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Logix 3400MD Digital Positioner FCD LGENIM3404-00 – 9/09

15 Troubleshooting

Table XVIII: Troubleshooting

Failure

Probable Cause

Corrective Action

No LED is blinking

Voltage of supply source is not high enough

Verify that voltage source can supply at least 9 V

Current draw incorrect

Verify current draw of device (23 mA) and that of other

devices on the loop aren’t pulling too much current

Erratic communications

Maximum cable length or cable impedance exceeded

Check cable conduction size, length and capacitance. Refer

to Section 6.4, “Cable Requirements”

Improper grounding

Terminate and ground segment properly.

Interference with I.S. barrier

Must use FF-compatible I.S. barrier

Host FB card not configured or connected correctly

Check connections and configurations of card

Unit does not respond to Final

Value commands

Unit is in Auto mode

Put in OOS mode

Error occurred during calibration

Check blink codes on positioner and correct

calibration error. Recalibrate

Valve position reading is not what

is expected

Positioner tubing backwards

Re-tube the actuator

Stem position sensor mounting is off 180°

Remount position sensor

Stroke not calibrated

Perform RE-CAL

Tight shutoff is active

Verify settings using PC or handheld software

Customer characterization or soft stops active

Verify customer characterization and soft stops

Position is driven fully open or

closed and will not respond to

command

Stroke not calibrated

Check DIP switch settings and calibrate valve stroke

Inner-loop hall sensor not connected

Verify hardware connections

Wrong air action entered in software

Check ATO (Air-to-open) and ATC

(Air-to-close) settings. Recalibrate

Actuator tubing backward

Verify ATO/ATC actuator tubing

Driver module Electro-pneumatic converter malfunctioning

Replace driver module

Control parameter inner-loop offset is too high/low

Adjust inner-loop offset and see if proper control resumes

Sticking or hunting operation of

the positioner

Contamination of the driver module

Check air supply for proper filtering and meeting ISA

specifications ISA-7.0.01. Check the spool valve for

contamination

Control tuning parameters not correct

Adjust gain settings using local gain switch

Packing friction high

Enable the stability DIP switch on the local interface and

recalibrate. If problem persists, enable pressure control with

handheld communicator or SoftTools and recalibrate

Corroded or dirty spool valve

Disassemble and clean spool valve

* Final Value Cutoff

NOTE:

Refer to blink codes for self diagnostics of other errors. See document #VLAIM0046. Refer to Logix 3400/1400 Reference Manual for Fieldbus

related troubleshooting.

Содержание Logix 3400MD

Страница 1: ...Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance 3400MD Digital Positioner FCD LGENIM3404 00 6 09 ...

Страница 2: ...Logix 3400MD Digital Positioner FCD LGENIM3404 00 9 09 2 ...

Страница 3: ...Logix 3400MD Status Condition 17 7 10 Version Number Checking 18 7 11 375 Handheld Communicator 18 7 12 Device Description DD Files 18 7 13 Calibration 18 7 13 1 CALIBRATE_FLAGS 18 7 13 2 Control and Tuning 19 7 14 Alerts 20 7 14 1 FINAL_VALUE_CUTOFF 20 7 14 2 Effects of FINAL_VALUE_CUTOFF on Operation 20 7 14 3 Soft Limits 20 7 14 4 Travel Accumulator 20 7 14 5 Cycle Counter 21 7 14 6 Position De...

Страница 4: ...TION notes must be strictly followed Modifying this product substituting non factory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment and may void existing warranties 0 WARNING Standard industry safety practices must be adhered to when working on this or any process control product Specifically personal prote...

Страница 5: ...o valve installation If O rings are out of round deteriorated or both they must be replaced and the actuator rebuilt All actuators must then be disassembled and inspected If the actuator O rings are replaced complete the following steps 1 Replace the pressure balance plug O rings 2 Inspect the solenoid and positioner soft goods and replace as necessary 4 Logix 3400MD Positioner Overview The Logix ...

Страница 6: ...ain PCB Regulator Filter Flame Arrestor Digital Position Algorithm LED Display FF Input Signal Figure 2 System Positioning Algorithm Sensor Summer Integration I Offset Loop Inner Gmult Pmin Pmax Deviation FOUNDATION Fieldbus Signal Command In AO Block FOUNDATION Fieldbus Transducer Block CONTROL COMMAND Output D A Percentage Algorithm Control Supply Air Control Spool Loop Inner ATO Tubed Sensor Po...

Страница 7: ...ir Supply Requrements Dew Point At least 180 F 100 C below minimum anticipated ambient temperature Particulate Matter Filtered to 5 microns Oil Content Less than 1 ppm w w Contaminants Free of all corrosive contaminants Table VI Function Blocks AO One Analog Output DI Two Discrete Inputs DO One Discrete Output PID One PID Control Function OS One Output Splitter IS One Input Selector Table VII Haza...

Страница 8: ...ard quick open curve If Custom charac terization is enabled the input signal is mapped to either a default output curve or a custom user defined 21 point output curve The custom user defined 21 point output curve is defined using a handheld or the Host configuration tool software In addition two user defined features Soft Limits and Final Value Cutoff may affect the final input signal The actual c...

Страница 9: ...Control Command Since zero deviation exists the Stem Position is also at 50 percent With the stem at the 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 50 to 75 The positioner sees this as a Command source of 75 perce...

Страница 10: ...Fasten with 1 4 bolts 4 Screw one mounting bolt into the hole on the yoke mounting pad nearest the cylinder Stop when the bolt is approximately 3 16 from being 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...

Страница 11: ...n the mechanical stop of the follower arm positioner is reached rotate back approximately 15 degrees 3 Hold the take off arm in place tighten the screw of the take off arm NOTE The take off arm should be snug enough to hold the follower arm in place but allow movement when pushed 4 Connect regulated air supply to appropriate port in manifold 5 Remove main cover and locate DIP switches and RE CAL b...

Страница 12: ... shaft to the actuator shaft is very important since improper alignment can cause excess wear and friction to the positioner 5 5 Tubing Positioner to Actuator The Logix 3400MD digital positioner is insensitive to supply pressure changes and can handle supply pressures from 30 to 150 psig A supply regulator is recommended if the customer will be using the diagnostic features of the Logix 3400MD but...

Страница 13: ...owserve representative Figure 6 Field Termination Shielded Cable FF Signal Connect Shield at Source Housing EARTH Terminal External Bonding Location FF Field Terminators Environmental Seal 6 1 FF Command Input Wiring The Logix 3400MD is non polarity sensitive Wire FF source to the input terminals see Figure 6 Minimum operating voltage is 9 VDC The FF signal to the Logix 3400MD digital positioner s...

Страница 14: ...ient temperature Determine if the segment will support the Logix 3400MD digital positioner by performing the following calculation Voltage Compliance Voltage 23 mA 23 mA Rbarrier Rwire Equation 1 The calculated voltage must be greater than 9 VDC in order to safely support the Logix 3400MD digital positioner Example DCS Compliance Voltage 19 VDC Rbarrier 300 Ω Rwire 25 Ω Currentmax 23 mA Voltage 19...

Страница 15: ... The function of each switch is described below Air Action This must be set to match the configuration of the valve actuator mechanical tubing connection and spring location since these deter mine the air action of the system ATO air to open Selecting ATO if increasing output pressure from the positioner is tubed so it will cause the valve to open ATC air to close Selecting ATC if increasing outpu...

Страница 16: ...g the last RE CAL Off Off forces the positioner to use one of the factory preset tuning sets determined by the adjustable GAIN selector switch Settings A through H are progressively higher gain predefined tuning sets The GAIN selector switch is live and can be adjusted at any time to modify the tuning parameters NOTE E is the default adjustable GAIN selector switch setting for all actuator sizes R...

Страница 17: ...process will only allow the user to manually set the span zero position is automatically always set at the seat If an elevated zero is needed a handheld or other PC based configuration software is required When performing a jog calibration the LEDs will flash in a sequence of Y G Y Y yellow green yellow yellow which indicates that the user must use the Jog buttons and to manually position the valv...

Страница 18: ...e representative The Logix 3400MD digital positioner supports and is supported by the 375 Handheld Communicator The Device Description DD files and the manuals listed below can be obtained from the FF Foundation or from your Flowserve representative For more information please see the following guides Product Manual for the 375 Communicator Logix 3400MD Digital Positioner Reference Manual Diagnost...

Страница 19: ...nature in Progress 5 9 Signature in progress YGGR Initializing 0 10 Initialization in progress YGYG Stroke Cal in Progress 24 11 Calibration in progress YGYG Command Loop Cal in Progress 25 YGYG Pressure Cal in Progress 26 YGYG Analog Output Cal in Progress 27 YGYG Setting Inner Loop Offset 28 YGYY Joc Command Mode 4 12 Local jog command mode YGYR Jog Calibration Set 100 Position 62 13 Jog cal wai...

Страница 20: ...w a stem position of 3 percent and above a stem position of 97 percent This is to prevent integration windup from calibration shifts due to lower pressure or a damaged seat that may prevent fully closing the valve Integration Summer The integral summer within the Logix 3400MD digital positioner is clamped at 20 percent and 20 percent If the integration summer is fixed at 20 percent or 20 percent i...

Страница 21: ...ctuator saturation will occur The actuator will maintain full saturation below 5 percent command signal Now as the command increases the positioner will remain saturated until the command reaches 6 percent remember the 1 percent hysteresis value added by the positioner At this point the stem position will follow the command signal If the FINAL_VALUE_CUTOFF_LO is set to 3 percent but the valve will...

Страница 22: ...nches will be added to the travel accumulator The travel accumulator units will be inches If Stroke length is 90 degrees for a rotary the travel accumulator will now have units of degree A 0 percent to 100 percent stroke will add 90 to the travel accumulator Note Stroke length is for information only and is not used during calibration Table IX Transducer Block Characterization Parameters Parameter...

Страница 23: ... as defined by SIG_START and will begin ramping to the desired ending position as defined by SIG_STOP Notice that the valve will move and FINAL_POSITION_VALUE will change 12 SIG_FLAGS indicates SIG COMPLETE 13 Return the MODE_BLK to auto 14 Notify control room the valve is back on line The stored signature will remain in the Logix 3400MD digital positioner RAM until the either the unit is powered ...

Страница 24: ...hich indicate the total number of integer counts which can be used to measure a sensor or other input To determine the total integer count raise 2 to the power of the number of bits Example 12 bit A D Total integer number 2 Number of Bits 212 4096 Resolution is the measurement range divided by the maximum integer number Example A valve has a 2 inch stroke and a 12 bit A D is used to measure positi...

Страница 25: ...ion Fieldbus Defined Parameter 9 TRANSDUCER_ DIRECTORY ALL ARRAY N A N A N A N A NR Foundation Fieldbus Defined Parameter 10 TRANSDUCER_TYPE ALL UNSIGNED 16 N A N A N A N A NR Foundation Fieldbus Defined Parameter 11 XD_ERROR ALL UNSIGNED 8 N A N A N A N A R Foundation Fieldbus Defined Parameter 12 COLLECTION_ DIRECTORY ALL ARRAY N A N A N A N A NR Foundation Fieldbus Defined Parameter Control Pos...

Страница 26: ...N A SRW Used to limit the command position received from the AO block FB Only Parameter Control Configuration Gain Parameters 107 CONTROL_CONFIG XDTB_MAIN BIT_STRING 38 U_CHAR NO Control_Config NRW Setup Valve Configuration Std Adv DA SA etc 87 CURVE_SELECT XDTB_TECH UNSIGNED 8 39 U_CHAR NO Curve_Select SRW Select Characterization type when the Characterization DIP switch is set to Other 28 P_GAIN...

Страница 27: ...E_X XDTB_TECH FLOAT 67 S_INT 100 CURVEx 12 21 SRW Setup SW Characterization X Axis Points 12 21 44 CURVE_Y XDTB_TECH FLOAT 68 S_INT 100 CURVEy 1 11 SRW Setup SW Characterization Y Axis Points 1 11 44 CURVE_Y XDTB_TECH FLOAT 69 S_INT 100 CURVEy 12 21 SRW Setup SW Characterization Y Axis Points 12 21 Control Calibration Parameters 25 CALIBRATE XDTB_MAIN UNSIGNED 8 33 U_CHAR NO Cal_State RW Test Cali...

Страница 28: ...ameters 33 USER_INTERFACE_ INSTANT XDTB_TECH BIT_STRING 36 U_INT NO UI_Instant R Curent hardware DIP switch and GAIN control seetings not applied to control algorythms 34 USER_INTERFACE_ ACTIVE XDTB_TECH BIT_STRING 37 U_INT NO UI_Saved RW Setup button and DIP switch setting currently applied to control algorythms 24 TEST_MODE XDTB_MAIN BIT_STRING 32 U_CHAR NO control_ disable_flg RW Turns on and o...

Страница 29: ...dvanced or Pro Models 83 PORT_A_PRESSURE_PCT XDTB_TECH FLOAT N A N A N A N A R Port A Pressure in Percent Only active in Advanced or Pro Models 84 PORT_B_PRESSURE_PCT XDTB_TECH FLOAT N A N A N A N A R Port B Pressure in Percent Only active in Advanced or Pro Models User Information Parameters 95 ACT_AREA XDTB_MAIN FLOAT 209 U_INT 10 ACTarea NRW Actuator Area 70 VALVE_MAN_ID XDTB_MAIN UNSIGNED 8 21...

Страница 30: ... Actuator Type 94 ACT_SIZE XDTB_MAIN UNSIGNED 8 233 U_CHAR NO ACTsize NRW User Info Actuator Size 95 ACT_AREA XDTB_MAIN FLOAT 209 U_INT 10 ACTarea NRW Actuator Area 96 SPRING_TYPE XDTB_MAIN UNSIGNED 8 234 U_CHAR NO SPRINGtype NRW User Info Actuator Spring Type single dual etc 97 PO_DATE XDTB_MAIN VISIBLE_ STRING 235 STRING NO PO_date NRW User Info Purchase Order Date 98 INSTALL_DATE XDTB_MAIN VISI...

Страница 31: ...sure Flags 16 INNERLOOP_MASK XDTB_TECH BIT_STRING 276 U_CHAR NO Inner Loop_Mask NRW Status Alarm Inner Loop Flags 18 OUTERLOOP_MASK XDTB_TECH BIT_STRING 277 U_CHAR NO Outer Loop_Mask NRW Status Alarm Outer Loop Flags 20 CONFIGURATION_MASK XDTB_TECH BIT_STRING 279 U_CHAR NO Configuration_ Mask NRW Status Alarm Configuration Flags 113 BLINK_CODE XDTB_MAIN UNSIGNED 8 283 U_CHAR NO Blink_Code R LED St...

Страница 32: ...lTravel R Spool Travel in Percent 38 SPOOL_TRAVEL_HIGH_ START_LIMIT XDTB_MD FLOAT 312 U_LONG 100 ST_HighStart Limit RW Spool Travel High Start Limit 39 SPOOL_TRAVEL_HIGH_ END_lIMIT XDTB_MD FLOAT 313 U_LONG 100 ST_HighEnd Limit RW Spool Travel High End Limit 41 SPOOL_TRAVEL_ PERCENT_YELLOW XDTB_MD FLOAT 314 U_INT 100 ST_pctYellow NR Spool Travel Percent Yellow 35 SPOOL_CYCLES XDTB_MD UNSIGNED 32 31...

Страница 33: ... 100 PS_LowStart Limit RW Supply Pressure Low Start Limit 68 SUPPLY_PRESSURE_ LOW_END_LIMIT XDTB_MD FLOAT 355 U_INT 100 PS_LowEnd Limit RW Supply Pressure Low End Limit 69 SUPPLY_PRESSURE_ HIGH_PERCENT XDTB_MD FLOAT 356 U_INT 100 PS_HighPct Yellow NR Supply Pressure High Percent 70 SUPPLY_PRESSURE_ LOW_PERCENT XDTB_MD FLOAT 357 U_INT 100 PS_LowPct Yellow NR Supply Pressure Low Percent 82 FRICTION_...

Страница 34: ...Current Software Master N A N A N A N A 174 U_INT NO temp_unit N A Test FRAM Delay Before Saving N A N A N A N A 175 U_CHAR NO EEchksum N A Test FRAM Checksum Value N A N A N A N A 176 U_CHAR NO ReadyFlag N A Test System Used internally by the OS Scheduler N A N A N A N A 177 U_INT NO NoSupplyCnt N A Test Piezo Force Memory Pulse to Active N A N A N A N A 178 U_INT NO ef_crc N A For Future Use N A...

Страница 35: ... Future Use 110 RESERVED XDTB_MAIN FLOAT N A N A N A N A RW Reserved for Future Use 112 RESERVED XDTB_MAIN FLOAT N A N A N A N A RW Reserved for Future Use Definitions XDTB_MAIN Main Transducer Block Contains parameters used mostly for command XDTB_TECH Technician Transducer Block Contains diagnostics and uncommon setup parameters XDTB_MD MD Transducer Block Contains the PRO diagnostic parameters ...

Страница 36: ...emely tight Contamination in the block or on the spool may cause the spool to hang Figure 15 Driver Module Barbed Fitting BSCFE JUUJOH MBU PO PVTJOH MBU PO SJWFS PEVMF SJWFS PEVMF PWFS 6 Remove the spool valve block by removing the two Phillips head screws and carefully sliding the block off the spool Figure 14 7 Carefully remove the spool by sliding the end of the spool out of the connection clip...

Страница 37: ...ads are fully engaged rotate the driver module counter clockwise until the flat on the driver module and the flat on the housing are aligned This will align the screw hole for the next step 19 Verify that the nylon gasket is in the counter bore in the driver module retaining screw hole as shown in Figure 14 20 Insert a driver to housing screw into the driver housing through the counterbored hole i...

Страница 38: ...16 5 Remove the retaining screw from the main PCB assembly 6 Remove the five wire connections from the main PCB assembly and lift the main PCB out of the housing 7 Remove the four screws from the regulator base Verify that as regulator is removed the O ring and filter remain in the counter bore 8 Remove tubing and barbed fitting from the regulator base 9 Install barbed fitting and tubing to the ne...

Страница 39: ...sed or in a safe condition 2 Disconnect the power and air supply to the unit 3 Remove the spool valve cover by removing the screw and sliding the cover assembly backwards until the tab is clear of the slot It is not necessary to remove the sheet metal cap hydrophobic filter or O ring from this assembly Figure 18 0 WARNING The spool extending from the driver module assembly is easily damaged Use ex...

Страница 40: ...ve shroud onto spool valve cover 7 Place the spool valve cover assembly in place by setting it on the ramp and sliding it until the tab seats in the slot Figures 13 and 18 and secure with a 8 32 screw Figure 18 Spool Valve Cover Assembly 0 SJOH ZESPQIPCJD JMUFS 4QPPM 7BMWF PWFS 4QPPM 7BMWF 4ISPVE 8 6 Stem Position Sensor The position feedback assembly transmits valve positions information to the p...

Страница 41: ...ower and air supply to the positioner and perform a stroke calibration 8 7 Main PCB Assembly The main printed circuit board PCB assembly contains the circuit boards and processors that perform control functions of the positioner The main PCB is to be replaced as a unit None of the components on the main PCB are serviceable It consists of a controller board and a Fieldbus communication board Replac...

Страница 42: ...wing tools are required Phillips screwdriver 1 Make sure the valve is bypassed or in a safe condition 2 Disconnect the power and air supply to the unit 3 Remove the main cover 4 Remove the plastic board cover by removing the three retaining screws see Figure 16 5 Remove the two screws holding the pressure sensor plug plate to the housing Lift the metal stiffener plate off the pressure sensor plug ...

Страница 43: ...nd 20 A standard Logix 3400MD positioner is vented directly to the atmo sphere When supply air is substituted with sweet natural gas piping must be used to route the exhausted natural gas to a safe environment This piping system may cause some positioner back pressure in the main chamber from the modulator and regulator and spool chamber from the actuator Back pressure limitations are described be...

Страница 44: ...over Short 2 7 Screw Main PCB Cover Long 8 Main PCB Assembly 9 Screw Main PCB Assembly Retaining 11 Screw Pressure Sensor Board 2 12 Pressure Sensor Board Stiffener Item No Part 13 Pressure Sensor Board Advanced Only 14 Pressure Sensor Plug Plate Standard Only 15 O ring Pressure Sensor to Housing 2 16 Pressure Regulator 5 to 30 psig Includes 2 O rings 17 Screw Regulator Plate to Housing 4 18 Hex B...

Страница 45: ...Feedback Shaft 54 O ring Feedback Shaft 55 Torsion Spring 56 E ring Table XI Parts continued 11 Logix 3400MD Spare Parts Kits See Figure 22 for item numbers Table XII Spare Parts Kits Item No Description Quantity Kit 2 Driver Module Assembly 40 to 80 C Kit P N 199786 999 000 16 Pressure Regulator 1 17 Screw Regulator to Housing 4 33 Driver Module Assembly 1 34 Hex Barbed Fitting w Captive O ring 1...

Страница 46: ...4 Screw User Interface to Housing 3 25 User Interface Board 1 26 O ring User Interface Board 1 Kit 13 Position Feedback Potentiometer Kit P N 199794 999 000 49 Screw Feedback Potentiometer to Housing 2 50 Metal Washer 2 51 Position Feedback Potentiometer 1 Table XII Spare Parts Kits continued 12 Logix 3400MD Mounting Kits 12 1 Valtek Mounting Kits Table XIII Valtek Linear Mounting Kits Spud 25 in2...

Страница 47: ...0 10 173298 Valtek Trooper 166636 0 75 1 50 Std Automax R314 141180 HD SNA115 NK313A Vangard 37 64 175128 Air Torque AT Series AT0 AT6 Consult factory Automax SNA Series SNA3 SNA2000 N Series N250 300 R Series R2 R5 Bettis RPC Series RP TPC11000 G Series G2009 M11 G3020 M11 EL O Matic E Series E25 E350 P Series P35 P4000 Hytork XL Series XL45 XL4580 Unitorq M Series M20 M2958 Worcester 39 Series 2...

Страница 48: ...e valve will not go below 10 percent A Is a lower soft stop enabled The lower soft stop must be less than or equal to zero percent in order for the Final Value Cutoff to become active If a positive lower soft stop is written this stop will take priority over the Final Value Cutoff feature When the lower soft stop is reached the positioner will blink a GYGYs code Q Will soft stops prevent the valve...

Страница 49: ...A B C D E F G 02 INMETRO BR EX ia IIC T4 T5 BR Ex d IIB H2 T5 South America 06 Flame Proof EEx d IIB H2 ATEX II 2 G 07 General Purpose 14 Ex ia IIC ATEX II 1 G 15 Ex nA nL IIC ATEX II 3 G 20 IECEx Ex ia IIC 21 Shaft Feedback Shaft DD 316 SSl Shaft Valtek Standard D6 D6 NAMUR 316 SSl VDI VDE 3845 N6 Conduit Connections Threaded Connections 1 2 NPT E E M20 M Action 4 way Double Acting 04 04 3 way Si...

Страница 50: ... PC or handheld software Customer characterization or soft stops active Verify customer characterization and soft stops Position is driven fully open or closed and will not respond to command Stroke not calibrated Check DIP switch settings and calibrate valve stroke Inner loop hall sensor not connected Verify hardware connections Wrong air action entered in software Check ATO Air to open and ATC A...

Страница 51: ...51 Logix 3400MD Digital Positioner FCD LGENIM3404 00 9 09 flowserve com ...

Страница 52: ... contained herein is to be construed as a warranty or guarantee express or implied regarding any matter with respect to this product Because Flowserve is continually improving and upgrading its product design the specifications dimensions and information contained herein are subject to change without notice Should any question arise concerning these provisions the purchaser user should contact Flo...

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