise at the time the input current increases).
Gain suppression spring (2) is used to immediately feedback the movement of exhaust valve to
counter-weight (4) and it increases the loop stability. For zero-point adjustment, change the
tension of zero-point adjust spring (3).

SUP
Zero Restrictor
adjusting ) (
spring
Rotation angle
IN current Torque + + Nozzle Exhaust Inlet Oscillating OUT
○

○ Diaphragm
motor - - flapper valve valve actuator

Gain
suppression
spring

Feedback Span Feedback

adjusting Cam
spring lever shaft

Fig.3 Block diagram of Type IP8100

9
IP8100(Rotary type cam feedback)
double actionpositive operation M
A
View X
Stopper screw Automatic/Manual change-over screw
(Do not move) (Built-in restrictor)
SUP OUT2 OUT1 Sensitivity adjusting screw
(1) Pilot valve X (Adjusts GAIN)
Inlet valve A
Inlet valve B
For reverse position,set by
turning over the cam and
Exhaust reversing connections of
EXH. Diaphragm (7) valve outlets OUT1 and OUT2.
(4) Counter weight
(8) Cam
(2) Gain suppression spring (5) Flapper Span
(6) Nozzle (9) adjusting lever (15) Transmission lever
(3) Zero adjusting spring Bearing
Zero adjusting screw
(10)
Feedback spring
E
(11) Feedback shaft
(16)
(12) Leaf spring Oscillating
actuator
(13) Torque motor
Input (14)
current terminal Armature

Fork joint

Fig.4 Drawing for IP8100 operation principle

10
3.Attaching

! Warning
(1) Make a space needed for maintenance on the setting area.
(2) Take care that fingers are not pinched during mounting and positioning the cam. Cut E
supply pressure and release compressed air in positioner and actuator in advance.

! Caution
(1) Confirm actuator and positioner are connected properly and tightly.

3-1. Type IP8000

3-1-1 Example of attaching to actuator
The type IP8000 positioner is compatible with Type IP600 and IP6000 in the attaching
pitch. If you are using IP600 and IP6000 already, the bracket for those positioner can
be used to attach IP8000 to the actuator.

Bracket Bracket
Positoiner Positioner Positioner

Bracket shape Bracket shape

example example

Fig.5 Directly attaching to Fig.6 L-shape bracket Fig.7 Front bracket

diaphragm valve
Directly attach using the Attach using the screw Attach using the screw
screw hole at a side of the hole at a side of the hole at the positioner back
positioner and the screw positioner and the screw and the screw hole at the
hole at the yoke side of hole at the front mount of front mount of diaphragm
diaphragm. diaphragm valve. valve.

11
 3-1-2 Connection with external feedback lever
Tightening spring (1)Attach to the position that the valve stem and lever
Right angle form the right angle when the input signal is
Input current 0%(or 100%)position
50%(distribute evenly with 50% input signal set as
Input current 50% position
Feedback Input current 100%(or 0%)position the reference).
lever
Connection (2)Attach to the position that the runout angle is within
Posirioner body Valve stem
the range of 10°to 30°.
(3)To move the valve stem downward at the time of
Fig.8 Attaching the feedback lever input current increase(normal actuation), attach to
Stem direction
the position at which the tightening spring comes
to the upper side of the connection, as shown in
Fig.9.
(The stem moves down as the input increases)
To move the valve stem upward(reverse
Stem direction actuation), turn-over the feedback lever and attach
to the position at which the tightening spring
comes to the lower side of connection.
(The stem moves up as the input increases)
Fig.9 Use position of feedback lever

3-2 Type IP8100

3-2-1 Example of attaching to actuator
The type PI8100 positioner is compatible with type IP610 and IP6100 in the attaching
pitch. If you are using IP610 or IP6100 already, the bracket can be used to attach
IP8100 to the actuator. If you change from IP6100 to IP8100 and select accessory H
(with external scale plate), fork lever type fitting needs to be adjusted at lower position.

OUT1 OUT2 OUT1 OUT2

Bracket shape
Bracket shape example
example

Fig.10 Mounting by positioner side Fig.11 Mounting by positioner back screw

screw Attach using the screw hole at the positioner
Attach using the screw hole at a side of back and the screw hole at the actuator top.
the positioner and the screw hole at the
actuator top.
12
 3-2-2 Connection with feedback shaft

Positioner body
(1) Attach to the position at which the
positioner feedback shaft and the rotary
Fork pin unit actuator main shaft are alsmost
(P368010-23)
concentric (range in which the spring pin
of feedback shaft edge enters the hole of
Fork lever assembly fork lever assembly shaft edge).
Spring pin (P368010-24)
(2) If the separation joint type for IP610 is

M8X1.25 made in a special specification, it can be

Actuator main shaft used for this connection.

Fig.12 Example of attaching using fork lever type joint

3-2-3 Cam attaching procedure

(1) Use the DA face of cam to turn the actuator main shaft clockwise (viewed from the positioner
front cover side) at the time of input signal increase. Use the RA face to turn it
counter-clockwise (reverse actuation). Correctly attach the cam to the flange part of feedback
shaft.
(2) Attach the cam in the procedure of loosening the hexagonal nut with flange first, setting the
using actuator to the starting position and then setting the cam reference line and the bearing
contact point of span adjusting arm unit to the matching position.
(3) Do not apply the supply pressure when attaching the cam as otherwise it is very dangerous.
(4) When the positioner is shipped from our plant, the cam is tentatively tightened to the shaft. Be
sure to firmly lock the cam to the lock nut (Tightening torque 3.6～4.1 Nm) E

Hex.nut with flange

Counter-clockwise Clockwise

R
A

A
D

0 0

Cam reference line

Bearing
(Reverse actuation) (Normal actuation)

Fig.13 Example of cam attaching

13
4.Piping and Attaching of Internal Feedback Unit

14
15
 ! Caution
Prior to piping, flush enough and remove chip, cutting oil and dust in tube so that obstruction
wouldn’t intrude into positioner.

Confirm specification and working direction of actuator, and mount pipes and
internal feedback unit in accordance with table 2 and 3.

5.Electrical Wiring
5-1 Positioner with terminal box

(1) Connect the (+) and (-) output terminals from

the regulator with the (+) and (-) input terminals,
respectively, of the positioner terminal box. The
port diameter at the conduction wire drawing port
is the size of G1/2 parallel screw for piping and
the depth is for a 16.5mm female screw.
(2) Two drawing ports, marked as Part A and Part
B in Fig.14, are provided. Use either one as fitted.
(Part B is used in the figure).

Fig 14.Positioner with terminal box

5-2 Positioner without terminal box

(1)Connect the (+) and (-) output
terminals from the regulator with the (+)
and (-) input terminals, respectively, of
the positioner terminal box. The port
diameter at the conduction wire
drawing port is the size of G1/2 parallel
screw for piping and the depth is for a
20 mm female screw.

Fig.15 Positioner without terminal box

Fig. 15 Positioner without terminal box

16
6.Explosion-Protected construction

! Warning
If the positioner is used as the product with Flameproof type of Explosion-Protection, leading
external conductors into a flameproof terminal box in accordance with “Recommended Practice
for Explosion-Protected Electrical Installations in General Industries” by Technology institution
of industrial safety Japan”.

(1) This product conforms to ExdⅡBT5 based on International Standard (IEC Standard 79).

Method of leading external conductors and cables into a terminal box shown as below.

In the case where this is used as ExdⅡBT5

A) Flameproof packing type leading method.
Cable Ground (refer to Table4 Option) is used as shown in Fig.16.

B) Metal conduit leading method.

Sealing fittings should be attached to leading port of external conductor.

(Please refer to “Recommended Practice for

Explosion-Protected Electrical Installations in General
Industries” by Technology institution of industrial safety
Japan” for details.)

Screw for shrouds

(across flats 1.5) Applicable Cable
Part name Part number
O.D.
Flameproof P368010-32 φ7.0～10.0
packing type
Packing P368010-33 φ10.1～φ12.0
connector unit
Table4 Flameproof packing type cable ground (Option)
Cable
Flameproof packing type connector unit

Fig.16 Flameproof packing type leading method

17
7.Adjustment

! Caution
(1) For this positioner, span and zero point adjustment of each actuator is necessary.
Adjustment shall be done based on each actuator size.
(2) Keep in mind that span and zero point adjustment interfere in each other.
(3) Characteristics changes due to change of mounting position, ambient temperature and
supply pressure.
(4) If it takes long time until operation after initial adjustment, check and adjust this product.
(5) Sensitive adjustment is effective for only double acting actuator.
(6) Manual change function is effective for single acting actuator which is controlled by using
OUT1.

Check the following prior to start the adjustment.

(1) Check that the pipeline is correctly connected with the pressure supply port and OUT1
and OUT2 ports.
(2) Check that the wires are correctly connected with the (＋), (－) and grounding terminals.
(3) Check that the actuator and positioner are sturdily connected.
(4) Check for locking of the auto/manual changeover screw of pilot valve (fully tightened in
the clockwise direction).
(5) Check that the span adjusting lever of internal feedback lever (Type IP8000) is attached
to the correct (normal or reverse) position. (Refer to Tables 2.)
(6) Check for correct use of the cam surface (normal or reverse) in Type IP8100 and that the
flange nut is firmly locked.
(Refer to Table 3.)

18
7-1 Zero-point adjustment and span adjustment
Table 5 Adjustment procedure

(1) Set the input current to 0% (4mADC in the standard (1) Set the input current to 0% (4mADC in the standard

specification) and turn the zero adjusting knob by hand to specification) and turn the zero adjusting knob by hand to

set it to the actuator starting point. set it to the actuator starting point.

(2) Then, set the input current to 100% (20mADC in the (2) Then, set the input current to 100% (20mADC in the

standard specification) and check the actuator stroke. At standard specification) and check the actuator stroke. At

this point, depending on whether the span is too large or this point, depending on whether the span is too large or too

too small, loosen the lock screw and then adjust the span small, adjust the span as shown in the illustration above.

as shown in the illustration above. (3) Set the input current to 0% and conduct the zero-point

(3) Set the input current to 0% and conduct the zero-point adjustment, as done in Step (1) again.

adjustment, as done in Step (1) again. (4) Repeat the above operations until the predetermined

(4) Repeat the above operations until the predetermined stroke of the actuator is obtained to the input current.

stroke of the actuator is obtained to the input current.

19
 7-2 Sensitivity adjustment

Auto/Manual changeover screw

M (Built-in restrictor)
A

Stopper screw
(Do not move)

Sensitivity adjust screw

Fig.18 Input/output-pressure characteristic

Fig.17 Pilot valve

Fig.18 shows the input current –output pressure characteristics of OUT1 and OUT2 of the pilot
valve. The sensitivity adjust screw (Fig. 17) is adjusted at the time of shipment to optimize the E
output pressure (Fig. 18) and this needs no adjustment ordinarily.

! Caution
The sensitivity adjustment of pilot valve is effective to the double action actuator only. If the
sensitivity is poor because of the actuator type of load condition, turn the sensitivity adjust screw
clockwise. If hunching occurs, turn the sensitivity adjust screw counter-clockwise.
(The amount of turning depends on actuators. Turn it by 1/16 to one turn. Do not loosen the
stopper screw at this time since it is set to avoid the screw coming off.)
* If hunching occurs with an actuator of small capacity, refer to the description in 11-1 (for both
single action and double action.)

7-3 Manual switching

(1) Supply pressure and the OUT1 output are connected by rotating the Auto/Manual changeover E

screw towards M (Fig. 17). Manual stroke adjustment of the diaphragm valve and single acting
actuator can be adjusted by using the supply pressure setting reducing valve Mode switching is
available by approx. 1/8 turn. Keep the rotation within 1/4 to 1/8 turn.
(2) To operate based on the input current, tighten the Auto/Manual changeover screw towards A. (See
Fig. 17).

! Caution
On this manual switching, SUP and OUT1 are conducted through the pilot valve and when the
pilot valve becomes out of order, the manual switching is not functioning. Note that the stopper
small screw set to the top is for prevention from coming off. Do not loosen it.
The sensitivity adjust screw is adjusted before shipping. Do not rotate it. E

20
8.Maintenance and Check

! Warning
(1) After installation, repair or disassembly, connect compressed air and conduct tests
to confirm appropriate function and leakage.
Do not use the positioner when noise from the bleeder sounds louder compared with the
initial state, or when it does not operate normally. If these occur, check immediately if
assembled and mounted correctly.
Never modify electrical construction to maintain explosion-proof construction.

! Caution
(1) Check if supply air is clean or not. Inspect compressed air cleaning system periodically
and keep condition to be able to always get clean air so that dust, oil and humidity which
cause malfunction and failure wouldn’t include into the equipment.

(2) If handled improperly, compressed air can be dangerous. Maintenance and replacement
of unit parts should be performed only by trained and experienced personnel for
instrumentation equipment as well as following the product specifications.

(3) Perform an annual inspection of the positioner. D

Zero point and span may have deviated. During regular maintenance, check for the
following and replace any components as necessary.
When an excessively worn O-ring or other packing is found, or any unit (the pilot valve F
unit etc.) has been damaged, replace with new ones. Treatment at an early stage is
especially important if the positioner is used in a place of severe environments.

(4) Before removing the positioner for maintenance or replacing unit parts after installation,
make sure the supply pressure is shut off and all residual air pressure is released from
piping.

(5) When the fixed orifice is clogged with carbon particles or others, remove the pilot valve
Auto/Manual changeover screw (built-in restrictor) and clean it by inserting a ø0.2 wire
into the aperture. If it must be replaced with new one, stop the supply pressure and
remove the stopper screw of the pilot valve.

(6) It is recommended to replace the pilot valve unit every 3 years. DF

(7) Check air leak from piping which compressed air flows. Air leak from air piping could
deteriorate characteristics.
Air is normally discharged from a bleed port, but this is a necessary air consumption
based on the construction of the positioner, and is not an abnormality if the air
consumption is within the specified range.

21
9.Caution on Handling
■Operation
! Warning
(1) Do not use this positioner out of the range of its specifications as this can cause failure.
(Refer to 1. Specifications.)
(2) If the system is supposed to be in danger because of failure of the positioner, prepare
the system with a safety circuit to avoid danger.
(3) If the positioner is used as the product with Flameproof type of Explosion-Protection,
leading external conductors into a flameproof terminal box in accordance with
“Recommended Practice for Explosion-Protected Electrical Installations in General
Industries”
(4) Do not remove the terminal cover at a dangerous position during power conduction.
(5) Be sure that the terminal cover and body cover are put on during the operation.

! Caution D

(1) Do not touch the actuator and operating part of the valve when they are pressurized.
as this can be dangerous.
(2) Take care not to get your fingers caught during mounting or positioning the cam. Stop
supplying pressure beforehand to release compressed air in the positioner and
actuator.
(3) Be sure to operate the positioner with the body cover unit mounted.
IP65 may not be satisfied depending on the body cover mounting condition. Apply
correct tightening torque (2.8 to 3.0 Nm) to satisfy IP65.
(4) Flush the inside of the piping while connecting it so that foreign matter such as
cutting debris does not enter into the piping.
(5) The opening degree of the actuator may be unstable if a booster relay is used.
(6) Make sure to perform grounding as a countermeasure against input current noise, to
avoid malfunction due to noise and static electricity.
(7) When a pressure gauge is used with the positioner, use it as a reference only.
(8) When frozen air is supplied to the internal mechanical parts of the positioner, the
behaviour of the pressure gauge indicator will become unstable.

■For operators D

! Caution
(1) Read and understand the operation manual carefully before assembling, operating or
providing maintenance to the product.

22
■Handling
! Warning
(1) Avoid giving impact to the body and torque motor of positioner, and giving excessive
force to armature because it leads to failure. Handle with care during transport and
operation.
(2) In an operating site with vibration, wrap the lead wires using a cable tie to protect them D
from damage.
(3) If the positioner is left unused at the operation site for an extended period, ensure the D
body cover unit is fitted, and mount a plug on the wiring and piping ports. If the
atmosphere is of high temperature or high humidity, take measures to avoid condensation
inside. The condensation control measures must be taken thoroughly for exportshipment.
(4) Avoid to set positioner near magnetic field because characteristics are effected.

■Air supply
! Warning
(1) Use dehumidified and dust-removed clean air as the supplying air source.
(2) Positioner has fine paths in it. Therefore, please use clean air which is dehydrated and
filtered, and also avoid employing Lubricator which causes malfunction. In addition, it is
recommended to use a mist separator as an air-cleaning equipment.
(3) Avoid using compressed air compressed air containing chemicals, synthetic fluid
including organic solvent, salinity, and corrosive gas as it may cause malfunction.
(4) If atmosphere is below freezing point, take measure to avoid condensation.

■Environment
! Warning
(1) Do not use in an environment where the product is exposed to corrosive gas,
chemicals, salt water, water or steam.
(2) Do not operate the product in a location where it is subject to strong vibration and/or
shock.
(3) If the positioner is used under temperature outside of the specification, the sealing
materials deteriorate quicker and also the positioner may not operate normally.

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10.Troubleshooting

1.The positioner does not operate

Open the cover and lightly hit the nozzle or

flapper section to activate.

Switched between OUT1 and Not switched between OUT1

OUT2 of pilot valve. and OUT2 of pilot valve.

Incorrect connection of The Auto/Manual changeover The restrictor or nozzle is

input current + and -. switch is loosened. clogged.

Check the connection. Check the Auto/Manual Check and clean the restrictor
(Refer to 5. Electrical wiring) changeover switch. and nozzle.
(Refer to 7-3 Manual switching). (Refer to 8.Maintenance and
check).

2.The actuator is turned ON/OFF

The cam front/back is used Incorrect piping for OUT1 and

incorrectly. OUT2.

Check the cam attaching. Review the pipe connection.

(Refer to 3-2-3 Cam attaching (Refer to 4. Piping and
procedrue) attaching of internal feedback
unit)

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 3.Hunching occures

The actuator used is too small The restrictor is clogged. The actuator sizing is inadequate
in the capacity. (too large resistance of actuator
gland packing)

Use a pilot valve with output Clean the restrictor. Review the actuator
throttle. (Refer to 8. Maintenance and
(Refer to 11-1 Pilot valve output check)
with throttle)

Change the gain suppression

spring from standard to (A) ※

※Part No.: P22401123

4.Too large consumption flow rate

Leakage in the piping Leakage in the actuator. Dust caught in the positioner
pilot valve.

Check and find out the leakage Check whether or not the O- Disassemble and check the
ring and packing in the actuator pilot valve.
is broken

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 5.Poor linearity

The supply pressure fluctuates. Poor span/zero adjustment. The external feedback lever is
not used in proper distribution.

Check the regulator for supply Check the span/zero Check the attaching of
pressure. adjustment. external feedback lever.
(Refer to 3-1-2 Connection
with external feedback lever)

6.Poor hysteresis

Improper adjustment of Play in the connection The connecting screw in the

sensitivity adjust screw. between the positioner and positioner is loosened.
actuator.

Re-adjust the sensitivity adjust Remove the backlash. Check and re-tighten the
screw. screw.
(Note) Double action type only
(Refer to 7-2 Sensitivity
adjustment)

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11.Option
11-1 Pilot valve with output throttle
Hunching may occur when the positioner is attached to a small capacity actuator.
In such a case, use a pilot valve having a throttle for OUT1 and OUT2.
The throttle is removable.
(Refer to Figs.19 and 20 for mounting and dismounting the throttle.)

Table 6 Throttle types

Pilot unit No. having the
Quite for actuator Throttling diameter Part No.
Throttle shown at left
90cm3 φ0.7 P36801080 P565010-18
180cm3 φ1 P36801081 P565010-19

Throttling diameter

OUT2 OUT1
Throttle O-ring P5
Fig. 19 Throttle mounting Fig. 20 Pilot valve bottom drawing

(Note 1) When mounting the throttle, pay attention not to let dust and others enter
the port hole.
Be sure to mount an O-ring after mounting the throttle.
(Note 2) If the hunching does not stop even after mounting the throttle, use
gain suppression spring(A), separately provided.【Part No. P22401123】

11-2 Fork lever type joint ( Type IP8100 )

Two types of joint, having different attaching sizes for different bracket attaching methods,
are available as the fork lever type joint of rotary type IP8100.

Table 7 Type of fork lever type joint

Description Part No.
Fork lever assembly M P368010-24
Fork lever assembly S P368010-25

Fig.21 Example of side attaching Fig.22 Example of backside attaching

B
using fork lever assembly M using fork lever assembly S

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 In the case of side attaching, if you use fork lever assembly M, it is compatible with our IP610
positioner in the attaching size. Also, in the case of backside attaching, if you use fork lever
assembly S, it is compatible with our IP610 positioner in the attaching size.

11-3 External feedback lever ( Type IP8000 )

Levers having different stroke sizes are available for the feedback lever of lever type IP8000.
Order them to match your valve stroke.

Table 8 Feedback lever types

Stroke Unit No.
10～85mm(Standard accessory) P368010-20
35～100mm P368010-21
50～140mm P368010-22

11-4 Resin cable cramp unit (Type non-explosion protection)

As non-explosion prove resin cable clamp unit used for type without terminal box
(IP8※00-※※0), there are two types available which are compatible with different
cable in diameter.
The cable is made of resin and available only in the indoor use.

Table 9 Cable cramp unit

Description Part No. Suitable cable dia.
Cable cramp unit (A) P368010-26 φ7～φ9

Cable cramp unit (B) P368010-27 φ9～φ11

Fig.23 Non-explosion proof resin cable clamp unit

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11-5 Scale plate unit
! Caution
Locate scale plate with care not to make finger pinched between needle and plate

Adjustment of scale plate

（１）Perform adjustment of zero span in positioner before installing the positioner to either
face of DA or RA with consideration of operating direction.（Refer to Fig. 24.）
（２）Stop positioner at intermediate opening of actuator (where input signal of 50% finishes
to enter to the positioner) and adjust the position of needle to meet with 50＋% of scale
plate. (Refer to Fig.25) If the needle can’t be met with 50+% even with adjustment,
stop pressure supply once, reposition fork lever type fitting and cam, and readjust zero
span.
（３）At the end of start and stop of actuator, confirm needle points 0% and 100% of scale
plate respectively. If the needle points others, position the needle by loosening cross
recessed hexagon bolt holding scale plate with spanner and sliding the scale plate. Ａ
(Refer to Figure 26, 27.)

Reverse Normal
Fig.24 Scale plate

Cross recessed hexagon bolt

for scale plate mounting Needle adjusting screw

Fig.25 Positioning of needle

Back side

Positioning on center
Cross-recessed hexagon bolt
slide

line means 90 degree.

for scale plate mounting

Fig.26 Scale plate (Back side) Fig.27 Positioning for Scale plate

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 12.How to order

ＩＰ８＊＊＊－０ ＊ ＊－ ＊ － ＊ － ＊ D

Type CE marking
000 Lever type Nil
100 Rotary type Q CE marked product

Connection

Pressure gauge Applicable model

Symbol Air Electric
IP8□00-0□0 IP8□00-0□1
Symbol Pressure
Nil Rc1/4 G1/2 ● ●
0 None
M Rc1/4 M20×1.5 ● ―
1 0.2 MPa
N Rc1/4 1/2NPT ● ―
2 0.3 MPa
1 1/4NPT G1/2 ● ●
3 1.0 MPa
2 1/4NPT M20×1.5 ● ―
3 1/4NPT 1/2NPT ● ―
4 G1/4 G1/2 ● ●
Note 1)
Construction 5 G1/4 M20×1.5 ● ―
0 No terminal box 6 G1/4 1/2NPT ● ―
With terminal box
1 (Exsd Ⅱ BT5) TIIS (Japan) Note 2)
explosion-proof Accessories
Applicable model
Symbol Accessories
IP8000 IP8100
Nil None (Standard) ● ●
Note 3)
A φ0.7 Output restriction with pilot valve ● ●
Note 3)
B φ1.0 Output restriction with pilot valve ● ●
C Fork lever-type fitting M ― ●
D Fork lever-type fitting S ― ●
E For stroke 35 to 100 mm with lever unit
Note 4)
● ―
F For stroke 50 to 140 mm with lever unit
Note 4)
● ―
Note 5)
G Compensation spring(A) ● ●
H With external scale plate ― ●
With opening current transmission （ 4 to 20mADC ）
J ― ●
/Positive operation Note 6)
With opening current transmission （ 4 to 20mADC ）
JR ― ●
/Reverse operation Note 6) C
Note1) For construction No.1(With terminal box), the ambient and fluid temperatures are as follows:
・ExdⅡBT5: －20 to 60oC
・Non-explosion proof(Non hazardous locations only): －20 to 80℃
Label of Explosion-Protected specification(ExdⅡBT5) is on the body.
(See page3 Item: Explosion-protected construction)
Note2) If two or more accessories are required, the part numbers should be made according to
alphabetical order (ex. IP8000-011-AG)
Note3) “A” is applied to approx. 90cm３-capacity actuator.
“B” is applied to approx.180cm３-capacity actuator.
Note4) Standard lever is not attached.
Note5) The following combinations are available: A+G or B+G
Note6) "J" has a terminal box, but it is non-explosion-proof specifications. ＡF

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12.Attached Drawing D

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 Revision history
Revision D 10/ 7/2020
Revision E 25/12/2020
Revision F 25/ 4/2022

4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN

Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362
URL https://www.smcworld.com

Note: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer.
© 2019 SMC Corporation All Rights Reserved

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