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Flowserve Logix 3200MD Plus, User Instructions

The Flowserve Logix 3200MD Plus is a robust and reliable control valve with advanced features. For User Instructions, download the free manual from manualshive.com. Learn how to maximize the functionality of your valve and ensure optimal performance. Download the manual now for a seamless user experience.

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 Logix

®

  Digital Positioners FCD LGENIM0110-0 05/16 

 

flowserve.com

 

         

3

 

 

 

 
 

CONTENTS 

 
 
 
 
 

1

 

SCOPE OF MANUAL .......................................... 5

 

2

 

INTENDED USE .................................................. 5

 

3

 

PRODUCT IDENTIFICATION ............................. 5

 

4

 

LOGIX 3200+ MODIFICATION ........................... 6

 

5

 

SAFETY ............................................................... 6

 

6

 

PACKAGING & TRANSPORT ............................ 6

 

7

 

STORAGE ........................................................... 6

 

8

 

UNPACKING ....................................................... 6

 

9

 

PRE-INSTALLATION INSPECTION ................... 6

 

10

 

PROTECTIVE CLOTHING .................................. 6

 

11

 

QUALIFIED PERSONNEL .................................. 7

 

12

 

VALVE & ACTUATOR VARIATIONS ................. 7

 

13

 

SPARE PARTS .................................................... 7

 

14

 

SERVICE / REPAIR ............................................. 7

 

15

 

PRINCIPLES OF OPERATION ........................... 8

 

15.1

 

B

ASIC 

O

PERATION

.......................................................... 8

 

15.2

 

HART ........................................................................... 8

 

15.3

 

P

OSITION 

D

EFINITION

 ...................................................... 8

 

15.4

 

C

OMMAND 

I

NPUT AND 

F

INAL 

C

OMMAND

 ............................ 8

 

15.5

 

O

UTER 

L

OOP

 ................................................................. 9

 

15.6

 

I

NNER 

L

OOP

 ................................................................... 9

 

15.7

 

D

ETAILED 

S

EQUENCE OF 

P

OSITIONER 

O

PERATIONS

 .......... 9

 

15.8

 

I

NNER 

L

OOP 

O

FFSET

 ...................................................... 9

 

16

 

SPECIFICATIONS ............................................. 11

 

16.1

 

I

NPUT 

S

IGNAL

 ...............................................................11

 

16.2

 

P

NEUMATIC 

O

UTPUT

 ......................................................11

 

16.3

 

A

IR 

S

UPPLY

 ..................................................................11

 

16.4

 

A

NALOG 

O

UTPUT 

–

 

M

ULTI

-F

UNCTION 

C

ARD

 ....................11

 

16.5

 

S

TROKE 

O

UTPUT

 ...........................................................12

 

16.6

 

R

EMOTE 

M

OUNT 

S

PECIFICATIONS

 ...................................12

 

16.7

 

P

OSITIONER 

P

ERFORMANCE 

C

HARACTERISTICS

 ...............12

 

16.8

 

P

HYSICAL 

S

PECIFICATIONS

 ............................................12

 

16.9

 

T

EMPERATURE

 ..............................................................12

 

16.10

 

V

ALVE

S

IGHT

®

 

DTM

 

S

OFTWARE 

S

PECIFICATIONS

 .............12

 

17

 

HAZARDOUS AREA CERTIFICATIONS.......... 13

 

18

 

MOUNTING AND INSTALLING ........................ 15

 

18.1

 

M

OUNTING TO 

M

ARK 

O

NE 

L

INEAR 

V

ALVES

 ......................15

 

18.2

 

M

OUNTING TO 

S

TANDARD 

V

ALTEK 

R

OTARY 

V

ALVES

 ........16

 

18.3

 

O

PTIONAL 

V

ALTEK 

R

OTARY 

M

OUNTING 

P

ROCEDURE

 ........18

 

18.4

 

M

OUNTING TO 

R

OTARY 

NAMUR

 

(A

UTO

M

AX

)

 

V

ALVES

 .....19

 

19

 

TUBING ............................................................. 20

 

19.1

 

D

ETERMINE 

A

IR 

A

CTION

 ................................................ 20

 

19.2

 

C

ONNECT 

S

UPPLY 

P

ORT

 ............................................... 21

 

19.3

 

V

ENTED 

D

ESIGN

 ........................................................... 21

 

20

 

ELECTRICAL CONNECTIONS ........................ 23

 

20.1

 

E

LECTRICAL 

T

ERMINALS

................................................ 23

 

20.2

 

C

OMMAND 

I

NPUT 

(4-20

 M

A)

 

C

ONNECTION

 ...................... 23

 

20.3

 

M

ULTI

-F

UNCTION 

C

ARD 

(AO,

 

DO,

 

DI) ............................ 25

 

20.4

 

R

EMOTE 

M

OUNT

 ........................................................... 26

 

20.5

 

C

ONNECTIONS FOR 

I

NTRINSICALLY 

S

AFE 

O

PERATION

 ....... 27

 

21

 

STARTUP .......................................................... 27

 

21.1

 

Q

UICK 

S

TART 

I

NSTRUCTIONS

 ......................................... 27

 

21.2

 

L

OCAL 

U

SER 

I

NTERFACE 

O

VERVIEW

 ............................... 27

 

21.3

 

C

ONFIGURATION 

S

WITCH 

S

ETTINGS

 ................................ 28

 

21.4

 

S

TROKE 

C

ALIBRATION

................................................... 29

 

21.5

 

A

NALOG 

O

UTPUT 

(AO)

 

C

ALIBRATION

 ............................. 30

 

22

 

POSITIONER FUNCTIONS ............................... 30

 

22.1

 

L

IVE 

M

ANUAL 

T

UNING 

(A

DJUSTING THE 

G

AIN

) ................. 30

 

22.2

 

L

OCAL 

C

ONTROL 

O

F 

V

ALVE 

P

OSITION

 ............................ 30

 

22.3

 

C

OMMAND 

S

OURCE 

R

ESET

 ............................................ 30

 

22.4

 

F

ACTORY 

R

ESET

 ........................................................... 30

 

22.5

 

V

IEWING 

V

ERSION 

N

UMBERS

 ......................................... 31

 

22.6

 

A

NALOG 

I

NPUT 

C

ALIBRATION

 ......................................... 31

 

22.7

 

S

ELECT AND 

C

ALIBRATE 

A

NALOG 

O

UTPUT

 ..................... 31

 

22.8

 

S

ELECT 

D

ISCRETE 

O

UTPUT

 ........................................... 31

 

23

 

HART COMMUNICATION ................................. 32

 

23.1

 

V

ALVE

S

IGHT

®

 

DTM ...................................................... 32

 

23.2

 

HART

 

375/475

 

H

ANDHELD 

C

OMMUNICATOR

 .................. 32

 

23.3

 

C

HANGING 

HART

 

V

ERSIONS

 ......................................... 32

 

23.4

 

B

URST 

M

ODE

 ............................................................... 33

 

24

 

MODEL FEATURES .......................................... 34

 

24.1

 

MD+

 

P

OSITIONER 

D

IAGNOSTIC 

L

EVELS

 .......................... 34

 

24.2

 

V

ALVESIGHT

®

 

DTM

 

D

IAGNOSTIC 

L

EVELS

 ........................ 34

 

25

 

MULTI-FUNCTION CARD ................................. 35

 

25.1

 

A

NALOG 

O

UTPUT 

(AO) ................................................. 35

 

25.2

 

D

ISCRETE 

O

UTPUT 

(DO) ............................................... 35

 

25.3

 

D

ISCRETE 

I

NPUT 

(DI) .................................................... 35

 

26

 

REMOTE MOUNT ............................................. 36

 

26.1

 

R

EMOTE 

M

OUNT 

O

PEREATION

 ....................................... 36

 

27

 

POSITIONER MAINTENANCE ......................... 37

 

27.1

 

S

CHEDULED 

M

AINTENANCE

 ........................................... 37

 

27.2

 

R

EQUIRED 

T

OOLS AND 

E

QUIPMENT

 ................................ 37

 

27.3

 

T

ORQUE 

R

EQUIREMENTS FOR 

S

CREWS

 ........................... 37

 

27.4

 

R

EPLACING THE 

M

ULTI

-F

UNCTION 

C

ARD

......................... 37

 

27.5

 

R

EPLACING A 

M

AIN 

B

OARD

 ........................................... 38

 

27.6

 

R

EPLACING THE 

P

RESSURE 

S

ENSOR 

B

OARD

 ................... 38

 

27.7

 

R

EPLACING AND 

C

LEANING A 

S

POOL 

V

ALVE

 ................... 39

 

27.8

 

R

EPLACING A 

D

RIVER 

M

ODULE 

A

SSEMBLY

 ..................... 40

 

28

 

TROUBLESHOOTING ...................................... 42

 

28.1

 

T

ROUBLESHOOTING 

G

UIDE

 ............................................ 42

 

28.2

 

S

TATUS 

C

ODE 

I

NDEX

 ..................................................... 43

 

28.3

 

S

TATUS 

C

ODE 

D

ESCRIPTIONS

 ........................................ 44

 

28.4

 

H

ELP 

F

ROM 

F

LOWSERVE

 ............................................... 52

 

29

 

DISPOSAL ......................................................... 52

 

30

 

POSITIONER DIMENSIONS ............................. 53

 

Quick Start Instructions

 

Page 277 

Summary of Contents for Logix 3200MD Plus

Page 1: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 Installation Operation Maintenance Manual USER INSTRUCTIONS...

Page 2: ...options It is required that only trained and qualified technicians are authorized to adjust repair or work on control valves actuators positioners and other accessories Review this bulletin prior to i...

Page 3: ...PUT 4 20 MA CONNECTION 23 20 3 MULTI FUNCTION CARD AO DO DI 25 20 4 REMOTE MOUNT 26 20 5 CONNECTIONS FOR INTRINSICALLY SAFE OPERATION 27 21 STARTUP 27 21 1 QUICK START INSTRUCTIONS 27 21 2 LOCAL USER...

Page 4: ...IGURE 15 LINEAR SINGLE ACTING AIR TO OPEN 20 FIGURE 16 EXHAUST VENTS 21 FIGURE 17 PNEUMATIC CONNECTIONS 22 FIGURE 18 TERMINAL DIAGRAM 23 FIGURE 19 COMPLIANCE VOLTAGE 24 FIGURE 20 CONDUIT AND GROUNDING...

Page 5: ...Air sweet natural gas nitrogen and CO2 Sour natural gas is not acceptable For Type nA and Type tb installation only air or inert gas may be connected to the air supply inlet The air supply must be fre...

Page 6: ...box Packaging may use cardboard plastic wrap foam or paper as packing material Filling material may be a carton type or paper Shipping marks display product and package dimensions and weight Packing g...

Page 7: ...r fastening materials from other manufactures If FLOWSERVE products especially sealing materials have been in storage for longer periods check these for corrosion or deterioration before using these p...

Page 8: ...T 475 communicator or other host software See Section 10 for more information 15 3 Position Definition Whether in Analog or Digital Source The position at 0 is always defined as the valve in a closed...

Page 9: ...sabled therefore characterization is Linear No soft limits enabled No MPC set Valve has zero deviation with a present input signal of 12 mA Loop calibration 4 mA 0 command 20 mA 100 command Actuator i...

Page 10: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 flowserve com 10 Figure 4 Logix 3200MD Digital Positioner Schematic Double Acting Relay Air To Open...

Page 11: ...pon loss of power Double Acting Relay Port 1 16 3 Air Supply Table 3 Air Supply Minimum Input Pressure 2 1 Bar 30 PSI Maximum Input Pressure 10 3 Bar 150 PSI Air Supply Quality The air supply must be...

Page 12: ...ISA 75 13 16 8 Physical Specifications Table 8 Physical Specifications For dimensions see section 30 POSITIONER DIMENSIONS Housing Material Cast powder painted aluminum EN AC AlSi12 Fe Soft Goods Fluo...

Page 13: ...ia IIC T4 T6 Ga IP65 T4 Ta 52 C to 85 C T6 Ta 52 C to 45 C Non Incendive Class I Div 2 Groups A B C D T4 Ta 52 C to 85 C T6 Ta 52 C to 45 C Nema Type 4X IP65 ATEX Flame Proof FM16ATEX0006X II 2 G Ex...

Page 14: ...he specific installation Once the type of protection has been marked it shall not be changed Conditions sp ciales pour une utilisation en toute s curit Le mat riel doit tre install de sorte r duire au...

Page 15: ...n the back of the positioner bracket assembly over the mounting bolt Slide the small end of the teardrop under the mounting bolt and align the upper mounting hole 6 Insert the upper mounting bolt and...

Page 16: ...ing four 1 4 20 x 1 2 bolts fasten positioner to universal bracket using appropriate hole pattern stamped on bracket 5 Using a end wrench and two 5 16 18 X bolts attach bracket to actuator transfer ca...

Page 17: ...calibration fails as indicated by a RGGY blink code retry the calibration If it still fails the feedback values were exceeded and the arm must be adjusted away from the positioner s limits Rotate the...

Page 18: ...g the star washer and 10 32 nut 4 Attach tripper and tripper clamp to valve shaft using two 20 bolts and two 20 locknuts Leave tripper loose on shaft until final adjustment 5 Thread ball joint linkage...

Page 19: ...sticker on main board cover and set DIP switches accordingly See section 21 STARTUP 8 Press the QUICK CAL ACCEPT button for three to four seconds or until the positioner begins to move The positioner...

Page 20: ...uator has been tubed If the valve is double acting port the valve labeled 2 to the other side of the actuator DANGER Proper tubing orientation is critical for the positioner to function correctly and...

Page 21: ...oute the exhausted natural gas to a safe environment The housing chamber exhaust port is located on the backside of the positioner The actuator exhaust port is located on the front of the positioner B...

Page 22: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 flowserve com 22 Port Double Acting Configuration Single Acting Configuration 1 1 1 S Supply Supply 2 2 Plug Figure 17 Pneumatic Connections...

Page 23: ...es that the current loop system allow for a 10 VDC drop across the positioner at maximum loop current The operating current range is from 3 9 to 24 mA In order to determine if the loop will support th...

Page 24: ...k Ccable Example Ccable 72 000072 Max Cable Length 0 08 F 000072 Max Cable Length 1111 To control cable resistance 24 AWG cable should be used for runs less than 5000 feet For cable runs longer than 5...

Page 25: ...han 10 V m Portable EM devices such as hand held two way radios should not be used within 30 cm of the device Ensure proper wiring and shielding techniques of the control lines and route control lines...

Page 26: ...The remote mount option can be used where excessive vibration or environmental factors prevent the placement of a positioner directly on the valve Wire the remote mount board according to Table 13 Re...

Page 27: ...he positioner is ready for control CAUTION During the QUICK CAL operation the valve may stroke unexpectedly Notify proper personnel that the valve will stroke and make sure the valve is properly isola...

Page 28: ...mA signal the AO will show a 20 mA signal at closed 21 3 4 Characterization Switch The Characterization Switch allows a better match between the input command and the actual fluid flow through the va...

Page 29: ...ective with Advanced or Pro diagnostic levels 21 3 8 Spare Switch If special features have been purchased they may be controlled by this switch See associated documentation for more details 21 4 Strok...

Page 30: ...tton In this case the previous settings will be retained 21 4 4 On Line Stroke Calibration Adjustments At times an adjustment to the calibration is desired but the process cannot be interrupted The st...

Page 31: ...Y R G 15 Y R Y 16 Y R R 17 R G G 18 R G Y 19 R G R 20 R Y G 21 R Y Y 22 R Y R 23 R R G 24 R R Y 25 R R R 26 For example if holding the Up button gave a G G R code and holding the Down gave a Y Y G cod...

Page 32: ...om www valvesight com Figure 28 ValveSight DTM Dashboard 23 2 HART 375 475 Handheld Communicator The Logix 3200MD digital positioner supports and is supported by the HART 375 475 Handheld Communicator...

Page 33: ...wn in the table below Table 15 Default HART Parameters for Burst Mode HART Variable Data Description Primary 4 20 Command Secondary Final Command Tertiary Purchased with Standard Diagnostics Temperatu...

Page 34: ...w for a richer interface and additional functionality including viewing the dashboard charts annunciator panel test comparisons and data logs and printing reports The DTM also comes in two versions Ba...

Page 35: ...when closed If the valve closes with a 20 mA signal the AO will show a 20 mA signal when closed 25 2 Discrete Output DO Use the Discrete Output function of the MFC to indicate a variety of conditions...

Page 36: ...signals are routed some distance to the positioner Tubing is connected to the positioner The feedback signal wires are connected to a remote mount board installed in the Logix 3200MD positioner See Fi...

Page 37: ...m 5 in lb User Interface terminal connections 0 5 0 6 N m 4 5 in lb 27 4 Replacing the Multi Function Card Removal 1 Make sure the valve is bypassed or in a safe condition 2 Disconnect the power to th...

Page 38: ...tom in place 3 Plug in the hall sensor cable the piezo cable current source cable and the feedback pot cable into the main board Ensure the connectors locking features engage 4 Place the main board on...

Page 39: ...chined portions of spool The tolerances between the block and spool are extremely tight Contamination in the block or the spool may cause the spool to hang 3 Remove the spool valve block by removing t...

Page 40: ...o thread out without tangling or cutting wires 12 Grasp the base of the driver module and turn it counterclockwise to remove After it is threaded out carefully retract the driver module from the housi...

Page 41: ...screw and tighten securely See Figure 38 14 Install the plastic board cover Insert the three retaining screw through the plastic cover into the threaded boss and tighten evenly using a Phillips screwd...

Page 42: ...lve position reading is not what is expected 1 Stem position sensor mounting is off 180 degrees 2 Stroke not calibrated 3 Tight shutoff MPC Minimum position cutoff is active 4 Custom characterization...

Page 43: ...face Off GGYG Low Battery WRN YRRG Main Board Fail WRN RYRR Memory Error WRN YYYR No Motion Time Out RGYY Opened Too Far WRN YYGY Piezo Volts ALM RRRY Piezo Volts High ALM RRRY Piezo Volts High WRN YR...

Page 44: ...olding both the UP and DOWN buttons and briefly pressing the QUICK CAL ACCEPT button GGYR INITIALIZING Description The positioner has powered up and is displaying a blink sequence 3 times Possible Sol...

Page 45: ...input command positioning the valve at a preconfigured set point The DI signal is active and the positioner is attempting to control the valve at the set point Possible Solutions Configure the DI func...

Page 46: ...he user This may be an indication of corrosion build up on the valve stem or in the actuator low or restricted supply pressure or a sticking positioner relay Possible Solutions This warning will clear...

Page 47: ...ases the chance of limit cycling and excessive air consumption The pilot relay is part of the inner loop and consists of the driver module assembly with piezo I P relay which is coupled to the spool v...

Page 48: ...escription Upon loss of air supply the valve may not move to the fail safe position The spring alone is not adequate to overcome the friction and process load in the system The system is relying on pn...

Page 49: ...the IOM for warnings RGRY STROKE SHIFT Description The 0 and 100 valve positions have both shifted in the same direction since the last stroke calibration This may be related to a bent or adjusted fe...

Page 50: ...arm linkage Recalibrate If the problem persists return the unit for repair RYRY PRESSURE SENSOR BOARD FAILURE WARNING Description One or more pressure sensors may have failed Possible Solutions Check...

Page 51: ...ns Check the stem and actuator for loose components RRYR DRIVER MODULE ALARM Description The pilot relay can t open the pilot relay can t shut or the Hall sensor circuit has failed Possible Solutions...

Page 52: ...ght of positioners will often settle through packing peanuts and pop large air packets 6 Please insert a copy of the completed RGA form inside the package and write the RGA number on the outside of th...

Page 53: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 flowserve com 53 30 POSITIONER DIMENSIONS 30 1 Positioner Dimensions...

Page 54: ...aft 3rd Party Actuators D Action Four way Double Acting 1 1 Three way Single Acting 2 Three way Purge Single Acting 3 3 Four way Vented Double Acting 4 Three way Vented Single Acting 5 Special Options...

Page 55: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 flowserve com 55 Figure 42 Exploded View...

Page 56: ...ure Sensor to Manifold 3 20 O ring Regulator to Housing 1 22 O ring Customer Interface Cover 1 26 O ring Customer Interface Board 1 35 Flexible Tube 1 37 Nylon Washer 1 41 O ring Spool Valve to Housin...

Page 57: ...135432 135430 135431 0 63 135429 135437 135430 135433 135431 0 75 135429 135438 135430 137212 135431 0 88 135429 135439 135430 137213 135431 135434 1 12 135429 135430 137214 135431 137218 1 50 135429...

Page 58: ...Menu 40 Limit Switch 11 32 33 53 57 Local Control Of Valve Position 38 Local User Interface 34 M Main Board 61 Maintenance 14 57 Mark One Linear Valves 15 MaxFlo Rotary Valves 20 23 Minimum Close Time...

Page 59: ...Logix 3200MD Digital Positioners FCD LGENIM0110 0 05 16 flowserve com 59 Appendix 1 FM Control Drawing...

Page 60: ...lected this Flowserve product is designed to perform its intended function safely during its useful life However the purchaser or user of Flowserve products should be aware that Flowserve products mig...

Page 61: ...Certs to remove IS and NI references per Steve C Changed Model Code Chart February 3 2016 B Added note to model code chart on page 54 that says M20 Threads are not available for certification code 34...

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