Azbil 700 series User manual

Smart ESD Device
700 Series for Safety
Instrumented Systems
Model AVP77_/78_/79_
User’s Manual
CM2-AVP772-2001

Important
• Make sure that this manual is delivered to the user of this product.
• Copying or reprinting this manual in whole or in part without permission is
prohibited.
• The contents of this manual are subject to change without notice.
• Although we have taken all possible measures to ensure the accuracy of this
manual, please contact us if you find any errors or missing information.
• Note that we cannot be held responsible for the results of device operation by
the customer.
• HART® is a registered trademark of the FieldComm Group.
©2015–2019 Azbil Corporation. All Rights Reserved.

i
Introduction
Thank you for purchasing our Smart emergency shutdown (ESD) device. Model
AVP77_/78_/79_ supports the safety instrumented systems (SIS), and is a smart ESD
Device that can connect to signal lines of 4-20 mA DC, 0-20 mA DC or 0/24 V DC.
The auto setup function makes it easy to set up the valve.
You can use the HART communication to conduct various adjustments and settings, and
use the local user interface (LUI), which is composed of an LCD (liquid crystal display)
and operation buttons, to easily monitor and conduct basic adjustments of the input signal,
valve opening, pressure displays, as well as activate and verify the result of the PST (partial
stroke test).
Furthermore, the built-in pressure sensor can be used to measure the supply air pressure
and output air pressure. With this, you can not only use this equipment for self diagnosis,
but can also combine with “Valstaff,” a valve maintenance support system, to monitor
valve’s characteristics, operating condition, etc., which will contribute to the valve’s
maintenance efficiency. This user manual explains how to handle the equipment. Please
use this manual to optimize the characteristics of this product.
Scope of this manual and related documents
This manual describes functions, as well as the installation and adjustment procedures.
For handling that is subject to conditions that are in line with the functional safety
standards of IEC61508 or IEC61511, please refer to the safety manual that is included in
the package of this device.
For details on HART communication, please refer to “Safety Instrumented Systems (SIS)
Specification - Communication Specification” (No. CM2-AVP772-2002 (T.B.D)*).
For details on valve diagnostic criteria, please refer to “Control Valve Diagnosis Function
Manual” (No. CM2-AVP700-2003).
* For any questions regarding the detail, please contact the office listed at the end of this manual.

ii
Safety precautions
JSymbols
The purpose of the safety precautions listed here is to ensure the user uses the product safely and correctly, to
prevent harm to the user and other people and damage to property. Make sure to observe the safety precautions.
Many different symbols are used in this manual.
Their appearance and meaning are described below. Thoroughly understand the explanation before starting to
read the main text.
Warning Wrong handling may cause the death or severe injury of the user.
Caution Wrong handling may cause a minor injury to the user or damage to equipment.
JSample symbols
This symbol indicates warnings and cautions for handling the device.
This symbol indicates prohibited actions that must not be taken.
This symbol indicates instructions for an action that must be taken.
JConventions used in this instruction manual
Handling Precautions : This symbol indicates a point to be noted when handling the device.

iii
Precautions for safe work
Warning
Do not perform wiring with wet hands or while the device is energized. This may lead to electric
shock. Turn the power off before starting the work and work with dry hands or use gloves.
Follow the work procedure defined in the explosion protection guidelines of countries when
performing the power distribution work in an explosion-proof area.
For devices equipped with the pressure-resistant, explosion-proof specifications, open/close the
explosionproof enclosure and the cover according to "Chapter 7 Notes on the Explosion-Proof".
Caution
Do not get on the installed device or use it as a step stool. This is dangerous because the device may
tip over.
Do not touch the device during operation without reason. This is dangerous because the surface may
be hot or cold depending on the usage environment.
Be careful not to touch the edge of the cover or the screw threads of the main unit when opening the
cover of the terminal box. You may be injured by these parts.
Use a DC power supply with overload protection. Overload may cause smoke or fire.
If a tool or other item touches the glass part of the display, it may break, leading to an injury. Be
careful. Wear safety glasses during work.
This product is heavy. Be careful where you step and wear safety shoes during work.
Do not touch the feedback lever or other moving parts while the device is operating. You may be
injured by getting your hand or other body part caught in them.
Properly use the power supply based on the specifications. Inputting a different power supply may
damage the device.
Use gloves and other protective equipment during work in a hot, cold, or other severe environment.
Do not bring magnets or magnetic screwdrivers near the device. They may activate the valve.
Supply appropriate air pressure according to the specifications. Too much pressure may cause
abnormal valve function, damage to the pressure gauge, etc.

iv
Unpacking, Verification, and Storage of Product
Unpacking
This device is precision measuring equipment. Carefully handle it to prevent accidents or
damage. After unpacking, check that the items below are included.
• The device
• Feedback lever and hexagon socket bolts × 2
• (4mm) hexagon wrench × 1 (for feedback lever).
(Included only when the device is shipped alone.)
• Regulator (KZ03) (optional)
• Mounting plate set (optional)
• Pressure-resistant packing cable adapter and pressure-resistant elbow
(option for explosion-proof specifications)
• Instruction manual (this document) (included if specified at the time of purchase.)
• Safety manual
• Extension lever and hexagon socket bolts × 2 (optional)
Specifications check
Specifications are written on the product nameplate. Furthermore, please verify that the
phrase “Smart ESD Device for SIS” is printed on the front cover. Verify that all ordered
items are present. Please especially take note of the following.
• Tag No.
• Model
• Production No. (PROD.)
• Input current range (INPUT)
• Supply air pressure (SUPPLY)
• Explosion protection certification seal (for explosion-proof specifications)
• Functional Safety Authorization FS Symbol
Warning
For use in an explosion-proof area, be sure to select a model that satisfies
the necessary explosion-proof requirements. Non-explosion-proof products
cannot be used in an explosion-proof area.
Contact
If any part of the specification is unclear, please contact our service representative.
When contacting us, please always have your model number and production number ready.
Storage
When storing the device after purchase, observe the following precautions.
• When storing the device before it has been used
1. Store the device as packed at shipment.
2. Store the device at an indoor location with little vibration or shocks and at normal
temperature and humidity (about 25°C, 65%RH).
• When storing the device after it has been used
1. Tightly secure the terminal box cover and block the conduit connection port with
tape to prevent humidity intrusion.
2. Block the three pneumatic piping connection ports (SUP, OUT1 and OUT2) with
tape to prevent humidity and dust intrusion.
3. Pack the device in the same way as at shipment.
4. Store the device at an indoor location with little vibration or shocks where it will not
be exposed to rain or water and at normal temperature and humidity (about 25°C,
65%RH).

v
Table of Contents
Chapter 1 Structure of the Control System...............................1-1
1-1 Model Number Configuration ........................................................1-1
1-2 System Configuration ................................................................1-1
1-3 System Configuration (Model AVP7_2) without Output Signal .........................1-2
1-3-1 In the Case of Current Signal Input............................................1-2
1-3-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-2
1-4 System Configuration with Travel Transmission (Model AVP7_1) .......................1-3
1-4-1 In the Case of Current Signal Input............................................1-3
1-4-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-3
1-5 System Configuration with Contact Output (Model AVP7_0) ...........................1-4
1-5-1 In the Case of Current Signal Input............................................1-4
1-5-2 In the Case of Voltage Signal (0/24 V DC) ......................................1-4
1-6 Structure of the Device and Description of Each Part ..................................1-5
Chapter 2 Installation..................................................2-1
2-1 Usage Conditions ....................................................................2-1
2-2 Selection Criteria for Installation Location.............................................2-2
2-3 Installation Procedure ................................................................2-4
2-3-1 Attaching the 700 Series to the Actuator ......................................2-4
2-3-2 Pneumatic Piping Connection ...............................................2-10
2-3-3 Electrical Wiring Connection.................................................2-13
2-3-4 Input Signal and Output Signal Power .......................................2-17
2-3-5 Cables (For Input or Output Signal) ..........................................2-18
2-4 Cable gland and flameproof universal elbow for TIIS flameproof apparatus............2-20
Chapter 3 Operation ...................................................3-1
3-1 Local User Interface (LUI) .............................................................3-1
3-2 Adjustment before Operation ........................................................3-5
3-2-1 Auto Setup ..................................................................3-5
3-2-2 Zero/Span Adjustment .......................................................3-8
3-2-3 Supply Bypass ..............................................................3-10
3-2-4 Partial Stroke Test (PST) .....................................................3-12
3-2-5 Control Parameters..........................................................3-14
3-2-6 Password ...................................................................3-16
3-3 Starting Operation ..................................................................3-17
3-3-1 Preoperation Check .........................................................3-17
Chapter 4 Operation with HART Communication. . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 Operation with HART Communication ................................................4-1
4-1-1 HART Communication........................................................4-1
4-2 Setup and Adjustment of Device .....................................................4-2
4-2-1 Process Variables .............................................................4-2
4-2-3 Input Signal Range (Input Range) (Model AVP77_/78_ Current Signal Input) ...4-4
4-2-4 Valve System.................................................................4-5
4-2-5 Control Configuration ........................................................4-6
4-2-6 Input Characterization .......................................................4-7
4-2-7 Travel Cutoff .................................................................4-8
4-2-8 Units ........................................................................4-9
4-2-9 SIS Positioner Mode ..........................................................4-9
4-2-10 Travel Calibration ...........................................................4-10

vi
4-2-11 Input Signal Calibration (Model AVP77_/78_ Current Signal Input) ............4-11
4-2-12 Pressure Sensor Adjustment.................................................4-12
4-2-13 Simulation ..................................................................4-12
4-2-14 Adjustment of EPM Drive Signal (Pneumatic Modules)........................4-12
4-2-15 Restore factory settings .....................................................4-12
4-2-16 Operator Action Records ....................................................4-13
4-2-17 Real Time Clock .............................................................4-13
4-2-18 Password ...................................................................4-13
4-2-19 Device Information..........................................................4-13
4-2-20 Option......................................................................4-15
4-2-21 Diagnostic Messages ........................................................4-16
4-2-22 Valve Diagnosis .............................................................4-17
4-2-23 PST (Partial Stroke Test)......................................................4-18
4-2-24 FST (Full Stroke Test). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Chapter 5 Troubleshooting.............................................5-1
5-1 Troubleshooting .....................................................................5-1
5-1-1 If the Valve does not Close Fully (the output air pressure does not go down to 0) ...5-1
5-1-2 If the Device does not Operate (No Output Air Pressure).......................5-1
5-1-3 If the Valve Behaves Abnormally (Output Air Is Present)........................5-2
5-1-4 Failure to Communicate with the Communicator..............................5-3
5-1-5 Adjustment Procedure When Hunting Occurs .................................5-3
5-1-6 Description of Messages .....................................................5-4
Chapter 6 Maintenance ................................................6-1
6-1 A/M Switch ..........................................................................6-1
6-2 Replacement of Filter and Maintenance of Flow Constriction ..........................6-4
6-3 Cleaning the Flapper .................................................................6-5
6-4 Adjusting the Pilot Relay .............................................................6-6
6-5 Insulation Resistance Test ............................................................6-7
6-6 Adjustment Procedure When Using the Device with a Booster Relay Attached..........6-8
6-7 List of Default Values for Internal Data ................................................6-9
6-8 Internal Block Diagram of the 700 Series .............................................6-10
6-9 Replacement Parts ..................................................................6-11
6-9-1 Procedure for Changing Switch Block ........................................6-14
6-9-2 Procedure for Changing the Pilot Relay ......................................6-15
Chapter 7 Notes on Explosion-Proof Structure...........................7-1
7-1 TIIS Flameproof Model ...............................................................7-2
7-2 IECEx Flameproof and Dust Ignition Protection........................................7-3
7-3 FM Explosion-proof / Dust Ignition Protection.........................................7-5
7-4 FM Intrinsically Safe Explosion-Proof Type (ic) and Non-incendive Type.................7-6
7-5 FMC Explosion-proof / Dust Ignition Protection ......................................7-11
7-6 NEPSI Flameproof / Dust Ignition Protection .........................................7-12
7-7 KOSHA Flameproof Type ............................................................7-15
7-8 INMETRO Flameproof / Dust Ignition Protection......................................7-16
7-9 EAC Flameproof.....................................................................7-18
7-10 ATEX Intrinsic Safety and Dust Ignition Protection ....................................7-19
7-11 IECEx Intrinsic Safety and Dust Ignition Protection....................................7-20
Appendix A LUI Display Examples ....................................... A-1
Appendix B Menu List .................................................. B-1

vii
Appendix C Specifications ...............................................C-1
Appendix D Model Number Configuration Table .......................... D-1
Appendix E External Dimension..........................................E-1

viii

1-1
Chapter 1 Structure of the Control System
Chapter 1 Structure of the Control System
This chapter describes device configuration in a control system that uses the device.
• Description of the configuration of the input/output system of the device
• Description of the structure of the main unit of the device and the name and function of
each part
1-1 Model Number Configuration
Smart ESD Device 700 Series for Safety Instrumented Systems
Model AVP7 _ _
7: 4-20 mA DC input signal
8: 0-20 mA DC input signal
9: 0/24 V DC input signal
0: with contact output
1: with travel transmission
2: without output signal
1-2 System Configuration
This device is a smart ESD device that can be connected to 4-20mADC, 0-20mADC, or
0/24VDC controller output signal lines. Various adjustments can be done electronically,
so the relationship between input signals and valve travel can be set to any desired value.
In addition, having a 4-line connection enables the output of the amount of valve travel
to a host monitoring system via 4-20mADC analog signal, as well as the transmission of
failure output to the monitoring system via burnout indication of the contact output signal
or the travel transmission signal. (Model AVP7_1 have travel transmission, and Model
AVP7_0 have contact output.)
The basic concept of a valve control system using this device is shown in the following
diagram.
Host
monitoring
system
Air supply
system
Host
controller 4-20 mA DC, 0-20 mA DC,
0/24 V DC
4-20 mA DC analog signal
or contact output signal
Shuto
valve
Regulator
with lter
Supply air
Device
Air to the actuator
Valve
Process uid
S
m
a
r
t
E
S
D
D
e
v
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f
o
r
S
I
S
Figure 1-1. Concept Diagram of Control System

1-2
Chapter 1 Structure of the Control System
1-3 System Configuration (Model AVP7_2) without Output Signal
1-3-1 In the Case of Current Signal Input
Illustrates the system configuration for Model AVP772/782.
Host
controller
4-20 mA DC or
0-20 mA DC IN
IN
HART Modem
Device
HART
conguration
tool
S
m
a
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t
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S
D
D
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v
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f
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S
I
S
Figure 1-2. System Configuration with Current Signal Input without Output Signal
(Model AVP772/782)
1-3-2 In the Case of Voltage Signal (0/24 V DC)
Illustrates the system configuration for Model AVP792.
Host
controller
Resistance: 500 Ω
0/24 V DC
IN
IN
HART Modem
Device
HART
conguration
tool
S
m
a
r
t
E
S
D
D
e
v
i
c
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f
o
r
S
I
S
Figure 1-3. System Configuration With Voltage Signal Input without Output Signal
(Model AVP792)

1-3
Chapter 1 Structure of the Control System
1-4 System Configuration with Travel Transmission (Model AVP7_1)
Model AVP7_1 has a function for transmitting the amount of valve travel.
This travel transmission signal will change to burnout indication (failure output) in the
preset direction when an abnormality of this device or the valve is detected during self-
diagnosis or in the PST (partial stroke test).
To output the travel signal to the host monitoring device using analog values, configure the
system with travel transmission.
Normally, travel of 0% and 100% is output at 4mA and 20mA, respectively.
Failure output is
LO side: less than 3.6mA
HI side: greater than 21mA.
The following is an example of system configuration.
With this system configuration, analog signals are output directly to the host monitoring
system from this device.
1-4-1 In the Case of Current Signal Input
Illustrates the system configuration for Model AVP771/781.
Device
Analog Signal
4-20 mA DC
OUT
OUT
IN
IN
4-20 mA DC or
0-20 mA DC
Host
controller
Host monitoring
system
(current input)
HART Modem
HART conguration tool
250 Ω
Resistance *1
24 V DC
Power *1
S
m
a
r
t
E
S
D
D
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v
i
c
e
f
o
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S
I
S
Figure 1-4. System Configuration with Current Signal Input and Travel Transmission
Signal (Model AVP771/781)
1-4-2 In the Case of Voltage Signal (0/24 V DC)
Illustrates the system configuration for Model AVP791.
Device
Analog Signal
4-20 mA DC
Host
controller
Host monitoring
system
(current input)
HART Modem
HART conguration tool
250 Ω
Resistance *1
24 V DC
Power *1
Resistance: 500 Ω
0/24 V DC
OUT
OUT
IN
IN
S
m
a
r
t
E
S
D
D
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v
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f
o
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S
I
S
Figure 1-5. System Configuration with Voltage Signal Input and Travel Transmission
Signal (Model AVP791)
*1. For details on power and resistance, please refer to section 2-3-4, “Input Signal and Output Signal Power”

1-4
Chapter 1 Structure of the Control System
1-5 System Configuration with Contact Output (Model AVP7_0)
Model AVP7_0 has a function for transmitting a contact output signal.
This contact output is not related to valve travel, but rather transmits failure output when
an abnormality of this device or of the valve is detected during self-diagnosis or in the PST
(Partial Stroke Test).
Normal output: closed. Failure output: open.
The following is an example of system configuration.
With this system configuration, contact output is output directly to the host monitoring
system from this device.
1-5-1 In the Case of Current Signal Input
Device
Contact Signal
4-20 mA DC or
0-20 mA DC
Host
controller
Host monitoring
system
(Contact input)
HART Modem
HART conguration tool
24 V DC
Power *1
OUT
OUT
IN
IN
S
m
a
r
t
E
S
D
D
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v
i
c
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f
o
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S
I
S
Figure 1-6. System Configuration with Cu rrent Signal Input and Contact Output Signal
(Model AVP770/780)
1-5-2 In the Case of Voltage Signal (0/24 V DC)
Device
Contact Signal
Host
controller
Host monitoring
system
(Contact input)
HART Modem
HART conguration tool
24 V DC
Power *1
Resistance: 500 Ω
0/24 V DC
OUT
OUT
IN
IN
S
m
a
r
t
E
S
D
D
e
v
i
c
e
f
o
r
S
I
S
Figure 1-7. System Configuration with Voltage Signal Input and Contact Output Signal
(Model AVP790)
*1. For details regarding the power, please refer to section 2-3-4, “Input Signal and Output Signal Power.”

1-5
Chapter 1 Structure of the Control System
1-6 Structure of the Device and Description of Each Part
Structure of the Device

Major components
The structure of the main unit of the device is shown in the figure below.
Mounting plate (optional)
Feedback lever
Supply air pressure gauge
Main unit
Local user
interface (LUI)
Output air pressure gauge
Output air connection port (OUT1)
Explosion-proof and Functional
Safety Nameplate
Figure 1-8. Structure of the Device (Top)
Electrical conduit connection port
Pilot relay cover
External grounding terminal
Terminal box cover
Exhaust cap
Output air connection port (OUT2)
Supply air connection port (SUP)
Nameplate
Figure 1-9. Structure of the Device (Bottom)

1-6
Chapter 1 Structure of the Control System
 Name and description of each part
The table below describes each part.
Table 1-1. Description of Each Part
Name Description
Main unit
• Houses electronic circuits, an electro-pneumatic trans-
ducer (EPM), a position sensor (VTD), and a pressure
sensor.
Pilot relay cover
• Cover of the pilot relay that amplifies the air signal from
the EPM (electro-pneumatic transducer) and transduces
it into the air signal sent to the actuator.
• To adjust the balance pressure to switch between the pilot
relay for the single-acting actuator and the pilot relay for
the double-acting actuator, remove this cover.
Auto/Manual (A/M)
switch
• This switch is used to switch how the output air between
the auto operation status and the manual operation status
is controlled. This switch is built into the pilot relay. This
switch can be seen by removing the pilot relay cover.
Feedback lever • Detects the valve lift and relays it to VTD (position sen-
sor).
Local user interface (LUI)
• The LUI allows you to adjust the zero / span, perform
auto setup, and manually operate the device with the LCD
(liquid crystal display) and operation buttons without
using the communicator.
Supply air pressure gauge • Indicates the pressure of the supply air.
Output air pressure gauge • Indicates the pressure of the output air.
Supply air connection port
(SUP)
• Supply air is input to this port.
• “SUP” is displayed at this port.
Output air connection port
(OUT1)
• Output air is sent out of this port to the actuator.
• “OUT1” is displayed at this port.
Output air connection port
(OUT2)
• Output air is sent out of this port to the actuator.
• This port is blocked with a blind plug in the single-acting
actuator.
• OUT2 is displayed at the output port for the double-
acting actuator.
Mounting plate (optional)
• The mounting plate is used to mount the device onto the
actuator.
• The shape of the mounting plate differs depending on the
specifications (actuator model).

1-7
Chapter 1 Structure of the Control System
Structure of the Terminal Box

Major components
This contains the input signal (controller output) terminal, output signal (travel
transmission or contact output) terminal, and internal ground terminal.
The structure of the terminal box is as shown below.
Lock screw
Conduit connection port (2)
Conduit connection port (1)
Terminal
box cover
Figure 1-10. Structure of the Terminal Box
HART check pin
Terminal for output signals
M4 screw
Terminal for input signals
M4 screw
Terminal for internal grounding
M4 screw
Terminal for external grounding
M4 screw
Figure 1-11. Terminal Block in the Terminal Box

1-8
Chapter 1 Structure of the Control System
 Name and description of each part
The table below describes each part of the terminal box.
Name Description
Terminal box cover
• Lid of terminal box.
• This cover has a pressure-resistant explosion-proof struc-
ture.
Lock screw • Used to secure the terminal box cover.
Terminal for input signals • Labeled IN.
• Connects the signal cable from the host controller.
Terminal for output Signals
• Labeled OUT.
• Connects the signal cable for output signal.
• The Model AVP7_2 (without output signal) does not have
the terminal screws.
Internal grounding terminal • Internal terminal for grounding. The cable for grounding
is connected to this terminal.
Conduit connection port (1) • Port for a cable.
Conduit connection port (2) • Port for a cable.
• This port is normally blocked with a blind plug.
Check pin for HART com-
munication
• By connecting the connection hook for the setting device
communication cable to this pin, it is possible to commu-
nicate with this device.
Warning
When using a pressure-resistant explosion-proof model in a dangerous place,
be sure to use the specified cable adapter for pressure-resistant packing for
the conduit connection port. Securely close the terminal box cover all the way.
Then, rotate the lock screw counterclockwise to secure the terminal box cover.
Handling Precautions:
Ground either the external or internal grounding terminal according to the
specifications. Be careful not to ground the device at two points.

1-9
Chapter 1 Structure of the Control System
Local User Interface (LUI) Display
3
6
7
1
10
5
8
9
2
4
Figure 1-12. Segments of the LCD
Table 1-3. Description of Each Part
No. Displayed element Main display
(1) 7 segments
(5 digits) Main numerical values such as the specified opening.
(2) Minus sign Sign (+/−) for the 7-segment number.
(3) Decimal point
(five places) Decimal point for the 7-segment number.
(4) 16 segments
(7 digits) The unit, status, or other data.
(5) Dot (6 places) Delimiter, etc., for 16-segment auxiliary display.
(6) % Percentage.
(7) Bar graph (22 bars) Bar graph showing percentage of set point, etc.
(8) Key symbol
Displayed: LUI cannot be used
Hidden: LUI is operable
Flashing: LUI is busy
(9) Flag symbol
The flag mark is displayed when the self diagnosis alarm is
activated.
For details on the alarm, please refer to the status monitor
described on page 3-4.
(10) Display refresh sym-
bol
Display during operation
White and black circles alternately blink while updating.
For a display example, refer to “LUI Display List” in Appendix A.
Handling Precautions:
The LUI buttons may not respond well near an electromagnetic inductor (such as
a large transformer or high-frequency furnace).
Remove sand, dust, and other foreign objects from the rubber parts of the
operation buttons before operating the LUI. Operating the LUI with foreign
objects on it may damage the rubber parts.
Do not pull the rubber parts of the operation buttons. This may deteriorate the
adhesive property, possibly causing malfunction.

1-10
Chapter 1 Structure of the Control System