Flowserve 3200MD User Manual
USER INSTRUCTIONS
FCD LGAIM0058-00
Installation
Digital Positioner 3200MD
3200MD Digital Positioner
LGENIM0059-09 12/13
Installation, Operation and Maintenance Instructions
Operation
Maintenance
Safety Manual
Contents
User instructions - Digital Positioner 3200MD LGENIM0059-08 10/13
1 Terms Concerning Safety 3
2 General Information 3
3.1 Unpacking 3
3.2 Storage 3
3.3 Pre-installation Inspection 3
4 Logix 3200MD
Positioner Overview 4
4.1 Specifi cations 4
4.2 Positioner Operation 6
4.3 Detailed Sequence
of Positioner Operations 7
5 Mounting and Installation 8
5.1 Mounting to Valtek Linear
Mark One Valves 8
5.2 Mounting to Standard
Valtek Rotary Valves 9
5.3 Optional Valtek Rotary
Mounting Procedure 10
5.4 NAMUR Rotary Mounting 11
5.5 Tubing Positioner to Actuator 11
6 Wiring and Grounding Guidelines 12
6.1 4-20 mA Command Input Wiring 12
6.2 Grounding Screw 12
6.3 Compliance Voltage 12
6.4 Cable Requirements 13
6.5 Intrinsically Safe Barriers 14
7 Startup 14
7.1 Logix 3200MD Local Interface Operation 14
7.2 Initial DIP Switch Settings 14
7.3 Operation of Confi guration
DIP Switch Settings 14
7.4 Setup of the Cal Dip-Switch for the Quick Calibration
operating mode. 16
7.5 QUICK-CAL Operation 16
7.6 Local Control of Valve Position 17
7.7 Factory Reset 17
7.8 Command Reset 17
7.9 Version number checking 17
7.10 Logix 3200MD Status Condition 17
7.11 ValveSight Confi guration and Diagnostic Software and
HART 375 Handheld Communicator 17
8 Maintenance and Repair 21
8.1 Driver Module Assembly 21
8.2 Regulator 23
8.3 Checking or Setting Internal Regulator Pressure 23
8.4 Spool Valve 24
8.5 Spool Valve Cover 24
8.6 Stem Position Sensor 25
8.7 Main PCB Assembly 26
8.8 Pressure Sensor Board 26
8.9 Customer Interface Board 27
9 Optional Hardware 28
9.1 Vented Design 28
9.2 HART Modem 28
9.3 4-20 mA Analog Output Board 29
10 Requirements for Safety Integrity 30
10.1 Fail Safe State 30
10.2 Safety Function 30
10.3 Fail Safe State Response Time 30
10.4 Diagnostic Annunciation and Response Time 30
10.5 Maximum Achievable SIL 31
10.6 Model Selection and Specifi cation of Flowserve 3200MD
Positioner 31
10.7 Installation 31
10.8 Firmware Update 31
10.9 Required Confi guration Settings 31
10.10 Reliability Data 31
10.11 Lifetime Limits 32
10.12 Proof Testing 32
Steps for Proof Test 32
10.13 Maintenance 32
10.14 Repair and Replacement 32
10.15 Training Requirements 32
11 Parts List 34
12 Logix 3200MD Spare Parts Kits 35
13 Logix 3200MD Mounting Kits 35
13.1 Valtek Mounting Kits 35
13.2 Logix O.E.M. Mounting Kits 36
13.3 NAMUR Accessory Mounting Kit
Part Numbers 36
15 How to Order 38
16 Troubleshooting 39
2
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
1 Terms Concerning Safety
The safety terms DANGER, WARNING, CAUTION and NOTE are
used in these instructions to highlight particular dangers and/
or to provide additional information on aspects that may not be
readily apparent.
DANGER: Indicates that death, severe personal injury
and/or substantial property damage will occur if proper
precautions are not taken.
WARNING: Indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
CAUTION: Indicates that minor personal injury and/or
property damage can occur if proper precautions are not
taken.
! NOTE: indicates and provides additional technical informa-
tion, which may not be very obvious even to qualifi ed personnel.
Compliance with other, not particularly emphasized notes, with
regard to transport, assembly, operation and maintenance and
with regard to technical documentation (e.g., in the operating
instruction, product documentation or on the product itself) is
essential, in order to avoid faults, which in themselves might
directly or indirectly cause severe personal injury or property
damage.
2 General Information
The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Valtek
3200MD digital positioners. Series 3000 is the term used for all
the positioners herein; however, specifi c numbers indicate features
specifi c to model (i.e., Logix 3200 indicates that the positioner has
®
HART
protocol). See Logix 3200MD Model Number table in this
manual for a breakdown of specifi c model numbers. Product users
and maintenance personnel should thoroughly review this bulletin
prior to installing, operating, or performing any maintenance on the
valve.
Separate Valtek Flow Control Products Installation, Operation,
Maintenance instructions cover the valve (such as IOM 1 or IOM 27)
and actuator (such as IOM 2 or IOM 31) portions of the system and
other accessories. Refer to the appropriate instructions when this
information is needed.
To avoid possible injury to personnel or damage to valve parts,
WARNING and CAUTION 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.
®
Logix®
WARNING: Standard industry safety practices must be
adhered to when working on this or any process control
product. Specifi cally, personal protective and lifting devices
must be used as warranted.
WARNING: Substitution of components may impair intrin-
sic safety.
3 Unpacking and Storage
3.1 Unpacking
1. While unpacking the Logix 3200MD positioner, check the
packing list against the materials received. Lists describing the
system and accessories are included in each shipping
container.
2. When lifting the 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 the center of gravity may be above
the lifting point. Therefore, support must be given to prevent the valve/actuator from rotating. Failure to do so can
cause serious injury to personnel or damage to nearby
equipment.
3. In the event of shipping damage, contact the shipper
immediately.
4. Should any problems arise, contact a Flowserve Flow Control
Division representative.
3.2 Storage
Control valve packages (a control valve and its instrumentation)
can be safely stored in an enclosed building that affords environmental protection; heating is not required. Control valve packages
must be stored on suitable skids, not directly on the fl oor. The
storage location must also be free from fl ooding, dust, dirt, etc.
3.3 Pre-installation Inspection
If a valve control package has been stored for more than one year,
inspect one actuator by disassembling it per the appropriate Installation, Operation, and Maintenance Instructions (IOM) prior to 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.
3
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
2. Inspect the solenoid and positioner soft goods and replace as
necessary.
4 Logix 3200MD
Positioner Overview
The Logix 3200MD digital positioner is a two-wire 4-20 mA input digital
valve positioner. The positioner is confi gurable through the local user
interface. The Logix 3200MD utilizes the HART protocol to allow twoway remote communications with the positioner. The Logix 3200MD
positioner can control both double- and single-acting actuators with
linear or rotary mountings. The positioner is completely powered by
the 4-20 mA input signal. Start up current must be at least 3.6 mA
without AO card or 3.85 mA with AO card.
4.1 Specifi cations
Table I: Electrical Specifi cations
Power Supply
Compliance Voltage 10.0 VDC @ 20 mA
Effective Resistance
Communications HART Protocol
Minimum Operating
Current
Maximum Voltage 30.0 VDC
Table II: ValveSight Suite Software Specifi cations
Computer
Ports 1 minimum available with 8 maximum possible. (Can
HART Modem RS-232/PCMCIA card/USB
HART Filter
HART MUX MTL 4840/ELCON 2700
Two-wire, 4-20 mA
10.0 to 30.0 VDC
495 Ω @ 20 mA Typical
Add 20 Ω when HART communication active
3.6 mA without AO board
3.85 mA with AO board
Minimum Pentium processor running Windows 95, 98,
NT, 2000, XP, 32 MB total memory (64 MB recommended), 30 MB available hard disk space, CD-ROM
drive
also communicate via PCMCIA and USB connections)
May be required in conjunction with some DCS
hardware
Table III: Environmental Conditions
Operating Temperature Range Standard
Transport and Storage
Temperature Range
Operating Humidity 0 - 100% non-condensing
! NOTE: The air supply must conform to ISA Standard ISA 7.0.01 (a dew
point at least 18 degrees Fahrenheit below ambient temperature, particle
size below fi ve microns—one micron recommended—and oil content not
to exceed one part per million).
-40° to 176°F (-40° to 80°C)
-40° to 176°F
(-40° to 80°C)
Table IV: Physical Specifi cations
Housing Material Cast, powder-painted aluminum, stainless steel
Soft Goods Buna-N / Florosilicone
Weight
8.3 pounds (3.9 kg) aluminum
20.5 pounds (9.3 kg) stainless steel
Table V: Positioner Specifi cations
Deadband <0.1% full scale
Repeatability <0.05% full scale
Linearity <0.5% (rotary), <0.8%, (sliding stem) full scale
3
Air Consumption <0.3 SCFM (0.5 Nm
Air Capacity 12 SCFM @ 60 psi (4 barg) (0.27 Cv)
/hr) @ 60 psi (4 barg)
Table VI: 4 to 20 mA Analog Output Specifi cations
Potential Range of Rotation 40° - 95°
Power Supply Range 12.5 to 40 VDC, (24 VDC typical)
Maximum Load Resistance (ohms) (Supply voltage - 12.5) / 0.02
Current Signal Output 4-20 mA
Linearity 1.0% F.S.
Repeatability 0.25% F.S.
Hysteresis ≤ .2% F.S.
Operating Temperature -40° to 176°F, -40° to 80°C
4
Table VII: Hazardous Area Certifi cations
Flame Proof
SIRA 03ATEX1387
II 2 GD
Ex d IIB+H2 T5 IP65
Ex tD A21 IP65 T95˚C (Ta =-40°C to +80°C)
T5 (Ta = -40˚C to +80C
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
North America (FM/CSA)
Explosion Proof
Class I, Div 1, Groups B,C,D
DIP Class II, III, Div 1 Groups E,F,G
Class I, Zone 1, Ex d IIB+H2 (CSA Only)
T5 Tamb = -40˚C ≤ Ta ≤ +80˚C (CSA Only)
T6 Tamb = -40˚C ≤ Ta ≤ +60˚C
Type 4X
Intrinsically Safe
SIRA 03ATEX2299X
II 1 GD
Ex ia IIC Ex iaD 20 T95˚C
T4 (Ta = -52˚C to +85˚C) (Ta = -52˚C to +80˚C)
T5 (Ta = -52˚C to +55˚C)
Entity Parameters
Ui = 30V
Ii = 100mA
Pi = 800mW
Ci = 30nF Co = 36nF
Li = 0
Non-Incendive
SIRA 08ATEX4006
II 3 GD
Ex nL nA IIC
Ex tD A22 T95˚C (Ta = -52°C to +80°C)
T4 (Ta = -52˚C to +85˚C)
T5 (Ta = -52˚C to +55˚C)
IECEx InMetro
Explosion Proof
IECEx SIR 04.0023X
Ex d IIB+H2 T5
Ta = -40˚C to +55˚C
Intrinsically Safe
IECEx FMG 05.0003X
Ex ia IIC Ex iaD 20 T95˚C
T4 Ta = -40˚C to +85˚C Ta = -40C to +80˚C
T5 Ta = -40˚C to +55˚C
Entity Parameters
Ui = 30V
Ii = 100mA
Pi = 800mW
Ci = 30nF
Li = 0
Intrinsically Safe
Class I,II, III, Div 1, Groups A,B,C,D,E,F,G
Class I, Zone 0, AExia IIC (FM Only)
T4 Tamb = -50˚C ≤ Ta ≤ +85˚C
T5 Tamb = -50˚C ≤ Ta ≤ +55˚C
Type 4X
Entity Parameters
Ui = 30V
Ii = 100mA
Pi = 800mW
Ci = 30nF
Li = 0
Non-Incendive
Class I, Div 2, Groups A,B,C,D
T4 Tamb = -50˚C ≤ Ta ≤ +85˚C
T5 Tamb = -50˚C ≤ Ta ≤ +55˚C
Type 4X
Barriers Not Required
Explosion Proof
TÜV 11.0070
Ex d IIB+H2 T5 Gb IP65
Ta = -40˚C -Ta - +80˚C
Instrinsically Safe
TÜV 11.0071X
Ex ia IIC Ga IP65 Ex ia IIIC T95˚C Da IP65
T4 Ta = -40˚C-Ta- +85˚C Ta = -40˚C-Ta- +85˚C
T5 Ta = -40˚C-Ta- +55˚C
Entity Parameters
Ui = 30Vcc
Ii = 100mA
Pi= 800mW
Ci = 30nF
Li = 0
KOSHA Gost
Explosion Proof
10-AV4BO-0560X
Ex d IIB+H2 T5
T5 Ta = -20°C to +50°C
Special Conditions for Safe Use:
• The equipment must be installed in such a manner as to minimize the risk of impact or friction with other metal surfaces.
• To avoid possibility of static discharge clean only with a damp Cloth
• In order to maintain the explosion proof certifi cations do not remove or loosen covers while circuits are live.
• For Intrinsically Safe installations the positioner must be connected to suitably rated intrinsically safe equipment, and must be installed in accordance
with intrinsically safe installation standards.
• Substitution of components may impair Intrinsic Safety.
5
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
Display
4.2 Positioner Operation
The Logix 3200MD positioner is an electric feedback instrument.
Figure 1 shows a Logix 3200MD positioner installed on a doubleacting linear actuator for air-to-open action.
The Logix 3200MD receives power from the two-wire, 4-20 mA
input signal. However, since this positioner utilizes HART communications, two sources can be used for the command signal:
Analog and Digital. In Analog source, the 4-20 mA signal is used for
the command source. In Digital source, the level of the input 4-20
mA signal is ignored and a digital signal, sent via HART, is used as
the command source. The command source can be accessed with
ValveSight software, the HART 375 communicator, or other host
software.
Whether in Analog or Digital Source, 0% is always defi ned as the
valve closed position and 100% is always defi ned as the valve
open position. In Analog Source, the 4-20 mA signal is converted
to a percentage. During loop calibration, the signals corresponding
to 0% and 100% are defi ned. The input signal in percent passes
through a characterization/limits modifi er block. The positioner no
longer uses CAMs or other mechanical means to characterize the
output of the positioner. This function is done in software, which
allows for in-the-fi eld customer adjustment. The positioner has three
basic modes: Linear, Equal Percent (=%) and Custom characteriza-
tion. In Linear mode, the input signal is passed straight through to
the control algorithm in a 1:1 transfer. In Equal Percent (=%) mode,
the input signal is mapped to a standard 30:1 rangeability =% curve.
If Custom characterization is enabled, the input signal is mapped to
either a default =% output curve or a custom, user-defi ned 21-point
output curve. The custom user-defi ned 21-point output curve is
defi ned using a handheld or ValveSight software. In addition, two
user-defi ned features, Soft Limits and MPC (Minimum Position
Cutoff), may affect the fi nal input signal. The actual command being
used to position the stem, after any characterization or user limits
have been evaluated, is called the Control Command.
The Logix 3200MD uses a two-stage, stem-positioning algorithm.
The two stages consist of an inner-loop, spool control and an outerloop, stem position control. Referring again to Figure 1, a stem
position sensor provides a measurement of the stem movement.
The Control 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 spool up or down, depending upon
the deviation. The inner-loop then quickly adjusts the spool position.
The actuator pressures change and the stem begins to move. The
stem movement reduces the deviation between Control Command
and Stem Position. This process continues until the deviation goes
to zero.
The inner-loop controls the position of the spool valve by means of
a driver module. The driver module consists of a temperature-compensated hall effect sensor and a piezo valve pressure modulator.
Figure 1: Logix 3200MD Digital Positioner Schematic (air-to-open confi guration)
HART Terminals
Command
Input Signal
Spool Valve
Output 1
Flame
Arrestor
Exhaust
Output 2
OO
Flame
Arrestor
Analog Output Signal
Pressure
Sensor Board
Air Supply
Main PCB
Digital Position Algorithm
Flame
Arrestor
Filter
LED
Stem
Position
Sensor
6
Hall Effect
Sensor
Piezo Valve
Regulator
Figure 2: System Positioning Algorithm
4-20
mA
(Analog
Mode)
Command
In
(Digital
Mode)
Input
Signal
Analog
Digital
Linear Mode
Characterization
Soft Limits
MPC
CONTROL
COMMAND
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
Air
Supply
Control
Algorithm
Pmax
Pmin
Gmult
Deviation
+
-
Integration
Summer
I
Inner
Loop
Offset
+
+
+
D/A
Output
Percentage
Inner-Loop
Output
-
+
Sensor
Inner
Loop
Spool
Control
Piezo
Valve
Voltage
Tubed
ATO
Stem
Position
Sensor
The piezo valve pressure modulator controls the air pressure under
a diaphragm by means of a piezo beam bender. The piezo beam
defl ects in response to an applied voltage from the inner-loop electronics. As the voltage to the piezo valve increases, the piezo beam
bends, closing off against a nozzle causing the pressure under
the diaphragm to increase. As the pressure under the diaphragm
increases or decreases, the spool valve moves up or down respectively. The hall effect sensor transmits the position of the spool back
to the inner-loop electronics for control purposes.
4.3 Detailed Sequence
of Positioner Operations
A more detailed example explains the control function. Assume the
unit is confi gured as follows:
• Unit is in Analog command source.
• Custom characterization is disabled (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% com-
mand.
• Actuator is tubed and positioner is confi gured air-to-open.
Given these conditions, 12 mA represents a Command source of
50 percent. Custom characterization is disabled so the Command
source is passed 1:1 to the 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 12 mA to 16 mA. The positioner sees this as a Command source of 75 percent. With Linear
characterization, the Control Command becomes 75 percent. Deviation is the difference between Control 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 up, the supply air is applied to the bottom of the actuator and air is exhausted from the top of the actuator. This new pressure differential causes the stem to start moving towards the desired
position of 75 percent. As the stem moves, the Deviation begins to
decrease. The control algorithm begins to reduce the spool opening.
This process continues until the Deviation goes to zero. At this point,
the spool will be back in its null or balanced position. Stem movement will stop and the desired stem position is now achieved.
One important parameter has not been discussed to this point: Inner
loop offset. Referring to Figure 2, a number called Inner loop offset
is added to the output of the control algorithm. In order for the spool
to remain in its null or balanced position, the control algorithm must
output a non-zero spool command. This is the purpose of the Inner
loop offset. The value of this number is equivalent to the signal that
must be sent to the spool position control to bring it to a null position with zero deviation. This parameter is important for proper control and is optimized and set automatically during stroke calibration.
7
Figure 3: Linear Mark One Control Valve Mounting
Stem Clamp
Logix 3200IQ
Positioner
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
Bracket
Bolts
Locknut
Washer
Nut
Lock Washer
Take-off Arm
Nut
5 Mounting and Installation
5.1 Mounting to Valtek Linear
Mark One Valves
To mount a Logix 3200MD positioner to a Valtek linear Mark One
valve, refer to Figure 3 and proceed as outlined below. The following
tools are required:
9
•
⁄16" open-end wrench (or ½ " for spud sizes 2.88 and smaller)
7
•
⁄16" box wrench
3
•
⁄8" open-end wrench
1. Remove washer and nut from follower pin assembly. Insert pin
into the appropriate hole in follower arm, based on stroke length.
The stroke lengths are stamped next to their corresponding
holes in the follower arms. Make sure the unthreaded end of the
pin is on the stamped side of the arm. Reinstall lock washer and
tighten nut to complete follower arm assembly.
2. Slide the double-D slot in the follower arm assembly over the
fl ats on the position feedback shaft in the back of the positioner.
Make sure the arm is pointing toward the customer interface
side of the positioner. Slide lock washer over the threads on the
8
shaft and tighten down the nut.
Follower Pin
Bolts
Bracket
Positioner
Bolts
Nut
Metal Washers
3. Align the bracket with the three outer mounting holes on the
positioner. Fasten with ¼ " 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 fl ush 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 to the take-off arm bolting and
insert through washers into stem clamp. Leave bolts loose.
8. Slide the appropriate pin slot of the take-off arm, based on
stroke length, over the follower arm pin. The appropriate stroke
lengths are stamped by each pin slot.
9. Center the take-off arm on the rolling sleeve of the follower pin.
10. Align the take-off arm with the top plane of the stem clamp and
tighten bolting. Torque to 120 in-lb.
! NOTE: If mounted properly, the follower arm should be
hole pattern as indicated on
horizontal when the valve is at 50% stroke and should move
approximately ±30° from horizontal over the full stroke of the
valve. If mounted incorrectly, a stroke calibration error will
occur and the indicator lights will blink a RGGY code indicating
the position sensor has gone out of range on one end of travel.
Reposition the feedback linkage or rotate the position sensor to
correct the error.
5.2 Mounting to Standard
Valtek Rotary Valves
(See Figure 4)
The standard rotary mounting applies to Valtek valve/actuator assemblies that do not have mounted volume tanks or handwheels.
The standard mounting uses a linkage directly coupled to the valve
shaft. This linkage has been designed to allow for minimal misalignment between the positioner and the actuator. The tools required for
the following procedure are:
5
•
⁄32" Allen wrench
• ½ " open-end wrench
7
•
⁄16" open-end wrench
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
3
⁄8" socket with extension
•
3
•
⁄16" nutdriver
1. Fasten the spline lever adapter to the splined lever using two 6 x
½ " self-tapping screws.
2. Slide the take-off arm assembly onto the spline lever adapter
shaft. Insert the screw with star washer through the take-off
arm and add the second star washer and nut. Tighten nut with
socket so arm is lightly snug on the shaft but still able to rotate.
This will be tightened after linkage is correctly oriented.
3. Attach follower arm to positioner feedback shaft using the star
washer and 10-32 nut.
! NOTE: The arm will point up when feedback shaft is in the free
position.
4. Using four ¼ -20 x ½ " bolts, fasten positioner to universal
bracket using appropriate hole pattern (stamped on bracket).
5. Using a ½ " end wrench and two
to actuator transfer case pad. Leave these bolts slightly loose
until fi nal adjustments are made.
6. Rotate take-off arm so the follower pin will slide into the slot on
the take-off arm. Adjust the bracket position as needed noting
the engagement of the follower pin and the take-off arm slot.
5
⁄16-18 x ½ " bolts, attach bracket
Figure 4: Standard Rotary Mounting
Logix 3200MD
Digital Positioner
Positioner Bolts ¼-20 (4)*
5
-18 (2, not shown)
/
Bracket Bolts
16
Take-off Arm, Rotary
Lock Washer (2)
10-32 Bolt
10-32 Nut
Self-tapping Screws (2)
Spline Lever Adapter
10-32 Nut
Lock Washer
Follower Arm
* Located in appropriate
bracket. (25, 50, 100/200)
9
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
The pin should extend approximately 1⁄16" past the take-off arm.
When properly adjusted, securely tighten the bracketing bolts.
Orienting the Take-off Arm for Final Lock Down
1. Tube the Logix 3200MD positioner to the actuator according
to the instructions given in Section 5.5, “Tubing Positioner to
Actuator.”
2. With supply pressure off, rotate the follower arm in the same
direction the shaft would rotate upon a loss of supply pressure.
When 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 QUICK-CAL
button.
6. Refer to sticker on main board cover and set DIP switches
accordingly. (A more detailed explanation of the DIP switch
settings is given in Section 7, “Startup.”)
7. Press the QUICK-CAL button for three to four seconds or
until the positioner begins to move. The positioner will now
perform a stroke calibration.
8. If the calibration was successful the green LED will blink GGGG
or GGGY and the valve will be in control mode. Continue with
step 9. If calibration failed, as indicated by a RGGY blink code,
the A/D feedback values were exceeded and the arm must be
adjusted away from the positioners limits. Return to step 2 and
rotate the arm back approximately 10 degrees.
! NOTE: Remember to remove the air supply before re-adjusting
take-off arm.
9. Tighten the nut on the take-off arm. The socket head screw of
the take-off arm must be tight, about 40 in-lb.
! NOTE: If the take-off arm slips, the positioner must be
recalibrated.
WARNING: Failure to follow this procedure will result in
positioner and/or linkage damage. Check air-action and
stroke carefully before lockdown of take-off arm to spline
lever adapter.
5.3 Optional Valtek Rotary
Mounting Procedure
(See Figure 5)
The optional rotary mounting applies to Valtek valve/actuator assem-
blies that are equipped with mounted volume tanks or handwheels.
The optional mounting uses a four-bar linkage coupled to the valve
shaft. The following tools are required:
3
•
⁄8" open-end wrench
7
•
⁄16" open-end wrench
• ½ " open-end wrench
Figure 5: Optional Rotary Mounting
* Tie Rod must be cut to desired length.
Locknuts (2)
Tripper Clamp
Tripper
Bolts (2)
Tie Rod*
10-32 Nut
Lock Washer
Valtek
5
Bracket Bolts
Ball Joint Ends
Follower Arm
Rotate Positioner 90°
Mounting Bolts ¼-20 (4)
/16-18 (2)
10
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
1. Using a ½ " open-end wrench and two 5⁄16-18 x ½ " bolts, attach
bracket to actuator transfer case pads. Leave bracket loose to
allow for adjustment.
2. Using four ¼ -20 x ½ " bolts and a
positioner to universal bracket, using the four-hole pattern that
locates the positioner the farthest from the valve. Rotate positioner 90 degrees from normal so gauges are facing upward.
3. Attach follower arm to positioner feedback shaft, using the star
washer and 10-32 nut.
4. Attach tripper and tripper clamp to valve shaft using two ¼ -20
bolts and two ¼ -20 locknuts. Leave tripper loose on shaft until
fi nal adjustment.
5. Thread ball joint linkage end to tripper and tighten (thread
locking compound such as Loctite is recommended to prevent
back threading). Adjust the length of tie rod so follower arm and
tripper rotate parallel to each other (the rod must be cut to the
desired length). Connect the other ball joint end to follower arm
using a star washer and a 10-32 nut.
6. Tighten bracket and tripper bolting.
7. Check for proper operation, note direction of rotation.
WARNING: If rotating in wrong direction, serious dam-
age will occur to the positioner and/or linkage. Check
air action and stroke direction carefully before initiating
operation.
7
⁄16" open-end wrench, fasten
5.4 NAMUR Rotary Mounting
The Logix 3200MD includes an option for NAMUR Rotary mounting.
The NAMUR shaft option provides mounting to standard brackets
for valve automation. The NAMUR option is not recommended for
high performance valves since the normal alignment tolerances can
cause a degradation in valve performance. Care must be taken when
mounting the positioner using a NAMUR confi guration to prevent
damage to the shaft. Mount the positioner and rotate into position
using the following table:
Logix 3200 Positioner NAMUR Mounting
Actuator Rotation from
FAIL POSITION (as viewed from
positoner mounting end)
Counter Clockwise
Clockwise
NAMUR Positioner shaft
preloading instructions
Insert positioner shaft into
feedback slot with valve in the
FAIL POSITION and rotate 105°
and bolt into place.
Insert positioner shaft into
feedback slot with valve in FAIL
Position and rotate positioner
CCW 15° and bolt in place
5.5 Tubing Positioner to Actuator
The Logix 3200MD 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 3200MD but is not required. In
applications where the supply pressure is higher than the maximum
actuator pressure rating a supply regulator is required to lower the
pressure to the actuator’s maximum rating (not to be confused with
operating range). An air fi lter is highly recommended for all applications where dirty air is a possibility.
! NOTE: The air supply must conform to ISA Standard ISA 7.0.01
(a dew point at least 18°F below ambient temperature, particle
size below fi ve microns—one micron recommended—and oil
content not to exceed one part per million).
Air-to-open and air-to-close are determined by the actuator tubing,
not the software. When air action selection is made during confi guration, that selection tells the control which way the actuator
has been tubed. The top output port is called Output 1. It should be
tubed to the side of the actuator that must receive air to begin the
correct action on increasing signal. Verify that tubing is correct prior
to a stroke calibration. Proper tubing orientation is critical for the
positioner to function correctly and have the proper failure mode.
Refer to Figure 5 and follow the instructions below:
Linear Double-acting Actuators
For a linear air-to-open actuator, the Output 1 port of the
positioner manifold is tubed to the bottom side of the actuator.
The Output 2 port of the positioner manifold is tubed to the top
side of the actuator. For a linear air-to-close actuator the above
confi guration is reversed.
Rotary Double-acting Actuators
For a rotary actuator, the Output 1 port of the positioner manifold
is tubed to the bottom side of the actuator. The Output 2 port of
the positioner manifold is tubed to the top side of the actuator.
This tubing convention is followed regardless of air action. On
rotary actuators, the transfer case orientation determines the air
action.
Single-acting Actuators
For single-acting actuators, the Output 1 port is always tubed to the
pneumatic side of the actuator regardless of air action. The Output 2
port must be plugged.
11
6 Wiring and Grounding
Guidelines
(See Figure 6)
WARNING: This product has electrical conduit connec-
tions in either thread sizes ½ " NPT or M20 which appear
identical but are not interchangeable. Housings with
M20 threads are stamped with the letters M20 above
the conduit opening. Forcing dissimilar threads together
will damage equipment, cause personal injury and void
hazardous location certifi cations. Conduit fi ttings must
match equipment housing threads before installation. If
threads do not match, obtain suitable adapters or contact
a Flowserve representative.
6.1 4-20 mA Command Input Wiring
Verify polarity when making fi eld termination connection. The Logix
3200 is reverse polarity protected. Wire 4-20 mA current source to
the input terminal labeled 4-20 mA Input on the user interface board
(See Figure 6). Never connect a voltage source directly across the
Logix 3200MD terminals. The current must always be limited for
4-20 mA operation. Minimum operating current is 3.6 mA.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13
Output compliance voltage refers to the voltage limit that can be
provided by the current source. A current loop system consists of
the current source, wiring resistance, barrier resistance (if present),
and the Logix 3200MD positioner impedance. The Logix 3200MD
digital positioner requires that the current loop system allows for
a 10.0 VDC drop across the positioner at maximum loop current.
The 10.0 VDC drop across the Logix 3200MD positioner terminals
is generated by the positioner from the 4-20 mA loop current input.
The actual voltage at the terminals varies from 9.8 to 10.0 VDC
depending on the current mA signal, HART communications, and
ambient temperature.
Figure 6: Field Termination
ANALOG
HART
4-20 mA INPUT
OUTPUT
HART Terminals
4-20 mA Feedback
Terminals (Optional)
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.
! NOTE: The Logix 3200MD positioner carries an intrinsically safe
barrier rating of 100 mA. Input currents should not exceed 100
mA.
6.2 Grounding Screw
The green grounding screw, located inside the termination cap,
should be used to provide the unit with an adequate and reliable
earth ground reference. This ground should be tied to the same
ground as the electrical conduit. Additionally, the electrical conduit
should be earth grounded at both ends of its run.
WARNING: The green grounding screw must not be used
to terminate signal shield wires.
6.3 Compliance Voltage
(See Figure 7)
Field
Terminators
Housing EARTH
Terminal
Connect Shield at Source
Ground 4-20 mA Current Source
Shielded Cable
4-20 mA Current Source
12
Loading...