Azbil AVP300, AVP301, AVP202, AVP200, AVP302 User Manual

Smart Valve Positioner

CM2-AVP300-2001

300

Series

Model AVP300/301/302 (Integral Type)

200 Series

Model AVP200/201/202 (Remote Type)

User's Manual

NOTICE

• Make sure that this manual is available to the user.

• Reproduction or transmission of this manual, in whole or in part, is

prohibited.

• e descriptions in this manual are subject to change without notice.

• It is our hope that this manual is complete and accurate, but in the event that there is content which is incomplete or whose accuracy is in question, please contact us.

• Please understand that we cannot in some cases accept responsibility for the results of use of this equipment by the customer.

• HART® is a trademark of FieldComm Group.

Introduction

■ Introduction

Thank you for purchasing an Azbil Corporation Smart Valve Positioner 200/300 Series. Smart Valve Positioner 200/300 Series (the devices) can be connected to a 4 to 20 mA signal line. Since all adjustments can be performed electrically using CommStaff, any desired relationship can be set between the input signal and the position of the control valve. Split range and other special settings are also easy to specify. This manual describes the use of the Smart Valve Positioner. Use this manual to get the most from the features of the device.

i

Safety precautions

■ Symbols

These safety precautions are intended to help you to use the product safely and correctly, and to prevent injury to yourself or others as well as damage to property. Be sure to follow all safety precautions.

This manual makes use of a variety of symbols. The symbols and their meanings are as follows. Gain a good understanding of this information before reading the main text of this manual.

Cases in which it is conceivable that dangerous situations might arise

Warning

Caution

in which the user of the product could be seriously or fatally injured if the product is misused.

Cases in which it is conceivable that a dangerous situation might arise in which the user of the product could sustain minor injuries, or physical damage could occur, if the product is misused.

■ Examples of visual indicators

This indicates a warning or caution that the user should be aware of during use.

This indicates a prohibited action.

This indicates an instruction that the user should be sure to carry out.

ii

Cautions to ensure safe operation

Do not perform wiring work, turn on the electricity, etc., when your hands are wet. There is a risk of electric shock. Perform this work with the power supply turned off, and with dry or gloved hands.

When wiring in a hazardous area, work according to the methods prescribed by the guidelines for the hazardous area.

For flameproof explosion-proof specifications, do not under any circumstances open the cover during operation (when powered up).

After installing the device, do not place your body weight on it, use it as a scaffold, etc. There is a risk that it could fall over.

Introduction

Warning

Caution

Do not touch the device unnecessarily while it is in operation. Depending on the environment in which the device is used, there is a danger that the surface of the device may be very hot or very cold.

When opening the cover of the terminal box, be careful of the edges of the cover, the threads of the screws on the main unit, etc. There is a possibility of injury.

Use a DC power supply that has overload protection. An overload can cause the emission of smoke and fire.

Bringing tools and the like into contact with the glass portion of the display can cause damage or injury. Exercise sufficient caution. In addition, be sure to wear safety glasses.

As this product is extremely heavy, watch your footing, and be sure to wear safety shoes.

When the device is in operation, do not touch moving parts such as the feedback lever. Your hand may become caught, resulting in injury.

Supply power correctly based on the specifications. An incorrect power input can damage the instrument.

When working in a high-temperature or low-temperature environment, wear gloves and other protective equipment.

Do not bring magnets or magnetic screwdrivers near the device. There is a possibility that the control valve will move in response.

iii

Basic use

■ Basic model number structure

Model AVP 0

0: No transmission

1: With travel transmission (4 to 20mA DC or DE transmission)

2: HART

0: Fixed

■ Positioner and Actuator Types

® protocol communication

2: Remote type

3: Integral type

Positioner Type

Actuator Type

Single-acting linear diaphragm (Azbil Corporation actuator model numbers: PSA, HA, HK, VA, VR, RSA, GOM)

Double-acting linear cylinder (Azbil Corporation actuator model numbers: VP, SLOP, DAP)

Single-acting rotary cylinder

(actuator for ball valves and butterfly valves)

Model AVP300/301/302

(Integral Type)

Model AVP200/201/202

(See p. v.) (See p. xiii.)

(See p. vii.) (See p. xvi.)

(Remote Type)

Double-acting rotary cylinder

(actuator for ball valves and butterfly valves)

(See p. ix.) (See p. xix.)

(See p. xi.) (See p. xxi.)

iv

Combination of model AVP300/301/302 (integral type) and single-acting linear diaphragm actuator

Introduction

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the body of the device when it is packed. As a result, the feedback lever must be attached to the body of the device prior to installation of the device.

The length of the feedback lever can if necessary be adjusted by attaching the extension lever between the feedback lever and the body of the device. Adjustment of the feedback lever length is determined based on the form of the actuator.

If the actuator type is specified when ordering, and the extension lever is included:

If the actuator type is specified when ordering, and the extension lever is not included:

If the actuator type is not specified when ordering:

Manufacturer Extension Lever Actuator Type Code

No

Azbil

Corporation

Ye s

No #240, #280, #330 TA, TD

Motoyama

Masoneilan

Nihon Koso

Ye s

No #11, #13 MA, MB Ye s #15, #18 MC, MF No #270, #320 TA, TD Ye s #400, #500 TB, TE

When connecting an actuator other than those in the table, connect the device and the actuator, and then switch to manual mode and move the actuator slowly and ensure that the feedback lever does not interfere with the full stroke of the actuator.

Attach the extension lever to the body of the device, and then attach the feedback lever.

The extension lever is not necessary. Attach the feedback lever directly to the body of the device.

The extension lever will be included. Refer to the table below to determine, based on the actuator with which the device is equipped, whether or not the extension lever is necessary.

PSA1, 2, PSK1 YS

HA1 YA

HA2, 3 YT

HK1 YK

VA1 to 3 YQ

PSA3, 4 YQ

PSA6 YL

HA4 YN

PSA7 Y8

VA4 to 6 YL

RSA1 YF RSA2 YU

VR1 YV

VR2, 3 YR

VR3H Y6

GOM83S, 84S, 103S YG

GOM124S YM

#400, #500S, #500L TB, TE

#650S, #650L TC, TF

If the feedback lever alone cannot cover a full stroke, attach the extension lever to it.

Attach the feedback lever securely, working from the front of the device, using the two included hexagon socket head bolts.

Attachment of Feedback Lever

Attach the extension lever securely, working from the front of the device, using the two included hexagon socket head bolts. Then, in the same way, attach the feedback lever securely, working from the back of the device. (The feedback lever can be attached from the front as well.)

Attachment of Extension Lever and Feedback Lever

2. Attachment and installation

[1] Attachment to the actuator

Attach to the actuator with a mounting plate that is appropriate for the actuator.

[2] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Set the A/M switch to manual operation.

(See 5.2, “A/M Switch.”)

2 Supply air, and adjust the actuator air pressure such that the

actuator stem reaches the travel midpoint.

3 Adjust the actuator such that the feedback lever reaches a

90° angle to the device's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the device, or it may be performed by moving a pin.

4 Set the A/M switch to automatic operation.

(See 5.2, “A/M Switch.”)

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ±2°.

v

Adjustment of Attachment Positions

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case UP (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

3. Air piping and electric wiring connection

Connect the air piping and electrical wiring. For details, see 2.2, “Installation Method,” in this document.

4. Auto-setup

(1) Set the input signal to 18 ±1mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction (the DOWN direction for Azbil Corporation's VR and RSA actuators for VFR type control valves), and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, adjust it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

DOWN direction: VFR type

UP direction: direct type

External zero/span adjustment switch

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

• Using the setup device, either change the actuator size

(Param) or individually set the valve position control PID. Regarding the configuration method, see 4.4.4, “Control configuration,” below.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

vi

Introduction

Combination of model AVP300/301/302 (integral type) and double-acting linear cylinder actuator

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the body of the device when it is packed. As a result, the feedback lever must be attached to the body of the device prior to installation of the device.

The length of the feedback lever can if necessary be adjusted by attaching the extension lever between the feedback lever and the body of the device. Adjustment of the feedback lever length is determined based on the form of the actuator.

If the actuator type is specified when ordering, and the extension lever is included:

If the actuator type is specified when ordering, and the extension lever is not included:

If the actuator type is not specified when ordering:

Manufacturer Extension Lever Actuator Type Code

Azbil

Corporation

(SLOP type and DAP type are limited to products with stroke of 100 mm or less)

When connecting an actuator other than those in the table, connect the device and the actuator, and then, via manual operation, move the actuator slowly and ensure that the feedback lever does not interfere with a full stroke of the actuator.

If the feedback lever alone cannot cover a full stroke, attach the extension lever to it.

Attach the feedback lever securely, working from the front of the device, using the two included hexagon socket head bolts.

Attach the extension lever to the body of the device, and then attach the feedback lever.

The extension lever is not necessary. Attach the feedback lever directly to the body of the device.

The extension lever will be included. Refer to the table below to determine, based on the actuator with which the device is equipped, whether or not the extension lever is necessary.

VP5, 6, 7 Y1

SLOP560, 1000, 1000X Y2

Yes

SLOP1500, 1500X Y3

DAP560, 1000, 1000X Y4

DAP1500, 1500X Y5

Attach the extension lever securely, working from the front of the device, using the two included hexagon socket head bolts. Then, in the same way, attach the feedback lever securely, working from the back of the device. (The feedback lever can be attached from the front as well.)

Main unit

Bolt with hexagonal hole

Attachment of Extension Lever and Feedback Lever

Extension lever

Feedback lever

Spring

2. Attachment and installation

[1] Attachment to the actuator

Attach to the actuator with a mounting plate that is appropriate for the actuator.

[2] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Using for example the manual handle of the actuator

or manual operation via the external pressure regulator with filter, set the position to 50%. (With a double-acting actuator, manual operation cannot be performed using the A/M switch.)

2 Adjust the actuator such that the feedback lever reaches a

90° angle to the device's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the device, or it may be performed by moving the

pin.

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ±2°.

Attachment of Feedback Lever

Adjustment of Attachment Positions

vii

3. Air piping and electric wiring connection

• Air piping connection

(1) If control operation of control valve is direct operation

This refers to the state in which the valve moves in the closing direction as the input signal increases. Connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

(2) If control operation of control valve is reverse operation

This refers to the state in which the valve moves in the opening direction as the input signal increases. Connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

For details, see air piping connection and electric wiring connection in 1.3, “Description of Device Structure and Functions,” and 2.2, “Installation Method,” in this document.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case UP (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

5. Operation confirmation

Vary the input signal, and check the zero point and span point.

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ±1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

4. Auto-setup

(1) Set the input signal to 18 ±1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction (clockwise), and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system”)

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, move it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

Rotate in UP direction

External zero/span adjustment switch

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

•

Using the setup device, either change the actuator size (Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

viii

Introduction

Combination of model AVP300/301/302 (integral type) and single-acting rotary cylinder actuator

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the body of the device when it is packed. As a result, the feedback lever must be attached to the body of the device prior to installation of the device.

Attach the feedback lever securely, working from the front of the device, using the two included hexagon socket head bolts.

Main unit

Feedback lever

3. Air piping and electric wiring connection

Connect the air piping and electrical wiring. For details, see section 2.2, “Installation Method,” in this document.

Adjustment of Attachment Positions

Bolt with hexagonal hole

Spring

Attachment of Feedback Lever

2. Attachment and installation

[1] Attachment to the actuator

Attach to the actuator with a mounting plate that is appropriate for the actuator.

[2] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Set the A/M switch to manual operation.

(See 5.2, “A/M Switch.”)

2 Supply air, and adjust the actuator air pressure such that the

actuator stem reaches the travel midpoint.

3 Adjust the actuator such that the feedback lever reaches a

90° angle to the device's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the device, or it may be performed by moving

the pin.

4 Set the A/M switch to automatic operation.

(See 5.2, “A/M Switch.”)

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ± 2°.

4. Auto-setup

(1) Set the input signal to 18 ± 1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction (clockwise), and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.4, “Control configuration,” in this document.

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, adjust it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

Rotate in UP direction

External zero/span adjustment switch

• Auto-setup can be performed with CommStaff as well.

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

ix

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case in the UP direction (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ±1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

Using the setup device, either change the actuator size (Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

x

Introduction

Combination of model AVP300/301/302 (integral type) and double-acting rotary cylinder actuator

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the body of the device when it is packed. As a result, the feedback lever must be attached to the body of the device prior to installation of the device.

Attach the feedback lever securely, working from the front of the device using the two included hexagon socket head bolts.

Adjustment of Attachment Positions

3. Air piping and electric wiring connection

• Air piping connection

(1) If control operation of control valve is direct operation

This refers to the state in which the valve moves in the closing direction as the input signal increases. Connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Attachment of Feedback Lever

2. Attachment and installation

[1] Attachment to the actuator

Attach to the actuator with a mounting plate that is appropriate for the actuator.

[2] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Using for example the manual handle of the actuator

or manual operation via the external pressure regulator with filter, set the position to 50%. (With a double-acting actuator, manual operation cannot be performed using the A/M switch.)

2 Adjust the actuator such that the feedback lever reaches a

90° angle to the device's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the device, or it may be performed by moving the

pin.

Next, connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

(2) If control operation of control valve is reverse operation

This refers to the state in which the valve moves in the opening direction as the input signal increases. Connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

For details, see air piping connection and electric wiring connection in 1.3, “Description of Device Structure and Functions,” and 2.2, “Installation Method,” in this document.

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ± 2°.

xi

4. Auto-setup

(1) Set the input signal to 18 ± 1 mA.

Using a flat-blade screwdriver, turn the external zero/span

(2)

adjustment switch in the upper part of the case 90° in the UP direction, and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, adjust it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

Rotate in UP direction

External zero/span adjustment switch

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case UP (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

• Using the setup device, either change the actuator size

(Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

xii

Introduction

Combination of model AVP200/201/202 (remote type) and single-acting linear diaphragm actuator

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the valve travel detector when it is packed. As a result, the feedback lever must be attached to the valve travel detector prior to installation of the device.

The length of the feedback lever can if necessary be adjusted by attaching the extension lever between the feedback lever and the valve travel detector.

Adjustment of the feedback lever length is determined based on the form of the actuator.

If the actuator type is specified when ordering, and the extension lever is included:

If the actuator type is specified when ordering, and the extension lever is not included:

If the actuator type is not specified when ordering:

Manufacturer Extension Lever Actuator Type Code

No

Azbil

Corporation

Ye s

No #240, #280, #330 TA, TD

Motoyama

Masoneilan

Nihon Koso

Ye s

No #11, #13 MA, MB

Ye s #15, #18 MC, MF

No #270, #320 TA, TD

Ye s #400, #500 TB, TE

Attach the extension lever to the body of the device, and then attach the feedback lever.

The extension lever is not necessary. Attach the feedback lever directly to the body of the device.

The extension lever will be included. Refer to the table below to determine, based on the actuator with which the device is equipped, whether or not the extension lever is necessary.

PSA1, 2, PSK1 YS

HA1 YA

HA2, 3 YT

HK1 YK

VA1 to 3 YQ

PSA3, 4 YQ

PSA6 YL

HA4 YN

PSA7 Y8

VA4 to 6 YL

RSA1 YF

RSA2 YU

VR1 YV

VR2, 3 YR

VR3H Y6

GOM83S, 84S, 103S YG

GOM124S YM

#400, #500S, #500L TB, TE

#650S, #650L TC, TF

When connecting an actuator other than those in the table, connect the device and the actuator, and then, via manual operation, move the actuator slowly and ensure that the feedback lever does not interfere with a full stroke of the actuator.

If the feedback lever alone cannot cover a full stroke, attach the extension lever to it.

Attach the feedback lever securely, working from the front of the device, using the two included hexagon socket head bolts.

Attachment of Feedback Lever

Attach the extension lever securely, working from the front of the device, using the two included hexagon socket head bolts. Then, in the same way, attach the feedback lever securely, working from the back of the device. (The feedback lever can be attached from the front as well.)

Attachment of Extension Lever and Feedback Lever

2. Attachment and installation

[1] Attachment to the actuator of the valve travel detector

When attaching the valve travel detector to the actuator, install the cable outlet such that it does not face upward. If it faces upward, change the direction of the feedback lever. For details, see 2.3, “Remote Type Handling.”

[2] Positioner body configuration

Install the body of the positioner onto the 2B stanchion.

xiii

[3] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Set the A/M switch to manual operation.

(See 5.2, “A/M Switch.”)

2 Supply air, and adjust the actuator air pressure such that the

actuator stem reaches the travel midpoint.

3 Adjust the actuator such that the feedback lever reaches a

90° angle to the valve travel detector's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the valve travel detector, or it may be performed by moving the pin.

4 Set the A/M switch to automatic operation.

(See 5.2, “A/M Switch.”)

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ± 2°.

4. Auto-setup

(1) Set the input signal to 18 ±1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP (clockwise) direction (the DOWN direction for Azbil Corporation's VR and RSA actuators for VFR type control valves), and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, adjust it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

DOWN direction: VFR type

UP direction: direct type

External zero/span adjustment switch

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

Adjustment of Attachment Positions

3. Air piping and electric wiring connection

[1] Air piping connection

For details, see air piping connection in 2.2, “Installation Method,” in this document.

[2] Electrical wiring connection (cables between valve travel detector and positioner)

When shipped from the factory, the valve travel detector and the positioner body are normally shipped separated at the connector unit on the positioner body.

Referring to 2.3, “Remote Type Handling,” in this document, connect the valve travel detector cable to the body of the device using the remote cable. When laying cable, follow appropriate electrical work guidelines.

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case in the UP direction (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

xiv

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

• Using the setup device, either change the actuator size

(Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.3, “Valve system,” in this document.

Introduction

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

Note: When performing valve maintenance, first detach the valve travel detector of the remote type from the mounting plate.

xv

Combination of model AVP200/201/202 (remote type) and double-acting linear cylinder actuator

1. Attachment of feedback lever

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the valve travel detector when it is packed. As a result, the feedback lever must be attached to the valve travel detector prior to installation of the device.

The length of the feedback lever can if necessary be adjusted by attaching the extension lever between the feedback lever and the valve travel detector.

Adjustment of the feedback lever length is determined based on the form of the actuator.

If the actuator type is specified when ordering, and the extension lever is included:

If the actuator type is specified when ordering, and the extension lever is not included:

If the actuator type is not specified when ordering:

Attach the extension lever to the body of the device, and then attach the feedback lever.

The extension lever is not necessary. Attach the feedback lever directly to the body of the device.

The extension lever will be included. Refer to the table below to determine, based on the actuator with which the device is equipped, whether or not the extension lever is necessary.

Attach the extension lever securely, working from the front of the device, using the two included hexagon socket head bolts. Then, in the same way, attach the feedback lever securely, working from the back of the device. (The feedback lever can be attached from the front as well.)

Attachment of Extension Lever and Feedback Lever

2. Attachment and installation

[1] Attachment to the actuator of the valve travel detector

When attaching the valve travel detector to the actuator, install the cable outlet such that it does not face upward. If it faces upward, change the direction of the feedback lever. For details, see 2.3, “Remote Type Handling.”

Manufacturer Extension Lever Actuator Type Code

VP5, 6, 7 Y1

Azbil

Corporation

(SLOP type and DAP type are limited to products with stroke of 100mm or less)

Ye s

SLOP560, 1000, 1000X Y2

SLOP1500, 1500X Y3

DAP560, 1000, 1000X Y4

DAP1500, 1500X Y5

When connecting an actuator other than those in the table, connect the device and the actuator, and then, via manual operation, move the actuator slowly and ensure that the feedback lever does not interfere with a full stroke of the actuator.

If the feedback lever alone cannot cover a full stroke, attach the extension lever to it.

Attach the feedback lever securely, working from the front of the device, using the two included hexagon socket head bolts.

[2] Positioner body configuration

Install the body of the positioner onto the 2B stanchion.

[3] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Set the A/M switch to manual operation.

(See 5.2, “A/M Switch.”)

2 Supply air, and adjust the actuator air pressure such that the

actuator stem reaches the travel midpoint.

3 Adjust the actuator such that the feedback lever reaches a

90° angle to the valve travel detector's central vertical axis. Depending on the actuator being used, adjustment may be performed by moving the valve travel detector, or it may be performed by moving the pin.

4 Set the A/M switch to automatic operation.

(See 5.2, “A/M Switch.”)

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ± 2°.

Attachment of Feedback Lever

xvi

Introduction

4. Auto-setup

(1) Set the input signal to 18 ± 1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction, and hold that position for three sec-

onds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system.”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, move it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

Adjustment of Attachment Positions

3. Air piping and electric wiring connection

[1] Air piping connection

(1) If control operation of control valve is direct operation

This refers to the state in which the valve moves in the closing direction as the input signal increases. Connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

(2) If control operation of control valve is reverse operation

This refers to the state in which the valve moves in the opening direction as the input signal increases. Connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

For details, see on air piping connection and electric wiring connection in 1.3, “Description of Device Structure and Functions,” and 2.2, “Installation Method,” in this document.

[2] Electrical wiring connection (cables between valve travel detector and positioner)

When shipped from the factory, the valve travel detector and the positioner body are normally shipped separated at the connector unit on the positioner body.

Referring to 2.3, “Remote Type Handling,” in this document, connect the valve travel detector cable to the body of the device using the remote cable. When laying cable, follow appropriate electrical work guidelines.

If performing auto-setup

Note: When closing the valve of the single-acting type device with the lever in the upward direction,

Rotate in UP direction

External zero/span adjustment switch

first set it to reverse close.

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case in the UP direction (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

xvii

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

Check whether the electronics module (terminal block) is installed correctly in the case on the body of the device.

[2] If hunting occurs

• Using the setup device, either change the actuator size

(Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal%, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

Note: When performing valve maintenance, first detach the valve travel detector of the remote type from the mounting plate.

xviii

Introduction

Combination of model AVP200/201/202 (remote type) and single-acting rotary cylinder actuator

1. Attachment of feedback lever (pin)

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the valve travel detector when it is packed. As a result, the feedback lever (pin) must be attached to the valve travel detector prior to installation of the device.

Using the two accompanying hexagonal nuts, attach the feedback lever (pin) firmly to the valve travel detector as shown in the diagram.

Adjustment of Attachment Positions

3. Air piping and electric wiring connection

[1] Air piping connection

For details, see air piping connection in 2.2, “Installation Method,” in this document.

Attachment of feedback lever (pin)

2. Attachment and installation

[1] Attachment to the actuator of the valve travel detector

When attaching the valve travel detector to the actuator, install the cable outlet such that it does not face upward. If it faces upward, change the direction of the feedback lever. For details, see 2.3, “Remote Type Handling.”

[2] Positioner body configuration

Install the body of the positioner onto the 2B stanchion.

[3] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Set the A/M switch to manual operation.

(See 5.2, “A/M Switch.”)

2 Supply air, and adjust the actuator air pressure such that the

position reaches the travel midpoint.

3 By adjusting the attachment position of the arm that

holds up the feedback pin, adjust the actuator such that the feedback lever reaches a 90° angle to the valve travel detector's central vertical axis.

4 Set the A/M switch to automatic operation.

(See 5.2, “A/M Switch.”)

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ± 2°.

[2] Electrical wiring connection (cables between valve travel detector and positioner)

When shipped from the factory, the valve travel detector and the positioner body are normally shipped separated at the connector unit on the positioner body.

Referring to 2.3, “Remote Type Handling,” in this document, connect the valve travel detector cable to the body of the device using the remote cable. When laying cable, follow appropriate electrical work guidelines.

xix

4. Auto-setup

(1) Set the input signal to 18 ±1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction (the DOWN direction for Azbil Corporation's VR and RSA actuators for VFR type control valves), and hold that position for three seconds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system.”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, move it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

If performing auto-setup

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

• Using the setup device, either change the actuator size

(Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

Rotate in UP direction

External zero/span adjustment switch

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case UP (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50 % opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal %, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

Note: When performing valve maintenance, first detach the valve travel detector of the remote type from the mounting plate.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

xx

Introduction

Combination of model AVP200/201/202 (remote type) and double-acting rotary cylinder actuator

1. Attachment of feedback lever (pin)

In order to minimize the risk of damage to the feedback lever while it is carried or transported, and to minimize the packaging as well, the feedback lever is detached from the valve travel detector when it is packed. As a result, the feedback lever (pin) must be attached to the valve travel detector prior to installation of the device.

Using the two accompanying hexagonal nuts, attach the feedback lever (pin) firmly to the valve travel detector as shown in the diagram.

Adjustment of Attachment Positions

3. Air piping and electric wiring connection

[1] Air piping connection

(1) If control operation of control valve is direct operation

This refers to the state in which the valve moves in the closing direction as the input signal increases. Connect

Attachment of Feedback Lever (Pin)

2. Attachment and installation

[1] Attachment to the actuator of the valve travel detector

When attaching the valve travel detector to the actuator, install the cable outlet such that it does not face upward. If it faces upward, change the direction of the feedback lever. For details, see 2.3, “Remote Type Handling.”

[2] Positioner body configuration

Install the body of the positioner onto the 2B stanchion.

[3] Adjustment of attachment positions

Procedure for adjustment of attachment positions

Step Procedure

1 Using for example the manual handle of the actuator or

manual operation via the external pressure regulator with filter, set the position to 50 %.

(With a double-acting actuator, manual operation cannot be performed using the A/M switch.)

2 By adjusting the attachment position of the arm that

holds up the feedback pin, adjust the actuator such that the feedback lever reaches a 90° angle to the valve travel detector's central vertical axis.

Note: The accuracy specifications can be satisfied by making the attachment angle 90° ±2°.

the reversing relay output OUT1 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

(2) If control operation of control valve is reverse operation

This refers to the state in which the valve moves in the opening direction as the input signal increases. Connect the reversing relay output OUT2 to the cylinder chamber that performs output in order to close the valve in response to increased pressure.

Next, connect the reversing relay output OUT1 to the cylinder chamber that performs output in order to open the valve in response to increased pressure.

For details, see air piping connection and electric wiring connection in 1.3, “Description of Device Structure and Functions,” and 2.2, “Installation Method,” in this document.

[2] Electrical wiring connection (cables between valve travel detector and positioner)

When shipped from the factory, the valve travel detector and the positioner body are normally shipped separated at the connector unit on the positioner body.

Referring to 2.3, “Remote Type Handling,” in this document, connect the valve travel detector cable to the body of the device using a special-purpose connector. When laying cable, follow appropriate electrical work guidelines.

xxi

4. Auto-setup

(1) Set the input signal to 18 ±1 mA.

(2) Using a flat-blade screwdriver, turn the external zero/

span adjustment switch in the upper part of the case 90° in the UP direction, and hold that position for three sec-

onds.

Note: For reverse close (when the valve's fully closed position is on top), set the valve action to reverse close beforehand. See 4.4.3, “Valve system.”

(3) The valve will automatically start to move, and will stop

in about 3 to 4 minutes.

(4) When it stops, move it to a position that fits the input

signal.

(5) After that, check whether it has been adjusted correctly.

6. If suitable adjustment was not accomplished

[1] If auto-setup does not operate

• Check whether the input signal is 18 mA ± 1 mA.

• Check whether the A/M switch is set to automatic. If it is

set to manual, switch it to auto. See 5.2, “A/M Switch,” in this document for information on operating procedures.

• Check the duty value of the electro-pneumatic module.

Regarding the confirmation method, see “EPM (electropneumatic module) operation confirmation procedure” on page 3-9 in this document.

• Check whether the electronics module (terminal block) is

installed correctly in the case on the body of the device.

[2] If hunting occurs

If performing auto-setup

Note: When closing the valve of the single-acting type device with the lever in the upward direction, first set it to reverse close.

Rotate in UP direction

External zero/span adjustment switch

• Auto-setup can be performed with CommStaff as well.

Warning

When auto-setup is performed, the valve moves from fully closed to fully open, so there is a danger of, for example, getting your hand caught or affecting the process. Before performing auto-setup, move away from the valve, and confirm that the process is safe.

Check the span point and perform span adjustment.

(1) Set the input signal to the span point (URV). (Zero ad-

justment can be performed if the input signal is adjusted to the zero point, and span adjustment can be performed if the input signal is adjusted to the span point.)

(2) Using a flat-blade screwdriver, turn the external zero

span adjustment switch on the upper part of the case UP (clockwise) to cause the valve to move such that the feedback lever rises upward, or turn it DOWN (counterclockwise) to cause the valve to move such that the feedback lever drops downward.

• Using the setup device, either change the actuator size

(Param) or change the individual PID settings that control the AVP’s degree of opening. Regarding the configuration method, see 4.4.4, “Control configuration,” in this document.

[3] If the zero point floats or span adjustment cannot be performed

Referring to Table 3-1, “Integral type setting,” in 3.1, “Autosetup,” in this document, check whether valve action is configured correctly. If not, it will be necessary to change the valve action (the direct/reverse setting). Referring to 4.4.3, “Valve system,” in this document, configure the valve action correctly.

[4] If linearity characteristic is poor

• Check whether, when the attachment position of the feed-

back lever is the 50% opening position, it is attached horizontally. If not, refer to 2.2, “Installation Method,” in this document and correctly attach the feedback lever.

• Check the flow rate characteristics data. If equal %, quick

open, or the like has been specified, and these are fundamentally unnecessary, refer to 4.4.6, “Flow Type,” in this document and change this setting to linear.

Note: When performing valve maintenance, first detach the valve travel detector of the remote type from the mounting plate.

5. Operation confirmation

Vary the input signal, and check the zero point and span

point.

xxii

Product unpacking, verification, and storage

■ Unpacking

This device is a precision instrument. Handle it carefully in order to prevent accidents, injuries, etc.

Upon unpacking the product, verify that the following items are included. (When the device is shipped individually)

• Main unit

• Feedback lever and hex socket head cap bolts (2)

• Hexagonal bar wrench (1) (for feedback lever)

• Regulator (model KZ03) (optional)

• Mounting bracket (optional)

Introduction

• Flameproof packing cable gland and flame-proof elbow (explosion-proof option)

• User's Manual (this document) (included when specified during purchase)

• Extension lever and two hex socket head cap bolts (optional)

■ Checking specifications

The specifications are written on the nameplate on the body of this device. Referring to the Appendix, confirm that these are as designated. In particular, be sure to check the following points.

• Tag number (TAG NO.)

• Model number (MODEL)

• Production number (PROD)

• Input current range (INPUT) (since the input range can be changed using Com-

mStaff, the inscription on the nameplate is fixed to 4 to 20 mA as per explosionproofing regulations.

• Supply air pressure (SUPPLY)

• Explosion-proofing test conformity label (if explosion-proofing specification applies)

■ Contact point for inquiries

If anything in the specifications is unclear, please contact the office that appears at the end of this manual. When making an inquiry, be sure to include the model number (MODEL) and production number (PROD).

xxiii

■ Storage

If the device that you have purchased is to be stored, please observe the following precautions.

• If storing the device unused

1. Store the device in the packed state in which it was shipped.

2. Store the device indoors in a low-vibration, low-shock area, and maintain normal indoor temperature and humidity (about 25°C and 65%).

• If storing the device after being used

1. Prevent humidity from entering the device by attaching the terminal box cover firmly and cover the conduit connection port with tape.

2. Prevent humidity and contaminants from entering the device by covering the two air piping connections (SUP and OUT) and the pilot cover bleed holes with tape.

3. Return the product to the packed state in which it was shipped.

4. Store the device indoors in a low-vibration, low-shock area, and maintain normal indoor temperature and humidity (about 25°C and 65 %).

xxiv

This device is a smart valve positioner that can be connected to a 4 to 20 mA signal line from the output of a controller. Since all adjustments can be performed electrically, any desired relationship can be set between the input signal and the position of the control valve. Split range and other special settings are also easy to specify. In addition, by using a four-line connection, the device can transmit the control valve position to the host monitoring system as either a 4 to 20 mA analog signal or as a DE digital signal.* (Only models AVP301 and AVP201 have travel transmission.)

An overview of the control valve control system used by this device is shown below.

Host monitoring

system

Actuator air

4-20 mA DC analog signal or DE digital signal (model AVP301/201)

Host controller

Air supply

system

4-20 mA DC analog signal

Shuto

valve

Regulator with lter

Supply air

Process uid

Control valve

Figure 1-1. Control System Overview Diagram

*DE and the DE protocol are registered trademarks of Honeywell International, Inc. in the United States.

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Chapter 1: Control System Structure

1.2 Travel Transmission Output (Models AVP301 and AVP201)

This device (models AVP301 and AVP201) has the ability to transmit the position of the control valve. The device’s travel transmission system offers two output formats, depending on the purpose. There is a system that outputs an analog signal and a system that outputs a digital signal.

■ Analog output

To output the position only to the host monitoring device using a analog values, set up the analog output system. Normally, the range from the fully closed position to the fully open position is output as a 4–20 mA range.

■ Digital output

To output the position along with a variety of device settings and self-diagnostic results to the host monitoring device, set up the digital output system.

■ Output format switching

The output format provided by the device is specified by the user as configuration data when ordering the device. The device is set at the factory to either analog output specifications or digital output specifications.

Note, however, that the output format can be switched freely by the user using the CommStaff CFS100 field communication software or the HART

1.2.1 Structure of system without travel transmission output

This figure shows the system structure of the device when the travel transmission function is not used.

4–20 mA DC

Host

controller

HART

® Communicator

(Models AVP302 and AVP202 only)

or CommStaff

® Communicator.

Main Unit

CommStaff

Figure 1-2. Structure of System without Output (Model AVP300, AVP302, AVP200, and AVP202)

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1.2.2 Structure of system with travel transmission (analog output)

This figure shows an example of the structure of a system in which the position detected by the device is output as a 4–20 mA DC analog signal.

In this system structure, the analog signal from the device is directly output to the host monitoring system.

250 Ω 24 V DC

I

OUT

I

OUT

I

IN

I

IN

Figure 1-3. Structure of System with Analog Output (Models AVP301 and AVP201)

1.2.3 Structure of system with travel transmission (digital output)

This figure shows the structure of a system in which the position detected by the device, the values of the device settings, and the results of self diagnostics are output in the DE (Digital Enhancement) protocol* for digital signal transmission.

In this system structure, the digital signals in the DE protocol* transmitted from the device are output to a monitoring system that is capable of directly inputting these signals.

Figure 1-4. Structure of System with Digital Output (Models AVP301 and AVP201)

STIM II (Smart Transmitter Interface Module)

• An interface module for digital signals based on the DE protocol.*

PM100 (process controller, R20 or later)

• A process controller on the UCN. Simultaneously performs functions such as

adjustment control, sequencing, calculation, process I/O, etc.

Caution

•

If the device outputs the travel transmission output signal as a PV using the STIM II, be sure to set the valve forced fully closed value (SHUT OFF) to −0.2 % or greater so that the value of the process variable for the position signal STI point will not be BadPV.

* DE and the DE protocol are registered trademarks of Honeywell International, Inc. in the United

States.

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1.3 Description of Device Structure and Functions

The structure of the body of the device is shown below.

Reversing relay

Output air connection (OUT1)

Chapter 1: Control System Structure

Output air

pressure gauge

Terminal

box cover

Figure 1-5-1. Body Structure (Front)

Output air connection (OUT2)

Output air connection

Pilot relay cover

Body

External zero/span adjustment switch

Mounting plate (optional)

Feedback lever

Reversing relay supply air connection

A/M switch

Positioner body

Supply air connection

External ground terminal

Supply air pressure gauge

Figure 1-5-2. Body Structure (Rear)

Position detector

Figure 1-5-3. 200 Series

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Each component is described in the following table.

Name Description

Main unit (also “Body”) • Houses the electronics module, EPM (electro-pneumatic module), and

VTD (position sensor).

Pilot relay • Amplifies the pneumatic signal from the EPM (electro-pneumatic

module) and converts it to a pneumatic signal for the actuator.

Feedback lever • Receives the motion of the control valve lift and transmits it to the

VTD (position sensor).

A/M switch • Switches the output air control method between the automatic

operation state and the manual operation state. See 5.2 for information on operating procedures.

External zero/span adjustment switch

Supply air pressure gauge • Indicates the pressure of the supplied air.

Output air pressure gauge • Indicates the pressure of the output air.

Supply air connection • The air supply goes to this connection.

Output air connection • The output air is delivered from this connection to the actuator.

Mounting plate (optional) • Used to mount the device on the actuator.

Reversing relay • Used when a double-acting actuator is used.

Output air connection (OUT1)

Output air connection (OUT2)

• Enables the zero and span to be adjusted and auto setup to be performed with just a flat-blade screwdriver, without using a setup device.

• Labeled “SUP.”

• Labeled “OUT.”

• Its shape differs depending on the specifications (the actuator type).

The reversing relay is added at the output connection of the device. The reversing relay provides two outputs: output air pressure 1 (OUT1), which is the device's output air pressure without modification, and output air pressure 2 (OUT2), which is the output air pressure resulting when the air pressure supplied to OUT1 is subtracted from the reversing relay (SUP). Connecting these outputs to the two cylinder chambers of the double-acting cylinder allows the cylinder to function as a double-acting actuator.

• The output air is delivered from this connection to the actuator.

• “O1” is stamped on the lower section of the reversing relay.

• The output air is delivered from this connection to the actuator.

• “O2” is stamped on the lower section of the reversing relay.

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1.4 Terminal Box

Chapter 1: Control System Structure

Houses an input signal (controller output) terminal, an output signal (travel transmission) terminal, and an internal ground terminal.

The structure of the terminal box is shown below.

Figure 1-6. Structure of Terminal Box

Figure 1-7. Terminal Block of Terminal Box

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Each component of the terminal box is described in the following table.

Name Description

Terminal box cover • The cover has a pressure-resistant flameproof structure.

Cover locking screw • Be sure to tighten this when an explosion-proof model is used in a

hazardous area.

Input signal terminal • Labeled “I IN.”

• Connect the signal cable from the host controller.

Output signal terminal • Labeled “I OUT.”

• Connect the signal cable for travel transmission.

• This terminal screw is not present in model AVP300/302/200/202 (without travel transmission).

External ground terminal (Figure 1-5-2)

Internal ground terminal • When using the device, use either the internal or external ground

Conduit connection (1) • Port for wiring cables.

Conduit connection (2) • Port through which wiring cables are pulled.

Check pins for setup device

• Ground this pin in accordance with the specifications.

terminal.

• When using an explosion-proof model in a hazardous area, be sure to use the specified flameproof cable gland (available as an option).

• This port is normally sealed with a blind cap.

• The device can communicate with a setup device if the connection hooks of the setup device communication cable are connected to these

pins.

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Chapter 2: Installation

■ Overview of this chapter

This chapter describes installation of the device and connection of its piping and wiring.