AZBIL SVX100 (01) PDF DOCUMENT

When installing the AZBIL SVX100, please adhere to the following warnings:

• When installing, use proper fittings and proper tightening torque for connections to the process and to the exhaust. Gas leakage is dangerous because process gas and calibration gas are flammable. Please refer to the leak check instructions in this manual and verify that there is no gas leakage.

• Do not use the product except at the rated pressure, specified connection standards, and rated temperature. Use under other circumstances might cause damage that leads to a serious accident.

• For wiring work in an explosion-proof area, follow the work method stated in the explosion-proof policy.

Additionally, please observe these cautions:

• After installation, do not step or stand on this unit. Doing so may damage the device or cause injury.

• Bumping the glass of the display with a tool may cause damage or injury. Be careful.

• Install the device correctly. Incorrect or incomplete installation will cause output errors and violation of regulations.

• This product is quite heavy. Protect your feet with safety shoes when working.

• Do not subject the product to shock or impact.

Please follow these safety precautions for wiring the AZBIL SVX100:

WARNING: Do not do wiring work with wet hands or while electricity is being supplied to the product. There is a danger of electric shock. When working, keep hands dry or wear gloves, and turn off the power.

CAUTION:

• When wiring, check the specifications carefully and make sure to wire correctly. Incorrect wiring can cause device damage or malfunction.

• Supply electric power correctly according to the specifications. Supplying power that differs from the specifications can damage the device.

• Use a DC power supply that has overload protection.

When performing maintenance on the AZBIL SVX100, please observe the following precautions:

WARNING:

• When removing this device for maintenance, be careful of residual pressure or residual process gas. Leakage of process gas is dangerous.

• When working on the vent, check its direction so that people do not come into contact with vented gas. There is a danger of burns or other physical harm.

• When the device is being used in an explosion-proof area, do not open the cover. Opening the cover may cause an explosion.

CAUTION:

• This product was kept under carefully controlled conditions until it was shipped. Never try to modify this device. Doing so could damage it.

When you unpack your AZBIL SVX100, handle it with care to prevent damage. Check that the following items are included:

• Smart Valve Positioner for Rotary Valve model SVX100, SVX102

• Feedback lever

• Two hex socket bolts (only for stroke lever type)

• Hex bolt and spring washer (only for fork lever type)

• Hex wrench (for feedback lever – only for stroke lever type)

• Mounting kit (option)

• Manual (Option)

The specifications for the AZBIL SVX100 are written on the nameplate on the body of the positioner itself. Compare these specifications to those in the appendix and verify that your device matches your order. In particular, be sure to check the following items:

• Tag number (TAG NO.)

• Model number (MODEL)

• Factory number (PROD.)

• Input current range (INPUT)

• Air supply pressure (SUPPLY)

Ideally, the AZBIL SVX100 should be stored in the original packaging. However, if the original packaging is not available, store the SVX indoors at normal temperature (25°C {77°F}) and humidity (60% RH) in a place free from vibration and shock and not exposed to rain or water. If you are storing the SVX after it has been used, clean the SVX and then firmly tighten the terminal box cover and seal the wiring, piping connections and bleed hole in the pilot cover using the Azbil Corporation-supplied caps or tape to prevent entry of moisture.

There are three ways to communicate with the AZBIL SVX100:

1. Manual configuration: Initial SVX configuration is typically performed using a switch Auto-Setup, which detects the characteristics of the valve. Zero and span adjustment can also be performed automatically.

2. Using the Field Communication Software (model CFS100): Azbil Corporation’s Field Communication Software can be used for all configuration, calibration, and maintenance of the SVX. See the user’s manual for model CFS100 to learn more about the product.

3. Using a HART communicator: An Emerson Electric HART communicator can be used for all configuration, calibration, and maintenance of model SVX102. See the HART communicator manual to learn more. According to need, update the software and device description files of the HART communicator.

The AZBIL SVX100 is designed to withstand severe operating conditions. It is designed to operate in the following environments:

• Ambient temperature range of -40 to +80°C (-40 to +176°F).

• In relative humidity of 10 to 90% RH.

• Where there is no chance of sudden temperature or humidity changes.

• Where magnetic field induction is not more than 400 A/m (Avoid locations near large-scale transformers, high-frequency furnaces, and similar equipment.)

• Vibration under 19.6 m/s² (5 to 400 Hz).

Note: The vibration conditions for this equipment is stipulated for the vibration at the positioner.

Follow this procedure to install the AZBIL SVX100 fork lever type:

Step 1: The SVX comes with an actuator mounting kit appropriate to your control valve and actuator. Fasten the mounting plate to the rear of the SVX securely, using the four hexagon head bolts (M6 × 12) and spring washers provided.

Step 2: Fasten the SVX (mounting plate) securely to the actuator’s mounting structure using the bolts and washers provided. During this operation, pass the actuator’s feedback pin through the slot in the SVX feedback lever.

Follow this procedure to install the AZBIL SVX100 stroke lever type:

Step 1: The SVX comes with an actuator mounting kit appropriate to your control valve and actuator. Fasten the mounting plate to the rear of the SVX securely, using the two hexagon head bolts (M8 × 20) and spring washers provided.

Step 2: Fasten the SVX (mounting plate) securely to the actuator’s mounting structure using the bolts and washers provided. During this operation, pass the actuator’s feedback pin through the slot in the SVX feedback lever.

Note: Please avoid mounting the feedback lever pin between the valve stem and the positioner lever rotary shaft.

Follow this procedure for the direct mounting type of the AZBIL SVX100:

Step 1: The SVX comes with an actuator mounting kit appropriate to your control valve and actuator. Fasten the mounting plate to the rear of the SVX securely, using the four hexagon head bolts (M6×12) and spring washers provided.

Step 2: Fasten the SVX (mounting plate) securely to the actuator’s mounting structure using the bolts and washers provided. During this operation, put the SVX feedback stem in the actuator stem with a joint.

CAUTION: Confirm that the direction of valve stem rotation matches the SVX feedback stem direction when SVX is mounted on the actuator. If the direction does not match, the apparatus is broken.

The following points must be observed when connecting the AZBIL SVX100 feedback lever and the feedback pin on the actuator. These parts must be connected correctly.

1. Only a 6 mm diameter pin may be used.

2. The pin must be caught between the guide and the spring.

3. The angle between the feedback lever and the pin must be 90° when seen from above.

4. Assemble the feedback lever and the SVX using the two hex socket bolts provided. The feedback lever rotates up to 20° from the horizontal (40° travel). If this limit is exceeded, then the SVX will not operate properly. (Minimum angle of rotation is ±4°).

Clean and dry supply air ensures the long-term stability of the AZBIL SVX100. The quality of the instrumentation equipment air to be supplied is defined as follows:

• Solid body: there must be no particles whose diameter is over 3 µm.

• Oil: It must be less than 1 ppm in mass.

• Humidity of the supplied air: The dew point temperature must be at least 10 degrees Celsius lower than the temperature of the equipment body.

This is taken from JIS C1805-1 (2006).

Recommended piping practices include:

• Air supply pipes should have an inside diameter of 6 mm {1/4 inch} (8 mm {3/8 inch} outside diameter tubing recommended).

• Pipes should match the installation environment (e.g., for a corrosive environment, use vinyl-covered copper pipes).

• Use joints that precisely fit the pipes.

• Sealing tape is preferable to solid or liquid sealants for pipe joints to SVX 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.

Follow these steps for air pipe connection:

1. Remove the dust plug from the output air connection on the SVX.

2. Connect the joint to the air output connection using sealing tape. (Note: Sealing tape is preferable to solid or liquid sealant for pipe joints to SVX air connections. Prevent sealing tape/sealant from pipes.)

3. Connect the other air connection to each joint. (Note: Completely flash pipes before use, checking for burrs and other problems. Use the right length of piping and avoid excess lengths.)

4. Check for leaks after installation.

WARNING: ELECTRICAL SHOCK HAZARD! Turn off power before performing any wiring.

Follow this procedure for electrical wiring:

1. Unscrew 4 screws and remove the cover. (Note: Be careful not to scratch painted surfaces with tools at this time.)

2. Remove blind plugs according to how the wiring for the SVX will be performed.

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. (Note: Be careful not to damage the cable sheath at this time.)

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

5. Apply adequate waterproofing measures to the conduits to prevent the entry of rainwater or water from any other source. (Note: We recommend the use of silicon resin based non-hardening seal materials.)

6. Screw 4 screws onto the SVX until it is hand-tight. (Note: Be careful not to scratch painted surfaces with tools at this time.)

Auto-setup automatically makes various positioner adjustments. After installing your AZBIL SVX100, auto-setup should be performed. To initiate auto-setup using the zero and span adjustment switches, follow these steps:

1. Set the input signal to the SVX to 18 ±1 mA DC.

2. Hold the “UP” switch down until the auto-setup program starts (approx. 3 seconds), then release the “UP” switch.

3. 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.

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

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

Note: After auto-setup, the SVX is calibrated 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 SVX, then adjust zero or span manually.

Zero and span adjustments can be made by pressing the “UP” or “DOWN” button switches. The feedback lever moves up when the “UP” switch is pressed and down when the “DOWN” switch is pressed.

Procedure to adjust valve to fully shut position (zero):

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

2. Adjust the valve fully shut position by pressing the “UP” or “DOWN” adjustment button switch. (If the forced ON/OFF function is operating, the valve will not move. The default value is set to 0.5%.)

Procedure to adjust valve to fully open position (span):

1. Input the setting current value that corresponds to the valve being fully open from the controller (constant-current supply). (Example: 20 mA)

2. Adjust the valve fully open position by pressing the “UP” or “DOWN” adjustment button switch. The default value is set to 99%.

Note: After completing the adjustments, hold the input signal at a level over 4 mA for at least 3 seconds to write the set positions.

Operation Startup Procedure:

The SVX and the control valve form a manipulator used in process control. Always observe adequate safety precautions when starting control valve operation using the SVX.

1. Verify that the SVX is installed correctly. Verify that nothing interferes when the control valve operates.

2. Verify that the SVX electrical wiring is installed and connected securely. Also verify that the air lines are installed and connected securely and that there are no air leaks.

3. Verify that the valve operates as set up according to the input signal.

Stopping Operation Procedure:

1. Stop operation of the process. (Move each valve to the air fail position.)

2. Turn off the input signal (power supply) to the SVX.

3. Turn off the air supply to the SVX. (Note: If the SVX is installed in an adverse environment, for example, in a corrosive atmosphere, we recommend not turning off the air supply to prevent corrosive gasses from entering the SVX.)

If your AZBIL SVX100 is not operating and there is no output air pressure, follow these steps:

1. Make sure that the SVX 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 the air supply.

3. Check electrical input signals.

4. Check the Auto/Manual switch is in the Auto position.

5. Check that the flapper and the filter are clear.

6. If communication can be made with the Communicator, perform self-diagnostics and take action based on error messages.

If the AZBIL SVX100 is not achieving a full stroke or is responding slowly, follow these steps:

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

2. Check that the EPM drive signals are within the range of 50+/-25%.

3. Check that the filter and the flapper are clean.

To address hunting or overshoot with the AZBIL SVX100, try the following:

1. Change the hysteresis setting from LIGHT to MEDIUM, or from MEDIUM to HEAVY. If the problem persists, set hysteresis at HEAVY and change the actuator size setting to smaller PARAM numbers.

2. If the problem persists, set the PARAM number to zero (0). Varying the gain may be required for your valve; refer to “4-4-4: Control configuration”.

3. Check the permissible angle of rotation of the feedback lever.

The Auto/Manual (A/M) switch on the AZBIL SVX100 selects the control method for the pneumatic output.

WARNING: 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.

CAUTION: The double acting actuator has no manual operation function.

• Automatic operation: An air pressure output corresponding to the input signal is output from the SVX.
• Manual operation: The supplied air pressure is output directly from the positioner, allowing manual operation using a pressure regulator.

Operating Procedure:

• Switching from automatic to manual: Use a flat-bladed screwdriver to turn the A/M switch once fully in the counterclockwise direction.

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

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

Contamination from instrumentation air can be removed from the restriction in the AZBIL SVX100 during maintenance. Always use a Phillips screwdriver for this procedure.

1. Cut off the air supply to the SVX.

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

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

4. Use nippers or another tool to cut the holder and remove the old filter. (Note: Dispose of the old holder and filter appropriately.)

5. 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.)

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

7. Screw down the A/M switch until it stops.

8. Reassemble the A/M switch section by holding the two O-rings and A/M switch cover plate together and then securely tighten using the setscrew.

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

CAUTION: If air pressure is supplied to the SVX, the nozzle back pressure may change, causing the valve position to 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:

1. Remove the cover.

2. Remove four screws from the cover plate.

3. Remove the plate by sliding it to the left.

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

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

6. After cleaning the gap, reassemble the plate and cover.

If the EPM balance point is displaced due to mechanical shocks or contamination, an EPM adjustment may 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:

1. Remove the cover and the cover plate.

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

3. Observe the EPM drive signal using the communicator.

4. Adjust the EPM drive signal to have a 50% ±5% duty by turning the EPM adjustment screw. Turning the screw counterclockwise increases the EPM drive signal (duty value), while turning it clockwise decreases the signal.

The following table lists the replaceable parts for the AZBIL SVX100: