Valtek Logix 1200e/1210e
Digital Positioner
GENERAL INFORMATION
The following instructions are designed to assist in
unpacking, installing and pe rforming maintenanc e as
required on Valtek
Series 1000 is the term used for all the positioners
herein; however, specific numbers indicate features
specific to a model (i .e. Logix 1200 e indicat es th at the
positioner uses HART
maintenance per sonnel should thorou ghly review this
bulletin prior to inst allin g, operating, or per forming any
maintenance on the valve.
Separate Valtek Flow Control Products Installation,
Operation, Maintenance instructions cover the valve
(such as IOM 1 or IOM 27) and actuator (such as IOM
2 or IOM 31) por tio ns of the system and o ther accessories. Refer to the appropria te instruc tions when this
information is needed.
WARNING: To avoid possible injury to personnel or damage to valve parts, users must
strictly adhere to WARNING and CAUTION
notes. Modifying this product, substituting
non-factory or inferior parts, or using maintenance procedures other than outlined could
drastically affect performance and be hazardous to personnel and equipment, and may
void existing warranties.
®
Logix® 1200e digital positioners.
®
protocol). Product users and
WARNING: Standard industry safety practices
must be adhered to when working on this or any
process control product. Specifically, personal
protective and lifting devices must be used as warranted.
Valve and Instrumentation Storage Procedures
Storage
Control valve packages (a control valve and its instrumentation) can be safely stored in an enc losed building that affords environmental protection; heating is
not required. Contr ol valve packages must be stored
on suitable skids, not directl y o n th e fl oor. The storage
location must also be free from flooding, dust, dirt, etc.
Pre-installation Inspection
If a valve control package has been stored for more
than one year, inspect one actuator by disassembling
it per the appropriate
Maintenance In struct ions
tion. If O-rings are out-of-r ound, deter iorated, or both ,
they must be replaced and the actuator rebuilt. All
actuators must then be disassembled and inspected. If
the actuator O-rings are replaced, complete the following steps:
1. Replace the pressure-balanced plug O-rings.
2. Inspect the solenoi d and positioner so ft goods and
replace as necessary.
Installation, Operation, and
(IOM) pr ior to valve inst alla-
Valtek SKU 138430 44-1
Table of Contents
General Information ...................................................1
Valve and Instrumentation Storage Procedures....1
Logix 1200e Positioner Overview...............................3
Specifications.............................................................3
Positioner Operation...................................................4
Detailed Sequence of Positioner Operations.........4
Logix 1000 Series Positioner Vented-design
Conversion.................................................................5
Tubing Positioner to Actuator ................................ 6
Wiring and Grounding Guidelines..........................6
Available Spare Part Kits for Logix 1200e digital
postioner.............................................................. 22
4 to 20 mA Analog Output Retrofit.......................24
General Information.............................................24
Calibration............................................................25
Troubleshooting........................................................30
Introduction..........................................................30
Theory of Operation.............................................30
Mounting and Installation.....................................31
Calibration............................................................33
Control and Tuning............................ ...... ....... ..... 34
HART Communication......................................... 35
Alarms..................................................................37
Alerts....................................................................38
Advanced Features.................................................. 40
Logix 1200e Digital Positioner
on Valtek Mark One Control Valve
44-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Unpacking
Logix 1200e Positioner Overview
1. While unpacking the Logix 1 200e p ositi oner, check
the packing list against the materials received. Lists
describing the system and accessories are
included in each shipping container.
2. When lifting the system from the shipping con-
tainer, position lifting straps to avoid damage to
mounted accessories. Systems with valves up to
six inches may be lifted by actuator lifting ring. On
larger systems, lift uni t using li fting straps or hooks
through the yoke legs and outer end of body.
WARNING: W hen lifting a v alve/actuator assembly with lifting straps, be aware the center of
gravity may be above the lifting point. Therefore, support must be given to prevent the
valve/actuator from rotating. Failure to do so
can cause serious injury to personnel or damage to nearby equipment.
3. In the event of shipping damage, contact the ship-
per immediately.
4. Should any problem arise, contact a Flowserve
Flow Control Division representative.
The Logix 1200e digital positioner is a two-wire,
4-20 mA input, digital valve positioner. The Logix
1200e positioner also utilizes the HART protocol to
allow two-way remote communications with the positioner. The Logix 1200e positioner can control both
double and single-acting actuators with linear and
rotary mountings. Start up current must be at least
3.5 mA but once started, the L ogix 120 0e digita l positioner operates with a signal as low as 2.8 mA . Below
2.8 mA, the operation and communication are suspended.
Since the positione r is insensitive to supply pr essure
changes and can handle suppl y pressures from 30 to
150 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). An air filter is required for all
applications due to the close clearances in the spool.
NOTE: The air su pply must conform to ISA Standard
ISA 7.0.01 (a dew point at least 18 degrees Fahrenheit
below ambient temperature, particle size below five
microns – one micr on re co mme nde d – and oil content
not to exceed one part per million).
Specifications
Table I: Electrical Specifications
Power supply Two-wire, 4-20 mA 12.0 VDC
Compliance voltage 12.0 VDC
Effective resistance 625 Ω @ 20 mA
Communications HART Protocol
Minimum required
start-up current
Minimum oper ati ng
current
Maximum voltage 40.0 VDC
Table II: SoftTools Suite Software Specifications
Minimum Pentium processor running Win-
Computer
HART Modem RS-232 Modem or PCMCIA card
HART Filter
HART MUX MTL 4840 system
dows 95 or NT, 16-MB total memory
(32-MB recommended), 20-MB available
hard disk space, one CD-ROM drive
May be required in conjunction with some
DCSs
3.5 mA
2.8 mA
Table III: Physical Specifications
Operating
Temperature Range
Housing
Weight
-40° F to +185° F
(-40° C to +85° C)
Cast, powder -painted aluminum,
stainless steel
8.3 pounds (3.9 kg) aluminum 20.5
pounds (9.3 kg) stainless steel
Table IV: Positioner Specifications
Dead band <0.1% full scale
Repeatability < 0.05% full scale
Linearity
Air Consumption at
< 0.5% (rotary), < 0.8%
(sliding stem) full scale
< 0.3 SCFM (0.5 Nm
(4 barg)
Table V: Hazardous Area Certifications
Explosion Proof
Non-incendive
Intrinsically Safe
FM/CSA Class 1, Div 1, Groups B, C, D
CENELEC EExd IIB+H2 T5, IP-66
FM/CSA Class 1, Div 2, Groups A, B, C,
D; CENELEC IIC Exn, T6,BS 6941,
IP-66, T
FM/CSA Class 1, Div 1, Groups A, B, C,
D; CENELEC EExib, T4 & T5, IP-66
3
/hr)@60 psig
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-3
.
O
Digital Position
Algorithm
LED
Display
Air-to-open
Configuration
Flame Arrestors
Spool Valve
Exhaust
OUTPUT 1
Collector Board
Pressure Sensor
Air Supply
OUTPUT 2
Exhaust
Flame
Arrestor
Stem Position Sensor
Hall Effect Sensor
Electro magnetic Coil
Nozzle
Figure 1: Logix 1200e Digital Positioner Schematic
Positioner Operation
The Logix 1200e positioner is an electric feedback
instrument. Fig ure 1 shows a Logi x 1200e positioner
installed on a double-acting actuator for air-to-open
action. Positioning is based on a bal ance of two signals: one proportional to the command input signal
and the other proportional to the valve stem position.
The supply pressure for the positioner pressure modulator is tapped off the main supply. Next it passes
through an inter n al pres su re regul ato r that regul ates it
to approximately 22 psig. The air the n pass es throug h
an orifice that restricts the flow and air consumption.
The pressure modulator further controls the air to
6-10 psig, when operatin g current is applied, using a
spring-diaphragm fl apper that is attracted by an electromagnet to a nozzle. A temperature compensated
hall effect sensor mounted on a circuit board senses
the spool valve position. The hall effect sensor and circuitry create an inner feedback loop, which determines
how much current to send to the ele ctromagnet for a
desired spool valve position. The electro-magnet in
the feedback loop varies the nozzle-flapper spacing,
which regulates the o utput p ressure to 6-10 psig, proportional to the digital position algorithm.
When the command and stem position signals are
equal, the system will be in equilibrium and the valve
stem will be in the posi tion ca lled for by the command
signal. If these opposing signals are not equal, the
spool valve will move up (or down) and, by means of
Main PCB Tray
Ribbon Cable
Flame Arrestor
Filter
Regulator
Orifice
Flapper
the pressure modulato r, change output pressures an d
flow rate. This will cause the actuator pi ston to move
until the signal of the position sensor equalizes with
the command signal.
Detailed Sequence of Positioner Operations
The detailed sequen ce of positioner operations is as
follows: An increase in the command signal causes
the modulator pressur e to incr ease, push ing the spool
assembly upward from its equilibrium position. This
opens the spool valve ports, su pplying air to Output 1
and exhausting air from Output 2. This causes the
actuator piston to move upward.
The upward motion of the piston is transmitted back to
the positioner through the s tem pos ition feedback linkage, changing propor tionally to the valve stem position. The piston continues to stroke upward until the
stem position signal of the sensor increases sufficiently to counter th e signal being sent to the control
algorithm. At this po int, the spool is at its equilibriu m
position as the pres sures in the cylinde r stabilize and
the air flow to the actu ator decreases. The positio ner
will then make small null adjustments to fine-tune the
desired position and compensate for changes in
dynamic loading.
A decrease in the command signal reverses the
described actions, causing a proportional downward
movement of the actuator piston and stem.
44-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Logix 1000 Series Positioner Vented-d esign Conversion
A standard Logix 1000 series positioner is vented
directly to the atmosp here. When supply air is su bstituted with sweet natural gas, the following changes
and considerations must be met . Piping must be u sed
to route the exhausted natural g as to a safe environment. This piping system may cause som e positioner
back pressure in the main chamber (from mod ulator)
and spool chambers (fro m actuator). This increase i n
pressure is due to restrictions caused by piping losses
from the pipe and fittings
Maximum Allowable Housing
Back Pressure
1 psi (0.07 bar)
1
4
-inch NPT x 4-inch
Swagelok Tube Fitting
1
4
-inch FNTP x 8-inch
MNPT Reducer
1
Figure 3: Main Housing Vent
1
Two chambers must be vented on the Logix 1000
series positio ners: the main hou sing cham ber and the
spool valve chamber (Figures 1 and 2). The main
chamber vent is located on the backside of the positioner (see Figur e 1). Ther e is a small, silver-colored
cover (item 24, SKU 10097867), protecting the vent
which must be removed and can be discarded.
1
A fitting may now be threaded into th e
/8-inch NPT
hole and tubing/piping attached.
NOTE: On rotary prod ucts, the mounting bracket covers the main housing vent. An adequate size access
hole must be drilled in the bracket at the time of
assembly to allow access to the main housing vent.
Field Terminations
HAR T Connection
Terminals
The maximum all owa ble back pressure fr om the collection device on the main housing vent is 1.0 psi
3
(0.07 bar). Vent flow rate is 244 standard in
/min.
WARNING: The back pressure must never rise
above 2.0 psi (0.14 bar).
If this occurs the weather seal boot (SKU 130884),
found on the early versions of the Logix 1000 positioner, identified by the diagonal window in the main
cover, must be checked for proper sealing, as overpressure will move the seal out of place. (See
Figure 4). Damage will not oc cur to the s eal, only s eal
alignment will be affected. A typic al sign of boot lea kage is a dramatic deterioration of positioner performance. To correct the seal, remove the driver module
and simply re-ali gn back into its groove. If back pressure of 3.5 psi (0.24 bar) is reached, total valve control
will be lost.
4-20 mA Feedback
Terminals (optional)
Housing EARTH
Terminal
Seal Boot
Shielded
Connect Shield at Source Ground
Cable
4-20 mA Current Source
Figure 2: Field Termination
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-5
Figure 4: Seal on Modulator
3
/8-inch NPT x 3/8-inch
Swagelok Tube Fitting
Maximum Allowable
spool Back Pressure
8 psi (0.55 bar)
will cause problems with overshoot but permanent
damage will not occur until pressures exceed 20 psi
(1.4 bar).
Tubing Positioner to Actuator
Proper tubing orientation is critical for the posit ion er to
function correctly and have the proper failure mode.
Refer to Figure 1 and note that for air-to-open valves,
the Output 1 port of the positioner mani fold is tubed to
the bottom side of the ac tuator. The Output 2 port of
the positioner manifold is tubed to the top side of the
actuator. For air-to-close valves the above configuration is reversed.
For single-acting actuators Output 1 port is always
tubed to the actuator regardless of air action. Output 2
port must be plugged.
WARNING: This product has electrical conduit
connections in either thread sizes 0.5- inch NPT or
M20 which appear identical but are not interchangeable. Forcing dissimilar threads together
will damage equipment, cause personal injury and
void hazardous location cer tifications. Conduit fittings must match equipment housing threads
before installation. If threads do not match, obtain
suitable adapters or contact a Flowserve office.
Customer Connection
3
/8-inch Tubing
Figure 5: Spool Cover Vent
The spool valve chamber has two parts: the spool
valve cover, (item 9, SKU 130811) and spool valve
shroud (item 10, SKU 1308 25). The spo ol valve cover
is replaced by SKU 101346 49 for early versions of the
Logix 1000 posi tioner or SKU 1016 0335 for later versions (identified by the 1200e or the round win dow in
the main cover). This new cover has a
hole where tubing/pipin g must be attach ed. The sp ool
valve shroud is discarded and not replaced with a nything. The maximum allowable back pressure while
stroking the valve is 8 psi (0.55 bar). Hi ghe r p re ssur es
3
/8-inch NPT
Wiring and Grounding Guidelines
Input Cable Shielding (Figure 2)
The input loop current signal to the Logix 1200e 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.
Grounding Screw
The green grounding scr ew, locate d inside the term ination cap, should be used to provide the unit with an
adequate and reliable earth ground reference. This
ground should be tied to the same ground as the electrical conduit. Additionally , the electrical conduit should
be earth grounded at both ends of its run.
The green grounding screw must not be used to
terminate signal shield wires
.
44-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Figure 6: Co mpliance Voltage
Compliance Voltage (Figure 6)
Output compliance voltage refers to the voltage limit
that can be provided by the current source. A current
loop system consists of the current source, wiring
resistance, barrier resistance (if present), and the
Logix 1200e posi tioner impedance. The Logix 1200 e
digital positioner r equires that the current lo op system
allows for a 12.0 VDC drop across the positioner at
maximum loop current. The 12.0 VDC drop across the
Logix 1200e positi oner terminals is ge nerated by the
positioner from the 4-20 mA loop current input.
CAUTION: Never connect a voltage source directly
across the positioner terminals. This co uld cause
permanent circuit board damage.
Determine if the loop will support the Logix 1200e digital positioner by performing the following calculation.
Voltage = Compliance Voltage (
- Current
MAX
*(R
barrier+Rwire
)
@
Current
MAX
)
The calculated voltage must be greater than 12 VDC
in order to support the Logix 1200e digital positioner.
Example: DCS Compliance Voltage = 19 V
Cable Requirements
The Logix 1200e 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
1200e Hz and 220 0 Hz. In order to prevent distortio n
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/foot rating
will allow longer cable 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 formu la.
C
network
Example: R
= 50
R
wire
Ω
µF()
barrier
C
cable
≤
--------------------------------------------------------------
R
()
barrierRwire
= 300
Ω
22ρF
--------------
65
++
foot
390
0.000022µF
--------------------------------==
foot
0.0032
–
R
= 300
barrier
= 25
R
wire
Ω
CURRENT
Ω
= 20 mA
MAX
65
---------------------------------------
30050390
++
Max Cable Length
0.0032–0.08µFC
==
C
-----------------------------------=
network
C
network
network
µF()
Max
µF()
()
Voltage = 19 V - 0.020 A*(300 Ω + 25 Ω)
= 12.5 V
Max Cable Length
0.08µF
-----------------------------------------------=
0.000022µF foot
⁄
The voltage 12.5 V is greater than the required 12.0 V;
therefore, this system will support the Logix 1200e digital positioner. The Logix 1200e positioner has an
input resistance equivalent to 625 Ω at a 20 mA input
current.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-7
To control cable resistance, No. 24 AWG cable should
be used for runs less than 5000 feet. For cable runs
longer than 5000 feet, No. 20 AWG cable should be
used.
Driver Module Assembly
Minimum Pressure
Set Screw (factory
calibrated)
Collector Board
Pressure
Modulator
Connection
Hall Sensor
Connection
O-ring
Install orifice before driver
module is in housing
Position wires to
the rear of Modulator
Hall Sensor Connector
Pressure Modulator Connector
Figure 7: Driver Module Assembly
Driver Module Assembly
The driver module assembly moves the spool valve by
means of differential pressures on its diaphragm. Air is
routed to the module from the regulator through a
hose that connects to the assembly through a hose
barb with an integral orifice. Wires from the module
connect the hall effect sensor an d the pr es su re modulator coil to the collector board.
Driver Module Assembly Replacement
To replace the driver module assembly, refer to
Figure 7, 8, 9, 11, 20 and procee d as outlined below.
The following tools are required:
Flat plate/bar about
Phillips screwdriver
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
3. Remove the driver module cover (Figure 9), using
flat bar/plate in slot.
1
/8-inch thick
4. Remove the spool valve cover by removing the
screw and sliding the cover assembly backwards
until the tab is clear of the slot. Removing the sheet
metal cap, hydrophobic filter, or O-ring from this
assembly is not necessary (Figure 11).
5. Being careful not to l ose the nylon washer, remove
the Phillips-head screw that attaches the driver
module to the main housing (Figure 8).
6. Remove the spool valve block by removing the two
Phillips-head scr ews and carefully slidin g the block
off the spool (Figure 8).
CAUTION: The spool (extending from the driver
assembly) is easily damaged. Use extreme caution when handling the spool and spool valve
block.
7. Carefully remove spool by slid ing end of spool ou t
of connecting clip. Excessive force may bend spool.
8. Remove main cover.
44-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Spool Valve
Screws
Spool Valve BlockHousing
Ny lon
Gaskets
Driver to
Housing Screws
Figure 8: Spool and Block
Spool
opening. This will al low the dri ver module to threa d
out without tangling or cutting the wires.
12.Grasp the driver module pressure modulator cap to
rotate the entire driver module. Turn it counter
clockwise to remove. After it is threaded ou t, carefully retract the driver module from the housing.
13.Take new driver module, and verify that the O-ring
is in place. Lay the wires back and along modulator
as shown in Figure 7, and hold in place by hand.
14.Gently direct the driver module into the housing
bore. Turn the dr iver module clockwise to thread it
into the housing. Continue rotating the module until
it bottoms out.
15.Once the threads are fully engaged, rotate the
driver module counter clockwise until the flat on the
driver module and the flat on the housing are
aligned. This wi ll align the sc rew holes for the next
step.
16.Verify that nylon gasket is in the counter bore in the
driver module retaining screw hole as shown in
Figure 8.
Orifice
Driver
Modul e
Cover
Figure 9: Driver Module Orifice
9. Remove the tubing from the orifice in the driver
module assembly (Figure 9) .
10.Remove the two wiring connections that link the
driver module assembly to the collector board.
17.Insert a driver-to-housing screw into the driver
housing through the counter-bored hole in positioner main housing. T ighten with a phillips screwdriver.
18.Feed the driver module wires in to the main chamber of the housing , an d c onn ec t th em to th e c olle ctor board.
19.Verify that the three O-rings are in the counterbores on the machined platform where the spool
valve block is to be placed (Figure 20).
20.Carefully slide the spool in to the connec ting clip of
the driver module assembly.
21.Carefully slide the block over the spool, using the
machined surface of the housing base as a register
(Figure 8). Slide the block toward the driver module
until the two retaining holes line up with the
threaded holes in the base.
22.Install two spo ol-valve screws and ti ghten se curely
with a Phillips screwdriver.
23.Slide the spool valve cover assembly over the spool
valve until the tang engages into housing slot.
Install spool valve cover screw and tighten securely .
11.Feed the wires back through the housing so they
extend backward, out toward the driver module
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-9
24.Thread main cover and driver module cover into
the main housing.
Spool Valve
To replace the spoo l valve, refe r to Figure 8, 10 & 1 1
and proceed as outlined below.
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
3. Remove the spool valve cover by removing the
screw and sliding the cover assembly backwards
until the tab is clear of the slot. It is not neces sary
to remove the sheet metal cap, hydrophobic filter,
or O-ring from this assembly (Figure 11).
5. Grasp the bottom of the regulator and unscrew it
from the interface plate.
6. Ver ify that the O-ri ngs are in place on the base of
the new regulator and thread it into the hole in
interface plate.
7. Install four screws to fasten the collector boar d into
the housing. Replace the four wire connections.
8. Attach the flexible tubing to the orifice.
9. Re-install all covers.
4. Remove the spool valve block by removing the two
phillips-head s crews and car efully sl iding the block
off the spool (Figure 8).
CAUTION: Spool (extending from driver assembly) is easily damaged. Use extreme caution
when handling spool and spool valve block.
5. Carefully remove spool by sliding en d of spool out
of connecting clip. Excessive force may bend the
spool.
6. Verify that the three O-rings are in the counterbores on the machined platform where the new
spool valve block is to be placed (Figure 20).
7. Careful slide the spool into the connecting clip of
the driver module assembly.
8. Carefully slide the block over the spool, using the
machined surface of the housing base as a register
(Figure 8). Slide the block toward the driver module
until the two retaining holes line up with the
threaded holes in the base.
9. Install two spool-valve screws and tighten securely
with a phillips screwdriver.
10.Slide the spool valve cover assembly over the spool
valve until the tang engages into housing slot.
Install the spool valve cover screw and tighten
securely.
O-ring
Hyd rophobic
Filter
Spool Valve Cover
Spool
Valve Shroud
Figure 10: Spool Valve Cover Assembly
Spool Valve Cover
The spool valve cover incorporates a coalescing filter
element in a t wo-piece cover. This protects t he spool
valve chamber from moisture and provides a low back
pressure vent for exhaust air from the spool valve.
Replacing Filter in Spool Valve Cover
1. Make sure valve is bypassed or in a safe condition.
Regulator
The regulator reduces the pressure of the incoming
supply air to a level that the driver module can use.
Replacing Regulator
2. Disconnect the power and air supply to the unit.
3. Remove the spool cover by removing the screw
and sliding the cover assembly backwards until the
tab is clear of the slot. The sheet metal cover may
be removed and cleaned with a brush or by blowing
out with compressed air (Figure 11).
1. Make sure valve is bypassed or in a safe condition.
4. Remove the O-ring from around hydrophob ic filter
2. Disconnect the power and air supply to the unit.
3. Remove the main cover.
4. Remove the four wire connections from the c ollector board. Next remove the four screws that fasten
the collector board to the housing.
44-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
element and set aside (Figure 10).
5. Remove the molded filter element by pulling
straight out of chamber cover vent piece.
6. Install O-ring into base of chamber cover vent piece
as shown in Figure 10.
7. Place new molded filter element into the chamb er
cover vent piece. This element provides part of the
track to secure the O-ring installed in the last step.
8. Place spool valve shroud onto spool valve cover.
9. Place the spool valve cover assembly in place by
setting it on the ramp and sliding it until the tab seats
in the slot (Figure 11) and secure with No. 8-32
screw.
Spool Valve Cover
Screw
Main PCB Assembly
The main PCB assembly contains the circuit board
and processor that perform control functions of the
positioner. The board is encapsulat ed in a tray with a
protective silicon coating. This module can be easily
replaced if necess ar y. None of the compo nents insid e
the tray are serviceable. This module is to be replaced
as a unit.
Replacing Main PCB Assembly (Figure 12)
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
3. Remove the main cover and disconnect the ribbon
cable from the collector board.
CAUTION: To avoid damaging any components,
exercise caution by gently raising the locking
tab to release the ribbon cable.
4. Remove the PCB assembly by removing the three
No. 6-32 screws and lifting the tray out of housing.
5. Place the new PCB assembly on th e bo ss es i nsid e
the positioner housing.
6. Insert three No. 6-32 screws through the tray into
the threaded bosses and tighten evenly, using a
phillips screwdriver. Do not overtighten.
Figure 11: Spool Valve Cover Assembly
Ribbon Cable
7. Reconnect the ribbon ca ble to the collect or board
Main PCB
Assembly
Screws (3)
Figure 12: Main PCB Assembly
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-11
Collector Board
The collector board assem bly provides a central routing for all electronic connec tio ns in the pos it ion er, linking the pressure modulato r coil, hall effect sensor and
field in put s to the mai n el ect ro nics. The collector b oar d
assembly also provides for mount ing of the pressure
sensors used in the advanced model.
Removing Collector Board (Figure 20)
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
3. Remov e th e main co v er an d discon nect t he wi ring to
the collector board. Each cable has its own unique
connector to prevent mistakes in reconnecting.
4. Remove the four No. 8-32 screws holding the
collector board to the housing.
5. Remove the collector board.
NOTE: Th e two screws through the stiffener plate
are longer.
5. Tighten all four screws.
6. Connect the main ribbon from the electronics tray.
7. Reconnect wiring to the collector board.
Field Terminations
The customer interface board provides a connection
point inside the explosion proo f housing for all hookups to positioner. While the board is not li kely to experience a failure, it can easily be replaced.
Replacing Customer Interface Board
(Figure 2 & 20)
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
3. Remove the main cover and disconnect the customer interface cable from collector board.
Replacing Collector Board
NOTE: A Logix 120X (standard model) cannot be
upgraded to a Logix 1210e (advanced model) by
changing out the co llect or bo ard. T he Logi x 12 0X an d
Logix 1210e use different positioner housings.
1. Advanced collector board only – Verify that pressures sensors are in place on back of collector
board, and that the two O-rings are in place.
2. Set collector board assembly in place.
3. Advanced collector boards req uire a stiffener plate
above the pressure sensors (Figure 2 0) .
4. Insert four No. 8-32 screws through the collector
board into the threaded holes of the housing.
4. Remove the customer interface cover and the three
No. 8-32 screws.
5. Remove customer interface board, c aref ully p ullin g
wiring through bore.
6. Verify that the O-ring is in pl ac e in the co unte r bore
in the positioner housing.
7. Feed wiring through p assageway into main chamber of housing.
8. Set the circuit board in pl ac e a nd s ecur e wit h th re e
No. 8-32 screws.
9. Connect customer interface cable to collector
board.
10.Replace covers.
44-12 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Stem Position Sensor
The position feedback assembly transmits valve position information to the proces so r. This is accom p li sh ed
by means of a rotar y position sensor that con nects to
the valve stem through a feedback linkage. To provid e
for accurate tracking of the pin in the slot, the follower
arm is biased against one side of the slot with a rotary
spring. This spring also automatically moves the position feedback assembly to its limit in the unlikely event
of failure of any component in the linkage.
8. Route wires alon g the position sensor and reconnect to collector board.
Mounting to Linear Mark One Valves
(See Figure 14)
The tools required for the following procedure are:
9
/16-inch open-end wrench
7
/16-inch box wrench
3
/8-inch open-end wrench
Bearing
Housing
Stem Position
Sensor Dot
Stem Position
Sensor
Sensor
Cable
Feedback Shaft
Figure 13: Stem Position Sensor
Orientation
Stem Position Sensor Replacement
(Figure 13, 20)
1. Make sure valve is bypassed or in a safe condition.
2. Disconnect the power and air supply to the unit.
1. Remove washer and nut first 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. Reinsert lock washer and tighten nut to
complete follower arm assembly.
2. Slide the double-D slot i n 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 customer interface side of the
positioner. Slide lock washer over the threads on
the shaft and tighten down the nut.
3. Align the bracket with the three outer mounting
holes on the positioner. Fasten with
1
/4-inch bolts.
4. Screw mounting bolt into the hole on the yoke
mounting pad nearest the cy linder. Stop when the
bolt is approximately
/
from being flush with
3
16-inch
mounting pad.
5. Slip the large end of teardrop shaped mounting
hole in the back of the position er/bracket assembly
over mounting bolt. Slide the small end of teardrop
under mounting bo lt and align the lower mountin g
holes.
3. Remove the main cover and disconnect rotary
6. Insert lower mounting bolt and tighten bolting.
position sensor wires from collector board.
7. Slide appropriate pin slot on the take-off arm, based
4. Remove the two screws from rotary position sensor
and remove the sensor from the housing.
5. Turn position sensor shaft until the dot on the slot is
oriented with the wires on the pot (Figure 13).
on stroke length, over follower arm pin. The appropriate stroke lengths are stamped by each pin slot.
8. Position the take-off arm mounting slot aga inst the
stem clamp mounting pad. Apply Loctite 222 to
take off arm bolting and insert through washers into
6. Insert the position sensor into the shaft with wires
stem clamp. Torque to 120 in-lbs.
pointing toward the main PCB assembly. Tur n the
position sensor clockwise until bolting slots align
with the housing screw holes an d the wires on th e
sensor protrude over the main PCB assembly tray.
7. Carefully center positi on sensor on the s haft bore,
insert and tighten the screws.
Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-13
Do not over tigh ten.
9. Center the take-off ar m on the rolling sleeve of the
follower pin.
10.Align take-off ar m wit h top pl ane of th e s tem cl am p
and tighten bolting.
Logix 1200 Positioner
Locknut
Washer
Follower
Arm
Take-off Arm
Nut
Lock Washer
Nut
Follower Pin
Bracket Bolts
Bracket
Positioner
Bolts
Nut
Stem Clamp
Bolts
Figure 14: Linear Mark One Control Valve Mounting
Standard Rotary Mounting Procedure
(See Figure 15)
The standard rotar y mounting applies to valve/actuator assemblies that do not have mounted volume tanks
or handwheels. The standard mounting uses a linkage
directly coupled to the valve shaft. This linkage has
been designed to allow for minimal misalignment
between the positioner and the actuator. The tools
required for the following procedure are:
5
/32 allen wrench
1
/2-inch end wrench
7
/16-inch end wrench
3
/8-inch socket with extension
3
/16 nutdriver
1. Fasten spline lever adapter to splined lever using
two No. 6 x 0.50-inch self tapping screws.
2. Slide take-off arm assembly onto spline lever
adapter shaft. Insert screw with star washer
through take-off arm and add second star washer
and nut. Tighten nut with socket so arm is lightly
snug on shaft but still able to rotate. This will be
tightened after linkage is correctly oriented.
Metal
Washers
3. Attach follower arm to positioner feedback shaft
using the star washer and No. 10-32 nut.
NOTE: Arm will poi nt up when feedback shaft is in
the free position.
1. Using four 0.25-20 x 0.50 L. bolts, fasten positioner
to universal bracket using appropr iate hole patter n
(stamped on bracket).
2. Using a
1
/2-inch end wrench and two 0.3125-18 x
0.50 L. bolts, attach bracket to actuator transfer
case pad. Leave these bolts slightly loose until final
adjustments are made.
3. Rotate take-off arm so the follower pin will slide into
its slot. Adjust bracket position not ing the engagement of the follower pin and the take-off ar m slot.
1
The pin should extend approximately
16-inch
/
past
take-off arm. When properly adjusted, securely
tighten the bracketing bolts.
Orienting the Take-off Arm for Final Lock Down
Tube positioner to valve in the following manner:
1. OUTPUT 1 por t of the m anifold to the bottom side
of the Actuator.
44-14 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611
Loading...