Flowserve 520si User Manual

Logix 520 si Digital Positioner

ADK041400E - 04.03

This product meets the requirements of

1

Table of Content Page

General information...................................................................................... 3

Unpacking .............................................................................................. 4

Logix 520 si Overview .................................................................................. 5

Specifications .............................................................................................. 5

Principle of operation ................................................................................... 6

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

Wiring .............................................................................................. 7

Cable Requirements ..................................................................................... 8

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

Local User interface .......................................................................... 8

Configuration .................................................................................... 9

Calibration......................................................................................... 9

Use of 275 Handheld ........................................................................ 10

Use of SoftTools communication software ....................................... 10

Integration of third-party communication software .......................... 10

Error codes .............................................................................................. 12

Trouble shooting .......................................................................................... 15

Spare Part Kits ............................................................................................. 16

Mounting Kits .............................................................................................. 16

2

1 USING FLOWSERVE VALVES, ACTUATORS

AND ACCESSORIES CORRECTLY

1.1 Using

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
(e.g. with regard to medium, pressure, 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, CAUTION and
NOTE are used in these instructions to highlight par-

ticular dangers and/or to provide additional informa­tion on aspects that may not be readily apparent.

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.

DANGER:

indicates that death, severe personal in­jury and/or substantial property damage will occur if
proper precautions are not taken.

WARNING:

jury and/or substantial property damage can occur if

STOP!

indicates that death, severe personal in-

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.

1.5 Installation

DANGER:

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.

Fire protection must be provided by the user.

Before installation check the order-no,

3

1.6 Spare parts

1.9 Valve and actuator variations

Use only FLOWSERVE original spare parts.
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.

These instructions cannot claim to cover all details
of all possible product variations, nor in particular
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.

WARNING:

FLOWSERVE for repair or service FLOWSERVE must

STOP!

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.

Before products are returned to

4

3 LOGIX 520 si OVERVIEW

The Logix 520 si is a two-wire, 4-20 mA input digital valve
positioner. The Logix 520 also utilizes the HART protocol to
allow two-way remote communication with the positioner. The
Logix 520 si positioner controls single-acting actuators with
linear and rotary mountings. The Logix 520 si is completely
powered by the 4-20 mA input signal. The minimum input
signal required to function is 3,6 mA.

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

4 SPECIFICATIONS

Table 1: Input Signal

Input Signal Range 4 - 20 mA
(with HART)

Compliance Voltage 12,0 VDC
(with HART signal)

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 due to the close
tolerances in the positioner.

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).

Table 5: Performance

Characteristics (typical)

Linearity < ± 1,0%
Resolution < 0,1%

Repeatability < 0,2%
Voltage Supply (maximum) 30 VDC
Minimum Required 3,6 mA

Operating Current

Table 2: Stroke Output

Feedback Shaft 0° to 90° normal
Rotation 0° to 40° minimum

Table 3: Supply Air

Supply Air Quality Free from moisture, oil and

dust per IEC 770 and ISA-7.0.01
Input Pressure Range 1,5 to 6,0 bar (22 – 87 psi)
Air Consumption 0,08 Nm3/h @ 1,5 bar

(steady state) 0,047 SCFM @ 22 psi

0,120 Nm3/h @ 6,0 bar

0,071 SCFM @ 87 psi

Table 4: Output Signal

Output Pressure 0 - 100 % of supply air
Range pressure

Output Flow Capacity 2,4 Nm3/h @ 1,5 bar
(input @ pressure) 1,41 SCFM @ 22 psi

7,0 Nm3/h @ 6,0 bar

4,12 SCFM @ 90 psi

Deadband < 0,2%

Table 6: Environmental Conditions

Operating Temperature Standard -20 – ˚80 C

-4 – 178 ˚F

Low -40 – 80 ˚C

-40 – 178 ˚F

Transport and Storage -40 – 80 ˚C
Temperature -40 – 178 ˚F

Operating Humidity 0 – 100% non-condensing
Intrinsic Safety Logix 520 si - 15:

ATEX II1 G EEx ia IIC T6

Table 7: Physical Specifications

Housing Material Cast aluminum,

powder-painted
Soft Goods Nitrile
Weight 1,2 kg (2,7 lbs)

Table 8: Shipping weights

Shipping weights
(incl. mounting kit)

Specification Logix 520 si
with pressure gauges 1,6 kg

without pressure gauges 1,2 kg

5

Supply Air

Filter / Regulator

for Supply Air

22 – 87 psi (1.5 – 6.0 bar)

2 Electro-pneumatic

Converter Module

1 Digital Control Circuit

Inner Loop

Piezo Control

-

Inner Loop

Position Feedback

Local
User
Interface

4 – 20 mA
+ HART

HART

∑

+

Micro

Processor

Gain

Figure 1: Logix 520 si Principle of Operation

5 PRINCIPLE OF OPERATION

The Logix 520 si positioner is a digital positioner that incor­porates HART protocol for communication. The positioner
consists of three main modules:

1. The microprocessor-based electronic control
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 refer­ring 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 two­way 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

6

Pressure Regulator

Pneumatic

Piezo Valve

Amplifier

3 Valve Position

Sensor

Stroke

Control

Valve

position, the pneumatic amplifier output is held at zero, which
holds the valve in a constant position.

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 500 si 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 Nm3/hr @ 6 bar / 4,12 scfm @ 87 psi).

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

M8

47

M6

17.7

17.7

28.6

173,5

63,5

17.7

17.7

28.6

100

28.6

1/4" NPT

ø 10

19,9

M 8

ø 10

M 20 x 1,5 or 1/2" NPT

11,9

23,9

60

96.5

Figure 2: Dimensional Drawing of the Logix 500 si Series Digital Positioner

7 WIRING AND GROUNDING GUIDELINES

Electrical connections: signal cable with cable passage (NPT,

PG13,5, 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: 12,0 VDC / 600 Ω / at
20 mA

To calculate the maximum network capacitance use the fol­lowing formula.

The performance is ensured only for a minimum input cur­rent of 3,6 mA.

For wiring, the following notes should be observed:

NOTE: The input loop current signal to the Logix 520
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 8)

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

-12 (Figure 5).

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.

ø 4,8

ø 10

11,9

23,9

Compliance Voltage (Figure 4)
Output compliance voltage refers to the voltage limit the cur-

rent source can provide. A current loop system consists of
the current source, wiring resistance, barrier resistance (if
present), and the Logix 520 si impedance. The Logix 520 si
requires that the current loop system allow for a 12,0 VDC
drop across the positioner at maximum loop current.

CAUTION: Never connect a voltage source directly
across the positioner terminals. This could cause per­manent circuit board damage.

In order to determine if the loop will support the Logix 520 si,
perform the following calculation.

Voltage = Compliance Voltage (@Current

- Current

MAX

*(R

barrier

+ R

wire

)

MAX

)

The calculated voltage must be greater than 12.0 VDC in or­der to support the Logix 520.

Example: DCS Compliance Voltage = 19 V

R

= 300 Ω

barrier

R

= 25 Ω

wire

CURRENT

= 20 mA

MAX

Voltage = 19 V - 0,020 A*(300 Ω + 25 Ω)

= 12,5 V

The voltage 12,5 V is greater than the required 12.0 V; there­fore, this system will support the Logix 520. The Logix 520 si
has an input resistance equivalent to 600 Ω at a 20 mA input
current.

7

Enhanced
Quick-Cal
Configuration
Switches

LED Status
Lights

Autotune

Lockout
Switch

4-20 mA input
with HART
Communications

Terminals for Optional Limit Switches

Figure 3: Logix 520 si Local Interface

8 CABLE REQUIREMENTS

The Logix 520 si digital positioner utilizes the HART commu­nication protocol. This communication signal is
superimposed on the DC 4-20 mA current signal. The two
frequencies used by the HART protocol are 1200 Hz and 2200
Hz. To prevent distortion of the HART communication, 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/mm rating will allow
longer cable runs. In addition to cable capacitance, the net­work resistance also affects the allowable cable length.

Jog Calibrate
Buttons

Gain Selector

Quick-Cal Button

To control cable resistance, No. 24 AWG cable should be used
for runs less than 1500 m. For cable runs longer than this,
No. 20 AWG cable should be used.

Electromagnetic Compatibility

The Logix 520 si 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.

65Ω

C

(µF) < - 0,0032

network

(R

barrier

+ R

+ 390Ω)

wire

Example:

R

= 300 Ω (if present)

barrier

R

= 50 Ω

wire

C

(300 + 50 + 390)

Max. Cable Length =

72 ρF 0.000072 µF

= =

cable

m m

65

- 0,0032 = 0,08 µF= C

C

(µF)

network

C

cable

0,08 µF

Max. Cable Length = = 1111 m

0.000072 µF/m

network

(µF)(Max)

Ensure proper wiring and shielding techniques of the control
lines, and route control lines away from electromagnetic
sources that may cause unwanted 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 520 si
positioner to restore operation.

9 STARTUP

9.1 Logix 520 si Local Interface

The Logix 520 si local user interface allows the user to
configure the basic operation of the positioner, tune the re­sponse, and calibrate the positioner without additional tools
or configurators. The local interface consists of a Quick-Cal™
button for automatic zero and span setting, along with two
jog buttons for spanning valve/actuators with no fixed inter­nal stop in the open position. There is also a switch block
containing eight switches. Six of the switches are for basic
configuration settings, two are for calibration options. There
is also a rotaryselector switch for adjusting the positioner gain

8

settings. For indication of operational status or alarm condi­tions there are three LEDs on the local user interface.

Initial DIP Switch Setting

Before placing the unit in service, set the DIP switches in the
“Configuration” and “Cal” boxes to the desired control op­tions.

NOTE:

The switch settings in the Configuration box
are activated only by pressing the Quick-Cal button or
by utilizing the stroke calibration features provided by
a handheld or by Flowserve PC software.

9.2 Operation of Configuration DIP Switches Setup

The first six DIP switches are for basic configuration

1. Air Action – Must be set to match the configuration of the
valve/actuator mechanical configuration.

ATO

(air-to-open) – Select ATO if increasing output pres-
sure from the positioner is tubed so it will cause the valve
to open.

ATC

(air-to-close) – Selecting ATC if increasing output

pressure from the positioner is tubed so it will cause the
valve to close.

2. Signal at Closed – Normally this will be set to 4 mA for an
air-to-open actuator, and 20 mA for an air-to-close actua­tor configuration.

Selecting
signal is 4 mA and fully open when the signal is 20 mA.

Selecting
signal is 20 mA and fully open when the signal is 4 mA.

3. Pos. Characterization
Select

proportional to the input signal.
Select

is set in conjunction with the next switch, labeled

tional Pos. Char

4. Optional Pos. Char. – If the
is set to optional, this switch is active with the following
options:

The =% option will characterize the actuator
response to the input signal based on a standard 30:1
equal percent rangability curve.

If

Custom

to a custom table that must be set-up using a properly
configured HART 275 handheld or other host software.

5. Auto Tune – This switch controls whether the positioner
will auto tune itself every time the Quick-Cal button is
pressed

On

determine the positioner gain settings every time a Quick­Cal is performed based on the setting of the rotary
switch.

If the rotary
autotune switch On, a Flowserve nominal
response tuning set will be calculated and used.

If the rotary
the

4 mA

will make the valve fully closed when the

20 mA

will make the valve fully closed when the

Linear

if the actuator position should be directly

Optional

if another characteristic is desired, which

Op-

.

Pos. Characterization

is selected, the positioner will be characterized

enables an auto tune feature that will automatically

switch

Gain

Gain

selector switch is set to E with the

Gain

Auto Tune

selector switch is set to

switch On, progressively lower gain set-

D, C, B,

or A with

tings will be calculated and used.
If the rotary

the

Auto Tune

tings will be calculated and used.

Off

forces the positioner to use one of the factory preset
tuning sets determined by the rotary
Settings A through H are progressively higher gain
predefined tuning sets. The positioner is preset to Autotune

- On at the factory. This is the recomended setting.

6. Config. Switches — By selecting
will read all of the configuration switches each time a

Quick-Cal

Selecting
(from the last successful calibration) before the switch
was set to
zeros and spans the positioner.

9.3 Calibration switches

9.3.1 Stability Switch – This switch adjusts the position
control algorithm of the positioner for use with low
friction control valves or high friction automated
valves.

• Placing the switch to the left 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.

• 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.

9.3.2 Setup of the Cal DIP Switch for the Quick
Calibration operating mode

• Select
internal stop in the 100% stroke position. In
mode the positioner will fully close the valve and
register the 0% position and then open the valve to
the stop to register the 100% position when perform­ing a self-calibration. See detailed instructions in the
next section on how to perform an auto positioner
calibration.

• Select
calibration stop in the open position. In the
the positioner will fully close the valve for the 0%
position and then wait for the user to set the open
position using the
down arrows. See the detailed instructions in the next
section on how to perform a manual calibration using
the

WARNING:

may stroke unexpectedly. Notify proper personnel

STOP!

that the valve will stroke, and make sure the valve is

Gain

selector switch is set to

switch On, progressively higher gain set-

Enabled

is performed to determine the configuration.

Disabled

retains the last configuration in memory

Disabled

Auto

Jog

. With this setting a

if the valve/actuator assembly has an

if the valve/actuator assembly has no

F, G,

Gain

selector switch.

, the Logix 520 si

Quick-Cal

or H with

Jog

Jog

buttons labeled with the up and

Jog

buttons.

During the Quick-Cal operation the valve

only

Auto

mode

properly isolated.

Quick-Cal Operation

The

Quick-Cal

the positioner. Pressing and holding the

button is used to locally initiate a calibration of

Quick-Cal

button for

9

approximately three seconds will initiate the calibration. If the

Config-Switches

option is enabled, the settings of all the
configuration switches are read and the operation of the
positioner adjusted accordingly. The

Gain Selector

switch is
also read and action will be taken to adjust the gain according
to the settings of the calibration switches as described in the
previous section. A
briefly pressing the

Quick-Cal

Quick-Cal

can be aborted at any time by

button and the previous settings

will be retained.
If the

Quick calibration

Quick-Cal

button) is set to Auto and the valve/actuator as-

switch (not to be confused with the

sembly has the necessary internal stops, the calibration will
complete automatically. While the calibration is in progress
you will notice a series of different lights flashing indicating
the calibration progress. When the lights return to a sequence
that starts with a green light, the calibration is complete. (See
the appendix for an explanation of the various light sequences.)

WARNING:

When operating using local control of the

valve, the valve will not respond to external
commands. Notify proper personnel that the valve

STOP!

will not respond to remote command changes, and
make sure the valve is properly isolated.

If the

Quick calibration

switch is set to

Jog

, the calibration
will initially close the valve then cause a small jump in the
valve position. The jog calibration process will only allow

the user to manually set the span; zero position is auto­matically always set at the seat. If an elevated zero is needed

a handheld or other PC based configuration software is re­quired. The LEDs will then flash in a sequence of Y-R-R-G
(yellow-red-red-green) which indicates the user must now use
the

Jog

keys to manually position the valve to the desired

100% position. Now press both

Jog

buttons simultaneously
to proceed to the next step. The valve will then stroke and
then wait while flashing the Y-R-R-G sequence again, allow­ing the user to adjust the valve position a second time to ex­actly 100% using the
positioned press both

Jog

buttons. When the stem is properly

Jog

buttons simultaneously again to
register the 100% position and proceed. 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. (See the appendix for an ex­planation of the various light sequences.)

Factory reset — hold

Quick-Cal

button while applying power
and 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 need to
be restored. A factory reset will always reset the command
source to analog 4-20 mA.

Special settings––several adjustments to the Logix 520 such
as split-range, MPC, soft stop, etc. cannot be set using the
local interface.

To set these parameters please refer to the appropriate com­munications tool manual.

9.4 HART 275 HANDHELD COMMUNICATOR

The Logix 520 si supports and is supported by the HART 275
Handheld Communicator. The DD and the manuals listed be­low can be obtained from the HART Communication Founda­tion or from your Flowserve representative. For more infor­mation please see the following guides:

•

Product Manual for the HART Communicator

• Logix 520 si Digital Positioner with HART 275
Communicator User Guide

9.5 USE OF SOFTTOOLS COMMUNICATION SOFTWARE

Flowserve corporation has written custom configuration and
diagnostic software for the Logix 500 si series called
SoftTools™. This software and the

SoftTools Quick Start Guide

are available from a Flowserve representative.

9.6 INTEGRATION OF THIRD-PARTY SOFTWARE

The Logix 520 si positioner can be used with:

– Siemens PDM™
– Fisher Rosemount AMS™

Local control of valve position — Can be done from the user
interface by holding both jog buttons and then simultaneously
pressing the

Quick-Cal

button. While in this mode the LEDs
will flash a Y-G-R-R (yellow-green-red-red) sequence. To exit
the local control mode and return to normal operation, briefly
press the

Quick-Cal

button.

10

12.0 VDC

520

si

Figure 4: Compliance Voltage

PIEZO

Y

RELAY

4-20 mA Signal

Internal Housing
EARTH Terminal

Shielded Cable

Z

Limit Switch 1

Limit Switch2

Connect Shield at Source Ground

­4-20 mA Current Source

+

Figure 5: Wiring Diagram

POT.

LS1

LS2

Table 9: Connection Table

Connection Description

+11 Input+ 4..20 mA

-12 Input- 4..20 mA

+41* Limit switch 1+

-42* Limit switch 1-

+51* Limit switch 2+

-52* Limit switch 2­Y Pneumatic output signal (outlet)
Z Air supply

* 0ptional

11

10 STATUS CODES

Logix 520 si Status Condition Codes

Colors Identifier Indication and resolution
G - - - Any sequence starting with a Green light flashing first is a normal operating mode and indicates that

there are no internal problems.
GGGG 1 No errors, alerts, or warnings; and the unit is in analog control mode.
GGGY 2 MPC active - The command is below the user set limit for tight shutoff feature. This is a normal

condition for a closed valve. The factory default setting is 1% command. To clear the condition use

handheld or Flowserve supplied software to reset the MPC if the range is incorrect or adjust the

command signal above the specified MPC value.
GGYG 3 Digital command mode - The analog 4-20 mA input signal is ignored in this mode and a handheld or

Flowserve supplied software is needed to change the position command. (Note a factory reset is the only

method to reset the command back to analog control mode from the local interface if a PC or handheld

configurator is not available. A reset will cause the loss of other data.

(See page 14 for more information)
GGYR 4 Initializing, or LED test mode - This sequence should only be visible for 3 sequences when powering

up the unit.
GGRG 5 Cycle limit - The cycle limit set by the user has been exceeded. To clear use handheld or Flowserve

supplied software to reset.
GGRY 6 Travel limit -The total accumulated travel limit set by the user has been exceeded. To clear use handheld

or Flowserve supplied software to reset.
GYYR 7 Soft Stop Lower - The unit is being commanded to exceed a user defined lower travel limit and the

internal software is holding the position at the limit. To clear the condition use handheld or Flowserve

supplied software to reset the limit if more travel is needed or adjust the command signal back in the

specified range.
GYRY 8 Soft Stop Upper - The unit is being commanded to exceed a user defined upper travel limit and the

internal software is holding the position at the limit. To clear the condition use handheld or Flowserve

supplied software to reset the limit if more travel is needed or adjust the command signal back in the

specified range.
GRYR 9 Position Lower - The position has reached or is exceeding a user defined lower travel indicator similar to

a limit switch indicator. To clear the condition use handheld or Flowserve supplied software to reset the

indicator if more travel is needed or adjust the command signal back in the specified range.
GRRY 10 Position Upper - The position has reached or is exceeding a user defined upper travel indicator similar to

a limit switch indicator. To clear the condition use handheld or Flowserve supplied software to reset the

indicator if more travel is needed or adjust the command signal back in the specified range.

12

Logix 520 si Status Condition Codes

Colors Identifier Indication and resolution

Y - - - Any sequence starting with a yellow light indicates that the unit is in a special calibration or test mode, or

that there was a calibration problem.

YGYG 11 Signature test in progress- This is a test initiated by Flowserve supplied software that can only be

cancelled by that software.

YYYG 12 Loop Calibration in Progress - Calibration sequence controlled by a handheld or Flowserve supplied

software that can only be cancelled by that software.

YRGG 13 Stroke Calibration in Progress - Calibration sequence started either using the local Quick-Cal button or

by a handheld or Flowserve supplied software. It may be cancelled by briefly pushing the Quick-Cal
button.

YGRR 14 JOG Control Mode - the unit has been placed in a local override mode where the valve can only be

stroked using the two local jog buttons. It may be cancelled by briefly pushing the Quick-Cal button.

YYYR 15 Command 0 saturated - Calibration error indicating that the 4-20 mA signal corresponding to 0%

position was out of range. Adjust the signal to the correct range and re-do the calibration. This error may
be cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration.

YYRY 16 Command 100 saturated - Calibration error indicating that the 4-20 mA signal corresponding to 100%

position was out of range. Adjust the signal to the correct range and re-do the calibration. This error may
be cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration.

YYRR 17 Command span - Calibration error indicating that the 4-20 mA signal was below the minimum calibration

span. The minimum calibration span is 1.28 mA. This error may be cleared by briefly pushing the Quick­Cal button, which will force the positioner to use the parameters from the last good calibration.

YRRG 18 Waiting for JOG set point from User - only used during Jog calibration see explanation in Quick-Cal

section of main document for operation.

YRYG 19 Setting IL Offset (in Stroke Cal) - An automatic step in the calibration process that is done with the valve

at 50% position. This must be completed for proper calibration.

YRYY 20 Feedback no-motion during calibration - Indicates that there was no motion of the actuator based on the

current stroking time configuration. 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 pushing the Quick-Cal button, which will force the positioner to use
the parameters from the last good calibration.

YRYR 21 Feedback 0 saturated - Calibration error indicating that the position sensor was out of range during the

calibration. To correct the condition, adjust the positioner mounting, linkage or feedback potentiometer to
move the position sensor back into range then restart the calibration. This error may be cleared by briefly
pushing the Quick-Cal button, which will force the positioner to use the parameters from the last good
calibration.

YRRY 22 Feedback 100 saturated - Calibration error indicating that the position sensor was out of range during

the calibration. To correct the condition, adjust the positioner mounting, linkage or feedback
potentiometer to move the position sensor back into range then restart the calibration. This error may be
cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration.

YRRR 23 Feedback span - The range of motion of the position feedback arm was too small. Check for loose

linkages and/or adjust the feedback pin to a position closer to the follower arm pivot to create a larger
angle of rotation. This error may be cleared by briefly pushing the Quick-Cal button, which will force the
positioner to use the parameters from the last good calibration.

YRGR 24 Feedback unstable during calibration - Check for loose linkages or loose position sensor. This error

may be cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the
parameters from the last good calibration.

YRGY 25 Feedback unstable setting IL Offset - Check for loose linkages or loose positioner sensor. This can also

be caused by over tightened packing, very sticky packing, or very high gain settings. This error may be
cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration.

13

Logix 520 si Status Condition Codes

Colors Identifier Indication and resolution
R - - - Any sequence starting with a red light indicates that there is an operational problem with the unit.

RGRR 26 Position Deviation - The position has exceeded user defined error band between command and

position.

RYYY 27 Hall sensor non-motion - Check to make sure the air supply is connected. This error may be cleared

by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters from the
last good calibration. If the positioner still does not operate replace the pneumatic relay assembly.

RYYR 28 Hall sensor lower position - Check to make sure the air supply is connected. This error may be

cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration. If the positioner still does not operate replace the pneumatic relay
assembly.

RYRY 29 Hall sensor upper position - Check to make sure the air supply is connected. This error may be

cleared by briefly pushing the Quick-Cal button, which will force the positioner to use the parameters
from the last good calibration. If the positioner still does not operate replace the pneumatic relay

assembly.
RRGG 30 1,23 V reference - Bad electronic assembly, replace.
RRGR 31 12-bit A/D reference - Bad electronic assembly, replace.
RRYG 32 Temperature limit - The internal positioner temperature is currently exceeding operational limits of

-40 ˚C (-40 ˚F) or 85 ˚C (185 ˚F).
RRYY 33 Piezo voltage - Bad electronic assembly, replace.
RRYR 34 Board current high - Check internal wiring and connectors for electrical shorts, if no shorts bad

electronic assembly, replace.
RRRG 35 12-bit D/A reference - Bad electronic assembly, replace.
RRRY 36 EEprom checksum error - The checksum of the internal data has become corrupted. Cycle power and

complete a Quick-Cal if needed. Check internal data to verify correct settings. If the error still occurs,

bad electronic assembly, replace.

13 Version number checking- The version number of the embedded code may be checked at any time except during a

calibration by holding down the ∆ 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 ∇ button will give the minor version number
without affecting operation. The version codes are interpreted by adding up the numbers assigned according to the
following table:

Color First blink value Second blink value Third blink value

Green 0 0 0
Yellow 9 3 1
Red 18 6 2

For example if holding the ∆ button gave a G-G-R code, and holding the ∇ button gave a Y-Y-G code then the resulting version number
would be (0+0+2).(9+3+0) or version 2.12.

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11 TROUBLE SHOOTING

Logix 520 si Symptoms and Solutions

Failure Probable Cause Corrective action

No LED is blinking 1. Current source below 3,6 mA 1. Verify current source suppies at least 3,6 mA

2. Incorrect wiring polarity 2. Check wiring for correct polarity

Erratic communications 1. Current source bandwidth not 1. Maximum allowable current source rate of

limited to 25Hz change is 924 mA per second

2. Maximum cable length or cable 2. Check cable conductor size, length and
impedance exceeded capacitance. Refer to ‘Cable Requirements’ on

page 11.

3. HART modem connected to PC RS-232 3. Verify laptop battery is not low
port not receiving enough power

4. Interference with I.S. barrier 4. Must use HART compatible I.S. barrier

5. Current source stripping (filtering) 5. Use the HART filter (VHF) available from
HART signal Flowserve (FLS part-No. 10156843)

Alternatively a 250 Ω and a 22 µF capacitor,
installed according to the following schematic
drawing can be used to establish communication

22 µF

250 Ω

Control system

Unit does not respond 1. Unit is in digital command mode 1. Switch to analog command mode with handheld
to analog commands communicator or Soft Tools.

2. Error occurred during calibration 2. Correct calibration error. Recalibrate

Valve position reading 1. Stem position sensor mounting 1. Reposition sensor
is not what is expected is off 180 degrees

2. Stroke not calibrated 2. Calibrate stroke

3. Tight shutoff MPC (Minimum 3. No action
position cutoff) is active

4. Custom characterization or soft 4. No action
stops active

Position is driven fully 1. Stroke not calibrated 1. Calibrate valve stroke
open or closed and will 2. Inner-loop hall sensor not connected 2. Verify hardware connections
not respond to command 3. Wrong air action entered in software 3. Check ATO (Air-to-open) and ATC (Air-to-Close)

settings. Recalibrate

4. Actuator tubing backward 4. Verify ATO/ATC actuator tubing

5. Electro-pneumatic converter 5. Replace electro-pneumatic converter
malfunctioning

6. Control parameter inner-loop offset 6. Adjust inner-loop and see if proper control
is too high/low resumes

Sticking or hunting 1. Contamination of the 1. Check air supply for proper filtering and meeting
operation of the positioner electro-pneumatic converter. ISA specifications ISA-7.0.01

2. Control tuning parameters not correct 2. Lower proportional gain settings

15

12 SPARE PART KITS

Item No. Description Part-No.

.

1 Cover Assembly Yellow

White
2 PC Board Assembly H10014000
3 Repair kit for Logix 500-Relay Module Assembly H10011500
4 Repair kit for Potentiometer Assembly H10011600
5 Position Feedback Assembly H194500003
8 Follower Arm Assembly Max. stroke 65 mm H194512001

Max. stroke 110 mm H194512002

Mounting Kits

Item No. Description Part-No.

– IEC 534 part 6 (Valtek 2000, Kämmer KA, Kämmer KP, and standard NAMUR linear valves) H192685001
– Rotary VDI/VDE 3845 (DIN ISO 5211) H194984001

Gauge Kits

Item No. Description Part-No.

–2 gauge set, 6 bar / 4 bar, brass, nickel plated H179379013
–2 gauge set, 6 bar / 4 bar, stainless steel H179379015

Regional Headquarters

Manderscheidstr. 19 1350 N. Mt. Springs Prkwy. 12 Tuas Avenue 20
45141 Essen Springville, UT 84663
Germany USA Republic of Singapore 638824
Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

Main Sales Offices (Europe, Middle East, Africa)

von-Braun-Straße 19a 12, av. du Québec Station Road Allee du Quartz 1
48681 Ahaus 91965, Courtaboeuf Cedex Pershore, Worcestershire CH-2300 La-Chaux-de Fonds
Germany France England WR102BZ Switzerland
Telephone: [phone] Telephone: [phone] Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: [phone] Facsimile: [phone] Facsimile: [phone]

Units 1 and 2 C/O Saleh & Abdulaziz Abahsain
26, Imvuba Road, Sebenza Ext 6 P.O. Box 209
Edenvale, Gauteng
Edenglen 1613 Al Khobar 31952
South Africa Saudi Arabia
Telephone: [phone] Telephone: [phone]
Facsimile: [phone] Facsimile: 9663 859 5284

©03.2002 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation

All data subject to change without notice

16