Flowserve Logix 510+ Page 65 User Instructions Download

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Logix

520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16

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19 TROUBLESHOOTING

19.1 Troubleshooting Guide

Table 27: Troubleshooting Guide

Failure

Probable Cause

Corrective Action

No LED is blinking

1. Current source too low.

2. Voltage of current source is too low.

3. Incorrect wiring polarity.

1. Verify current source supplies at least 3,8 mA.

2. Verify voltage source supplies at least 10VDC.

3. Check wiring for correct polarity.

Erratic communications

1. Current source bandwidth not limited to 25Hz.

2. Maximum cable length or cable impedance exceeded.

3. HART modem connected to PC RS-232 port not

receiving enough power

4. Interference with I.S. barrier.

5. Current source stripping (filtering) HART signal.

1. Maximum allowable current source rate of change is 924

mA per second.

2. Check cable size, length and capacitance. See Section 7

ELECTRICAL CONNECTIONS.

3. Verify laptop battery is not low.

4. Must use HART compatible I.S. barrier.

5. Use a 250Ω resistor and a 22 µF capacitor to create a

HART filter according to the following schematic.

Unit does not respond to analog

commands.

1. The positioner is in digital command mode.

2. An error occurred during calibration.

1. Switch to analog command mode using the procedure

outlined in Section 9.3 Command Source Reset, use the
ValveSight DTM, or use a handheld communicator.

2. Check Status Codes. Correct calibration error. Recalibrate.

Valve 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 or soft stops are active.

1. Reposition the sensor.

2. Perform a Stroke calibration (Quick-Cal).

3. Verify Tight Shutoff settings.

4. Verify custom characterization or soft-stop limits

Position is driven fully open or

closed and will not respond to

command.

1. Stroke is not calibrated.

2. Inner-loop hall sensor is not connected.

3. Wrong air action was entered in software.

4. Actuator tubing is backward.

5. Electro-pneumatic converter is malfunctioning.

6. Control parameter inner-loop offset is too high/low.

1. Perform stroke calibration (Quick-Cal)

2. Verify hardware connections.

3. Check ATO (Air-to-open) and ATC (Air-to-Close) settings.

Recalibrate using Quick-Cal to apply settings.

4. Verify ATO/ATC actuator tubing.

5. Replace electro-pneumatic converter.

6. Adjust inner-loop and see if proper control resumes.

Sticking or hunting operation of

the positioner

Contamination of the electro-pneumatic converter.

Control tuning parameters not correct.

Packing friction is high.

Spool valve is corroded or dirty.

Check air supply for proper filtering and meeting

ISA specifications ISA-7.0.01.

Lower proportional gain settings.

Enable the stability DIP switch on the local interface and
recalibrate. If problem persists, adjust pressure control
window with handheld communicator or ValveSight and
recalibrate.

Disassemble and clean spool valve

LCD backlight flickering or dim.

The backlight uses any residual power not used by
other functions of the circuitry.

Fluctuations in the LCD backlight are normal. No action
required.

Control System

HART

Comm

Device

22 μF

250Ω

Summary of Contents for Logix 510+

Page 1: ...Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance Logix 520MD and 510 Digital Positioners FCD LGENIM0105 15 AQ 05 16 ...

Page 2: ... Levels 51 13 Multi Function Card 52 13 1 Analog Output AO 52 13 2 Discrete Output DO 52 13 3 Discrete Input DI 52 14 V To I Card 53 15 Limit Switches 53 15 1 Limit Switch Operation 53 15 2 Limit Switch Types 53 Contents 1 General Information 5 1 1 Using This Document 5 1 2 Terms Concerning Safety 5 1 3 Protective Clothing 5 1 4 Qualified Personnel 5 1 5 Valve And Actuator Variations 5 1 6 Spare P...

Page 3: ...6 18 Maintenance And Repair 57 18 1 Scheduled Maintenance 57 18 2 Required Tools And Equipment 57 18 3 Torque Specification For Screws 57 18 4 Installing A Limit Switch 57 18 5 Replacing The LCD Board 59 18 6 Replacing An Auxiliary Card 59 18 7 Replacing A Main Board 61 18 8 Replacing The Pressure Sensor Board 61 18 9 Cleaning And Replacing A Double Acting Pilot Relay 62 18 10 Replacing A Single A...

Page 4: ...DTM Dashboard 49 Figure 41 Hart Dip Switch 50 Figure 42 Multi Function Card 52 Figure 43 V To I Card 53 Figure 44 Limit Switches 54 Figure 45 Remote Mount Board 54 Figure 46 Tools For Positioner Maintenance 57 Figure 47 Limit Switch 58 Figure 48 Inner Cover 59 Figure 49 LCD 59 Figure 50 Auxiliary Card 60 Figure 51 Main Board Screws 61 Figure 52 Main Board Connectors 61 Figure 53 Pressure Sensor Bo...

Page 5: ... which in themselves might directly or indirectly cause severe personal injury or property damage 1 3 Protective Clothing Flowserve positioners use high pressure gas to operate Use eye protection when working around pressurized equipment Follow proper procedures for working with natural gas if it is used c DANGER Standard industry safety practices must be adhered to when working on this or any pro...

Page 6: ...roperly instructed in performing the disassembly and reassembly procedure Metal parts should be scrapped with the remaining materials disposed of according to national regulations PRINCIPLES OF OPERATION 1 9 Basic Operation The Logix 500 digital positioner is a two wire 4 20 mA input digital valve positioner which uses the HART protocol to allow two way remote communications The positioner is comp...

Page 7: ...op pilot relay control and an outer loop stem position control Referring again to Figure 1 a stem position sensor provides a measurement of the stem movement The Final Command is compared against the Stem Position If any deviation exists the control algorithm sends a signal to the inner loop control to move the relay in a direction depending upon the deviation The inner loop then quickly adjusts t...

Page 8: ...The position er sees this as a command source of 75 percent With Linear charac terization the Final Command becomes 75 percent Deviation is the difference between Final Command and Stem Position Deviation 75 50 25 where 50 percent is the present stem position With this positive deviation the control algorithm sends a signal to move the spool up from its present position As the spool moves the supp...

Page 9: ...ut 10 Hall Sensor Assembly 11 Exhaust 12 Port B 13 Supply Pressure 14 Pressure Sensor Board 15 Supply In 16 Pressure Sensor Cable 17 Feedback Cable 18 Exhaust 19 Port A 20 Feedback Potentiometer 21 Actuator Housing 22 Spring 23 Piston 24 Stem 25 Yoke 26 Take Off Arm Figure 3 Logix 500 Digital Positioner Schematic Double Acting Relay Air To Open 1 2 3 4 5 6 7 8 9 10 21 16 17 19 20 26 25 24 23 22 18...

Page 10: ... is exhausted upon loss of power Single Acting Relay Port B Double Acting Relay Port A 2 3 Air Supply Table 3 Air Supply Minimum Input Pressure 1 5 Bar 22 PSI Maximum Input Pressure Single Acting Relay 6 2 Bar 90 PSI Double Acting Relay 10 3 Bar 150 PSI Air Supply Quality The air supply must be free from moisture oil and dust by conforming to the ISA 7 0 01 standard A dew point at least 18 degrees...

Page 11: ... 100 C 13 F to 212 F Inductive Proximity P F SJ2 SN NAMUR NC 5 Load Current Plate 1 mA No Plate 3 mA Voltage 5 25 VDC Nominal 8 VDC Temperature 40 C to 100 C 40 F to 212 F Inductive Sensor P F NBB2 V3 E2 PNP NO General Purpose Only Load Current 0 100 mA Voltage 10 30 VDC Temperature 25 C to 70 C 13 F to 158 F 2 8 V to I Board Specifications Table 8 V to I Board Specifications Board Input Voltage R...

Page 12: ...3 Server 2003 R2 Server 2008 32 bit 64 bit Versions Server 2008 R2 32 bit 64 bit Versions and 7 32 bit 64 bit Versions Memory 64MB Available HARD Disk Space 64MB Ports 1 minimum available with 8 maximum possible Can also communicate via serial PCMCIA and USB connections HART Modem RS 232 PCMCIA card or USB HART Filter May be required in conjunction with some DCS hardware HART MUX MTL 4840 ELCON 27...

Page 13: ... following IECEx standards IEC 60079 0 2011 IEC 60079 11 2011 IEC 60079 15 2010 IEC 60079 31 2013 IEC 60079 26 2006 Assessed to the following US standards Class 3600 2011 Class 3610 2010 FM 3611 Class 3810 2005 ANSI NEMA 250 2008 ANSI IEC 60529 2004 ANSI ISA 60079 0 2013 ANSI ISA 60079 1 2009 ANSI ISA 60079 11 2011 ANSI ISA 60079 15 2012 ANSI ISA 60079 31 2013 Assessed to the following CAN standar...

Page 14: ...MD positioner check the packing list against the materials received Lists describing the system and accessories are included in each shipping container In the event of shipping damage contact the shipper immediately Should any problems arise contact a Flowserve Flow Control Division representative 4 3 Pre installation Inspection When installing a positioner verify the shaft has not been damaged an...

Page 15: ...k of the positioner bracket assembly over the mounting bolt Slide the small end of the teardrop under the mounting bolt and align the lower mounting hole 6 Insert the lower mounting bolt and tighten the bolting 7 Position the take off arm mounting slot against the stem clamp mounting pad Apply Loctite 222 to the take off arm bolting and insert through washers into stem clamp Leave bolts loose 8 Sl...

Page 16: ... Mounting 4 Assemble the take off pin to the take off plate and mount the take off plate to the valve stem using the two screws Adjust the follower pin to match the correct location as indicated on the follower arm s embossed scale 5 Place the actuator O ring 6 Place the positioner on the actuator ensuring the take off pin is inside the follower arm slot Adjust the follower arm as needed NOTE The ...

Page 17: ...arm must be adjusted away from the positioner s limits Ro tate the feedback shaft so that the full free travel of the feedback shaft is in the range of the actuator movement Optionally con tinue to attempt the calibration Each calibration attempt adjusts the acceptable limits and it should pass eventually a CAUTION Remember to remove the air supply before re adjusting take off arm NOTE If mounted ...

Page 18: ... Adjust the bracket position as needed noting the engagement of the follower pin and the take off arm slot The pin should extend approximately 2 mm past the take off arm When properly adjusted securely tighten the bracketing bolts 5 Using four 1 4 20 x 1 2 bolts fasten positioner to universal bracket using appropriate hole pattern stamped on bracket 6 Using a end wrench and two 5 16 18 X bolts att...

Page 19: ...ink GGGG or GGGY and the valve will be in control mode 15 If 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 Ro tate the feedback shaft so that the full free travel of the feedback shaft is in the range of the actuator movement Optionally con tinue to attempt...

Page 20: ...ate the follower arm so the take off pin will slide into the slot on the follower arm Adjust the bracket position as needed noting the engagement of the follower pin and the take off arm slot The pin should extend approximately 2 mm past the take off arm When properly adjusted securely tighten the bracketing bolts Figure 15 MaxFlo Assembly NOTE The feedback shaft has a clutch mechanism that allows...

Page 21: ...k shaft has a clutch mechanism that allows for over rotation of the shaft for easy adjustments 3 Mount the positioner onto the actuator using the washers and nuts See Figure 18 4 Connect regulated air supply to appropriate port in manifold See section 6 TUBING 5 Connect the power to the 4 20 mA terminals See section 7 ELECTRICAL CONNECTIONS 6 Remove main cover and locate DIP switches and QUICK CAL...

Page 22: ...Logix 520MD and 510 Digital Positioners FCD LGENIM0105 15 AQ 05 16 22 Figure 17 AutoMax Bracket Figure 18 AutoMax Assembly ...

Page 23: ... for easy adjustments NOTE A slight unsymmetrical mounting increases the linearity deviation but does not affect the performance of the device NOTE Depending on the actuator size and stroke it may be necessary to flip the take off arm Figure 3 by 180 and attach it to the opposite side of the stem clamp bracket 8 Connect regulated air supply to appropriate port in manifold See section 6 TUBING 9 Co...

Page 24: ... the control which way the actuator has been tubed If the valve is double acting port the valve labeled Y2 to the other side of the actuator c DANGER Proper tubing orientation is critical for the positioner to function correctly and have the proper failure mode Example Tubing Linear Double Acting Actuators For a linear air to open actuator the Y1 port of the positioner is tubed to the bottom side ...

Page 25: ...A Contact your local Flowserve Representative for more information regarding the purging option 6 4 Vented Design A standard Logix 500 positioner is vented directly to the atmosphere When supply air is substituted with sweet natural gas piping must be used to route the exhausted natural gas to a safe environment The housing chamber exhaust port is located on the backside of the positioner The actu...

Page 26: ... Digital Positioners FCD LGENIM0105 15 AQ 05 16 26 Port Relay Single Acting Spool Style Relay Double Acting Spool Style Relay Single Acting S Supply Supply Supply B Y1 Y2 Plug A Plug Y1 Y1 Figure 24 Pneumatic Connections ...

Page 27: ...00 requires that the current loop system allow for a 10 VDC drop across the positioner at maximum loop current The operat ing current range is from 3 8 to 24 mA In order to determine if the loop will support the Logix 500 perform the calculation in the following equation The Available Voltage must be greater than 10VDC in order to support the Logix 500 Also see Table 1 Input Signal Equation 1 Avai...

Page 28: ...In general shield wire should be connected at the source not at the positioner 7 2 3 Intrinsically Safe Barriers When selecting an intrinsically safe barrier make sure the barrier is HART compatible Although the barrier will pass the loop current and allow normal positioner control if not compatible it may prevent HART communication 7 2 4 Grounding and Conduit The grounding terminals located by th...

Page 29: ...r eliminate noise Flowserve Part Number 10156843 In the event of a severe electrostatic discharge near the positioner the device should be inspected to ensure correct operability It may be necessary to recalibrate the Logix 500 positioner to restore operation 7 3 Multi Function Card AO DO DI The Multi Function Card can act as an Analog Output AO a Discrete Output DO or a Discrete Input DI Connecti...

Page 30: ...re 29 MFC Discrete Output Circuit 7 3 3 Discrete Input For the DI function wire the MFC in series with a 0 to 40 VDC power supply Keep the voltage low under normal circumstances Raise the voltage to create a tripped input state See Figure 30 Figure 30 MFC Discrete Input Circuit Table 14 Auxiliary Card Status Card Condition Status Indication Multi Function Card MFC AO Monitoring Position typical 4 ...

Page 31: ...hanging the voltage may result in lack of position linearity and accuracy Wire the V to I card according to Figure 32 V to I Card Circuit Con nect the voltage input to the V to I card terminal Connect the red wire from the V to I card to the positive terminal on the main board 4 20 mA input connector Connect the black wire from the V to I card to the negative terminal on the main board 4 20 mA inp...

Page 32: ...s on page 11 See Figure 34 Table 15 Limit Switch Connections Terminal See Figure 34 Switch 1 2 3 4 5 6 Mechanical Cherry DG 13 B2RA 1 4 NC NC NO C NC NO C LS1 LS2 Reed Hamlin 59165 1 S 00 C NO LS1 LS2 Inductive Sensor P F NJ2 V3 N NAMUR NC BN BU BN BU LS1 LS2 Inductive Proximity P F SJ2 S1N NAMUR NO BN BU BN BU LS1 LS2 Inductive Proximity P F SJ2 SN NAMUR NC BN BU BN BU LS1 LS2 Inductive Sensor P ...

Page 33: ...e Wire the remote mount board according to Table 16 Remote Mount Card Connections For more information see Table 6 Remote Mount Specifications on page 11 Table 16 Remote Mount Card Connections Terminal See Figure 35 Remote Mount Board A B C From Remote Mount Red White Black Figure 35 Remote Mount Board 7 7 Connections for Intrinsically Safe Operation See section 3 HAZARDOUS AREA CERTIFICATIONS for...

Page 34: ... make sure the valve is properly isolated 8 2 Local User Interface Overview The Logix 500 local user interface allows the user to calibrate configure the basic operation and tune the response of the positioner without additional tools or configurators See Figure 36 Configuration Switches 8 Used to set basic configuration See explanations in section 8 3 Configuration Switch Settings Interface Butto...

Page 35: ... 8 3 4 Characterization Switch The Characterization Switch allows a better match between the input command and the actual fluid flow through the valve This feature is typically used with valves that have non linear flow characteristics The positioner makes a correction by applying an adjustment to the input command according to a characterization curve Linear Select Linear if the actuator position...

Page 36: ...matically After a stroke calibration the positioner is ready to control To perform a Quick Cal first ensure the Quick Calibration Switch is set to Auto or Jog as appropriate Press and hold the ACCEPT QUICK CAL button for approximately 3 seconds This will initiate the automatic stroke calibration While the calibration is in progress the LED lights will flash status codes indicating the calibration ...

Page 37: ...s into the A parameters allowing a starting point for modification Similarly changing the switch from J to A will write the standard J settings into the A parameters Custom tuning values can then be entered using the Display Menu a Handheld or ValveSight DTM With the Selectable GAIN Switch set to A the tuning will not be modified during a Quick Cal 8 4 3 Aborting a Quick Cal The Quick Cal can be a...

Page 38: ...re the valve is properly isolated 9 3 Command Source Reset Performing a command source reset will reset the command source to analog if it has been inadvertently left in digital mode This is done by holding down both the Up and Down buttons then briefly pressing the ACCEPT QUICK CAL button 9 4 Factory Reset To perform a factory reset hold ACCEPT QUICK CAL button while applying power All of the int...

Page 39: ... the ACCEPT QUICK CAL button 9 7 Select and Calibrate Analog Output To change the Multi Function Card to the Analog Output function and calibrate hold down both the BACK and the Up button for about 3 seconds The blink code should change to GYRG If desired adjust the output current for the 0 position by pressing the Up or Down button Briefly press the ACCEPT QUICK CAL button The blink code should c...

Page 40: ...he Pro upgrade Training Percent Complete Training tracks key parameters for a period of time This data can be used to set more meaningful Alarm and Warn ing limits Training will begin automatically after 24 hours of continuous operation and end after 90 days of positioner operation Or use the DTM to initialize this function The training status will show only if training has occurred Training Hours...

Page 41: ...change to pressure control This means the pressures will be held constant locked improving the stability of the valve position The point at which the pressure control is locked depends on the Valve Stability switch on the positioner When the switch is set to Lo Friction the locking point is self adjusting to optimize accuracy When the switch is set to Hi Friction and the deviation is smaller than ...

Page 42: ...trol Soft Limits Shutoff High Soft Limit Low Soft Limit Upper Position Shutoff Lower Position Shutoff Set Date Time1 User Preferences All Units Pressure Units1 Force Units1 Temperature Units Air Flow Units1 Actuator Area Units1 Date Format1 Number Format LCD Orientation Burst Mode1 ON OFF Positioner Revs SW Rev Bld Date Bld Time HW Rev CPU Rev HART Ver Card 1 Card 2 Factory Reset Aux Card 1 or Car...

Page 43: ...crements every time the valve moves beyond the dead band window The travel is displayed in of full stroke Card 1 Value shows the configuration and status of the auxiliary card in slot 1 A tripped state is represented by a 0 A nominal state is repre sented by a 1 Card 2 Value shows the configuration and status of the auxiliary card in slot 2 A tripped state is represented by a 0 A nominal state is ...

Page 44: ...range is 4 to 20 mA The Set 0 value must be lower than the Set 100 value Split Range Example A split range is easily configured For example a 4 to 12 mA signal can be set to correspond to a 0 to 100 stroke When the display shows Set 0 set the command input current to 4 mA The display will show a low Analog to Digital Count ADC that corresponds to 4 mA Then press the ACCEPT QUICK CAL button to set ...

Page 45: ...as possible The default values are 0 seconds meaning the positioner will move the valve as quickly as possible Gain Set with Dual selected applies independent gains in the open and closing directions default With Single selected the most con servative gains found during calibration are applied in both the open and closing directions 10 3 6 Configuration Characterization Configuration Characterizat...

Page 46: ...48 90 84 00 64 80 93 20 78 60 56 71 90 0 90 00 78 40 57 70 87 80 72 50 95 50 84 70 67 84 95 0 95 00 85 00 69 20 92 10 81 30 97 80 91 20 81 03 100 0 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 Figure 39 Characterization Curves Select the appropriate curve as required by the process design Custom Select Custom for a standard 30 1 linear equal percent rangeability curve The curve may be c...

Page 47: ...ommand passes a set limit Though Shutoff and Soft Limit features should not be used together if both are set the greater of the two settings will take precedence at the closed end and the lesser of the two settings will take precedence at the open end 10 3 9 Configuration Set Time and Date Configuration Set Date Time1 1 Not available with 510 The positioner has an internal clock The clock allows t...

Page 48: ... a CAUTION Performing a factory reset may result in the inability to operate the valve until reconfigured properly Notify proper personnel that the valve may stroke and make sure the valve is properly isolated 10 3 14 Card 1 or Card 2 Two slots are available for auxiliary cards The Multi Function Card MFC can be configured for analog output AO Discrete Input DI and Discrete Output DO NOTE With Log...

Page 49: ...t Limits will still apply 10 3 15 Language Language English German French Spanish Portuguese Russian Turkish Italian The display menu is available in several languages To navigate directly to the language menu select the following se quence of buttons Up Up QUICK CAL ACCEPT 11 HART COMMUNICATION The Logix 520MD series positioners use the HART communication protocol specified by the HART Communicat...

Page 50: ...available with a handheld device In the handheld se lect the Burst Mode feature under the Configuration Menu Variables that are transmitted in burst mode are shown in the table below Table 21 Default HART Parameters for Burst Mode HART Variable Data Description Primary 4 20 Command Secondary Final Command Tertiary Purchased with Standard Diagnostics Temperature C Purchased with Advanced or Pro Dia...

Page 51: ...cluding viewing the dashboard charts annunciator panel test comparisons and data logs and printing reports The DTM also comes in two versions Basic and Advanced The Basic DTM provides an intuitive easy to use user interface to the positioner It includes calibration configuration auxiliary card information and off line diagnostic tests A dashboard gives a quick view of important information The Adv...

Page 52: ...sed 13 2 Discrete Output DO Use the Discrete Output function of the MFC to indicate a variety of conditions such as alarms warnings position limits etc Alarms that are masked will not cause the DO to trip The current is normally high and drops low when one of the pre configured states occurs Configuration of the discrete output signal is done using the ValveS ight DTM or push buttons To change the...

Page 53: ... with a limit switch unit The unit has two main parts the electrical switch board and the vane The switch board is connected to the Inner cover The vane connects to the feedback shaft which extends through the positioner and moves with the valve The vane can hold a cam or ferromagnetic device As the shaft rotates the pick up switch LS1 or LS2 is activat ed The switching point can be adjusted Four ...

Page 54: ...o the positioner Tubing is connected to the positioner The feedback signal wires are connected to a remote mount board installed in the Logix 500 positioner See Figure 45 Remote Mount Board Table 25 Remote Mount Cross References Information Section Page Electronic Specifications 2 6 Remote Mount Specifications 11 Electronic Connections 7 6 Remote Mount 33 Ordering a Remote Mount Board 21 2 Spare P...

Page 55: ...or 0 75 inch 19 mm stroke ambient temperature 74 F 23 3 C 60 PSI 4 1 bar supply quarter inch tubing starting at 50 open moving to fully closed Friction was calculated with a bi directional ramp test at a rate of 10 seconds 100 A typical response time for the poppet relay to move to a fail safe state due to a sudden command change was found to be 0 10 s at 22 C 0 23 s at 40 C and 13 s at 85 C Tests...

Page 56: ...erage of 95 for the 520MD can be claimed if PST has not been implemented as a diagnostic To be considered as a diagnostic the PST has to be imple mented in a SIL rated logic solver If PST has been implemented then no additional failure modes will be detected by the proof test Failure modes not covered include possible valve sticking in the travel range not tested and leaking of the valve seat for ...

Page 57: ...Relay 2 Screws 0 56 N m 5 in lb Main PCB MFC V to I Limit switch terminal connections 0 5 0 6 N m 4 5 in lb 18 4 Installing a Limit Switch The Logix 500 digital positioner can be equipped with an additional limit switch unit Part of the switching unit attaches to the feedback shaft The sensors attach to the inner cover Connections to the limit switch are independent of other connections to the pos...

Page 58: ...Logix 520MD and 510 Digital Positioners FCD LGENIM0105 15 AQ 05 16 58 Figure 47 Limit Switch ...

Page 59: ...eplacing an Auxiliary Card Up to two auxiliary cards can be installed at a time Each communicates independently to the main processor though only one cable is used to connect both cards See Figure 50 Removal 1 Make sure the valve is bypassed or in a safe condition 2 Disconnect the power to the positioner 3 Remove the main cover 4 Disconnect the two wire connection from the side of the Card 5 Unscr...

Page 60: ...Route the external cable through the electrical conduit ports in the base and connect the external cable to the auxiliary card See Figure 42 Multi Function Card 9 Replace the auxiliary card clips 10 Reinstall the main cover Auxillary Card Terminals Figure 50 Auxiliary Card ...

Page 61: ...hes upwards while keeping the top in place 3 Connect the pressure sensor board cable the hall sensor cable and the feedback cable Ensure the connector s locking features engage 4 Place the main board on the positioner base ensuring the cables are clear of the feedback gears Insert the two retaining screws 5 Replace the inner cover by inserting the 6 retaining screws 6 Calibrate Figure 51 Main Boar...

Page 62: ...fold O ring Cleaning 1 Using acetone and a cotton cloth wipe down the block and manifold 2 Use cotton swabs to reach inside air passage ways 3 Dry components thoroughly a CAUTION Follow precautions on acetone label and MSDS Installation 1 Place the manifold gasket and manifold O ring into the base 2 Place the manifold assembly 3 Place the 2 manifold screws 4 Place the manifold gasket 5 Ensure the ...

Page 63: ...w and O ring 5 Remove the Manifold gasket Installation 1 Place the Manifold gasket 2 Place the supply plug O ring and screw 3 Place the single acting relay 4 Place the two relay assembly screws 5 Reassemble the main board and covers and calibrate Figure 55 Double Acting Relay Assembly Spool Block Screws 2 Base Manifold O Ring Double Acting Relay Manifold Assembly Manifold Screws 2 Manifold Gasket ...

Page 64: ...Logix 520MD and 510 Digital Positioners FCD LGENIM0105 15 AQ 05 16 64 Figure 57 Single Acting Relay Assembly Relay Assembly Screws 2 Single Acting Relay Supply Plug Screw O Ring Manifold Gasket Base ...

Page 65: ...f 180 degrees 2 Stroke not calibrated 3 Tight shutoff MPC Minimum position cutoff is active 4 Custom characterization or soft stops are active 1 Reposition the sensor 2 Perform a Stroke calibration Quick Cal 3 Verify Tight Shutoff settings 4 Verify custom characterization or soft stop limits Position is driven fully open or closed and will not respond to command 1 Stroke is not calibrated 2 Inner ...

Page 66: ...on Time Out RGYY Opened Too Far WRN YYGY Piezo Volts ALM RRRY Piezo Volts High ALM RRRY Piezo Volts High WRN YRRY Piezo Volts Low ALM RRRY Piezo Volts Low WRN YRRY Piezo Volts WRN YRRY Pilot Cycles WRN YGGY Pilot Response ALM RRGG Pilot Response WRN YRGG Pilot Travel WRN YGGY Pneumatic Leak WRN YRYR Position ADC Range RGGY Position ADC Range RGGY Position Limit Alert YGGG Position Range Small RGGY...

Page 67: ...a handheld the Dashboard page of the DTM or performing a manual Command Reset Perform the Com mand Reset by holding 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 Solutions Wait for 3 blink sequences to complete GGRR SQUAWK MODE Description A user has set t...

Page 68: ...MAND INPUT CALIBRATION IN PROGRESS Description A calibration sequence is in progress The inner loop offset is an important step of the stroke calibration Possible Solutions The calibration can be canceled from the corre sponding calibration page of the DTM from the handheld or by briefly pressing the BACK button GRGR DI COMMAND OVERRIDE Description The Multi Function Card has been configured as a ...

Page 69: ...has larger swings or is oscillating faster than desirable Possible Solutions Verify the limits are set at an appropriate level Re view the control loop parameters and equipment Adjust as necessary YGRY CONTINUOUS STROKE TEST FAILED WARNING Description During the continuous stroke test the valve did not move after 5 consecutive attempts This could mean the valve has increased friction a change in p...

Page 70: ...ace the main circuit board YYRG SOFTWARE ERROR WARNING Description There has been a watch dog time out stack overflow warning or CPU usage warning Possible Solutions If the problem persists perform a factory reset If it still persists reprogram or replace the main board YYRY AIR SUPPLY HUMID WARNING Description The supply gas has high relative humidity which can lead to condensation on electronic ...

Page 71: ...ts This warning could be caused by rapidly power cycling the positioner Possible Solutions The battery is not replaceable Verify or reset the time and date Replace the main board if the problem persists for several days YRRY PIEZO VOLTAGE HIGH WARNING PIEZO VOLTAGE LOW WARNING Description If the voltage to the piezo is too high this could indicate an error with the relay or the main board This may...

Page 72: ...s and air supply to make sure the system is properly connected If the time out occurred because the actuator is very large then simply retry the QUICK CAL and the positioner will automatically adjust for a larger actuator by doubling the time allowed for movement This error may be cleared by briefly pushing the QUICK CAL ACCEPT RGYR ANALOG OUTPUT RANGE TOO SMALL Description During an Analog Output...

Page 73: ... on valve response Check for high friction If the problem persists replace the relay RYYG SUPPLY PRESSURE LOW ALARM Description The supply pressure is below the user set warning limit Low supply pressure can cause poor valve response or positioner failure The minimum recommended supply pressure for proper operation is 1 3 bar 19 PSI Possible Solutions Regulate the supply pressure at the positioner...

Page 74: ...t Low friction is an indication of improperly loaded packing and in severe cases can be an indication of the process fluid leaking at the valve stem Possible Solutions Check for a packing leak Tighten or replace the valve packing RRGR FRICTION HIGH ALARM Description The valve and actuator friction has passed the user set limit High friction can cause loop oscillations poor position control jerky m...

Page 75: ...pon loss of signal power This condition may occur briefly on an air to close valve that is held for long periods of time in the closed position or an air to open valve held in the open position Possible Solutions Ensure the supply pressure is not low If alarm persists for more than 30 minutes the Piezo assembly is damaged Replace the pilot relay RRRR POSITION DEVIATION ALARM Description The differ...

Page 76: ...he return 4 Complete the RGA form Write any specific issues with the posi tioner you would like us to evaluate Please include the customer name and contact information 5 When packaging please secure the unit in a method that will insure it will reach our facility undamaged the weight of posi tioners will often settle through packing peanuts and pop large air packets 6 Please insert a copy of the c...

Page 77: ...77 Logix 520MD and 510 Digital Positioners FCD LGENIM0105 15 AQ 05 16 flowserve com 20 Positioner Dimensions 20 1 Positioner Dimensions ...

Page 78: ...12ATEX0009X II 2 D IP65 Ex tb IIIC T 100 C Db Ta 52 C to 85 C Intrinsically Safe North America IP66 Class I Div 1 Groups A D T4 T6 428 Intrinsically Safe North America IP66 Class I Zone 0 AEx ia IIC T4 T6 Ga Intrinsically Safe North America IP66 Class I Zone 0 Ex ia IIC T4 T6 Ga Non Incendive North America IP65 Class I Div 2 Groups A D T4 T6 Non Sparking North America IP65 Class I Zone 2 AEx nA II...

Page 79: ... 2 Auxiliary Card Slot 2 Slot 2 No Card 0 0 Slot 2 Multi Function Card 3 6 1 Limit Switches or Remote Mount No Switches 0 3 Mechanical Limit Switch 4 1 Reed Switch 2 Namur V3 type proximity switch P F NJ2 V3 N 8 3 Slot Type NAMUR Sensor P F SJ2 S1N 8 4 Slot Type NAMUR Sensor P F SJ2 SN 8 5 Namur V3 type proximity switch P F NBB2 V3 E2 4 6 Remote Mount Feedback 5 7 1 HART 6 standard Can be configur...

Page 80: ...Relay Module 10 Single Acting Poppet 283458 999 000 11 Double or Single Acting Spool 283459 999 000 12 Pneumatic Restrictor 291750 999 000 Limit Switches 13 Mechanical Switch 291751 999 000 14 Reed Switch 291752 999 000 15 P F SJ2 SN 291753 999 000 16 P F SJ2 S1N 291754 999 000 17 P F NJ2 V3 N 291755 999 000 18 P F NBB2 V3 2N 291755 999 000 Only available for general purpose certification option 1...

Page 81: ...999 000 Single Acting Spool 2 325208 999 000 Double Acting Spool 3 291763 999 000 UCC Pressure Test Plug 0 325211 999 000 Schrader 645A 0 325212 999 000 Table 31 Gage Block Aluminum G Gage Internal Material Pressure Units Relay No Gages Part no N A N A N A 0 325223 999 000 Brass PSI Bar kPa Single Acting Poppet 2 325070 999 000 Single Acting Spool 2 325209 999 000 Double Acting Spool 3 325213 999 ...

Page 82: ...07310 999 000 Poppet 2 Stainless PSI Bar kPa 307311 999 000 Poppet 2 Stainless PSI kg cm2 307312 999 000 Spool 0 N A N A 307313 999 000 Spool 3 Brass PSI Bar kPa 307314 999 000 Spool 3 Brass PSI kg cm2 307315 999 000 Spool 3 Stainless PSI Bar kPa 307316 999 000 Spool 3 Stainless PSI kg cm2 307317 999 000 21 5 Mounting Kits Table 33 Mounting Kits Description Part no Shaft Converter D to NAMUR 31458...

Page 83: ...0 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 45 Minimum Open Time 45 Mounting 15 Mounting Kits 82 Multi Function Card 10 29 48 52 53 N NAMUR AutoMax Valves 21 O Outer Loop 7 P Partial Stroke Test 42 43 51 69 Performance 11 Pneumatic Leak 40 43 51 67 ...

Page 84: ...dwide operations or offices 2016 Flowserve Corporation Irving Texas USA Flowserve is a registered trademark of Flowserve Corporation For more information about Flowserve Corporation contact www flowserve com or call USA 1 800 225 6989 FCD LGENIM0105 15 AQ Printed in USA 05 16 Control per SPP 250 Flowserve Headquarters 5215 N O Connor Blvd Suite 2300 Irving TX 75039 Phone 1 972 443 6500 Flowserve C...

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