AZBIL SVX102 (01) PDF DOCUMENT

For the safe use of your AZBIL SVX102, the following precautions must be observed:

Installation Precautions:

WARNING:

• When installing, use proper fittings and tightening torque. Gas leakage is dangerous as process and calibration gases are flammable. Always perform a leak check.

• Do not use the product outside of its rated pressure, specified connection standards, and rated temperature to avoid damage and serious accidents.

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

CAUTION:

• After installation, do not step or stand on the unit to prevent damage or injury.

• Avoid bumping the glass of the display with a tool.

• Install the device correctly to avoid output errors and violation of regulations.

• This product is heavy. Wear safety shoes when working.

• Do not subject the product to shock or impact.

Wiring Precautions:

WARNING:

• Do not perform wiring with wet hands or while electricity is being supplied to the product due to the danger of electric shock. Keep hands dry, wear gloves, and turn off the power.

CAUTION:

• Check specifications carefully and ensure correct wiring to prevent device damage or malfunction.

• Supply electric power according to the specifications. Incorrect power can damage the device.

• Use a DC power supply that has overload protection.

Maintenance Precautions:

WARNING:

• When removing the device for maintenance, be careful of residual pressure or process gas, as leakage is dangerous.

• When working on the vent, check its direction so that people do not come into contact with vented gas to avoid burns or other physical harm.

• When the device is used in an explosion-proof area, do not open the cover to prevent an explosion.

CAUTION:

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

When you unpack your AZBIL SVX102, please 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 your AZBIL SVX102 Smart Valve Positioner are written on the name plate on the body of the positioner. Compare these specifications to those in the appendix and verify that the device matches your order. Pay particular attention to the following items:

• Tag number (TAG NO.)

• Model number (MODEL)

• Factory number (PROD.)

• Input current range (INPUT)

• Air supply pressure (SUPPLY)

Ideally, the AZBIL SVX102 should be stored in its original packaging. If the original packaging is not available, store the device indoors at a normal temperature of 25°C (77°F) and 60% relative humidity. The storage location should be free from vibration and shock, and not exposed to rain or water.

If you are storing the AZBIL SVX102 after it has been used, clean the device, then firmly tighten the terminal box cover and seal the wiring, piping connections, and bleed hole in the pilot cover using the supplied caps or tape to prevent moisture from entering.

The AZBIL SVX102 is designed to withstand severe operating conditions and should be installed in a site that meets the following criteria:

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

• Relative humidity of 10 to 90% RH.

• No chance of sudden temperature or humidity changes.

• 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 are stipulated for the vibration at the positioner.

Follow this procedure to install the fork lever type AZBIL SVX102:

1. The AZBIL SVX102 comes with an actuator mounting kit appropriate for your control valve and actuator. Securely fasten the mounting plate to the rear of the SVX using the four provided hexagon head bolts (M6 × 12) and spring washers.

2. Securely fasten the SVX with the mounting plate to the actuator’s mounting structure using the provided bolts and washers. During this step, pass the actuator’s feedback pin through the slot in the SVX feedback lever.

Follow this procedure to install the stroke lever type AZBIL SVX102:

1. The AZBIL SVX102 comes with an actuator mounting kit appropriate for your control valve and actuator. Securely fasten the mounting plate to the rear of the SVX using the two provided hexagon head bolts (M8 × 20) and spring washers.

2. Securely fasten the SVX with the mounting plate to the actuator’s mounting structure using the provided bolts and washers. During this step, 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 to install the direct mounting type AZBIL SVX102:

1. The AZBIL SVX102 comes with an actuator mounting kit appropriate for your control valve and actuator. Securely fasten the mounting plate to the rear of the SVX using the four provided hexagon head bolts (M6×12) and spring washers.

2. Securely fasten the SVX with the mounting plate to the actuator’s mounting structure using the bolts and washers provided. During this operation, insert the SVX feedback stem into the actuator stem with a joint.

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

To ensure proper operation of the AZBIL SVX102, observe the following points when connecting the feedback lever and the feedback pin on the actuator:

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

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

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

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

Clean and dry supply air ensures the long-term stability of the AZBIL SVX102. The quality of the instrumentation equipment air must meet the following specifications:

• Solid body: There must be no particles with a diameter over 3 µm.

• Oil: Must be less than 1 ppm in mass.

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

You should also use a pressure regulator with a 3 µm or better filter. If a filter is not provided on the regulator, insert a separate filter immediately before the regulator. A shutoff valve is also recommended to temporarily shut off the air supply for ease of maintenance.

Follow these recommended practices for piping the air supply to your AZBIL SVX102:

• 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., use vinyl-covered copper pipes for a corrosive environment).

• Use joints that precisely fit the pipes.

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

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

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

• Check for leaks after installation.

Follow this procedure 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 preferred over solid or liquid sealant. Prevent tape or sealant from entering the pipes.

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

4. Check for leaks after installation.

When wiring your AZBIL SVX102, use cables that meet the following requirements:

• Use stranded cables with a conductor cross-section of 1.25 mm² and suitable for 600V.

• The outside diameter of the cables must be between 7 mm to 12 mm (1/4 inch to 7/16 inch).

• In locations affected by electrical noise, run shielded wires through a metal conduit.

• Select a sheath material that can withstand the installation environment (ambient temperature, corrosive gases, corrosive liquids).

• Bring the cable to the terminal box through the conduit connection port (G1/2 internal thread, 1/2NPT internal thread).

• If a pressure-resistant packing type cable adapter is used, only use a packing that matches the outer diameter of the cable.

• We recommend using M4 screw size crimp-on terminals with an insulating sleeve.

• The maximum cable length is 1500 meters.

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

Follow these steps for wiring the AZBIL SVX102:

1. Unscrew the 4 screws and remove the cover. Be careful not to scratch painted surfaces.

2. Remove blind plugs according to how the wiring 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. Be careful not to damage the cable sheath.

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 water. We recommend using silicon resin-based non-hardening seal materials.

6. Screw the 4 screws onto the SVX until it is hand-tight. Be careful not to scratch painted surfaces.

CAUTION: Avoid installing cables near noise-making devices like large transformers. Do not lay signal/control cables in the same tray or duct with noisy switching power cables.

Auto-setup automatically makes various positioner adjustments and should be performed after installing your AZBIL SVX102.

WARNING: While auto-setup is running, the valve cycles from open to closed. Take appropriate measures to prevent injury to personnel and adverse effects on the process.

To initiate auto-setup using the zero and span adjustment switches:

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

2. Press and hold the “UP” switch down for approximately 3 seconds until the auto-setup program starts, then release the switch.

3. The valve will move from fully shut to fully open twice. It will then open to about 50% and stay in this position for up to three minutes.

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

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

After auto-setup is complete, verify valve operation by varying the input signal. The SVX is now calibrated to the fully shut (zero) and fully open (span) values of the valve.

You can make zero and span adjustments by pressing the “UP” or “DOWN” button switches. These adjustments do not interfere with each other and can be done independently.

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 (e.g., 4 mA).

2. Adjust the valve’s fully shut position by pressing the “UP” or “DOWN” adjustment button switch.

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 (e.g., 20 mA).

2. Adjust the valve’s fully open position by pressing the “UP” or “DOWN” adjustment button switch.

Important Notes:

• The adjustment function uses the input signal to identify whether a zero or span adjustment is being performed. This function will not operate if the input signal is not within ±1 mA of the set current values for the open and closed positions.

• Use the adjustment switches only if the supply air pressure is stable and the valve can move freely.

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

Operation Startup Procedure:

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

1. Verify that the SVX is installed correctly and 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.

Once these items are checked, operation may be started.

Stopping Operation Procedure:

1. Stop the operation of the process. Move each valve to its 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, such as a corrosive atmosphere, it is recommended not to turn off the air supply to prevent corrosive gases from entering the SVX.

The Auto/Manual (A/M) switch selects the control method for the pneumatic output from the positioner.

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 (Normal) 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 for manual operation using a pressure regulator.

Switching 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 during maintenance. Use dry air cleaned of 3 µm or smaller solid particles. You will need a Phillips screwdriver.

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. Dispose of the old holder and filter appropriately.

5. Use a wire to remove contamination from the restriction (diameter 0.3 mm). Be careful not to damage the restriction. Do not use an air gun or allow oils/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, it needs to be cleaned.

CAUTION: If air pressure is supplied to the SVX, cleaning the flapper may cause the valve position to change suddenly. Only clean the flapper in a state where no one will be injured and plant operation will not be adversely affected by sudden valve movement.

Procedure:

1. Remove the cover.

2. Remove the 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 work).

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 excessive shocks or contamination, an adjustment may be necessary if cleaning the flapper area does not resolve the issue.

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 it.

CAUTION: Do not perform the insulation resistance test. Performing this test will damage the built-in varistor for surge current absorbance. If it is required, please carefully follow these procedures.

Procedure:

• Remove the external wiring.

• Short-circuit both the plus and minus input signal terminals.

• Perform the test between these short-circuited sections and the grounding terminal.

Criterion:

The test result should be 2×10^7 Ω or above when the test voltage is 25 V DC (at 25°C, 60% RH or less). To prevent damaging the instrument, do not apply a voltage of more than the value given.

If your AZBIL SVX102 is not operating and there is no output air pressure, follow these troubleshooting 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 provide the necessary feedback lever length.

2. Check for air leaks in the air supply.

3. Check the electrical input signals.

4. Check that 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 the error messages.

If you are experiencing an absence of full stroke or slow response with your AZBIL SVX102, try the following:

1. Check that the zero (fully closed) and span (fully opened) positions 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 problems, follow these steps:

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

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