Flowserve Logix 520MD+ User Instructions Download

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User Instructions - Logix® 520MD+ Series Digital Positioner

FCD LGENIM0105-00

Field Trial Version – Printed October 28, 2011

17 TROUBLESHOOTING

17.1 Troubleshooting Guide

Table 21: 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 the HART filter (VHF) available from Flowserve

(FLS part-No. 10156843) See Figure 8: HART
Filter on page 17. Alternatively, a 250

Ω

and a 22

µF capacitor, installed according to the following
schematic drawing can be used to establish
communication.

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

1. Contamination of the electro-

pneumatic converter.

2. Control tuning parameters not

correct.

3. Packing friction is high.

4. Spool valve is corroded or dirty.

1. Check air supply for proper filtering and meeting

ISA specifications ISA-7.0.01.

2. Lower proportional gain settings.
3. 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.

4. Disassemble and clean spool valve.

LCD backlight flickering or
dim.

1. The backlight uses any residual

power not used by other functions of
the circuitry.

1. Fluctuations in the LCD backlight are normal. No

action required.

22 µF 250

Ω

Control System

Summary of Contents for Logix 520MD+

Page 1: ...Logix 520MD Series Installation Operation Maintenance Safety Manual Digital Positioner FCD LGENIM0105 00 ...

Page 2: ...7 7 5 GROUNDING AND CONDUIT 17 7 6 ELECTROMAGNETIC COMPATIBILITY 18 7 7 INTRINSICALLY SAFE BARRIERS 18 7 8 MULTI FUNCTION CARD AO DO DI 18 7 9 SAFETY DISCRETE OUTPUT SAFETY DO 19 7 10 LIMIT SWITCHES 19 8 STARTUP 20 8 1 QUICK START INSTRUCTIONS 20 8 2 LOCAL USER INTERFACE OVERVIEW 20 8 3 CONFIGURATION SWITCH SETTINGS 20 8 4 STROKE CALIBRATION 21 9 POSITIONER FUNCTIONS NO DISPLAY REQUIRED 23 9 1 LIV...

Page 3: ...rsonal protective and lifting devices must be used as warranted FLOWSERVE products are often used in problematic applications e g extremely high pressures dangerous toxic or corrosive mediums In particular valves with bellows seals point to such applications When performing service inspection or repair operations always ensure that the valve and actuator are depressurized and that the valve has be...

Page 4: ...with FLOWSERVE manufactured replacements as outlined in this manual WARNING Substitution of with non factory positioner components may impair intrinsic safety WARNING Before products are returned to FLOWSERVE for repair or service FLOWSERVE must be provided with a certificate which confirms that the product has been decontaminated and is clean FLOWSERVE will not accept deliveries if a certificate ...

Page 5: ...t passes through a characterization limits modifier block This function is done in software which allows for in the field customer adjustment The characterization block can apply no adjustment Linear one of several pre defined characterization curve adjustments including several Equal Percent or a 21 point Custom Characterization curve adjustment In Linear mode the input signal is passed straight ...

Page 6: ...e desired position the spool valve will be at a middle position that balances the pressures above and below the piston in the actuator This is commonly called the null or balanced spool position Assume the input signal changes from 12 mA to 16 mA The positioner sees this as a command source of 75 percent With Linear characterization the Final Command becomes 75 percent Deviation is the difference ...

Page 7: ...ral gas is not acceptable Air Consumption Single Acting Relay 0 069 Nm h 1 5 bar 0 041 SCFM 22 PSI 0 082 Nm h 4 1 bar 0 048 SCFM 60 PSI Double Acting Relay 0 297 Nm h 1 5 bar 0 175 SCFM 22 PSI 0 637 Nm h 4 1 bar 0 375 SCFM 60 PSI 3 3 Pneumatic Output Table 3 Pneumatic Output Output Pressure Range 0 to 100 of air supply pressure Output Air Capacity Single Acting Relay 9 06 Nm h 1 5 bar 5 33 SCFM 22...

Page 8: ...00 mA Voltage 200VDC Temperature 40 to 105 C 40 F to 221 F Inductive Proximity P F SJ2 SN NAMUR NC 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 Proximity P F SJ2 S1N NAMUR NO Load current Plate 1 mA No Plate 3 mA Voltage 5 25 VDC Nominal 8 VDC Temperature 25 C to 100 C 13 F to 212 F Inductive Sensor P F NJ2 V3 N NAMUR NC Loa...

Page 9: ...n each shipping container When lifting a valve system from the shipping container position lifting straps to avoid damage to mounted accessories Systems with valves up to six inches may be lifted by actuator lifting ring On larger systems lift unit using lifting straps or hooks through the yoke legs and outer end of body WARNING When lifting a valve actuator assembly with lifting straps be aware t...

Page 10: ...g flush with mounting pad 5 Slip the large end of the teardrop shaped mounting hole in 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 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...

Page 11: ...User Instructions Logix 520MD Series Digital Positioner FCD LGENIM0105 00 Flowserve Corporation 11 Field Trial Version Printed October 28 2011 5 2 Mounting Positioner to Flow Top Linear Valves Text here ...

Page 12: ... Instructions Logix 520MD Series Digital Positioner FCD LGENIM0105 00 Flowserve Corporation 12 Field Trial Version Printed October 28 2011 5 3 Mounting Positioner to Standard Valtek Rotary Valves Text here ...

Page 13: ...User Instructions Logix 520MD Series Digital Positioner FCD LGENIM0105 00 Flowserve Corporation 13 Field Trial Version Printed October 28 2011 5 4 Mounting Positioner to NAMUR Rotary Valves Text here ...

Page 14: ...le Acting Actuators below 6 2 Connect Supply Port The positioner ports are threaded with either G or NPTF as indicated on the housing In order to maintain the recommended air quality a coalescing filter should always be installed in the supply gas line An air filter is highly recommended for all applications where dirty air is a possibility The positioner passage ways are equipped with small filte...

Page 15: ...l Positioner FCD LGENIM0105 00 Flowserve Corporation 15 Field Trial Version Printed October 28 2011 6 5 Pneumatic Terminals Figure 6 Pneumatic Connections Port Single Acting Poppet Style Relay Double Acting Spool Style Relay Supply B Y1 Y2 A Y1 ...

Page 16: ...0 VDC drop across the positioner at maximum loop current The operating current range is from 3 8 to 24 mA In order to determine if the loop will support the Logix 520MD perform the calculation in the following equation The Available Voltage must be greater than 10VDC in order to support the Logix 520MD Also see Table 1 Input Signal Equation 1 Available Voltage Controller Voltage Current Current R ...

Page 17: ...ed for runs less than 5000 feet For cable runs longer than 5000 feet 20 AWG cable should be used The input loop current signal to the Logix 3200MD digital positioner should be in shielded cable Shields must be tied to a ground at only one end of the cable to provide a place for environmental electrical noise to be removed from the cable In general shield wire should be connected at the source not ...

Page 18: ...on 7 8 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 Connections to the Multi Function Card are made directly to the card terminals For detailed information about voltage and current limits see Table 12 Auxiliary Card Status below For AO and DO functions wire the MFC in series with a 10 to 40 VDC power supply includi...

Page 19: ...imits see Table 12 Auxiliary Card Status above Figure 13 Safety Discrete Output Circuit 7 10 Limit Switches Limit switches provide an independent verification of the position of the feedback shaft Wire the limit switches according to the following table For more information see table Table 10 Limit Switch Specifications on page 8 Table 13 Limit Switch Connections Terminal See Figure 14 Switch 1 2 ...

Page 20: ... Up o Down o Back Selectable GAIN Switch Rotary Used to manually fine tune the performance LED Indicators Red Yellow and Green Indicate status alarms and warnings Display Optional Provides a full menu of detailed information and configuration options Figure 15 Local User Interface 8 3 Configuration Switch Settings Before placing the unit in service set the Configuration Switches to the desired con...

Page 21: ...he Selectable Gain Switch during a Quick Cal allows the user to use and preserve manually adjusted gains See section 8 4 Stroke Calibration for more details NOTE The gain switch is live meaning that regardless of the Auto Tune selection the gain settings can be adjusted at any time during operation by changing the selectable GAIN switch position Figure 16 Selectable GAIN Switch 8 3 6 Quick Calibra...

Page 22: ... to E Then perform a Quick Cal During the Quick Cal custom tuning parameters will be determined based on measured response parameters The gains can then be fine tuned by adjusting the Selectable GAIN Switch Selecting D C or B will progressively provide a more stable response Selecting F through J will progressively provide a more active response In most cases selecting E will give the best results...

Page 23: ... remote command changes and make sure 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 ACCCEPT QUICK CAL button 9 4 Factory Reset To perform a factory reset hold ACCEPT QUICK CAL button...

Page 24: ... slot 2 DIP Switch Override This indicates that the Configuration DIP Switches do not reflect the actual configuration of the positioner This can happen if a Configuration Switch is changed after a Quick Cal or if the configuration is was changed from the DTM Performing a Quick Cal will reset the configuration to what the Configuration Switches show which may not be desirable in this case Ensure t...

Page 25: ... held at a constant position for extended periods of time the Continuous Stroke Test can provide assurance that the valve is still responsive When CST is on the positioner will cause a very small amount of valve movement From this movement the positioner can find information about the health of the valve actuator and positioner This is not recommended for valves intended for high accuracy or stabi...

Page 26: ...Tuning Characterization Pressure Control Soft Limits Cutoff High Soft Limit Low Soft Limit Upper Position Cutoff Lower Position Cutoff Set Date Time User Preferences All Units Pressure Units Force Units Temperature Units Air Flow Units Actuator Area Units Date Format Number Format LCD Orientation Burst Mode ON OFF Positioner Revs EC Major Rev EC Minor Rev EC Build Date and Time Universal Rev Hardw...

Page 27: ...shows current and past alarms warnings alerts and calibrations Current Alarms displays all events that are actively sounding Event History displays past 32 events including alarms warnings alerts and calibrations The event that occurred most recently is displayed first event 32 with later events recorded below Each event has a time stamp and shows if it was turning on or off 10 3 3 Partial Stroke ...

Page 28: ...ypically responsiveness is different in each direction NOTE Only those with specific training in PID tuning algorithms should attempt to adjust the tuning by manually changing the PID values Open Stroke Time is the fastest time it took the valve to stroke from 0 to 100 during Quick Cal Changing this parameter will affect the responsiveness of the valve in the opening direction Close Stroke Time is...

Page 29: ... de energized state regardless of the Soft Limits Upper Position Shutoff and Lower Position Shutoff This feature also called Minimum Position Cutoff or MPC is 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 Final Command Command Input Linear MaxFlo Linear MaxFlo Valdisk Linear Valdisk ShearStream Linear ShearStream Custom Table 16 Characteristic Curve Data Command Input Final Com...

Page 30: ...ecimal Point LCD Orientation Use this selection to turn the turn the display upside down 180 degrees Use this feature when the positioner is mounted upside down 10 3 11 Configuration Burst Mode Burst Mode continuously transmits HART information On Off Use this feature to turn burst mode on and off 10 3 12 Configuration Positioner Revs Positioner revisions are shown in this menu SW Rev The revision...

Page 31: ...ion switch on the positioner For example if the switch is set to 4 mA the Set 0 current must be less than the Set 100 current If Set As DO Card Use DTM The DO is highly configurable Use the ValveSight DTM to set the function of the DO If Set As DI Card Set to No Action Use this option if only an acknowledgement of the DI state is desired Set to Trigger PST Use this option to initiate a partial str...

Page 32: ...m the HART Communication Foundation or from your Flowserve representative 11 3 Burst Mode Burst Mode is available with a handheld device In the menu of the handheld select the Burst Mode feature under the Configuration Menu 11 4 Change from HART 6 to HART 5 The Logix 520MD positioner comes standard with the HART 6 communication protocol Follow this procedure to change to HART 5 by removing the HAR...

Page 33: ...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 Advanced DTM provides a view of the positioner s full health analysis and interfaces to all of the positioner s Pr...

Page 34: ... point can be adjusted Four types of Limit Switches can be used with the Logix 520MD 13 2 Limit Switch Types Mechanical switches are triggered by the use of a mechanical cam and followers Reed switches are triggered by a magnetic force No physical contact occurs Inductive Slot switches are triggered when the sensor detects a ferromagnetic vane inserted between the coils No physical contact occurs ...

Page 35: ...th a 4 mA signal the AO will show a 4 mA signal when closed If the valve closes with a 20 mA signal the AO will show a 20 mA signal when closed 14 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 The current is normally high and drops low when one of the pre configured states occurs Configuration of the...

Page 36: ...nformation IOM Section Safety DO Specifications 3 6 Safety Discrete Output Electronic Connections 7 9 Safety Discrete Output Safety DO DO Status Table 12 Auxiliary Card Status Figure 22 Safety Discrete Output Card The Safety DO card uses a relay type circuit which can be closed or open Normally the circuit is closed An open circuit indicates the positioner has detected one of the following errors ...

Page 37: ... to the positioner For electrical connection diagrams see Table 13 Limit Switch Connections For electrical specifications see Table 10 Limit Switch Specifications WARNING For units installed in hazardous areas special installation cautions and procedures are required The installation of hazardous location electrical equipment must comply with the procedures contained in the certificates of conform...

Page 38: ...rocessor though only one cable is used to connect both cards 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 Unscrew and remove the auxiliary card clips 6 Gently slide the card from the slot If two cards are present remove both cards from the slots 7 Ge...

Page 39: ...screws 6 Calibrate Figure 27 Main Board Screws Figure 28 Main Board Connectors 16 6 Replacing the Pressure Sensor Board Removal 1 Remove the main board See procedure above Disconnecting the hall sensor and feedback cables is not required 2 Unscrew the 6 screws holding the pressure sensor board in place 3 Remove the pressure sensor board Installation 1 Place the pressure sensor o rings in the three...

Page 40: ...pply plug screw 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 Replace other components and calibrate Figure 32 Single Acting Relay Assembly Spool Clip Spring Block Base Double Acting Relay Manifold Assembly Manifold Screws 2 Manifold Gasket 2 of 2 Spoo...

Page 41: ...ration 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 limit...

Page 42: ...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 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 A...

Page 43: ...button is briefly pressed 2 The Squawk mode is turned off remotely 3 More than one hour has passed since the command was issued GYGY SOFT STOP HIGH LIMIT ALERT SOFT STOP LOW LIMIT ALERT Description The Final Command would move the valve beyond the user set Soft Limit but the internal software is holding the position at the limit The function is similar to a mechanical limit stop except it is not a...

Page 44: ...LVE CYCLES WARNING VALVE TRAVEL WARNING Description The cycle or travel limit of the valve actuator bellows or pilot relay has been exceeded Each cycle represents two reversals of the direction of valve movement The cycle counting criterion and count limit for the valve actuator and bellows are set by the user to track the usage of the valve assembly Possible Solutions Follow routine procedures fo...

Page 45: ...ctuation Ratio is based on the ratio of available force to the required force to actuate Control may be lost if this ratio reaches 100 It is affected by the process load friction spring force and available supply pressure Possible Solutions Increase the supply pressure Reduce the friction Check the actuator spring Resize the actuator Adjust user set limits YYYR MEMORY ERROR WARNING Description The...

Page 46: ...pool valve for excessive wear YRRG LOW BATTERY WARNING Description The battery for the real time clock is low The battery is designed for a 15 year life with the positioner unpowered The battery is not required for the positioner to control properly but is used only to maintain the time and date upon loss of power The time and date affect the time stamps of alarms warnings and other events This wa...

Page 47: ...rated The unit will not respond to commands and will remain in the failsafe position until a calibration is successfully completed Possible Solutions Perform a Stroke Calibration QUICK CAL by holding the QUICK CAL ACCEPT button down for 3 seconds or perform a Pressure or Friction calibration if desired See the Calibration section of the IOM for warnings RGRY STROKE SHIFT Description The 0 and 100 ...

Page 48: ...or board connections Recalibrate the pressure sensors If the problem persists replace the pressure sensor board RYRR MAIN BOARD ELECTRONIC FAILURE WARNING Description There has been an oscillator fault position sensor ADC failure supply voltage error reference voltage error shunt voltage error or piezo voltage error Possible Solutions This may be caused by transient conditions If the error persist...

Page 49: ...ator 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 Check the internal wiring connections Replace the pilot relay RRRY PIEZO VOLTAGE HIGH ALARM Description The voltage driving the piezo is above the alarm limit This could indicate an error with the relay or the main board The p...

Page 50: ...r Instructions Logix 520MD Series Digital Positioner FCD LGENIM0105 00 Flowserve Corporation 50 Field Trial Version Printed October 28 2011 18 POSITIONER DIMENTIONS 18 1 Positioner Dimensions Figures here ...

Page 51: ...User Instructions Logix 520MD Series Digital Positioner FCD LGENIM0105 00 Flowserve Corporation 51 Field Trial Version Printed October 28 2011 18 2 Positioner Dimensions with Options Figures here ...

Page 52: ...le Relay 2 Four way Double Acting Spool Style Relay 3 Position Indicator No Indicator 0 F Flat F Domed D Special Options No special options 0 0 Optional Mechanical Add Ins Manifold No Manifold 00 AG Gauge Manifold Aluminum AG VDI VDE 3847 Semi Integrated Manifold Aluminum VE Gauges No Gauges 0 2 Supply Output Output SS with Brass Internals psi bar kPa Valtek Standard qty 3 1 Supply Output Output S...

Page 53: ......

Page 54: ...9 000 283456 999 000 283457 999 000 9 10 Pilot Relay Module Single Acting Poppet Double or Single Acting Spool 283458 999 000 283459 999 000 11 12 13 14 15 16 Switches Mechanical Switch Reed Switch P F SJ2 SN P F SJ2 S1N P F NJ2 V3 N P F NBB2 V3 E2 2 wire configuration TBD TBD TBD TBD TBD TBD 19 3 Mounting Kits Table 25 Mounting Kits Description Part no IEC 534 part 6 FloTop Kämmer KA Kämmer KP an...

Page 55: ...ner Loop 6 Installation 10 L Language 31 LCD Board 38 LCD Menu 24 Limit Switch 8 19 34 37 Local Control Of Valve Position 23 Local User Interface 20 M Main Board 39 Maintenance 37 Minimum Close Time 28 Minimum Open Time 28 Mounting 10 Mounting Kits 54 Multi Function Card 18 31 35 O Outer Loop 5 P Partial Stroke Test 26 27 33 43 Performance 8 Pneumatic Leak 24 27 33 42 Positioner Dimensions 50 Pres...

Page 56: ...a 65 6879 8900 Flowserve Corporation has established industry leadership in the design and manufacture of its products When properly selected 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 might be used in numerous applications under a wide variety of indus...

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