Azbil AVP702, AVP701 User Manual

Smart Valve Positioner 700 Series

with HART Communication Protocol

Model AVP701/702

User's Manual

CM2-AVP702-2001

Notice

• Make sure that this manual is delivered to the user of this product.

• It is prohibited to copy or reprint this manual in whole or in part without

permission.

• The contents of this manual are subject to change without notice.

• Although Azbil took all possible measures to ensure the accuracy of

this manual, contact us if you find any errors or missing information.

• Note that we cannot be held responsible for the results of customer

operation.

• HART® is a registered trademark of the FieldComm Group.

Introduction

Thank you for purchasing our AVP702 Smart Valve Positioner. The AVP702 (called “the device” below) is a smart valve positioner that can be connected to the 4 to 20 mA loop.

The auto setup function makes it easy to set up the valve.

All adjustments and setup can be performed from the HART communication. The Local User Interface (LUI), which consists of the LCD (liquid crystal display) and operation buttons, facilitates monitoring of input signals, valve opening, pressure display, and other items as well as basic adjustments.

In addition, the built-in pressure sensor can be used to measure the supply air pressure and output air pressure. As a result, the device can not only perform self-diagnostics but can also be combined with the control valve maintenance support system called “Valstaff” in order to monitor the characteristics, operating status, and other data of the control valve, helping to improve the maintenance efficiency of control valves. This instruction manual describes how to handle the device. Read this manual to make full use of the features of this product.

Scope of this manual and related documents

This document describes the functions and method of installation and adjustment of this device. For details on HART communication, refer to

with HART Communication Protocol Model AVP701/702 HART Communication Manual

(No. CM2-AVP702-2002*).

For details on the control valve diagnostic items, refer to the “Smart Valve Positioner 700 Series Control Valve Diagnostic Function Manual” (No. CM2-AVP700-2003*).

* If you need the above documents, please contact one of our sales representatives.

Smart Valve Positioner 700 Series

Safety precautions

■ Symbols

The purpose of the safety precautions listed here is to ensure the user uses the product safely and correctly, to prevent harm to the user and other people and damage to property. Make sure to obey the safety precautions. Many different symbols are used in this manual. Their appearances and meanings are as described below. Thoroughly understand the explanation before starting to read the main text.

Warning

Cautions

■ Samplesymbols

This symbol indicates “warnings” and “cautions” that you must pay attention to when handling the device.

This symbol indicates “prohibited” actions that must not be taken.

This symbol indicates “instructions” for the action that must be taken.

Wrong handling may cause the death or severe injury of the user.

Wrong handling may cause a minor injury to the user or damage to equipment.

Precautions for safe work

Do not perform wiring with wet hands or while the device is energized. This may lead to electric shock. Turn the power off before starting the work and work with dry hands or use gloves.

Follow the work procedure defined in the explosion protection guidelines when performing the power distribution work in an explosion-proof area.

For devices equipped with the pressure-resistant, explosion-proof specifications, do not open the cover during operation (while the power is on).

Do not get on the installed device or use it as a step stool. This is dangerous because the device may tip over.

Do not touch the device during operation without reason. This is dangerous because the surface may be hot or cold depending on the usage environment.

Be careful not to touch the edge of the cover or the screw threads of the main unit when opening the cover of the terminal box. You may be injured by these parts.

Warning

Cautions

Use a DC power supply with overload protection. Overload may cause smoke or fire.

If a tool or other item touches the glass part of the display, it may break, leading to an injury. Be careful. Wear safety glasses during work.

This product is heavy. Be careful where you step and wear safety shoes during work.

Do not touch the feedback lever or other moving part while the device is operating. You may be injured by getting your hand or other body part caught in them.

Properly use the power supply based on the specifications. Inputting a different power supply may damage the device.

Use gloves and other protective equipment during work in a hot, cold, or other severe environment.

Do not move the device close to a magnet or magnetic driver. The control valve may operate.

Apply the correct supply air pressure in acoordance with the specification of the device. The overpressure may cause abnormal actions of the control valve or damage to the pressure gauge.

iii

Unpacking, Verification, and Storage of Product

Unpacking

This device is precision measuring equipment. Carefully handle it to prevent accidents or damage. After unpacking, check that the items below are included.

• The device

• Feedback lever and hexagon socket bolts x 2

•

(4-mm) hexagon wrench x 1 (for feedback lever) (Included only when the device is shipped alone.)

• Regulator (KZ03) (optional)

• Mounting plate set (optional)

• Pressure-resistant packing cable adapter and pressure-resistant elbow (option for explosion-proof specifications)

• Instruction manual (this document) (Included if specified at the time of purchase.)

• Extension lever and hexagon socket bolts x 2 (optional)

Specifications check

The specifications are shown on the nameplate of the main unit. Check that the specifications are the same as what you specified. In particular, confirm the following points.

• Tag No. (TAG No.)

• Model (MODEL)

• Work No. (PROD.)

• Input current range (INPUT)

• Supply air pressure (SUPPLY)

• Explosion protection certification seal (for explosion-proof specifications)

Contact

Storage

WARNING

When using the device in an explosion-proof area, be sure to select the model that satisfies the necessary explosion-proof requirements. Non-explosion-proof products cannot be used in an explosion-proof area.

For inquiries about this device, please contact us.

When contacting us, let us know the model number and production number.

When storing the device after purchase, obey the following precautions.

• When storing the device before it has been used

1. Store the device as packed at shipment.

2. Store the device at an indoor location with little vibration or shocks and at normal temperature and humidity (about 25°C, 65%).

• When storing the device after it has been used

1. Tightly secure the terminal box cover and block the conduit connection port with tape to prevent humidity intrusion.

2. Block the three pneumatic piping connection ports (SUP , OUT1 and OUT2) with tape to prevent humidity and dust intrusion.

3. Pack the device in the same way as at shipment. Store the device at an indoor location with little vibration or shocks where it will not be

4. exposed to rain or water and at normal temperature and humidity (about 25°C, 65%).

Chapter 1 Structure of the 700 Series Control System ..............1-1

1-1 System Configuration ...............................................1-1

1-2 System Configuration without Motion Transmission ........................1-2

1-3 System Configuration with Motion Transmission ..........................1-2

1-4 Structure of the Device and Description of Each Part .......................1-3

1-4-1 Structure of the Device .........................................1-3

1-4-2 Structure of Terminal Box .......................................1-5

1-4-3 Display on the Local User Interface (LUI) ...........................1-7

Chapter 2 Installation of the 700 Series ..........................2-1

2-1 Usage Conditions ..................................................2-2

2-2 Selection Criteria for Installation Location ................................2-3

2-2-1 Selection Criteria for Installation Location ..........................2-3

2-2-2 Criteria for instrumentation air ...................................2-3

2-3 Installation Procedure ...............................................2-5

2-3-1 Mounting the 700 Series onto the Actuator ..........................2-5

2-3-2 Pneumatic Piping Connection ...................................2-12

2-3-3 Electrical Wiring Connection ....................................2-15

2-3-4 Input Signals and Travel Transmission Power ......................2-17

2-3-5 Cables .....................................................2-18

2-4 Cable gland and flameproof universal elbow for TIIS Flameproof apparatus ....2-20

Chapter 3 Operation of the 700 Series ...........................3-1

3-1 Local User Interface (LUI) ............................................3-2

3-2 Adjustment before Operation .........................................3-5

3-2-1 Auto Setup ..................................................3-5

3-2-2 Zero Span Adjustment .........................................3-9

3-2-3 Supply Bypass ..............................................3-12

3-2-4 Control Parameters ...........................................3-13

3-2-5 Password ..................................................3-15

3-3 Starting Operation .................................................3-16

3-3-1 Preoperation Check ..........................................3-16

Chapter 4 Operation with HART Communication ..................4-1

4-1 Operation with HART Communication ..................................4-1

4-2 Setup and Adjustment of Device .......................................4-2

4-2-1 Process Variables .............................................4-2

4-2-2 Auto Setup ..................................................4-3

4-2-3 Input Range .................................................4-5

4-2-4 Valve System ................................................4-5

4-2-5 Control Configuration ..........................................4-6

4-2-6 Input Characterization ..........................................4-8

4-2-7 Travel Cutoff .................................................4-8

4-2-8 Units .......................................................4-9

4-2-9 Travel Calibration ............................................4-10

4-2-10 Input Calibration .............................................4-12

4-2-11 Pressure Sensor Adjustment ...................................4-12

4-2-12 Simulation .................................................4-12

4-2-13 Adjustment of EPM Drive Signal (Pneumatic Modules) ...............4-13

4-2-14 Restore factory settings .......................................4-13

4-2-15 Operator Action Records ......................................4-13

4-2-16 Real Time Clock .............................................4-13

4-2-17 Password ..................................................4-13

4-2-18 Device Information ...........................................4-14

4-2-19 Option ....................................................4-16

4-2-20 Diagnostic Messages .........................................4-17

4-2-21 Control Valve Diagnostic Messages ..............................4-19

Chapter 5 Troubleshooting ....................................5-1

5-1 Troubleshooting ...................................................5-2

5-1-1 The Device Does Not Operate. (There Is No Output Air Pressure.) .......5-2

5-1-2 The Control Valve Operates Abnormally (There Is Output Air Pressure.) ...5-2

5-1-3 Failure to communicate with the communicator ......................5-2

5-1-4 Adjustment Procedure When Hunting Occurs .......................5-3

5-1-5 Auto Setup Failure ............................................5-4

5-2 Description of Messages .............................................5-5

Chapter 6 Maintenance .......................................6-1

6-1 A/M Switch .......................................................6-2

6-2 Replacement of Filter and Maintenance of Flow Restriction ..................6-4

6-3 Cleaning the Flapper ................................................6-5

6-4 Adjusting the Pilot Relay .............................................6-6

6-5 Insulation Resistance Test ...........................................6-7

6-6 Adjustment Procedure When Using the Device with the Booster Relay Attached . 6-8

6-7 List of Default Values for Internal Data ..................................6-9

6-8 Internal Block Diagram of the 700 Series ...............................6-10

6-9 Resale Parts .....................................................6-11

6-9-1 Procedure to Change Switch Block ..............................6-15

6-9-2 Procedure to Change Pilot Relay ................................6-16

Chapter 7 Notes on the Explosion-Proof 700 Series ...............7-1

7-1 TIIS Flameproof Model ..............................................7-2

7-2 ATEX Flameproof and Dust Ignition Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3 IECEx Flameproof and Dust Ignition Protection ...........................7-5

7-4 FM Explosionproof / Dust Ignition Protection .............................7-7

7-5 FM Intrinsically safe (ic) and Nonincendive ..............................7-8

7-6 FMC Explosionproof / Dust Ignition Protection ...........................7-13

7-7 NEPSI Flameproof / Dust Ignition Protection ............................7-14

7-8 KOSHA Flameproof ...............................................7-16

7-9 INMETRO Flameproof / Dust Ignition Protection .........................7-17

7-10 EAC Flameproof ..................................................7-19

7-11 ATEX Intrinsic Safety and Dust Ignition Protection ........................7-20

7-12 IECEx Intrinsic Safety and Dust Ignition Protection .......................7-21

Appendix A LUI Display Example ................................A-1

Appendix B Menu List ..........................................B-1

Appendix C Specification .......................................C-1

Appendix D Model Selection ....................................D-1

Appendix E Outline Dimensional Drawing .........................E-1

Chapter 1 Structure of the 700 Series Control System

This chapter describes the device configuration of the control system that uses the device.

• Description of the configuration of the input/output system in the device

• Description of the structure of the main unit of the device and the name and function of

each part

1-1 System Configuration

This device is a smart valve positioner that can be connected to the 4–20 mA DC signal lines of the controller output. It makes various adjustments using electricity, so the relationship between input signals and control valve travel can be set to any desired value. In addition, by connecting the device using four lines, the control valve travel is transmitted to the host monitoring system as a 4–20 mA DC analog signal. (Only the AVP701 model supports valve travel transmission.)

Air to the actuator

Host monitoring system

Host controller

Air supply system

DC4–20mA analog signal (AVP701)

DC4–20mA analog signal

Shutoff Solenoid valve

with filter

valve

Device

Supply air

Control valve

Figure1-1 Concept Diagram of the 700 Series Control System

Process fluid

1-1

1-2 System Configuration without Motion Transmission

This shows the configuration for a system that does not use the motion transmission function of this device (model AVP702).

Host controller

HART configuration tool

DC4–20mA

HART Modem

I IN

Device

Figure1-2 System Configuration without Motion Transmission (Model AVP702)

1-3 System Configuration with Motion Transmission

This device (model AVP701) has a function for motion transmission of the control valve.

To output the travel signal to the host monitoring device using analog values, configure the system with motion transmission. Normally, the travel from fully closed to fully open are output as 4–20 mA DC.

This shows an example of a system configuration for outputting valve travels detected with this device as 4–20 mA DC analog signals.

With this system configuration, analog signals are output directly to the higher-order host monitoring system from this device.

250Ω

Host

monitoring

system

(current input)

Host controller

*1: For the detailed information of the power supply and resistor, please

refer to the figure 2-18 of 2-3-4 Input Signals and Travel Transmission

Resistor

*1 *1

Analog signal DC4–20mA

DC4–20mA

DC24V

Power supply

HART Modem

Device

HART configuration tool

Figure1-3 System Configuration with Motion Transmission (Model AVP701)

1-2

1-4 Structure of the Device and Description of Each Part

1-4-1 Structure of the Device

1) Major components

The structure of the main unit of the device is shown in the figure below.

Output air connection port (OUT1)

Main unit

Output air pressure gauge

Mounting plate (optional)

Feedback lever

Local user

interface (LUI)

Exhaust cap

Supply air pressure gauge

Figure1-4 Structure of the Device (Upper)

Output air connection port (OUT2)

External grounding terminal

Pilot relay cover

Electrical conduit connection port

Supply air connection port (SUP)

Terminal box cover

Figure1-5 Structure of the Device (Lower)

1-3

2) Name and description of each part

The table below describes each part.

Table 1-1 Description of Each Part

Name Description

Main unit

Pilot relay cover

Auto/Manual (A/M) switch

Feedback lever

Local user interface (LUI)

Supply air pressure gauge - Indicates the pressure of supply air.

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

Supply air connection port (SUP)

Output air connection port (OUT1)

Output air connection port (OUT2)

Mounting plate (optional)

- Houses electronic circuits, an electro-pneumatic transducer (EPM), a position sensor (VTD), and a pressure sensor.

- Cover of the pilot relay that amplifies the air signal from the EPM (electro-pneumatic transducer) and transduces it into the air signal sent to the actuator.

- When you must adjust the balance pressure to switch between the pilot relay for the single-acting actuator and the pilot relay for the double-acting actuator, remove this cover.

- This switch is used to switch how the output air between the auto operation status and the manual operation status is controlled. This switch is built into the pilot relay. This switch can be seen by removing the pilot relay cover.

- Extracts and transmits the movement of the control valve lift to the VTD (position sensor).

- The LUI allows you to adjust the zero span, perform auto setup, and manually operate the device with the LCD (liquid crystal display) and operation buttons without using the communicator.

- Supply air is input to this port.

- “SUP” is displayed at this port.

- Output air is sent out of this port to the actuator.

- “OUT1” is displayed at this port.

- Output air is sent out of this port to the actuator.

- This port is blocked with a blind plug in the single-acting actuator.

- OUT2 is displayed at the output port for the double-acting actuator.

- The mounting plate is used to mount the device onto the actuator.

- The shape of the mounting plate differs depending on the specifications (actuator model).

1-4

1-4-2 Structure of Terminal Box

1) Major components

This contains the input signal (controller output) terminal, output signal (motion transmission) terminal, and internal ground terminal.

The structure of the terminal box is as shown below.

Lock screw

Terminal box cover

Conduit connection port (1)

Conduit connection port (2)

Figure1-6 Structure of Terminal Box

Terminal for output signals M4 screw

HART check pin

Terminal for input signals M4 screw

Terminal for internal grounding M4 screw

Figure1-7 Terminal Block in the Terminal Box

1-5

Terminal for external grounding M4 screw

2) Name and description of each part

The table below describes each part of the terminal box.

Table 1-2 Description of Each Part

Name Description

Terminal box cover

Lock screw - Used to secure the terminal box cover.

Terminal for input signals

Terminal for output signalsl

Internal grounding terminal

Conduit connection port (1) - Service entrance for a cable.

Conduit connection port (2)

Check pin for HART communication

- Lid of terminal box.

- This cover has a pressure-resistant explosion-proof structure.

- Shown as IN.

- Connects the signal cable from the host controller.

- Shown as OUT.

- Connects the signal cable for motion transmission.

- The AVP702 model (without motion transmission) does not have the terminal screws.

- Internal terminal for grounding. The cable for grounding is connected to this terminal.

- Service entrance for a cable.

- This entrance is normally blocked with a blind plug.

- By connecting the connection hook for the setting device communication cable to this pin, it is possible to communicate with this device.

Warning

When using a pressure-resistant explosion-proof model in a dangerous place, be sure to use the specified cable adapter for pressure-resistant packing for the conduit connection port. Securely close the terminal box cover all the way. Then, rotate the lock screw counterclockwise to secure the terminal box cover.

Handling Precautions:

Ground either the external or internal grounding terminal according to the specifications. Be careful not to ground the device at two points.

1-6

1-4-3 Display on the Local User Interface (LUI)

Figure1-8 Segments on the LCD

Table 1-3 Description of Each Part

No. Displayed element Main display

(1) 7 segments (5 digits) Displays the main numerical values such as the specified opening.

(2) Minus sign Displays the sign for the 7-segment number.

Decimal point

(3)

(five places)

16 segments

(4)

(7 digits)

(5) Dot (6 places) Displays the 16-segment auxiliary display, separator, or other data.

(6) Percentage Displays %.

(7) Bar graph (22 bars) Displays the bar graph in percentage at a set point, etc.

(8) Key mark

(9) Flag mark

(10) Display refresh mark

Displays the decimal point for the 7-segment number.

Displays the unit, status, or other data.

On: LUI operation is unavailable. Off: LUI operation is available. Blinking: LUI is in operation.

When the self-diagnostic alarm is activated, the key mark is displayed. For detailed information of the alarms,please refer to the status monitor of page 3-4.

Display during operation White and black circles alternately blink.

For a display example, refer to "LUI Display List" in Appendix A.

Handling Precautions:

The LUI buttons may not respond well near an electromagnetic inductor (such as a large transformer or high-frequency furnace). Remove sand, dust, and other foreign objects from the rubber parts of the operation buttons before operating the LUI. Operating the LUI with foreign objects on it may damage the rubber parts. Do not pull the rubber parts of the operation buttons. This may deteriorate the sealability, possibly causing malfunction.

1-7

1-8

Chapter 2 Installation of the 700 Series

This chapter describes the usage conditions, installation, piping, and wiring of the device.