Flowserve Logix 520si Series User Instructions

User Instructions Logix 520si - LGENIM2520-00 09/09

®

USER INSTRUCTIONS

Logix 520si Series

Digital Positioner

FCD LGENIM2520-00 09/09

Installation

Operation

Maintenance

Experience In Motion

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User Instructions Logix 520si - LGENIM2520-00 09/09

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Table of Contents Page

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

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

Logix 520si Overview ...................................................................... 4

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

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

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

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

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

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

Logix 520si Local Interface Operation ......................................... 8

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

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

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

Factory Reset .............................................................................. 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 ac-

cessories 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, CAUTION

and NOTE are used in these instructions to highlight
particular dangers and/or to provide additional infor­mation on aspects that may not be readily apparent.

DANGER: indicates that death, severe personal in-

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

WARNING: indicates that death, severe personal injury

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

CAUTION: indicates that minor personal injury and/or

property damage can occur if proper precautions are
not taken.

NOTE: indicates and provides additional technical

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.

Fire protection must be provided by the user.

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User Instructions Logix 520si - LGENIM2520-00 09/09

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1.6 Spare parts

Use o nly FLOWSE R V E original spare par t s .

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 pr oducts are 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.

3

3 LOGIX 520SI OVERVIEW

User Instructions Logix 520si - LGENIM2520-00 09/09

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The Logix 520si 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 520si positioner controls single­acting actuators with linear and rotary mountings. The
Logix 520si is completely powered by the 4-20 mA input
signal. The minimum input signal required to function is
3,6 mA. As 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

4 SPECIFICATIONS

Table 1: Input Signal

Input Signal Range 4 - 20 mA (HART)

Compliance Voltage 12 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%

4

3,6 mA

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)

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 due to the close tolerances in the positioner.
Optional limit switch unit and a directly attachable double
acting module complete the Logix 520si positioner acces­sories.

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 II1G Ex ia IIC T4 - T6

II3G Ex ic IIC T4 - 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)

User Instructions Logix 520si - LGENIM2520-00 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 mA
+ HART

HART

®

Figure 1: Logix 520si Principle of Operation

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 520si positioner is a digital positioner that incor-

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

1.The microprocessor-based electronic control module includes

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-

HART communications and direct local user interface switches

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 two-stage 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.

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

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User Instructions Logix 520si - LGENIM2520-00 09/09

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Table 10: Connection Table

Y

Z

Internal Housing
EARTH Terminal

Shielded Cable

Figure 2: Wiring Diagram

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 require-

ments. 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

or reverse).

4-20 mA Signal

Connect Shield at Source Ground

-

4-20 mA Current Source

+

3

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

Connection Description

+11 Input+ 4..20 mA

-12 Input- 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: 12 VDC / 600 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
520si 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 520si impedance. The Logix
requires that the current loop system allow for a 12 VDC

520si

drop

across the positioner at maximum loop current.

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User Instructions Logix 520si - LGENIM2520-00 09/09

510

Controller

Voltage

Compliance

Voltage

12V

®

520si

Figure 3: Compliance Voltage

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 520si,

perform the following calculation:

Available Voltage = Controller Voltage (@Current

- Current

MAX

*(R

barrier

The calculated available voltage must be greater than 12

VDC in order to support the Logix 520si.

Example:

DCS Controller Voltage = 19 V

R

R

CURRENT

barrier

= 25 Ω

wire

= 300Ω

MAX

= 20 mA

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

= 12,5 V

The available voltage 12,5 V is greater than the required
12

V; therefore, this system will support the Logix 520si.

The

Logix 520si has an input resistance equivalent to 500 Ω

at a 20 mA input current.

8 CABLE REQUIREMENTS

The Logix

520si

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

+ R

wire

rating will allow longer cable runs. In addition to cable
capacitance, the network resistance also affects the
allowable cable length.

65Ω

C

(µF) < - 0,0032

network

(R

)

MAX

)

Example:

R

barrier

R

wire

C

= 300 Ω (if present)

= 50 Ω

72 ρF 0.000072 µF

= =

cable

m m

65

(300 + 50 + 390)

Max. Cable Length =

Max. Cable Length = = 1111 m

+ R

barrier

wire

- 0,0032 = 0,08 µF= C

+ 390Ω)

C

(µF)

network

C

cable

0,08 µF

network

(µF)(Max)

0.000072 µF/m

To control cable resistance, No. 24 AWG cable can 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 520si 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.

7

®

Configuration Switches

User Instructions Logix 520si - LGENIM2520-00 09/09

LED Status
Lights

Jog Calibrate
Buttons

Gain Selector

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 520si positioner to restore opera­tion.

9 STARTUP

9.1 Logix 520si Local Interface

The Logix 520si 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 rotary selector switch for adjusting the positioner
gain settings. For indication of operational status or
alarm conditions there are three LEDs on the local user

8

interface.

4-20 mA Input Quick-Cal Button

Figure 4: Logix 520si Local Interface

9.2 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) – Select ATC if increasing output pres-

sure 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 4 mA will make the valve fully closed when the

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

Selecting 20 mA will make the valve fully closed when the

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

User Instructions Logix 520si - LGENIM2520-00 09/09

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3. Pos. Characterization

Select Linear if the actuator position should be directly

proportional to the input signal.

Select Optional if another characteristic is desired, which

is set in conjunction with the next switch, labeled Optional
Pos. Char.

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

The =% option w ill characteri ze the actu ator

response to the input signal based on a standard 30:1
equal percent rangability curve.

If Custom is selected, the positioner will be characterized

to a custom table that must be set-up ValveSight DTM
software or a HART handheld.

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

On enables an auto tune feature that will automatically

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

NOTE: there is a small black arrow indicating the selection.

The slot does not indicate the chosen gain.

If the rotary Gain selector switch is set to E with
the Auto Tune switch On, a Flowserve nominal
response tuning set will be calculated and used.

If the rotary Gain selector switch is set to D, C, B, or A

with the Auto Tune switch On, progressively lower gain
settings will be calculated and used.

If the rotary Gain selector switch is set to F, G, or H with

the Auto Tune switch On, progressively higher gain set­tings will be calculated and used.

Off forces the positioner to use one of the factory preset

tuning sets determined by the rotary Gain selector switch.
Settings A through H are progressively higher gain pre-
defined tuning sets. The positioner is preset to Autotune

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

The gain selector operates as a “live” switch. This means

that changes to the switch position while the positioner
is in normal operation will have immediate effect on the
control algorithm.

6. Stability Switch – This switch adjusts the position control
algorithm of the positioner for use with low friction control

Indicator arrow

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 Calibration switches

9.3.1 Setup of the Cal DIP Switch for the Quick

Calibration operating mode

Select Auto if the valve/actuator assembly has an internal

stop in the 100% stroke position. In Auto 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 Jog if the valve/actuator assembly has no cali-

bration stop in the open position. In the Jog mode the
positioner will fully close the valve for the 0% position
and then wait for the user to set the open position using
the Jog buttons labeled with the up and down arrows.
See the detailed instructions in the next section on how
to perform a manual calibration using the Jog buttons.

WARNING: During the Quick-Cal operation the valve

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

9.4 Quick-Cal Operation

The Quick-Cal button is used to locally initiate a

calibration of the positioner. Pressing and holding the
Quick-Cal button for 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 Quick-Cal can be aborted at any
time by briefly pressing the Quick-Cal button and the
previous settings will be retained.

If the Quick calibration switch (not to be confused

with the Quick-Cal button) is set to Auto and the valve/
actuator assembly 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

9

User Instructions Logix 520si - LGENIM2520-00 09/09

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®

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 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 calibra-

tion 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 Jog buttons. When the
stem is properly positioned press both 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.)

9.6 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.

9.7 Special settings

Several adjustments to the Logix 520si such as split-range,

MPC, soft stop, etc. cannot be set using the local interface.

To set these parameters please use SoftTools software or

a HART handheld.

9.5 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-G­R-R(yellow-green-red-red) sequence. To exit the local
control mode and return to normal operation, briefly
press the Quick-Cal button.

10

11 LIMIT SWITCH UNIT

STOP!

User Instructions Logix 520si - LGENIM2520-00 09/09

®

CAUTION: The installation of hazardous location electrical

equipment must comply with the procedures contained
in the certificates of conformance. Country specific
regulations may apply. Electrical safety is determined
only by the power supply device. (Positioner operation
with limited voltage only).

11.1 General

The Logix 520si digital positioner can be equipped with

an additional limit switch unit.

11.2 Principle of Operation

The lever / coupling moves the vane into the slot of the

limit switches LS1 or LS2. The sensors are designed as
a proximity vane type switch. The switching function is
triggered if a ferromagnetic object (vane) is inserted
between the coils. The switching point can be set by
adjustment of the vane.

11.3 Installation (Figure 7)

The limit switch unit is fitted to the positioner when

delivered but can be retrofitted. Fit 3 spacer screws (1)
to positioner housing. Place PC board (2) on spacer
screws (1), secure with 3 mounting screws (3).

11.4 Adjusting switches

Use the following procedure to adjust the switches

1. Loosen the two screws on the vane (4), figure 7.

2. Stroke the valve to the first switching position.

3. Set the switching point of the limit switch by adjusting
the lower vane for the lower switch (LS2).

4. Stroke the valve to the second switching position (LS1).

5. Set the switching point of the limit switch by adjusting
the vane for the upper switch.

6. Tighten the two screws on the vane (4), figure 7.

7. Check the two switching points and repeat the adjust­ment steps 1 to 6, if necessary.

Switches (Figure 8)
Install vane assembly (4) and secure with 2 screws. For

electrical connect see Figure 8.

WARNING: For units installed in Hazardous areas special

installation cautions and procedures are required.

4

3

1

2

Figure 7: Limit switches Figure 8: Switch connections

11

12 STATUS CODES

User Instructions Logix 520si - LGENIM2520-00 09/09

®

Colors

G - - -

Identifier

Indication and resolution

Any sequence starting with a Green light flashing first is a normal operating mode and indi cates 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).

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 sup-

plied 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

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

12

User Instructions Logix 520si - LGENIM2520-00 09/09

®

Colors

Y - - -

Identifier

Indication and resolution

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 can-

celled by that software.

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

ware 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 correspond ing 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 corre sponding 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 mini mum calibration

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

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

tion 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 actu ator 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, link age 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, link age 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 link-

ages 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 sen sor. 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 sen sor. 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

User Instructions Logix 520si - LGENIM2520-00 09/09

®

Colours Identifier Indication and resolution

R - - -

RGRR 26 Position Deviation - The position has exceeded user defined error band between com mand and posi-

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

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

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

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

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 elec-

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

Any sequence starting with a red light indicates that there is an operational problem with the unit.

tion.

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.

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.

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.

˚C (-40 ˚F) or 85 ˚C (185 ˚F).

tronic assembly, replace.

complete a Quick-Cal if needed. Check internal data to verify correct set tings. 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
Δ 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 affecating 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 Δ 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.

14

User Instructions Logix 520si - LGENIM2520-00 09/09

®

14 TROUBLE SHOOTING

Logix 520si Symptoms and Solutions

Failure Probable Cause Corrective action

No LED is blinking 1. Current source below 3,7 mA 1. Verify current source supplies at least 3,7 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 250Ω and a 22 µF capacitor,
installed according to the following schematic
drawing can be used to establish communication

22 µF

250Ω

Control system

Unit does not respond 1. Unit is in digital command mode 1. Switch to analog command mode with ValveSight
to analog commands DTM software or handheld communicator.

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

User Instructions Logix 520si - LGENIM2520-00 09/09

®

1

3

4

Figure 9: Exploded drawing for spare parts

15 SPARE PARTS KITS

Item No. Description Part-No.

1 Cover Assembly Yellow 255240.999.000

White 218771.999.000

Black 218772.999.000

3

4 Repair kit for Potentiometer Assembly 218774.999.000

5 Position Feedback Assembly 218774.999.000

8 Follower Arm Assembly Max. stroke 65 mm 214323.999.000

Mounting Kits

– IEC 534 part 6 (FloTop, Kämmer KA, Kämmer KP, and standard NAMUR linear valves) 213619.999.000

– Rotary VDI/VDE 3845 (DIN ISO 5211) 188151.999.000

– Flowserve direct mounting 214004.999.000

– Linear VDI / VDE 3847 255242.999.000

Relay Module Assembly: -20ºC to 85ºC (-4ºF to 185ºF) 230103.999.000

Relay Module Assembly: -40ºC to 85ºC (-40ºF to 185ºF) 218773.999.000

Max. stroke 110 mm 214322.999.000

Description Part-No.

16

®

EXTERIOR
GROUNDING

SCREW

User Instructions Logix 520si - LGENIM2520-00 09/09

LED WINDOW

22.95

.90

"D" SHAFT OPTION

(STANDARD)

M8

10.00

.39

2.31

57.20

2.25

.09

28.60

1.13

35.40

1.39

M20X1,5 OR

1/2" NPT

64.10

2.52

FRONT VIEW

174.10

6.85

28.60

1.13

G1/4" OR
1/4" NPT

98.14

3.9

10.00

53.00

2.09

4.00

4.80

.2

.4

100.00

.2

"N" SHAFT OPTION

(VDI/VDE 3845, NAMUR)

3.94

32.00

1.3

4.00

.2

17.70

.70

Figure 10: Dimensional Drawing for the Logix 520si Series Digital Positioner

17.70

.70

35.40

1.39

57.20

2.25

M6

M8X1,25 OR 5/16"-18UNC

BACK VIEW

MM

INCH

17

User Instructions Logix 520si - LGENIM2520-00 09/09

FIG. 6 - DIMENSIONAL DRAWING FOR OPTIONS

®

SINGLE PRESSURE GAUGE

100.00

3.94

216.18

8.51

AUXILIARY OPTIONS - “GA” (GAUGE ADAPTER)

1/4" NPT

TWO PRESSURE GAUGES

47.63

1.88

100.00

3.94

1/4" NPT

63.50

2.50

216.87

8.54

AUXILIARY OPTIONS - “GM”

DOMED

INDICATOR

100.00

3.94

173.50

6.83

(GAUGE MANIFOLD)

POSITION INDICATOR - “D” (DOMED INDICATOR)

127.69

5.03

MM

INCH

Figure 11: Dimensional Drawing for the Logix 520si with options

18

User Instructions Logix 520si - LGENIM2520-00 09/09

®

19

Contact:

User Instructions Logix 520si - LGENIM2520-00 09/09

®

Flowserve Headquarters

5215 N. O'Connor Blvd.
Suite 2300
Irving, Tx. 75039
Phone: [phone]

Flowserve Corporation
Flow Control

1350 N. Mt. Springs Parkway
Springville, UT 84663
USA
Phone: [phone]
Fax: [phone]

Flowserve (Austria) GmbH

Control Valves - Villach Operation
Kasernengasse 6
9500 Villach
Austria
Phone: [phone]
Fax: [phone]

Flowserve Australia Pty Ltd.

14 Dalmore Drive
Scoresby, Victoria 312020
Australia
Phone: [phone]
Fax: [phone]

China

585, Hanwei Plaza
7 Guanghau Road
Beijing, China 100004
Phone: [phone]

Flowserve India Controls Pvt. Ltd

Plot # 4, 1A, E.P.I.P, Whitefield
Bangalore Kamataka
India 560 066
Phone: [phone]
Fax: [phone]

Flowserve Essen GmbH

Manderscheidtstr. 19
45141 Essen
Germany
Phone: [phone]
Fax: [phone]

Flowserve S.A.S.

7, Avenue del la Libération - BP 60
63307 Thiers Cedex
France
Phone: [phone]
Fax: [phone]

Flowserve Pte Ltd.

12 Tuas Avenue 20
Singapore 638824
Singapore
Phone: [phone]
Fax: [phone]

NAF AB

Gelbgjutaregatan 2
SE-581 87 Linköping
Sweden
Phone: [phone]
Fax: [phone]

Kämmer Valves INC.

1300 Parkway View Drive
Pittsburgh, Pa 15205
USA
Tel.: [phone]
Fax: [phone]

All data subject to change without notice

© 09.2009 Flowserve Corporation. Flowserve and Kämmer are trademarks of Flowserve Corporation

20