Flowserve 500+ User Manual

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Logix ® 500+ Series

FCD LGENIM0105-10 11/13

Installation

Safety Manual

USER INSTRUCTIONS

Digital Positioner

Operation

Maintenance

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Quick Start

Instructions

Page 26

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

CONTENTS

1.1 USING THIS DOCUMENT ............................................................4

1.2 TERMS CONCERNING SAFETY ......................................................4

1.3 PROTECTIVE CLOTHING .............................................................4

1.4 QUALIFIED PERSONNEL .............................................................4

1.5 VALVE AND ACTUATOR VARIATIONS .............................................4

1.6 SPARE PARTS .........................................................................4

1.7 SERVICE / REPAIR ....................................................................4

1.8 BASIC OPERATION ...................................................................5

1.9 HART ..................................................................................5

1.10 POSITION DEFINITION ...............................................................5

1.11 COMMAND INPUT AND FINAL COMMAND ......................................5

1.12 OUTER LOOP ..........................................................................5

1.13 INNER LOOP ...........................................................................6

1.14 DETAILED SEQUENCE OF POSITIONER OP ERATIONS ...........................6

1.15 INNER LOOP OFFSET.................................................................6

2 SPECIFICATIONS ............................................... 8

2.1 INPUT SIGNAL ........................................................................8

2.2 AIR SUPPLY ...........................................................................8

2.3 PNEUMATIC OUTPUT................................................................8

2.4 STROKE OUTPUT .....................................................................8

2.5 ANALOG OUTPUT – MULTI-FUNCTION CARD ..................................8

2.6 REMOTE MOUNT SPECIFICAT IONS................................................8

2.7 LIMIT SWITCH SPECIFICAT IONS ....................................................9

2.8 POSITIONER PERFORMANCE CHARACTERISTICS ................................9

2.9 PHYSICAL SPECIFICATIONS ..........................................................9

2.10 TEMPERATURE ........................................................................9

2.11 VALVESIGHT DTM SOFTWARE SPECIFICATIONS ...............................9

10 POSITIONER FUNCTIONS (LCD DISPLAY) .... 31

10.1 MAIN DISPLAY VIEW .............................................................. 31

10.2 MENU OVERVIEW ................................................................. 33

10.3 MENU FEATURES .................................................................. 34

11 HART COMMUNICATION ................................. 39

11.1 VALVESIGHT DTM ................................................................ 39

11.2 HART 375/475 HANDHELD COMMUNICATOR ............................ 39

11.3 CHANGING HART VERSIONS .................................................... 39

11.4 BURST MODE ....................................................................... 39

12 MODEL FEATURES .......................................... 40

12.1 LOGIX 505+ ........................................................................ 40

12.2 LOGIX 510+ ........................................................................ 40

12.3 LOGIX 520MD+ ................................................................... 40

12.4 MD+ POSITIONER DIAGNOSTIC LEVELS ....................................... 40

12.5 VALVESIGHT DTM DIAGNOSTIC LEVELS ....................................... 40

13 MULTI-FUNCTION CARD ................................. 41

13.1 ANALOG OUTPUT (AO) .......................................................... 41

13.2 DISCRETE OUTPUT (DO) ......................................................... 41

13.3 DISCRETE INPUT (DI) ............................................................. 41

14 LIMIT SWITCHES .............................................. 42

14.1 LIMIT SWITCH PRINCIPLES OF OPERATION .................................... 42

14.2 LIMIT SWITCH TYPES .............................................................. 42

15 REMOTE MOUNT .............................................. 42

15.1 REMOTE MOUNT OPEREATION ................................................. 42

3 HAZARDOUS AREA CERTIFICATIONS.......... 10

4 STORAGE AND UNPACKING .......................... 11

4.1 STORAGE ............................................................................ 11

4.2 UNPACKING ......................................................................... 11

4.3 PRE-INSTALLATION INSPECTION ................................................. 11

5 MOUNTING AND INSTALLATION ................... 12

5.1 MOUNTING TO MARK ONE LINEAR VALVES ................................. 12

5.2 MOUNTING TO FLOWTOP LINEAR VALVES ................................... 13

5.3 MOUNTING TO STANDARD VALTEK ROTARY VALVES ....................... 15

5.4 MOUNTING TO MAXFLO ROTARY VALVES ................................... 17

5.5 MOUNTING TO ROTARY NAMUR (AUTOMAX) VALVES ................. 18

5.6 MOUNTING TO A LINEAR NAMUR PNEUMATIC ACTUATOR ............. 19

6 TUBING ............................................................. 20

6.1 DETERMINE AIR ACTION ......................................................... 20

6.2 CONNECT SUPPLY PORT .......................................................... 20

6.3 PURGING SINGLE ACTING ACTUATORS ........................................ 20

6.4 VENTED DESIGN .................................................................... 21

7 ELECTRICAL CONNECTIONS ......................... 22

7.1 ELECTRICAL TERMINALS ........................................................... 22

7.2 COMMAND INPUT (4-20 MA) CONNECTION ................................ 22

7.3 MULTI-FUNCTION CARD (AO, DO, DI) ...................................... 24

7.4 LIMIT SWITCHES .................................................................... 25

7.5 REMOTE MOUNT .................................................................. 25

7.6 CONNECTIONS FOR INTRINSICALLY SAFE OPERATION ....................... 25

8 STARTUP .......................................................... 26

8.1 QUICK START INSTRUCTIONS .................................................... 26

8.2 LOCAL USER INTERFACE OVERVIEW ............................................ 26

8.3 CONFIGURATIO N SWITCH SETTINGS (505+) ................................. 27

8.4 CONFIGURATIO N SWITCH SETTINGS (510+ AND 520MD+) ............. 27

8.5 STROKE CALIBRATION ............................................................. 28

8.6 ANALOG OUTPUT (AO) CALIBRATION ........................................ 29

9 POSITIONER FUNCTIONS (NO DISPLAY

REQUIRED) ....................................................... 30

9.1 LIVE MANUAL TUNING (ADJUSTING THE GAIN) ............................. 30

9.2 LOCAL CONTROL OF VALVE PO SITION ......................................... 30

9.3 COMMAND SOURCE RESET ...................................................... 30

9.4 FACTORY RESET .................................................................... 30

9.5 VIEWING VERSION NUMBERS ................................................... 30

16 REQUIREMENTS FOR SAFETY INTEGRITY .. 43

16.1 FAIL SAFE STATE ................................................................... 43

16.2 SAFETY FUNCTION ................................................................. 43

16.3 FAIL SAFE STATE RESPONSE TIME .............................................. 43

16.4 POSITIONER MOD EL SELECTION AND SPECIFICATION ....................... 43

16.5 INSTALLATION ...................................................................... 43

16.6 REQUIRED CONFIGURATION SETTINGS......................................... 43

16.7 MAXIMUM ACHIEVABLE SIL..................................................... 43

16.8 RELIABILITY DATA .................................................................. 43

16.9 LIFETIME LIMITS .................................................................... 43

16.10 PROOF TESTING .................................................................... 43

16.11 MAINTENANCE ..................................................................... 44

16.12 REPAIR AND REPLACEMENT ...................................................... 44

16.13 TRAINING REQUIREMENTS ....................................................... 44

17 MAINTENANCE AND REPAIR ......................... 45

17.1 SCHEDULED MAINTENANCE ...................................................... 45

17.2 REQUIRED TOOLS AND EQUIPMENT ............................................ 45

17.3 TORQUE SPECIFICATION FOR SCREWS.......................................... 45

17.4 INSTALLING A LIMIT SWITCH ..................................................... 45

17.5 REPLACING THE LCD BOARD .................................................... 46

17.6 REPLACING AN AUXILIARY CARD ................................................ 46

17.7 REPLACING A MAIN BOARD ..................................................... 47

17.8 REPLACING THE PRESSURE SENSOR BOARD................................... 47

17.9 CLEANING AND REPLACING A DOUBLE ACTING PILOT RELAY ............. 48

17.10 REPLACING A SINGLE ACTING PILOT RELAY ................................... 49

18 TROUBLESHOOTING ....................................... 50

18.1 TROUBLESHOOTING GUIDE ...................................................... 50

18.2 STATUS CODE INDEX .............................................................. 51

18.3 STATUS CODE DESCRIPTIONS .................................................... 52

18.4 HELP FROM FLOWSERVE ......................................................... 59

19 POSITIONER DIMENSIONS.............................. 60

19.1 POSITIONER DIMENSIONS ........................................................ 60

20 HOW TO ORDER ............................................... 61

20.1 POSITIONERS ........................................................................ 61

20.2 SPARE PARTS KITS ................................................................. 62

20.3 GAGE BLOCK ........................................................................ 62

20.4 VDI/VDE 3847 MOUNTING BLOCK S ........................................ 62

20.5 MOUNTING KITS ................................................................... 62

INDEX ........................................................................... 62

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

GENERAL INFORMATION

1.1 Using This Document

Product users and maintenance personnel should thoroughly review this manual prior to installing, operating, or performing any maintenance on the positioner.

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Logix® 500MD+ positioners. Series 500 is the term used for all the positioners herein; however, specific numbers indicate features specific to model (i.e., Logix 520 indicates that the positioner has HART® protocol). See Logix 500MD+ Model Number table in this manual for a breakdown of specific model numbers.

Separate Flow Control Products User Instruc tions cover the valve, actuator, or portions of the system and other accessories. Refer to the appropriate instructions when this information is needed. In most cases FLOW SERVE valves, actuators and accessories are designed for specific applications with regard to medium, pressure and temperature. For this reason they should not be used in other applications without first contacting the manufacturer.

To avoid possible injury to personnel or damage to positioner parts, DANGER and CAUTION notes must be strictly followed.

1.2 Terms Concerning Safety

The safety terms DANGER, 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.

 NOTE: Indicates and provides additional technical

information, which may not be very obvious even to qualified personnel.

CAUTION: Indicates that minor personal injury and/or

property damage can occur if proper precautions are not taken.

 DANGER: Indicates that death, severe personal injury

and/or substantial property damage can occur if proper precautions are not taken.

Compliance with other, not particularly emphasized notes, with regard to assembly, operation and maintenance and 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.

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.

 DANGER: Standard industry safety practices must be

adhered to when working on this or any process control product. Specifically, personal protective equipment must be used as warranted.

1.4 Qualified Personnel

Qualified personnel are people who, on account of their training, experience, instruction and their knowledge of relevant standards, specifications, accident prevention regulations and operating conditions, have been authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers.

In unpacking, installing and performing maintenance as required on FLOWSERVE products, product users and maintenance personnel should thoroughly review this manual prior to installing, operating or performing any maintenance.

1.5 Valve and Actuator Variations

These instructions cannot claim to cover all details of all possible product variations, nor can they provide information for every possible example of installation, operation or maintenance. This means that the instructions normally include only the directions to be followed by qualified personal where the product is being used for its defined purpose. If there are any uncertainties in this respect particularly in the event of missing product-related information, clarification must be obtained via the appropriate Flowserve sales office.

1.6 Spare Parts

Use only FLOWSERVE original spare parts. FLOW SERVE cannot accept responsibility for any damages that occur from using spare parts or fastening materials from other manufactures. If FLOW SERVE products (especially sealing materials) have been in storage for longer periods check these for corrosion or deterioration before using these products. See section 4 STORAGE AND UN PACK ING more information.

1.7 Service / Repair

To avoid possible injury to personnel or damage to products, safety terms must be strictly adhered to. Modifying this product, substituting non-fac tory parts, or using maintenance procedures other than outlined in this instruction could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties.

Between actuator and valve there are moving parts. To avoid injury FLOWSERVE provides pinch-point-protection in the form of cover plates, especially where side-mounted positioners are fitted. If these plates are removed for inspection, service or repair special attention is required. After completing work the cover plates must be refitted.

Logix 500+ positioner repair is limited to the replacement of sub-assemblies and circuit boards with FLOWSERVEmanufactured replacements as outlined in this manual.

 DANGER: Substitution of with non-factory positioner

components may impair intrinsic safety.

CAUTION: 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 has not been provided (a form can be obtained from FLOWSERVE).

Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use, all recognized regulations for safety and good engineering practices must be followed.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Piezo

Hall

Sensor

Air Supply

Poppet

Valve

Single Acting

Pilot Relay

Piezo

Voltage

Piezo Kill

Inner

Control

Position

Feedback

Control

Valve

Actuator

Final

Command

Signal

Characterization,

Tight Shutoff

Digital

Input

Analog

Output

P I D

Inner-Loop

Output

Inner-Loop

Offset

Vent

PRINCIPLES OF OPERATION

1.8 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 completely powered by the 4-20 mA input signal. Start-up current must be at least 3.8 mA. The positioner is configurable through the local user interface, hand-held or DTM. The Logix 500+ positioner can control both doubleand single-acting pneumatic actuators with linear or rotary mountings.

The Logix 500+ digital positioner is an electronic and pneumatic closed-loop feedback instrument. Figure 1 s hows a schematic of a Logix 500+ positioner installed on a singleacting linear actuator for air-to-open action. Figure 2 shows the feedback algorithm.

1.9 HART

The Logix 500+ 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 (used only for power) and a digital signal, sent via the HART communication protocol, is used as the command source. The command source can be accessed with ValveSight software, the HART 375 communicator, or other host software. See section 11 HART COMMUNICATION for more information.

1.10 Position Definition

Whether in Analog or Digital Source, The position at 0% is always defined as the valve in a closed position and 100% is always defined as the valve in an open position. In Analog Source, the 4-20 mA signal is converted to a position (in percent). During loop calibration, the signals corresponding to 0% and 100% are defined.

1.11 Command Input and Final Command

The Command Input signal (in percent) 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 through to the control algorithm in a 1:1 transfer. In Equal Percent (=%) mode, the input signal is mapped to a standard rangeability equal percent curve. If Custom Characterization is enabled, the input signal is mapped to a custom, user-defined 21-point output curve. The custom user-defined 21-point output curve is defined using a handheld or ValveSight software. In addition, two user-defined features, Soft Limits and Tight Shutoff may affect the position. The actual command being used to position the stem after the evaluation of characterization curves and user limits, is called the Final Command.

1.12 Outer Loop

The Logix 500+ uses a two-stage, stem-positioning algorithm. The two stages consist of an inner-loop (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 the spool position. The actuator pressures change and the stem begins to move. The stem movement reduces the deviation between Final Command and Stem Position. This process continues until the deviation goes to zero.

Command

Input

Soft Limits,

Comman

d Input

(4-20 mA)

Circuit

Command

Percentage

Loop

Spool

Valve

Figure 1: Principles of Operation of Logix 500+

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Piezo Valve

Hall

Sensor

Air

Supply

Spool Valve

Double Acting

Pilot Relay

Control

Valve

Actuator

Figure 2: Double Acting Relay Operation

1.13 Inner Loop

The inner-loop controls the position of the relay valve by means of a driver module. The driver module consists of a temperature-compensated hall-effect sensor and a Piezo valve pressure modulator. The Piezo valve pressure modulator controls the air pressure under a diaphragm by means of a Piezo beam bender. The Piezo beam deflects in response to an applied voltage from the inner-loop electronics. As the voltage to the Piezo valve inc reases, 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 or poppet valve moves up or down respectively. The Hall Effect sensor transmits the position of the spool or poppet back to the inner-loop electronics for control purposes.

1.14 Detailed Sequence of Positioner Operations

A more detailed example explains the control function. Assume the unit is configured 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%

command.

• Actuator is tubed and positioner is configured 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 Final 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 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. W ith this positive deviation, the control algorithm sends a signal to move the spool up from its present position. As the spool moves, 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 wil l be back in its null or balanced position. Stem movement will stop and the desired stem position is now achieved.

1.15 Inner Loop Offset

The position of the spool (or poppet) at which the pressures are balanced, holding the valve position in a s teady state, is called the Inner Loop Offset. The controlling algorithm uses this value as a reference in determining the Piezo voltage. This parameter is important for proper control and is optimized and set automatically during stro ke calibration.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

(Double Acting Relay - Air To Open)

Logix 500+ Digital Positioner Schematic

1 - Piezo Assembly

1 2 3

4 5 6

10 9 7

15- Supply In 10- Hall Sens or Assembly

21- Actuator Housing

26- Take-Off Arm

2 - Block 3 - Spool 4 - Regulator Assembly 5 - Piezo Cable 6 - Hall Sensor Cable 7 - Auxiliary Card 8 - Main Board 9 - 4-20 mA Input

11- Exhaust 12- Port B 13- Supply Pressure 14- Pressure Sensor Board

Figure 3:

16- Pressure Sensor Cable 17- Feedback Cable 18- Exhaust 19- Port A 20- Feedback Potentiometer

22- Spring 23- Piston 24- Stem 25- Yoke

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table 1: Input Signal

Positioner Alone

Communications

HART protocol

Table 2: Air Supply

Table 3: Pneumatic Output

is exhausted upon loss

Table 4: Stroke Output

Table

For entity parameters, see section 3 HAZARDOUS AREA CERTIFICATIONS.

Table

For entity parameters, see section 3 HAZARDOUS AREA CERTIFICATIONS.

Use only with Logix® Remote Mount Option device.

2 SPECIFICATIONS

2.1 Input Signal

or with

Multi-Function Card

Power Supply Two-wire, 4-20 mA

10.0 VDC plus line losses.

Input Signal Range

Compliance Voltage

Effective Resistance

Minimum Required Operating Current

Maximum Shutdown Current

2.2 Air Supply

Minimum Input Pressure

Maximum Input Pressure

Air Supply Quality The air supply must be free from moisture,

Operating Humidity 0 - 100% non-condensing Acceptable Supply

Gasses

Air Consumption Single Acting Relay –

1.5 Bar (22 PSI)

Single Acting Relay – 6.2 Bar (90 PSI) Double Acting Relay – 10.3 Bar (150 PSI)

oil and dust by conforming to the ISA

7.0.01 standard. (A dew point at least 18 degrees Fahrenheit below ambient temperature, particle size below five microns—one micron recommended—and oil content not to exceed one part per million).

Air, sweet natural gas, nitrogen and CO2 are acceptable supply gasses.

Sour natural gas is not acceptable.

0.069 Nm³/h @ 1.5 bar (0.041 SCFM @ 22 PSI)

0.082 Nm³/h @ 4.1 bar (0.050 SCFM @ 60 PSI)

Double Acting Relay –

0.297 Nm³/h @ 1.5 bar (0.175 SCFM @ 22 PSI)

0.637 Nm³/h @ 4.1 bar (0.375 SCFM @ 60 PSI)

4 - 20 mA (HART)

10.0 VDC @ 20 mA

500 Ω @ 20 mA Typical

3.8 mA

3.6 mA

2.3 Pneumatic Output

Output Pressure Range

Output Air Capacity Single Acting Relay –

Primary Output Ports (Port is pressurized in energized state. Port

of power.)

0 to 100% of air supply pressure.

9.06 Nm³/h @ 1.5 bar (5.33 SCFM @ 22 PSI)

20.8 Nm³/h @ 4.1 bar (12.2 SCFM @ 60 PSI)

Double Acting Relay –

14.3 Nm³/h @ 1.5 bar (8.44 SCFM @ 22 PSI)

30.6 Nm³/h @ 4.1 bar (18.0 SCFM @ 60 PSI)

Single Acting Relay – Port B Double Acting Relay – Port A

2.4 Stroke Output

Feedback shaft Rotation

Min 15°, Max 90° 45° recommended for linear applications.

2.5 Analog Output – Multi-Function Card

5: 4 to 20 mA Analog Output Specification

Power Supply Range 10.0 to 40 VDC, (24 VDC Typical) Current Signal Output 4 to 20 mA Linearity 1.0% F.S. Repeatability 0.25% F.S. Hysteresis 1.0% F.S. Operating Temperature -52 to 85°C (-61.6 to 185°F)

2.6 Remote Mount Specifications

6: Remote Mount Specifications

Remote Mount Device Max Cable and Tube Distance 30.5 m (100 ft)

Operating Temperature -52 to 85°C (-61.6 to 121°F)

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

For entity parameters, see section 3 HAZARDOUS AREA CERTIFICATIONS.

(-13 °F to 212 °F)

(-40 °F to 212 °F)

Table 8: Performance Characteristics

Better than or equal to the following values on a 25 square inch Mark I actuator.

1.0%

Table

EN AC-AlSi12(Fe)

1.88 kg (4.14 lb)

Table 10: Temperature

Table 11: ValveSight DTM Software Specifications

2.7 Limit Switch Specifications

Table 7: Limit Switch Specifications

Switch Specifications

Mechanical Cherry DG 13-B(X)RA NO and/or NC

General Purpose Only Reed

Hamlin 59050-030 NO

Inductive Sensor P&F NJ2-V3-N NAMUR NC -3

Inductive Proximity P&F SJ2-S1N NAMUR NO-4

Inductive Proximity P&F SJ2-SN NAMUR NC-5

Load Current: 3/2 AAC/ADC Voltage: 125/30 VAC/VDC Temperature: -25 to + 85 °C

(-13 °F to 185 °F)

Load Current: 500 mA Voltage: 200VDC Temperature: -40 to + 105 °C

(-40 °F to 221 °F)

Load Current: Plate: ≤ 1 mA;

No Plate: ≥ 3 mA

Voltage: Nominal 8.2 VDC Temperature: -25 °C t o 100 °C

Load Current: Plate: ≤ 1 mA;

No Plate: ≥ 3 mA

Voltage: 5-25 V DC

(Nominal 8 VDC)

Temperature: -25 °C t o 100 °C

(-13 °F to 212 °F)

Load Current: Plate: ≤ 1 mA;

No Plate: ≥ 3 mA

Voltage: 5-25 V DC

(Nominal 8 VDC)

Temperature: -40 °C t o 100 °C

2.9 Physical Specifications

9: Physical Specifications

For dimensions, see section 19 POSITIONER .

Housing Material Cast, powder-painted aluminum

Soft Goods Fluorosilicone Weight of Base

Positioner Without Accessories

With Single Acting Relay

1.76 kg (3,88 lb)

With Double Acting Relay

2.10 Temperature

Operating Temperature Range

Transport and Storage Range

-52 to 85°C (-61.6 to 185°F)

 NOTE: Reduced performance possible at low

temperatures.

2.11 ValveSight DTM Software Specifications

Inductive Sensor P&F NBB2-V3-E2 PNP NO

General Purpose Only

Load Current: 0…100 mA Voltage: 10...30 VDC Temperature: -25 °C t o 70 °C

(-13 °F to 158 °F)

2.8 Positioner Performance Characteristics

Resolution Linearity +/-1.25% Repeatability Hysteresis Deadband Sensitivity Stability Long term drift Supply Pressure Effect

≤ 0.25%

≤

≤ 0.3%

≤ 0.25%

≤ 0.4% ≤ 0.5% ≤ 0.2%

 NOTE: Performance tested according to ISA 75.13.

Computer Minimum Pentium processor running

Ports 1 minimum avail abl e with 8 maximum

HART Modem RS-232,

HART Filter May be required in conjunction with some

HART MUX MTL 4840/ELCON 2700

Windows 95, 98, NT, 2000, XP, 7, 32 MB total memory (64 MB recommended), 30 MB available hard disk space, CD-ROM drive

possible. (Can also communicate via serial, PCMCIA and USB connections)

PCMCIA card, or USB

DCS hardware.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table 12: Logix 500+ Series Hazardous Locations Information

-02

Barriers Not Required when installed per the NEC/CEC

-02

3 HAZARDOUS AREA CERTIFICATIONS

 DANGER: Certifications listed on the positioner are correct for that positioner. Before us ing the information on this page,

ensure the certifications on the positioner label match the certifications on this page.

ATEX

Intrinsically Safe

FM12ATEX0009X II 1 G Ex ia IIC Ga T4/T6 T4 Tamb = -20˚C ≤ Ta ≤ +85˚C T6 Tamb = -52˚C ≤ Ta ≤ +45˚C IP 66

Entity

Parameters

Ui (Vdc)= 30 30 10.6 Vo = 5V

Ii (mA)= 100 100 29.7 Io = 79mA

Pi (mW)= 800 800 79 Po = 129mW

Ci (nF)= 0 0 1 Co = 2uF Li (µH)= 47 0 1 Lo = 100uH

4-20

Input

MFC

Limit

Switches

Remote

Mount

IECEx

Intrinsically Safe

FMG 12.0001X Ex ia IIC Ga T4/T6 T4 Tamb = -20˚C ≤ Ta ≤ +85˚C T6 Tamb = -52˚C ≤ Ta ≤ +45˚C IP 66

Entity

Parameters

Ui (Vdc)= 30 30 10.6 Vo = 5V

Ii (mA)= 100 100 29.7 Io = 79mA

Pi (mW)= 800 800 79 Po = 129mW

Ci (nF)= 0 0 1 Co = 2uF Li (µH)= 47 0 1 Lo = 100uH

4-20

Input

MFC

Limit

Switches

Remote

Mount

Intrinsically Safe

Class I, Div 1, Groups A,B,C,D Class I, Zone 0, AExia IIC (US) Class I, Zone 0, Ex ia IIC (Canada) T4 Tamb = -20˚C ≤ Ta ≤ +85˚C T6 Tamb = -52˚C ≤ Ta ≤ +45˚C Type 4X

Entity

Parameters

Ui (Vdc)= 30 30 10.6 Vo = 5V

Ii (mA)= 100 100 29.7 Io = 79mA

Pi (mW)= 800 800 79 Po = 129mW

Ci (nF)= 0 0 1 Co = 2uF Li (µH)= 47 0 1 Lo = 100uH

Non-Incendive

Class I, Div 2, Groups A,B,C,D, T4 Tamb = -20˚C ≤ Ta ≤ +85˚C T6 Tamb = -52˚C ≤ Ta ≤ +45˚C Type 4X

Notes

• Reference installation drawing # 291780

Warning!

• Lim i t S witc h options -01, -03, -04, -05, -06 are not rated for use in hazardous areas. Select these options only when installing in non-explosive atmospheres.

• Covers m ust be properly installed in order to maintain environmental ratings.

Special Conditions for Safe Use:

• The equi pm ent must be inst alled in such a manner as to minimize the risk of impact or friction with other metal surfaces.

• To avoid poss i bi lit y of static discharge clean only with a damp Cloth

• For I ntrinsically Safe installations the positioner must be connected to suitably rated intrinsically safe equipment, and must be installed in accordance with applicable intrinsically safe installation standards.

• S ubst i t ution of components may impai r Intrins ic Saf ety.

• Us e appropriately rated cable insulation at higher

temperatures.

North America (cFMus)

4-20

Input

MFC

Limit

Switches

Remote

Mount

Conditions spéciales pour une utilisation en toute sécurité:

• Le matériel doit être installé de sorte à réduire au minimum le risque de choc ou de frottement avec d'autres surfaces métalliques.

• P our évit er l es risques de décharge d'élect ri cité statique Nettoyez uniquement avec un chiffon humide

• P our les i nst al l ations en sécurité intrins èque, le positionneur doi t être connecté à un équipement sécurité intrinsèque

convenablement qualifié, et doit être installé conformément aux normes d'installation séc urité i ntri nsèque applicables.

• La s ubst itution de composants peut compromettre la sécurité intrinsèque.

• Uti l is er une isol ation appropri ée du c âbl e à des températures plus élevées.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

4 STORAGE AND UNPACKING

4.1 Storage

FLOWSERVE Control valve packages (a control valve and its instrumentation) are typically well protected from corrosion. Nevertheless FLOWSERVE products must be stored in a clean, dry environment such as an enclosed building that affords environmental protection. Heating is not required. Control valve packages must be stored on suitable skids, not directly on the floor. The storage location must also be free from flooding, dust, dirt, etc. Plastic caps are fitted to protect the flange faces and positioner ports to prevent the ingress of foreign materials. These caps should not be removed until the valve or positioner is actuall y moun ted i nto the system.

If FLOWSERVE products (especially sealing materials) have been in storage for longer periods check these for corrosion or deterioration before using these products. Fire protection for FLOWSERVE products must be provided by the end user.

4.2 Unpacking

While unpacking the valve and/or Logix 500MD+ 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 and that the plugs and cover are in place. The plugs keep debris and moisture from damaging the internal components of the positioner. If the positioner has been contaminated, clean the positioner components gently with a soft damp cloth. Some components may be removed for better access. See section 17 MAINTENANCE AND REPAIR. When cleaning a Double Acting Relay (Spool and Block) take care not to bend or force the spool. A Single Acting Relay may be removed, but do not disassembled the relay. Check connectors to ensure that no debris is present. Port screens can be removed with a flat screwdriver for access to internal passages.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Follower Pin

Follower Arm

Bracket

Positioner

Take-Off Arm

Stem Clamp

Take-Off Arm

5 MOUNTING AND INSTALLATION

5.1 Mounting to Mark One Linear Valves

To mount a Logix 500+ positioner to a Valtek linear Mark One valve, refer to Figure 4: Mounting to Mark I Linear Valves and proceed as outlined below.

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 slot in the follower arm assembly over the flats

on the position feedback shaft in the back of the positioner. Make sure the arm is pointing toward the side of the positioner with ports A, B, and Supply. Slide the lock washer over the threads on the shaft and tighten down the nut.

3 Align the bracket with the three outer mounting hol es on

the positioner. 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 hole.

6 Insert the lower mounting bolt and tighten the bolting. 7 Position the take-off arm mounti n g sl ot aga i ns t t he s te m

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.

 NOTE: The feedback shaft has a clutch mechanism that

allows for over-rotation of the shaft for easy adjustments.

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

horizontal when the val ve 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 or the travel is too small. Reposition the feedback linkage or rotate the position sensor to correct the error.

 NOTE: To virtually eliminate non-lin ear it y, use the

Linearization feature in the Custom Characterization page of the DTM.

Feedback Shaft

Pin Slot

Figure 4: Mounting to Mark I Linear Valves

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

FlowTop Port

Spacer

Positioner O-ring

FlowTop Mounting Bracket

Positioner Screws

Follower Arm

Feedback Shaft

Follower Arm Nut

Port B

5.2 Mounting to FlowTop Linear Valves

To mount a Logix 500+ positioner to a FlowTop linear actuator and valve (with direct mounting / integrated tubing), proceed as outlined below.

1 Remove the FlowTop port plug screw. Plug port B. 2 Ensure positioner O-ring surface is clean. Then install

the O-ring, and FlowTop mounting block using the positioner screws.

3 Attach the follower arm to the feedback shaft using the

follower arm nut.

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Figure 5: FlowTop Mounting Bracket

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Actuator Screws

Take-Off Plate

Take-Off Pin

Take-Off Plate Screws Actuator O-ring

Refer to Figure 6: FlowTop 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 feedback shaft has a clutch mechanism that

allows for over-rotation of the shaft for easy adjustments.

7 Use the actuator screws to secure the positioner in

place. 8 Connect regulated air supply to appropriate port in

manifold. See section 6 TUBING. 9 Connect the power to the 4-20 mA terminals. See

section 7 ELECTRICAL CONNECTIONS. 10 Remove main cover and locate DIP switches and

QUICK-CAL/ACCEPT button. 11 Refer to sticker on main board cover and set DIP

switches accordingly. See section 8 STARTUP.

12 Pre ss the QUICK-CAL/ACCEPT button for three to four

seconds or until the positioner begins to move. The positioner will now perform a stroke calibration.

13 If the calibration was successful the green LED will blink

GGGG or GGGY and the valve will be in control mode.

14 If calibration fails, as indicated by a RGGY blink code,

retry the calibration. If it still fail s, the feedback values were exceeded and the arm must be adjusted away from the positioner’s limits. Rotate the feedback shaft so that the full free travel of the feedback shaft is in the range of the actuator movement. Optionally, continue to attempt the calibration. Each calibration attempt adjusts the acceptable limits and it should pass eventually.

CAUTION: Remember to remove the air supply before

re-adjusting take-off arm.

 NOTE: If mounted properly, the follower arm should be

horizontal when the valve is at 50% stroke and should move approximately ±30° from horizontal over the full stroke of the valve.

 NOTE: To virtually eliminate non-linearity, use the

Linearization feature on the Custom Characterization page of the DTM.

Figure 6: FlowTop Mounting

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Spline

Take-Off

Follower Arm

Feedback Shaft

Universal Bracket

5.3 Mounting to Standard Valtek Rotary

Valves

The standard rotary mounting applies to Valtek valve/actuator assemblies that do not have mounted volume tanks or hand-wheels. 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.

1 Fasten the spline lever adapter to the splined lever

using two 6 x 1/2" self-ta ppi ng screws. 2 Slide the take-off arm onto the spline lever adapter

shaft, orienting the arm to the current valve position.

Insert the screw with star washer through the take-off

arm and add the second star washer and nut and

tighten.

4 Rotate the follower 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. 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 7 Using a ½” end wrench and two 5/16-18 X ½” bolts,

attach bracket to actuator transfer case pad. Leave

Lever Adapter

Arm Assembly

Figure 8: Valtek Rotary Take-Off Arm

3 Attach follower arm to positioner feedback shaft using

the star washer and 10-32 nut.

Figure 9: Valtek Rotary Follower Arm

Figure 7: Valtek Rotary Mounting

these bolts slightly loose until final adjustments are

made.

8 Rotate follower arm so the follower pin will slide into the

slot on the take-off arm. Over-rotate the follower arm if

needed so the arm moves freely through the intended

travel.

 NOTE: The feedback shaft has a clutch mechanism that

allows for over-rotation of the shaft for easy adjustments.

9 Adjust the bracket position as needed noting the

engagement of the follower pin and the take-off arm

slot. The pin should extend approximately 1⁄16" past the

take-off arm. When properly adjusted, securely tighten

the bracketing bolts. 10 Connect regulated air supply to appropriate port in

manifold. See section 6 TUBING. 11 Connect the power to the 4-20 mA terminals. See

section 7 ELECTRICAL CONNECTIONS. 12 Remove main cover and locate DIP switches and

QUICK-CAL/ACCEPT button. 13 Refer to sticker on main board cover and set DIP

switches accordingly. See section 8 STARTUP. 14 Pres s the QUICK-CAL/ACCEPT button for three to four

seconds or until the positioner begins to move. The

positioner will now perform a stroke calibration. 15 If the calibration was successful the green LED will blink

GGGG or GGGY and the valve will be in control mode. 16 If calibration fails, as indicated by a RGGY blink code,

retry the calibration. If it still fails, the feedback values

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

were exceeded and the arm must be adjusted away from the positioner’s limits. Rotate the feedback shaft so that the full free travel of the feedback shaft is in the range of the actuator movement. Optionally, continue to attempt the calibration. Each calibration attempt adjusts the acceptable limits and it should pass eventually.

CAUTION: Remember to remove the air supply before

re-adjusting take-off arm.

 NOTE: If mounted properly, the follower arm should be

horizontal when the valve is at 50% stroke and should move approximately ±30° from horizontal over the full stroke of the valve.

 NOTE: To virtually eliminate non-linearity, use the

Linearization feature on the Custom Characterization page of the DTM.

Figure 10: Valtek Rotary Final Orientation

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Take-Off Arm

Take-Off Pin

Mounting Plate

Follower Arm

Feedback Shaft

5.4 Mounting to MaxFlo Rotary Valves

1 Slide the take-off arm onto the 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.

4 Rotate 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.

 NOTE: The feedback shaft has a clutch mechanism that

allows for over-rotation of the shaft for easy adjustments.

Figure 11: MaxFlo Take-Off Arm

2 Attach the mounting plate to the positioner using 4

screws.

3 Attach follower arm to positioner feedback shaft.

Figure 13: MaxFlo Follower Arm

Figure 12: MaxFlo Assembly

Figure 14: MaxFlo Connection

5 Connect regulated air supply to appropriate port in

manifold. See section 6 TUBING. 6 Connect the power to the 4-20 mA terminals. See

section 7 ELECTRICAL CONNECTIONS. 7 Remove main cover and locate DIP switches and

QUICK-CAL/ACCEPT button. 8 Refer to sticker on main board cover and set DIP

switches accordingly. See section 8 STARTUP. 9 Press the QUICK-CAL/ACCEPT button for three to four

seconds or until the positioner begins to move. The

positioner will now perform a stroke calibration. 10 If the calibration was successful the green LED will blink

GGGG or GGGY and the valve will be in control mode. 11 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. Rotate the feedback shaft

so that the full free travel of the feedback shaft is in the

range of the actuator movement. Optionally, conti nue

to attempt the calibration. Each calibration attempt

adjusts the acceptable limits and it should pass

eventually.

CAUTION: Remember to remove the air supply before

re-adjusting take-off arm.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

5.5 Mounting to Rotary NAMUR (AutoMax) Valves

1 Attach the mounting plate to the positioner using 4

screws.

2 Rotate the feedback shaft to match the orientation of

the receiver on the actuator.

 NOTE: The feedback 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.

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/ACCEPT button.

7 Refer to sticker on main board cover and set DIP

switches accordingly. See section 8 STARTUP.

8 Press the QUICK-CAL/ACCEPT button for three to four

seconds or until the positioner begins to move. The positioner will now perform a stroke calibration.

9 If the calibration was successful the green LED will blink

GGGG or GGGY and the valve will be in control mode.

10 If calibration fails, as indicated by a RGGY blink code,

retry the calibration. If it still fails, remove power from the positioner, disconnect the air, and remove the positioner from the actuator. Rotate the feedback shaft so that the full free travel of the feedback shaft is in the range of the actuator movement. Optionally, continue to attempt the calibration. Each calibration attempt adjusts the acceptable limits and it should pass eventually.

CAUTION: Remember to remove the air supply before

re-adjusting take-off arm.

Figure 15: AutoMax Bracket

Figure 16: AutoMax Assembly

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Follower Arm

Take Off Arm

Follower Pin

Stem Clamp

5.6 Mounting to a Linear NAMUR Pneumatic Actuator

The mounting of a rod actuator kit and actuator (accord ing t o IEC 534 part 6) is described in the following example.

1 Mount the follower arm by unscrewing the lock nut for

the follower arm attachment. Place the follower arm on the shaft at the back of the positioner and fasten it with the lock nut. The follower pin should point away from the positioner.

2 Attach the stem clamp bracket to the stem clamp and

fasten it with two hexagon socket screws and lock washers.

3 Attach the take-off arm to the stem clamp bracket and

fasten it with a hexagon socket caps crew and a washer.

CAUTION: Maximum torque 0,25 Nm (0,18 ft-lbs).

4 To mount the positioner, adjust the actuator to mid-

stroke.

5 Pre-assemble the mounting bracket on the left actuator

leg and hand-tighten the two U-bolts, nuts and lockwashers.

6 Attach the positioner to the pre-ass emb led mount i ng

bracket and fasten it with two hexagon screws and two lock washers. Check that the follower pin is inserted in the slot of the take-off arm and the follower arm is positioned parallel to the take-off arm.

7 Tighten all screws and nuts.

 NOTE: The feedback shaft has a clutch mechanism that

allows for over-rotation of the shaft for easy adjustments.

Figure 17: Mounting to a Linear Actuator

 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 necessa ry 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 Connect the power to the 4-20 mA terminals. See

section 7 ELECTRICAL CONNECTIONS.

10 Remove main cover and locate DIP switches and

QUICK-CAL/ACCEPT button.

11 Refer to sticker on main board cover and set DIP

switches accordingly. See section 8 STARTUP.

12 Pre ss the QUICK-CAL/ACCEPT button for three to four

seconds or until the positioner begins to move. The positioner will now perform a stroke calibration.

13 If the calibration was successful the green LED will blink

GGGG or GGGY and the valve will be in control mode.

14 If calibration fails, as indicated by a RGGY blink code,

CAUTION: Remember to remove the air supply before

re-adjusting take-off arm.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

S Spool Relay

S Poppet Relay

6 TUBING

After mounting has been completed, tube the positioner to the actuator using the appropriate compression fitting connectors. For best performance, use 10 mm (3/8 inch) tubing for 645 square cm (100 square inch) actuators or larger.

6.1 Determine Air Action

The port labeled “Y1” delivers air when an air supply is present and the relay is energized. (For positioners with double acting relays, this is port A. For positioners with single acting relays, this is port B.) Typically, the port labeled “Y1” should be tubed to the pneumatic side of the actuator (the side that would result in the air compressing the actuator spring). When tubed this way, the spring is designed to return the valve to the fail safe state should supply air or power to the unit fail.

Tube the port labeled “Y1” to the side of the actuator that must receive air to begin moving away from the fail safe state.

If air from “Y1” should open the valve, set the Air Action configuration switch on the positioner to Air-to-Open, otherwise set it to Air-to-Close.

The Air-to-Open and Air-to-Close selection is determined by the actuator tubing, not the software. When air action selection is made during configuration, the sel ection t ells 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.

 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 of the actuator (closest to the valve). The “Y2” port of the positioner is tubed to the top side of the actuator. For a linear air-to-close actu ator the tubing configuration is reverse d.

Figure 18: Tubing Linear, Double Acting, Air to Open

Example: Tubing Rotary Double-Acting Actuators

For a rotary actuator, the “Y1” port of the positioner manifold is tubed to the far side of the actuator. The “Y2” port of the positioner manifold is tubed to the side of the actuator closer to the transfer case. This tubing convention is followed

B (Y2) A (Y1)

regardless of air action. On rotary actuators, the transfer case orientation determines the air action.

Figure 19: Tubing Rotary, Double Acting, Air to Open

Example: Tubing Single-acting Actuators

For single-acting actuators, the “Y1” port is always tubed to the pneumatic side of the actuator regardless of air action. If a double acting (spool style) relay is installed in the positioner, plug port B (Y2). If a single acting - poppet style relay is installed, plug port A (Y2). Or, port A may be used for purging. See

Figure 20: Tubing Linear, Single Acting, Air to Open

Purging Single Acting Actuators below.

B (Y2) A (Y1)

B (Y1) A (Y2) Plug

6.2 Connect Supply Port

The positioner ports are threaded with either G ¼ or ¼ 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 filters, which remove medium and coarse size dirt from the pressurized air. If necessary, they are easily accessible for cleaning.

A supply regulator is recommended if the customer will be using the diagnostic features of the Logix 500+ 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 actua tor’s maximum rating.

6.3 Purging Single Acting Actuators

Purging allows the non-pressurized side of a single acting actuator to fill with exhaust gas instead of atmospheric air. This configuration helps prevent corrosion of actuator components in harsh environments. When a single acting

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Relay

Housing Actuator

relay is used, a special procedure can be performed to configure the positioner to purge properly using port 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 actuator exhaust port is located on the bottom of the positioner. Both ports are tapped with either ¼ NPTF or G ¼ threads and covered with a protective cap. To control vented gas, remove the caps and connect the necessary tubing/piping to these ports. See Figure 21: Exhaust Vents.

Chamber Exhaust (0.14 barg Max)

This piping system may cause some positioner back pressure. Back pressure in the housing chamber is from the modulator and regulator. Back pressure in the exhaust port is from the actuator.

The maximum allowable back pressure from the housing chamber is 0.14 barg (2.0 PSIG). For flow rates, see section

2.2 Air Supply. The maximum allowable back pressure from the exhaust port

is 0.55 barg (8.0 PSIG) for double acting relays and is 0.14 barg (2.0 PSIG) for single acting relays. Higher pressure may result in decreased performance. For output flow rates, see section 2.3 Pneumatic Output.

CAUTION: The back pressure in the main housing must

never rise above 0.14 barg (2.0 PSIG). This could cause the positioner to become unresponsive under some circumstances.

Exhaust (0.55 barg Max)

Figure 22: Pneumatic Connections

Figure 21: Exhaust Vents

Port

Single Acting

Poppet Style

S Supply Supply

B Y1 Y2

A (Plug) Y1

Double Acting

Spool Style

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Limit Switch

Housing EARTH Terminal

7 ELECTRICAL CONNECTIONS

7.1 Electrical Terminals

7.2 Command Input (4-20 mA)

The Logix 500+ is reverse polarity protected, however, verify polarity when making field termination connection. Wire 4-20 mA current source to the input terminal labeled “HART 420mA INPUT”. See Figure 23: Terminal Diagram. Depending on the current source, a HART filter may be required. See 18.1 Troubleshooting Guide.

7.2.1 Compliance Voltage

Output compliance voltage refers to the voltage limit the current s ou r c e can provide. A current loop system consists of the current source, wiring resistance, barrier resistance (if present), and the Logix 500+ impedance.

The Logix 500+ requires that the current loop system allow for a 10 VDC drop across the positioner at maximum loop current. The operating current range is from 3.8 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.

Terminals 1-6

Auxiliary Cards

Slot 2

Slot 1

HART 4-20 mA

Input +

Input -

Figure 23: Terminal Diagram

Connection

Example:

DCS Controller Voltage = 19 

Equation 1

Available Voltage = Controller Voltage

Current





Available Voltage = 19 V  0.020 A × (300 + 25

Available Voltage = 12.5 V

The available voltage (12.5 V) is greater than the required voltage (10.0 V) therefore; this system will support the Logix 500+. The Logix 500+ has an input resistance equivalent to 500 Ω at a 20 mA input current.

CAUTION: The current must always be limited for 4-20

mA operation. Never connect a voltage source directly across the Logix 500+ terminals. This could cause permanent circuit board damage.





= 300

= 25

×(R



= 20

+ R

Internal External

)



(

@Current



)



)

flowserve.com 22

Barrier

Wire

Compliance 10 Voltage VDC

Controller

Current

Grounding Terminals

Electrical Conduit

Thread Size

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

(If Present)

4-20 mA

Current Source

Voltage

Figure 24: Compliance Voltage

7.2.2 Cable Requirements

The Logix 520MD+ digital positioner utilizes the HART Communication protocol. This communication signal is superimposed on the 4-20 mA current signal. The two frequencies used by the HART protocol are 1200 Hz and 2200 Hz. In order to prevent distortion of the HART communication signal, cable capacitance and cable length restrictions must be calculated. The cable length must be limited if the capacitance is too high. Selecting a cable with lower capacitance/foot rating will allow longer c able runs. In addition to the cable capacitance, the network resistance also affects the allowable cable length.

In order to calculate the maximum network capacitance, use the following formula:

Equation 2



(F)

Example:

= 300 (if present)



= 50





(F)

In order to calculate the maximum cable length, use the following formula:

Equation 3

Max Cable Length =

Example:

= 72



= .000072





Max Cable Length =

Max Cable Length = 1111 



(

 







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0.08 F

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Logix

520MD+

To control cable resistance, 24 AWG cable should be used 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 520MD+ 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 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 the electrical conduit ports 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. Addi tionally, the electrical conduit should be earth grounded at both ends of its run.

 NOTE: The grounded screw must not be used to

terminate signal shield wires. Shield wires should be terminated only at the signal source.

This product has electrical conduit connections in either thread sizes 1/2" NPTF or M20x1.5 which appear identical but are not interchangeable. The thread size is indicated on the side of the positioner near the conduit connections. Conduit fittings must match equipment housing threads before installation. If threads do not match, obtain suitable adapters or contact a Flowserve representative. See Figure 25: Conduit and Grounding.

Conduit Connections

Figure 25: Conduit and Grounding

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Less than 8 V on AO terminals.

Low

(typically 0.5 mA)

High (input > 8.0 VDC)

10 VDC

MFC

8 VDC

MFC

0 VDC

MFC

Discrete Input

1 kΩ

Switch Amp

7.2.5 Electromagnetic Compatibility

The Logix 500+ digital positioner has been designed to operate correctly in electromagnetic (EM) fields found in typical industrial environments. Care should be taken to prevent the positioner from being used in environments with excessively high EM field strengths (greater than 10 V/m). Portable EM devices such as hand-held two-way radios should not be used within 30 cm of the device.

Ensure proper wiring and shielding techniques of the control lines, and route control lines away from electromagnetic sources that may cause unwanted electrical noise. An electromagnetic line filter can be used to further 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). Connections to the Multi-Function Card are made directly to the card terminals. For detailed information about voltage and c urrent limits, see Table 13: Auxiliary C ard Statu s below.

See section 13 MULTI-FUNCTION CARD for more information.

7.3.1 Analog Output

For AO function wire the MFC in series with a 10 to 40 VDC power supply, including a method to determine the current. When configured as an AO, the current will follow the valve position.

Minimum

Figure 27: 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.

to 40 VDC Voltage

Source

Typical

Voltage Loop

(Logix Input)

40 VDC

Voltage

Source

Figure 26: MFC Analog Output Circuit

7.3.2 Discrete Output

For DO function, wire the MFC in series with a 8 to 40 VDC power supply, including a method to determine the current such as a resistor. Or use a NAMUR switch amplifier made for this purpose. In DO configuration, the card is a NAMUR switch.

When configured as a DO, current will remain high until the user-defined condition (an alarm ) is active, and then drop low when tripped.

Figure 28: MFC Discrete Input Circuit

Table 13: Auxiliary Card Status

Card Condition Status Indication

Multi-Function Card

Monitoring Position

MFC (AO)

MFC (DO)

MFC (DI)

(typical 4-20mA )

High (output > 2.1 mA) (typically 3 mA)

(1.2 mA > output >

0.1 mA)

Less than 0.1 mA No Loop Power Low

(input < 2.5 VDC)

Output (mA)

No Loop Power

1 - Nominal

0 - Tripped

1 - Nominal

0 - Tripped

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table

Terminal (See Figure 29)

Switch

1 2 3 4 5 6 Mechanical

Cherry DG 13-B2RA

1 & 4 NC

Reed

Hamlin 59165-1-S-00-C

Inductive Sensor

P&F NJ2-V3-N

NAMUR NC

BU BN

Inductive Proximity

P&F SJ2-S1N

BU BN

NAMUR NO

Inductive Proximity

P&F SJ2-SN

BU BN

NAMUR NC

Inductive Sensor

P&F NBB2-V3-E2

PNP NO

General Purpose Only

SW+

Table

Terminal (See Figure 30:

Remote Mount Board)

A B C

LS1

LS2

Terminals

7.4 Limit Switches

Limit switches provide an independent verification of the position of the feedback shaft. Wire the limit switches according to Table 14: Limit Switch Connections. For more information, see Table 7: Limit Switch Specifications on page

Figure 29: Limit Switch Board

14: Limit Switch Connections

7.5 Remote Mount

The remote mount option can be used where excessive vibration or environmental factors prevent the placement of a positioner directly on the valve. Wire the remote mount board according to Table 15: Remote Mount Card Connections. For more information, see Table 6: Remote Mount Specifications on page 8.

Figure 30: Remote Mount Board

15: Remote Mount Card Connections

NC NO C NC NO C

+ + - + + -

LS1

+ -

LS1

LS2

+ -

LS2

From Remote Mount Red White Black

7.6 Connections for Intrinsically Safe Operation

See section 3 HAZARDOUS AREA CERTIFICATIONS for entity parameters and control drawing reference.

+ - + -

LS1 LS2

+ - + -

LS1 LS2

+ - + -

LS1 LS2

BN BU BK BN BU BK

Vcc+ -

Vcc+ - SW+

LS1 LS2

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Display

LED Status

QUICK-CAL/

UP Button

Selectable Configuration

BACK

HART Card Slot 2

Card Slot 1

8 STARTUP

8.1 Quick Start Instructio n s

Once the positioner is installed, adjusting the DIP switch settings and performing a Quick-Cal function will typically get the positioner working properly. This simple procedure takes only seconds for most valves.

1 Using the Configuration Switches, select the desired

configuration.

2 Hold the Quick-Cal button for 3 seconds. This will

initiate a stroke calibration.

After the stroke calibration is complete, the positioner is ready for control.

CAUTION: During the QUICK-CAL operation the valve

may stroke unexpectedly. Notify proper personnel that the valve will stroke, and make sure the valve is properly 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.

8.2.1 Logix 505+

The Logix 505+ local interface has the following features:

• Configuration Switches (4) – Used to set basic

configuration. See explanations in section 8.3 Configuration Switch Settings.

• QUICK-CAL button – Used to calibrate the positioner.

• LED Indicators (Red, Yellow, and Green) – Indicate

status, alarms and warnings.

8.2.2 Logix 510+ and 520MD+

• Configuration Switches (8) – Used to set basic

configuration. See explanations in section 8.3 Configuration Switch Settings.

• Interface Buttons – Used to calibrate the positioner,

perform special functions and navigate the display menu.

o ►QUICK-CAL / ACCEPT o ▲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.

4-20 mA Input

Switches

GAIN Switch

Figure 31: Local User Interface

Button

Lights

ACCEPT Button

DOWN Button

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

8.3 Configuration Switch Settings (505+)

Before placing the unit in service, set the Configuration Switches to the desired control options.

 NOTE: The Configuration Switch settings are activated

only by performing a Stroke calibration (pressing the “QUICK-CAL” button for 3 seconds). However, the Configuration Switch settings may be edited from the DTM or Handheld at any time.

8.3.1 Air Act i o n Switch

This must be set to match the configuration of the valve/actuator mechanical tubing connection since the tubing determines the air action of the system.

If Single Acting (Poppet) Relay

ATO - Increasing pressure from Port B (labeled “Y1”) causes the valve to open. ATC - Increasing pressure from Po rt B (labeled “Y1”) causes the valve to close.

If Double Acting (Spool) Relay

ATO - Increasing pressure from Port A (labeled “Y1”) causes the valve to open. ATC - Increasing pressure from Po rt A (labeled “Y1”) causes the valve to close.

8.3.2 Split Range Switch

The Split Range feature allows the valve to move the full length of travel with either a 4-12mA signal or a 12-20mA signal.

Off - Select Off to disable the split range feature. On - Select On to enable the split range feature.

8.3.3 Range Select Switch

If the Split Range switch is On, the Range Select Switch designates which input range will control the positioner.

4-12 - Selecting 4-12 will cause the valve to travel from 0 to 100% over a 4 to 12 mA input range. 12-20 - Selecting 12-20 will cause the valve travel from 0 to 100% over a 12 to 20 mA input range.

8.3.4 Gain Switch

The Gain switch changes the tuning parameters. Changes to this switch take effect immediately. (Other DIP switches take effect only during a QUICK-CAL.

Normal – The Normal selection is typically suitable for most applications. Low – The Low selection can be used to increase the stabil ity of the valve control.

8.4 Configuration Switch Settings (510+ and 520MD+)

Before placing the unit in service, set the Configuration Switches to the desired control options.

 NOTE: The Configuration Switch settings are activated

only by performing a Stroke calibration (pressing the “QUICK-CAL” button for 3 seconds). However, the Configuration Switch settings may be edited from the DTM or Handheld at any time.

8.4.1 Air Action Switch

This must be set to match the configuration of the valve/actuator mechanical tubing connection since the tubing determines the air action of the system.

If Single Acting (Poppet) Relay

ATO - Increasing pressure from Port B (labeled “Y1”) causes the valve to open. ATC - Increasing pressure from Port B (labeled “Y1”) causes the valve to close.

If Double Acting (Spool) Relay

ATO - Increasing pressure from Port A (labeled “Y1”) causes the valve to open. ATC - Increasing pressure from Port A (labeled “Y1”) causes the valve to close.

8.4.2 Actuator Switch

This must be set to match the configuration of the actuator and is used in some diagnostics.

Double - Select Double when both sides of the actuator are pressurized. Single - Select Single when only one side of the actuator is pressurized.

8.4.3 Signal at Closed Switch

Normally this will be set to 4 mA for an Air-To-Open actuator configuration, and 20 mA for Air-To-Close.

4 mA - Selecting 4 mA will make the valve close when the signal is low (4 mA) and open when the signal is high (20 mA). 20 mA - Selecting 20 mA will make the valve close when the signal is high (20 mA) and open when the signal is low (4 mA).

 NOTE: When using an Analog Output (AO) function of

the Multi-Function Card, the AO signal corresponds with the Signal At Closed selection. If the valve closes with a 4 mA signal, the AO will show a 4 mA signal at closed. If the valve closes with a 20 mA signal, the AO will show a 20 mA signal at closed.

8.4.4 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.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Linear - Select Linear if the actuator position should be directly proportional to the command input signal. (For most rotary valves, this setting gives an =% Cv characteristic due to their inherent = % characteristics.)

Other - Select Other if one of the pre-set characterization curves or a custom curve is desired. The default will be the Custom curve which is populated with a standard 30:1 equal percent rangeability curve which generally opens less than the input command. To select one of the other curve options, use the LCD menu, a Handheld or the ValveSight DTM. To modify the Custom curve, use the DTM. See section Configuration (Characterization) for more information.

10.3.6

8.4.5 Auto Tune Switch

This switch controls whether the positioner will automatically tune itself during the stroke calibration (Quick-Cal), or use preset tuning parameters.

On - Selecting On enables an auto tune feature that will automatically determine the positioner gain settings. The automatic tuning will be based on response parameters measured during the latest Quick-Cal. The valve response is a combination of these response parameters and the current position of the Selectable GAIN Switch.

Off - Selecting Off forces the positioner to use one of the factory preset tuning sets determined by the Selectable GAIN Switch. Settings “B” through “J” are progressively higher predefined tuning sets.

Selecting “A” on the Selectable Gain Switch during a QuickCal allows the user to use and preserve manually adjusted gains.

See section 8.5 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.

Responsive

Figure 32: Selectable GAIN Switch

8.4.6 Quick Calibration Switch

This switch selects between Auto and Jog calibration modes. Auto - Use the Auto setting if the fully opened position of the

valve has a mechanical stop. This is typical for most valves. In Auto mode during a stroke calibration (Quick-Cal), the positioner will fully close the valve and register the 0% position, then fully open the valve to register the 100% position.

Jog - Use the Jog setting if the fully opened position of the valve has no hard stop, but needs to be set manually. In Jog mode during a stroke calibration (Quick-Cal), the positioner will fully close the valve and register the 0% position, then wait for the user to m ove the valve to the 100% open position

using the ▲Up and ▼Down buttons. Press the ►ACCEPT/QUICK-CAL button to accept the 100% location.

See section 8.5 Stroke Calibration for more details.

Stable

8.4.7 Valve Stability Switch

This switch adjusts the position control algorithm of the positioner for use with low-friction control valves or highfriction automated valves.

Lo Friction - Placing the swi tch to Lo Friction optimizes the response for low friction, high performance control valves. This setting provides for optimum response times when used with most low friction control valves.

Hi Friction - Placing the switch to the right optimizes the response for valves and actuators with high friction levels. This setting slightly slows the response and will normally stop limit cycling that can occur on high friction valves. See section details.

10.3.7 Configuration (Pressure Control) for more

 NOTE: This option is more effective on with Advanced or

Pro diagnostic levels.

8.4.8 Spare Switch

If special features have been purchased they may be controlled by this switch. See associated documen tation for more details.

8.5 Stroke Calibration

The ►ACCEPT/QUICK-CAL button is used to initiate an automatic stroke calibration. The stroke calibration determines the closed (0%) and open (100%) positions of the valve and gathers information about the response of the valve (such as valve stroke time) in order to determine the gains. The gains are then set automatically. After a stroke calibration, the positioner is ready to contro l.

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 progress. See sect ion

18.3 Status Code Descriptions for an explanation of the

status code sequences. The initial calibration of extremely large or very small

actuators may require several calibration attempts. The positioner adapts to the actuator performance and begins each calibration where the last attempt ended. On an initial installation it is recommended that after the first successful calibration that one more calibration be completed for optimum performance.

8.5.1 Quick Calibration Switch – Jog

Set the Quick Calibration Switch to Jog if the valve/actuator assembly has no internal mechanical stop at the fully open position. In this case, follow these instructions:

1 Press and hold the ►ACCEPT/QUICK-CAL button for

approximately 3 seconds.

This will initiate the jog stroke calibration. The positioner will then close the valve and set the zero position. The zero position is automatically always set at the valve seat. At this point the LED‘s will flash i n a sequence of G-R-R-R (greenred-red-red) which indicates that the user must use the jog keys to manually position the valve to approxim ately 100%.

2 Use the up and down keys to position the valve at

approximately 100% open.

3 Press the ►ACCEPT/QUICK-CAL button to proceed.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

No more user actions are required while the calibration process is completed. When the lights return to a sequence that starts with a green light the calibration is complete.

The jog calibration process will only allow the user to set the span. If an elevated zero is needed a handheld or ValveSight DTM are required.

8.5.2 Tuning Options

Quick-Cal Cus tom Gai ns - This is typically the fastest way to achieve ideal gains. Set the Auto Tune Configuration Switch to On and the Selectable GAIN Switch 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. This is the default setting for all actuator sizes. Raising or lowering the Selectable GAIN Switch setting is a function of the positioner/valve response to the control signal, and is not actuator size dependent.

Standard Preset Gains - If standard, preset gains are desired, set the Auto Tune Configuration Switch to Off. After performing a Quick-Cal, use the Selectable GAIN switch to the desired level (“B” – “J”). The standard, preset gain settings are not affected by Quick-Cal. It may be necessary to set the gain switch before the Quick Cal. Very fast stroking valves may need to be at lower gains and very slow stroking valves may need to be at higher gains.

It may be necessary to set the gain switch BEFORE the Quick Cal. Very fast stroking valves may need to be at lower gains and very slow stroking valves may need to be at higher gains.

Custom Manual Gains - To set gains manually, set the selectable GAIN switch to “A”. Changing the switch from “B” to “A” will write the standard “B” settings 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.

8.5.3 Aborting a Quick -Cal

The Quick-Cal can be aborted at any time by briefly pressing the ►ACCEPT/QUICK-CAL button again. In this case, the previous settings will be retained.

8.5.4 On Line Stroke Calibration Adjustments

At times an adjustment to the calibration is desired, but the process cannot be interrupted. The stroke calibration can be adjusted with minimal valve movement. Contact your local Field Service Technician for more information.

8.6 Analog Output (AO) Calibration

The Analog Output (position feedback) function of the MultiFunction Card can be configured calibrated using the DTM or LCD. Ensure the card is installed, the positioner recognizes the card, and it is configured to be an AO.

The DTM AO calibration wizard is found here: Configuration / Card Slot 1 (or 2) / Multi-Function Card / Analog Output Calibration.

The LCD AO calibration features are found here: Card 1 (or Card 2) / Multi-Function Card / Config/Cal

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

First

Blink Color

Second

Blink Color

Third

Blink Color

Version Number

G G G

G G Y

G G R 2 G Y G 3 G Y Y 4 G Y R 5 G R G 6 G R Y 7 G R R 8 Y G G 9 Y G Y

10 Y G R 11 Y Y G 12

Y Y Y

Y Y R

14 Y R G 15 Y R Y 16 Y R R 17 R G G 18 R G Y 19 R G R 20 R Y G 21 R Y Y 22 R Y R 23 R R G 24

R R Y

R R R

9 POSITIONER FUNCTIONS (No

Display Required)

The following features can be performed using the local interface. No display is required for these features. Additional features are offered with the use of a display, Handheld or DTM.

 NOTE: In order to prevent unintentional adjustments of

the configuration, tuning, or control of the valve, the Tamper Lock feature may be used. This is set in the DTM and disables the buttons and menus except for the ability to view the status of the positioner. When locked, the positioner may be temporarily unlocked by entering a PIN. (An LCD is required to enter the PIN.) Or, the positioner can be unlocked from the DTM.

9.1 Live Manual Tuning (Adjusting the Gain)

Use the Selectable GAIN Switch to adjust the gain at any time during operation. This adjustment takes effect immediately. For faster response select settings above “E” (F-J). For more stable response, select settings below “E” (B-D). See Error! Reference source not found. on page

Error! Bookmark not defined..

9.2 Local Control Of Valve Position

To manually adjust the position of the valve regardless of the input command (analog or digital), press and hold the ▲Up,

▼Down and ◄ BACK buttons for about 3 seconds. The

▲Up, ▼down buttons can then be used to position the valve.

While in this mode the LED‘s will flash a GRRY (green-redred-yellow) sequence. To exit the local control mode and return to normal operation, briefly press the ► ACCEPT/QUICK-CAL button.

CAUTION: When operating using local control of the

valve, the valve will not respond to external commands. Notify proper personnel that the valve will not respond to remote command changes, and make sure the valve is properly isolated.

9.3 Command Source Reset

Performing a command source reset will reset the c ommand 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 while applying power. All of the internal variables including calibration will be reset to factory defaults. The positioner must be re-calibrated after a factory reset. Tag names and other user configured limits, alarm settings, and valve information will also be lost and need to be restored. A factory reset will always reset the command source to analog 4-20 mA.

 NOTE: Once the Multi-Function Card (MFC) type has

been configured, the type selection will still remain after a factory reset.

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.

9.5 Viewing Version Numbers

The version number of the embedded code may be checked at any time except during a calibration. To see the major version number, hold the ▲Up button. This will not alter the operation of the unit other than to change the blink sequence to 3 blinks indicating the major version number. Holding the ▼Down button will give the minor version number without affecting operation. The version codes are interpreted according to the followi ng table:

Table 16: Viewing Version Numbers

For example, if holding the ▲Up button gave a G-G-R code, and holding the ▼Down gave a Y-Y-G code then the resulting version number would be 2.12.

flowserve.com 30

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Standard

Advanced upgrade

Pro upgrade

Analog command mode

Digital command mode

Out of service

Training in progress

Training complete

(blank)

Training not started

Pressure control locked

(blank)

Pressure control not locked

HART communication currently in progress

Burst mode in progress

(blank)

No HART communication currently in progress

CST ramping up

CST ramping down

(blank)

CST holding steady

CST not activated

10 POSITIONER FUNCTIO NS ( LCD

Display)

The optional LCD display provides a variety of useful information and functions. The Main View shows important information using icons and scrolling status lines. Using the directional buttons (▼▲►◄) to navigate the menu, the user can view detailed information perform commonly used functions.

 NOTE: The LCD backlight may change brightness during

use. This is normal. The backlight uses any residual power not used by other functions of the circuitry. When current supply is low (4mA) the light will appear darker. When current supply is high (20mA) the light will appear brighter.

10.1 Main Display View

The main view provides an instant display of important status parameters: Position, Final Command, Scrolling Status Message, Current Alarm Status and Status Icons.

10.1.1 Position and Command

The current Position and Command are always shown. This shows the Final Command which has been adjusted according to a Characterization Curve, MPC, or Soft Limits that have been applied and should match the Position.

10.1.2 Scrolling Status Messages

The Scrolling Status Message provides the following information as applicable: Date and Time – The date and time format is adjustable. See Section 10.3.9 Configuration (Set Time and Date) for more information. Ambient Temperature – This is the temperature inside the positioner. Supply Pressure – The supply pressure is available with Advanced and Pro upgrades. Friction – This is calculated when the valve moves. Friction is available with the Pro upgrade. Actuation Ratio – This is the amount of available force used to move the valve. Pneumatic Leak – This is leak beyond normal air consumption. Pneumatic Leak is available with the 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 Warning 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 Remaining - This shows the hours left in the training session if training is currently in progress. Auxiliary Card 1 Status - This shows the type of card in auxiliary card slot 1. Auxiliary Card 2 Status - This shows the type of card in auxiliary card 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 the Configuration Switches are set properly before performing a Quick-Cal.

10.1.3 Current Alarm Status

The Current Alarm Status area shows the highest priority alarm, warning, alert or status indication. This matches the code indicated by the flashing LEDs.

10.1.4 Status Icons

Status icons continuously show the state of the features and modes.

Table 17: Status Icons

Icon Location Icon Icon Meaning

Upgrade Level

Command

Source

Training Mode

Pressure

Control

HART

Communicatio

Continuous Stroke Test

(CST)

Upgrade Level Icons - The upgrade levels provide increased functionality beginning at none, then Standard, Advanced and finally Pro. These levels also correspond to the model numbers 510+, 520MD+, 521MD+ and 522MD+ respectively. A 510+ positioner has limited diagnostics and cannot be upgraded. A Standard (520MD+) has positioner positionbased diagnostics and can be upgraded to a 521MD+ in the field. An Advanced (521MD+) positioner includes pressure sensor functions and can be upgraded to a 522MD+ in the field. A Pro (522MD+) positioner includes the pressure sensor functions along with full diagnostic capabilities and is fully upgraded.

Command Source Icons – The positioner is in Analog Command mode if it is using th e 4-20 mA signal to control the location of the valve. In Digital Command mode, the positioner ignores the 4-20 command and responds to the position command given through HART. In Out Of Service mode, the positioner is performing a calibration, signature, partial stroke test or is in a factory reset state.

Training Mode Icons – The positioner can keep track of several key data parameters for a period of time specified by the user. This data can be viewed while setting alarm limits to make them more meaningful. For example, if supply pressure cycles every day from 5 bar to 4 bar in normal operation, this information will be displayed where the supply pressure warning limits are set. Seeing that the supply

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Final Command

Status Icon

Position

Scrolling Status

Current Alarm

typically drops to 4 bar, the user can then set the supply pressure low warning to a value below 4 bar. See the DTM User Manual for more information.

Pressure Control – When the position of the valve gets very close to the commanded position, the positioning algorithm will 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 +/-

1.0%, the pressure “locks”. This value can be adjusted using

the Display Menu or DTM. See section (Pressure Control

HART Communications Icons – When the positioner is sending or receiving data via the HART communication protocol, the icon will be displayed. During burst mode, a pulsating heart icon will be displayed.

Continuous Stroke Test (CST) – For valves that are normally 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 stability.

To achieve the CST function, the positioner adds a small deviation to the command. The deviation is ramped at a rate of 0.05%/second up to 5%. However, the instant the valve moves, the ramp reverses and begins to grow in the opposite direction. So, with low friction, the actual movement will be quite small. If the valve does not move by the time the deviation equals 5%, a counter will start. After 5 consecutive failed attempts to move, the CST warning will appear. The ramp rate, maximum limit, and frequency of the CST can be adjusted using the DTM.

10.3.7 Configuration

10.1.5 Adjusting the Display Contrast

To adjust the display contrast, hold the ◄ Back button for 3 seconds. Use the ▲Up and ▼ Down buttons to adjust the contrast. Use the ►ACCEPT/QUICK-CAL to accept the settings.

Message

Status

Figure 33: Display Main View

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

10.2 Menu Overview

Status

Command (mA) Command (%) Position (%) PS (Supply Pressure)* PA (Port A Pressure)* PB (Port B Pressure)* Friction** Actuation Ratio** Pneumatic Leak** Temperature Valve Cycles Valve Travel (%) Card 1 Value Card 2 Value

Alerts and Alarms

Current Alarms (Prioritized) Event History

Last Event 2nd Event 3rd Event

* * *

32nd Event

Partial Stroke Test

Start Last Result

Calibration

Stroke/Quick Calibration Pressure Sensor Calibration Friction Calibration Triple Calibration Command Input Calibration Calibration Dates

Configuration

Positioner 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 Hardware Rev

Factory Reset

Card 1 (or Card 2)

No Card: “No Card” Multi-Function Card

Not Configured Set as AO Card Set as DO Card Set as DI Card Config/Cal

If Not Configured – “No Configuration Allowed” If AO

Set 0%

Set 100% If DO – “Use DTM” If DI

Set to No Action

Set to Trigger PST

Set to Command Override

Set Command Point

Language

English German French Spanish Portuguese Russian Turkish Italian

* Requires Advanced positioner upgrade. ** Requires Pro positioner upgrade.

flowserve.com 33

10.3 Menu Features

►Status

** Requires Pro positioner upgrade.

►Alerts and Alarms

►

►Partial Stroke Test

►Calibration

►Calibration Dates

10.3.1 Status

►Command (mA) ►Command (%) ►Position (%) ►PS (Supply Pressure)* ►PA (Port A Pressure)* ►PB (Port B Pressure)* ►Friction** ►Actuation Ratio** ►Pneumatic Leak** ►Temperature ►Valve Cycles ►Valve Travel (%) ►Card 1 Value ►Card 2 Value

* Requires Advanced positioner upgrade.

The Status menu is used to view information about the configuration and operation of the system.

Command displays the final command in mA. Command displays the final command in %. Position displays the valve position in %. PS displays the supply pressure. PA displays the pressure in port A. This is the primary port if using a poppet-style relay module. PB displays the pressure in port B. This is the primary port if using a spool-style relay module. Friction displays the friction of the actuator/valve assembly. Actuation Ratio displays the force required to actuate the valve as a percentage of the total force available. The value is an estimate of the force that would be required to move the valve to the end of travel, fully compressing the actuator spring(s). Pneumatic Leak is an estimate of leak in addition to regular air consumption. Temperature displays the temperature inside the positioner. Valve Cycles are counted each time the positioner changes direction. The movement must be beyond a dead-band window. This window is set to 0.5% as a default, but can be changed using the DTM. Valve Travel is counted in small increments 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 represented 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 represented by a 1.

For example, if the Multi-Function Card (MFC) was in slot 1, configured as an analog output (AO), and giving 12.34 mA, the display would show “AO 1 12.34mA”. If no card is in the slot, the display will show “No Card”.

For more information about auxiliary card status, see Table 13: Auxiliary Card Status.

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

10.3.2 Alerts and Alarms

►Current Alarms (Prioritized) ►Event History

►Last Event ►2nd Event ►3rd Event

* * * 32nd Event

The Alerts and Alarms menu 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 Test

►Start ►Last Result

The Partial Stroke Test (PST) menu provides the user the ability to start a PST and see the results of the latest PST.

CAUTION: Performing a Partial Stroke Test will result in

valve movement and the inability to operate the valve until the test is complete. Notify proper personnel that the valve may stroke, and make sure the valve is properly isolated if required by plant procedures .

Start allows the user to initialize the (PST). Last Result shows “Pass” or “Fail” from the last PST attempt.

10.3.4 Calibration

►Stroke/Quick Calibration ►Pressure Sensor Calibration ►Friction Calibration ►Triple Calibration ►Command Input Calibration

The Calibration menu allows the user to calibrate the positioner’s sensors. The positioner can accurately control with only a Quick-Cal. Typically this is all that is needed. A friction calibration is recommended if the positioner has been upgraded to Pro diagnostics. See section 8 STARTUP for more details.

CAUTION: Performing a calibration may result in valve

movement and the inability to operate the valve until the calibration is complete. Notify proper personnel that the valve may stroke, and make sure the valve is properly isolated before proceeding.

Stroke/Quick Calibration starts an automatic calibration o f the position feedback sensor. The stroke calibration determines the closed (0%) and open (100%) positions of the valve and gathers information about the response of the valve (such as valve stroke time) in order to determine the gains. The gains are then set automatically. After a stroke calibration, the positioner is ready to control. See section Calibration for more information.

8.5 Stroke

flowserve.com 34

Pressure Sensor Calibration starts an automatic calibration of

►Configuration

►

►Configuration

the pressure sensors. The pressure sensors are calibrated at the factory and typically will not need calibration. Use this feature if new pressure sensors are installed. If desired, configure the positioner to use the most recent pressure calibration values after a factory reset. To do this, write a 1 to variable 104 using the Edit Variables page of the ValveSight DTM. Friction Calibration starts an automatic calculation of total system friction. This also determines the spring rate and other values critical to the Pro diagnostic functions.

 NOTE: Friction forces may change quickly when a valve

is first placed into service.

Triple Calibration performs Stoke, Pressure and Friction calibrations in one step. Command Input Calibration is used to adjust the input range. Set the lowest current (Set 0%) and the highest current (Set 100%) that will be used. The default input 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% strok e . 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 the value. Press the ▼Down button to move to “Set 100%”. Set the command

input current to 12 mA. (The display will show a high ADC to correspond to 12 mA.) Again press the ►ACCEPT/QUICKCAL button to set the value. Select the ◄Back Button to exit.

Signal At Closed = 20mA Example:

If the desired signal at closed is 20 mA, first set the Signal at Closed DIP switch to 20 mA. Then perform a stroke calibration by pressing the ►ACCEPT/QUICK-CAL button for more than 3 seconds. This registers the DIP switch settings. Then, in the Command Input Calibration menu, when the display shows “Set 0%” it is expecting the lowest current value. Set the input current to 4 mA. For “Set 100%”, it is looking for the highest current value. Set the input curren t to 20 mA. After accepting theses values, the positioner will interpret the 20 mA input as 0% valve position and the 4 mA input as 100%.

Calibration Dates lists the most recent date of each calibration.

 NOTE: To calibrate the Analog Output, see section 13

MULTI-FUNCTION CARD.

10.3.5 Configuration (Positioner Tuning)

►Positioner Tuning

The Configuration – Positioner Tuning menu allows the user to manually adjust individual tuning parameters. All tuning parameters are automatically set to optimal values during

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

►P-Gain Open ►I-Gain Open ►D-Gain Open ►P-Gain Close ►I-Gain Close ►D-Gain Close ►Open Stroke Time ►Close Stroke Time ►Minimum Open Time

Minimum Close Time

Quick-Cal. Typically a Quick-Cal is all that is needed for positioner tuning. See section 8 STARTUP for more details.

CAUTION: Adjusting the tuning parameters will affect

the responsiveness of the valve and could cause rapid changes to the valve position. Notify proper personnel that the valve may stroke, and make sure the valve is properly isolated before proceeding.

P-Gain, I-Gain and D-Gain are the proportional, integral, and differential elements of the feedback algorithm. These gains are different for the openi ng and c losing directions because typically responsiveness is differ ent in each dire cti on.

 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. Increasing this parameter will affect the responsiveness of the valve in the opening direction. Close Stroke Time is the fastest time it took the valve to stroke from 100% to 0% during Quick-Cal. Increasing this parameter will affect the responsiveness of the valve in the closing direction. Minimum Open Time and Minimum Close Time (Speed Limits) are used to prevent the valve from moving too quickly. This can be used when the process is sensitive to rapid flow or pressure changes. This shows the time (in seconds) that the positioner will allow the valve to travel a full stroke. This speed limit applies to smaller movements of the valve too.

For example, if the Minimum Open Time were set to 20 seconds, and the command was changed from 40% to 50%, the positioner would move the valve at a constant rate, taking 2 seconds to complete the move. If the Minimum Close Time was set to 0, and the command was changed from 50% back to 40%, the positioner would make the move as quickly as possible.

The default values are 0 seconds, meaning the positioner will move the valve as quickly as possible.

10.3.6 Configuration (Characterization)

►Characterization

►MaxFlo Linear ►MaxFlo Equal % ►Valdisk Linear ►Valdisk Equal % ►ShearStream Linear ►ShearStream Equal % ►Custom

The Configuration – Characterization menu allows the user to change the characterization of the command. Thi s 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. The table below shows the available characterization curve options. Each point of the Custom curve can be adjusted using the ValveSight DTM.

To view the characterization curve options, set the Characterization switch “Other” before performing a QuickCal. Otherwise, the only option available is “Linear”. If a Quick-Cal is not possible, use the ValveSight DTM to select the curve.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table 18: Characteristic Curve Data

Final Command

0.0

0.00

5.0

5.00

6.50

1.00

13.00

4.00

25.00

8.00

0.62

10.0

10.00

11.60

2.00

20.00

6.00

35.00

14.00

1.35

15.0

15.00

16.20

3.00

26.25

7.80

44.00

17.00

2.22

20.0

20.00

20.50

4.40

32.10

9.30

50.20

21.00

3.25

25.0

25.00

24.60

5.80

37.50

11.50

55.50

24.00

4.47

30.0

30.00

28.50

7.40

42.60

14.00

60.20

27.50

5.91

35.0

35.00

32.40

9.30

47.40

16.50

64.30

31.50

7.63

40.0

40.00

36.20

11.20

51.80

19.30

68.00

35.50

9.66

45.0

45.00

40.00

13.50

56.00

22.50

71.50

39.50

12.07

50.0

50.00

43.80

16.10

60.00

26.00

74.70

43.90

14.92

55.0

55.00

47.60

19.10

63.60

30.00

77.70

48.10

18.31

60.0

60.00

51.50

22.40

67.20

34.70

80.50

52.80

22.32

65.0

65.00

55.50

26.20

70.60

39.60

83.20

57.40

27.08

70.0

70.00

59.50

30.60

73.90

45.10

85.90

62.40

32.71

75.0

75.00

63.80

35.70

77.20

51.30

88.40

67.50

39.40

80.0

80.00

68.20

41.70

81.30

57.80

90.80

72.90

47.32

85.0

85.00

73.00

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

►Configuration

►

►Configuration

Command

Input

Characterizatio

n DIP set to

“Linear”

Linear

MaxFlo

Linear

MaxFlo

Valdisk

Linear

Characterization

DIP set to

“Other”

Valdisk

Shear-

Stream

Linear

Shear-

Stream

Custom

(Default)

(Linear =%)

100

90 80 70 60 50 40

Final Command

30 20 10

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 customized point-by point. To modify the Custom curve, use the ValveSight DTM.

CAUTION: Changing the characterization curve may

cause the valve to move suddenly. Notify proper personnel that the valve may stroke and if required, make sure the valve is properly isolated before proceeding.

10.3.7 Configuration (Pressure Control)

►Pressure Control

0 10 20 30 40 50 60 70 80 90 100

Command Input

Figure 34: Characterization Curv es

Window

Linear

MaxFlo Linear

MaxFlo =%

Valdisk Linear

Valdisk =%

ShearStream Linear

ShearStream =%

Custom

The Configuration (Pressure Control) menu allows the user to change the size of the pressure control window. This window becomes active when the Valve Stability Switch is set to “Hi”. The Valve Stability Switch optimizes the response for valves and actuators with high friction levels. When set to “Hi”, it slightly slows the response and will normally stop limit cycling that can occur on high friction valves.

Window - When the position of the valve gets within the pressure control window, the positioning algorithm will change to pressure control. This means the pressures will be held constant (locked), improving the stability of the valve position.

10.3.8 Configuration (Soft Limits and Shutoff)

►Soft Limits & Shutoff

►High Soft Limit ►Low Soft Limit ►Upper Position Shutoff ►Lower Position Shutoff

Soft Limits allows the user to limit the movement of the valve. Shutoff allows the user to tightly shut the valve with all available force.

High Soft Limit and Low Soft Limit - This feature is us ed to simulate physical blocks on the valve that restrict movement past a set point. Once the Soft Limit is set, the positioner will not attempt to move the valve position (final command) beyond the set point, regardless of the analog or digital command input signal.

CAUTION: Changing the Soft Limits may limit the

movement of the valve. The valve may not shut or open fully.

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 NOTE: Removing power to below 3.6 mA will still cause

International

(Default)

North

(English)

Options

kg/cm2,

kPa

slpm,

Nm3/hr

►Configuration

►

►Configuration

►On/Off

►Configuration

► HART Ver

►Configuration

► Factory Reset

the valve to move to the 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 used to tightly close or open the valve. It is used when a tight seal is needed or when debris or friction may otherwise interfere with complete closure. When the valve is commanded past the Shutoff points, the pilot relay will direct full supply pressure to the appropriate port, applying all available force to close (or open) the valve. The Shutoff points apply to the Final Command.

CAUTION: Changing the Shutoff limits may cause the

valve to fully open or fully close after the command 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)

►Set Date & Time

The positioner has an internal clock. The clock allows time and date information to be stored with alarms and other events. The clock does not account for daylight savings.

Set Time and Date – Use the ▲Up and ▼Down buttons to set the time and date. The format of the time and date is displayed above the input fields.

10.3.10 Configuration (User Preferences)

►User Preferences

The User Preferences menu allows the user to format how information is displayed.

The following table shows the available options. By default the positioner is set to show information in International System (SI) units. To change all units to North American (English), make the selection under All Units. Each selection can also be changed individually.

►All Units ►Pressure Units ►Force Units ►Temperature Units ►Air Flow Units ►Actuator Area Units ►Date Format ►Number Format

LCD Orientation

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table 19: User Preference Options

Units/Format

All Units SI North American -

Pressure bar PSI

Force N lbf kg

Temperature degrees C degrees F -

Air Flow slph scfm

Actuator Area

Date Format Day.Mon.Year Mon/Day/Year -

Number Comma Decimal Point -

System (SI)

cm2 in2

American

Other

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

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 Revs

► SW Rev ► Bld Date ► Bld Time ► HW Rev ► CPU Rev

Positioner revisions are shown in this menu. SW Rev –The revision of the embedded software.

Bld Date –The date of the embedded software build. Bld Time –The time of day of the embedded software build. HW Rev –The revision of the main board. CPU Rev – The revision of the CPU. HART Ver –The revision of the HART protocol (5, 6, or 7).

10.3.13 Configuration (Factory Reset)

At times, it may be convenient to reset all of the variables to a default state. In this case, perform a Factory Reset.

Factory Reset – Use this feature to reset all variables to their factory default state. All of the internal variables including calibration will be reset to factory defaults. The positioner must be re-calibrated after a factory reset. Tag names and other user configured limits, alarm settings, and valve information will also be lost and will need to be restored. A factory reset will always reset the command source to analog 4-20 mA.

flowserve.com 37

 NOTE: Once the Multi-Function Card (MFC) type has

►Card 1 (or Card 2)

►

► Language

►Italian

been configured, the type selection will still remain after a factory reset.

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 MultiFunction Card (MFC) can be configured for analog output (AO), Discrete Input (DI) and Discrete Output (DO).

►No Card

No Card – This is displayed when no card is present in the slot.

►Multi-Function Card

►Not Configured ►Set as AO Card ►Set as DO Card ►Set as DI Card ►Config/Cal

► ►If AO

►If DO – “Use DTM” ►If DI

Multi-Function Card – This is displayed when a MultiFunction Card is present in the slot. Configuration options follow. See section information. Not Configured – The MFC is not configured for any function by default. The configuration must be set by using the following functions. Set as AO Card – Use this feature to set the MFC as an analog output card. Set as DO Card – Use this feature to set the MFC as a discrete output card. Set as DI Card – Use this feature to set the MFC as a discrete input card. Config/Cal – Use this feature to further configure the FMC. The menu items below this level will change according to the MFC configuration type selected.

If Not Configured

No Configuration Allowed – Because the card type has not been selected, no configuration option s are avail able .

If Set As AO Card

Set 0% - Set the current (mA) that will correspond to the 0% (closed) valve position. Set 100% - Set the current (mA) that will correspond to the 100% (open) valve position.

 NOTE: The AO calibration values are required to match

the “Signal At Closed” configuration 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.

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

If Not Configured – “No Configuration Allowed”

►Set 0% ►Set 100%

►Set to No Action ►Set to Trigger PST ►Set to Command Override

Set Command Point

13 MULTI-FUNCTION CARD for more

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 stroke test when the DI state goes high. Set to Command Override - Use this option to override the analog or digital command input to move the valve to a set position as long as the DI state remains high. Set Command Point – Use this feature to set the override position. The position is a final command (not characterized). Tight Shutoff settings and Soft Limits will still apply.

10.3.15 Language

►English ►German ►French ►Spanish ►Portuguese ►Russian ►Turkish

The display menu is available in several languages. To navigate directly to the language menu, select the

following sequence of buttons: ▲Up , ▲Up, ►QUICK-CAL / ACCEPT.

flowserve.com 38

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Variable

Primary

4-20 Command (%)

Secondary

Final Command (%)

Tertiary

Purchased with Standard Diagnostics:

Quaternary

Valve Position (%)

HART DIP Switch

HART 6

HART 7

1 2 3 4

HART 5

1 2 3 4

11 HART COMMUNICATION

The Logix 520MD+ series positioners use the HART communication protocol specified by the HART Communication Foundation.

11.1 ValveSight DTM

Flowserve Corporation has produced a custom Device Type Manager (DTM) for the Logix 520MD+ digital positioners to support the ValveSight diagnostics platform.

The DTM contains a high level “Dashboard” view of the system health and status information. It also contains comprehensive user-friendly interfaces for control and reporting of alarms, of-line and on-line diagnostic tests, calibrations and system configurations.

The ValveSight DTM is available from a Flowserve representative or from www.valvesight.com.

(default)

Figure 35: ValveSight DTM Dashboard

11.2 HART 375/475 Handheld Communicator

The Logix 520MD+ digital positioner supports and is supported by the HART 375/475 Handheld Communicator. The Device Description (DD) files can be obtained from the HART Communication Foundation or from your Flowserve representative.

11.3 Changing HART Versions

The Logix 520MD+ positioner comes standard with the HART 6 communication protocol. Follow this procedure to change to HART 5 or 7.

1 Remove the outer cover. 2 Remove the inner cover by removing the 6 inner cover

retaining screws.

CAUTION: Observe precautions for handling

electrostatically sensitiv e devi c es.

3 With a clean, non-conductive instrument, change the

position of DIP switch according to Figure 36: HART DIP Switch. After changing the DIP switch, the positioner will immediately recognize the new HART communication protocol.

4 Replace the covers.

Figure 36: HART DIP Switch

11.4 Burst Mode

Burst Mode is available with a handheld device. In the handheld, select the Burst Mode feature under the Configuration Menu. Variables that are transmitted in burst mode are shown in the table below.

Table 20: Default HART Parameters for Burst Mode

HART

Data Description

Temperature (C) Purchased with Advanced or Pro Diagnostics: Supply Pressure (bar)

 NOTE: These variable assignments are reestablished

during a factory reset. A field upgrade will not change the tertiary variable.

 NOTE: The DTM will not function while the positioner is in

Burst Mode.

flowserve.com 39

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table

ValveSight Basic

ValveSight Advanced

Logix 505+

Logix 510+

Logix 520MD+ (Standard)

Logix 521MD+ (Advanced)

Logix 522MD+ (Pro)

Hardware

Software

(Monitor and Save Sensor Data)

(Supply, Port A, Port B)

Control)

(High Speed Internal Data Capture)

15: Logix 500+ and ValveSight DTM Features

12 MODEL FEATURES

DTM Positioner

12.1 Logix 505+

The Logix 505+ digital positioner includes –

• the QUICK-CAL feature that allows the positioner to be

calibrated at the push of one button.

• limited diagnostics that monitor position, the pilot relay

and electronics.

• a 4-DIP configuration switch includes air action, split

range options and a gain adjustment.

12.2 Logix 510+

The Logix 510+ digital positioner includes –

• an 8-DIP configuration switch for flexible set-up.

• a 10-position gain selector switch is also included for

quick adjustments to responsiveness.

• an LCD option provides a dashboard for viewing current

status and a complete menu for viewing and configuring detailed settings.

• up to two auxiliary cards for analog output (AO), discrete

input (DI) and discrete output (DO) functions.

Quick Calibration Button 3-LED Indicator 4-DIP Configuration 8-DIP Configuration 10-Position Gain Adjustment Switch LCD Display Option Auxiliary Cards (AO, DO, DI)

12.3 Logix 520MD+

The Logix 520MD+ digital positioners include –

• HART communication.

• a DTM for viewing and controlling advanced features.

• Additional diagnostics depending on the diagnostic level

chosen.

12.4 MD+ Positioner Diagnostic Levels

The Logix 520MD+ digital positioners have three levels of diagnostics, “Standard”, “Advanced”, and “Pro”.

• “Standard” diagnostics provide complete safety and

position-related diagnosti cs an d data.

• “Advanced” diagnostics provide additional pressure

data.

• “Pro” diagnostics enhance the off-line tests with

additional force data, and provide powerful on-line monitoring capabilities including friction, data logging functions, and comprehensive system health information.

12.5 Valvesight DTM Diagnostic Levels

The DTM is not required for the positioner to function, but the graphical capabilities of the DTM allow for a richer interface and additional functionality, including viewing the dashboard, charts, annunciator panel, test comparisons, and data logs and printing reports.

The DTM also comes in two versions: “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 “Pro” diagnostic functionality.

It is generally wise to use the Advanced DTM with the Advanced and Pro positioners.

Pressure Sensors On Board Clock Humidity Sensor

HART Communication Off-Line Diagnostics

(Ramp Test, Step Test, HDRL, Partial Stroke Test )

Data Monitor

Pressure Sensor Data

Pro Diagnostics

(Force, Actuation, Pneumatic Leak, Continuous Stroke Testing, etc.)

Health Evaluation

(Valve, Positioner, Actuator and

Training (Determines Typical Behavior)

Data Logging

Long-Term Trend Logging (14 parameters over 15 years)

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X X

X X

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Analog Output Specifications

Electronic Connections

MultiCard

13 MULTI-FUNCTION CARD

The optional Multi-Function Card (MFC) can be configured to act as an Analog Output, Discrete Output, or Discrete Input. Up to two MFCs may be installed at one time. MFCs are immune to RFI/EMI disturbances. See certifications in section

Table 21: Multi-Function Card Cross-References

Information IOM Section

2.5 Analog Output

7.3 Multi-Function Card (AO, DO, DI)

Configuration 10.3.14 Card 1 (or Card 2) Certifications 3 Hazardous Area Certifications Status Table 13: Auxiliary Card Status

Function

Figure 37: Multi-Function Card

13.1 Analog Output (AO)

Configure the MFC as an Analog Output device to produce a 4-20 mA signal that corresponds to the position of the valve. Output follows actual position of valve, including all failure modes of positioner except loss of power. An output of < 1.0 mA is transmitted when the positioner loses pow er .

Calibration of the analog output signal is performed using the display menu, a HART handheld communicator, or the ValveSight DTM .

The MFC configured as an AO does not interfere with positioner operation.

 NOTE: The AO signal corresponds with the Signal At

Closed configuration switch setting. If the valve closes with 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.

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 occu rs.

Configuration of the discrete output signal is done using the ValveSight DTM.

The MFC configured as a DO does not interfere with positioner operation.

The MFC DO complies with DIN 19234 standard. For specific curren t li mits, see Table 13: Auxiliary Card Status.

13.3 Discrete Input (DI)

Use the Discrete Input function of the MFC to signal the positioner to begin a partial stroke test, or move to a predefined position as long as the signal remains.

Supply a low voltage (or no voltage) to indicate a normal state. Raise the voltage to indicate the tripped state.

Configuration of the discrete output signal is done using the display menu, a HART handheld Communicator, or the ValveSight DTM .

For specific voltage limits, see Table 13: Auxiliary Card Status.

 NOTE: When 2 cards are configured as DI at the same

time, where both are configured to override the position command, the card in slot 1 will take priority regardless of the order in which the override commands are triggered.

CAUTION: During the use of the Discrete Input function,

the valve may stroke unexpectedly. Follow internal procedures, ensuring that the configured movement of the valve (performing a PST or moving to a set-point) is allowed . Notify proper personnel that the valve will strok e, and make sure the valve is properly isolated if required.

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Electronic Specifications

Electronic Connections

Install or Adjust the Limit Switch

Ordering Limit Switches

Ordering a Board

Ordering a Device

Limit Switches

Vane

Terminals

14 LIMIT SWITCHES

15 REMOTE MOUNT

14.1 Limit Switch Principles of Operation

The Logix 500+ digital positioner can be equipped 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 activated. The switching point can be adjusted.

Four types of Limit Switches can be used with the Logix 500+.

14.2 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.

Inductive switches are triggered when the sensor detects a ferromagnetic vane approaching the coils in the switch. No physical contact occurs.

Table 22: Limit Switch Cross-References

15.1 Remote Mount Opereation

The remote mount option can be used where excessive vibration or environmental factors prevent the placement of a positioner directly on the valve.

The remote mount unit consists of just the feedback mechanism enclosed in a sturdy container. This assembly is mounted to the valve/actua tor ass emb ly . The actuator tubing and feedback signals are routed some distance to the positioner. Tubing is connected to the positioner. The feedback signal wires are connected to a remote mount board installed in the Logix 500+ positioner.

Table 23: Remote Mount Cross-References

Information Section Page

Electronic Specifications

Electronic Connections

Remote Mount

For more information on the remote mount option, see Logix Remote Mount Option user instructions, FCD LGENIM0001.

2.6 Remote Mount Specifications 8

7.5 Remote Mount 25

20.2 Spare Parts Kits 62

20.5 Mounting Kits 62

Information IOM Section

2.7 Limit Switch Specifications

7.4 Limit Switches

17.4 Installing a Limit Switch

20.2 Spare Parts Kits

Figure 39: Remote Mount Board

Figure 38: Limit Switches

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

16 REQUIREMENTS FOR SAFETY

INTEGRITY

This section provides information and additional user responsibilities in order to meet up to Safety Integrity Level 3 (SIL 3) per IEC 61508.

The safety function of the positioner is to go to the fail-safe state (vent air from the actuator) given a low power condition to the 4 to 20 mA input terminal.

16.1 Fail Safe State

The fail safe state for a positioner with a three-way (SingleActing), Poppet Style Relay is when the relay valve is at less than 5% of full stroke such that output port B (Y1) is venting.

The fail safe state for a positioner with a three-way (SingleActing), Spool Style Relay is when the relay valve is at less than 5% of full stroke such that output port A (Labeled Y1) is venting.

The fail safe state for a positioner with a four-way (DoubleActing), Spool Style Relay is when the relay valve is at less than 5% of full stroke such that output port A (labeled Y1) is venting and port A (labeled Y2) is open to supply pressure.

NOTE: The fail safe states above represent the fail safe state of the positioner. The v alve fail safe state may be different depending on spring configuration and tubing. Ensure the valve fail-safe state is appropriate for your appl ication.

16.2 Safety Function

The Logix 520MD+ positioner moves to fail-safe stat e upon the removal of analog input power (less than 3.6 mA)

16.3 Fail Safe State Response Time

Test to find the final valve assembly response time to ensure it meets application-specific requirements. Response times will vary widely with actuator size, the use of boosters, stroke length, starting position, fail-safe direction, tubi ng siz e, sup pl y pressure, and temperature. The air flow capacity also affects the response time. See section 2.3 Pneumatic Output for air flow capacity.

A typical* response time for the spool relay to move to a failsafe state due to a sudden command change was found to be 0.06 seconds. (The response time was 0.50 s at -40C and .35 s at 85C.)

The time for the valve to move to fr om 50% to 0% under the same conditions was found to be 0.22 s. Friction in this case was 49.5 lbs (220 N).

*Tests were with a 25 inch doubl e acting Mark 1 actuator, 0.75 inch (19 mm ) stroke, ambien t temperature 74°F ( 23.3 °C), 60 PSI (4.1 bar) s upply, 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 were with 60 PSI (4.1 bar) supply pressure.

NOTE: During the stroke calibration (Quick-Cal), valve stroke times are measured and recorded in the positioner. To view them, see tuning parameters on the positioner menu or in the DTM.

16.4 Positioner Model Selection and

Specification

Any Logix 520MD+ positioner can be used for up to SIL 3 applications as stated above.

16.5 Installation

Ensure installation of the positioner is properly performed according to this manual. Ensure tubing is configured to the actuator so that the fail-safe state of the positioner matches the desired fail-safe state of the valve.

16.6 Required Configuration Settings

The following user settable options must be properly configured for the individual application in order to provide the designed safety integrity for that application.

• Calibrate the analog input (command). The fail safe state of the valve must correspond to the analog input command at less than 3.6 mA.

• It is recommended to lock the local interface to prevent unintended adjustments of the settings by an unauthorized user.

16.7 Maximum Achievable SIL

The Flowserve 520MD+ Valve Positioner covered by this safety manual is suitable for use in low demand mode of operation Safety Integrity Functions (SIF) up to SIL 2 in simplex (1oo1) and SIL 3 in redundant (1oo2) configurations. The achieved SIL for a particular SIF needs to be verified by PFD rates of the associated sensors and valves that are also part of the SIF.

For details, contact your Flowserve representative for Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report number 520+ is FLO 11-02-062 R001 for Logix 520MD+.

calculation for the entire SIF including the failure

AVG

16.8 Reliability data

For reliability data, a detailed Failure Mode, Effects, and Diagnostics Analysis (FMEDA) report has been prepared and is available from Flowserve with all failure rates and failure modes for use in SIL verification. See FMEDA report number FLO 11-02-062 R001 for Logix 520MD+.

NOTE: The failure rates of the associated sensors, logic solver, valves and actuators need to be accounted for in the Safety Instrumented Function (SIF) level PFD

calculation.

AVG

16.9 Lifetime limits

The expected lifetime of the Flowserve 520MD+ Positioner is approximately 10 years. The reliability data listed the FMEDA report is only valid for this period. The failure rates of the Flowserve 520MD+ Valve Positioner may increase sometime after this period. Reliability calculations based on the data listed in the FMEDA report for lifetimes beyond 10 years may yield results that are too optimistic, i.e. the calculated Safety Integrity Level may not be achieved.

16.10 Proof Testing

The objective of proof testing when used in low demand mode of operation is to detect failures within the Flowserve 520MD+ Valve Positioner and its associated sensors and actuators that may not be detected by the normal selfdiagnostics. Of main concern are undetected failures that prevent the safety instrumented function from performing its intended function.

The frequency of the proof tests (or the proof test interval) is to be determined in the reliability calculations for the safety instrumented functions for which the Flowserve 520MD+ Valve Positioner is applied. The actual proof tests must be performed at least as frequently as specified in the calculation in order to maintain required safety integrity of the safety instrumented function.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

3. Ensure that the attached valve is fully in the safe state (defined by application) and has moved to that position

could prevent the closure of the valve, including electronic

Valve Positioner for any visible

damage or contamination and ensure the follower arm has

restore normal operation.

The following tests need to be specifically executed when a proof test is performed. The results of the proof test need to be documented and this documentation should be part of a plant safety management system.

NOTE: Positioner failures that are detected should be reported to Flowserve.

To perform the proof testing, an LCD display or HART communicator such as a 375 Handheld or software such as ValveSight DTM for Logix 520MD+ are required.

Steps for Proof Test

Step Action

1. Bypass the safety PLC or take other appropriate action to avoid a false trip.

2. Set the analog input command to less than 3.6 mA.

within the allowed time. This will test for all failures that and mechanical faults, as well as valve faults.

4. Inspect the 520MD+

16.12 Repair and replacement

In the unlikely event that the Flowserve 520MD+ Valve Positioner fails, the fail ure should be reported to Flowserve. Replace faulty components according to section 17 of this manual or return the positioner to Flowserve for service. With experience and the right parts, repair times for any component can be less than an hour, however a 24 hour mean time to repair should be assumed for safety availability calculations.

16.13 Training Requirements

Activities specified in this manual shall be performed by a service technician trained in the installation and maintenance of process instrumentation. See section 1.4 Qualified Personnel

sufficient spring bias if applicable.

5. Check the errors generated by accessing the Alerts and Alarms menu on the LCD or the Alarm Annunciator in the DTM or other HART system using command 48.

6. Remove the bypass from the safety PLC or otherwise

When the tests listed above are executed, a proof test coverage 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 implemented 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 leaking of the valve seat for fail closed valves.

Steps for Partial Stroke Test (PST)

Step Action

1. Verify the control loop is ready for valve movement in the amount set for the PST.

2. Execute the PST via the LCD menu, DD, or DTM.

3. View the results of the PST via the LCD menu, DD, or DTM.

4. Check the errors generated by accessing the Alerts and Alarms menu on the LCD menu, DD, or the Alarm Annunciator in the DTM or other HART system using command 48.

When the tests listed above are executed, a proof test coverage 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 implemented in a SIL rated logic solver. If PST has been impleme nted 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 fail closed valves.

16.11 Maintenance

Follow routine maintenance. See section 17.1 Scheduled Maintenance.

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User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

4 5 3

Philips Screwdriver #2 ________

17 MAINTENANCE AND REPAIR

The kits listed in section 20.2 Spare Parts Kits can be replaced by a technician trained in positioner function and handling of static sensitive device s.

CAUTION: Depressurize the positioner before servicing. CAUTION: Use eye protection. CAUTION: When touching the circuit boards, observe

precautions for handling electrostatically sensitive devices.

17.1 Scheduled Maintenance

The supply gas filter(s) should be scheduled for regular maintenance as required to maintain supply gas quality. If contamination is found in the filter, the inside of the positioner should be visually inspected for contamination. If contamination is found in the positioner, the positioner should be replaced.

17.2 Required Tools and Equipment

The Logix 500+ digital positioner has modular components that can be replaced using these tools:

Philips Screwdriver #1 ________ Slot Screwdriver (≤ 3.5mm) ________

2.5 mm Hex Key ________

2.0 mm Hex Key ________

Figure 40: Tools for Positioner Maintenance

The spool, block and manifold of the double acting relay can be cleaned using acetone, a soft cotton cloth and cotton swabs.

17.3 Torque Specification for Screws

Table 24: Torque Specification for Screws

Outer Cover (4 Screws) 1.7 N-m (15 in-lb) Limit Switch (3 Screws) 0.56 N-m (5 in-lb) Limit Switch Vane (2 Screws) 0.34 N-m (3 in-lb) Inner Cover (6 Screws) 0.34 N-m (3 in-lb) LCD (4 Screws) 0.34 N-m (3 in-lb) Main Board (2 Screws) 0.34 N-m (3 in-lb) Pressure Board ( 6 Screws) 0.68 N-m (6 in-lb) Double Acting Relay Block ( 2 Screws) 0.56 N-m (5 in-lb) Double Acting Relay manifold (2 Screws) 0.56 N-m (5 in-lb) Single Acting Relay (2 Screws) 0.56 N-m (5 in-lb)

17.4 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 positioner.

For electrical connection diagrams, see Table 14: Limit Switch Connections. For electrical specific ations, s ee Table 7: Limit Switch Specifications.

 DANGER: 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 conformance. Country specific regulations may apply. Electrical safety is determined only by the power supply device. (Positioner oper at ion w ith limit ed volt age onl y).

Installation 1 Remove the outer cover. 2 Place the limit switch board (1) onto the Inner cover (2)

and secure it with 3 mounting screws (3).

3 Install vane assembly (4) and secure with 2 screws (5). Adjusting Switches

1 Loosen the two screws on the vane (5). 2 Stroke the valve to the first switching position. 3 Set the switching point of the limit switch by adjusting

the lower vane for the lower switch (LS2). 4 Stroke the valve to the second switching position (LS1). 5 Set the switching point of the limit switch by adjusting

the vane for the upper switch. 6 Tighten the two screws on the vane (5). 7 Attach wires to terminals. See section 7.4 Limit

Switches. 8 Check the two switching points and repeat the

adjustment steps 1 to 6, if necessary. 9 Replace the outer cover.

Figure 41: Limit Switch

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Auxiliary Card Clips

Auxiliary Card LCD

Inner Screws

17.5 Replacing the LCD Board

The LCD board connects to the main board providing additional functionality at the local user interface.

Removal 1 Make sure the valve is bypassed or in a safe condition. 2 Disconnect power to the positioner. 3 Remove the inner cover by removing the 6 inner cover

retaining screws. 4 Unscrew the 4 screws holding the LCD Board in place. 5 Gently pry the locking feature on the connector with a

small flat screwdriver and separate the connector from

the main board. Be careful not to pull the cable, as this

may cause damage to the cable. Installation

1 Connect the LCD Board to the Main Board using the

cable. Ensure the connector’s locking features engage. 2 Align the LCD Board with the 4 stand-offs on the main

board. 3 Screw the LCD Board to the 4 stand-offs. 4 Replace the Inner Cover.

 NOTE: The LCD backlight may change brightness during

Cover

17.6 Replacing 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.

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 Gently pry the locki ng feature on the connector with a

small flat screwdriver and separate the connector from

the card. Be careful not to pull the cable, as this may

cause damage to the cable. 8 Replace the second card (if present) back int o the slot. 9 Replace the auxiliary card clips.

Installation 1 Make sure the valve is bypassed or in a safe condition. 2 Disconnect the power to the unit. 3 Remove the main cover. 4 Unscrew and remove the auxiliary card clips. 5 If a card is present, gently slide the card from the slot to

access the internal connector. 6 Connect the card to the main board using the internal

connector cable. Ensure the connector’s locking

features engage. 7 Gently slide the card(s) into the slot(s).

CAUTION: Ensure proper circuitry is used before

connecting cables to the auxiliary card. See section 7 ELECTRICAL CONNECTIONS for more information.

8 Route the external cable through the electrical co nduit

ports in the base and connect the external cable to the

auxiliary card. See Figure 37: Multi-Function Card. 9 Replace the auxiliary card clips. 10 Reinstall the main cover.

Figure 42: Inner Cover

Screws

Figure 43: LCD

Terminals

+ -

Figure 44: Auxiliary Card

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Feedback Connector

Piezo

Pressure Connector

Hall Connector

Main Screws

Pressure Screws

17.7 Replacing a Main Board

Removal 1 Make sure the valve is bypassed or in a safe condition. 2 Remove the outer cover. 3 Disconnect the power to the positioner. 4 Remove the inner cover. See Figure 42: Inner Cover

above. 5 Disconnect the power cable to the main board. 6 Disconnect the auxiliary card cable if present. See

Figure 44: Auxiliary Card on page 46. 7 Disassemble the switch mechanism if present. 8 Remove the inner cover by removing the 6 retaining

screws. See Figure 42: Inner Cov er. 9 Remove the screws from the main circuit board. See

Figure 45: Main Board Screws. 10 Gently lift the main board rotating the bottom up while

keeping the top in place. 11 Disconnect the pressure sensor board cable, the hall

sensor cable, the piezo cable and the feedback cable.

(Use a small flat screwdriver to pry the locking features

and carefully separate the connector from the main

board. Be careful not to pull the cable, as this may

cause damage to the cable.) Installation

1 Place the main board on the positioner base with the 4-

20 mA input on the same side as the electronic access

ports. 2 Lift the main board rotating the bottom (configuration

switches) 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 Plac e 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.

17.8 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 holes. 2 Cover the O-rings with the pressure sensor board. 3 Insert the 6 screws. Tighten until the pressure sensor

board makes firm contact with the base.

Calibration 1 Initiate a Pressure or Triple Cal ibration from the LCD or

DTM.

2 To calibrate the supply pressure sensor 0 value,

disconnect the supply air. Go to Edit Variables. Write the value from variable 74 (PS ADC Count) to variable

71. (PS ADC Count at 0 psi). Reconnect the supply air.

3 To keep the calibration values even after a Factory

Reset, write a 1 to Variable 104.

Sensor

Figure 47: Pressure Sensor Board

Board

Figure 45: Main Board Screws

Pot

Connector

Figure 46: Main Board Connectors

Sensor

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Spool

Clip Block

Base

Double

Manifold Screws (2)

Manifold Gasket (2 of 2)

Spool/ Block Assembly

Spool Block Screws (2)

Manifold Gasket (1 of 2)

Manifold

Spool and Clip Spring

Piston

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

17.9 Cleaning and Replacing a Double Acting Pilot Relay

Removal 1 Remove the Main Board. See procedure above. 2 Fully loosen the 2 spool block screws. By squeezing

the two screws toward each other, grip the spool block and pull it straight out. Take care to slide the spool straight out of the spool seat to avoid bending the spool or damaging the clip spring. The small clip spring

should remain attached to the spool. 3 Remove the first manifold gasket. 4 Remove the 2 manifold screws. 5 Remove the manifold assembly. 6 Remove the second manifold gasket and manifold 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.

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 spool is oriented properly in the block.

Ensure the clip spring is oriented properly on the spool.

(See 48-Figure 50. ) Holding the block level, slide the

spool/block/clip spring assembly onto the manifold

ensuring the proper placement of the spool and clip

spring into the piston slot and tighten the 2 spool block

screws. 6 Reassemble the main board and covers and calibrate.

Figure 48: Inserting the Double Acting Block Assembly

Acting Relay Manifold Assembly

O-Ring

Figure 49: Double Acting Relay Assembly

Spring

Figure 50: Clip Spring Orientation

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Base

Manifold

Supply

Single Acting Relay

Relay Assembly Screws (2)

17.10 Replacing a Single Acting Pilot Relay

Removal 1 Remove the Main Board. See procedure above. 2 Remove the two relay assembly screws. 3 Remove the single acting relay. 4 Remove the supply 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 Reassemble the main board and covers and calibrate.

Plug Screw and O-Ring

Gasket

Figure 51: Single Acting Relay Assembly

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Table 25: Troubleshooting Guide

3. Incorrect wiring polarity.

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

1. Maximum allowable current source rate of change is

to create

1. Switch to analog command mode using the

1. Perform stroke calibration (Quick-Cal)

1. Check air supply for proper filtering and meeting

22 µF 250Ω

Control System

HART

Device

→

To Logix

18 TROUBLESHOOTING

18.1 Troubleshooting Guide

Failure Probable Cause Corrective act ion

No LED is blinking.

Erratic communications.

Unit does not respond to analog commands.

Valve position reading is not what is expected.

1. Current source too low.

2. Voltage of current source is too low.

1. Current source bandwidth not limited to 25Hz.

2. Maximum cable length or cable impedance exceeded.

3. HART modem connected to PC RS232 port not receiving enough power

4. Interference with I.S. barrier.

5. Current source stripping (filtering) HART signal.

1. The positioner is in digital command mode.

2. An error occurred during calibration.

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.

2. Verify voltage source supplies at least 10VDC.

3. Check wiring for correct polarit y .

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 a HART filter according to the following schematic.

Comm

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.

1. Reposition the sensor.

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

3. Verify Tight Shutoff settings.

4. Verify custom characterization or soft-st op lim its .

Position is driven fully open or closed and will not respond to command.

Sticking or hunting operation of the positioner

LCD backlight flickering or dim.

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. Contamination of the electropneumatic converter.

2. Control tuning parameters not correct.

3. Packing friction is high.

4. Spool valve is corroded or dirty.

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

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.

ISA specifications ISA-7.0.01.

2. Lower proportional gain settings.

3. En able the stability DI P switch on the local interface and recalibrate. If problem persists, adjust pressure control wi ndow with handheld communicator or ValveSight and recalibrate.

4. Disassemble and clean spool valve.

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

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18.2 Status Code Index

 NOTE: Not all status codes are available with all pos iti on er models.

Table 26: Status Code Index

Description Status Code

A/O Cal in Prog GRGY A/O Range Small RGYR Actuation Ratio WRN YYYY Actuator Cycles WRN YGGY Actuator Travel WRN YGGY Air Supply Humid WRN YYRY Air Supply Icing WRN YYRR Analog In < ADC Range RGGG Analog In > ADC Range RGGG Analog In Cal Error RGGG Analog In Cal in Prog GRGY Analog In Range Small RGGG Backlash ALM RRYY Backlash WRN YRYY Bellows Cycles WRN YGGY Bellows Travel WRN YGGY Calibration in Progress GRGY Card 1 Error RYYR Card 1 Fail WRN RYYR Card 1 No Loop Pwr RYYR Card 1 WRN RYYR Card 2 Error RYYY Card 2 Fail WRN RYYY Card 2 No Loop Pwr RYYY Card 2 WRN RYYY Closed Too Far WRN YYGY Cmd Amplitude ALM RYGY Cmd Amplitude WRN YGYR Cmd Control ALM RYGY Cmd Control WRN YGYR Cmd Frequency ALM RYGY Cmd Frequency WRN YGYR CST Failed WRN YGRY DI Cmd Override GRGR Digital Cmd Mode GGYY Driver Module ALM RRYR Factory Reset State RGRR Feedback Cal Change RGRY

Feedback Cal Error RGGY Feedback Linkage ALM RRYG Friction Cal in Prog GRGY Friction Cal Req GYYY Friction High ALM RRGR Friction High WRN YRGR Friction Low ALM RRGY Friction Low WRN YRGY ILO Time Out RGGR Initializing GGYR Jog Cal Set 100% Pos GRRR Jog Cmd Mode GRRY Local Interface 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 < ADC Range RGGY Position > ADC Range RGGY Position Limit Alert YGGG Position Range Small RGGY Position Shift WRN YYGY Power ON GGGG Press Board Fail WRN RYRY Pressure Cal in Prog GRGY Pressure Cal Req GYYG Psn Amplitude ALM RYGR Psn Amplitude WRN YGYY

Psn Control ALM RYGR Psn Control WRN YGYY Psn Deviation ALM RRRR Psn Frequency ALM RYGR Psn Frequency WRN YGYY Psn High Limit Alert YGGG Psn Low Limit Alert YGGG Psn Sensor Fail ALM RYRG PST Failed WRN YGRR PST Scheduled GYYR Setting ILO GRGY Settle Time Out RGYG Signature or PST GRGG Soft Stop Alert GYGY Soft Stop High Alert GYGY Soft Stop Low Alert GYGY Software Error WRN YYRG Spring Fail WRN YRRR Squawk Mode GGRR Stroke Cal in Prog GRGY Stroke Cal Req RGRG Stroke Shift RGRY Stroke Span Decrease RGRY Stroke Span Increase RGRY Supply Press Hi WRN YYGR Supply Press Lo ALM RYYG Supply Press Lo WRN YYYG Temperature High WRN YYGG Temperature Low WRN YYGG Temperature WRN YYGG Tight Shut Off Mode GGGY Valve Can't Move ALM RYGG Valve Can't Open ALM RYGG Valve Can't Shut ALM RYGG Valve Cycles WRN YGGY Valve Cycles WRN YGGY Valve Travel WRN YGGY

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18.3 Status Code Descriptions

 NOTE: Not all status codes are available with all

positioner models.

GGGG ●●●●

POWER ON

Description: No issues. Possible Solutions: Not applicable.

GGGY ●●●●

TIGHT SHUT OFF MODE

Description: (Also called MPC.) The Final Command is beyond the user set limit for the tight shutoff feature and the positioner is applying full actuator pressure to close (or open) the valve. This is a normal condition for all valves when closed. The factory default setting triggers this at command signals below 1%. This indication may also occur on 3 way valves at both ends of travel if the upper Tight Shut Off value has been set.

Possible Solutions: If tight shutoff is not desired reset the tight shutoff limits or adjust the command signal inside of the specified Tight Shut Off values.

GGYG ●●●●

LOCAL INTERFACE OFF

Description: Control and configuration features are locked at the positioner's local interface. This is to prevent unauthorized or accidental adjustments. The buttons can still be used to view information on the LCD. The status code is only present for a short time when the user attempts to make a change through the display menu.

Possible Solutions: The DTM's Local Interface page is used to unlock the local interface, turn this feature on and off, and to set the PIN. For temporary access, a Personal Identification Number (PIN) can be entered from the positioner if an LCD is installed.

GGYY ●●●●

DIGITAL COMMAND MODE

Description: The input command is set by a digital HART command instead of the 4-20 mA signal.

Possible Solutions: The input command source can be changed back to the 4-20 mA signal by using a handheld, the Dashboard page of the DTM, or performing a manual Command Reset. Perform the Command 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 the positioner to flash a special sequence so that it can be visually located.

Possible Solutions: This mode is cancelled if one of the following occurs: 1) The QUICK-CAL/ACCEPT 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 active if the unit is unpowered.

Possible Solutions: If more travel is needed, reset the Soft Limits. If not, adjust the Final Command signal back into the specified range.

GYYG ●●●●

PRESSURE CALIBRATION REQUIRED

Description: A Factory Pressure Calibration has not been performed. Unlike a regular pressure sensor calibration, a Factory Pressure Calibration saves the calibration values to memory, making them available should a factory reset be performed. Proper pressure sensor calibration is required for proper pressure sensing and diagnostics. Calibration values from a regular pressure sensor calibration will be lost when a factory reset is performed. Typically no pressure calibration is required with a new positioner.

Possible Solutions: After replacing a main board or a pressure sensor board, perform a Factory Pressure Calibration. To do this, see the Pressure Sensor Board Removal and Installation section of the IOM.

GYYY ●●●●

FRICTION CALIBRATION REQUIRED

Description: No friction calibration has been performed since the last factory reset. The friction calibration determines a preliminary friction value, spring forces and direction and other information used for proper diagnostics. If no friction calibration is performed, the positioner will soon determine the operating friction, but other diagnostic information will be missing.

Possible Solutions: Perform a Friction Calibration using the display menu, handheld, or Sensor Calibration page of the DTM. See the Calibration section of the IOM for warnings.

GYYR ●●●●

PARTIAL STROKE TEST SCHEDULED

Description: The schedule established by the user shows that a partial stroke test is due .

Possible Solutions: Follow internal procedures to initiate a partial stroke test (PST). A partial stroke test will cause the valve to move suddenly and the positioner will not respond to commands while the PST is in progress. See the Partial Stroke Test page of the DTM to verify PST settings.

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GRGG ●●●●

SIGNATURE OR PARTIAL STROKE TEST IN PROGRESS

Description: The positioner is in Out Of Service (OOS) mode because a test or signature has been initiated. These include Step Test, Ramp Tes t, or Partial Stroke Test.

Possible Solutions: Signatures and tests can be defined, initiated, and cancelled through the Off-Line Diagnostics pages of the DTM.

GRGY ●●●●

STROKE CALIBRATION IN PROGRESS SETTING INNER LOOP OFFSET PRESSURE CALIBRATION IN PROGRESS FRICTION CALIBRATION IN PROGRESS ANALOG OUTPUT CALIBRATION IN PROGRESS COMMAND 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 corresponding 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 Discrete Input (DI) and to override the input command, positioning the valve at a preconfigured set point. The DI signal is active and the positioner is attempting to control the valve at the set point.

Possible Solutions: Configure the DI function and set point using the menu, a handheld or the Multi-Function Card Configuration page of the DTM.

GRRY ●●●●

JOG COMMAND MODE

Description: The positioner has been placed in a local override mode where the valve can only be stroked using the UP and DOWN buttons. The positioner will not respond to analog or digital input commands from HART.

Possible Solutions: Control the valve using the UP and DOWN buttons. This mode may be cancelled by briefly pushing the QUICK-CAL/ACCEPT button.

GRRR ●●●●

JOG CALIBRATION SET 100% POSITION

Description: During a jog calibration, the unit is waiting for the user to manually adjust the valve position to the desired 100% open position.

Possible Solutions: Use the Up and Down buttons on the positioner to adjust the valve to the desired fully open position. The QUICK-CAL/ACCEPT button to accept.

YGGG ●●●●

POSITION HIGH LIMIT ALERT POSITION LOW LIMIT ALERT

Description: The position has reached or is exceeding a user defined position limit. This is similar to a limit switch indicator.

Possible Solutions: Set the l imit to a higher (or lower) value if more travel is needed, or adjust the command signal back in the specified range.

YGGY ●●●●

ACTUATOR CYCLES WARNING ACTUATOR TRAVEL WARNING BELLOWS CYCLES WARNING BELLOWS TRAVEL WARNING PILOT RELAY CYCLES WARNING PILOT RELAY TRAVEL WARNING VALVE 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 for maintenance when the limit is reached. For example valve inspection may include checking the packing tightness, and checking linkages for wear, misalignment, and tightness. Bellows inspection may include checking bellows for cracking or leaking. Actuator inspection may include checking the actuator seals and lubrication. Relay inspection may include checking for high air consumption and signs of wear on the spool. After maintenance, reset the travel accumulator.

YGYY ●●●●

POSITION AMPLITUDE WARNING POSITION FREQUENCY WARNING

Description: The amplitude or frequency of the position s ignal is above the warning li mit. The positioner is controlling the position of the valve with large or rapid corrections.

Possible Solutions: Verify the limits are set at an appropriate level. Adjust the selectable Gain switch to a lower setting or use the Hi Friction setting. Perform a QUICK-CAL which sets the gains based on valve response. Check for high friction. If the problem persists replace the relay.

YGYR ●●●●

COMMAND AMPLITUDE WARNING COMMAND FREQUENCY WARNING

Description: The amplitude or frequency of the command signal is above the warning limit. This could mean the control loop has larger swings or is oscillating faster than desirable.

Possible Solutions: Verify the limits are set at an appropriate level. Review 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 process load or inadequate supply pressure.

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Possible Solutions: Check friction, supply pressure and other alarms or warnings that would indicate difficulty in moving the valve. Check packing, and air supply. The warning will clear when the CST function is turned off or when a successful attempt to move the valve occurs.

YGRR ●●●●

PARTIAL STROKE TEST FAILED WARNING

Description: Measured times or forces during the last partial stroke test did not pass the criteria set by the user. This may be an indication of corrosion build-up on the valve stem or in the actuator, low or restric ted supply pressure, or a sticking positioner relay.

Possible Solutions: This warning will clear upon completion of a successful partial stroke test.

YYGG ●●●●

TEMPERATURE HIGH WARNING TEMPERATURE LOW WARNING

Description: The temperature of the internal electronics has exceeded the manufacturer set limits of -40°C (-40°F) to 85°C (176°F). Low temperature may inhibit responsiveness and accuracy. High temperature may affect performance or limit the life of the positioner.

Possible Solutions: Regulate the temperature of the positioner by shading or cooling supply gas. Heat the positioner if needed. If the temperature reading is in error, replace the main board.

YYGY ●●●●

VALVE CLOSED TOO FAR WARNING VALVE OPENED TOO FAR WARNING

Description: While the valve was in use, it closed or opened farther than it did at the last calibration by 0.5%.

Possible Solutions: Check the feedback arm linkage and ensure the valve stem connection is tight. Recalibrate the stroke. If the process cannot be interrupted a service technician may be able to adjust the calibration.

YYGR ●●●●

SUPPLY PRESSURE HIGH WARNING

Description: The supply pressure is above the user set warning limit. Supply pressure that exceeds the maximum rating on the actuator can become a potential hazard.

Possible Solutions: Regulate the supply pressure at the positioner below the maximum limit recommended for your actuator. Recalibrate pressure sensors. Check the pressure sensor board connections. Replace pressure sensor board if necessary.

YYYG ●●●●

SUPPLY PRESSURE LOW WARNING

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 above 1.3 bar (19 PSI). Ensure system air/gas supply is adequate. Repair kinked or restricted supply

tubing. Check for pneumatic leaks in the actuator and actuator tubing. Recalibrate pressure sensors. Check the pressure sensor board connections and replace pressure sensor board if necessary.

YYYY ●●●●

ACTUATION RATIO WARNING

Description: The force required to control the system is close to the maximum available force. Actuation Ratio is based on the ratio of available force to the required force to fully 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 microprocessor's memory has a problem. Possible Solutions: Error may clear with time. If error

persists, cycle power and complete a QUICK-CAL. If the error still persists, perform a factory reset, reprogram or replace 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 components and failure of electronic functions.

Possible Solutions: Ensure supply gas is clean and dry. Check and clean the regulator filter.

YYRR ●●●●

AIR SUPPLY ICING WARNING AIR SUPPLY ICING WARNING

Description: The supply gas has high relative humidity and the temperature is close to 0 °C (32 °F). Under these conditions ice may form in the pilot relay causing diminished or total loss of position control.

Possible Solutions: Ensure supply gas is clean and dry. Check and clean the regulator filter.

YRGG ●●●●

PILOT RELAY RESPONSE WARNING

Description: The pilot relay is sticking or slow to respond. This affects the responsiveness, increases the chance of limit cycling and excessive air consumption. The pilot relay is part of the inner loop and consists of the driver module assembly

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with piezo (I-P relay) which is coupled to the spool valve or poppet. The value of this indicator corresponds with inner loop lag. Delayed response can be caused by a partially clogged piezo or debris, oil, corrosion, or ice on the spool, or low supply pressure.

Possible Solutions: Check response of the valve. If OK, adjust Pilot Relay Response limits. Check supply pressure. Check the spool or poppet for debris, oil, corrosion, ice on the spool. Clean or replace the spool or poppet assembly. Replace the piezo or driver module assembly. Maintain a clean, water-free air/gas supply.

YRGY ●●●●

FRICTION LOW WARNING

Description: The friction has passed below the user set limit. 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 packing leak. Tighten or replace the valve packing.

YRGR ●●●●

FRICTION HIGH WARNING

Description: The valve and actuator friction has passed the user set limit. High friction can cause loop oscillations, poor position control, jerky motion, or valve sticking. It can be caused by build-up from the process on the stem, trim or seat , by a failing bearing or guides in the valve and actuator, galling of the trim or stem, excessively tightened packing, linkages, or other valve or actuator mechanical issues.

Possible Solutions: Determine if the friction is significantly interfering with the valve control. If not, consider increasing the friction warning limit. Consider the following to reduce friction: Stroke the valve to clear off build-up. Clear any external mechanical obstruction, loosen the packing, clean the stem, repair or replace the actuator. Highly localized friction or very jerky travel can indicate internal galling. Repair or replace internal valve components.

YRYY ●●●●

BACKLASH WARNING

Description: The amount of detected backlash has passed the user set warning limit. This may affect valve stability.

Possible Solutions: Check the stem and actuator for loose components.

YRYR ●●●●

PNEUMATIC LEAK WARNING

Description: The positioner has detected a leak in the actuation assembly. Leakage from the actuator can cause decreased responsiveness and excessive air/gas consumption.

Possible Solutions: Repair pneumatic leaks at the tubing junctions and actuator seals. Check spool 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 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, thi s could indicate an error with the relay or the main board. This may result from an extended period of inactivity, but in this case should not persist for more than 30 minutes when the valve is controlling. The positioner may still be functioning, but have reduced performance under some circumstances. If the voltage to the piezo is too low, the piezo may be damaged. This may prevent the proper failure position upon loss of signal/power. This condition may occur briefly on an air-toclose valve that is held for long periods of time in the c losed 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.

YRRR ●●●●

SPRING UNABLE TO FAIL SAFE WARNING

Description: Upon loss of air supply, the valve may not move to the fail-safe position. The spring alone is not adequate to overcome the friction and process load in the system. The system is relying on pneumatic force to actuate in the direction the spring is pushing. The failsafe spring may have failed, or it was not sized properly for the application. Friction or process load may have increased.

Possible Solutions: Repair or replace actuator spring. Check for high friction. Reduce process load.

RGGG ●●●●

COMMAND INPUT BELOW ADC RANGE COMMAND INPUT ABOVE ADC RANGE COMMAND INPUT RANGE TOO SMALL

Description: During Command Loop Calibration, the signal was out of the Analog to Digital Converter (ADC) range, or difference between the signal at 0% and the signal at 100% was too small. The system is designed to accept a difference greater than 5 mA and between 10 and 4085 ADC.

Possible Solutions: Recalibrate making sure to use valid command signal values.

RGGY ●●●●

POSITION RANGE TOO SMAL L POSITION SENSOR ABOVE ADC RANGE POSITION SENSOR BELOW ADC RANGE

Description: During calibration, the range of motion of the position feedback arm was too small for optimum performance or the feedback sensor moved beyond its range of operation.

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Possible Solutions: Check for loose linkages. Adjust the positioner mounting. Adjust the feedback pin back into range. Adjust the feedback pin to a position closer to the follower arm pivot to create a larger angle of rotation and recalibrate. The minimum angle of rotation should be greater than 15 degrees. Briefly pressing the QUICK-CAL/ACCEPT button acknowledges a small range and the positioner will operate using the short stroke calibration if otherwise a good calibration.

RGGR ●●●●

INNER LOOP OFFSET TIME OUT

Description: During calibration the Inner Loop Offset (ILO) value did not settle. This could result in less accurate positioning.

Possible Solutions: Repeat the stroke calibration to get a more accurate ILO value. To proceed using the less accurate ILO value, this error may be cleared by briefly pushing the QUICK-CAL/ACCEPT button. Lowering the setting on the gain selection switch may help if the actuator is unstable during the calibration.

RGYG ●●●●

SETTLE TIME OUT

Description: During calibration, the position feedback sensor showed movement, but did not settle.

Possible Solutions: Check for loose linkages or a loose positioner sensor. This error may appear on some very small actuators during the initial calibration. Recalibrating may clear the problem, or this error may be cleared by briefly pushing the QUICK-CAL/ACCEPT button.

RGYY ●●●●

NO MOTION TIME OUT

Description: During a stroke calibration, there was no valve motion detected. Because some valves are quite large, this indicator can take up to 9 minutes to detect an error.

Possible Solutions: Check linkages 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 pus hing the QUICK-CAL/ACCEPT.

RGYR ●●●●

ANALOG OUTPUT RANGE TOO SMALL

Description: During an Analog Output Calibration the difference between the milliamp signal at 0% and the milliamp signal at 100% was too small.

Possible Solutions: Recalibrate making sure to use a larger difference between signal limits. This notification can be cleared by briefly pressing the QUICK-CAL/ACCEPT button.

RGRG ●●●●

STROKE CALIBRATION REQUIRED

Description: A factory reset was perform ed and the positioner has not yet been calibrated. The unit will not respond to commands and will remain in the failsafe position until a calibration is successfully complete d.

Possible Solutions: Perform a Stroke Calibration (QUICKCAL) 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% valve positions have both shifted in the same direction since the last stroke calibration. This may be related to a bent or adjusted feedback linkage, loose positioner mounting, or an over rotated feedback potentiometer.

STROKE SPAN DECREASE

Description: The 0% and 100% valve positions are closer together compared to the last stroke calibration. This could indicate debris or build up at valve seat.

STROKE SPAN INCREASE

Description: The 0% and 100% valve positions are farther apart compared to the last stroke calibration. This could indicate seat wear.

Possible Solutions: Ensure the feedback linkage is not bent and the positioner is mounted securely. If the feedback potentiometer is over-rotated, repeat the stroke calibration until the S t rok e Shift error is no longer present. Inspect valve or schedule valve for inspection. This notification can be cleared by briefly pressing the QUICK-CAL/ACCEPT button.

RGRR ●●●●

FACTORY RESET STATE

Description: The positioner is in factory reset state. Calibration is required to enable control.

Possible Solutions: Perform a Stroke Calibration (QUICKCAL).

RYGG ●●●●

VALVE CAN'T OPEN ALARM VALVE CAN'T SHUT ALARM

Description: Pressure has been applied (or removed) to open or shut the valve, but the valve is not moving. This may be caused by excessive friction.

Possible Solutions: Verify adequate supply pressure is applied. Verify the feedback linkage is connected. View the friction trends if available. Consider the following: Clear any external or internal mechanical obstruction, loosen the packing, clean the stem, repair or replace the actuator, repair the valve if galling is suspected.

RYGY ●●●●

COMMAND AMPLITUDE ALARM COMMAND FREQUENCY ALARM

Description: The amplitude or frequency of the command signal is above the alarm limit. This could mean the control loop has larger or faster swings than desirable.

Possible Solutions: Verify the limits are set at an appropriate level. Review the control loop parameters and equipment. Adjust as necessary.

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RYGR ●●●●

POSITION AMPLITUDE ALARM POSITION FREQUENCY ALARM

Description: The amplitude or frequency of the position signal is above the alarm limit. The positioner is controlling the position of the valve with large or rapid corrections.

RYYG ●●●●

SUPPLY PRESSURE LOW ALARM

Possible Solutions: Regulate the supply pressure at the positioner above 1.3 bar (19 PSI). Ensure system air/gas supply is adequate. Repair kinked or restricted supply tubing. Check for pneumatic leaks in the actuator and actuator tubing. Recalibrate pressure sensors. Check the pressure sensor board connections and replace pressure sensor board if necessary.

RYRG ●●●●

POSITION SENSOR FAILURE ALARM

Description: The feedback arm may be disconnected from the valve assembly or the sensor has failed.

Possible Solutions: Check the feedback arm linkage. Recalibrate. If the problem persists return the unit for repair.

RYRY ●●●●

PRESSURE SENSOR BOARD FAILURE WARNING

Description: One or more pressure sensors may have failed. Possible Solutions: Check the supply pressure to ensure it is between 1.3 and 10.3 bar (19 and 150 PSI). Check the pressure sensor 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 persists, replace the main board.

RYYY ●●●●

AUX CARD 2 ERROR

Description: Auxiliary Card 2 has an electrical problem.

AUX CARD 2 FAILURE WARNING

Description: Auxiliary Card 2 is not communicating.

AUX CARD 2 NO LOOP POWER

Description: Auxiliary Card 2 has no loop current. Possible Solutions: MFC: Check auxiliary loop wiring and

ensure adequate compliance voltage and current. Check auxiliary card connection to the main board. Replace card if condition persists.

RYYR ●●●●

AUX CARD 1 ERROR

Description: Auxiliary Card 1 has an electrical problem.

AUX CARD 1 FAILURE WARNING

Description: Auxiliary Card 1 is not communicating.

AUX CARD 1 NO LOOP POWER

Description: Auxiliary Card 1 has no loop current. Possible Solutions: MFC: Check auxiliary loop wiring and

ensure adequate compliance voltage and current. Check auxiliary card connection to the main board. Replace card if condition persists.

RRGG ●●●●

PILOT RELAY RESPONSE ALARM

Description: The pilot relay is sticking or extremely slow to respond. This affects the responsiveness, increases the chance of limit cycling and excessive air consumption. The pilot relay consists of the driver module assembly with piezo (I-P relay) which is coupled to the spool valve or poppet. Delayed response can be caused by a partially clogged piezo or debris, oil, corrosion, or ice on the spool, or low supply pressure.

Possible Solutions: Check response of the valve. If OK, adjust Pilot Relay Response limits. Check the supply pressure. Check the spool or poppet for debris, oil, corrosion, ice on the spool. Clean or replace the spool assembly. Replace the piezo or driver module assembly. Maintain a clean, water-free air/gas supply.

RRGY ●●●●

FRICTION LOW ALARM

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 motion, or valve sticking. It can be caused by build-up from the process on the stem, trim or seat, by a failing bearing or guides in the valve and actuator,

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galling of the trim or stem, excessively tightened packing, linkages, or other valve or actuator mechanical issues.

RRYG ●●●●

FEEDBACK LINKAGE ALARM

Description: The feedback linkage is broken or the position feedback POT is out of range.

Possible Solutions: arm unti l full motion is within the range of the POT.

Fix broken linkage or adjust feedback

RRYY ●●●●

BACKLASH ALARM

Description: The amount of detected backlash has passed the user set alarm limit. This may affect valve stability.

Possible Solutions: Check the stem and actuator for loose components.

RRYR ●●●●

DRIVER MODULE ALARM

Description: The pilot relay can't open, the pilot relay can't shut, or the Hall sensor circuit has failed.

Possible Solutions: 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 positioner may still be functioning, but have reduced performance under some circumstances.

PIEZO VOLTAGE LOW ALARM

Description: The voltage to the piezo is too low. The piezo may be damaged. This may prevent the proper failure position upon 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 difference between the command and the actual position has been greater than the user-set limit for longer than a user-set time.

Possible Solutions: Review active alarms and warnings to find root causes of this alarm. The deviation settings can be changed in the Valve Health page of the DTM.

flowserve.com 58

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

18.4 Help From Flowserve

18.4.1 Phone Support

Over-the-phone troubleshooting is often available for positioner issues. Should your positioner be experiencing problems, or if you have questions that are not answered by this manual, feel free to call your local sales representative or a Quick Response Center (QRC). See the back cover of this manual for contact details.

18.4.2 Returning the 500+ Positioner for Service

If troubleshooting is unable to solve the problem, the unit may be returned. Please follow the steps below.

1. Request a Return Goods Authorization (RGA) form. An RGA form will be e-mailed to you to accompany the unit being returned.

2. Remove all fittings, brackets, filters, feedback arms, etc. from the unit before packaging.

3. If the unit was operated with a gas other than clean air, please include the related MSDS with the return.

4. Complete the RGA form. Write any specific issues with the positioner 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 positioners will often settle through packing peanuts and pop large air packets).

6. Please insert a copy of the completed RGA form inside the package and write the RGA number on the outside of the package. Send the unit to the address at the bottom of the form.

If the cause of the unit failure is found to be a manufacturing defect and the unit is within the warranty period (18 months from manufacture) it will be repaired free of charge. If no problem is found with the unit and the unit is still under warranty, a fee for the evaluation will be required. If the cause of the unit failure is not covered under the warranty a fee will be charged for the evaluation and a quote will be provided showing the cost of the repair. If the customer decides to purchase a new positioner, the evaluation fee will be waved.

flowserve.com 59

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Housing Exhaust Cover

19 POSITIONER DIMENSIONS

19.1 Positioner Dimensions

Actuator Exhaust Cover

flowserve.com 60

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table 27: 500+ Positioner Configurations

Selection

Description

Code

Example

Base Model

Logix 500+ Series

HART; 8-DIP Se t-Up with LCD Option; Standard (Basic Functionality)

1, 2

20MD+

HART; 8-DIP Set-Up with LCD Option; Advanced (With Pressure Sensing)

1, 2

21MD+

HART; 8-DIP Set-Up with LCD Option; Pro (With Full ValveSight Diagnostics) 1

22MD+

General Purpose

Intrinsically Safe, IP66, North America/ATEX/IECEx Ex ia

Positioner Configuration

Aluminum - Black Base with White Cover

Aluminum - Black Base with Yellow Cover

Aluminum - Black Base with Black Cover (Automax)

Aluminum - Black Base with Black Cover (Accord)

Mounting: 5/16" 18 UNC, Pneumatics: 1/4" NPTF, Conduit: 1/2" NPTF, Vents 1/4" NPTF

Mounting: M8 x 1.25, Pneumatics: 1/4" NPTF, Conduit: M20 x 1.5, Vents 1/4" NPTF

Mounting: M8 x 1.25, Pneumatics: G1/4", Conduit: M20 x 1.5, Vents G1/4"

D - 316 Stainless Steel Shaft (Valtek Standard)

NAMUR - 316 Stainless Steel Shaft (VDI/VDE 3845)

Three-way (Single-Acting), Poppet Style Relay

Three-way (Single-Acting), Spool Style Relay

Four-way (Double-Acting), Spool Style Relay

No Indicator

Flat Indicator

Domed Indicator

No special options

Chinese Configuration6

Optional Mechanical Add-Ins

No Manifold

Gauge Manifold - Aluminum (required for gauges)

No Gauges

Nickel Plated with Brass Internals, psi (bar/kPa)

Nickel Plated with Brass Internals. psi (kg/cm2 )

SS with SS Internals. psi (bar/kPa)

SS with SS Internals. psi (kg/cm2 )

UCC Press Test Plug, 1/8" NPT

Valve, Tank, Schrader 645A

Optional Electronic Add-Ins

No LCD

LCD6

Slot 1 - No Card

Slot 1 - Multi-Function Card

Slot 2 - No Card

Slot 2 - Multi-Function Card

No Switches

Mechanical Limit Switch4

Reed Switch

Namur V3 type proximity switch, P+F NJ2-V3-N4

Slot Type NAMUR Sensor, P+F SJ2 S1N4

Slot Type NAMUR Sensor, P+F SJ2 SN4

Namur V3 type proximity switch, P+F NBB2-V3-E24

Remote Mount Feedback

20 HOW TO ORDER

20.1 Positioners

Communications and

Diagnostics

5 20MD+

Certifications

Housing

Threaded Connections

Feedback Shaft

Action

Position Indicator

Special Options

Manifold

Pressure Gauges

Display

Auxiliary Card Slot 1

Auxiliary Card Slot 2

Limit Switches

Remote Mount

1 HART 6 standard. Can be configured as HART 5 or HART 7 in the field. 2 Can be upgraded to 521MD+ or 522MD+ in the field. 3 Can be configured as Analog Output, Discrete Output or Discrete Input in the field. Slot 2 available only after

slot 1 is filled. 4 Only available for general purpose (certification option 14). 5 Includes adapter board (installed in the positioner) and the low profile remote mount unit (which may be

shipped separately). 6 Only available with the 520MD+ model.

flowserve.com 61

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Table

Cover:

Yellow Black White

283450.999.000

283451.999.000

283452.999.000

Boards:

MD+ LCD Pressure Sensor Multi Multi

283453.999.000

283454.999.000

283455.999.000

283456.999.000

314887.999.000

Pilot Relay Module:

Single Acting Double or Single Acti Pneumatic Restrictor

283458.999.000

283459.999.000

291750.999.000

Limit Switches:

Mechanical Switch* Reed Switch P&F SJ2 P&F SJ2 P&F NJ2 P&F N

291751.999.000

291752.999.000

291753.999.000

291754.999.000

291755.999.000

Table

Gage Internal

Material

Relay

Type

No.

Gages

Gage Internal

Material

Table

Shaft Converter

Direct Mount

(IEC 534 part 6 FlowTop, Kämmer KA, Kämmer KP, and

20.2 Spare Parts Kits

28: Spare Parts Kits

Ref. Description Part-no.

1 2 3

4 5 6 7 8

10 11 12

Main

-Function Card (Slot1)

-Function Card (Slot2)

(Poppet)

ng (Spool)

20.5 Mounting Kits

31: Mounting Kits

standard NAMUR linear valves)

Description Part-no.

- D to NAMUR 314586.999.000

– 500MD+

307303.999.000

13 14 15 16 17 18

-SN*

-S1N*

-V3-N*

BB2-V3-2N*

* Only available for general purpose (certification option 14).

 NOTE: Multi-function cards and limit switches may be

purchased as upgrades and installed after the initial purchase of the positioner. In this case, the positioner label must be modified to reflect the change.

20.3 Gage Block

29: Gage Block (Aluminum)

No. Gages

0 N/A N/A 291759.999.000 2 Brass PSI (Bar/kPa) 307318.999.000 2 Brass PSI (k g/cm2) 307319.999.000 2 Stainless PSI (Bar/kPa) 307320.999.000 2 Stainless PSI (kg/cm2) 307321.999.000 3 Brass PSI (Bar/kPa) 291760.999.000 3 Brass PSI (k g/cm2) 291761.999.000 3 Stainless PSI (Bar/kPa) 291762.999.000 3 Stainless PSI (kg/cm2) 291763.999.000

Pressure Units Part-no.

20.4 VDI/VDE 3847 Mounting Blocks

Table 30: VDI/VDE 3847 Mounting Block (Aluminum)

13 - 18

7 - 9

1 - 3

10, 11

Poppet 0 N/A N/A 307308.999.000 Poppet 2 Brass PSI (Bar/kPa) 307309.999.000 Poppet 2 Brass 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 Spool 3 Stainless PSI (Bar/kPa) 307316.999.000 Spool 3 Stainless PSI (kg/cm2) 307317.999.000

flowserve.com 62

Pressure Units Part-no.

PSI (kg/cm2) 307310.999.000

PSI (kg/cm2) 307315.999.000

INDEX

Figure 52: Spare Parts Kits

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

Actuation Ratio · 31, 34, 51, 54 Air Action Switch · 27 Air Supply · 8 Analog Output · 8, 41 Auto Tune Switch · 28 Auxiliary Card · 24, 31, 46

Calibration · 28, 29, 33, 34, 35, 41, 51, 52, 55, 56 Characterization · 27, 28, 35 Command Source Reset · 30 Compliance Voltage · 22 Configuration Switch Settings · 27 Continuous Stroke Test · 32

Date and Time · 31, 37 Diagnostic Features · 40 DIP Switch Override · 31 Discrete Input · 41 Discrete Output · 41 Display Contrast · 32 Double Acting Relay · 21, 48

Electrical Connections · 22 Event History · 33, 34

Factory Reset · 30, 37 FloTop Linear Valves · 13 Friction · 28, 31, 32, 33, 34, 35, 51, 52, 53, 55, 56, 57

Handheld Communicator · 39 HART · 4, 5, 8, 9, 31, 32, 37, 39, 44 Hazardous Area Certifications · 10

Inner Loop · 6 Installation · 12

Language · 38 LCD Board · 46 LCD Menu · 31 Limit Switch · 9, 25, 42, 45 Local Control Of Valve Position · 30 Local User Interface · 26

Main Board · 47 Maintenance · 11, 45 Mark One Linear Valves · 12 MaxFlo Rotary Valves · 17, 19 Minimum Close Time · 35

Minimum Open Time · 35 Mounting · 12 Mounting Kits · 62 Multi-Function Card · 8, 24, 38, 41

NAMUR AutoMax Valves · 18

Outer Loop · 5

Partial Stroke Test · 33, 34, 40, 52, 53 Performance · 9 Pneumatic Leak · 31, 34, 40, 51 Positioner Dimensions · 60 Pressure Control · 28, 32, 36 Pressure Sensor Board · 47

Quick Calibration Switch · 28 Quick-Cal · 26

Remote Mount · 8, 25, 42 Repair · 45

Safety · 4 Shutoff · 36 Signal at Closed Switch · 27 Single Acting Relay · 21, 49 Soft Limits · 36 Spare Parts · 4, 62 Specifications · 8 Status Code · 28, 51, 52 Status Icons · 31 Status Messages · 31 Stroke Calibration · 26, 28, 29 Stroke Time · 35

Temperature · 8, 9, 31, 33, 34, 37, 51 Training · 31 Troubleshooting · 22, 50 Tubing · 20 Tuning · 30, 35

Valtek Rotary Valves · 15 Valve Action Switch · 27 Valve Cycles · 34, 51 Valve Stability Switch · 28 Valve Travel · 34, 51 ValveSight DTM · 9, 39 Vented Design · 21 Version Numbers · 30, 37

flowserve.com 63

Flowserve Headquarters

Bulletin FCD LGENIM0105-10 11/13

To find your local Flowserve representative please

Flowserve Corporation has established i ndustr y leadership in the design and manufacture of its products. When properl y sel ec ted, this Flowserve product is

Download 500+ Manual

on positioner label are valid.)

use the Sales Support Locator System found at www.flowserve.com

Or call Europe +43 (0) 4242 41181 999 North America +1 801 489-2300 Asia + (65) 6879 8900 digitalproductstac@flowserve.com

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 industrial service conditions. Alt hough Flowserve can (and often does) provide general guidelines, it cannot provide specifi c data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Instal lation Operation Maintenance (IOM) instructi ons i nc luded with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, t hey ar e supplied for informative purposes only and should not be considered certified or as a guarantee of sati sfactory results by reliance thereon. Nothing 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 questi on ari se concer ning these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.

© 2012 Flowserve Corporation, Irving, Texas, USA . Fl owserve is a registered trademark of Flowserve Corporation. For more information about Flowserve Corpor ation, contact www.flowserve.com or call USA 1-800-225-6989.

User Instructions - Logix® 5 00+ Series Digital Positioners FCD LGENIM0105-10 11/13

5215 N. O'Connor Blvd. Suite 2300 Irving, Tx. 75039 Phone: +1 972 443 6500

Flowserve Corporation

Flow Control 1350 N. Mt. Springs Parkway Springville, UT 84663 USA Phone: +1 801 489 8611 Fax: +1 801 489 3719

Flowserve S.A.S.

12, avenue du Quebec B.P. 645 91965 Courtaboeuf Cedex France Phone: +33 (0) 1 60 92 32 51 Fax: +33 (0) 1 60 92 32 99

Flowserve Pte Ltd.

12 Tuas Avenue 20 Singapore 638824 Singapore Phone:+ 65 6868 4600 Fax: +65 6862 4940

Flowserve Australia Pty Ltd.

14 Dalmore Drive Scoresby, Victoria 3179 Australia Phone: +61 7 32686866 Fax: +61 7 32685466

Flowserve Ltda .

Rua Tocantins, 128 São Caetano do Sul, SP 09580-130 Brazil Phone: +55 11 2169 6300 Fax: +55 11 2169 6313

Flowserve Control Valves gmbH

Control Valves - Villach Operation Kasernengasse 6 9500 Villach Austria Phone: +43 (0)4242 41181 0 Fax: +43 (0)4242 41181 50

Flowserve (China)

585, Hanwei Plaza 7 Guanghau Road Beijing, China 100004 Phone: +86 10 6561 1900

Flowserve India Controls

Pvt. Ltd Plot # 4, 1A, E.P.I.P, Whitefield Bangalore Kamataka India 560 066 Phone: +91 80 284 10 289 Fax: +91 80 284 10 286

(Certification information in manual may not be applicable. Certifications

Flowserve Essen GmbH

Schederhofstr. 71 45145 Essen Germany Phone: +49 (0)201 8919 5 Fax: +49 (0)201 8919 600

Kämmer Valves inc.

1300 Parkway View Drive Pittsburgh, Pa 15205 USA Tel.: +1 412 787 8803 Fax: +1 412 787 1944

NAF Ab

Gelbgjutaregatan 2 SE-581 87 Linköping Sweden Phone: +46 (0)13 31 61 00 Fax: +46 (0)13 13 60 54

flowserve.com 64

Flowserve 500+ User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Using This Document

1.2 Terms Concerning Safety

1.3 Protective Clothing

1.4 Qualified Personnel

1.5 Valve and Actuator Variations

1.6 Spare Parts

1.7 Service / Repair

1.8 Basic Operation

1.9 HART

1.10 Position Definition

1.11 Command Input and Final Command

1.12 Outer Loop

1.13 Inner Loop

1.14 Detailed Sequence of Positioner Operations

1.15 Inner Loop Offset

2 SPECIFICATIONS

2.1 Input Signal

2.2 Air Supply

2.3 Pneumatic Output

2.4 Stroke Output

2.5 Analog Output – Multi-Function Card

2.6 Remote Mount Specifications

2.7 Limit Switch Specifications

2.9 Physical Specifications

2.10 Temperature

2.11 ValveSight DTM Software Specifications

2.8 Positioner Performance Characteristics

3 HAZARDOUS AREA CERTIFICATIONS

4 STORAGE AND UNPACKING

4.1 Storage

4.2 Unpacking

4.3 Pre-installation Inspection

5 MOUNTING AND INSTALLATION

5.1 Mounting to Mark One Linear Valves

5.2 Mounting to FlowTop Linear Valves

5.4 Mounting to MaxFlo Rotary Valves

5.5 Mounting to Rotary NAMUR (AutoMax) Valves

5.6 Mounting to a Linear NAMUR Pneumatic Actuator

6 TUBING

6.1 Determine Air Action

6.2 Connect Supply Port

6.3 Purging Single Acting Actuators

6.4 Vented Design

7 ELECTRICAL CONNECTIONS

7.1 Electrical Terminals

7.2.1 Compliance Voltage

7.2.2 Cable Requirements

7.2.3 Intrinsically Safe Barriers

7.2.4 Grounding and Conduit

7.2.5 Electromagnetic Compatibility

7.3 Multi-Function Card (AO, DO, DI)

7.3.1 Analog Output

7.3.3 Discrete Input

7.3.2 Discrete Output

7.4 Limit Switches

7.5 Remote Mount

7.6 Connections for Intrinsically Safe Operation

8 STARTUP

8.1 Quick Start Instructio n s

8.2 Local User Interface Overview

8.2.1 Logix 505+

8.2.2 Logix 510+ and 520MD+

8.3 Configuration Switch Settings (505+)

8.3.1 Air Act i o n Switch

8.3.2 Split Range Switch

8.3.3 Range Select Switch

8.3.4 Gain Switch

8.4 Configuration Switch Settings (510+ and 520MD+)

8.4.1 Air Action Switch

8.4.2 Actuator Switch

8.4.3 Signal at Closed Switch

8.4.4 Characterization Switch

8.4.5 Auto Tune Switch

8.4.6 Quick Calibration Switch

8.4.7 Valve Stability Switch

8.4.8 Spare Switch