Flowserve Logix MD+ ValveSight User Manual

with HART®

ValveSight™ Diagnostics DTM Manual

Logix® MD+ Positioners

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Table of Contents

LOGIX MD+ .................................................................... 3

QUICK START GUIDE ................................................... 4

S

YSTEM REQUIREMENT

DTM I

NSTALLATION

C

REATE A FIELD NETWORK

DTM L

ICENSING

..................................................................................................... 6

......................................................................................................... 8

.............................................................................................. 10

............................................................................................................ 16

BASIC DASHBOARD ................................................... 17

ADVANCED DASHBOARD .......................................... 20

ANNUNCIATOR PANELS ............................................ 25

A

LARMS ANNUNCIATOR

M

ANAGEMENT ANNUNCIATOR

E

VENT HISTORY

.................................................................................................. 26

........................................................................................ 43

............................................................................................................. 55

HEALTH ....................................................................... 58

V

ALVE HEALTH

P

OSITIONER HEALTH

A

CTUATOR HEALTH

C

ONTROL HEALTH

T

RAINING

.............................................................................................................. 59

Friction .............................................................................................................. 64

Bellows Cycles & Travel ................................................................................... 72

....................................................................................................... 76

Teperature & Humidity .................................................................................... 82

Pilot Relay ........................................................................................................ 84

Piezo Voltage .................................................. ................................................. 88

........................................................................................................ 90

Actuator Pnuematic Leak ................................................................................. 94

Supply Pressure ................................................................................................ 97

Actuation Ratio .............................................................................................. 100

Actuator Cycles & Travel ................................................................................ 102

........................................................................................................ 106

Deviation ........................................................................................................ 110

Position Alerts ................................................................................................ 113

Command Frequency ..................................................................................... 116

Command Amplitude ..................................................................................... 119

Position Frequency ......................................................................................... 122

Position Amplitude ......................................................................................... 125

................................................................................................................... 128

ON-LINE DIAGNOSTICS ............................................ 130

D

ATA MONITOR

T

RENDS

C

ONTINUOUS STROKE TEST

.......................................................................................................... 131

...................................................................................................................... 137

............................................................................................ 142

OFF-LINE DIAGNOSTICS .......................................... 144

R

AMP TEST

................................................................................................................. 145

Ramp Compare ............................................................................................... 155

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

S

TEP TEST

................................................................................................................... 160

Step Test Compare ......................................................................................... 167

HDRL T

EST

................................................................................................................. 171

HDRL Compare ............................................................................................... 179

P

ARTIAL STROKE TEST

Partial Stroke Compare .................................................................................. 189

Partial Stroke Schedule .................................................................................. 193

................................................................................................... 183

FCD- LGENSF0014-00

CALIBRATION ........................................................... 195

S

ENSOR CALIBRATION

C

OMMAND CALIBRATION

C

ALIBRATION ERRORS

................................................................................................... 196

.............................................................................................. 202

................................................................................................... 206

CONFIGURATION ...................................................... 213

C

ONFIGURATION MANAGEMENT

DTM L

ICENSE MANAGEMENT

P

OSITIONER UPGRADE MANAGEMENT

P

OSITIONER UPGRADE

L

OCAL INTERFACE

C

ONTROL

.................................................................................................................... 237

Position Shutoff .............................................................................................. 238

Soft Limits ....................................................................................................... 240

Positioner Gain ............................................................................................... 242

Pressure Control ............................................................................................. 245

Stroke Characterization ................................................................................. 247

I

NFORMATION

Actuator ......................................................................................................... 260

Valve Body ...................................................................................................... 262

Valve Trim ...................................................................................................... 264

Positioner & HART® Information ................................................................... 266

C

ARD SLOT

U

NITS

................................................................................................................. 268

Multi-Function Card ....................................................................................... 269

........................................................................................................................ 277

.................................................................................................. 229

......................................................................................................... 231

Stroke Characterization (Custom) ................................................................... 254

............................................................................................................. 259

Analog Output Calibration ............................................................................... 271

Discrete Output (DO) ........................................................................................ 275

.................................................................................... 214

........................................................................................ 223

............................................................................ 225

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Welcome to the Logix MD+

Welcome to the Flowserve ValveSight® DTM for the Logix MD+ series digital positioners. This package offers unparalleled functionality for configuring, calibrating, maintaining and diagnosing control valve operation.

This package follows the standard FDT/DTM conventions. The Frame application controls the menu bar at the top of the page and the Frame connection tree at the far left of the frame window.

The DTM application contains a menu tree on the left side showing the available pages for configuring, calibrating, maintaining and diagnosing control valve operation.

At the top of the DTM window, the device tag is shown, and some basic information for the actuator and valve that is currently connected to the system.

The bar right below the device information contains two icons, one to toggle the menu bar on and off and the other to show this help.

At the bottom of the page below the Flowserve logo is an icon indicating the status of the connection to the field device. If the icon has a green check and the tow plugs touching it indicates that communications are taking place and the device shown at the top of the page is online. Two green arrows to the right of the connection symbol are visible when the DTM is requesting information from the device.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Quick Start Guide

GENERAL INFORMATION This Document

This document details the installation and functions of the ValveSight® Device Type Manager (ValveSight DTM) for the Logix® MD+ series of digital positioners including the Logix 520MD+.

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 authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers.

Additionally, product users and maintenance personnel should thoroughly review the Logix MD+ Series Digital Positioner Instruction, Operation, Maintenance and Safety Manual prior to installing, operating, or performing maintenance on the valve or positioner.

System Disclaimer

The installation instructions herein show an example of how to install, navigate, or commission the ValveSight Logix MD+ DTM in a WINDOWS 7 64 bit operating system, using the fdtCONTAINER FRAME Application. Any variation of operating system and/or FRAME application may result in a different procedure to install, operate, or commission the ValveSight Software.

Terms Concerning Safety

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

To avoid possible injury to personnel or damage to valve parts, DANGER and CAUTION notes must be strictly followed. Modifying this product, substituting nonfactory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties.

NOTE: indicates and provides additional technical information, which may not be very obvious even to qualified personnel.

CAUTION: Indicates that minor personal injury and/or property damage can occur if proper precautions are not taken.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

DANGER: Indicates that death, severe personal injury and/or substantial property damage can occur if proper precautions are not taken.

Compliance with other, not particularly emphasized notes, with regard to 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.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

System Requirement

Computer System

The ValveSight® DTM has been successfully tested with the following Operating System with a minimum of 512 M RAM:

• Windows XP

• Windows 7

Power Supply

• Non-filtered, 4-20 mA

Modem

• IFAC HART Modem

• Viator RS 232 Serial HART Modem

• UX Multiplexor

Communication DTM

• CodeWrite COMM DTM

• M&M – OEM HART COMM DTM (recommended)

• Yokogawa COMM DTM

• ABB COMM DTM

FRAMES

The ValveSight Logix MD+ DTM has been successfully tested in the following FRAME Applications:

• fdtCONTAINER FRAME Application

• PactWare (Point to Point) FRAME Application

DD Testing

The DD has been successfully tested on the following system components:

• HART Tokenizer Version 6

• SDC-625

• 475 HandHeld

Certifications

• Logix MD+ DTM Certification with FDT Group will be performed after field trial tests.

• DD Certification with the HART foundation will be performed after field trial tests.

System Assumptions

This Quick Start Guide document will assume that you already have the FRAME Application and Communication DTM installed.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

DTM Installation

Please log in to the Flowserve FTP Site (ftp://fcdftp) or open the CD to download the Logix MD+ ValveSight DTM, FdtCONTAINER, or HART COMM DTM Installs. These installs will allow you to install the ValveSight Logix MD+ DTM, FRAME application, and COMM DTM respectively. NOTE: This document will ONLY cover the installation of the Logix 520MD+ ValveSight DTM.

Follow the installation instructions

Frame and COMM DTM Install

If you do not have the FRAME Application or the HART Communication DTM installed, check the two boxes below and follow the installation instruction for both Frame and Communication DTM, else uncheck the already installed component.

Runtime Libraries

The ValveSight installation will check to see if the computer already has the necessary Microsoft Libraries, else it will prompt you to install the Libraries. Select

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

“Yes” on the following pages.

FCD- LGENSF0014-00

Resuming ValveSight Install

Once the install complete the installation and the Dongle and the Microsoft Runtime Libraries it will resume the installation of the DTM. Click Next

Accept the Agreement

Read and accept the agreement, then click next.

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Select DTM destination Browse and select the location where the DTM will install:

FCD- LGENSF0014-00

Follow and complete the installation as prompted.

10

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Create a Field Network

HART Modem

• If the modem is a serial port, move on to the next step

• The USB Modem requires that you install the driver for it. Make sure you

remember what slot you put the USB Driver, in case you unplug and plug in a different slot you will need to install the driver for the different slot.

• Right Click on My Computer and select Manage.

• Click on Device Manager and select Ports

• Check what port the modem was installed

FCD- LGENSF0014-00

Create a Field Network

The remainder of the Quick Start Guide will give instructions on how to create a Field Network using the fdtCONTAINER FRAME Application.

Device Catalog

Double click on the FDT Container, which is the M&M • Frame to open it. You will see a widow on the right of the page called “Device Catalog”. At the bottom of the page, click on Update. This should allow the Frame to identify both the COMM DTM and the ValveSight DTM.

11

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Add the COMM DTM

On the left side of the page you will see a window “Network View”. Right click on the My Network icon. Select “Add…”

To configure the communication port, right click the OEM HART Communication DTM in the “Network Views” window. Select “Configuration”.

12

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Set Port Address

• Select the correct port where the modem is installed.

• Check with the modem manufacturer to select the correct “Access Mode”.

• Under the “Communications Mode”, set the correct “Access Mode”

• Click the Apply or Ok button to apply modem configuration changes.

Add ValveSight Logix MD+ DTM

To add the ValveSight Logix MD+ DTM, right click on the OEM HART Communication DTM in the “Network Views” window and select “Add”.

13

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Select the “LogixMD+”

FCD- LGENSF0014-00

Optional: Save the project to your desktop or somewhere easy to remember. This will save you time so you do not have to create a field network in the future.

Starting the ValveSight MD+ DTM

To launch the ValveSight DTM, ensure the modem is connected to a device and the device is powered on. Right click on the “HART Channel 0> LogixMD+” and select “Go Online”

14

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Double click the “HART Channel 0> LogixMD+”, or right click and select Online Parameter

Troubleshooting

If communications is not established:

1. Verify the HART modem is functional. Some HART modems will report a positive self-check, but still be non-functional.

2. If another primary master is connected in the system, use a communication DTM other than the M&M fdtCONTAINER. This communication DTM does not support a primary master other than itself.

15

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

DANGER: Using certain features of the DTM can result in valve movement and the inability to operate the valve until the operation is complete. Notify proper personnel that the valve may stroke, and make sure the valve is properly isolated before proceeding.

16

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

DTM Licensing

License ValveSight

To take advantage of the full diagnostic capabilities of ValveSight®, license the Advanced ValveSight DTM for the Logix MD+.

Steps to license the Advance DTM:

1. In the menu tree, select “Configuration” -> “DTM License Management”

2. Write “beta” in the “Feature code:” (make sure it is all lower case)

3. Click the “Activate / Deactivate”

NOTE: The ValveSight Advance License will only apply to the specific PC.

17

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Basic Dashboard

The Basic Dashboard is a high level view of the status of the positioner. It is the main view of the ValveSight® DTM.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Command and Position

This area contains a graphical representations of the valve command and position. The blue bar tracks the final command value (after adjustments for characterization curves). The green position bar indicates the current measured position of the valve. The smaller pointers show the settings of the travel alert settings (these can be changed on the Travel Alerts page located under Alarms/Alerts). Grayed out zones at the top or bottom of the graphs indicate the settings of soft travel limits.

18

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Input Source

Select the analog or digital control mode. In analog mode, the positioner will position the valve according to the 4-20 mA supplied current. In digital mode, the positioner will position according to the value entered in the Digital Input field.

Pressure

Supply, port A and port B pressures are seen in this box. If the Supply Pressure field is yellow or red, there is a problem with the supply pressure to the positioner. The fields in the Pressure box are only active if the positioner is upgraded to have Advanced or Pro diagnostics.

19

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Ambient Temperature

The temperature and relative humidity inside the positioner are shown here. The units for temperature can be changed in the Positioner Configuration - Units page.

Dip Switch Configuration

The box shows the current configuration of the DIP switches on the front of the positioner. These switches should be set on the positioner before calibration. The configuration that is set by the DIP switches can be overridden in the software using the DTM. (See the Basic/Local Interface page of the DTM). If this is the case, an X will be shown in the box to the right of the item. Be careful when changing the configuration in software because performing a position calibration (Quick-Cal) will reset the configuration according to the physical DIP switch settings. See you instructions for the positioner for a detailed explanation of the switches.

HART Status

Communication with the DTM is displayed here. The Transmit field displays a data packet transmitted to the positioner. The Receive field shows data packets received from the positioner. These are constantly updating. If they appear static, there may be a problem with communications.

20

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Advanced Dashboard

The Dashboard view is the main diagnostic view of the ValveSight® DTM. Generally, the color green signifies a healthy condition, yellow signifies some degradation has taken place, and red signifies a problem that needs to be addressed right away. You can identify problems right away by observing any red areas on this page.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Command and Position

This area contains a graphical representations of the valve command and position. The blue pointer tracks the final command value after adjustments for characterization curves, Soft Limits, and Tight Shut Off. The green position bar indicates the current measured position of the valve. The smaller pointers show the settings of the travel alert settings (these can be changed on the Travel Alerts page located under Alarms/Alerts). Grayed out

21

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

zones at the top or bottom of the graphs indicate the settings of Soft Limits. The command chart also displays the settings for travel limits and position Tight Shut Off (Minimum Position Cut Off (MPC)) limits. If the positioner has been configured for Tight Shut Off this will show up in the field below the position bar. The Pressure Lock field indicates if the positioner is locked on a steady command by controlling the pressures, or tracking a moving command signal.

Input Source

The command source can be changed to analog or digital mode. In analog mode, the positioner will position the valve according to the 4-20 mA supplied current. In digital mode, the positioner will position the valve according to the value entered in the Digital Input field.

HART Status

The status of HART communication with the DTM is displayed here. The Transmit field displays a data packet transmitted to the positioner. The Receive field shows data packets received from the positioner. These are constantly updating. If they appear static, there may be a problem with communications.

22

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Health Status

The Health Status box has health indication bars for Valve, Position, Actuator, and Control which are displayed in 4 bar graphs in the center of the dashboard. These are powerful, visual diagnostic tools. Information from all of the diagnostic indications are rolled up into these health bars. As the graphs turn color (from green to yellow to red) they indicate developing issues. The health of the four key components of a control valve can be identified quickly by looking at the color of the bar. If the bars only show green then everything is operating within normal limits and no further action is required. If the bar is partially yellow it is pointing out a degraded condition. The further the bar goes to the right the more serious the degradation. If the bar is red then action should be taken immediately because the ability to control may be compromised. To learn more about any of the 4

health areas, click the double arrows ( ) button at the end of the bar. This leads to the detailed health status page for that particular item.

NOTE: Health Status bars are only available with the Advanced ValveSight® license viewing positioners with Advanced or Pro diagnostics. See the licensing and upgrade pages under Positioner Configuration in the DTM for more information.

Dip Switch Configuration

The box shows the current configuration of the DIP switches on the front of the positioner. These switches should be set on the positioner before calibration. The configuration that is set by the DIP switches can be overridden in the software using the DTM. (See the Basic/Local Interface page of the DTM). If this is the case, an X will be shown in the box to the right of the item. Be careful when changing the configuration in software because performing a position calibration (Quick-Cal) will reset the configuration according to the physical DIP switch settings. See you instructions for the positioner for a detailed explanation of the switches.

23

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Pressure

Pressure values are shown here. The units for pressure can be changed in the Positioner Configuration - Units page. The pressure gages for Port 1 and Port 2 read directly from the pressure sensors in the positioner. For single acting configurations, the Port 2 gage is not be active. Should the DTM view a device with no pressure sensors, all 3 gauges will be inactive. Pressure sensors are calibrated in the factory. A pressure calibration is not required unless there has been sever pressure or thermal stress on the positioner. See the Calibration - Sensor Calibration page.

NOTE: Pressure gauges are only available while viewing positioners with Advanced or Pro diagnostics. See the Positioner Upgrade page under Positioner Configuration in the DTM for more information.

Temperature

This gage shows the temperature on the circuit board in the positioner. The units for temperature can be changed in the Positioner Configuration - Units page.

24

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Humidity

This gage shows the Humidity on the circuit board inside the positioner. Since the positioner should be run with a dry air supply, this value should be near zero most of the time. Elevated humidity inside the positioner may significantly shorten the life of the positioner. Sensor accuracy is +/-10% RH. The sensors are calibrated in the factory. No other calibration is required.

25

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Annunciator Panels

Annunciator Panels allow quick viewing of the current state and history of diagnostic indicators and allows masking of alarms, warnings and alerts. This selection automatically redirects to the Alarms Annunciator page.

26

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Alarms Annunciator

The Alarm Annunciator page displays the status of all

diagnostic indicators. The status is shown in by the indicator "light". The checkboxes allow masking of indicators.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given below. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

27

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Legend

Each indicator group box may contain the following components:

• An "LED light" indicates health status. Warning and alarm limits (set by the user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

FCD- LGENSF0014-00

Cycles & Travel Status

Valve Cycles

• Definition: The valve cycle limit has been exceeded.

28

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Implications: Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the cycle accumulator.

Valve Travel

• Definition: The total accumulated valve travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the travel accumulator.

Actuator Cycles

• Definition: The actuator cycle limit has been exceeded.

• Implications: Each cycle represents two reversals of the direction of

valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the actuator seals and lubrication. After maintenance, reset the travel accumulator.

Actuator Travel

• Definition: The total accumulated actuator travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the actuator seals and lubrication. After maintenance, reset the travel accumulator.

Bellows Cycles

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of bellows movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Bellows Travel

• Definition: The bellows cycle limit has been exceeded.

FCD- LGENSF0014-00

29

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Implications: The bellows may be reaching the end of its fatigue life. Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Pilot Cycle

• Definition: The pilot relay cycle limit set by the user has been exceeded.

• Implications: The pilot relay cycles indicate the activity level of the pilot relay as it maintains a valve’s position. Excessive cycles can contribute to a worn relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

Pilot Travel

• Definition: The total accumulated pilot relay travel (% of full relay span) set by the user has been exceeded.

• Implications: The pilot relay travel indicates the activity level of the relay as it maintains a valve’s position. Excessive travel can contribute to a worn pilot relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

Feedback Loop Status

FCD- LGENSF0014-00

Position Deviation

• Definition: The device is not controlling at the set point.

• Implications: The difference between the command and the actual

position has been greater than the user-set limit for longer than a userset time.

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

Position Sensor Fail

• Definition: The feedback arm may be disconnected from the valve assembly.

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

30

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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

Closed Too Far

• Definition: The valve has closed farther than it did at the last calibration.

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

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

Opened Too Far

• Definition: The valve has opened farther than it did at the last calibration.

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

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

PST Failed -

• Definition: Measured times or forces during the last partial stroke test did not pass the criteria set by the user.

• Implications: This may be an indication of corrosion build-up on the valve stem or in the actuator, low or restricted supply pressure, or a sticking positioner relay.

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

CST Failed

• Definition: During the continuous stroke test, the valve did not move after 5 consecutive attempts.

• Implications: This could mean the valve has increased friction, a change in process load or inadequate supply pressure.

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

Inner Loop Status

FCD- LGENSF0014-00

31

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Pilot Response

• Definition: The pilot relay is sticking or slow to respond.

• Implications: This affects the responsiveness, increases the chance of

limit cycling and excessive air consumption. The pilot relay is part of the inner loop and consists of the driver module assembly with piezo (I-P relay) which is coupled to the spool valve or poppet. The value of this indicator corresponds with inner loop lag. Delayed response can be caused by a partially clogged piezo or debris, oil, corrosion, or ice on the spool, or low supply pressure.

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

Piezo Volts High

• Definition: The voltage driving the piezo is above the warning limit.

• Implications: This could indicate an error with the relay or the main

board. This may result from an extended period of inactivity, but in this case should not persist for more than 30 minutes when the valve is controlling. The positioner may still be functioning, but have reduced performance under some circumstances.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

Piezo Volts Low

• Definition: The voltage to the piezo is too low.

• Implications: The piezo may be damaged. This may prevent the

proper failure position upon loss of signal/power. This condition may occur briefly on an air-to-close valve that is held for long periods of time in the closed position, or an air-to-open valve held in the open position.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

Driver Module

• Definition: Driver module alarm.

• Implications: The pilot relay can't open, the pilot relay can't shut, or the

Hall sensor circuit has failed.

• Possible Solutions: Check the internal wiring connections. Replace the pilot relay.

Control Status

FCD- LGENSF0014-00

Command Frequency

32

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Definition: The frequency of the command signal is above the warning or alarm limit. This could mean the control loop is oscillating faster than normal.

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

Command Amplitude

• Definition: The amplitude of the command signal is above the warning or alarm limit. This could mean the control loop has larger swings than desirable.

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

Position Frequency

• Definition: The frequency of the position signal is above the warning or alarm limit. The positioner is controlling the position of the valve with rapid corrections.

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

Position Amplitude

• Definition: The amplitude of the position signal is above the warning limit. The positioner is controlling the position of the valve with large corrections.

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

Electronic Error Status

FCD- LGENSF0014-00

Aux. Card 1 Fail

• Definition: Auxiliary Card 1 is not communicating.

• Possible Solutions: Check auxiliary card connection to the main

33

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

board. If the problem persists, replace the card.

Aux. Card 1 No Loop Power

• Definition: Auxiliary Card 1 has no loop current.

• Possible Solutions: Check auxiliary card connection to loop current. If

the problem persists, replace the card.

Aux. Card 1 Error

• Definition: Auxiliary Card 1 has an electrical problem.

• Possible Solutions: MFC: Check auxiliary loop wiring and ensure

adequate compliance voltage. Replace card if condition persists

Aux. Card 2 Fail

• Definition: Auxiliary Card 1 is not communicating.

• Possible Solutions: Check auxiliary card connection to the main

board. If the problem persists, replace the card.

Aux. Card 2 No Loop Power - Auxiliary Card 2 has no loop current

• Definition: Auxiliary Card 2 has no loop current.

• Possible Solutions: Check auxiliary card connection to loop current. If

the problem persists, replace the card.

Aux. Card 2 Error

• Definition: Auxiliary Card 2 has an electrical problem.

• Possible Solutions: MFC: Check auxiliary loop wiring and ensure

adequate compliance voltage. Replace card if condition persists

Pressure Board Fail Warning

• Definition: One or more pressure sensors may have failed.

• Possible Solutions: Check the supply pressure to ensure it is between

1.3 and 10.3 bar (19 and 150 PSI). Check the pressure sensor board connections. Recalibrate the pressure sensors. If the problem persists, replace the pressure sensor board.

Low Battery Warning

• Definition: The battery for the real time clock is low.

• Implications: The battery is designed for a 15+ year life with the

positioner unpowered. The battery is not required for the positioner to control properly, but is used only to maintain the time and date upon loss of power. The time and date affect the time stamps of alarms, warnings and other events. This warning could be caused by rapidly power cycling the positioner.

• Possible Solutions: The battery is not replaceable. Verify or reset the time and date. Replace the main board if the problem persists for several days.

Mode Status

34

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Factory Reset State

• Definition: The positioner is in factory reset state.

• Implications: Calibration is required to enable control.

• Possible Solutions: Perform a Stroke Calibration (QUICK-CAL).

Calibration in Progress

• Definition: A calibration is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor

Calibration page of the DTM, from the handheld, or by briefly pressing the BACK button.

Signature or PST

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

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

Jog Command Mode

• Definition: The positioner has been placed in a local override mode where the valve can only be stroked using the UP and DOWN buttons.

• Implications: The positioner will not respond to analog or digital input commands from HART.

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

PST Scheduled

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

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

DI Command Override

• Definition: The Multi-Function Card has been configured as a Discrete Input (DI) and to override the input command, positioning the valve at a preconfigured set point. The DI signal is active and the positioner is attempting to control the valve at the set point.

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

FCD- LGENSF0014-00

35

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

DTM.

Position Status

Soft Stop High Alert

• Definition: The Final Command would move the valve beyond the user-set Soft Limit, but the internal software is holding the position at the limit.

• Implications: The function is similar to a mechanical limit stop except it is not active if the unit is un-powered.

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

Soft Stop Low Alert

• Definition: The Final Command would move the valve beyond the user-set Soft Limit, but the internal software is holding the position at the limit.

• Implications: The function is similar to a mechanical limit stop except it is not active if the unit is un-powered.

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

Position High Limit Alert

• Definition: The position has reached or is exceeding a user defined upper position indicator.

• Implications: This is similar to a limit switch indicator.

• Possible Solutions: Set the limit to a higher value if more travel is

needed, or adjust the command signal back in the specified range.

Position Low Limit Alert

• Definition: The position has reached or is exceeding a user defined lower position indicator similar to a limit switch indicator.

• Implications: This is similar to a limit switch indicator.

• Possible Solutions: Set the limit to a lower value if more travel is

needed, or adjust the command signal back in the specified range.

Feedback Linkage Alarm

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

• Possible Solutions: Fix broken linkage or adjust feedback arm until full motion is within the range of the POT.

Actuation Status

FCD- LGENSF0014-00

36

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Supply Pressure High

• Definition: The supply pressure is above the user set warning limit.

• Implications: Supply pressure that exceeds the maximum rating on the

actuator can become a potential hazard.

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

Supply Pressure Low

• Definition: The supply pressure is below the user set warning or alarm limit.

• Implications: Low supply pressure can cause poor valve response or positioner failure. The minimum recommended supply pressure for proper operation is 1.3 bar (19 PSI).

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

Actuation Ratio

• Definition: The force required to control the system is close to the maximum available force.

• Implications: Actuation Ratio is based on the ratio of available force to the required force to fully actuate. Control may be lost if this ratio reaches 100%. It is affected by the process load, friction, spring force, and available supply pressure.

• Possible Solutions: Increase the supply pressure. Reduce the friction. Check the actuator spring. Resize the actuator. Adjust user set limits.

Spring Fail

• Definition: Upon loss of air supply, the valve may not move to the fail- safe position.

• Implications: The spring alone is not adequate to overcome the friction and process load in the system. The system is relying on pneumatic force to actuate in the direction the spring is pushing. The failsafe

FCD- LGENSF0014-00

37

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

spring may have failed, or it was not sized properly for the application. Friction or process load may have increased.

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

Pneumatic Leak

• Definition: The positioner has detected a leak in the actuation assembly.

• Implications: Leakage from the actuator can cause decreased responsiveness and excessive air/gas consumption.

• Possible Solutions: Repair pneumatic leaks at the tubing junctions and actuator seals. Check spool valve for excessive wear.

Air Supply Humid

• Definition: The supply gas has high relative humidity which can lead to condensation on electronic components and failure of electronic functions.

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

Air Supply Icing

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

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

Main Board Status

FCD- LGENSF0014-00

Main Board Fail

• Definition: There has been an oscillator fault, position sensor ADC failure, supply voltage error, reference voltage error, shunt voltage error, or piezo voltage error.

• Possible Solutions: This may be caused by transient conditions. If the error persists, replace the main board.

Software Error

• Definition: There has been a watch dog time out, stack overflow warning, or CPU usage warning.

• Possible Solutions: If the problem persists, perform a factory reset. If it still persists, reprogram or replace the main board.

Memory Error

38

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Definition: The microprocessor's memory has a problem.

• Possible Solutions: Error may clear with time. If error persists, cycle

power and complete a QUICK-CAL. If the error still persists, perform a factory reset, reprogram or replace the main circuit board.

Temperature High

• Definition: The temperature of the internal electronics has exceeded the manufacturer set limit of 85°C (176°F). High temperature may affect performance or limit the life of the positioner.

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

Temperature Low

• Definition: The temperature of the internal electronics has exceeded the manufacture set limit of -40°C (-40°F). Low temperature may inhibit responsiveness and accuracy.

• Possible Solutions: Regulate the temperature of the positioner. If the temperature reading is in error, replace the main circuit board.

Friction Status

FCD- LGENSF0014-00

Friction High

• Definition: The valve and actuator friction has passed the user set

• Implications: High friction can cause loop oscillations, poor position

• Possible Solutions: Determine if the friction is significantly interfering

Friction Low

• Definition: The friction has passed below the user set limit.

• Implications: Low friction is an indication of improperly loaded packing

limit. control, jerky motion, or valve sticking. It can be caused by build-up

from the process on the stem, trim or seat , by a failing bearing or guides in the valve and actuator, galling of the trim or stem, excessively tightened packing, linkages, or other valve or actuator mechanical issues.

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

and, in severe cases, can be an indication of the process fluid leaking at

39

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

the valve stem.

• Possible Solutions: Check for packing leak. Tighten or replace the valve packing.

Valve Can't Open

• Definition: Pressure has been applied (or removed) to open the valve, but the valve is not opening.

• Implications: This may be caused by excessive friction.

• Possible Solutions: Verify adequate supply pressure is applied. Verify

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

Valve Can't Shut

• Definition: Pressure has been removed (or applied) to close the valve, but the valve is not closing.

• Implications: This may be caused by excessive friction.

• Possible Solutions: Verify adequate supply pressure is applied. Verify

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

Action Buttons

The Apply button will save changes to the connected device.

FCD- LGENSF0014-00

The Retrieve button will retrieve the latest information from the device.

The Print Report button will print a report to default printer (see example below). Information includes:

• Information about the connected device

• The active status of the alarms, warnings and alerts.

• The masked status.

• The current value (where applicable).

• The value threshold (where applicable).

NOTE: It is possible to print the report to save to a PDF file. Instructions:

1. Download and install the free version of PDFCreator.

2. Install the PDFCreator

3. Set PDFCreator as the default Printer

40

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

4. Click Print Report and save the report to a pdf file in your computer.

41

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

42

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

43

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Management Annunciator

The Management Annunciator page displays all modes, setup, configuration and calibration errors and their current status. If a particular indicator is not wanted then a check in the box for a particular item will mask that item and it will not be shown in the active indicator field at the top of each page nor will it affect the status of the health bar on the main dashboard view.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Legend

Each indicator group box may contain the following components:

•

An "LED light" indicates health status. Warning and alarm limits (set by the

44

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

Start Up Status

Initializing

• Definition: The positioner has powered up and is displaying a blink sequence 3 times.

• Possible Solutions: Wait for 3 blink sequences to complete.

Stroke Calibration Required

• Definition: A factory reset was performed and the positioner has not yet been calibrated. The unit will not respond to commands and will remain in the fail-safe position until a calibration is successfully completed.

• Possible Solutions: Perform a Stroke Calibration (QUICK-CAL) by holding the QUICK-CAL/ACCEPT button down for 3 seconds, or perform a Pressure or Friction calibration if desired. See the Calibration section of the IOM for warnings.

Pressure Calibration Required

45

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

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

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

Friction Calibration Required

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

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

Mode Status

FCD- LGENSF0014-00

Digital Command Mode

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

• Possible Solutions: The input command source can be changed back to the 4-20 mA signal by using a handheld, the Dashboard page of the DTM, or performing a manual Command Reset. Perform the Command Reset during a QUICK-CAL by holding both the UP and DOWN buttons and briefly pressing the QUICK-CAL/ACCEPT button. A new QUICK-CAL must be performed after resetting.

46

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Tight Shut Off Mode

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

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

Pressure Control Lock

• Definition: The pressures are held constant (locked), improving the stability of the valve position. When the position of the valve gets very close to the commanded position, the positioning algorithm will change to pressure control. The point at which the pressure control is locked depends on the Valve Stability switch on the positioner. When the switch is set to “Lo Friction”, the locking point is self-adjusting to optimize accuracy. When the switch is set to “Hi Friction” and the deviation is smaller than +/- 1.0% (default), the pressure “locks”. The High Friction window size can be changed to optimize 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.

• Possible Solutions: If "Hi Friction" is set and this indicator never comes on, the error band limits may need to be adjusted using the Pressure Control page of the DTM or the Display Menu. Use the Valve Stability Configuration Switch to toggle the Valve Stability from "Lo Friction" to "Hi Friction" mode. A QUICK-CAL must be performed to apply the switch settings. If a QUICK-CAL cannot be performed, use the DTM to activate and set the "Hi Friction" window setting. .

CST Mode (Continuous Stroke Test Mode)

• Definition: When there is no variation in the command input, this feature is deliberately moving the valve as little as possible in order to perform diagnostics and ensure the valve is functioning.

• Possible Solutions: If more stability is required, turn off Continuous Stroke Test mode, or configure the rate of travel, period, and allowable movement using the Continuous Stroke page of the DTM.

Training Mode

• Definition: The positioner is gathering data for a certain period of time. This data can be used in the DTM to help set reasonable limits for diagnostic warnings and alarms.

• Possible Solutions: Training has no effect on control. Allow the training to finish if the process conditions are typical. Or start the training over if new process conditions have been applied. See the Training Mode page in the DTM for configuration.

FCD- LGENSF0014-00

47

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Training Complete

• Definition: The positioner has finished gathering data for the specified amount of time. This data can now be used to benchmark typical conditions.

• Possible Solutions: Data is available to set more meaningful diagnostic warning and alarm limits.

Event Captured

• Definition: A user-defined condition was met and a data file was generated to show conditions at the time of the event.

• Possible Solutions: Use the Event Capture page of the DTM to view the data captured during the event.

Local Interface Enabled

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

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

Squawk Mode

• Definition: A user has set the positioner to flash a special sequence so that it can be visually located.

• Possible Solutions: This mode is cancelled if one of the following occurs: 1) The QUICK-CAL/ACCEPT button is briefly pressed. 2) The Squawk mode is selected again remotely. 3) More than one hour has passed since the command was issued.

Backup Control Mode

• Definition: The positioner is controlling the position based on actuator pressures instead of the feedback POT.

• Possible Solutions: The feedback linkage is probably broken or the feedback arm needs to be rotated because the POT is out of range.

Calibration Error Status

FCD- LGENSF0014-00

48

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Position Range Small

• Definition: During calibration, the range of motion of the position feedback arm was too small for optimum performance.

• Possible Solutions: 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 and recalibrate. The minimum angle of rotation should be greater than 15 degrees. Briefly pressing the QUICKCAL/ACCEPT button acknowledges this condition and the positioner will operate using the short stroke calibration if otherwise a good calibration.

Position < ADC Range

• Definition: During calibration, the feedback sensor moved beyond its range of operation at the 0% (closed) position.

• Possible Solutions: Adjust the positioner mounting, linkage or feedback potentiometer to move the position sensor back into range then restart the calibration.

Position > ADC Range

• Definition: During calibration, the feedback sensor moved beyond its range of operation at the 100% (open) position.

• Possible Solutions: To correct the condition, adjust the positioner mounting, linkage or feedback potentiometer to move the position sensor back into range then restart the calibration.

No Motion Time Out

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

49

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Possible Solutions: Check linkages and air supply to make sure the system is properly connected. If the time out occurred because the actuator is very large then simply retry the QUICK-CAL and the positioner will automatically adjust for a larger actuator by doubling the time allowed for movement. This error may be cleared by briefly pushing the QUICK-CAL/ACCEPT.

Settle Time Out

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

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

ILO Time Out

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

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

AO Range Small

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

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

Command Range Small

• Definition: During a Command Loop Calibration, the difference between the signal at 0% and the signal at 100% was too small. The system is designed to accept a difference greater than 5 mA.

• Possible Solutions: Recalibrate making sure to use a larger difference between command signal limits. The difference must exceed 5 mA.

Command < ADC Range

• Definition: During Command Loop Calibration, the 0% signal was out of the Analog to Digital Converter (ADC) range.

• Possible Solutions: The system is designed to accept a signal that is above 10 ADC counts. Recalibrate making sure the ADC counts are above that limit.

Command > ADC Range

• Definition: During Command Loop Calibration, the 100% signal was out of the Analog to Digital Converter (ADC) range.

• Possible Solutions: The system is designed to accept a signal that is below 4085 ADC counts. Recalibrate making sure the ADC counts are

FCD- LGENSF0014-00

50

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

below that limit.

Stroke Shift

• Definition: The 0% and 100% valve positions have both shifted in the same direction since the last stroke calibration. This may be related to a bent or adjusted feedback linkage, loose positioner mounting, or an over rotated feedback potentiometer.

• Possible Solutions: Ensure the feedback linkage is not bent and the positioner is mounted securely. If the feedback potentiometer is overrotated, repeat the stroke calibration until the Stroke Shift error is no longer present. This notification can be cleared by briefly pressing the QUICK-CAL/ACCEPT button.

Stroke Span Increase

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

• Possible Solutions: Inspect valve or schedule valve for inspection. This notification can be cleared by briefly pressing the QUICK-CAL/ACCEPT button

Stroke Span Decrease

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

• Possible Solutions: Inspect valve or schedule valve for inspection. This notification can be cleared by briefly pressing the QUICK-CAL/ACCEPT button.

Calibration Progress Status

FCD- LGENSF0014-00

Stroke Calibration in Progress

• Definition: A stroke calibration sequence is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor

Calibration page of the DTM, from the handheld, or by briefly pressing the Abort button.

Setting ILO

• Definition: This is an automatic step in the calibration process that is done with the valve at 50% position. This must be completed for proper calibration.

• Possible Solutions: The calibration can be canceled from the Sensor Calibration page of the DTM, from the handheld, or by briefly pressing

51

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

the Abort button.

Pressure Calibration in Progress

• Definition: A pressure calibration sequence is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor

Calibration page of the DTM, from the handheld, or by briefly pressing the Abort button.

Friction Calibration in Progress

• Definition: A friction and diagnostic calibration sequence is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor Calibration page of the DTM, from the handheld, or by briefly pressing the Abort button.

Command In Calibration in Progress

• Definition: The command input calibration sequence is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor

Calibration page of the DTM, from the handheld, or by briefly pressing the Abort button

A/O Calibration in Progress

• Definition: The analog output calibration sequence is in progress.

• Possible Solutions: The calibration can be canceled from the Sensor

Calibration page of the DTM, from the handheld, or by briefly pressing the Abort button

Jog Calibration in Progress

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

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

Electronic Configuration Status

FCD- LGENSF0014-00

Aux. Card 1 Present

• Definition: An auxiliary card is present in slot 1.

• Possible Solutions: Two cards may be installed. See manual for more

details.

Aux. Card 2 Present

• Definition: An auxiliary card is present in slot 2.

• Possible Solutions: Two cards may be installed. See manual for more

details.

Pressure Board Present

• Definition: Pressure sensors are physically present in the positioner.

52

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

• Possible Solutions: The sensors are required for many of the diagnostic and performance features. Positioner can accurately control without pressure sensors if the pressure sensor ports have been properly plugged.

LCD Present

• Definition: An LCD display is present on this unit.

• Possible Solutions: The LCD enhances the local user interface with

additional features.

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

The Print Report button will print a report to default printer (see example below). Information includes:

• Information about the connected device

• The active status of the alarms, warnings and alerts.

• The masked status.

• The current value (where applicable).

• The value threshold (where applicable).

NOTE: It is possible to print the report to save to a PDF file. Instructions:

1. Download and install the free version of PDFCreator.

2. Install the PDFCreator

3. Set PDFCreator as the default Printer

4. Click Print Report and save the report to a pdf file in your computer.

53

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

54

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

55

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Event History

The Event History page lists alarms, warnings, alerts, modes and calibration events that have become active or changed states. A time is given for each event.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Select History This box radio buttons to allow for selection of the set of events to view. The Event History displays the date and time when the event occurred, indicates the state of the event (On or Off), and the event indicator description. All information is read from the positioner (while connected to Device).

• The Last Calibration Events radio button displays the last 40 calibrations with

56

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

time information.

• The Last Alarm and Warning Events radio button displays the last 200 alarms, warnings and alerts with time information.

• The Last Calibration and Alarm Events radio button displays the 32 events with time information.

To see a detailed description of a specific event, click on the grid to select a row. The description will be shown in the box below.

The Clear History button will delete the existing event history from the device.

The Retrieve button will retrieve the event history of the selected history from the device. The Print Report button will print to the default printer the following: (See an example report

below.)

Information about the connected device

• The selected event history (calibration, alarms and warnings, or both)

• Each event detail retrieved from device:

• Date

• Time

• State

• Error #

• Indicator

NOTE: It is possible to print the report to save to a PDF file. Instructions:

1. Download and install the free version of PDFCreator.

2. Install the PDFCreator

3. Set PDFCreator as the default Printer

4. Click Print Report and save the report to a pdf file in your computer.

57

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

58

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Health

Health pages allow quick viewing of the state of all diagnostics. This selection automatically redirects to the Valve Health page.

59

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Valve Health

The Valve Health page shows information about all indicators related to the condition of the valve.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Indicators

Each indicator group box may contain the following components:

• An "LED light" indicates health status. Warning and alarm limits (set by the user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

60

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

• A radio button that when selected will show the Implications and Possible Solutions related to the selected indicator.

• The current value and units.

• A button to set values to 0.

•

Configure

A link to redirect the DTM to the configuration page.

Implications and Possible Solutions

When a radio button is checked for an indicator, the related implications and possible solutions are displayed. The Implications field describes the conditions that trigger the indicator. The Possible Solutions field describes actions you might take to restore normal operation.

NOTE: Flowserve does not recommend any action, only lists possible actions that could restore the system to normal operation. Qualified maintenance personnel should evaluate the possible solutions, all safety procedures and all other applicable factors on a case by case basis when determining the best action to take.

61

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Legend

The legend shows the purpose of the icons.

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Indicators

Friction High

• Definition: The valve and actuator friction has passed the user set limit.

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

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

Friction Low

• Definition: The friction has passed below the user set limit.

• Implications: Low friction is an indication of improperly loaded packing

and, in severe cases, can be an indication of the process fluid leaking at the valve stem.

• Possible Solutions: Check for packing leak. Tighten or replace the valve packing.

Valve Cycles

• Definition: The valve cycle limit has been exceeded.

• Implications: Each cycle represents two reversals of the direction of

valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and

FCD- LGENSF0014-00

62

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

checking linkages for wear, misalignment, and tightness. After maintenance, reset the cycle accumulator.

Valve Travel

• Definition: The total accumulated valve travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the travel accumulator.

Bellows Cycles

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of bellows movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Bellows Travel

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Valve Can't Open

• Definition: Pressure has been applied (or removed) to open the valve, but the valve is not opening.

• Implications: This may be caused by excessive friction.

• Possible Solutions: Verify adequate supply pressure is applied. Verify

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

Valve Can't Shut

• Definition: Pressure has been removed (or applied) to close the valve, but the valve is not closing.

• Implications: This may be caused by excessive friction.

• Possible Solutions: Verify adequate supply pressure is applied. Verify

the feedback linkage is connected. View the friction trends if available. Consider the following: Clear any external or internal

FCD- LGENSF0014-00

63

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

mechanical obstruction, loosen the packing, clean the stem, repair or replace the actuator, repair the valve if galling is suspected.

Closed Too Far

• Definition: The valve has closed farther than it did at the last calibration

• Implications: While the valve was in use, it closed farther than it did at

the last calibration by 0.5%.

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

Opened Too Far

• Definition: The valve has opened farther than it did at the last calibration

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

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

FCD- LGENSF0014-00

64

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Friction

The Friction Tolerance Settings page allows you to adjust the warning and alarm limits related to friction. Friction is the force required to move the valve assembly. Friction is calculated by the positioner during normal operation or during a friction calibration.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Friction Histogram

The graph displays a histogram with current values and a histogram with data gathered during the training period. This is an easy way to see the range of typical values to set meaningful warning and alarm limits. It is also helpful to see how the data may have shifted since the training period. The histogram is frequently updated when the positioner is in operation.

65

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Reset Current Histogram

The reset button will clear the Current histogram, but leave the Training histogram.

Current Value

This is the value calculated by the positioner. This value is initially set during a Friction Calibration, then updated during operation.

Actuator Size

Verify that the actuator size is accurate. Changing the actuator size will affect the friction values. Actuator size can be adjusted on the Configuration - Information - Actuator page of the DTM.

Friction Warning and Alarm Limits

The friction limits (Low Alarm Limit, Low Warning Limit, High Warning Limit, and High Alarm Limit) can be easily adjusted on this page. These limits affect the health bar indicator on the Dashboard. For example, as the friction increases and passes the High Warning, the health bar will begin to turn yellow. As it approaches the High Alarm, the health bar will be completely yellow. When it passes the High Alarm, the health bar will turn red.

Setting Friction Limits

Here are three ways to adjust the friction warning and alarm limits. NOTE: The apply button must be selected for the changes to take affect.

1. Move the scale indicators. A scale indicating the current friction values and the warning and alarm limits is shown. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

66

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

3. Select a radio button. To automatically set friction tolerance limits, select one of the 4 radio buttons.

Upon selecting one of the tolerance buttons, a description of each setting (Tight tolerance, Normal Tolerance, Loose tolerance, and No Limits) is shown in the Implications box.

Upon selecting one of the tolerance buttons, the limits will automatically adjust according to the following table.

NOTE: Before setting automatic friction values, ensure the Current Value is reasonable, or that the valve has been in service for a period of time.

67

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Training Status

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warning and Alarms

Friction High

• Definition: The valve and actuator friction has passed the user set limit.

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

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

Friction Low

• Definition: The friction has passed below the user set limit.

• Implications: Low friction is an indication of improperly loaded packing

and, in severe cases, can be an indication of the process fluid leaking at the valve stem.

• Possible Solutions: Check for packing leak. Tighten or replace the valve packing.

68

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Valve Cycles & Travel

The Valve Cycles and Travel page allows you to set warning limits related to the number of valve cycles and the valve travel. The cycles and travel are recorded by the positioner during normal operation. These limits affect the health bar indicator on the Dashboard. For example, as the valve cycles increase and pass the Initial Warning, the health bar will begin to turn yellow. As it approaches the Final Warning. the health bar will be completely yellow.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Adjusting Limits

There are two ways to adjust the settings.

1. Move the scale indicators. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

69

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

NOTE: The apply button must be selected for the changes to take affect.

Set Valve Cycles Limits

The Current Value is the number of Valve Cycles counted by the positioner. The Cycle Deadband is the minimum amount of travel required in each direction before the cycle is counted. The Initial Warning is the point at which the Valve Cycle Warning will begin. The Full Warning is where the health bar on the Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Training Cycle Rate field displays average number of cycles per day of the valve during the training

period. For more information about Training, see the Health - Training page.

Set Valve Travel Limits

The Current Value is the total valve travel recorded by the positioner. The Travel Deadband is the minimum amount of travel required before the travel is counted. The Initial Warning is the point at which the Valve Travel Warning will begin. The Full Warning is where the health bar on the Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Accumulated Travel is the same as the Current Value, but converted to the stroke length units of measure selected by you. To change the units of measure for the stroke length, see the Configuration - Information -

Actuator page. The Training Travel Rate field displays average amount of travel per day of

the valve during the training period. For more information about Training, see the Health -

Training page.

70

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Training Status

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

NOTE: The Training function requires the Pro positioner upgrade level (522MD+).

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warning and Alarms

Valve Cycles

• Definition: The valve cycle limit has been exceeded.

• Implications: Each cycle represents two reversals of the direction of

valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the cycle accumulator.

Valve Travel

• Definition: The total accumulated valve travel limit has been exceeded.

• Implications: The travel is accumulated in both directions. The travel counting criterion and limit are set by the user to track the usage of the valve.

71

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking the packing tightness, and checking linkages for wear, misalignment, and tightness. After maintenance, reset the travel accumulator.

FCD- LGENSF0014-00

72

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Bellows Cycles and Travel

The Bellows Cycles and Travel page allows you to set warning limits related to the number of bellows cycles and the bellows travel. The cycles and travel are recorded by the positioner during normal operation. These limits affect the health bar indicator on the Dashboard. For example, as the bellows cycles increase and pass the Initial Warning, the health bar will begin to turn yellow. As it approaches the Final Warning. the health bar will be completely yellow.

From the technical brochure for Valtek Guardian II Metal Bellows Seal Control Valves.

73

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Adjusting Limits

There are two ways to adjust the settings.

1. Move the scale indicators. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

NOTE: The apply button must be selected for the changes to take affect.

Set Bellows Cycles Limits

The Current Value is the number of Bellows Cycles counted by the positioner. The Cycle Deadband is the minimum amount of travel required in each direction before the cycle is

counted. (This is the same variable as Valve Cycles Deadband.) The Initial Warning is the point at which the Bellows Cycle Warning will begin. The Full Warning is where the health bar on the Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Training Cycle Rate field displays average number of cycles per day of the bellows during the training period. For more information about Training, see the Health - Training page.

74

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Set Bellows Travel Limits

The Current Value is the total bellows travel recorded by the positioner. The Travel Deadband is the minimum amount of travel required before the travel is counted. (This is the same variable as Valve Travel Deadband.) The Initial Warning is the point at which the Bellows Travel Warning will begin. The Full Warning is where the health bar on the

Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Accumulated Travel is the same as the Current Value, but converted to the stroke length units of measure selected by you. To change the units of measure for the stroke length, see the Configuration - Information - Actuator page. The Training Travel Rate field displays average amount of travel per day of the bellows during the training period. For more information about Training, see the Health - Training page.

Training Status

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

NOTE: The Training function requires the Pro positioner upgrade level (522MD+).

75

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warning and Alarms

Bellows Cycles

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of bellows movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

Bellows Travel

• Definition: The bellows cycle limit has been exceeded.

• Implications: The bellows may be reaching the end of its fatigue

life. Each cycle represents two reversals of the direction of valve movement. The cycle counting criterion and count limit are set by the user to track the usage of the valve.

• Possible Solutions: Follow routine procedures for maintenance when the limit is reached such as checking bellows for cracking or leaking. After maintenance, reset the cycle accumulator.

FCD- LGENSF0014-00

76

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Positioner Health

The Positioner Health page shows information about all indicators related to the condition of the positioner.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

77

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Indicators

Each indicator group box may contain the following components:

• An "LED light" indicates health status. Warning and alarm limits (set by the user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

• A radio button that when selected will show the Implications and Possible Solutions related to the selected indicator.

FCD- LGENSF0014-00

• The current value and units.

• A button to set values to 0.

•

Configure

A link to redirect the DTM to the configuration page.

Implications and Possible Solutions

When a radio button is checked for an indicator, the related implications and possible solutions are displayed. The Implications field describes the conditions that trigger the indicator. The Possible Solutions field describes actions you might take to restore normal operation.

78

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

NOTE: Flowserve does not recommend any action, only lists possible actions that could restore the system to normal operation. Qualified maintenance personnel should evaluate the possible solutions, all safety procedures and all other applicable factors on a case by case basis when determining the best action to take.

Legend

The legend shows the purpose of the icons.

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warnings and Alarms

Pilot Response

• Definition: The pilot relay is sticking or slow to respond.

• Implications: This affects the responsiveness, increases the chance of

limit cycling and excessive air consumption. The pilot relay is part of the inner loop and consists of the driver module assembly with piezo (I-P relay) which is coupled to the spool valve or poppet. The value of this indicator corresponds with inner loop lag. Delayed response can be caused by a partially clogged piezo or debris, oil, corrosion, or ice on the spool, or low supply pressure.

• Possible Solutions: Check response of the valve. If OK, adjust Pilot

79

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Relay Response limits. Check supply pressure. Check the spool or poppet for debris, oil, corrosion, ice on the spool. Clean or replace the spool or poppet assembly. Replace the piezo or driver module assembly. Maintain a clean, water-free air/gas supply.

Piezo Volts High

• Definition: The voltage driving the piezo is above the warning limit.

• Implications: This could indicate an error with the relay or the main

board. This may result from an extended period of inactivity, but in this case should not persist for more than 30 minutes when the valve is controlling. The positioner may still be functioning, but have reduced performance under some circumstances.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

Piezo Volts Low

• Definition: The voltage to the piezo is too low.

• Implications: The piezo may be damaged. This may prevent the

proper failure position upon loss of signal/power. This condition may occur briefly on an air-to-close valve that is held for long periods of time in the closed position, or an air-to-open valve held in the open position.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

Temperature High

• Definition: The temperature of the internal electronics has exceeded the manufacturer set limit of 85°C (176°F). High temperature may affect performance or limit the life of the positioner.

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

Temperature Low

• Definition: The temperature of the internal electronics has exceeded the manufacture set limit of -40°C (-40°F). Low temperature may inhibit responsiveness and accuracy.

• Possible Solutions: Regulate the temperature of the positioner. If the temperature reading is in error, replace the main circuit board.

Air Supply Humid

• Definition: The supply gas has high relative humidity which can lead to condensation on electronic components and failure of electronic functions.

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

Aux. Card 1 Fail

• Definition: Auxiliary Card 1 is not communicating.

• Possible Solutions: Check auxiliary card connection to the main

board. If the problem persists, replace the card.

FCD- LGENSF0014-00

80

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Aux. Card 1 No Loop Power

• Definition: Auxiliary Card 1 has no loop current.

• Possible Solutions: Check auxiliary card connection to loop current. If

the problem persists, replace the card.

Aux. Card 1 Error

• Definition: Auxiliary Card 1 has an electrical problem.

• Possible Solutions: MFC: Check auxiliary loop wiring and ensure

adequate compliance voltage. Replace card if condition persists

Aux. Card 2 Fail

• Definition: Auxiliary Card 1 is not communicating.

• Possible Solutions: Check auxiliary card connection to the main

board. If the problem persists, replace the card.

Aux. Card 2 No Loop Power - Auxiliary Card 2 has no loop current

• Definition: Auxiliary Card 2 has no loop current.

• Possible Solutions: Check auxiliary card connection to loop current. If

the problem persists, replace the card.

Aux. Card 2 Error

• Definition: Auxiliary Card 2 has an electrical problem.

• Possible Solutions: MFC: Check auxiliary loop wiring and ensure

adequate compliance voltage. Replace card if condition persists

Pressure Board Fail Warning

• Definition: One or more pressure sensors may have failed.

• Possible Solutions: Check the supply pressure to ensure it is between

1.3 and 10.3 bar (19 and 150 PSI). Check the pressure sensor board connections. Recalibrate the pressure sensors. If the problem persists, replace the pressure sensor board.

Low Battery Warning

• Definition: The battery for the real time clock is low.

• Implications: The battery is designed for a 15+ year life with the

positioner unpowered. The battery is not required for the positioner to control properly, but is used only to maintain the time and date upon loss of power. The time and date affect the time stamps of alarms, warnings and other events. This warning could be caused by rapidly power cycling the positioner.

• Possible Solutions: The battery is not replaceable. Verify or reset the time and date. Replace the main board if the problem persists for several days.

Main Board Fail

• Definition: There has been an oscillator fault, position sensor ADC failure, supply voltage error, reference voltage error, shunt voltage error, or piezo voltage error.

• Possible Solutions: This may be caused by transient conditions. If the error persists, replace the main board.

Software Error

• Definition: There has been a watch dog time out, stack overflow

81

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

warning, or CPU usage warning.

• Possible Solutions: If the problem persists, perform a factory reset. If it still persists, reprogram or replace the main board.

Memory Error

• Definition: The microprocessor's memory has a problem.

• Possible Solutions: Error may clear with time. If error persists, cycle

power and complete a QUICK-CAL. If the error still persists, perform a factory reset, reprogram or replace the main circuit board.

Air Supply Icing

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

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

FCD- LGENSF0014-00

82

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Temperature & Humidity

The Temperature and Humidity page displays the current values and related warning limits. The values reflect temperature and relative humidity inside the positioner.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Positioner Temperature

The Positioner Temperature box displays a scale with the actual positioner temperature, a Temperature Value field with a numeric display of the temperature, a Low Warning field,

and a High Warning field. Any temperature outside of these limits will cause the health bar to turn yellow.

83

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Positioner Humidity

The Positioner Humidity box displays a scale with the actual positioner humidity and the Air Supply Humid Warning limit. The humidity warning limit is not user settable and will be triggered according to the rules below.

• Temperature is less than 35 F (1.7 C) and RH > 80%.

• Temperature is between 35 and 40 F(1.7-4.4 C) and RH > 70%.

• Temperature is between 40 and 45 F(4.4-7.2 C) and RH > 60%.

• Temperature is above 45 F(7.2 C) and RH > 50%.

Warnings and Alarms

Temperature High

• Definition: The temperature of the internal electronics has exceeded the manufacturer set limit of 85°C (176°F). High temperature may affect performance or limit the life of the positioner.

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

Temperature Low

• Definition: The temperature of the internal electronics has exceeded the manufacture set limit of -40°C (-40°F). Low temperature may inhibit responsiveness and accuracy.

• Possible Solutions: Regulate the temperature of the positioner. If the temperature reading is in error, replace the main circuit board.

Air Supply Humid

• Definition: The supply gas has high relative humidity which can lead to condensation on electronic components and failure of electronic functions.

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

84

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Pilot Relay

The Pilot Relay page shows detailed information about the responsiveness and travel of the pilot relay. The pilot relay is sometimes called the I/P relay (I to P relay). It converts a voltage to pneumatic output by controlling a spool or poppet valve. A hall effect sensor detects the location of the spool or poppet. The controller adjust the location of the spool or poppet to control the air to the actuator.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

85

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Adjusting Limits

There are two ways to adjust the settings.

1. Move the scale indicators. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

NOTE: The Apply button must be selected for the changes to take affect.

Pilot Relay Response

The Pilot Relay Response Time is the measure of the time it takes for the pilot relay to respond. This value is displayed in milliseconds. Normally movement in the relay take less than 0.05 seconds so a value of 50 or less is normal. The Current Value field displays the typical time to respond. A response time over the Warning limit will cause the health bar on the dashboard to turn yellow. A response time over the Alarm limit will cause the health bar on the dashboard to turn red.

Set Pilot Relay Cycle Limits

The Current Value is the total pilot relay cycles recorded by the positioner. The Initial Warning is the point at which the Pilot Relay Cycles Warning will begin. The Full Warning

is where the health bar on the Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Training Clycles Rate field displays average amount of cycles per day of the bellows during the training period. For more information about Training, see the Health - Training page.

86

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Set Pilot Relay Travel Limits

The Current Value is the total pilot relay travel recorded by the positioner. The Initial Warning is the point at which the Pilot Relay Travel Warning will begin. The Full Warning is

where the health bar on the Dashboard will show fully yellow. The Full Warning value is the only limit that can be modified. The Initial Warning is always 90% of the Full Warning value. The reset button will set the Current Value to zero. The Training Travel Rate field displays average amount of travel per day of the bellows during the training period. For more information about Training, see the Health - Training page.

Training Status

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

NOTE: The Training function requires the Pro positioner upgrade level (522MD+).

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

87

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Warnings and Alarms

Pilot Response

• Definition: The pilot relay is sticking or slow to respond.

• Implications: This affects the responsiveness, increases the chance of

limit cycling and excessive air consumption. The pilot relay is part of the inner loop and consists of the driver module assembly with piezo (I-P relay) which is coupled to the spool valve or poppet. The value of this indicator corresponds with inner loop lag. Delayed response can be caused by a partially clogged piezo or debris, oil, corrosion, or ice on the spool, or low supply pressure.

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

Pilot Cycle

• Definition: The pilot relay cycle limit set by the user has been exceeded.

• Implications: The pilot relay cycles indicate the activity level of the pilot relay as it maintains a valve’s position. Excessive cycles can contribute to a worn relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

Pilot Travel

• Definition: The total accumulated pilot relay travel (% of full relay span) set by the user has been exceeded.

• Implications: The pilot relay travel indicates the activity level of the relay as it maintains a valve’s position. Excessive travel can contribute to a worn pilot relay which can lead to high air consumption.

• Possible Solutions: Inspect for high air consumption and signs of wear.

FCD- LGENSF0014-00

88

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Piezo Voltage

The Piezo Voltage page shows detailed information about the circuit that drives the piezo valve in the pilot relay. The piezo valve converts the voltage to a pressure that acts to move the poppet or spool.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Piezo Voltage

The Piezo Voltage shows the Piezo Voltage and the warning and alarm limits. The Current Value field displays the measured piezo voltage. A outside the Warning limits will cause

the health bar on the dashboard to turn yellow. A voltage outside the Alarm limits will cause the health bar on the dashboard to turn red. The limits are not adjustable.

Warnings and Alarms

Piezo Volts High

• Definition: The voltage driving the piezo is above the warning limit.

• Implications: This could indicate an error with the relay or the main

board. This may result from an extended period of inactivity, but in this case should not persist for more than 30 minutes when the valve is controlling. The positioner may still be functioning, but have reduced performance under some circumstances.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

Piezo Volts Low

• Definition: The voltage to the piezo is too low.

• Implications: The piezo may be damaged. This may prevent the

proper failure position upon loss of signal/power. This condition may occur briefly on an air-to-close valve that is held for long periods of time

89

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

in the closed position, or an air-to-open valve held in the open position.

• Possible Solutions: Ensure the supply pressure is not low. If alarm persists for more than 30 minutes, the Piezo assembly is damaged. Replace the pilot relay.

FCD- LGENSF0014-00

90

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Actuator Health

The Actuator Health page shows information about all indicators related to the condition of the actuator.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Indicators

91

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

Each indicator group box may contain the following components:

• An "LED light" indicates health status. Warning and alarm limits (set by the user in many cases) determine the conditions when the color will turn from green to yellow to red. The most sever of the indicators on this page will be shown in the health bar on the Dashboard.

• Dark Green circle indicates a healthy condition where no attention is needed.

• Light Green indicates an occurrence of a normal activity that does

not affect the health of the valve system.

• Yellow circle indicates that an active warning, alert or mode is present.

• Red circle indicates that an active alarm or state is present that could seriously limit the operation of the valve.

• Gray circle indicates that the feature or condition is not available because the configuration of the hardware or software does not support it.

• A checkbox indicates the masked status. Check to mask. If a particular indicator is masked, it will not be shown in the active indicator field at the top of each screen, affect the status of the health bars on the main dashboard, be sent in command 48, or be seen on the blinking LEDs on the positioner. It will however continue to show on this page.

• A radio button that when selected will show the Implications and Possible Solutions related to the selected indicator.

FCD- LGENSF0014-00

• The current value and units.

• A button to set values to 0.

•

Configure

A link to redirect the DTM to the configuration page.

Implications and Possible Solutions

When a radio button is checked for an indicator, the related implications and possible solutions are displayed. The Implications field describes the conditions that trigger the indicator. The Possible Solutions field describes actions you might take to restore normal operation.

92

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

NOTE: Flowserve does not recommend any action, only lists possible actions that could restore the system to normal operation. Qualified maintenance personnel should evaluate the possible solutions, all safety procedures and all other applicable factors on a case by case basis when determining the best action to take.

Legend

The legend shows the purpose of the icons.

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warnings and Alarms

Supply Pressure High

• Definition: The supply pressure is above the user set warning limit.

• Implications: Supply pressure that exceeds the maximum rating on the

actuator can become a potential hazard.

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

Supply Pressure Low

• Definition: The supply pressure is below the user set warning or alarm

93

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

limit.

• Implications: Low supply pressure can cause poor valve response or positioner failure. The minimum recommended supply pressure for proper operation is 1.3 bar (19 PSI).

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

Actuation Ratio

• Definition: The force required to control the system is close to the maximum available force.

• Implications: Actuation Ratio is based on the ratio of available force to the required force to actuate. Control may be lost if this ratio reaches 100%. It is affected by the process load, friction, spring force, and available supply pressure.

• Possible Solutions: Increase the supply pressure. Reduce the friction. Check the actuator spring. Resize the actuator. Adjust user set limits.

Spring Fail

• Definition: Upon loss of air supply, the valve may not move to the fail- safe position.

• Implications: The spring alone is not adequate to overcome the friction and process load in the system. The system is relying on pneumatic force to actuate in the direction the spring is pushing. The failsafe spring may have failed, or it was not sized properly for the application. Friction or process load may have increased.

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

Pneumatic Leak

• Definition: The positioner has detected a leak in the actuation assembly.

• Implications: Leakage from the actuator can cause decreased responsiveness and excessive air/gas consumption.

• Possible Solutions: Repair pneumatic leaks at the tubing junctions and actuator seals. Check spool valve for excessive wear.

FCD- LGENSF0014-00

94

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Actuator Pneumatic Leak

The Actuator Pneumatic Leak page allows you to view the current value and set warning limits related to the pneumatic leak detected by the positioner. Leak is detected by the positioner during normal operation whenever the valve moves.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Pneumatic Leak Histogram

The graph displays a histogram with current values and a histogram with data gathered during the training period. This is an easy way to see the range of typical values to set meaningful warning and alarm limits. It is also helpful to see how the data may have shifted since the training period. The histogram is frequently updated when the positioner is in operation.

95

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Reset Current Histogram

The reset button will clear the Current histogram, but leave the Training histogram.

Pneumatic Leak

Pneumatic leak is detected by the positioner. The Current Value field shows the leak. The valve must move (even if it is a very small amount) before the value can be updated. The Initial Warning and Full Warning limits affect the health bar indicator on the Dashboard. For example, as the pneumatic leak increase and pass the Initial Warning, the health bar will begin to turn yellow. As it approaches the Final Warning, the health bar will be completely yellow.

Adjusting Limits

There are two ways to adjust the settings.

1. Move the scale indicators. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

NOTE: The apply button must be selected for the changes to take affect.

Training Status

96

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

NOTE: The Training function requires the Pro positioner upgrade level (522MD+).

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warnings and Alarms

Pneumatic Leak

• Definition: The positioner has detected a leak in the actuation assembly.

• Implications: Leakage from the actuator can cause decreased responsiveness and excessive air/gas consumption.

• Possible Solutions: Repair pneumatic leaks at the tubing junctions and actuator seals. Check spool valve for excessive wear.

97

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Supply Pressure

The Supply Pressure page allows you to view the current value and set warning limits related to the supply pressure detected by the positioner.

Status Area

The Active Indicator area shows the status of the most relevant active indicator. The color of the "LED light" corresponds to the Active Indicator and the first color of the blink code sequence on the positioner. Generally green indicates no immediate issues. Yellow indicates a developing issue. Red indicates the ability to control may be compromised. A detailed list of the indicators is given in the Alarm Congfiguraion - Alarm Annunicator page. The Command Source field indicates weather the positioner is being controlled by digital or an analog (4-20 mA) command source.

Supply Pressure Histogram

The graph displays a histogram with current values and a histogram with data gathered during the training period. This is an easy way to see the range of typical values to set meaningful warning and alarm limits. It is also helpful to see how the data may have shifted since the training period. The histogram is frequently updated when the positioner is in operation.

98

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Reset Current Histogram

The reset button will clear the Current histogram, but leave the Training histogram.

Supply Pressure

Supply Pressure is detected by the positioner. The Current Value field shows the supply pressure. The supply pressure limits (Low Alarm Limit, Low Warning Limit, and High Warning Limit) can be easily adjusted on this page. These limits affect the health bar indicator on the Dashboard. For example, as the supply pressure drops below Low Warning, the health bar will begin to turn yellow. As it approaches the Low Alarm, the health bar will be completely yellow. When it passes the Low Alarm, the health bar will turn red.

Adjusting Limits

There are two ways to adjust the settings.

1. Move the scale indicators. The limits can be adjusted by "dragging" each limit indicator with a mouse click.

2. Use the input boxes. Numbers can be directly typed. Clicking on the up and down arrows will also change the value.

NOTE: The apply button must be selected for the changes to take affect.

99

ValveSight™ Diagnostics DTM Manual for Logix MD+ Positioner with HART®

FCD- LGENSF0014-00

Training Status

Training Status is present on this page because one or more fields or graphs shows data that was gathered during the training process. The field shows one of the following states:

• Training Enabled - which indicates system data is being recorded. Training should run during normal system behavior.

• Training Disabled - which indicates NO system data is being recorded.

• Training Complete which indicates that the time period for training has expired and

the data is stored in the positioner.

NOTE: The Training function requires the Pro positioner upgrade level (522MD+).

Action Buttons

The Apply button will save changes to the connected device.

The Retrieve button will retrieve the latest information from the device.

Warnings and Alarms

Supply Pressure High

• Definition: The supply pressure is above the user set warning limit.

• Implications: Supply pressure that exceeds the maximum rating on the

actuator can become a potential hazard.

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

Supply Pressure Low

• Definition: The supply pressure is below the user set limit.

• Implications: Low supply pressure can cause poor valve response or

positioner failure. The minimum recommended supply pressure for proper operation is 1.3 bar (19 PSI).

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

100

Flowserve Logix MD+ ValveSight User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual