Azbil SVP3000 Alphaplus AVP100/102 Smart Valve Positioner User's Manual

SVP3000 Alphaplus

Smart Valve Positioner

Model: AVP100/102

User’s Manual

CM2-AVP100-2001

5th edition

Copyright, Notices and Trademarks

© 2001-2013 Azbil Corporation All Rights Reserved.

While this information is presented in good faith and believed to be accurate, Azbil Corporation disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer.

In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.

HART is registered trademark of the HART Communication Foundation.

Thank you for purchasing the Azbil Corporation’s SVP3000 Alphaplus model AVP100/102 Smart Valve Positioner.

The SVP3000 Alphaplus (also referred to as SVP in this manual) is an intelligent valve positioner that can be connected to a 4-20 mA signal line. Since all adjustments can be performed electrically using the

Smart Field Communicator (SFC), or HART communicator model 275 the relation ship between the input signal and the position of the control valve can be set arbitrarily. Split range and other special settings are also easy to set up.

This user’s manual describes the use of the SVP3000 Alphaplus. Use this manual to get the most from the features of this product.

Azbil Corporation

Safety

Safety notice

Proper installation, correct operation, and post-installation maintenance are all essential for the safe use of your Smart Valve Positioner.

Safety instructions stated herein are classified as WARNINGs, CAUTIONs and

Notes.



WARNING

Denotes a potentially hazardous situation which, if not avoided, could result in death or serious injury.



CAUTION

Denotes a potentially hazardous situation which, if not avoided, could result in operator minor injury or damage to device.

~Note

Information that can be useful to the user.

Unpacking

Handle the equipment with all due care to prevent any damage to prevent damage.

Verify that the following items are included:

• SVP3000 Alphaplus Smart Valve Positioner

Model AVP100 (1) / AVP102(1)

• Feedback lever (1) and hex socket bolt (2).

• Hex wrench (1) for feedback

• Pressure gauge (option)

• Joint (option)

• Manual (option)

Storage

When storing your SVP without its original packaging, store it indoors, at normal temperature (25°C) and humidity (~65%) store it in a place free from vibration and shock and not exposed to rain or water.

If you are storing your SVP after it has been used, clean the SVP thoroughly and then firmly tighten the terminal box cover and seal the wiring, piping connections and bleed hole on the pilot cover using Azbil Corporation-supplied caps or tape to prevent entry of moisture.

Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner i

Safety Azbil Corporation

Precautions for worker safety

• Do not stand on the installed SVP or use it as a step.

• Take utmost care not to in voluntarily touch the SVP while it is in operation. Its surface may be very hot or very cold, depending on the operating environment.

Approval

NEPSI Intrinsically Safe Approval for Smart Valve Positioner

Model AVP100

1.PROTECTION CODES

Intrinsically Safe Apparatus for Ex ia IIC T4 - T6 Ga

2.SPECIAL CONDITIONS FOR SAFE USE

Special precautions must be taken to avoid an ignition hazard due to impact or friction for the use as EPL Ga apparatus.

3.CONDITIONS FOR SAFE USE

3.1 The relations between ambient temperature range and temperature class are shown in the table below:

Temperature class

T4/5

T6

Permissible ambient temperature

-40°C to +60°C

-40°C to +40°C

3.2 Only be connected to the certified associated apparatus, the positioner could be used in the explosive atmosphere. The connection shall be accordance with the requirements of the manual of the associated apparatus and the positioner.

Intrinsically safe parameters:

Max. input voltage

Ui (V)

30

Max. input current

Ii (mA)

95

Max. input power

Pi (W)

0.66

Max. internal parameter

Ci (nF) Li (mH)

6 0.2

3.3 The cable with shield is suitable for connection, and the shield shall be connected to the earth.

3.4 End users are forbidden to change the configuration to ensure the explosion protection performance of the product.

3.5 When installation, operation and maintenance the product, users shall comply with the relevant requirements of the product instruction manual and the following standards:

ii Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner

Azbil Corporation Safety

GB3836.13-1997 “Electrical apparatus for explosive gas atmospheres Part

13:Repair and overhaul for apparatus used in explosive gas atmospheres”

GB3836.15-2000 “Electrical apparatus for explosive gas atmospheres- Part

15:Electrical installations in hazardous area (other than mines)”


16:Inspection and maintenance of electrical installation (other than mines)”

GB50257-1996 “Code for construction and acceptance of electric device for explosion atmospheres and fire hazard electrical equipment installation engineering”

Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner iii

Safety Azbil Corporation

NEPSI Intrinsically Safe Approval for Smart Valve Positioner

Model AVP102

1.PROTECTION CODES

Intrinsically Safe Apparatus for Ex ia IIC T4 - T6 Ga

2.SPECIAL CONDITIONS FOR SAFE USE

Special precautions must be taken to avoid an ignition hazard due to impact or friction for the use as EPL Ga apparatus.

3.CONDITIONS FOR SAFE USE

3.1 The relations between ambient temperature range and temperature class are shown in the table below:

Temperature class

T4/5

T6

Permissible ambient temperature

-40°C to +60°C

-40°C to +40°C

3.2 Only be connected to the certified associated apparatus, the positioner could be used in the explosive atmosphere. The connection shall be accordance with the requirements of the manual of the associated apparatus and the positioner.

Intrinsically safe parameters:

Max. input voltage

Ui (V)

30

Max. input current

Ii (mA)

100

Max. input power

Pi (W)

1

Max. internal parameter

Ci (nF) Li (mH)

15 0.2

3.3 The cable with shield is suitable for connection, and the shield shall be connected to the earth.

3.4 End users are forbidden to change the configuration to ensure the explosion protection performance of the product.

3.5 When installation, operation and maintenance the product, users shall comply with the relevant requirements of the product instruction manual and the following standards:

GB3836.13-1997 “Electrical apparatus for explosive gas atmospheres Part

13:Repair and overhaul for apparatus used in explosive gas atmospheres”


15:Electrical installations in hazardous area (other than mines)”


16:Inspection and maintenance of electrical installation (other than mines)”

iv Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner

Azbil Corporation Safety

GB50257-1996 “Code for construction and acceptance of electric device for explosion atmospheres and fire hazard electrical equipment installation engineering”

Configuration of an intrinsically-safe system

System configuration

The system configuration is shown below. The diagram also shows the layout of an intrinsically-safe system consisting of a SVP, a portable setting display, a field type current indicator, and a Zener barrier. The system components except those connected to the non-intrinsically safe side of the barrier, must be certified by an authorized testing station.

Hazardous location Nonhazardous location

Portable setting display



SVP

Field-use current indicator

Zener barrier

Figure S-1 System Configuration of Intrinsically-safe SVP

Ordinary equipment

Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner v

Safety Azbil Corporation vi Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner

Table of Contents

Safety

• Safety notice ........................................................................................................... 1-i

• Note Unpacking ...................................................................................................... 1-i

• Storage ................................................................................................................... 1-i

• Precautions for worker safety ................................................................................. 1-ii

• Approval.................................................................................................................. 1-ii

Chapter 1 : Introduction

1-1: SVP models ....................................................................................................... 1-1

1-2: Communication .................................................................................................. 1-2

1-2-1: Manual communication .......................................................................... 1-2

1-2-2: Using a Smart Field Communicator (SFC or CommPad) ...................... 1-2

1-2-3: Using a HART communicator ................................................................ 1-2

1-2-4: HART communication (for model AVP102) ........................................... 1-3

1-3: SVP diagrams .................................................................................................... 1-4

Chapter 2 : Installation

2-1: SVP assembly.................................................................................................... 2-3

2-1-1: Attaching SVP feedback lever ............................................................... 2-3

2-2: SVP Installation procedure................................................................................. 2-5

2-3: Air supply ........................................................................................................... 2-7

2-4: Initial SVP adjustment ....................................................................................... 2-8

2-5: Electrical wiring .................................................................................................. 2-9

2-5-1: Wiring guidelines.................................................................................... 2-10

2-5-2: Wiring procedure.................................................................................... 2-10

2-6: SVP for springless double-acting actuators (Reversing relay)........................... 2-11

2-6-1: Installing the reversing relay on an SVP ................................................ 2-12

2-6-2: Double-acting SVP without air regulator directly attached..................... 2-13

2-6-3: Attaching double-acting SVP to a diaphragm actuator .......................... 2-14

2-6-4: Attaching double-acting SVP to a rotary actuator .................................. 2-14

2-6-5: Auto-setup.............................................................................................. 2-15

Chapter 3 : Adjustments

3-1: Auto-setup.......................................................................................................... 3-1

3-1-1: Auto-setup using the travel switch ......................................................... 3-2

3-2: Zero-span adjustment ........................................................................................ 3-3

3-3: Smart Field Communicator ................................................................................ 3-5

3-4: SFC keyboard operations .................................................................................. 3-6

3-5: SFC errors.......................................................................................................... 3-6

3-6: SFC starting communications ............................................................................ 3-6


3-7: Auto-setup and zero-span using the Smart Field Communicator ...................... 3-7

3-8: Manual SVP settings.......................................................................................... 3-11

3-9: Configuring control signal / Valve travel relationship using an SFC................... 3-14

3-9-1: Examples ............................................................................................... 3-15

3-10: Verifying SVP input signal, EPM output, and valve travel output..................... 3-18

Chapter 4: Configuration using a HART Communicator

4-1: HART communicator functions .......................................................................... 4-2

4-2: Starting communication...................................................................................... 4-4

4-3: Verifying and modifying the general information ................................................ 4-6

4-3-1 : Device information ................................................................................ 4-6

4-3-2 : Manufacturer......................................................................................... 4-7

4-4: Device condition................................................................................................. 4-8

4-4-1 : Current input value (units: mA) ............................................................. 4-8

4-4-2 : Input signal% (percentage) value (units:%) .......................................... 4-8

4-4-3 : Valve travel (units:%) ............................................................................ 4-8

4-4-4 : Drive sig

(EPM (Electro Pneumatic converter Module) drive signal) (units:%) ... 4-8

4-4-5 : Temperature (Equipment internal temperature) (units: °C)................... 4-8

4-4-6 : Last config data..................................................................................... 4-9

4-5: Config & Calib (Equipment setup and calibration) ............................................. 4-10

4-5-1 : Mode (Switching the SVP mode) .......................................................... 4-10

4-5-2 : Input signal range (Setting the current input values) ............................ 4-10

4-5-3 : Valve sys config (Valve system configuration)...................................... 4-11

4-5-4 : Dynamic chara (Dynamic characteristics)............................................. 4-12

4-5-5 : Valve chara (Valve characteristics)....................................................... 4-14

4-5-6 : Tvl cut off (Travel cut off) ...................................................................... 4-15

4-5-7 : Calibrate................................................................................................ 4-16

4-5-8 : Diag parameters (Diagnostic parameters) ............................................ 4-18

4-5-9 : Burst mode............................................................................................ 4-23

4-6: Initial setup ......................................................................................................... 4-24

4-7: Maintenance....................................................................................................... 4-25

4-7-1 : Dummy input sig (Dummy input signal) ................................................ 4-25

4-7-2 : Dummy drive sig (Dummy drive signal) ................................................ 4-25

4-7-3 : User data save...................................................................................... 4-26

4-7-4 : Correct reset ......................................................................................... 4-26

4-8: Device status...................................................................................................... 4-27

4-8-1 : Failures ................................................................................................. 4-27

4-8-2 : Notices .................................................................................................. 4-27

4-8-3 : Valve diagnostics .................................................................................. 4-28


Chapter 5 : Maintenance

5-1: Auto/Manual selection switch............................................................................. 5-1

5-1-1 : Structure of the A/M switch ................................................................... 5-1

5-1-2 : Operating procedure ............................................................................. 5-2

5-2: Filter replacement and restriction maintenance ................................................. 5-3

5-3: Cleaning the flapper ........................................................................................... 5-4

5-4: EPM (Electro-pneumatic converter module) balance adjustment ...................... 5-5

5-5: Insulation resistance test.................................................................................... 5-6

5-5-1 : Test procedures .................................................................................... 5-6

5-5-2 : Judgment criteria .................................................................................. 5-6

5-6: Adjustment procedure when using the SVP attached to the booster relay ........ 5-7

5-7: Table of default internal data values .................................................................. 5-8

5-8: SVP internal block diagram and SVP I/O flow ................................................... 5-9

Chapter 6 : Troubleshooting

6-1: Troubleshooting ................................................................................................. 6-1

6-1-1: Using an SFC......................................................................................... 6-1

6-1-2: Using a HART Communicator................................................................ 6-2

6-1-3: General troubleshooting......................................................................... 6-2

List of Figure

Figure S-1 System Configuration of Intrinsically-safe SVP ...............................................1-v

Figure 1-1 Overview...........................................................................................................1-1

Figure 1-2 Azbil Corporation Smart Field Communicator .................................................1-2

Figure 1-3 HART communication structure .......................................................................1-3

Figure 1-4 SVP diagram .....................................................................................................1-4

Figure 2-1 SVP feedback lever...........................................................................................2-3

Figure 2-2 SVP maximum range motion............................................................................2-4

Figure 2-3 ...........................................................................................................................2-4

Figure 2-4 ...........................................................................................................................2-5

Figure 2-5 ...........................................................................................................................2-6

Figure 2-6 ...........................................................................................................................2-7

Figure 2-7 ...........................................................................................................................2-8

Figure 2-8 ...........................................................................................................................2-9

Figure 2-9 ...........................................................................................................................2-11

Figure 2-10 Reverse relay installed on an SVP ....................................................................2-12

Figure 2-11 Double-acting SVP without air regulator directly attached ..............................2-13

SFC ID Key.......................................................................................................3-2

Figure 3-1 ...........................................................................................................................3-3

Figure 3-2 ...........................................................................................................................3-4

Figure 3-3 ...........................................................................................................................3-14

Figure 3-4 ...........................................................................................................................3-14

Figure 3-5 ...........................................................................................................................3-15

Figure 3-6 Flow characteristics overview...........................................................................3-16

Figure 4-1 HART Communicator .......................................................................................4-1

Figure 4-2 HART communication structure .......................................................................4-4

Figure 4-3 ...........................................................................................................................4-15

Figure 4-4 Forced fully open and forced fully closed values..............................................4-15

Figure 5-1 Structure of the A/M Switch..............................................................................5-1

Figure 5-2 Switching from automatic (normal) operating state to manual operating State 5-2

Figure 5-3 Switching from manual operating state to automatic operating state................5-2

Figure 5-4 A/M switch ........................................................................................................5-3

Figure 5-5 EPM balance adjustment ...................................................................................5-4

Figure 5-6 EPM balance adjustment ...................................................................................5-5

Figure 5-7 SVP block diagram............................................................................................5-9

Figure 5-8 SVP I/O flow .....................................................................................................5-10


Chapter 1 : Introduction

1-1: SVP models

The SVP is an intelligent valve positioner that can be connected to a 4-20 mA controller output signal line. Since all adjustments can be performed electrically, the relationship between the input signal and the position of the control valve can be set arbitrarily. Split range and other special settings are also easy to set up.

Integral type

Model AVP100: Analog signal (4-20 mA DC) without travel transmission

Model AVP102: Analog signal (4-20 mA DC) with HART communication protocol

SVP Alphaplus

Smart Valve Positioner

Actuator air

Smart Communicator

CommPad Model CFN100 or

SFC Model SFC160/260

Filtered

Air Supply

4-20mA Control Signal

HAR

LD CO FIE

MMUNICATIONS PROTOC T

OL

0 # % &

1

S T U

4

J K L

2 V W X

.

< >

_

: +

*

7

A B C

5

M N O

8

Y Z /

6

3

D E F

P Q R

9

G H I

O

F1

F2

HART Communicator

F3

F4

Control valve

HART communicator model 375

(for model AVP102)

Figure 1-1 Overview

Process fluid

Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner 1-1

Troubleshooting

1-2: Communication


There are three ways to communicate with the SVP: manually, using a Smart Field

Communicator (SFC) or using a HART communicator.

1-2-1: Manual communication

Initial SVP configuration’s is typically performed using a screwdriver. Auto-Setup and travel calibration, which detect the characteristics of the valve, as well as Zero/Span adjustment can all be performed manually.

Without further configuration, the SVP provides valve travel from fully open to fully closed from a 4-20 mA analog signal (refer to ordered specifications) or analogous

HART signal.

1-2-2: Using a Smart Field Communicator (SFC or CommPad)

Azbil Corporation’s Model SFC160/260 Smart Field Communicators can be used for all configuration, calibration and maintenance of the SVP. SVP-specific communicator functions are documented fully in this manual. See the SFC Smart Field vCommunicator Manual to learn more about the SFC.

SFC Model SFC160/260 CommPad Model CFN100

Figure 1-2 Azbil Corporation Smart Field Communicator

1-2-3: Using a HART communicator

Emerson Electric HART communicator model 375 can be used for all configuration, calibration and maintenance of model AVP102 SVP-specific communicator functions are documented fully in this manual. See the HART communicator manual to learn more about the HART communicator.

1-2 Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner

Azbil Corporation Troubleshooting

1-2-4: HART communication (for model AVP102)

This figure shows the structure of a system in which the position detected by the SVP, the values of the SVP settings, and the results of self diagnostics are output in the

HART communication protocol.

T

0

# % &

1

S T U

.

< >

4

J K L

2

V W X

_

*

: +

7

A B C

5

M N O

6

P Q R

9

G H I

3

Y Z /

8

D E F

F1

I

O

HART Comm

F2 unicator

F3

F4


I IN

+

-

I IN

4~20mA DC

-

+

Controller

Figure 1-3 HART communication structure


Troubleshooting

1-3: SVP diagrams


Output air connection

Pilot relay

Output air pressure gauge (option)

Zero/Span adjustment auto-setup switch

1-4

Auto/Manual switch

Conduit conn.

Air supply connection

Figure 1-4 SVP diagram

Feedback lever

Input air pressure gauge (option)

Cover

Main unit

Model AVP100/102 - SVP3000 Alphaplus Smart Valve Positioner


Chapter 2 : Installation

Installation and calibration of Azbil Corporation Smart Valve Positioners

The SVP is designed to withstand severe operating conditions. Still, the installation location must satisfy certain criteria or unexpected operation may result. The Smart

Valve Positioner is designed to operate:

• in ambient temperatures of -40°C to +80°C

• in relative humidity of 10 to 90%

• where there is no chance of sudden temperature and humidity changes

• where magnetic field induction is not more than 400A/m.

• Avoid installing the SVP near a large transformer, high-frequency furnace, etc.

• For HA Actuators, vibration cannot be more than 2G (5 to 400 Hz)

Azbil Corporation’s Smart Valve Positioners are designed for use in combination with a control valve that uses a direct- or reverseacting or rotary actuator. The main SVP unit weighs about 1.7 kg. It should be attached in the same way you would attach a conventional electropneumatic positioner.



WARNING

When attaching the SVP, take every precaution to avoid physical injury. Be aware of sharp objects such as the edges of the cover and any sharp edges on the unit.

Setting up the SVP includes opening and closing the valve several times, often unpredictably. Take appropriate measures to prevent injury to personnel and adverse effects on the process.

The type and size of the actuator determine the type of mounting plate as well as SVP settings. If you ordered your SVP with the actuator type specified, then the SVP should come with the proper mounting kit, and the correct actuator settings should already be programmed into the SVP. The Auto-setup program is then used to calibrate the SVP. Be aware that incorrect settings not only reduce the SVP’s effectiveness, but may also cause damage to or failure of the SVP.

If you are removing the SVP from an existing valve, first disconnect any operating lines providing air pressure, electric power, or a control signal to the positioner.

When the SVP is installed in a hazardous environment, (e.g. corrosive atmosphere), shutting off the air supply is not recommended unless the SVP is being removed. The air pressure prevents corrosive gas from entering the SVP.


Installation Azbil Corporation

Before installing the SVP, check for:

Variations

Clearance

Use the appropriate mounting plate and feedback lever length for the actuator.

Do not install the SVP in such a place that it will be difficult to maintain or that will interfere with piping, wiring, or adjustment.

Check for mechanical interference and valve operating clearance.

Orientation

Install the SVP in the correct direction. Avoid installation where the left of the SVP (where pilot relay is located) would be on top.

Fragility

Damage to the SVP may result from excessive impact or force. Do not force the feedback lever or bend the feedback pin.

Secureness

Be sure to tighten bolts and nuts securely on the SVP and control valve.



2-1: SVP assembly

Installation

2-1-1: Attaching SVP feedback lever

The SVP is factory shipped with the feedback lever removed. Follow the assembly procedures for the SVP and the feedback lever given below.

Linear motion actuator

• Assemble the feedback lever and the SVP using the two provided hex socket bolts.

• Ensure that the rotation angle of the feedback lever does not exceed 20° from the horizontal (40° travel). In case of exceeding 20°, use the optional extension lever.

Extension lever

Hex socket bolt

Hex socket bolt

Spring

Feedback lever

Extension lever (option)

Figure 2-1 SVP feedback lever



20

20

2-4

Figure 2-2 SVP maximum range motion

Rotary motion actuator

• Place the coupling onto the angle sensor and fasten it with the bolt.

• Insert the spring pin into the hole in the coupling.

• Install the feed back lever so that the tip of the spring pin fits into the small hole on it to meed to the tip of the spring pin.

• Fasten the feedback lever using the hex head bolt and washer.

SVP

Bolt

Figure 2-3

Angle sensor

Coupling

Spring pin

Feedback lever

Washer

Hex head bolt



2-2: SVP Installation procedure

Installation

The Smart Valve Positioner can be attached onto a variety of actuators. Example actuator mountings are shown below. Please refer to the installation instructions that were included with your actuator mounting kit.

Example1: How to mount the SVP onto a linear motion actuator.

• Fasten the mounting plate onto the SVP securely, using the 2 provided hexagon head bolts (M8) and spring washers.

• Assemble the connector pin assembly to the pointer with the hexagon socket head flange bolt.

• Set the valve travel to 50%.

• Fasten the assembled SVP to the actuator using the bolts and washers provided while guiding the 1/4 inch (6 mm) feedback pin through the slot on the feedback arm above the spring with the feedback lever set to be horizontal.

• Make sure that the feedback lever and pin form a right angle as shown below.

SVP

Yoke connection

Hexagon socket head flange bolt

Connector pin assembly

Pointer

Pin

Spring washer

Hexagon head bolt

Mounting plate

Spring

Feedback lever

Figure 2-4



Example 2: How to mount the SVP to a rotary motion Actuator

• Attach the mounting bracket to the SVP securely using the provided hexagon head bolts (M6) and washers.

• Assemble the arm and the connector pin with a hexagon nut and a washer.

• Set the valve travel to 50%.

• Fasten the assembled arm to the valve stem using a hexagon head bolt in the correct.

• Mount the SVP to the actuator using hexagon head and washers.

• Make sure the feedback lever will fit together with the connector pin at a right angle as shown below.

SVP

S

A A

Hexagon Head bolt (M6)

Connector pin

Hexagon nut

Bracket

O

Hexagon head bolt (M6)

Actuator

Arm

Feedback spring

Spring pin

Valve stem Hexagon head bolt (M5)

Figure 2-5

A - A



2-3: Air supply

Installation

Clean and dry supply air ensures long-term stability of the SVP. A typical air supply system is shown below:

To actuator

Air output connection

1/4NPT thread

Auto/Manual Switch

Regulator valve with filter Shutoff valve

Air supply

Figure 2-6

Air supply must be clean; it should not contain foreign substances (moisture, oil, or dust). The air must be dry, with a dew point at least 10°C lower than the SVP’s lowest site operating temperature. For example, if the lowest environmental temperature the

SVP is exposed to is 0°C, then supply air should not condense at temperatures under -

10°C.

A shutoff valve, an air regulator (if not provided with your SVP) and a 3

μm or better filter must be installed between the air supply and the SVP as close as possible to the

SVP unit. The shutoff valve enables disconnection of the SVP from the control valve for ease of maintenance.

Recommended piping practices:

• Air supply pipes should have an inside diameter of 6mm (10mm outside diameter tubing recommended).

• Pipes should match the installation environment, i.e. for a corrosive environment, use vinyl-clad copper pipes.

• Use joints that precisely fit the pipes.

Sealing tape is preferable to solid or liquid sealants for pipe joints to SVP air connections. Prevent sealing tape/sealant from entering pipes.

• Use the right length of piping; avoid excess lengths.

• Completely flash pipes before use, checking for burrs and other problems.

• Check for leaks after installation.


Installation

2-4: Initial SVP adjustment




WARNING

Switching the SVP air supply from automatic to manual will divert air directly to the actuator, actuate the control valve and affect the process. Take the necessary precautions before turning the A/M switch.

Valvetravel indicator at 50% travel

90

Stem connector pin assembly

Feedback lever

2-8

Figure 2-7

This step in the assembly is to ensure the correct initial relationship between the air supply and the feedback lever position.

(1) Using a flat-head screwdriver, rotate the A/M switch 180° counter-clockwise. This puts the SVP in Manual or bypass mode, allowing the regulator valve to change valve position. The supply and output air pressure gauges should both have the same reading.

(2) Position control valve to mid-travel (50% position) by adjusting air pressure regulator valve.

(3) Adjust the stem connector pin assembly so that the SVP feedback lever is horizontal and the stem connector pin forms a 90° angle with the feedback lever.

(4) Set the SVP back to Auto mode using a flat-head screwdriver to rotate the A/M switch 180° clockwise.



2-5: Electrical wiring

Installation

The wiring terminals are located in the main unit of the SVP. Typical wiring from the control room to the SVP and possible way to connect a Smart Field Communicator

(SFC) or HART communicator model 275 are illustrated below.

An SFC can be connected directly to the hooks. Apply sufficient waterproofing

.treatment using nonhardening sealants made of silicone resins.

HAR

FIEL D COM

MUN ICATION

S PROTOCOL

O

0

# % &

1

S T

.

< >

U

4

J K

L

2

V W

X

_

*

: +

7

A B C

5

M N O

3

8

Y Z /

6

D E F

P Q R

9

G H

I

F1

F2

HART Communicator F3

F4


(for model AVP102)

Smart Communicator

CommPad Model CFN100 or

SFC Model SFC160/260

I IN

I IN

4~20 mA DC

-

+

Controller

Figure 2-8



WARNING

Close the cover tightly and do not open it while the SVP unit is energized in a hazardous environment; doing so may cause an explosion.



2-5-1: Wiring guidelines

• Power down before doing any wiring.

• SVP requires a 4 to 20 mA DC control signal, which also provides power to the unit. SVP requires a minimum of 3.85 mA DC to operate and current should never exceed 24 mA DC.

• The SVP needs protective grounding on either the internal or external grounding terminal (<100

Ω resistance)

• Maximum permissible cable length is 1.28km.

• Use stranded cables having a conductor cross-section of 1.25 mm

2

and suitable for 600V such as shown in the conductor table in Article 310 of the NEC (National Electric Code). Outside diameter on cables must be

6.35mm to 11 mm. Use shielded wires for locations exposed to noise.

• Avoid installing cables near noise-making devices such as large capacity transformers and motors. Do not lay signal/control cables in the same tray or duct with noisy switching power cables.



WARNING

The barriers should be NEPSI certified types and comply with the condition as follows.

AVP100: Ui=30V, Ii=95mA, Pi=0.66W, Ci=6nF, Li=0.2mH

AVP102: Ui=30V, Ii=100mA, Pi=1.0W, Ci=0.015

μF, Li=0.2mH

Zener barrier should be installed in safe areas and observe the Zener Barrier Manual.

The circuit shall be considered to be connected to ground from a safety point of view.

When installation and maintenance for the Valve Positioner, user should also abide the Manual and the relevant requirements of national electrical code GB3836.1-

2000 and GB3836.4-2000.

2-5-2: Wiring procedure

(1) Unscrew the screw on the cover and remove the cover.

(2) Remove one or both of the supplied Azbil Corporation conduit connection blind plugs depending on how you plan to wire the SVP.

(3) Insert cables into the conduit connection. Strip and attach the appropriate wires to the terminals, checking for polarity. Crimp contacts with insulated sleeves are recommended.

(4) Tighten the terminal screws fully, to a torque of 1.5 N•m (15 kgf•cm).

(5) Put the cover onto the SVP and fasten the screw.


Azbil Corporation Installation

2-6: SVP for springless double-acting actuators

(Reversing relay)

When an SVP is installed on a valve with a springless (double-acting) actuator, air pressure is needed on both the bottom and top of the actuator diaphragm to provide valve opening and closing proportional to a control signal. A reversing relay is used for this purpose.

Supply air connection

(not shown)

Reversing relay

Output air connection 2

(not shown)

Output air connection 1

Relay air connection

Output air pressure gauge

Figure 2-9

~Note

Make sure that the air piping connections and air pressure ranges as inscribed on the bottom of the reversing relay match your SVP.

The reversing relay has two Output air connections:

• Output air connection 1 (OUT1) which passes through the SVP’s output air pressure

• Output air connection 2 (OUT2) with the balance of the supply pressure

(minus SVP output air)



2-6-1: Installing the reversing relay on an SVP

Remove the dust plug from the output air connection. Screw the Relay air connection of the reversing relay into the output air connection on the top of the SVP. Sealing tape is preferable to solid or liquid sealants for pipe joints to SVP air connections. Prevent sealing tape/sealant from entering pipes.

Figure 2-10 Reverse relay installed on an SVP



2-6-2: Double-acting SVP without air regulator directly attached

Using a T-connector, connect the air supply from the regulator and filter to both the

SVP Supply air connection and the Supply air connection on the reversing relay using sealing tape. Make sure to connect only one regulator to an SVP and reversing relay combination.

Figure 2-11 Double-acting SVP without air regulator directly attached

~Note

Please note that the Auto/Manual switch is not used on Double-Acting

SVPs. When using the SVP as a double-acting positioner, use the valve handwheel or air pressure regulator to perform SVP calibration such as

that shown on page 2-8 and the “Zero-span adjustment by air pressure” on page 3-10, ignoring the instructions to operate the A/M switch.



2-6-3: Attaching double-acting SVP to a diaphragm actuator

Reverse-acting actuator

Connect OUT1 of the Reversing Relay to the bottom actuator air port

Connect OUT2 of the Reversing Relay to the top actuator air port

Direct-acting actuator

Connect OUT1 of the Reversing Relay to the top actuator air port

Connect OUT2 of the Reversing Relay to the bottom actuator air port

2-6-4: Attaching double-acting SVP to a rotary actuator

Reverse-acting actuator (clockwise rotation with increased pressure)

Connect OUT1 of the Reversing Relay to the actuator chamber that rotates the trunnion clockwise with added pressure

Connect OUT2 of the Reversing Relay to the actuator chamber that rotates the trunnion counter-clockwise with added pressure

Reverse-acting actuator (counter-clockwise rotation with increased pressure)

Connect OUT1 of the Reversing Relay to the actuator chamber that rotates the trunnion counter-clockwise with added pressure

Connect OUT2 of the Reversing Relay to the actuator chamber that rotates the trunnion clockwise with added pressure

If the actual air piping is different than described above, the functions of the SVP as a positioner will not be affected. However, various valve and SVP diagnostics usually performed with the SFC will not return accurate information. To enjoy the capabilities of the SVP to the fullest, piping should match the diagrams and instructions above to maintain the relationship between the parameter settings described throughout this

user manual.

Lever

Valve direction

Control Valve

AVP Setting

Up

Down

Shut

(Up



Open



Down)

Shut



Open

(Down



Up)

Direct

Shut 4 mA, Open 4 mA

Reverse


Direct


Reverse


Reverse

Direct

Direct

Reverse

Reverse

Reverse

Direct

Direct



2-6-5: Auto-setup

Perform Auto-setup normally as per the instructions on page 3-1 through page 3-2

(perform the manual Zero-span adjustment on page 3-3 if necessary). When an SVP is

attached to a rotary actuator, Zero and Span are sometimes set in reverse. Use an SFC to manually set the Actuator to the correct action (Direct or Reverse) as per the steps

on page 3-11.

If after Auto-setup, the SVP exhibits excessive overshooting (hunting), decrease the

actuator parameter as per the steps on page 3-12.

• Perform Auto-setup by referring to page 3-1 through 3-3 “Auto Setup,

Zero-Span Adjustment”





Chapter 3 : Adjustments

3-1: Auto-setup

Auto-setup is a unique program for automatically making various positioner adjustments. After installing your SVP, Auto-setup should be performed. The travel switch on the SVP provides non-interactive closed and open valve position setting.

The following valve actuator characteristics are automatically detected during Autosetup:

• Zero-span adjustment

(However, as a default, the span point is taken to be 10% of the overstroke. If a span adjustment is performed after auto-setup completes, change the overstroke value and save the change value.)

• Actuator operation setup

• Lower Range Value (LRV) and Upper Range value (URV) of Input signal

If actuator operation is reverse operation: LRV = 4 mA, URV = 20 mA

If actuator operation is direct operation: LRV = 20 mA, URV = 4 mA

• Actuator size setting

• Hysteresis setting

(Hysteresis of ground packing is selected out of LIGHT, MEDIUM and HEAVY.)

• Valve assembly calibration

If you specified the type of actuator your SVP will be installed on, then the required overtravel for tight shut-off will have been programmed into your SVP. The required overtravel for tight shut-off is the maximum shut off less 1%. If you didn’t specify the type of actuator, and you are using a non-Azbil Corporation actuator, then please refer

to page 3-11 for instructions on how to enter the actuator type using an SFC (Smart

Field Communicator). Tight shut-off requires the proper overtravel setting.



WARNING

While Auto-setup is running, the valve will cycle from open to closed. Take appropriate measures to prevent injury to personnel and adverse effects on the process.

It is recommended that Auto-setup and initial calibration of your SVP be performed using the travel switch on the SVP.

You may also use a portable communicator to initiate Auto-setup and initial calibration.

Because Auto-Setup and Zero-Span calibration must be observed for accurate valve positioning, these two steps will typically be performed by the travel switch. Other functions including loop test, valve travel inquiry, split-ranging and tag number assignment require an SFC.


Adjustments Azbil Corporation

3-1-1: Auto-setup using the travel switch

Observation of the SVP is necessary when performing Auto-setup and Zero-span adjustment.

If the SVP was not ordered with the valve or actuator specified and the SVP is being used on a push down to open acting valve, then you must first set the valve action in

the SVP before performing Auto-setup. Refer to “3-8: Manual SVP settings” on page 3-11.

The travel switch is two position switches used for triggering Auto-setup and doing manual zero-span calibration.

Step

1

2

3

4

5

Procedure

Set the input signal to the SVP to 18 ±1 mA DC

Open the front cover of SVP, and push travel switch “UP” (“DOWN” for

FloWing Rotary VFR valve).

Hold this position until the valve starts to move (approximately 3 seconds). This starts the auto-setup routine. Release the travel switch.

The valve moves from fully shut to fully open twice. The valve then opens to about 50% and stays this way for up to three minutes.

Confirm that the auto-setup routine is complete by varying the input signals. The entire auto-setup procedure should take about three minutes.

~Note

While executing the auto setup program, do not set the input signal below 4 mA. (As long as the signal is in the range of 4-20 mA, changing the input signal during auto setup will not affect the program.)

If the input signal drops below 4 mA while auto-setup is running, then autosetup will fail and must be restarted. After completing auto-setup, keep at least 4 mA of signal (power) for at least thirty seconds to make sure data and parameters are stored in SVP memory.

After the operation has completed, check valve operation by varying the input signal and verifying that the valve goes to the correct position corresponding to the signal. If the span position has shifted, perform a span adjustment operation.

In some cases, the auto-setup routine will not properly detect your valve, especially if the valve's actuator is smaller than Azbil Corporation's HA1

type actuator (diaphragm capacity of (850 cm³ {52 inches³})) or the

operation stroke is smaller than 14.3 mm {9/16 inch}. Please contact an Azbil

Corp. representative for assistance.

If you have an Smart Field Communicator (SFC) connected to your SVP during an auto-setup routine and you performed the auto-setup with a screwdriver, be sure to press the ID key on the

SFC to read the new data from the SVP.

DE READ

ID

A

SFC ID Key



3-2: Zero-span adjustment

Adjustments

After Auto-setup, the SVP has calibrated itself to the fully shut (zero) and fully open

(span) values of the valve. If the valve is not achieving the proper relationship between its travel and the control signal of the SVP, then please adjust Zero-span manually by following the steps below.

~Note

Travel switch will only work if the shut off and full open input signals

(Example: 4-20) are the same as the shut off and full open input signal settings stored or factory set in the SVP.

Procedure for adjusting the shut valve position (zero)

Step

1

2

3

Procedure

Input current signal that corresponds to the value being fully shut from the controller (or constant - current supply). (Example: 4 mA)

Adjust the valve fully shut position by pushing the travel switch “UP” or

“DOWN”. See Figure 3-1 and Figure 3-2 for how to use the travel switch.

(If the forced shutdown function is operating, the valve will not move. To

change the forced shutdown setting, see “Zero-span adjustment by input signal” on page 3-8. The default value is set to 1.0%.)

If you changed the forced fully closed with an SFC, change it back to the proper setting now.

Figure 3-1



Figure 3-2

Procedure for adjusting the fully opened valve position (span)

Step

1

2

Procedure

From the controller or from a constant current supply, provide an input signal that corresponds to the valve fully opened (Example: 20 mA)

Adjust the fully opened valve position by pushing the travel switch “UP” or “DOWN” until the valve position moves slightly.

~Note

After completing Zero-span adjustment, verify accurate valve operation by varying the input signal.



3-3: Smart Field Communicator

The SFC has been developed as a communicator for connection to a range of Azbil Corporation Smart Field products. This section includes only those instructions necessary for using an SFC with the Azbil Corporation's

SVP. For further instructions, refer to the SFC Instruction

Manual (CM2-SFC100-2001).

Adjustments



WARNING

Ensure that a sudden action of the valve, caused by a communicator operation, will not in any way harm people or equipment.

When Auto-setup is started, it will open and close the valve regardless of input signal status. Take necessary precautions before starting Auto-setup to prevent any harm to process operations or to personnel.

Always use the communicator in a non-hazardous location, otherwise an explosion may result from an electrical discharge.

DE READ

ID

A

LRV E

0%

DE CONF.

MENU I

ITEM

M

A DE

Q

F/S DIR

STAT

U

URL

SPAN

Y

ALPHA

CONF

B

URV F

100%

INPUT

OUT- J

PUT

7

N

4

R

1

V

ACT PR

0

Z

C

DAMP

SET

G

RESET

COR- K

RECT

FEED

8

O

5

S

2

W

SCR PAD

6

T

SW VER

3

X

TIME

SHIFT

S-SFC

CLR

( No )

D

UNITS

NEXT

H

PREV

L

PRINT

9

P

NON-VOL

ENTER

( Yes )

~Note •

Make sure the software revision in your model SFC160/260 is version 7.8 or newer.

•

Make sure the polarity of the SFC wiring is correct.

•

•

If a colon (:) appears on the SFC screen in the 8th place on the upper line of the display, the battery needs replacement or recharging. Turn off the SFC and replace the batteries.

While auto-setup is running, do not drop the input signal below 4 mA or you will have to restart the Auto-setup procedure.

•

When any operation is completed, keep an input signal of at least 20 mA for at least 30 seconds to ensure that the settings are recorded in memory.

•

Power must be supplied on both input and output sides of the SVP when using an

SFC. If there is no controller available, connect a constant power supply (such as a CCS) to the input signal terminal.

•

Make sure the SVP is connected to a constant power supply. If the SVP is connected to a controller (a top-level control room), then make sure the loop is in manual and that a constant power supply will be maintained.

•

Connect the SFC (powered off) to the output testing clip loops next to the terminals screws.



3-4: SFC keyboard operations

• Press keys slowly and firmly. No reaction on the screen would indicate that the key pressed was not accepted.

• Keys pressed during communication with the SVP are ignored. Wait until communications are complete.

NON-VOL

• Questions displayed on the screen require that you press the

ENTER

( Yes )

or

CLR

( No )

key to acknowledge.

• During communication with the SVP, either the cursor on the screen will be invisible, or the following screen is displayed.

SVP PCV-123

WORKING...

3-5: SFC errors

If a hash (#) mark appears in the lower right corner of the screen, then an alarm condition exists. Either there is an error, the SVP is inforced fully shut/forced fully open state or the SVP is in Dummy I/O state.

Press the

F/S DIR

STAT

U

key to see what error conditions exist.

If there is more than one, then each error condition flashes for three seconds. See

"Chapter5: Maintenance" for further explanation and resolution of error conditions.

3-6: SFC starting communications

Step Operation

1 Power on the SFC.

• The SFC will ask if the position transmission loop is in manual mode or not.

2 If the position transmission host system is in manual control mode, press the

NON-VOL

ENTER

( Yes )

key.

3

Press the

DE READ

ID

A

key.

4 To change the tag number, proceed to the following page.

If you do not need to do so, press the

SVP

SVP

SFC screen

LOOP IN MANUAL ?

PRESS ID

TAG No.

PCV-123

CLR

( No )

key.

SVP

READY...

PCV-123

• The SFC will go to the command wait state.

• The SFC goes to the SVP mode immediately after the power is turned on.


Azbil Corporation Adjustments

3-7: Auto-setup and zero-span using the Smart

Field Communicator

Auto-setup procedure

Step

1

Operation

Press the

CONF

B

key to enter configuration mode

2

Press the

L

PREV

key twice

SFC screen

SVP CONFIG

SYSTEM CONFIG ?

MAINTE MODE

3

Press the

NON-VOL

ENTER

( Yes )

key.

MAINTE MODE

AUTO SETUP?

4

Press the

NON-VOL

ENTER

( Yes )

key.

AUTO SETUP

ARE YOU SURE?

5 Once Auto-setup begins, the SVP opens and closes the valve twice and then opens it to 50% for as long as 2 minutes to detect the valve characteristics.

6 Although actual time depends on the valve size, Auto-setup usually takes about 3 minutes.

7 Confirm proper valve operation by varying input signals. Follow the zero and span adjustment procedure below if

Auto-setup did not correctly set them.

8

DE READ DE READ

the , , keys

( No )

return to the ready state.

WAIT 2 minutes ...

______

______

______



Zero-span adjustment by input signal

First, you must set the forced fully closed setting to 0%

Step

1

Press the mode.

2

CONF

B

Operation

key

to enter configuration

Press

NEXT

H

four times

SFC screen

SVP CONFIG

SYSTEM CONFIG ?

SVP CONFIG

ON / OFF CONFIG ?

Press the

NON-VOL

ENTER

( Yes )

key

.

3 You will see the Shut Off Value screen.

Enter in a value of 0 and press the

NON-VOL

ENTER

( Yes )

key

.

4

Press the

NEXT

H

NON-VOL

key

twice, the

ENTER

( Yes )

key

,

SHUT OFF VALUE

0.500 % IIN

______

Shut-off is now set to 0%.

5 From the controller or from a constant current supply, provide an input signal that corresponds to the valve shut-off

(Example: 4 mA)

6 Make sure the SFC screen displays

______

SVP

READY...

PCV-123

7

Press the

LRV E

0%

key twice.

LRV

SHUT

PCV-123

8

RESET

Press the

COR- K

RECT

key to start adjusting the

Shut position. Default fine-tuning adjustment is 0.006°.

DE CONF.

Press the

MENU I

ITEM

key to cycle the adjustment between 0.006°, 0.03°, 0.3°, 3°, and

30°.

Press the

L

PREV

and the shut off position.

NEXT

H

keys to adjust

CORRECT LRV

INC / DEC 0.006



Step

9

Operation

Once the valve is shut, press the

CLR

( No )

NON-VOL

key

twice. Then press the

SHIFT

+

ENTER

( Yes )

keys to save.

10 From the controller or from a constant current supply, provide an input signal that corresponds to a full-open valve

(Example: 20 mA)


Adjustments

SFC screen

______

______

SVP

READY...

PCV-123

12

Press the

URV F

100%

key twice.

URV

OPEN

PCV-123

13

RESET

Press the

COR- K

RECT

key to start adjusting the

Open position. Default fine-tuning adjustment is 0.006°.

DE CONF.

Press the

MENU I

ITEM

key to cycle the adjustment between 0.006°, 0.03°, 0.3°, 3° and

30°.

Press the

L

PREV

and

NEXT

H

keys to adjust the shut off position.

14 Once the valve is fully open, press the

CLR

( No )

key twice. Then press the

SHIFT

+

NON-VOL

ENTER

( Yes )

keys to save.

CORRECT URV

INC / DEC 0.006º

______


Adjustments

Zero-span adjustment by air pressure

Step Operation

1 Set the forced fully closed setting to 0%

(Step 1 to 3 of “Zero-span adjustment by input signal” on page 3-8)

2 Using the Auto/Manual switch, set the

SVP to manual mode (see (1), page 2-8).

3 Using the air regulator valve, adjust the supply air pressure to fully close the valve.



SFC screen

______

______

______

SVP

READY...

PCV-123

5

Press the

LRV E

0%

key twice.

LRV

SHUT

PCV-123

6 Make sure the valve is in the shut-off position. The right screen is displayed.

VTD SET ?

7

Press

SET

G

NON-VOL

ENTER

( Yes )

CLR

( No )

NON-VOL

ENTER

( Yes )

keys to finish the zero setting and save.

8 Using the air regulator valve, adjust the supply air pressure to fully open the valve.


______

______

SVP

READY...

PCV-123

10

Press the

URV F

100%

key twice.

URV

OPEN

PCV-123

11 Make sure the valve is in the shut-off position.

VTD SET ?

12

SET

G

NON-VOL

ENTER

( Yes )

CLR

( No )

NON-VOL

ENTER

( Yes )

keys to finish the span setting and save.

13 Return the Auto/Manual switch to automatic.

14 Adjust the regulator valve to restore the original supply air pressure.

______

______

______



3-8: Manual SVP settings

Adjustments

If your SVP was ordered without a specified Actuator, then several parameters need to be entered manually into the SVP using an SFC.

SFC screen Step Operation

1

Connect an SFC to the SVP. (Refer to “2-

5: Electrical wiring” on page 2-9.)

2

From the Ready State, press the

CONF

B

key to enter configuration mode.

3

Press the

NON-VOL

ENTER

( Yes )

key, then press the

L

PREV

______

SVP CONFIG

SYSTEM CONFIG ?

and

NEXT

H

keys to cycle through the following tree of settings:

Press the

URV F

100%

key to choose an option and the

NON-VOL

ENTER

( Yes )

key to confirm.

______

Example Actuator types and sizes:

Actuator type

VA1, HA1, PSA1

VA2, HA2, PSA2

VA3, HA3, PSA3

VA4, HA4, PSA4

VA5

VA6

VR1

VR2

VR3

Other

PARAM

1

2

3

4

5

6

7

8

9

0

ACTUATOR ACTION

REVERSE

H

NEXT

L

PREV

POSI. ACTION

DIRECT

H

NEXT

L

PREV

VALVE ACTION

DIRECT

H

NEXT

L

PREV

ACTUATOR SIZE

PARAM 0

H

NEXT

L

PREV

DE CONF.

MENU I

ITEM

NON-VOL

ENTER

( Yes )

(Choose) (Accept)

DE CONF.

MENU I

ITEM

NON-VOL

ENTER

( Yes )

(Choose) (Accept)

DE CONF.

MENU I

ITEM

NON-VOL

ENTER

( Yes )

(Choose) (Accept)

DE CONF.

MENU I

ITEM

NON-VOL

ENTER

( Yes )

(Choose) (Accept)

HYSTERESIS

HEAVY

Select the size of hysteresis error resulting from the friction of the gland packing of the control valve:

DE CONF.

MENU I

ITEM

NON-VOL

ENTER

( Yes )

(Choose) (Accept)

Gland Packing Material

Graphite packing

Braided PTFE packing

PTFE Chevron packing

HYSTERSIS

HEAVY

MEDIUM

LIGHT



4 After you have changed all necessary settings, save the changes to the SVP.

5

Press the

L

PREV

or

NEXT

H

key until you see this screen:

6

NON-VOL

Press the to the SVP.

ENTER

( Yes )

key to write the settings

______

SYSTEM CONFIG

DOWNLOAD DATA?

SYSTEM CONFIG

DATA LOADED!

Manual SVP settings - Gain

If the predefined actuator types do not effectively control the valve, then choose the

unspecified actuator type (page 3-11). Once you set the actuator size to 0, you must

manually set the Gain to properly actuate the Valve. Also, in case of hunting or overshoot, varying the Gain may be required for your valve. Note that the CTL

CONFIG menu item won’t appear unless you have chosen an actuator size of 0.

Step

1

Operation

From the ready state, press the

CONF

B

key.

SFC screen

______

2

Press the

NEXT

H

key.

SVP CONFIG

CTL CONFIG?

3

4

NON-VOL

Press the

ENTER

( Yes )

key.

Using the number pad on the SFC, enter in a new Gain or fine-tuning amount (P).

If the SVP is hunting, then make the P value smaller.

“P=2.000” represents 2%

-1

= 1/2% =

50%

NON-VOL

the ,

PREV

CTL CONFIG

P = 2.000

CTL CONFIG

DOWNLOAD DATA ?

5

Then press the

NON-VOL

ENTER

( Yes )

key.

CTL CONFIG

DATA LOADED !



Manual SVP settings - PID

The SVP employs a gap-action type PID method with upper and lower limits to compensate for oscillation above and below a setpoint.

This method provides high responsiveness and high stability with relatively simple tuning.

The PID parameters are:

Parameter

P

I

D

GE

GP

GI

GD

Description

Reciprocal of the proportional band inside the gap

Reciprocal of the integrated time inside the gap

Differentiated time inside the gap

Gap width

Reciprocal of the proportional band outside the gap

Reciprocal of the integrated time outside the gap

Differentiated time outside the gap

If GE (Gap width) is set to 0, then GP, GI, and GD cannot be set.


CONFIG.

CONF

B

key. Press the

NEXT

H

key to get to CTL

Press the

L

PREV

or

NEXT

H

keys to cycle through P, I, D, GE, GP, GI, GD, and

DOWNLOAD. Press the parameter.

NON-VOL

ENTER

( Yes )

key and then enter the desired value for each

Press the

NON-VOL

ENTER

( Yes )

,

PREV

L

keys. save your changes.

CTL CONFIG

DOWNLOAD DATA ?

Press the

NON-VOL

ENTER

( Yes )

key to

Unit

%

-1

S

-1

S

%

%

-1

S

-1

S



3-9: Configuring control signal / Valve travel relationship using an SFC

Control valves normally provide a range of fully shut to fully open with a 4 to 20 mA

(or 20 mA to 4 mA for Direct-acting actuators) control signal. However, there are many situations where a linear 4 to 20 mA range is not appropriate. The valve may need to open with an equal percentage instead of linearly, or be a quick-opening valve.

You may also need to operate two valves in series, or two alternate valves (such as hot and cold) from a single control signal.

With the Azbil Corporation's SVP3000 Smart Valve Positioner, you can easily create the proper relationship between control signal and actual valve opening. Through the use of an SFC, any range curve, including split-ranging for two or more valves, can be set by entering an array of sixteen input (IN%) and output (OUT%) values.

The table and graph below show an example Flow Characteristic curve for a Reverseacting actuator operating within 4-20 mA with a custom curve. Sixteen points have been entered into the SVP. As you can see, where point 2 is closed, point 1 is forced fully shut (with an SFC value of -19999), producing tight shut-off. Points 13, 14, and

15 are redundantly set to fully open, and point 16 is forced fully open (with an SFC value of 19999).

100

Point

SFC IN % ENTRY

(Control signal input %)

SFC OUT % ENTRY

(Valve travel %)

80

1

2

-19999

0.000

-19999

0.000

3 2.0

5.0

60

40

4

5

6

7

2.9

4.7

7.6

12.4

10.0

20.0

30.0

40.0

#

20

0

0 20 40 60

IN %

Figure 3-3

80 100

8

9

10

11

12

13

14

15

16

20.2

32.7

53.1

76.5

90.7

100.0

200.0

400.0

19999

50.0

60.0

70.0

80.0

90.0

100.0

200.0

400.0

19999

As explained earlier (“Zero-span adjustment by input signal” on page 3-8 steps 1-4), the SVP has

forced fully shut and forced fully open settings, which depend on the actuator and valve to be used.

These will have already been programmed into your SVP.

100

0

Forced shut off value

Forced

100 full open value

Signal

Figure 3-4



3-9-1: Examples

Adjustments

Normal operation single valve

Fully shut with 4 mA signal

Fully open with 20 mA signal

Minimal flow operation single valve

25% open with 4 mA signal


Split range operation - 2 valves

Cooling Valve


Fully closed with 12 mA signal

Heating valve



Split range operation - 2 valves

Small valve



Large valve



4mA

4 - 20 mA control signal

8mA 12mA 16mA 20mA

Figure 3-5

Flow characteristics examples

Normal operation single valve

A single valve ranging from fully closed to fully open in a 4 to 20 mA signal.

Minimal flow operation single valve

A single valve might start at 25% open and range to fully open in a 4 to 20 mA signal

(Low fire burner application).

Split range operation - Hot + Cold valves

Two valves might be used in heating-cooling applications where one valve (heating) is fully open at 4 mA and fully shut at 12 mA, while the other valve (cooling) is also fully shut at 12 mA and fully open at 20 mA. They might be a gap between the operation of the two valves or they might overlap.

Split range operations - 2 valves

A small valve might be fully shut at 4 mA and fully open at 8 mA, with a larger valve fully shut at 8 mA and fully open at 20 mA.


Adjustments

3-16


100

0

LINEAR

EQUAL

SIGNAL

%

100

Figure 3-6 Flow characteristics overview

The SVP receives a control signal (typically 4 to

20 mA) and based on the flow characteristic setting in the SVP, provides a certain % valve opening.

This flow characteristic can be Linear, Equal %,

Quick Open, or a User-defined array of 16 points

defining a curve (see the examples on page 3-14

to page 3-15).

To set the flow characteristic of your SVP, connect an SFC and make sure it is in the Ready

State.

Step

1

Press the

CONF

B

Operation

key and then press the

SFC screen

SVP CONFIG

CONFORM CONFIG ?

L

PREV

key until you see the right screen.

2

Press the

DE CONF.

MENU I

ITEM

key to cycle between

LINEAR, EQUAL%, QUICK OPEN, and USER settings.

CONFORM CONFIG

LINEAR

3 to confirm the setting. If you chose

USER, then proceed to the steps below.

4 Once you have chosen the USER flow characteristic, you must determine the appropriate sixteen steps or points with input signal and valve % opening. Once you have defined a curve, you enter those values into the SVP using an SFC.

5

NON-VOL NON-VOL

Now

ENTER

( Yes )

PREV

L

ENTER

( Yes )

keys


CONF

B

______

______

6 key and then press the

L

PREV

key until you see the right screen. Press the key.

NON-VOL

ENTER

( Yes )

Press the

L

PREV

key to rotate between the sixteen points, enter in the value for each, and press the setting.

NON-VOL

ENTER

( Yes )

key to confirm each

______

______



Step Operation

7 Once you have set the sixteen points, you should see the screen shown.

SFC screen

CNV CONFIG

DOWNLOAD DATA ?

8

Press

NON-VOL

ENTER

( Yes )

to save your new settings.

9 If desired, you may print the settings on an SFC by pressing

L

PREV

until you see

10

Then press

NON-VOL

ENTER

( Yes )

to print.

______

______

______

If ordered with process conditions specified, then the SVP will be shipped with the proper input signal range. If you need to change these, or the SVP was sent without any valve or actuator specifications, and the input signal range is not 4 mA to 20 mA, then follow the steps below to set the proper input signal range.

Setting the input signal value for the shut-off valve

Step

1

Operation

From the Ready State, press the key three times.

LRV E

0%

SVP

READY...

SFC screen

PCV-123

Enter in a new input signal value for the shut-off valve.

LRV

SHUT

PCV-123

4.00 mA

2

Press the

NON-VOL

ENTER

( Yes )

key to save the shut-off

______ value. Press the ready state.

CLR

( No )

key to return to the

Setting the input signal value for the fully-open valve

Step

1

Operation


URV F

100%

key three times.

Enter in a new input signal value for the fully-open valve.

SVP

READY...

LRV

SHUT

SFC screen

PCV-123

PCV-123

20.00 mA

2

Press the

NON-VOL

ENTER

( Yes )

key to save the fully-

______ open value. Press the to the ready state.

CLR

( No )

key to return



3-10:Verifying SVP input signal, EPM output, and valve travel output

The mode of communication between the SVP and an SFC is normally in SVP or

Valve Positioner mode. Some functions require you to switch into SVT or Valve

Travel Transmitter mode. With the OUT PUT button, you can verify what input signal is being received by the SVP, the % DUTY output from the Electropneumatic Module.

DE CONF.


MENU I

ITEM

key to switch between SVP and SVT modes.

INPUT

Press the

OUT- J

PUT

key to display the information. (Press the determine EPM in SVT mode)

SHIFT

-

INPUT

OUT- J

PUT

keys to



Chapter 4:

Configuration using a HART

Communicator

This chapter describes operating the Azbil Corporation model AVP102 valve positioner using HART protocol communication. A HART Communicator is used for adjustment, setup, data readout from, and other operations on the model AVP102 product. Refer to the user's manual for the HART Communicator from Emerson

Electric Co. for information on the use of the HART Communicator itself.

Figure 4-1 HART Communicator


Configuration using a HART Communicator

4-1: HART communicator functions


The following operations can be performed using the HART Communicator.

Operations

Starting communication

Verifying and modifying the general information

• Device information

• Manufacturer

Device condition

• Current input value (units: mA)

• Input signal% (percentage) value (units:%)

• Valve travel (units:%)

• Drive sig (EPM (Electro Pneumatic converter Module) drive signal)

(units:%)

• Temperature (Equipment internal temperature) (units: °C)

• Last config data

Config & Calib (Equipment setup and calibration)

• Mode (Switching the SVP mode)

• Input signal range (Setting the current input values)

• Valve sys config (Valve system configuration)

• Dynamic chara (Dynamic characteristics)

• Valve chara (Valve characteristics)

• Tvl cut off (Travel cut off)

• Calibrate

• Diag parameters (Diagnostic parameters)

• Burst mode

Initial setup

Maintenance

• Dummy input sig (Dummy input signal)

• Dummy drive sig (Dummy drive signal)

• User data save

• Correct reset

Device status

• Failures

• Notices

• Valve diagnostics

Page

4-4

4-6

4-7

4-25

4-25

4-26

4-26

4-27

4-27

4-28

4-8

4-8

4-8

4-8

4-8

4-9

4-10

4-10

4-11

4-12

4-14

4-15

4-16

4-18

4-23

4-24




HART Communicator menu tree

1. Main menu

2. IIN_mA

3. IIN_%

4. Travel

5. Device status

1. General info

2. Device condition

3. Config & Calib

4. Initial setup

5. Maintenance

1. Device info

2. Manufacture

1. IIN_mA

2. IIN_%

3. Travel

4. Drive sig

5. Temperature

6. Last config data

1. Mode

2. Input signal range

3. Valve sys config

4. Dynamic chara

5. Valve chara

6. Tvl cut off

7. Calibrate

8. Diag parameters

9. Burst mode

1. Auto setup

1. Dummy input sig

2. Dummy drive sig

3. User data save

4. Correct reset

5. Ramp soak

1. Mode

2. Failures

3. Notices

4. Valve diagnostics

No failures found

LOW IIN/ Input signal too low

VTD FAULT/Valve travel detector error

A/D FAULT/A/D conversion module error

NVM FAULT/Non-volatile memory error

RAM FAULT/RAM error

ROM FAULT/ROM error

No notice found

SHUT ON/SVP is forced fuly shut-off

HI/LO EPM OUT/Electro-pneumatic module is outside normal range

EXT ZERO ACTIVE/External zero/span adjustment is being made

MANUAL MODE/Dummy input signal operation

FIXED EPM OUT/Dummy drive signal operation

CORRECT RESET/Configuration data is reset at the time of shipment

OVER TEMP/Abnormal environmental temperature

1. Alarms

2. Parameters status

1. Actuator size

2. Gland packing

3. GAP PID param

1. Select chara form

2. Chara data

1. Tvl cut off high

2. Tvl cut off low

1. Input sig calib

2. Zero span adjust

1. Stick Slip

2. Total Stroke

3. Cycle Count

4. Tvl Histogram

5. 0% Tvl Error

6. Shut-Off Cnt

7. Max Tvl Speed

8. Deviation Alarm

9. Temp Alarm

1. Burst mode enab

2. Burst command

1. Execution

2. Stop

No alarms found

Stick Slip alarm

Total Stroke alarm

Cycle Count alarm

Max Speed + alarm

Max Speed - alarm

0% Tvl Err + alrm

0% Tvl Err - alrm

Shut-Off Cnt alarm

Deviation + alarm

Deviation - alarm

Temp Hi alarm

Temp Lo alarm

1. Stick Slip

2. Total Stroke

3. Cycle Count

4. Tvl Histogram

5. Shut-Off Cnt

6. Max Tvl Speed

7. Deviation

1. Message

2. Tag

3. Descriptor

4. Data

5. Final assembly num

6. Num req preams

7. Poll addr

8. PROM No.

1. Manufacturer

2. Model

3. Device ID

4. Revision

5. Privat distributr

1. 0% tvl angle

2. 100% tvl angle

3. Stroke time

4. Hysteresis rate

1. LRV

2. URV

1. Actuator action

2. Valve action

3. Positioner action

1. Threshold

2. Alarm enable

3. Shut off cnt

1. Threshold +

2. Threshold -

3. Alarm enable

4. Max tvl speed +

5. Max tvl speed -

6. Data clear

1. Threshold +

2. Threshold -

3. Waiting time

4. Alarm enable

5. Deviation

1. Threshold Hi

2. Threshold Lo

3. Waiting time

4. Alarm enable

5. Temperature

1. HART Univ Rev

2. Fld dev rev

3. Software rev

4. S/W version

1. P

2. I

3. D

4. GE (+/-)

5. GP

6. GI

7. GD

1. Exit

2. IN1/OUT1

3. IN2/OUT2

4. IN3/OUT3

5. IN4/OUT4

6. IN5/OUT5

7. IN6/OUT6

8. IN7/OUT7

9. IN8/OUT8

10. IN9/OUT9

11. IN10/OUT10

12. IN11/OUT11

13. IN12/OUT12

14. IN13/OUT13

15. IN14/OUT14

16. IN15/OUT15

17. IN16/OUT16

1. XY threshold

2. Count threshold

3. Alarm enable

4. Stick slip

5. Stick slip count

1. Threshold

2. Dead band

3. Alarm enable

4. Total stroke

1. Threshold

2. Position Hi

3. Position Lo

4. Alarm enable

5. Cycle count

1 Tvl segmentation

2. Tvl histogram

1. Waiting time

2. Deviation +

3. Deviation -

4. Alarm enable

~Notes

• Refer to the HART Communicator user's manual provided by Emerson Process

Management when using the HART Communicator.

• This manual describes the functions of the model AVP102 version listed below.

Field device revision: 2

Software revision:1 (Azbil Corporation Software ver. 4.A)

HART Universal command revision:5

• When operating the model AVP102 with a HART Communicator, update the HART

Communicator firmware and modules as required.

• Also note that the SVP device descriptions are registered at the local programming

site in each country.




4-2: Starting communication

This section describes the wiring used for communication between the HART

Communicator and the model AVP102. The input signal line from the controller is used for the communication line between the HART Communicator and the model

AVP102.

Before starting communication

Verify the following points before starting communication.

• Verify that the cable connection between the SVP and the HART Communicator is

correct and complete. (See Chapter 2 : Installation.)

• Verify that an input signal (power supply) from the controller (constant current power supply) is provided.

~Note

If it is not possible to provide a 4-20 mA DC signal from the controller, connect a constant current power supply (3.85 to 21.5 mA DC) to the input signal terminals. The lines from the controller must be removed from the terminals before connecting the constant current power supply.

Procedure

(1) Connect an input signal line to the HART Communicator.



WARNING

If the HART Communicator is to be used in an environment with an explosive atmosphere, the communicator itself must have explosionproof specifications and non-incendiary wiring must be used. If the HART Communicator used does not meet these conditions, it must not be in an explosive atmosphere.

4-4

I IN

+

-

I IN

4~20mA DC

-

+


(only for model AVP102)

Figure 4-2 HART communication structure

Host

Controller




(2) Press the [I/O] button to turn on the HART Communicator power.

The initial screen shown below will be displayed and communication will start.

F1 F2 F3 F4




4-3: Verifying and modifying the general information

This section describes verifying and modifying the equipment information for the model AVP102 connected to the HART Communicator.

4-3-1 :Device information

Procedure

Select [Main menu] >> [General info] >> [Device info], and verify and modify the following items as required.

4-6

1 Message

2 Tag

3 Descriptor

4 Date

5 Final assembly num

(Final assembly number)

6 Num req params

(Number of requested preambles)

Menu

7 Poll addr

(Polling address)

8 PROM No.

Function

Verifies and/or modifies the messages registered in the

SVP.

Verifies and/or modifies the tag number allocated to the equipment.

Verifies and/or modifies the equipment type information required for equipment management.

Verifies and/or modifies the date of the last setup operation and other special dates in the equipment.

Verifies and/or modifies the date of the last setup operation and the special management numbers in the equipment and system.

Verifies the number of preambles characteristic to the equipment.

Specifies the equipment address when multiple units are connected in the same loop, for example when split range operation is used.

Verifies the model AVP102 ID information.




4-3-2 :Manufacturer

Procedure

Select [Main menu] >> [General info], and verify and modify the following items as necessary.

2 Model

Menu

1 Manufacturer

3 Device ID

4 Revision

5 Privat distributr

(Private label distributor)

Function

Verifies the manufacturer of the equipment. “Azbil

Corporation” will be displayed.

Verifies the name and model number of the equipment.

“SVP” will be displayed.

Verifies the unique ID information for the equipment.

Verifies the version information for the equipment software. The following items can be verified.

HART Universal command revision

Displays the revision number of the HART universal commands supported by the model AVP102.

Fld dev rev (Field device revision)

Displays the version number for the device description.

Software rev (Software revision)

Displays the version number for the software within the same field device revision.

S/W ver.

Displays the version number of the software. This is a

Azbil Corporation internal management number, and is in a one-to-one correspondence with the Software revision item described above.

Verifies the private label distributor of the equipment



4-4: Device condition


This mode allows the display of measured values during equipment operation and the verification of adjustment data. Use the following procedure to verify and set this data.

4-4-1 :Current input value

(units: mA)

Select [Main menu]

>> [Device condition]

>> [IIN_mA].

4-4-2 :Input signal% (percentage) value

(units:%)

Select [Main menu]


>> [IIN_%].

4-4-3 :Valve travel

(units:%)

Select [Main menu]


>> [Travel].

4-4-4 :Drive sig (EPM

(Electro Pneumatic converter Module)

drive signal)

(units:%)

Select [Main menu]


>> [Drive sig].

4-4-5 :Temperature (Equipment internal temperature)

(units: °C)

Select [Main menu]


>> [Temperature].



4-4-6 :Last config data


0% tvl angle (VTD sensor angle when fully closed)

(units: degrees)

Displays the angle set as the point where the valve is fully closed.

Procedure

• Select [Main menu]


>> [Last config data]

>> [0% tvl angle].

100% tvl angle (VTD sensor angle when fully open)

(units: degrees)

Displays the angle set as the point where the valve is fully open.

Procedure




>> [100% tvl angle].

Stroke time

(units: seconds)

Displays the valve full stroke time measured when auto setup was run.

Procedure




>> [Stroke time]

Hysteresis rate

(units:%)

Displays the friction level of the gland pack measured when auto setup was run.

Procedure




>> [Hysteresis rate].




4-5: Config & Calib

(Equipment setup and calibration)

The setup and calibration procedure sets up and calibrates the required basic functions for the equipment to operation correctly.

Before setting up the equipment, set the SVP mode to Out of service.



CAUTION

After completing calibration or adjustment, or after changing settings, return the mode to In service.

4-5-1 :Mode (Switching the SVP mode)

The SVP has two modes: In service and Out of service.

When performing calibration or adjustment, or when changing settings, first verify that these operations will not result in problems that could adversely influence plant operation. Then set the mode to Out of service.

After completing calibration or adjustment, or after changing settings, return the mode to In service. These operations cannot be performed when the SVP mode is In service.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Mode].

• Select the SVP mode (Out of service or In service) from the Mode menu.

4-5-2 :Input signal range (Setting the current input values)

This procedure sets the current input value when the valve is fully closed (LRV) and the current input value when the valve is fully open (URV).

An input in the range 4-20 mA can be used.

A split range can also be set up easily.



CAUTION

• Set these values so that the current input span (|LRV - URV|) is in the range 4 to

16 mA.

• If the span is under 8 mA, the precision will be 1.5% of full scale.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Input signal range] >> [LRV].

• Apply the current input value for the valve fully closed position and press F4.

• Select [Main menu] >> [Config & Calib] >> [Input signal range] >> [URV].

• Apply the current input value for the valve fully open position and press F4.




4-5-3 :Valve sys config (Valve system configuration)

This procedure set the control valve control system.

Actuator action

• Selects the operating direction of the actuator.

• Selects direct or reverse action (DIRECT/REVERSE). Specify direct operation

(DIRECT) if the feedback lever is to move from higher to lower positions as the air pressure increases, or specify reverse operation (REVERSE) if the feedback lever is to move from lower to higher positions.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Valve sys config] >> [Actuator action].

• Select the actuator operating direction (Direct or Reverse) and press F4.

Valve action

• Selects the direction of the valve plug.

• Selects direct or reverse plug action (DIRECT/REVERSE). Specify direct operation

(DIRECT) if the feedback lever is to move from higher to lower positions when the control valve moves in the open to closed direction, or specify reverse operation

(REVERSE) if the feedback lever is to move from lower to higher positions. See “3-

2: Zero-span adjustment” on page 3-3., in this section for the method for making this

selection.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Valve sys config] >> [Valve action].

• Select the valve operating direction (Direct or Reverse) and press F4.

Positioner action

• Selects the operating direction of the positioner.

• Selects direct or reverse action (DIRECT/REVERSE). Specify direct operation

(DIRECT) if the SVP output air pressure should go to zero if the power supply is disconnected, or specify reverse operation (REVERSE) if the SVP output air pressure should go to its maximum pressure.

The operating direction of the position is determined by the main unit hardware. The operating direction cannot be switched with this function. This item must be set to match the direction of the main unit specifications. Contact your Azbil Corporation service representative to change the operating direction.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Valve sys config] >> [Positioner action].

• Select the positioner operating direction (Direct or Reverse) and press F4.



4-5-4 :Dynamic chara (Dynamic characteristics)


Actuator size

• Selects the size of the actuator.

• Select one of parameter 0 to parameter 9 (PARAM0 to PARAM9).

~Note

The parameter set here determines PID calculation parameters used to control the control valve (That is, the dynamic characteristics are determined by this setting.)

If parameter 0 (PARAM0) is selected, it will be possible (and necessary) to perform the settings described in (B) Setting the Dynamic

Characteristics Data. Normally, this setting is not used.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Dynamic chara] >> [Actuator size].

• Select the parameter (Param 0 to 9) for the actuator size and press F4.

• If parameter 0 is selected, set the gap PID parameters.

Gland packing

• Selects the magnitude of the hysteresis difference due to friction in the control valve gland packing.

• Select one of heavy, medium, or light (HEAVY, MEDIUM, or LIGHT).

• Refer to Table 4-2: Hysteresis Parameter table and select a parallel appropriate for

the gland packing material.

~Note

The parameter set here determines PID calculation parameters used to control the control valve

This setting is not required if parameter 0 (PARAM0) in item (4) Actuator

Size Selection is selected.

Table 4-1: SVP PID parameter table

Actuator diaphragm capacity (cm³) Actuator model

*a

1000

3500

7600

14000

25300

8400

760

2200

5800

Values other than the above

*b

HA1, VA1, PSA1

HA2, VA2, PSA2

HA3, VA3, PSA3

HA4, VA4, PSA4

VA5

VA6, PSA6

VR1

VR2

VR3

Parameter (PARAM)

6

7

4

5

8

9

1

2

3

0

*ii

~Note *a. This is set according to the specifications and model number when shipped from the factory.

~Note *b. Consult an Azbil Corporation service representative.




Table 4-2: Hysteresis Parameter table

Gland packing material example

Graphite packing

Yarn packing

Type V PTFE packing

Hysteresis (HYSTERESIS)

Heavy (HEAVY)

Medium (MEDIUM)

Light (LIGHT)

Procedure

• Select [Main menu] >> [Config & Calib] >> [Dynamic chara] >> [Gland packing].

• Select the gland packing parameter (Light, Medium, or Heavy) and press F4.

Gap PID param (Gap PID parameters)

This item allows you to set the SVP dynamic characteristics data freely.

~Note

It will be possible (and necessary) to perform these settings only if parameter 0 (PARAM0) is selected in the actuator size selection

(ACTUATOR SIZE) item in the basic data settings.

The gap-action type PID method is adopted in the SVP to determine the dynamic characteristics.

In the gap-action type PID method, deviation values (the gap) above and below the target value are set up, and the PID parameters are changed depending on whether the process value is inside or outside the gap.

This method has the advantages that both rapid response characteristics and stability can be achieved with relatively simple tuning.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Dynamic chara] >> [Gap PID parameters].

• Enter the numeric values for the 7 PID parameters (P, I, D, GE, GP, GI, and GD) and press F4.



4-5-5 :Valve chara (Valve characteristics)


Select chara form

This item allows you to select flow characteristics.

The user can also set arbitrary characteristics.

• One of linear, equal percent, quick open, and user (LINEAR, EQUAL%, QUICK

OPEN, and USER) can be selected as the flow characteristics.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Valve chara] >> [Select chara form].

• Select the positioner flow characteristics (Linear, Quick opening, EQ%, or User defined).

• If the user defined characteristics option was selected, set up the flow characteristics conversion data.

Chara data

This item, (D) Setting the Flow Characteristics Conversion Data (CNV CONFIG), allows you to set up converted data for arbitrary user flow characteristics.

~Note

It will be possible (and necessary) to perform these settings only it user

(USER) is selected in setting the flow characteristics.

• There are 16 data points, corresponding to P = 1 to P = 16.

• For each point, both the input signal (IN%) and position (OUT%) are specified.

• The characteristics will consist of the line formed by linearly interpolating between adjacent points.

~Note

All 16 points (input value and valve position) must be set.

The values P = 1 to P = 16 must be set in order of increasing input values, starting with the smallest value.

The values used must have the property that no inflection points exist, that is, they must be monotonic increasing.

Values in the range -19999 to +19999 can be entered.

Procedure

• Select [Main menu] >> [Config & Calib] >> [Valve chara] >> [Chara data].

• Select IN1/OUT1 from the Chara data menu, and set the input signal (IN1%) and the position (OUT1%).

• Set the values for IN2/OUT2 through IN16/OUT16 in the same manner.




Printing the characteristics curve

The following presents an example of printing the characteristics curve and the input data used.

100

80

Point

1

2

3

SFC IN %

ENTRY

(Control signal input %)

-19999

0.000

2.0

SFC OUT %

ENTRY

(Valve travel %)

-19999

0.000

5.0

60

4 2.9

10.0

40

5

6

4.7

7.6

20.0

30.0

#

20

0

0 20 40 60

IN %

Figure 4-3

80 100

7

8

9

10

11

12

13

14

15

16

12.4

20.2

32.7

53.1

76.5

90.7

100.0

200.0

400.0

19999

40.0

50.0

60.0

70.0

80.0

90.0

100.0

200.0

400.0

19999

4-5-6 :Tvl cut off (Travel cut off)

This item allows you to set the current input values (%) that forcibly full open and full closed the value.

Forced fully open/fully closed settings

• The valve will be fully closed at input values less than the forced fully closed value, and it will be fully open at input values greater than the forced fully open value.

• The forced fully closed and forced fully open values can be set independently as percentages, IIN, of the current input value.

• The figure below presents an overview of the I/O characteristics when the forced fully closed and forced fully open values have been set.

~Note

These parameters must be set to values such that the forced fully open value

(SHUT OFF VALUE) is strictly less than the forced fully open value (FULL

OPEN VALUE).

Values in the range -19999 to +19999 can be entered.

% stroke

100

If the span setting is adjusted after an auto-setup operation, change the forced fully open value (FULL OPEN VALUE) to be 1% less than the overstroke percentage.

0

Forced shut off valve

Forced full open valve

Signal

100

% IIN

Figure 4-4 Forced fully open and forced fully closed values




Procedure

Tvl cut off high

• Select [Main menu] >> [Config & Calib] >> [Tvl cut off] >> [Tvl cut off high].

• Enter the forced fully open value as a percent of current input value and press F4.

Tvl cut off low

• Select [Main menu] >> [Config & Calib] >> [Tvl cut off] >> [Tvl cut off low].

• Enter the forced fully closed value as a percent of current input value and press F4.

4-5-7 :Calibrate

Input sig Calib (Input signal calibration)

This function corrects for differences between the 4-20 mA current input from the controller and the 4-20 mA input signal certified by the SVP.

Current input 4 mA calibration procedure

• Select [Main menu] >> [Config & Calib] >> [Calib] >> [Input sig calib] >> [4 mA calib].

• Set the current input (controller output) to 4 mA and press F4.

• When the confirm update message is displayed, press F4.

• When the update completed message is displayed, press F4.

Current input 20 mA calibration procedure

• Select [Main menu] >> [Config&Calib] >> [Calib] >> [Input sig calib] >> [20 mA calib].

• Set the current input (controller output) to 20 mA and press F4.



Zero span adjust

This section describes the procedures for adjusting zero and span using HART

Communicator. See “3-2: Zero-span adjustment” on page 3-3 for an overview of the

zero and span adjustments.

Zero and span adjustment using the HART Communicator procedure

<Setting the valve fully closed position>

• Select [Main menu] >> [Config & Calib] >> [Calib] >> [Zero span adjust]>> [Angle adjust]>> [Zero].

• Set up a current input value such that the valve closes fully and press F4.

• Select the combination of the amount of angle by which to adjust the setting from the

Zero adjust menu (for example, to increase by 0.006°, select increment/0.006) and press F4.

• Repeat the above operation several times. When the zero point has been adjusted, select [Exit] and press F4.

<Setting the valve fully open position>

• Select [Main menu] >> [Config & Calib] >> [Calib] >> [Zero span adjust] >>

[Angle adjust] >> [Span].

• Set up a current input value such that the valve opens fully and press F4.

• Select the combination of the amount of angle by which to adjust the setting from the

Zero adjust menu (for example, to increase by 0.006°, select increment/0.006) and press F4.

• Repeat the above operation several times. When the zero point has been adjusted, select [Exit] and press F4.




Changing the air supply pressure while adjusting the position procedure

<Setting the valve fully closed position>

• Apply a current value (any value) in the range 4-20 mA from the controller.

• Use the A/M switch to switch to manual operating mode. (See “5-1: Auto/Manual selection switch” on page 5-1.)


[Manual adjust] >> [Zero].

• Adjust the supplied air pressure using a regulator so that the valve closes fully and press F4.



<Setting the valve fully open position>

• Apply a current value (any value) in the range 4-20 mA from the controller.

• Use the A/M switch to switch to manual operating mode. (See “5-1: Auto/Manual selection switch” on page 5-1.)


[Manual adjust] >> [Span].

• Adjust the supplied air pressure using a regulator so that the valve opens fully and press F4.





4-5-8 :Diag parameters (Diagnostic parameters)


1. Stick Slip

Stick Slip is the value that showed movement of the valve that the stick slip which broke out by bites or fixation.

XY threshold

When Stick Slip becomes bigger than this value, it is a value to count it.

Procedure: Select [Main menu] >> [Config & Calib] >> [Diag parameters]

>> [Stick Slip] >> [XY Threshold].

Enter the XY threshold and press F4.

Count threshold

When the number that the Stick Slip value became bigger than XY value becomes bigger than this value, alarm is sent.


>> [Stick Slip] >> [Count threshold].

Enter the Count threshold and press F4.

Alarm enable

Select the enable/Disable of alarm.


>> [Stick Slip] >> [Alarm enable].

Select the Enable/Disable of alarm and press F4.

Stick Slip


>> [Stick Slip] >> [Stick Slip].

2. Total Stroke

Total stroke is the distance that the stem has moved.

Threshold

When Total Stroke becomes bigger than this value, alarm is sent.


>> [Total Stroke] >> [Threshold].

Enter the threshold and press F4.

Dead band

Dead band is the smallest value to count Total Stroke.

Procedure Select [Main menu] >> [Config & Calib] >> [Diag parameters]

>> [Total Stroke] >> [Dead band].

Enter the Dead band and press F4




Alarm enable

Select the Enable/Disable of alarm.


>> [Total Stroke] >> [Alarm enable].


Total Stroke


>> [Total Stroke] >> [Total Stroke].

3. Cycle Count

Cycle count is the number that how many times the valve travel is over the Position Hi or Position Lo.

Threshold

When Cycle Count becomes bigger than this value, alarm is sent.


>> [Cycle Count] >> [Threshold].


Position Hi, Position Lo

Procedure:

Position Hi

Select [Main menu] >> [Config & Calib] >> [Diag parameters]

>> [Cycle Count] >> [Position Hi].

Enter the [Position Hi] and press F4.

Position Lo


>> [Cycle Count] >> [Position Lo].

Enter the [Position Lo] and press F4.

Alarm enable



>> [Cycle Count] >> [Alarm enable].


Cycle count


>> [Cycle Count] >> [Cycle count].




4. Tvl Histogram (Travel Histogram)

Tvl Histogram shows the frequency of the valve travel position in each band width of max. 16.

Tvl segmentation (Travel segmentation)

Tvl segmentation is the valve travel position in each band width of max. 16.


>> [Tvl Histogram] >> [Tvl segmentation].

Set the Tvl segmentation and press F4.

Tvl histogram (Travel Histogram)


>> [Tvl Histogram] >> [Tvl histogram].

5. 0% Tvl Error (0% Travel Error)

0% Tvl Error is alarm of the deviation with the current zero position and setting zero position.

Waiting time

When the zero position error continues for a longer time than this waiting time, alarm is sent.


>> [0% Tvl Error] >> [Waiting time].

Enter the Waiting time and press F4.

Deviation

When the error becomes bigger than this value and the deviation error continues for a longer time than waiting time, alarm is sent.

Procedure:

Deviation +


>> [0% Tvl Error] >> [Deviation +].

Enter the Deviation + and press F4.

Deviation -


>> [0% Tvl Error] >> [Deviation -].

Enter the Deviation - and press F4.

Alarm enable



>> [0% Tvl Error] >> [Alarm enable].





6. Shut-Off Cnt (Shut-Off Count)

Shut-Off Cnt is a count of valve shut.

Threshold

When Shut-Off Cnt becomes bigger than this value, alarm is sent.


>> [Shut-Off Cnt] >> [Threshold].


Alarm enable

Select the Enable / Disable of alarm.


>> [Shut-Off Cnt] >> [Alarm enable].


Shut-Off Cnt


>> [Shut-Off Cnt] >> [Shut-Off Cnt].

7. Max. Tvl Speed (Maximum Travel Speed)

Max. Tvl Speed is maximum valve travel speed in unit time.

Threshold

When Max. Tvl Speed becomes bigger than this value, alarm is sent.

Procedure:

Threshold +


>> [Max Tvl Speed] >> [Threshold +]

Enter the Threshold + and press F4.

Alarm enable

Threshold -


>> [Max Tvl Speed] >> [Threshold -].

Enter the [Threshold -] and press F4.



>> [Max Tvl Speed] >> [Alarm enable].





Max Tvl Speed (Maximum Travel Speed)

Procedure

Max. Tvl Speed +


>> [Max tvl speed] >> [Max Tvl Speed +].

Max. Tvl Speed -


>> [Max tvl speed] >> [Max Tvl Speed -].

Data clear

Max. Tvl Speed is cleared.


>> [Max Tvl Speed] >> [Data clear] and press F4.

8. Deviation Alarm

Deviation alarm is alarm of deviation with control signal input and valve travel.

Threshold

When the travel deviation becomes bigger than this value, alarm is sent.

Procedure

Threshold +


>> [Deviation Alarm] >> [Threshold +].


Threshold -


>> [Deviation Alarm] >> [Threshold -].

Enter the Threshold - and press F4.

Waiting Time

When the valve travel error continues for a longer time than this waiting time, alarm is sent.


>> [Deviation Alarm] >> [Waiting time].


Alarm enable



>> [Deviation Alarm] >> [Alarm enable].


Deviation


>> [Deviation Alarm] >> [Deviation].




9. Temp Alarm (Temperature alarm)

Temp Alarm is alarm of abnormal environmental temperature.

Threshold

When the temperature becomes bigger than this value, alarm is sent.

Procedure

Threshold +


>> [Temp Alarm] >> [Threshold +].


Threshold -


>> [Temp Alarm] >>[Threshold]-.


Waiting Time

When the temperature error continues for a longer time than this waiting time, alarm is sent.


>> [Temp Alarm] >> [Waiting time].


Alarm enable



>> [Temp Alarm] >> [Alarm enable].


Temperature


>> [Temp Alarm] >> [Temperature].

4-5-9 :Burst mode

Burst mode enab

Select the enable/Disable of burst mode.

Procedure: Select [Main menu] >> [Config & Calib] >> Burst mode >>

[Burst mode enab].

Select the Enable/Disable of burst mode and press F4.

Burst command

Displays the method of Burst mode.

Procedure: Select [Main menu] >> [Config & Calib] >> [Burst mode] >>

[Burst command].

(Burst command is stationary with 3.)



4-6: Initial setup


Auto setup

The following auto setup items are performed.

• Zero and span adjustment

• Actuator direction setting

• Input signal LRV and URV setting

• Actuator size selection

• Hysteresis setting

• Position transmission burnout direction selection



WARNING

Performing the auto setup operation is dangerous because the valve moves rapidly from the fully closed position to the fully open position. Prepare yourself and the process in advance so that no one is injured and the process is not adversely affected when the valve operates.

~Note

When a model VR actuator is used, set the actuator size to one of

PARAM7 to PARAM9 before performing an auto setup operation. (See

“4-5-3 : Valve sys config (Valve system configuration)” on page 4-11.)

Do not lower the input signal (4-20 mA) to a level less than 4 mA. (The level of the signal can be set to any level in the 4-20 mA range without problem.)

The operation has completed when after the actuator has followed the input signal and the system has returned to the control state.

After the operation completes, hold the input signal at a level above 4 mA for 30 seconds to write the settings.

There are cases where the dynamic characteristics may not be set correctly due to the size of the actuator (when the actuator is smaller than the Azbil Corporation’s model HA1 actuator (diaphragm chamber capacity: 850 cm³)) or the operating stroke (when the stroke is less that

14.3 mm).

In these cases, refer to“ Gap PID param (Gap PID parameters)” on page 4-13.

After the auto setup operation completes, vary the input signal manually and verify that the actuator moves to the corresponding position. If the span position is displaced, adjust the span.

Procedure

• Select [Main menu] >> [Initial setup] >> [Auto setup].

• When the confirmation message is displayed, press F4.




• When the execution confirmation message is displayed, press F4.

• When the auto setup completed message is displayed 2 or 3 minutes later, press F4.

4-7: Maintenance

4-7-1 :Dummy input sig (Dummy input signal)

This function uses the SFC to set the input signal value regardless of the value of the input signal from the controller.

This function can be effective, for example, in isolating problems during troubleshooting. For example, if the control valve does not move in response to input signals from the controller, if the valve operates correctly in response to the simulated current input, then one can conclude that the problem is somewhere from the wiring to the host system.

Procedure

• Select [Main menu] >> [Maintenance] >> [Dummy input sig].


• Select the simulated input signal (0%, 50%, 100%, or Other) and press F4.

• If you selected Other, enter an arbitrary value (0 to 100%) and press F4.

Cancellation procedure

• Select [Main menu] >> Maintenance >> Dummy input sig


• Select Clear from the Dummy input sig menu and press F4.

4-7-2 :Dummy drive sig (Dummy drive signal)

• Normally, this function is not used.

• This function cuts the drive signal from the PID control unit block, and sets the simulated drive signal to the EPM (electro-pneumatic converter module).

Procedure

• Select [Main menu] >> Maintenance >> Dummy input sig.


• Select the EPM simulated input percentage (0%, 50%, 100%, or Other) and press F4.

• If you selected Other, enter an arbitrary value (0 to 100%) and press F4.

Cancellation procedure

• Select [Main menu] >> [Maintenance] >> [Dummy input sig].


• Select Clear from the Dummy input signal menu and press F4.




4-7-3 :User data save

• Saves all of the SVP internal data in place of the factory shipment data specifications

(data set according to the model number).

• Use the “Recall Factory Data” operation to recall the saved data.

• We recommend saving the settings data after installing the SVP and after all settings have been completed.

~Note

All the factory shipment data is lost.

When the data is written, the settings data is written to the SVP internal nonvolatile memory that is used for normal operation. This means that this data will not be lost even if the SVP power is turned off. This operation copies the contents of the memory used for normal operation to storage memory.

If a communications error occurs during communication (during storing), the data will not be stored. Repeat the store operation if this occurs.

Procedure

• Select [Main menu] >> [Maintenance] >> [User data save].

• When the confirm overwrite message is displayed, press F4.



4-7-4 :Correct reset

• This operation returns all the SVP internal data to the default (initial values) state.

• See the “Internal Data Default Values Table” for more information on default data

(initial values).

~Note

Since use of this function will require that the SVP be adjusted and set up again, this function should not be used by anyone other than Azbil

Corporation service personnel.

After recalling the data, start using the SVP from the Starting

Communication step.

If a communication error occurs during communication (or during initialization), the initialization operation will not be performed. Perform the initialization operation again if this happens.

Procedure

• Select [Main menu] >> [Maintenance] >> [Correct reset].

• When the confirm overwrite message is displayed, press F4.





4-8: Device status


This equipment includes a self diagnostics function. This function is convenient for troubleshooting.

See "Chapter 6 : Troubleshooting", for the appropriate actions to take for the different

messages.

4-8-1 :Failures

Procedure

• Select [Device status] >> [Failures].

• One of the following messages will be displayed if a fault was discovered.

-No failure found

-LOW IIN / Input signal too low

-VTD FAULT / Valve travel detector error

-A/D FAULT / A/D conversion module error

-NVM FAULT / Non-volatile memory error

-RAM FAULT / RAM error

-ROM FAULT / ROM error

4-8-2 :Notices

Procedure

• Select [Device status] >> [Notices].

• One of the following messages will be displayed if a fault was discovered.

-No failure found

-SHUT ON / SVP is forced fully shut-off

-HI/LO EPM OUT / Electro-pneumatic module is outside normal

-EXT ZERO ACTIVE / External zero / span adjustment is being made

-MANUAL MODE / Dummy input signal operation

-FIXED EPM OUT / Dummy drive signal operation

-CORRECT RESET / Configuration data is reset at the time of shipment

-OVER TEMP / Abnormal environmental temperature



4-8-3 :Valve diagnostics


Alarms

Procedure

Select [Device status] >> [Valve diagnostics] >> [Alarms]

One of the following message will be displayed if a valve diagnostic alarm was discovered.

- No alarm found - Shut-Off Cnt alarm

- Stick Slip alarm

- Total Stroke alarm

- Cycle Count alarm

- Deviation + alarm

- Deviation - alarm

- Temp Hi alarm

- Max Speed + alarm

- Max Speed - alarm

- 0% Tvl Err + alarm

- 0% Tvl Err - alarm

- Temp Lo alarm

Parameters status

Procedure

Select [Device status] >> [Parameters status].

Read the following valve diagnostic parameters

- Stick Slip

- Total Stroke

- Cycle Count

- Tvl Histogram

- Shut-Off Cut

- Max. Tvl Speed

- Deviation



Chapter 5 : Maintenance

5-1: Auto/Manual selection switch

The Auto/Manual switch selects the control method for the pneumatic output from the positioner to be either automatic operation or manual operation.

Automatic operation

• An air pressure output corresponding to the input signal is output from the SVP.

• See Figure 5-2.

Manual operation

• The supplied air pressure is output directly from the positioner.

• This allows manual operation using a pressure regulator.

• See Figure 5-3.



CAUTION

The double acting actuator has no manual operation function.



WARNIING

The valve may move suddenly when the A/M switch is operated. Prepare yourself and the process in advance so that the process is not adversely affected when the valve operates.

5-1-1 :Structure of the A/M switch

The structure of the A/M switch is shown below.

A/M switch

Figure 5-1 Structure of the A/M Switch


Maintenance Azbil Corporation

5-1-2 :Operating procedure

The technique for switching the A/M switch is shown below.

Switching from automatic (normal) operation to manual operation

• Use a flat-bladed screwdriver to turn the A/M switch once fully in the counterclockwise.

Do not loosen this screw

Figure 5-2 Switching from automatic (normal) operating state to manual operating State

~Note

Do not loosen the A/M switch cover plate screw.

Switching from manual operation to the automatic operation

• Use a flat-bladed screwdriver to turn the A/M switch in the clockwise direction until it stops.

Do not loosen this screw

Figure 5-3 Switching from manual operating state to automatic operating state


Azbil Corporation Maintenance

5-2: Filter replacement and restriction maintenance

The contamination from the instrumentation air that collects in the restriction in the

SVP can be removed during maintenance. For the instrumentation air, use dry air which has been cleaned of 3 µm (or smaller) solid particles. Always use a Phillips screwdriver.

Procedure

Step No.

1

2

Procedure

Cut off the air supply to the SVP.

Remove the setscrews from the A/M switch nameplate section.

3

4

~Note

Be careful not to drop the A/M switch cover plate washers and corrugated washers when removing the screws.

Turn the A/M switch to the MAN (manual) position.

Use nippers or another tool to cut the holder and remove the old filter.

5

6

7

8

~Note

Dispose of the old holder and filter appropriately.

Use wire to remove the contamination from the restriction. (diameter 0.3 mm)

~Note

Be careful not to damage the restriction when removing the contamination. Do not use an air gun. Do not allow any oils or greases to contaminate the restriction.

Wrap a new filter around the A/M switch, and press it in place with the holder.

Screw down the A/M switch until it stops.

Reassemble the A/M switch section name plate together with the A/M switch cover plate using the setscrews.

A/M switch

O-ring

Plate

Setscrew

Figure 5-4 A/M switch


Maintenance

5-3: Cleaning the flapper


If contamination from the instrumentation air has accumulated on the flapper, clean the flapper as described below.



CAUTION

If air pressure is supplied to the SVP, the nozzle back pressure may change causing the valve position may change suddenly when the flapper is cleaned. Only clean the flapper in a state where no one will be injured and plant operation will not be adversely influenced even if the valve moves suddenly.

Procedure

Step No.

3

4

1

2

5

6

Procedure

Remove the cover.

Remove four screws from the cover plate.

Remove the plate by sliding it to the left.

Provide pieces of paper with a thickness of 0.2 mm. Standard business cards will do.

Use the scraps of paper to clean the contamination from the gap between the EPM nozzle and the flapper.

After cleaning the gap, reassemble the plate and cover.

5-4

Cover plate

EPM adjustment screw

Business card

Figure 5-5 EPM balance adjustment

Approx.

0.2 mm



5-4: EPM

(Electro-pneumatic converter module)

balance adjustment

In situations such as when excessive mechanical shocks and other external disturbances have been applied to the SVP itself, or when contamination from the instrumentation air has collected in the nozzle flapper area, the internal EPM (electropneumatic converter module) balance point may be displaced and the response characteristics degraded. This can lead to malfunctions occurring. If the balance point displacement cannot be rectified by cleaning the nozzle flapper area, EPM adjustment will be necessary.



CAUTION

The EPM balance adjustment can cause the valve position to change rapidly. Only perform this adjustment in a state where no one will be injured and plant operation will not be adversely influenced even if the valve moves suddenly.

Procedure

Step No.

1

2

3

4

Procedure

Remove the cover and the cover plate.

After supplying the stipulated air pressure, set the input signal to 50%.

Observe the EPM drive signal using the SFC. (Refer to "Verifying SVP input signal, EPM output, and valve travel output" on page 3-18)

Adjust the EPM drive signal to have a 50% ±5% duty by turning the EPM adjustment screw.

Cover plate

EPM adjustment screw

Turning this screw in the counterclockwise direction increases the EPM drive signal (duty val

Turning this screw in the clockwise direction decreases the EPM drive signal (duty value).

Figure 5-6 EPM balance adjustment


Maintenance

5-5: Insulation resistance test




CAUTION

As a general rule, please do not perform the insulation resistance test.

Performing this test may result in damage to the varistor for absorbing internal surge voltage.

If you absolutely must perform the test, please perform it carefully in accordance with the designated procedures.

5-5-1 :Test procedures

• Disconnect the device's external wiring.

• Short circuit the + and - terminals of the input and output respectively.

• Perform the tests between ground terminal and its respective short-circuit between the + and - terminals.

• Applied voltage and judgment standards are as follows. To avoid damage to the instrument, do not apply voltage greater than the values listed below.

5-5-2 :Judgment criteria

The judgment standard for the test is as follows:

Test Judgment Standard

Insulation Resistance Test More than 20 M

Ω at test voltage 25V DC (25°C, under

60% RH)



5-6: Adjustment procedure when using the SVP attached to the booster relay

When using the device attached to the booster relay, please adjust using the following procedure:

Begin Adjustment

Mount the device and the booster relay on the control valve.

Please be sure to connect the air pipe between the device and the booster relay.

Adjust the sensitivity of the booster relay

Adjust the needle of the booster relay to control the air flow.

* In the case of the IL100 type, from the highest sensitivity state (the state where the needle is fully closed), turn the needle counterclockwise 1.5 turns and use the AVP in the state where the booster sensitivity dropped.

When using another booster relays as well, please decrease the sensitivity before using.

Execute auto setup program

State at the time of hysteresis measurement

Normal

Shut down the input signal once, then reduce the sensitivity again by turning the booster needle

1/4 to 1/2 turns.

Occurrence of valve hunting

Readjusting booster relay sensitivity

In the event that you have dynamic characteristic data for reference

Setting dynamic characteristics manually

Shut down the input signal once then interrupt the auto setup program. Then increase the input signal and use the SFC to change the following:

· size of the actuator *1

· hysteresis *2

· dynamic characteristic data *3

Dynamic characteristic test

Confirm the static and dynamic characteristics of the positioner by testing five points: 0%, 25%, 50%,

75%, and 100%.

Second change of dynamic characteristics

Use SFC to change the following:

· actuator size *1

· hysteresis *2

· dynamic characteristic data *3 etc.

· Large overshoot

(or large undershoot)

· It takes a long time to stabilize

Dynamic characteristics

Satisfactory

Permanent valve hunting

End

Finish the adjustment.

*1: Change the actuator size parameter from 6 to 5, 5 to 4, etc. in decreasing numerical order.

*2: Change the hysteresis parameters in order from light to medium and medium to heavy.

*3: Reduce P, GP, reduce I, GI, increase D, GD,etc.


Maintenance

5-7: Table of default internal data values


Item Default value

Tag number

Output format

Burnout direction

Actuator operation

Positioner operation

Valve operation

Actuator size

Hysteresis

PID parameters

(parameter 0)

Flow characteristics

I

P

D

GE

GP

GI

GD

User defined flow characteristics data

XXXXXXXX

ANALOG XMTR

DOWN SCALE

REVERSE

DIRECT

DIRECT

PARAM 1

HEAVY

1.200

4.000

0.5000

+/-0.000%

0.7000

4.000

0.5000

LINEAR

(Pressure balance type adjustment valve (ADVB/ADVM) linear characteristics data)

Valve fully closed value (LRV)

Valve fully open value (URV)

Forced fully closed input value

Forced fully open input value

4.000mA

20.00mA

0.5000%IIN

109.00%IIN

Digital output settings Output signal mode Single Range

Amount of data mode DE-4Byte

Failsafe mode F/S=B/O Hi



5-8: SVP internal block diagram and SVP I/O flow

Model AVP100

SFC

Surge absorber

Communication interface block

EPM driver block

EPM

(electropneumatic converter module)

A

A/M Switch

M

SUP

Air supply

140 to 700 kPa

Up down switch

Controller

IIN

4 to 20 mA DC

Microprocessor and digital control block

Surge absorber

Input signal conversion and power supply block

Analog interface and A/D converter block

Pilot relay

OUT

VTD

(position sensor)

Feedback lever

Control valve

Model AVP102

SFC

Up down switch

Surge absorber

Communication interface block

Microprocessor and digital control block

EPM driver block

EPM

(electropneumatic converter module)

A

A/M Switch

M

SUP

Air supply

140 to 700 kPa

HART 275

HART communication interface

Pilot relay

OUT

Controller

IIN

4 to 20 mA DC

Surge absorber

Input signal conversion and power supply block

Analog interface and A/D converter block

VTD

(position sensor)

Feedback lever

Control valve

Figure 5-7 SVP block diagram


Maintenance Azbil Corporation

Input signal 4-20mA

Input current correction

Input signal ranging

Input signal SVP INPUT mA

Forced fully open/fully closed signal conversion

Input signal SVP INPUT %IIN

Flow characteristics signal conversion

-

+

Valve position signal SVP OUTPUT

% STROKE

Zero and span ranging

PID control calculation

EPM

Positioner direct/reverse

EPM drive signal

SVT INPUT %DUTY

VTD

Valve position detection

Pilot relay

Pneumatic signal amplifier

Actuator

Actuator direct/reverse

Valve

Valve plug direct/reverse

Figure 5-8 SVP I/O flow



Chapter 6 : Troubleshooting

6-1: Troubleshooting

The SVP is a precision instrument and requires the same level of care as any other field device. Unlike an air-actuated control valve, the SVP contains many electronic components and mechanical parts which must have proper settings and calibration.

Poor SVP performance is usually easy to correct by adjusting settings.

A Minor Failure indicates no immediate danger or serious trouble in the operation of the SVP. The SVP will continue to operate normally. Connecting an SFC or HART

Communicator or requesting a self-diagnostic through the supervisory monitoring system (model AVP100/102) is necessary to discover and determine Minor Failures.

A Major Failure indicates serious trouble in the operation of the SVP and, if no action is taken, may lead to damage to the SVP itself. Should serious trouble occur during

SVP operations, the SVP will drive the valve to the fail-safe position. An SFC or

HART Communicator, or the supervisory monitoring system (model AVP102) are used to determine Major Failures.

6-1-1: Using an SFC

If you have an SFC connected to the SVP and a Hash (#) mark appears in the lower right corner of the screen, then an alarm condition exists.

To determine an error:

Step Procedure

1 Make sure the SFC is in the Ready State.

2 Confirm that the internal SVP settings for actuator size, hysteresis, etc. are

appropriate for your control valve. For model AVP100/102, refer to “3-8:

Manual SVP settings” on page 3-11.

3

Press

F/S DIR

STAT

U

to see which error conditions exist. If there is more than one, then each error condition flashes for 3 seconds. The following page lists error conditions, as well as the SFC error code and text message that is returned for each error, and possible solutions.


Troubleshooting Azbil Corporation

6-1-2: Using a HART Communicator

If you have a HART Communicator connected to the SVP, you can perform a selfdiagnostic:

Step Procedure

1 Make sure the HART Communicator is in the Ready State.

2 Select [5. Device Status] >> [2. Failures] or [3. Notices].

3 If the message is displayed, see the following page for a list of error conditions as well as the HART error code and possible solutions.

If after reading this troubleshooting section and solutions, the specifications of the

SVP still do not match your requirements, or the SVP fails, contact an Azbil

Corporation representative.“Troubleshooting codes” on page 6-4

6-1-3: General troubleshooting

If, after attaching your SVP to a control valve and performing Auto-Setup or manual calibration, you are experiencing performance problems, follow the troubleshooting steps below.

If the troubleshooting procedures below do not fix the problem, contact an Azbil

Corporation representative.

SVP does not operate (no output air pressure)

Step Procedure

1 Make sure that the SVP feedback lever is not exceeding a 20° angle of rotation. If it is, add an extension bracket to the feedback lever to provide the necessary feedback lever length.

2 Check for air leaks in air supply.

3 Check electrical input signals.

4 Check Auto/Manual switch in Auto.

5 Check the flapper and the filter clears.

6 If communication can be made with a SFC or HART Communicator, perform self diagnostics and take action based on errors messages. See

“Troubleshooting codes” on page 6-4.

Absence of full stroke or slow response

Step Procedure

1 Check the zero (fully closed) and span (fully opened) are properly adjusted.

2 Check the filter and the flapper clean.

3 Check the EPM drive signal is within range of 50 ±25% duty.



Hunting or Overshoot

Step Procedure

1 Change hysteresis setting from LIGHT to MEDIUM, or from MEDIUM to

HEAVY. If problem persists, set hysteresis at HEAVY and change the actuator size setting to smaller PARAM number.

2 If problem persists, PARAM number sets zero (0) and varying the gain may

be required for your valve, refer to “Manual SVP settings - Gain” on page 3-12.

3 Check permissible angle of rotation of feedback lever.

Abnormal action of control valve

(although output air is supplied, the control valve does not operate properly)

Step Procedure

1 Check the zero (fully closed) and span (fully opened) are properly adjusted.

2 Confirm that the internal SVP settings for actuator size, hysteresis, etc. are appropriate for your control valve. For model AVP100/102, refer to

“Manual SVP settings” on page 3-11. For model AVP102, refer to “4-5-3 :

Valve sys config (Valve system configuration)” on page 4-11.

No communication possible with an SFC or HART Communicator

Step Procedure

1 Check input signal wiring. 4 mA is required for the SVP to operate.

2 Check that the SFC or HART Communicator and SVP are wired properly.

For model AVP100/102, refer to “3-6: SFC starting communications” on

page 3-6. For model AVP102, refer to “4-2: Starting communication” on page 4-4.

3 If the SFC or HART Communicator will not power on, check the batteries.



Troubleshooting codes

Message Cause Correction

LO IIN

VTD FAULT

Input signal is too low

(3.8 mA or lower).

Provide an input signal of at least 3.8 mA.

(Valve position sensor)

Feedback lever has fallen off or has turned beyond the allowable turning angle (± 20°)

• VTD connector has become disconnected.

Check if feedback lever has fallen off and that it is within permissible turning angle.

Contact Azbil Corporation.

A/D FAULT

NVM FAULT

RAM FAULT

ROM FAULT

SHUT ON

• VTD input line has been disconnected or short-circuited.

(Analog/Digital conversion) Contact Azbil Corporation.

(Non-Volatile Memory) Contact Azbil Corporation.

(RAM error)

(ROM error)

SVP is forced fully closed



Apply an input signal above the forced fully shut value.

Use the SFC to check and/or adjust the forced fully open/ close values (%).

• Check air supply pressure

HI/LO EPM OUT Electro-pneumatic Module is outside normal range

- No air is being supplied

- Valve is closed

- Galling of valve stem

- Clogged nozzle

- Clogged orifice

- Input signal is 4 mA or less

• See that the input signal is 4 mA or greater

• Confirm A/M switch is Auto

• Clean air nozzle

• Clean orifice

• Adjust the EPM balance

(Refer to page 5-5)

EXT ZERO

ACTIVE

Zero and span adjustment switch is being made.

MANUAL MODE Dummy input signal from SFC/

HART.

FIXED EPM OUT Dummy EPM pseudo-drive signal from SFC/HART.

OUTPUT MODE Dummy pseudo-signal output state for SFC/HART.

CORRECT

RESET

OVER TEMP

Data was reset at the time of shipment.

Abnormal Temperature within

SVP unit.

• Change the input signal and check that the device is operating normally.

Release the zero and span adjustment switch.

Cancel the dummy current input.

Cancel the dummy EPM signal.

Cancel the dummy output.

Set actuator type and other parameters before use.

Check SVP temp and move it to a cooler location.



SFC message documentation (Communication and SFC problems)

RES

Message

COMM

ABORTED

FAILED COMM

CHK

LOW LOOP

HI RES/LO

VOLT

XMTR

RESPONSE

Cause

During communication, the

[CLR] key was pressed, canceling the communication.

Displays the error that occurred during communication.

The loop resistance does not exceed 250

Ω.

Either the loop resistance is too high or the supply voltage is too low.

There was no response from the SVP in response to a request from the SFC.

Correction

Check the resistance. If it is too low, insert addition resistors so that the resistance is over 250

Ω.

Check the wiring and the power supply.

Check the wiring and the power supply. Verify that the

SFC communication cable is connected correctly.

Check the wiring.

ILLEGAL

RESPONSE

NACK

RESPONSE

END AROUND

ERR

UNKNOWN

DIGITAL

The SFC was not able to interpret the response from the SVP.

There was an error in the data received by the SVP.

There was an error in the data received by the SFC.

A communication error occurred during digital communication.

XMTR IS BUSY The SVP is executing special processing.

STATUS

UNKNOWN

There was no response from the SVP, and the status is unknown.

SFI UNKNOWN It was not possible to identify the type of the transmitter.

Check the wiring.

Check the wiring.

Retry the communication operation.

Retry the communication operation.

Check the wiring and the power supply.

CLOCK FAIL!

The internal SFC clock failed.

PRINTER FAIL! The printer failed.

SFC RAM

FAILURE

The SFC RAM failed.

Turn off the SFC power and then turn it back on again.

Verify that the tag on the bottom of the SFC identifies it as either model SFC160 or model SFC260.

Contact an Azbil Corporation representative.






Document Number:

Document Name:

Date:

Issued/Edited by:

CM2-AVP100-2001

SVP3000 Alphaplus Smart Valve Positioner

Model: AVP100/102

User’s Manual

1st edition: Oct. 2001

5th edition: Oct. 2013

Azbil Corporation

Azbil SVP3000 Alphaplus AVP100/102 Smart Valve Positioner User's Manual

Assistant Bot

SVP3000 Alphaplus

Smart Valve Positioner

Model: AVP100/102

User’s Manual

Copyright, Notices and Trademarks

Safety

Safety notice

Unpacking

Storage

Precautions for worker safety

Approval

Table of Contents

Safety

Chapter 1 : Introduction

Chapter 2 : Installation

Chapter 3 : Adjustments

Table of Contents

Chapter 4: Configuration using a HART Communicator

Table of Contents

Chapter 5 : Maintenance

Chapter 6 : Troubleshooting

List of Figure

Chapter 1 : Introduction

1-1: SVP models

SVP Alphaplus

Smart Valve Positioner

1-2: Communication

1-2-1: Manual communication

1-2-2: Using a Smart Field Communicator (SFC or CommPad)

1-2-3: Using a HART communicator

1-2-4: HART communication (for model AVP102)

1-3: SVP diagrams

Chapter 2 : Installation

Before installing the SVP, check for:

2-1: SVP assembly

2-1-1: Attaching SVP feedback lever

2-2: SVP Installation procedure

2-3: Air supply

2-4: Initial SVP adjustment

2-5: Electrical wiring

2-5-1: Wiring guidelines

2-5-2: Wiring procedure

2-6: SVP for springless double-acting actuators

(Reversing relay)

2-6-1: Installing the reversing relay on an SVP

2-6-2: Double-acting SVP without air regulator directly attached

2-6-3: Attaching double-acting SVP to a diaphragm actuator

2-6-4: Attaching double-acting SVP to a rotary actuator

2-6-5: Auto-setup

Chapter 3 : Adjustments

3-1: Auto-setup

3-1-1: Auto-setup using the travel switch

3-2: Zero-span adjustment

3-3: Smart Field Communicator

3-4: SFC keyboard operations

3-5: SFC errors

3-6: SFC starting communications

3-7: Auto-setup and zero-span using the Smart

Field Communicator

3-8: Manual SVP settings

Manual SVP settings - Gain

Manual SVP settings - PID

3-9: Configuring control signal / Valve travel relationship using an SFC

3-9-1: Examples

3-10:Verifying SVP input signal, EPM output, and valve travel output

Chapter 4:

Configuration using a HART

Communicator

4-1: HART communicator functions

4-2: Starting communication

4-3: Verifying and modifying the general information

4-3-1 :Device information

4-3-2 :Manufacturer

4-4: Device condition

4-4-1 :Current input value

4-4-2 :Input signal% (percentage) value

4-4-3 :Valve travel

4-4-4 :Drive sig (EPM