Azbil AVP772, AVP782, AVP792 User Manual

Smart ESD Device

700 Series for Safety

CM2-AVP772-2001

Instrumented Systems

Model AVP77_/78_/79_

User’s Manual

Important

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

• Copying or reprinting this manual in whole or in part without permission is
prohibited.

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

• Although we have taken all possible measures to ensure the accuracy of this
manual, please contact us if you find any errors or missing information.

• Note that we cannot be held responsible for the results of device operation by
the customer.

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

©2015–2019 Azbil Corporation. All Rights Reserved.

Introduction

Thank you for purchasing our Smart emergency shutdown (ESD) device. Model
AVP77_/78_/79_ supports the safety instrumented systems (SIS), and is a smart ESD
Device that can connect to signal lines of 4-20 mA DC, 0-20 mA DC or 0/24 V DC.

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

You can use the HART communication to conduct various adjustments and settings, and
use the local user interface (LUI), which is composed of an LCD (liquid crystal display)
and operation buttons, to easily monitor and conduct basic adjustments of the input signal,
valve opening, pressure displays, as well as activate and verify the result of the PST (partial
stroke test).

Furthermore, the built-in pressure sensor can be used to measure the supply air pressure
and output air pressure. With this, you can not only use this equipment for self diagnosis,
but can also combine with “Valstaff,” a valve maintenance support system, to monitor
valve’s characteristics, operating condition, etc., which will contribute to the valve’s
maintenance efficiency. This user manual explains how to handle the equipment. Please
use this manual to optimize the characteristics of this product.

Scope of this manual and related documents

This manual describes functions, as well as the installation and adjustment procedures.

For handling that is subject to conditions that are in line with the functional safety
standards of IEC61508 or IEC61511, please refer to the safety manual that is included in
the package of this device.

For details on HART communication, please refer to “Safety Instrumented Systems (SIS)
Specification - Communication Specification” (No. CM2-AVP772-2002 (T.B.D)*).

For details on valve diagnostic criteria, please refer to “Control Valve Diagnosis Function
Manual” (No. CM2-AVP700-2003).

* For any questions regarding the detail, please contact the office listed at the end of this manual.

i

Safety precautions

J 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 observe the safety precautions.

Many different symbols are used in this manual.

Their appearance and meaning are described below. Thoroughly understand the explanation before starting to
read the main text.

Warning

Caution

J Sample symbols

This symbol indicates warnings and cautions for handling the device.

This symbol indicates prohibited actions that must not be taken.

This symbol indicates instructions for an action that must be taken.

J Conventions used in this instruction manual

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.

Handling Precautions : This symbol indicates a point to be noted when handling the device.

ii

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 of countries when
performing the power distribution work in an explosion-proof area.

For devices equipped with the pressure-resistant, explosion-proof specifications, open/close the
explosionproof enclosure and the cover according to "Chapter 7 Notes on the Explosion-Proof".

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.

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

Warning

Caution

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 parts 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 bring magnets or magnetic screwdrivers near the device. They may activate the valve.

Supply appropriate air pressure according to the specifications. Too much pressure may cause
abnormal valve function, damage to the pressure gauge, etc.

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 × 2

• (4mm) hexagon wrench × 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.)

• Safety manual

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

Specifications check

Specifications are written on the product nameplate. Furthermore, please verify that the
phrase “Smart ESD Device for SIS” is printed on the front cover. Verify that all ordered
items are present. Please especially take note of the following.

• Tag No.

• Model

• Production No. (PROD.)

• Input current range (INPUT)

• Supply air pressure (SUPPLY)

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

• Functional Safety Authorization FS Symbol

Contact

Storage

Warning

For use in an explosion-proof area, be sure to select a model that satisfies
the necessary explosion-proof requirements. Non-explosion-proof products
cannot be used in an explosion-proof area.

If any part of the specification is unclear, please contact our service representative.
When contacting us, please always have your model number and production number ready.

When storing the device after purchase, observe 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%RH).

• 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.

4. Store the device at an indoor location with little vibration or shocks where it will not

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

iv

Table of Contents

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

1-1 Model Number Configuration ........................................................1-1

1-2 System Configuration ................................................................1-1

1-3 System Configuration (Model AVP7_2) without Output Signal .........................1-2

1-3-1 In the Case of Current Signal Input ............................................1-2

1-3-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-2

1-4 System Configuration with Travel Transmission (Model AVP7_1) .......................1-3

1-4-1 In the Case of Current Signal Input ............................................1-3

1-4-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-3

1-5 System Configuration with Contact Output (Model AVP7_0) ...........................1-4

1-5-1 In the Case of Current Signal Input ............................................1-4

1-5-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-4

1-6 Structure of the Device and Description of Each Part ..................................1-5

Chapter 2 Installation ..................................................2-1

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

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

2-3 Installation Procedure ................................................................2-4

2-3-1 Attaching the 700 Series to the Actuator ......................................2-4

2-3-2 Pneumatic Piping Connection ...............................................2-10

2-3-3 Electrical Wiring Connection .................................................2-13

2-3-4 Input Signal and Output Signal Power .......................................2-17

2-3-5 Cables (For Input or Output Signal) ..........................................2-18

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

Chapter 3 Operation ...................................................3-1

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

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

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

3-2-2 Zero/Span Adjustment .......................................................3-8

3-2-3 Supply Bypass ..............................................................3-10

3-2-4 Partial Stroke Test (PST ) .....................................................3-12

3-2-5 Control Parameters ..........................................................3-14

3-2-6 Password ...................................................................3-16

3-3 Starting Operation ..................................................................3-17

3-3-1 Preoperation Check .........................................................3-17

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

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

4-1-1 HART Communication ........................................................4-1

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

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

4-2-3 Input Signal Range (Input Range) (Model AVP77_/78_ Current Signal Input) ...4-4

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

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

4-2-6 Input Characterization .......................................................4-7

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

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

4-2-9 SIS Positioner Mode ..........................................................4-9

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

v

4-2-11 Input Signal Calibration (Model AVP77_/78_ Current Signal Input) ............4-11

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

4-2-13 Simulation ..................................................................4-12

4-2-14 Adjustment of EPM Drive Signal (Pneumatic Modules) ........................4-12

4-2-15 Restore factory settings .....................................................4-12

4-2-16 Operator Action Records ....................................................4-13

4-2-17 Real Time Clock .............................................................4-13

4-2-18 Password ...................................................................4-13

4-2-19 Device Information ..........................................................4-13

4-2-20 Option ......................................................................4-15

4-2-21 Diagnostic Messages ........................................................4-16

4-2-22 Valve Diagnosis .............................................................4-17

4-2-23 PST (Partial Stroke Test) ......................................................4-18

4-2-24 FST (Full Stroke Test). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

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

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

5-1-1 If the Valve does not Close Fully (the output air pressure does not go down to 0) ...5-1

5-1-2 If the Device does not Operate (No Output Air Pressure) .......................5-1

5-1-3 If the Valve Behaves Abnormally (Output Air Is Present) ........................5-2

5-1-4 Failure to Communicate with the Communicator ..............................5-3

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

5-1-6 Description of Messages .....................................................5-4

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

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

6-2 Replacement of Filter and Maintenance of Flow Constriction ..........................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 a 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 Replacement Parts ..................................................................6-11

6-9-1 Procedure for Changing Switch Block ........................................6-14

6-9-2 Procedure for Changing the Pilot Relay ......................................6-15

Chapter 7 Notes on Explosion-Proof Structure ...........................7-1

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

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

7-3 FM Explosion-proof / Dust Ignition Protection .........................................7-5

7-4 FM Intrinsically Safe Explosion-Proof Type (ic) and Non-incendive Type .................7-6

7-5 FMC Explosion-proof / Dust Ignition Protection ......................................7-11

7-6 NEPSI Flameproof / Dust Ignition Protection .........................................7-12

7-7 KOSHA Flameproof Type ............................................................7-15

7-8 INMETRO Flameproof / Dust Ignition Protection ......................................7-16

7-9 EAC Flameproof .....................................................................7-18

7-10 ATEX Intrinsic Safety and Dust Ignition Protection ....................................7-19

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

Appendix A LUI Display Examples ....................................... A-1

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

vi

Appendix C Specifications ...............................................C-1

Appendix D Model Number Configuration Table .......................... D-1

Appendix E External Dimension ..........................................E-1

vii

viii

Chapter 1 Structure of the Control System

Model AVP7 _ _

7: 4-20 mA DC input signal
8: 0-20 mA DC input signal

2: without output signal

Air to the actuator

Valve

Process uid

Chapter 1 Structure of the Control System

This chapter describes device configuration in a control system that uses the device.

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

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

1-1 Model Number Configuration

Smart ESD Device 700 Series for Safety Instrumented Systems

9: 0/24 V DC input signal

0: with contact output
1: with travel transmission

1-2 System Configuration

This device is a smart ESD device that can be connected to 4-20mADC, 0-20mADC, or
0/24VDC controller output signal lines. Various adjustments can be done electronically,
so the relationship between input signals and valve travel can be set to any desired value.
In addition, having a 4-line connection enables the output of the amount of valve travel
to a host monitoring system via 4-20mADC analog signal, as well as the transmission of
failure output to the monitoring system via burnout indication of the contact output signal
or the travel transmission signal. (Model AVP7_1 have travel transmission, and Model
AVP7_0 have contact output.)

The basic concept of a valve control system using this device is shown in the following
diagram.

Host
monitoring
system

Host
controller

4-20 mA DC analog signal

or contact output signal

4-20 mA DC, 0-20 mA DC,
0/24 V DC

Supply air

S

m

a

r

t

E

S

D

c

i

D

v

e

Device

S

I

S

r

o

f

e

Air supply

system

Shuto
valve

Regulator
with lter

Figure 1-1. Concept Diagram of Control System

1-1

Chapter 1 Structure of the Control System

HART
conguration
tool

HART
conguration
tool

1-3 System Configuration (Model AVP7_2) without Output Signal

1-3-1 In the Case of Current Signal Input

Illustrates the system configuration for Model AVP772/782.

4-20 mA DC or

Host

0-20 mA DC

controller

HART Modem

Figure 1-2. System Configuration with Current Signal Input without Output Signal

1-3-2 In the Case of Voltage Signal (0/24 V DC)

Illustrates the system configuration for Model AVP792.

(Model AVP772/782)

IN

IN

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

Device

Host
controller

Resistance: 500 Ω

0/24 V DC

IN

IN

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

Device

HART Modem

Figure 1-3. System Configuration With Voltage Signal Input without Output Signal

(Model AVP792)

1-2

Chapter 1 Structure of the Control System

250 Ω

24 V DC

250 Ω

24 V DC

1-4 System Configuration with Travel Transmission (Model AVP7_1)

Model AVP7_1 has a function for transmitting the amount of valve travel.

This travel transmission signal will change to burnout indication (failure output) in the
preset direction when an abnormality of this device or the valve is detected during self­diagnosis or in the PST (partial stroke test).

To output the travel signal to the host monitoring device using analog values, configure the
system with travel transmission.

Normally, travel of 0% and 100% is output at 4mA and 20mA, respectively.

Fa ilure output is

LO side: less than 3.6mA
HI side: greater than 21mA.

The following is an example of system configuration.

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

1-4-1 In the Case of Current Signal Input

Illustrates the system configuration for Model AVP771/781.

Host monitoring

system

(current input)

Host
controller

Resistance *1

Analog Signal
4-20 mA DC

Power *1

4-20 mA DC or
0-20 mA DC

HART Modem

Figure 1-4. System Configuration with Current Signal Input and Travel Transmission

Signal (Model AVP771/781)

1-4-2 In the Case of Voltage Signal (0/24 V DC)

Illustrates the system configuration for Model AVP791.

Host monitoring

system

(current input)

Host
controller

Resistance *1

Analog Signal
4-20 mA DC

Resistance: 500 Ω

0/24 V DC

Power *1

HART Modem

OUT

OUT

OUT

OUT

Device

IN

IN

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

HART conguration tool

Device

IN

IN

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

HART conguration tool

Figure 1-5. System Configuration with Voltage Signal Input and Travel Transmission

Signal (Model AVP791)

*1. For details on power and resistance, please refer to section 2-3-4, “Input Signal and Output Signal Power”

1-3

Chapter 1 Structure of the Control System

24 V DC

24 V DC

1-5 System Configuration with Contact Output (Model AVP7_0)

Model AVP7_0 has a function for transmitting a contact output signal.

This contact output is not related to valve travel, but rather transmits failure output when
an abnormality of this device or of the valve is detected during self-diagnosis or in the PST
(Partial Stroke Test).
Normal output: closed. Failure output: open.

The following is an example of system configuration.

With this system configuration, contact output is output directly to the host monitoring
system from this device.

1-5-1 In the Case of Current Signal Input

Power *1

Host monitoring

system

(Contact input)

Host
controller

Contact Signal

4-20 mA DC or
0-20 mA DC

OUT

OUT

IN

IN

HART Modem

Device

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

HART conguration tool

Figure 1-6. System Configuration with Cu rrent Signal Input and Contact Output Signal

1-5-2 In the Case of Voltage Signal (0/24 V DC)

Power *1

Host monitoring

system

(Contact input)

Contact Signal

Resistance: 500 Ω

Host
controller

0/24 V DC

HART Modem

Figure 1-7. System Configuration with Voltage Signal Input and Contact Output Signal

*1. For details regarding the power, please refer to section 2-3-4, “Input Signal and Output Signal Power.”

(Model AVP770/780)

OUT

OUT

IN

IN

(Model AVP790)

Device

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

HART conguration tool

1-4

Chapter 1 Structure of the Control System

Mounting plate (optional)

interface (LUI)

Output air pressure gauge

Output air connection port (OUT1)

Safety Nameplate

Electrical conduit connection port

Terminal box cover

Output air connection port (OUT2)

1-6 Structure of the Device and Description of Each Part

Structure of the Device

Major components



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

Main unit

Feedback lever

Local user

Exhaust cap

Explosion-proof and Functional

Supply air pressure gauge

Figure 1-8. Structure of the Device (Top)

External grounding terminal

Pilot relay cover

Supply air connection port (SUP)

Nameplate

Figure 1-9. Structure of the Device (Bottom)

1-5

Chapter 1 Structure of the Control System



Name and description of each part

The table below describes 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 the supply air.

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

Supply air connection port
(SUP)

Output air connection port
(OUT1)

Output air connection port
(OUT2)

Mounting plate (optional)

Table 1-1. Description of Each Part

• 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.

• To 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.

• Detects the valve lift and relays it to 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 double­acting 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).

1-6

Structure of the Terminal Box

Lock screw

box cover

Terminal for output signals

M4 screw

Terminal for external grounding

Major components



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

The structure of the terminal box is as shown below.

Chapter 1 Structure of the Control System

Conduit connection port (1)

Terminal

Conduit connection port (2)

Figure 1-10. Structure of the Terminal Box

M4 screw

HART check pin

Terminal for input signals
M4 screw

M4 screw

Terminal for internal grounding

Figure 1-11. Terminal Block in the Terminal Box

1-7

Chapter 1 Structure of the Control System



Name and description of each part

The table below describes each part of the terminal box.

Name Description

Terminal box cover

Lock screw • Used to secure the terminal box cover.

Terminal for input signals

Terminal for output Signals

Internal grounding terminal

Conduit connection port (1) • Port 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.

• Labeled IN.

• Connects the signal cable from the host controller.

• Labeled OUT.

• Connects the signal cable for output signal.

• The Model AVP7_2 (without output signal) does not have
the terminal screws.

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

• Port for a cable.

• This port 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.

1-8

Local User Interface (LUI) Display

Chapter 1 Structure of the Control System

3

1

2

8

9

10

5

4

6

7

Figure 1-12. Segments of the LCD

Table 1-3. Description of Each Part

No. Displayed element Main display

7 segments

(1)

(5 digits)

Main numerical values such as the specified opening.

(2) Minus sign Sign (+/−) for the 7-segment number.

Decimal point

(3)

(five places)
16 segments

(4)

(7 digits)

Decimal point for the 7-segment number.

The unit, status, or other data.

(5) Dot (6 places) Delimiter, etc., for 16-segment auxiliary display.
(6) % Percentage.
(7) Bar graph (22 bars) Bar graph showing percentage of set point, etc.

Displayed: LUI cannot be used

(8) Key symbol

Hidden: LUI is operable
Flashing: LUI is busy

The flag mark is displayed when the self diagnosis alarm is

(9) Flag symbol

activated.
For details on the alarm, please refer to the status monitor
described on page 3-4.

Display refresh sym-

(10)

bol

Display during operation
White and black circles alternately blink while updating.

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
adhesive property, possibly causing malfunction.

1-9

Chapter 1 Structure of the Control System

1-10

Chapter 2 Installation

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

2-1 Usage Conditions

Install the device in a location that satisfies the following conditions.

Be sure to use it in accordance with the specifications.

Chapter 2 Installation

Table 2-2. Range of Usage Conditions

Units

Basic

operating

conditions

Normal

operating

conditions

Marginal

operating

conditions

Transportation

conditions

General model °C 23±2 −40 to +80 −40 to +80 −40 to +70
TIIS flameproof

model

°C 23±2 −20 to +55 −20 to +55 −40 to +70

IECEx/FM/FMC/

Operating
temperature
range

NEPSI/EAC/IN­METRO/KOSHA
flameproof model

FM Intrinsically
Safe Explosion­Proof Type (ic)/

°C 23±2 −30 to +75 −30 to +75 −40 to +70

°C 23±2 −24 to +75 −24 to +75 −40 to +70
Non-incendive
Typ e

ATEX/IECEx
Intrinsically Safe

°C 23±2 −40 to +60 −40 to +60 −40 to +70
model

LUI °C 23±2 0 to 50 −40 to +80 −40 to +70

15

(5 to 8 Hz)

20

(8 to 400 Hz)

Vibration

Amplitude

Acceleration

*1

*1 4

mm

m/s

p-p

0

2

0

Friction of the valve % 3 to 20 3 to 20

Supply air pressure Ps
(140 kPa ≤ Ps ≤ 700 kPa)

Installation orientation

*3

kPa Ps±1% 140 to 700 0 to 710 —

° ±1

*2

±180 ±180 ±180

15

(5 to 10 Hz)

40

(10 to 400 Hz)

0 to 3

20 to 100

15

(5 to 10 Hz)

40

(10 to 400 Hz)

—

Humidity range %RH 50±10 5 to 100 5 to 100 5 to 100

The types of operating condition are defined as follows.

• Basic operating condition: Range in which the accuracy is guaranteed

• Normal operating condition: Range in which the device normally operates

• Marginal operating condition: Range in which performance is not guaranteed but the
device can be used without being permanently damaged

• Transportation condition: Environment condition range in which the non­operating device will not be permanently damaged
during transportation

*1. When the positioner cover is centered in front.
*2. The status where the drive shaft of the direct acting actuator is perpendicular to the ground and that is used

as the reference.
*3. The tilt characteristics are not included.
*4. Not applicable to the pressure gauge.

2-1

Chapter 2 Installation

2-2 Selection Criteria for Installation Location

The device is designed to withstand severe conditions, but the installation location should
be selected according to the criteria described below to maximize performance.

1) Selection Criteria for Installation Location

Install the device in a location that satisfies all of the following conditions.

• Operating temperature range that conforms to the explosion protection rules

• Relative humidity: 5 to 100%RH

• Ambient temperature change rate: ±20°C/h or slower

• Electromagnetic induction: 400A/m or less (avoid places near a large transducer, high­frequency furnace, or other such equipment)

• Do not use a transceiver near the device.

2

• Vibration: 20m/s
(The vibration conditions defined for the device are vibrations at the main unit of the
device.)

2) Criteria for instrumentation air

(8 to 400Hz) or less

The device employs a nozzle flapper structure in the electropneumatic transduction
section. If instrumentation air is contaminated (includes oil, water, or other substance),
the main unit function of the device may not function properly or an irrecoverable failure
may occur. Therefore, the quality of instrumentation air supplied to the device is defined
as follows.

• Solid material: No particles with a diameter larger than 3 μm.

• Oil: Less than 1 ppm.

• Supply air humidity: The dew point temperature is at least 10°C lower than that of the

device. (This criterion is based on the Japanese industrial standard
JIS C 1805-1 (2001).)

Select a compressor and main line or terminal-installation type compressed air purifier by
referring to the above specifications.

(1) Compressed air purifier for the main line

Select a compressed air purifier for the main line, such as a main line filter or micro­alescer, to satisfy the above specifications.

Japanese compressed air purifier manufacturers: SMC Corporation and CKD Corporation

(2) Compressed air purifier to be installed on the terminal

If you cannot install the air purifier in the main line due to problems with valve setup,
please install a terminal-type compressed air cleaner, and make the above specification
attainable.

2-2

<Example devices>

 Products from SMC Corporation

Mist Separator, AM150 or AM250 series
(Filtering level: 0.3μm, Secondary oil mist concentration: 1.0 mg/m

 CKD Corporation

Oil mist filter, M1000 or M3000 Series
Mantle S Type (Filtering level: 0.3μm, Remaining oil: 1.0 mg/m

Handling Precautions:

Select a compressed air purifier with specifications suited to the usage conditions.
Even when you install the above oil removal equipment, it is necessary to properly
inspect and maintain the air circuit section for long-term stable operation. Install
the oil removal equipment before use and perform periodic inspection and
maintenance.

The warranty is void if the device fails because the quality of the instrumentation
air was not sufficient.

Chapter 2 Installation

3

)

3

)

2-3

Chapter 2 Installation

Drain plug

2-3 Installation Procedure

2-3-1 Attaching the 700 Series to the Actuator

This device is a smart ESD device that is used together with a valve having a direct or
rotary actuator. The weight of this device is about 4.2kg. The basic installation procedure
is the same as for a conventional electric/air positioner.

Be careful not to get injured by sharp parts such as the edge of the main unit
or actuator or screw threads during mounting.
The type of mounting plate, mounting method, and mounting procedure
differ depending on the actuator model to be mounted in the device.

If the device is not properly mounted, not only will it not be able to operate
at its true performance but it may be damaged or fail. Pay attention to the
following points.

• The mounting plate and its accessories differ depending on the
specifications (actuator model). Be sure to use the appropriate mounting
plate and accessories for the actuator to be mounted.

• When installing the valve, please consider ease of maintenance
(piping, wiring, adjustments, etc.) and have as much space as possible
surrounding it, and orient the equipment correctly.

• Deliver the device to the installation location in the packaged state if
possible.

• Do not apply excessive force to the feedback lever during mounting.

• Do not bend the feedback pin.

• Do not block the exhaust port located underneath.

•

Install the device so that the electrical conduit connection port does not
face upward.

• Securely tighten bolts.

• If the model KZ03 pressure regulator with filter is installed with the
device, install with the drain of the KZ03 facing downward. If the KZ03
cannot be attached vertically (with the drain facing downward), remove
it from the device.

• In order to avoid the possibility of rainwater entering the pressure gauge,
install the gauge such that it does not face upward or downward. In
addition, the pressure gauge has a rainwater drain on its underside, so
install the gauge with this hole facing downward.

Caution

2-4

1) Mounting the feedback lever

Assemble the feedback lever from the front of the main unit of the device using the two
included hexagon socket bolts.

Figure 2-13. Mounting Procedure for Feedback Lever

Assemble the extension lever as shown in the figure below if necessary.

Chapter 2 Installation

Figure 2-14. Mounting Procedure for Extension Lever

2-5

Chapter 2 Installation

Hexagon socket ange bolts (x 2)

Yok e

Hexagonal bolt

Hexagonal bolt

2) Mounting example

A typical mounting method is shown in the figure below. If your actuator is not shown in
the figure below, refer to the assembly diagram included with the device.

[Direct-Acting Actuator HA2 to 4, PSA1 to 4, 6, VA1 to 6 from Azbil Corporation]

AVP

Connector pin assembly

Plain washer

Spring washer

Feedback lever

Feedback pin

Figure 2-15. Mounting Procedure for Direct-Acting Actuator HA2 to 4, PSA1 to 4, 6, VA1

to 6 from Azbil Corporation

[RSA1, 2, VR3 actuator from Azbil Corporation]

AVP

Plain washer

Spring washer

Feedback pin

Feedback lever

Figure 2-16. Mounting Procedure for RSA1, 2, VR3 Actuator from Azbil Corporation

2-6

[Example of double-acting rotary cylinder actuator]

Hexagonal bolt

Figure 2-17. Mounting Procedure for Double-Acting Rotary Cylinder Actuator

3) Mounting procedure

The procedure for mounting the feedback lever onto the actuator is shown below.

Step Procedure

Spring
washer

SpacerAVP

Feedback pin

Arm

Spring washer

Hexagonal nut

Feedback lever

Chapter 2 Installation

Spring washer

Hexagonal bolt

1

Tightly secure the mounting plate by inserting hexagonal bolts (M8×20)
with spring washers into the (two) screw holes at the rear of the device.

Tightly secure the device (mounting plate) onto the mounting seat of the

2

actuator using bolts and washers. At this time, insert the actuator feedback
pin into the slotted hole of the feedback lever in the device.

2-7

Chapter 2 Installation

Pin

30°

30°

4) Connection of feedback pin and feedback lever

There are several points to be careful of when connecting the feedback lever to the device
and the actuator feedback pin. Connect correctly.

• Only a pin with a diameter of 6 mm can be used.

• Insert the pin between the guide and the spring.

Feedback lever (cross section)

Pin

Spring (cross section)

Figure 2-18. Connection of Feedback Lever and Feedback Pin

• Make the feedback lever perpendicular to the pin when viewed from the above.

90°

Feedback lever

Figure 2-19. Angle between Feedback Lever and Pin

• Mount the lever so that it is horizontal when opened 50%.

Contact us to find out how to mount the lever onto other actuators.

• The allowable rotation angle of the feedback lever is horizontal ±30°. If the angle exceeds
±30°, the self-diagnostic function detects VTD Travel Detector Out of Range and the
device will not operate normally. (The accuracy is guaranteed when the rotation angle is
between ±4° and ±20°.)

S

m

a

r

t

E

S

D

S

I

S

r

o

f

e

c

i

v

e

D

Figure 2-20. Operation Angle of Feedback Lever

• When attaching the lever to a rotary cylinder so that the shaft of the rotary cylinder is
positioned between the feedback pin and the positioner as shown in the figure below,
select Rotary/90° (for 90°) or Rotary/other (for angles other than 90°) as the Actuator

Type according to the rotation angle.

2-8

Sha of rotary cylinder

Positioner

Feedback pin

Positioner

Chapter 2 Installation

Feedback pin

S

m

a

r

t

E

S

S

I

S

r

o

f

e

c

i

D

v

e

D

Feedback lever

Figure 2-21. Connection of the Rotary Cylinder to the Feedback Pin and Feedback

Lever

• When the rotary cylinder is large and the lever is assembled so that the feedback pin is
positioned between the main unit and the shaft of the rotary cylinder as shown in the
figure below, select Rotary (sub)/90° (for 90°) or Rotary (sub)/other (for angles other
than 90°) as the Actuator Type according to the rotation angle.

S

S

I

m

S

a

r

r

o

t

f

E

e

S

c

i

D

v

e

D

Sha of rotary cylinder

Figure 2-22. Feedback Pin and Feedback Lever Connection for Rotary Cylinder

(Large Cylinder)

5) Maintenance space behind the device

The device has a nozzle flapper mechanism in the back of the main unit. When cleaning
the flapper, you must remove the pilot relay cover secured to the back with three screws.

Design the clamp and feedback mechanism to ensure maintenance space for cleaning.

2-9

Chapter 2 Installation

Supply air

2-3-2 Pneumatic Piping Connection

This section describes how to supply the air for the device to drive the actuator.

1) Air supply system

Supply air must be clean and dry for reliable use of the device for a long time. A typical
example of an air supply system is shown in the figure below.

Shuto

2) Supply air

Use supply air that conforms to the instrumentation air standards (on page 2-3).

3) Regulator with filter

• The regulator with filter is used to adjust the pressure of the supply air to the device.

• Install the regulator as close to the main unit of the device as possible.

• The regulator can be manually operated by using the A/M switching function.
(The double-acting actuator does not support manual operation.)

valve

Regulator
with lter

Output air

piping

Supply air piping

Figure 2-23. Air Supply System

S

m

S

a

I

r

S

t

r

E

o

f

S

D

e

c

i

D

v

e

• Use a 3μm or less filter.

• The filter removes solid materials from supply air.

• If the filter is not equipped, separately insert a (3μm or less) filter immediately before
the regulator.

• Install the regulator so that the drain faces downward.

• If you select the built-in KZ03 Azbil regulator, the filter is built into the device before
shipment.

4) Shutoff valve

• The shutoff valve is used to temporarily stop supplying air to the device.

• During maintenance, you can dismantle the equipment and valve without stopping the
whole air supply system.

2-10