Flowserve 520MD User Manual

User Instructions Logix 520MD - LGENIM0520-01 09/09

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USER INSTRUCTIONS

Logix 520MD Series

Digital Positioner

FCD LGENIM0520-01

Installation

Operation

Maintenance

Experience In Motion

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User Instructions Logix 520MD - LGENIM0520-01 09/09

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Table of Contents Page

General Information ......................................................................... 2

Unpacking ........................................................................................ 3

Logix 520MD Overview ................................................................... 4

Specifications ................................................................................... 4

Principle of Operation ...................................................................... 5

Tubing .............................................................................................. 6

Wiring .............................................................................................. 6

Cable Requirements ......................................................................... 7

Startup ............................................................................................. 8

Logix 520MD Local Interface Operation ...................................... 8

Operation of Configuration Dipswitch Setup ............................... 8

Calibrations switches .................................................................. 9

Quick-Cal Operation .................................................................... 9

Factory Reset .............................................................................. 10

4-20 mA Analog Output Board .................................................... 10

Error Codes ...................................................................................... 12

Trouble Shooting .............................................................................. 15

Limit switches .................................................................................. 16

Spare parts ...................................................................................... 17

Dimensions ...................................................................................... 18

1 USING FLOWSERVE VALVES, ACTUATORS AND

ACCESSORIES CORRECTLY

1.1 General usage

The following instructions are designed to assist

in unpacking, installing and performing main­tenance as required on FLOWSERVE products.
Product users and maintenance personnel should
thoroughly review this bulletin prior to installing,
operating or performing any maintenance.

In most cases FLOWSERVE 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.

1.2 Terms concerning safety

The safety terms DANGER, WARNING, CAU-

TION 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.

WARNING: indicates that death, severe personal injury

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

CAUTION: indicates that minor personal injury and/or

property damage can occur if proper precautions are
not taken.

NOTE: indicates and provides additional technical

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

Compliance with other, not particularly emphasised

notes, with regard to transport, assembly, operation
and maintenance and with regard to technical docu­mentation (e.g. in the operating instruction, product
documentation or on the product itself) is essential,
in order to avoid faults, which in themselves might
directly or indirectly cause severe personal injury or
property damage.

1.3 Protective clothing

FLOWSERVE products are often used in problematic

applications (e.g. extremely high pressures, danger­ous, toxic or corrosive mediums). In particular valves
with bellows seals point to such applications. When
performing service, inspection or repair operations
always ensure, that the valve and actuator are depres­surised and that the valve has been cleaned and is free
from harmful substances. In such cases pay particular
attention to personal protection (protective clothing,
gloves, glasses etc.).

1.4 Qualified personnel

Qualified personnel are people who, on account of their

training, experience and instruction and their knowl­edge of relevant standards, specifications, accident
prevention regulations and operating conditions, have
been authorised by those responsible for the safety of
the plant to perform the necessary work and who can
recognise and avoid possible dangers.

1.5 Installation

DANGER: Before installation check the order-no.,

serial-no. and/or the tag-no. to ensure that the valve/
actuator is correct for the intended application.

Do not insulate extensions that are provided for hot

or cold services.

Pipelines must be correctly aligned to ensure that the

valve is not fitted under tension.

DANGER: indicates that death, severe personal

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

2

Fire protection must be provided by the user.

User Instructions Logix 520MD - LGENIM0520-01 09/09

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1.6 Spare parts

Use only FL O W SERVE ori g inal spar e pa rts.

FLOWSERVE cannot accept responsibility for any
damages that occur from using spare parts or
fastening materials from other manufactures. If
FLOWSERVE products (especially sealing materials)
have been on store 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.

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 nonfactory 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.

1.9 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 is 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.

2 UNPACKING

Each delivery includes a packing slip. When unpacking,

check all delivered valves and accessories using this
packing slip.

Report transport damage to the carrier immediately.

In case of discrepancies, contact your nearest

FLOWSERVE location.

Apart from the operating instructions and the

obligatory accident prevention directives valid in the
country of use, all recognised regulations for safety
and good engineering practices must be followed.

WA R NING: Before produ c ts ar e ret u rned 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).

1.8 Storage

In most cases FLOWSERVE products are manufactured

from stainless steel. Products not manufactured
from stainless steel are provided with an epoxy resin
coating. This means that FLOWSERVE products
are well protected from corrosion. Nevertheless
FLOWSERVE products must be stored adequately
in a clean, dry environment. Plastic caps are fitted
to protect the flange faces to prevent the ingress of
foreign materials. These caps should not be removed
until the valve is actually mounted into the system.

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3 LOGIX 520MD OVERVIEW

The Logix 520MD is a two-wire, 4-20 mA input digital valve

positioner with HART communication. The Logix 520MD
positioner controls single-acting actuators with linear
and rotary mountings. The Logix 520MD is completely
powered by the 4-20 mA input signal. The minimum input
signal required to function is 3,6 mA.

4 SPECIFICATIONS

User Instructions Logix 520MD - LGENIM0520-01 09/09

Since the positioner is insensitive to supply pressure

changes and can handle supply pressures from 1,5 to 6 barg
(22 to 87 psig), a supply regulator is usually not required;
however, in applications where the supply pressure is
higher than the maximum actuator pressure rating a supply
regulator is required to lower the pressure to the actuator’s
maximum rating (not to be confused with operating range).
A coalescing air filter is recommended for all applications

Table 1: Input Signal

Input Signal Range 4 - 20 mA (HART)

Compliance Voltage 10 VDC

Voltage Supply (maximum) 30 VDC

Minimum Required Operating
Current

Table 2: Stroke Output

Feedback Shaft Rotation Min. 15°, max 90°

Table 3: Air Supply

Air Supply Quality Free from moisture, oil and dust

Input Pressure Range 1,5 to 6,0 bar (22 to 87 psi)

Air Consumption (steady state)

Table 4: Output Signal

Output Pressure Range 0 to 100% of air supply pressure

Output Flow Capacity 2,4 Nm³/h @ 1,5 bar

Table 5: Shipping Weights

Base Positioner without
Accessories

Table 6: Performance Characteristics (typical)

Linearity < +/- 1,0%

Resolution < 0,1%

Repeatability < 0,2%

Deadband < 0,2%

3,6 mA without AO
3,83 mA with AO

40° recommended for linear
applications

per IEC 770 and ISA-7.0.01

0,08 Nm³/h @ 1,5 bar
(0,047 SCFM @ 22 psi)
0,12 Nm³/h @ 6,0 bar
(0,071 SCFM @ 87 psi)

(1,41 SCFM @ 22 psi)
7,0 Nm³/h @ 6,0 bar
(4,12 SCFM @ 87 psi)

1,2 kg (2,65 lbs)

Table 7: Environmental Conditions

Operating Temperature
Standard

Operating Temperature
Low

Transport and Storage
Temperature

Operating Humidity 0 to 100% non-condensing

Table 8: Hazardous Area Specifications

ATEX II 1 G Ex ia IIC T5 - T6

II 3 G Ex ic IIC T5 - T6

FM

CSA Class I Division 1, Groups A,B,C,D

Table 9: Limit Switches (optional)

Type P&F SJ2-S1N

Load current < 1 mA < 3 mA

Voltage range 5 - 25 VDC

Hysteresis 0,2 %

Temperature -25

Type P&F SJ2-SN

Load current < 1 mA < 3 mA

Voltage range 5 - 25 VDC

Hysteresis 0,2 %

Temperature -40

Type P&F SJ2-N

Load current < 1 mA < 3 mA

Voltage range 5 - 25 VDC

Hysteresis 0,2 %

Temperature -25

Class I, Division 2, Groups A,B,C,D Temp. Class. T4 Ta = 85°C
Class I Zone = Group IIC T4 Ta = 85°C
Class I, Division 2, Groups A,B,C,D Temp. Class. T4 Ta = 85°C

Class I Division 2, Groups A,B,C,D

-20 °C to +80 °C
(-4 °F to +178 °F)

-40 °C to +80 °C
(-40 °F to +178 °F)

-40 °C to +80 °C
(-40 °F to +178 °F)

°C to

100

°C (

°C to

100

°C (

°C to

100

°C (

-13

-40

-13

°F to

°F to

°F to

212

212

212

°F)

°F)

°F)

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User Instructions Logix 520MD - LGENIM0520-01 09/09

Local
User
Interface

Inner Loop

Piezo Control

Stroke

Inner Loop

Position Feedback

1 Digital Control Circuit

2 Electro-pneumatic
Converter Module

3 Valve Position
Sensor

Filter / Regulator

for Supply Air

1.5 – 6.0 bar (22 – 87 psi)

Air Supply

-

Micro-

Processor

Gain

Pressure Regulator

Piezo Valve

Pneumatic

Amplifier

Control Valve

+

4 – 20 amA

Output

(0ptional)

4 – 20 mA
+ HART

HART

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Figure 1: Logix 520MD Principle of Operation

due to the close tolerances in the positioner. Optional analog
feedback system as well as limit switch unit and a directly
attachable double acting module complete the Logix 520MD
positioner accessories.

NOTE: The air supply must conform to ISA 7.0.01or IEC 770

(a dew point at least 10 ˚C / 18 ˚F below ambient temperature,
particle size below five microns – one micron recommended
– and oil content not to exceed one part per million).

5 PRINCIPLE OF OPERATION

The Logix 520MD positioner is a digital positioner that incor-

porates HART protocol for communication. The positioner
consists of three main modules:

1. T he m ic rop ro ces so r- ba sed e le ct r on ic con tr ol
module includes HART communications and direct local
user interface switches

2. The piezo valve-based electro-pneumatic converter module

3. The infinite resolution valve position sensor.

The basic positioner operation is best understood by refer-

ring to Figure 1. The complete control circuit is powered
by the two-wire, 4-20 mA command signal. The HART
module sends and receives the superimposed FSK HART

digital communications over the 4-20 mA signal wires
providing two-way remote digital communications to
the microprocessor. The analog 4-20 mA command is
passed to the microprocessor, where it is compared to
the measured valve stem position. The control algo­rithm in the processor performs control calculations
and produces an output command to the piezo valve,
which drives the pneumatic amplifier. The position of
the pilot valve in the pneumatic amplifier is measured
and relayed to the inner loop control circuit. This two­stage control provides for more responsive and tighter
control than is possible with a single stage control
algorithm. The pneumatic amplifier controls the airflow
to the actuator. The change of pressure and volume of
the air in the actuator causes the valve to stroke. As the
valve approaches the desired position, the difference
between the commanded position and the measured
position becomes smaller and the output to the piezo
is decreased. This, in turn, causes the pilot valve to
close and the resulting flow to decrease, which slows
the actuator movement as it approaches, the new
commanded position. When the valve actuator is at the
desired position, the pneumatic amplifier output is held
at zero, which holds the valve in a constant position.

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User Instructions Logix 520MD - LGENIM0520-01 09/09

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Table 10: Connection Table

Internal Housing
EARTH Terminal

Shielded Cable

4-20 mA Signal

Connect Shield at Source Ground

-

4-20 mA Current Source

+

Figure 2: Wiring Diagram

6 TUBING POSITIONER TO ACTUATOR

After mounting has been completed, tube the positioner

to the actuator using the appropriate compression fitting
connectors:

Air connections: 1/4” NPT (standard air connection)
Auxiliary power: Pressurized air or permissible

gases, free of moisture and dust in according with
IEC 770 or ISA 7.0.01.

Pressure range: 1,5 – 6,0 bar (22 – 87 psi)
For connecting the air piping, the following notes should

be observed:

1. The positioner passageways are equipped with filters,
which remove medium and coarse size dirt from the
pressurized air. If necessary, they are easily accessible
for cleaning.

2. Supply air should meet IEC 770 or ISA 7.0.01 require­ments. A coalescing filter should be installed in front of
the supply air connection Z. Now connect the air supply
to the filter, which is connected to the Logix 500si series
positioner.

3. With a maximum supply pressure of 6 bar (87 psi) a
regulator is not required.

4. With an operating pressure of more than 6 bar (87 psi),
a reducing regulator is required. The flow capacity of
the regulator must be larger than the air consumption
of the positioner (7 Nm
psi).

5. Connect the outlet connector Y of the positioner to the
actuator with tubing, independent of the action (direct

6

or reverse).

3

/hr @ 6 bar / 4,12 scfm @ 87

Y

Connection Description

+11 Input+ 4..20 mA

-12 Input- 4..20 mA

Z

+31* Output+ 4..20 mA

-32* Output– 4..20 mA

Limit switch 1 - separate board

Limit switch 2 - separate board

Y (0⇒) Pneumatic output signal (outlet)

Z (0⇐) Air supply

* 0ptional

7 WIRING AND GROUNDING GUIDELINES

Electrical connections: signal cable with cable passage

(NPT or M20 x 1,5) to terminals 2 x 2,5 mm

Input signal: 4 – 20 mA

NOTE: Observe the minimum requirements of voltage

and equivalent electrical load: 10,0 VDC / 500 Ω / at
20 mA

The performance is ensured only for a minimum input cur-

rent of 3,6 mA.

For wiring, the following notes should be observed:

NOTE: The input loop current signal to the Logix
520MD 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. (Figure 2)

Connect the 4-20 mA current source to terminals +11 and

-12 (Figure 2).

Grounding Screw

The grounding screw, located inside the positioner cover,

should be used to provide the unit with an adequate and
reliable earth ground reference. This ground should be tied
to the same ground as the electrical conduit. Additionally, the
electrical conduit should be earth grounded at both ends of
its run. The grounded screw must not be used to terminate
signal shield wires.

Compliance Voltage (Figure 3)

Output compliance voltage refers to the voltage limit the

current source can provide. A current loop system consists
of the current source, wiring resistance, barrier resistance
(if present), and the Logix 520MD impedance. The Logix
520MD requires that the current loop system allow for a 10 VDC
drop across the positioner at maximum loop current.