Flowserve logix 520md инструкция на русском

Related Manuals for Flowserve Logix 520MD+

USER INSTRUCTIONS
Installation
Operation
Maintenance
Safety Manual
Logix ® 520MD+ and 510+
Digital Positioners
FCD LGENIM0105-16 8/15
CONTENTS
Quick Start Instructions
Page 98
1.1
1.2
1.3
1.4
1.5
1.6
USING THIS DOCUMENT ................................... 5
TERMS CONCERNING SAFETY ............................. 5
PROTECTIVE CLOTHING .................................... 5
QUALIFIED PERSONNEL .................................... 5
VALVE AND ACTUATOR VARIATIONS .................... 5
SPARE PARTS ................................................ 5
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
SERVICE / REPAIR ........................................... 6
BASIC OPERATION .......................................... 6
HART ......................................................... 6
POSITION DEFINITION ...................................... 6
COMMAND INPUT AND FINAL COMMAND ............. 7
OUTER LOOP ................................................. 7
INNER LOOP ................................................ 72
DETAILED SEQUENCE OF POSITIONER OPERATIONS 72
INNER LOOP OFFSET ...................................... 72
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
SPECIFICATIONS ........................................... 74
INPUT SIGNAL .............................................. 74
PNEUMATIC OUTPUT ..................................... 74
AIR SUPPLY ................................................. 74
ANALOG OUTPUT – MULTI-FUNCTION CARD ....... 74
STROKE OUTPUT .......................................... 75
REMOTE MOUNT SPECIFICATIONS ..................... 75
LIMIT SWITCH SPECIFICATIONS ......................... 75
V TO I BOARD SPECIFICATIONS ......................... 75
POSITIONER PERFORMANCE CHARACTERISTICS ..... 75
PHYSICAL SPECIFICATIONS ............................... 75
TEMPERATURE ............................................. 75
VALVESIGHT DTM SOFTWARE SPECIFICATIONS .... 76
3
HAZARDOUS AREA CERTIFICATIONS ......... 77
4
STORAGE AND UNPACKING ......................... 78
STORAGE .................................................... 78
UNPACKING ................................................ 78
PRE-INSTALLATION INSPECTION ........................ 78
LABELS....................................................... 78
4.1
4.2
4.3
4.4
5
MOUNTING AND INSTALLING ....................... 79
5.1
5.2
5.3
5.4
5.5
MOUNTING TO MARK ONE LINEAR VALVES ......... 79
MOUNTING TO FLOWTOP LINEAR VALVES........... 80
MOUNTING TO STANDARD VALTEK ROTARY VALVES82
MOUNTING TO MAXFLO ROTARY VALVES ........... 84
MOUNTING TO ROTARY NAMUR (AUTOMAX)
VALVES ...................................................... 85
5.6 MOUNTING TO A LINEAR NAMUR PNEUMATIC
ACTUATOR.................................................. 87
6
TUBING ........................................................... 88
6.1
6.2
6.3
6.4
DETERMINE AIR ACTION ................................. 88
CONNECT SUPPLY PORT ................................. 89
PURGING SINGLE ACTING ACTUATORS ............... 89
VENTED DESIGN ........................................... 89
7
ELECTRICAL CONNECTIONS ........................ 91
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7.1
7.2
7.3
7.4
7.5
7.6
7.7
ELECTRICAL TERMINALS ...................................91
COMMAND INPUT (4-20 MA) CONNECTION ........91
MULTI-FUNCTION CARD (AO, DO, DI) ..............93
V TO I CARD CONNECTIONS..............................95
LIMIT SWITCHES ............................................96
REMOTE MOUNT ..........................................97
CONNECTIONS FOR INTRINSICALLY SAFE OPERATION97
8
STARTUP........................................................ 98
8.1
8.2
8.3
8.4
8.5
QUICK START INSTRUCTIONS ............................98
LOCAL USER INTERFACE OVERVIEW ....................98
CONFIGURATION SWITCH SETTINGS....................99
STROKE CALIBRATION ................................... 100
ANALOG OUTPUT (AO) CALIBRATION............... 101
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
POSITIONER FUNCTIONS (NO DISPLAY
REQUIRED)................................................... 102
LIVE MANUAL TUNING (ADJUSTING THE GAIN) ... 102
LOCAL CONTROL OF VALVE POSITION ............... 102
COMMAND SOURCE RESET ............................ 102
FACTORY RESET .......................................... 102
VIEWING VERSION NUMBERS ......................... 102
ANALOG INPUT CALIBRATION ......................... 103
SELECT AND CALIBRATE ANALOG OUTPUT .......... 103
SELECT DISCRETE OUTPUT ............................. 103
10
POSITIONER FUNCTIONS (LCD DISPLAY) . 104
10.1 MAIN DISPLAY VIEW .................................... 104
10.2 MENU OVERVIEW ....................................... 106
10.3 MENU FEATURES ........................................ 107
11
HART COMMUNICATION ............................. 113
11.1
11.2
11.3
11.4
VALVESIGHT DTM ...................................... 113
HART 375/475 HANDHELD COMMUNICATOR ... 113
CHANGING HART VERSIONS .......................... 113
BURST MODE ............................................. 114
12
MODEL FEATURES ...................................... 115
MD+ POSITIONER DIAGNOSTIC LEVELS ............. 115
VALVESIGHT DTM DIAGNOSTIC LEVELS............. 115
12.1
12.2
13
13.1
13.2
13.3
MULTI-FUNCTION CARD ............................. 116
ANALOG OUTPUT (AO) ................................ 116
DISCRETE OUTPUT (DO) ............................... 116
DISCRETE INPUT (DI).................................... 116
14
V TO I CARD ................................................. 117
15
LIMIT SWITCHES .......................................... 117
15.1 LIMIT SWITCH OPERATION ............................. 117
2
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
15.2 LIMIT SWITCH TYPES ................................... 117
16
REMOTE MOUNT .......................................... 118
16.1 REMOTE MOUNT OPEREATION ...................... 118
17
REQUIREMENTS FOR SAFETY INTEGRITY 119
17.1 FAIL SAFE STATE ......................................... 119
17.2 SAFETY FUNCTION ...................................... 119
17.3 FAIL SAFE STATE RESPONSE TIME.................... 119
17.4 POSITIONER MODEL SELECTION AND SPECIFICATION119
17.5 INSTALLATION ............................................ 119
17.6 REQUIRED CONFIGURATION SETTINGS .............. 119
17.7 MAXIMUM ACHIEVABLE SIL .......................... 119
17.8 RELIABILITY DATA ....................................... 119
17.9 LIFETIME LIMITS ......................................... 120
17.10
PROOF TESTING ................................... 120
17.11
MAINTENANCE .................................... 120
17.12
REPAIR AND REPLACEMENT ..................... 120
17.13
TRAINING REQUIREMENTS ...................... 120
18
MAINTENANCE AND REPAIR ...................... 121
18.1
18.2
18.3
18.4
18.5
18.6
18.7
18.8
18.9
SCHEDULED MAINTENANCE ........................... 121
REQUIRED TOOLS AND EQUIPMENT ................. 121
TORQUE SPECIFICATION FOR SCREWS ............... 121
INSTALLING A LIMIT SWITCH .......................... 121
REPLACING THE LCD BOARD ......................... 123
REPLACING AN AUXILIARY CARD ..................... 123
REPLACING A MAIN BOARD........................... 125
REPLACING THE PRESSURE SENSOR BOARD ........ 125
CLEANING AND REPLACING A DOUBLE ACTING PILOT
RELAY...................................................... 126
18.10
REPLACING A SINGLE ACTING PILOT RELAY.. 127
19
19.1
19.2
19.3
19.4
TROUBLESHOOTING ................................... 129
TROUBLESHOOTING GUIDE ............................ 129
STATUS CODE INDEX.................................... 131
STATUS CODE DESCRIPTIONS ......................... 132
HELP FROM FLOWSERVE............................... 140
20
POSITIONER DIMENSIONS .......................... 141
20.1 POSITIONER DIMENSIONS ............................. 141
21
HOW TO ORDER ........................................... 142
21.1
21.2
21.3
21.4
21.5
POSITIONERS ............................................. 142
SPARE PARTS KITS ...................................... 144
GAGE BLOCKS ............................................ 145
VDI/VDE 3847 MOUNTING BLOCKS .............. 146
MOUNTING KITS ........................................ 146
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
FIGURES
FIGURE 1: PRINCIPLES OF OPERATION OF LOGIX 500+ ........ 7
FIGURE 2: PRINCIPLES OF OPERATION OF LOGIX 500+ ...... 72
FIGURE 3: LOGIX 500+ DIGITAL POSITIONER SCHEMATIC.. 73
FIGURE 4: CERTIFICATION LABEL ....................................... 78
FIGURE 5: MODEL CODE LABEL ......................................... 78
FIGURE 6: MOUNTING TO MARK I LINEAR VALVES ........... 79
FIGURE 7: FLOWTOP MOUNTING BRACKET ...................... 80
FIGURE 8: FLOWTOP MOUNTING...................................... 81
FIGURE 9: VALTEK ROTARY FOLLOWER ARM .................... 82
FIGURE 10: VALTEK ROTARY TAKE-OFF ARM .................... 82
FIGURE 11: VALTEK ROTARY MOUNTING.......................... 82
FIGURE 12: VALTEK ROTARY FINAL ORIENTATION ............ 83
FIGURE 13: MAXFLO TAKE-OFF ARM................................. 84
FIGURE 14: MAXFLO FOLLOWER ARM .............................. 84
FIGURE 15: MAXFLO ASSEMBLY ........................................ 84
FIGURE 16: MAXFLO CONNECTION ................................... 84
FIGURE 17: AUTOMAX BRACKET ....................................... 86
FIGURE 18: AUTOMAX ASSEMBLY ..................................... 86
FIGURE 19: MOUNTING TO A LINEAR ACTUATOR ............. 87
FIGURE 20: LINEAR, DOUBLE ACTING, AIR TO OPEN ......... 88
FIGURE 21: ROTARY, DOUBLE ACTING, AIR TO OPEN ....... 88
FIGURE 22: LINEAR, SINGLE ACTING, AIR TO OPEN........... 89
FIGURE 23: EXHAUST VENTS ............................................. 89
FIGURE 24: PNEUMATIC CONNECTIONS ........................... 90
FIGURE 25: TERMINAL DIAGRAM ....................................... 91
FIGURE 26: COMPLIANCE VOLTAGE .................................. 92
FIGURE 27: CONDUIT AND GROUNDING ........................... 93
FIGURE 28: MFC ANALOG OUTPUT CIRCUIT ...................... 93
FIGURE 29: MFC DISCRETE OUTPUT CIRCUIT ..................... 94
FIGURE 30: MFC DISCRETE INPUT CIRCUIT ....................... 94
FIGURE 31: V TO I CARD .................................................... 95
FIGURE 32: V TO I CARD CIRCUIT....................................... 95
FIGURE 33: V TO I CARD INSTALLED .................................. 95
FIGURE 34: LIMIT SWITCH BOARD .................................... 96
FIGURE 35: REMOTE MOUNT BOARD ............................... 97
FIGURE 36: LOCAL USER INTERFACE .................................. 98
FIGURE 37: SELECTABLE GAIN SWITCH ............................ 100
FIGURE 38: DISPLAY MAIN VIEW ...................................... 105
FIGURE 39: CHARACTERIZATION CURVES ........................ 110
FIGURE 40: VALVESIGHT DTM DASHBOARD ................... 113
FIGURE 41: HART DIP SWITCH ......................................... 114
FIGURE 42: MULTI-FUNCTION CARD ............................... 116
FIGURE 43: V TO I CARD .................................................. 117
FIGURE 44: LIMIT SWITCHES ........................................... 118
FIGURE 45: REMOTE MOUNT BOARD ............................. 118
FIGURE 46: TOOLS FOR POSITIONER MAINTENANCE...... 121
FIGURE 47: LIMIT SWITCH ............................................... 122
FIGURE 48: INNER COVER................................................ 123
FIGURE 49: LCD................................................................ 123
FIGURE 50: AUXILIARY CARD ........................................... 124
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FIGURE 51: MAIN BOARD SCREWS .................................. 125
FIGURE 52: MAIN BOARD CONNECTORS ......................... 125
FIGURE 53: PRESSURE SENSOR BOARD ........................... 125
FIGURE 54: INSERTING THE DOUBLE ACTING BLOCK
ASSEMBLY ............................................................... 126
FIGURE 55: DOUBLE ACTING RELAY ASSEMBLY............... 127
FIGURE 56: CLIP SPRING ORIENTATION ........................... 127
FIGURE 57: SINGLE ACTING RELAY ASSEMBLY ................ 128
FIGURE 58: SPARE PARTS KITS ......................................... 144
4
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
GENERAL INFORMATION
1.1
Using This Document
Product users and maintenance personnel should thoroughly
review this manual prior to installing, operating, or performing
any maintenance on the positioner.
The following instructions are designed to assist in
unpacking, installing and performing maintenance as
required on Logix® 500MD+ positioners. Series 500 is the
term used for all the positioners herein; however, specific
numbers indicate features specific to model (i.e., Logix 520
indicates that the positioner has HART® protocol). See Logix
500MD+ Model Number table in this manual for a breakdown
of specific model numbers.
Separate Flow Control Products User Instructions cover the
valve, actuator, or portions of the system and other
accessories. Refer to the appropriate instructions when this
information is needed. In most cases FLOWSERVE valves,
actuators and accessories are designed for specific
applications with regard to medium, pressure and
temperature. For this reason they should not be used in other
applications without first contacting the manufacturer.
To avoid possible injury to personnel or damage to positioner
parts, DANGER and CAUTION notes must be strictly
followed.
1.2
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.
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.
1.3
FLOWSERVE positioners use high pressure gas to operate.
Use eye protection when working around pressurized
equipment. Follow proper procedures for working with
natural gas if it is used.
DANGER: Standard industry safety practices must be
adhered to when working on this or any process control
product. Specifically, personal protective equipment must be
used as warranted.
1.4
Compliance with other, not particularly emphasized notes,
with regard to assembly, operation and maintenance and
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.
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Qualified Personnel
Qualified personnel are people who, on account of their
training, experience, 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.
In unpacking, installing and performing maintenance as
required on FLOWSERVE products, product users and
maintenance personnel should thoroughly review this manual
prior to installing, operating or performing any maintenance.
1.5
Valve and Actuator Variations
These instructions cannot claim to cover all details of all
possible product variations, nor can they provide information
for every possible example of installation, operation or
maintenance. This means that the instructions normally
include only the directions to be followed by qualified
personal where the product is being used for its defined
purpose. If there are any uncertainties in this respect
particularly in the event of missing product-related
information, clarification must be obtained via the appropriate
Flowserve sales office.
1.6
DANGER: Indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
Protective Clothing
Spare Parts
Use only FLOWSERVE original spare parts. FLOWSERVE
cannot accept responsibility for any damages that occur from
using spare parts or fastening materials from other
manufactures. If FLOWSERVE products (especially sealing
materials) have been in storage for longer periods check
these for corrosion or deterioration before using these
products. See section 22 STORAGE AND UNPACKING
more information.
5
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
1.7
Service / Repair
To avoid possible injury to personnel or damage to products,
safety terms must be strictly adhered to. Modifying this
product, substituting non-factory parts, or using maintenance
procedures other than outlined in this instruction could
drastically affect performance and be hazardous to personnel
and equipment, and may void existing warranties.
Between actuator and valve there are moving parts. To avoid
injury FLOWSERVE provides pinch-point-protection in the
form of cover plates, especially where side-mounted
positioners are fitted. If these plates are removed for
inspection, service or repair special attention is required.
After completing work the cover plates must be refitted.
PRINCIPLES OF OPERATION
1.8
Basic Operation
The Logix 500+ digital positioner is a two-wire 4-20 mA input
digital valve positioner which uses the HART protocol to
allow two-way remote communications. The positioner is
completely powered by the 4-20 mA input signal. Start-up
current must be at least 3.8 mA.
The positioner is
configurable through the local user interface, hand-held or
DTM. The Logix 500+ positioner can control both doubleand single-acting pneumatic actuators with linear or rotary
mountings.
Logix 500+ positioner repair is limited to the replacement of
sub-assemblies and circuit boards with FLOWSERVEmanufactured replacements as outlined in this manual.
The Logix 500+ digital positioner is an electronic and
pneumatic closed-loop feedback instrument. Figure 1 shows
a schematic of a Logix 500+ positioner installed on a singleacting linear actuator for air-to-open action. Figure 2 shows
the double acting option.
DANGER: Substitution of with non-factory positioner
components may impair intrinsic safety.
1.9
CAUTION: Before products are returned to
FLOWSERVE for repair or service, FLOWSERVE must be
provided with a certificate which confirms that the product
has been decontaminated and is clean. FLOWSERVE will
not accept deliveries if a certificate has not been provided (a
form can be obtained from FLOWSERVE).
Apart from the operating instructions and the obligatory
accident prevention directives valid in the country of use, all
recognized regulations for safety and good engineering
practices must be followed.
HART
The Logix 500+ receives power from the two-wire, 4-20 mA
input signal. However, since this positioner utilizes HART
communications, two sources can be used for the command
signal: Analog and Digital. In Analog source, the 4-20 mA
signal is used for the command source. In Digital source, the
level of the input 4-20 mA signal is ignored (used only for
power) and a digital signal, sent via the HART
communication protocol, is used as the command source.
The command source can be accessed with ValveSight
software, the HART 375 communicator, or other host
software. See section 29 HART COMMUNICATION for more
information.
1.10 Position Definition
Whether in Analog or Digital Source, The position at 0% is
always defined as the valve in a closed position and 100% is
always defined as the valve in an open position. In Analog
Source, the 4-20 mA signal is converted to a position (in
percent). During loop calibration, the signals corresponding
to 0% and 100% are defined.
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6
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Single Acting
Pilot Relay
Analog
Comman
d Input
(4-20 mA)
Digital
Command
Input
Poppet
Valve
Air Supply
Piezo Kill
Circuit
Inner
Loop
Spool
Control
Command
Input
Signal
Piezo
Voltage
Actuator
Hall
Sensor
Piezo
Valve
P
+
Characterization,
Soft Limits,
Tight Shutoff
+
Final
Command
Σ_
I
+
+
Σ
+
Output
Percentage
Σ
_
Inner-Loop
Output
D
Inner-Loop
Offset
Position
Feedback
Control
Valve
Figure 1: Principles of Operation of Logix 500+
FLOWSERVE Control valve packages (a control valve
and its instrumentation) are typically well protected from
corrosion. Nevertheless FLOWSERVE products must
be stored in a clean, dry environment such as an
enclosed building that affords environmental protection.
Heating is not required. Control valve packages must be
stored on suitable skids, not directly on the floor. The
storage location must also be free from flooding, dust,
dirt, etc. Plastic caps are fitted to protect the flange faces
and positioner ports to prevent the ingress of foreign
materials. These caps should not be removed until the
valve or positioner is actually mounted into the system.
1.11 Command Input and Final Command
The Command Input signal (in percent) passes through a
characterization/limits modifier block. This function is done in
software, which allows for in-the-field customer adjustment.
The characterization block can apply no adjustment (Linear),
one of several pre-defined characterization curve
adjustments (including several Equal Percent), or a 21-point
Custom Characterization curve adjustment. In Linear mode,
the input signal is passed straight through to the control
algorithm in a 1:1 transfer. In Equal Percent (=%) mode, the
input signal is mapped to a standard rangeability equal
percent curve. If Custom Characterization is enabled, the
input signal is mapped to a custom, user-defined 21-point
output curve. The custom user-defined 21-point output curve
is defined using a handheld or ValveSight software. In
addition, two user-defined features, Soft Limits and Tight
Shutoff may affect the position. The actual command being
used to position the stem after the evaluation of
characterization curves and user limits, is called the Final
Command.
If FLOWSERVE products (especially sealing materials)
have been in storage for longer periods check these for
corrosion or deterioration before using these products.
Fire protection for FLOWSERVE products must be
provided by the end user.
2.2
While unpacking the valve and/or Logix 500MD+
positioner, check the packing list against the materials
received. Lists describing the system and accessories
are included in each shipping container.
1.12 Outer Loop
2
2.1
In the event of shipping damage, contact the shipper
immediately. Should any problems arise, contact a
Flowserve Flow Control Division representative.
The Logix 500+ uses a two-stage, stem-positioning
algorithm. The two stages consist of an inner-loop
(pilot relay control) and an outer-loop (stem
position control). Referring again to
2.3
Storage
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Unpacking
7
Pre-installation Inspection
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
When installing a positioner, verify the shaft has not
been damaged and that the plugs and cover are in
place. The plugs keep debris and moisture from
damaging the internal components of the positioner. If
the positioner has been contaminated, clean the
positioner components gently with a soft damp cloth.
Some components may be removed for better access.
See section 36 MAINTENANCE AND REPAIR. When
cleaning a Double Acting Relay (Spool and Block) take
care not to bend or force the spool. A Single Acting
Relay may be removed, but do not disassembled the
relay. Check connectors to ensure that no debris is
present. Port screens can be removed with a flat
screwdriver for access to internal passages.
2.4
Labels
Verify that the labels match the intended application.
Note: Mark checkbox next to hazardous area information for
protection method Logix 500MD+ is installed to.
Figure 4: Certification Label
Figure 5: Model Code Label
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
3 MOUNTING AND INSTALLING
3.1
Mounting to Mark One Linear
Valves
6
Insert the lower mounting bolt and tighten the
bolting.
7
Position the take-off arm mounting slot against the
stem clamp mounting pad. Apply Loctite 222 to the
take-off arm bolting and insert through washers into
stem clamp. Leave bolts loose.
To mount a Logix 500+ positioner to a Valtek linear Mark
One valve, refer to Figure 6: Mounting to Mark I Linear
Valves and proceed as outlined below.
1
2
8
Slide the appropriate pin slot of the take-off arm,
based on stroke length, over the follower arm pin.
The appropriate stroke lengths are stamped by
each pin slot.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
Remove washer and nut from follower pin
assembly. Insert pin into the appropriate hole in
follower arm, based on stroke length. The stroke
lengths are stamped next to their corresponding
holes in the follower arms. Make sure the
unthreaded end of the pin is on the stamped side of
the arm. Reinstall lock washer and tighten nut to
complete follower arm assembly.
Slide the slot in the follower arm assembly over the
flats on the position feedback shaft in the back of
the positioner. Make sure the arm is pointing
toward the side of the positioner with ports A, B,
and Supply. Slide the lock washer over the threads
on the shaft and tighten down the nut.
3
Align the bracket with the three outer mounting
holes on the positioner. Fasten with 1/4" bolts.
4
Screw one mounting bolt into the hole on the yoke
mounting pad nearest the cylinder. Stop when the
bolt is approximately 3⁄16" from being flush with
mounting pad.
5
Slip the large end of the teardrop shaped mounting
hole in the back of the positioner/bracket assembly
over the mounting bolt. Slide the small end of the
teardrop under the mounting bolt and align the
lower mounting hole.
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9
Center the take-off arm on the rolling sleeve of the
follower pin.
10
Align the take-off arm with the top plane of the
stem clamp and tighten bolting. Torque to 120 in-lb.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve. If mounted incorrectly, a
stroke calibration error will occur and the indicator lights
will blink a RGGY code indicating the position sensor
has gone out of range on one end of travel or the travel
is too small. Reposition the feedback linkage or rotate
the position sensor to correct the error.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature in the Custom Characterization
page of the DTM.
9
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
3.2
Mounting
Valves
to
FlowTop
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
14
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
Linear
To mount a Logix 500+ positioner to a FlowTop linear
actuator and valve (with direct mounting / integrated
tubing), refer to Figure 7 and proceed as outlined below.
NOTE: Because the integral mounting uses the
alternate pneumatic port, the positioner must have a
poppet style, single acting relay. This is indicated in the
model code with a “1” in the highlighted location:
521MD+14-W1ED1F0-GM2-1103
1
Remove the FlowTop port plug screw. Plug port B.
2
Ensure positioner O-ring surface is clean. Then
install the O-ring, and FlowTop mounting block
using the positioner screws.
3
Attach the follower arm to the feedback shaft using
the follower arm nut.
Refer to Figure 8: FlowTop Mounting.
4
Assemble the take-off pin to the take-off plate and
mount the take-off plate to the valve stem using the
two screws. Adjust the follower pin to match the
correct location as indicated on the follower arm’s
embossed scale.
5
Place the actuator O-ring.
6
Place the positioner on the actuator, ensuring the
take-off pin is inside the follower arm slot. Adjust
the follower arm as needed.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
7
Use the actuator screws to secure the positioner in
place.
8
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
9
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
10
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
11
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
12
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
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13
10
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature on the Custom Characterization
page of the DTM.
flowserve.com
11
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
3.3
Mounting to
Rotary Valves
Standard
Valtek
The standard rotary mounting applies to Valtek
valve/actuator assemblies that do not have mounted
volume tanks or hand-wheels. The standard mounting
uses a linkage directly coupled to the valve shaft. This
linkage has been designed to allow for minimal
misalignment between the positioner and the actuator.
Refer to Figure 10 through Figure 12.
1
Fasten the spline lever adapter to the splined lever
using two 6 x 1/2" self-tapping screws.
2
Slide the take-off arm onto the spline lever adapter
shaft, orienting the arm to the current valve
position. Insert the screw with star washer through
the take-off arm and add the second star washer
and nut and tighten.
3
Attach follower arm to positioner feedback shaft
using the star washer and 10-32 nut.
4
Rotate the follower arm so the follower pin will slide
into the slot on the take-off arm. Adjust the bracket
position as needed noting the engagement of the
follower pin and the take-off arm slot. The pin
should extend approximately 2 mm past the takeoff arm. When properly adjusted, securely tighten
the bracketing bolts
5
Using four 1/4-20 x 1/2" bolts, fasten positioner to
universal bracket using appropriate hole pattern
(stamped on bracket).
6
Using a ½” end wrench and two 5/16-18 X ½” bolts,
attach bracket to actuator transfer case pad.
Leave these bolts slightly loose until final
adjustments are made.
7
Rotate follower arm so the follower pin will slide
into the slot on the take-off arm. Over-rotate the
follower arm if needed so the arm moves freely
through the intended travel.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
8
Adjust the bracket position as needed noting the
engagement of the follower pin and the take-off
arm slot. The pin should extend approximately
1⁄16" past the take-off arm. When properly
adjusted, securely tighten the bracketing bolts.
9
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
10
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
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12
11
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
12
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
13
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
14
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
15
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature on the Custom Characterization
page of the DTM.
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13
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
3.4
1
Mounting
Valves
to
MaxFlo
Rotary
3.5
Slide the take-off arm onto the shaft. Insert the
screw with star washer through the take-off arm
and add the second star washer and nut. Tighten
nut with socket so arm is lightly snug on the shaft
but still able to rotate. This will be tightened after
linkage is correctly oriented. Refer to figures Figure
13 through Figure 16.
2
Attach the mounting plate to the positioner using 4
screws.
3
Attach follower arm to positioner feedback shaft.
4
Rotate the follower arm so the take-off pin will slide
into the slot on the follower arm. Adjust the bracket
position as needed noting the engagement of the
follower pin and the take-off arm slot. The pin
should extend approximately 2 mm past the takeoff arm. When properly adjusted, securely tighten
the bracketing bolts.
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
6
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
7
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
8
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
9
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
10
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
11
1
Attach the mounting plate to the positioner using 4
screws. See Figure 17.
2
Rotate the feedback shaft to match the orientation
of the receiver on the actuator.
3
Mount the positioner onto the actuator using the
washers and nuts. See Figure 18.
4
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
5
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
6
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
7
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
8
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
9
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
10
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, remove
power from the positioner, disconnect the air, and
remove the positioner from the actuator. Rotate
the feedback shaft so that the full free travel of the
feedback shaft is in the range of the actuator
movement.
Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
flowserve.com
NAMUR
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
5
Mounting to Rotary
(AutoMax) Valves
14
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
flowserve.com
15
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
3.6
Mounting to a Linear NAMUR
Pneumatic Actuator
The mounting of a rod actuator kit and actuator
(according to IEC 534 part 6) is described in the
following example. Refer to Figure 19.
1
Mount the follower arm by unscrewing the lock nut
for the follower arm attachment. Place the follower
arm on the shaft at the back of the positioner and
fasten it with the lock nut. The follower pin should
point away from the positioner.
2
Attach the stem clamp bracket to the stem clamp
and fasten it with two hexagon socket screws and
lock washers.
3
Attach the take-off arm to the stem clamp bracket
and fasten it with a hexagon socket caps crew and
a washer.
CAUTION: Maximum torque 0,25 Nm (0,18 ft-lbs).
4
To mount the positioner, adjust the actuator to midstroke.
5
Pre-assemble the mounting bracket on the left
actuator leg and hand-tighten the two U-bolts, nuts
and lock-washers.
6
Attach the positioner to the pre-assembled
mounting bracket and fasten it with two hexagon
screws and two lock washers. Check that the
follower pin is inserted in the slot of the take-off
arm and the follower arm is positioned parallel to
the take-off arm.
7
Tighten all screws and nuts.
NOTE: A slight unsymmetrical mounting increases
the linearity deviation but does not affect the
performance of the device.
NOTE: Depending on the actuator size and stroke it
may be necessary to flip the take-off arm (Figure 3) by
180° and attach it to the opposite side of the stem clamp
bracket.
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
9
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
flowserve.com
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
11
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
12
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
13
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
14
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, remove
power from the positioner, disconnect the air, and
remove the positioner from the actuator. Rotate
the feedback shaft so that the full free travel of the
feedback shaft is in the range of the actuator
movement.
Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
8
10
16
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
4 TUBING
Figure 20: Linear, Double Acting, Air to Open
After mounting has been completed, tube the positioner
to the actuator using the appropriate compression fitting
connectors.
For best performance, use 10 mm (3/8
inch) tubing for 645 square cm (100 square inch)
actuators or larger. See Figure 24 below.
4.1
Example: Rotary Double-Acting Actuators
For a rotary actuator, the “Y1” port of the positioner
manifold is tubed to the far side of the actuator. The “Y2”
port of the positioner manifold is tubed to the side of the
actuator closer to the transfer case. This tubing
convention is followed regardless of air action. On rotary
actuators, the transfer case orientation determines the
air action. See Figure 21.
Determine Air Action
The port labeled “Y1” delivers air when an air supply is
present and the relay is energized. (For positioners with
double acting relays, this is port A. For positioners with
single acting relays, this is port B.) Typically, the port
labeled “Y1” should be tubed to the pneumatic side of
the actuator (the side that would result in the air
compressing the actuator spring). When tubed this way,
the spring is designed to return the valve to the fail safe
state should supply air or power to the unit fail.
.
Tube the port labeled “Y1” to the side of the actuator that
must receive air to begin moving away from the fail safe
state.
If air from “Y1” should open the valve, set the Air Action
configuration switch on the positioner to Air-to-Open,
otherwise set it to Air-to-Close.
The Air-to-Open and Air-to-Close selection is determined
by the actuator tubing, not the software. When air action
selection is made during configuration, the selection tells
the control which way the actuator has been tubed.
Figure 21: Rotary, Double Acting, Air to Open
If the valve is double acting, port the valve labeled “Y2”
to the other side of the actuator.
Example: Tubing Single-acting Actuators
For single-acting actuators, the “Y1” port is always tubed
to the pneumatic side of the actuator regardless of air
action. If a double acting (spool style) relay is installed in
the positioner, plug port B (Y2). If a single acting poppet style relay is installed, plug port A (Y2) as in
Figure 22. Or, port A may be used for purging. See
Purging Single Acting Actuators below.
DANGER: Proper tubing orientation is critical for the
positioner to function correctly and have the proper
failure mode.
Example: Tubing Linear Double-Acting Actuators
For a linear air-to-open actuator, the “Y1” port of the
positioner is tubed to the bottom side of the actuator
(closest to the valve). The “Y2” port of the positioner is
tubed to the top side of the actuator. See Figure 20. For
a linear air-to-close actuator the tubing configuration is
reversed.
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17
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
The maximum allowable back pressure from the housing
chamber is 0.14 barg (2.0 PSIG). For flow rates, see
section 20.3 Air Supply.
The maximum allowable back pressure from the exhaust
port is 0.55 barg (8.0 PSIG) for double acting relays and
is 0.14 barg (2.0 PSIG) for single acting relays. Higher
pressure may result in decreased performance. For
output flow rates, see section 20.2 Pneumatic Output.
Figure 22: Linear, Single Acting, Air to Open
4.2
Connect Supply Port
The positioner ports are threaded with either G ¼ or ¼
NPTF as indicated on the housing.
CAUTION: The back pressure in the main housing
must never rise above 0.14 barg (2.0 PSIG). This could
cause the positioner to become unresponsive under
some circumstances
In order to maintain the recommended air quality, a
coalescing filter should always be installed in the supply
gas line. An air filter is highly recommended for all
applications where dirty air is a possibility. The positioner
passage ways are equipped with small filters, which
remove medium and coarse size dirt from the
pressurized air. If necessary, they are easily accessible
for cleaning.
A supply regulator is recommended if the customer will
be using the diagnostic features of the Logix 500+ but is
not required. In applications where the supply pressure
is higher than the maximum actuator pressure rating a
supply regulator is required to lower the pressure to the
actuator’s maximum rating.
4.3
Purging Single Acting Actuators
Figure 23: Exhaust Vents
Purging allows the non-pressurized side of a single
acting actuator to fill with exhaust gas instead of
atmospheric air.
This configuration helps prevent
corrosion
of
actuator
components
in
harsh
environments. When a single acting relay is used, a
special procedure can be performed to configure the
positioner to purge properly using port A. Contact your
local Flowserve Representative for more information
regarding the purging option.
4.4
.
Vented Design
A standard Logix 500+ positioner is vented directly to the
atmosphere. When supply air is substituted with sweet
natural gas, piping must be used to route the exhausted
natural gas to a safe environment.
The housing chamber exhaust port is located on the
backside of the positioner. The actuator exhaust port is
located on the bottom of the positioner. Both ports are
tapped with either ¼ NPTF or G ¼ threads and covered
with a protective cap. To control vented gas, remove the
caps and connect the necessary tubing/piping to these
ports. See Figure 23: Exhaust Vents.
This piping system may cause some positioner back
pressure. Back pressure in the housing chamber is from
the modulator and regulator. Back pressure in the
exhaust port is from the actuator.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
flowserve.com
19
Port
Poppet
Style
Relay
(Single
Acting)
Spool
Style
Relay
(Double
Acting)
Spool
Style
Relay
(Single
Acting)
S
Supply
Supply
Supply
B
Y1
Y2
(Plug)
A
(Plug)
Y1
Y1
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5 ELECTRICAL CONNECTIONS
5.1
Electrical Terminals
5.2
Command Input (4-20 mA)
Connection
Equation 1
Available Voltage = Controller Voltage @Current
Current
× R
+ R!
The Logix 500+ is reverse polarity protected, however,
verify polarity when making field termination connection.
Wire 4-20 mA current source to the input terminal
labeled “HART 4-20mA INPUT”. Tighten using 0.5 to 0.6
Nm torque. See Figure 25: Terminal Diagram.
Depending on the current source, a HART filter may be
required. See 37.1 Troubleshooting Guide.
Current "
R
R!
5.2.1
Compliance Voltage
= 20&'
= 300)
= 25)
Available Voltage = 19 V − 0.020 A × 300) + 25)
Output compliance voltage refers to the voltage limit the
current source can provide. A current loop system
consists of the current source, wiring resistance, barrier
resistance (if present), and the Logix 500+ impedance.
The Logix 500+ requires that the current loop system
allow for a 10 VDC drop across the positioner at
maximum loop current. The operating current range is
from 3.8 to 24 mA.
Available Voltage = 12.5 V
The available voltage (12.5 V) is greater than the
required voltage (10.0 V) therefore; this system will
support the Logix 500+. The Logix 500+ has an input
resistance equivalent to 500 Ω at a 20 mA input current.
CAUTION: The current must always be limited for
4-20 mA operation. Never connect a voltage source
directly across the Logix 500+ terminals. This could
cause permanent circuit board damage.
In order to determine if the loop will support the Logix
500+, perform the calculation in the following equation.
The Available Voltage must be greater than 10VDC in
order to support the Logix 500+. Also, see Table 1:
Input Signal.
flowserve.com
#
−
20
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
4-20 mA
Current
Source
Controller
Voltage
Barrier
(If Present)
Wire
R
R
+
Compliance 10
Voltage
VDC
-
Logix
520MD+
Current
Figure 26: Compliance Voltage
5.2.2
Cable Requirements
Max Cable Length =
The Logix 520MD+ digital positioner utilizes the HART
Communication protocol. This communication signal is
superimposed on the 4-20 mA current signal. The two
frequencies used by the HART protocol are 1200 Hz and
2200 Hz. In order to prevent distortion of the HART
communication signal, cable capacitance and cable
length restrictions must be calculated. The cable length
must be limited if the capacitance is too high. Selecting a
cable with lower capacitance/foot rating will allow longer
cable runs. In addition to the cable capacitance, the
network resistance also affects the allowable cable
length. See Figure 26.
Max Cable Length = 1111 &
To control cable resistance, 24 AWG cable should be
used for runs less than 5000 feet. For cable runs longer
than 5000 feet, 20 AWG cable should be used.
The input loop current signal to the Logix 520MD+ digital
positioner should be in shielded cable. Shields must be
tied to a ground at only one end of the cable to provide a
place for environmental electrical noise to be removed
from the cable. In general, shield wire should be
connected at the source, not at the positioner.
In order to calculate the maximum network capacitance,
use the following formula:
5.2.3
Equation 2
C.
/!0 1
μF ≤
5678
9:;<<=>< ? [email protected]=<>?AB78
− 0.0032
= 300) (if present)
R!
C.
Intrinsically Safe Barriers
When selecting an intrinsically safe barrier, make sure
the barrier is HART compatible. Although the barrier will
pass the loop current and allow normal positioner
control, if not compatible, it may prevent HART
communication.
Example:
R
0.08 μF
ML
. 000072
&
5.2.4
Grounding and Conduit
= 50)
/!0 1
μF ≤
5678
A77C? 67C?AB78
The grounding terminals, located by the electrical
conduit ports should be used to provide the unit with an
adequate and reliable earth ground reference. This
ground should be tied to the same ground as the
electrical conduit. Additionally, the electrical conduit
should be earth grounded at both ends of its run.
− 0.0032= 0.08 μF
In order to calculate the maximum cable length, use the
following formula:
Equation 3
Max Cable Length =
C. /!0
CH I
NOTE: The grounded screw must not be used to
terminate signal shield wires. Shield wires should be
terminated only at the signal source.
1
This product has electrical conduit connections in either
thread sizes 1/2" NPTF or M20x1.5 which appear
identical but are not interchangeable. The thread size is
indicated on the side of the positioner near the conduit
Example:
CH
I
KL
ML
= 72
= .000072
&
&
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21
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
connections. Conduit fittings must match equipment
housing threads before installation. If threads do not
match, obtain suitable adapters or contact a Flowserve
representative. See Figure 27: Conduit and Grounding.
5.3
Multi-Function Card (AO, DO, DI)
The Multi-Function Card can act as an Analog Output
(AO), a Discrete Output (DO), or a Discrete Input (DI).
Connections to the Multi-Function Card are made
directly to the card terminals. For detailed information
about voltage and current limits, see Table 14: Auxiliary
Card Status below.
See section 31 MULTI-FUNCTION CARD for more
information.
5.3.1
For AO function wire the MFC in series with a 10 to 40
VDC power supply, including a method to determine the
current. When configured as an AO, the current will
follow the valve position. See Figure 28.
Figure 27: Conduit and Grounding
5.2.5
Analog Output
Electromagnetic Compatibility
The Logix 500+ digital positioner has been designed to
operate correctly in electromagnetic (EM) fields found in
typical industrial environments. Care should be taken to
prevent the positioner from being used in environments
with excessively high EM field strengths (greater than 10
V/m). Portable EM devices such as hand-held two-way
radios should not be used within 30 cm of the device.
10 VDC
to
40 VDC
Voltage
Source
Ensure proper wiring and shielding techniques of the
control lines, and route control lines away from
electromagnetic sources that may cause unwanted
electrical noise. An electromagnetic line filter can be
used to further eliminate noise (FLOWSERVE Part
Number 10156843).
MFC
In the event of a severe electrostatic discharge near the
positioner, the device should be inspected to ensure
correct operability. It may be necessary to recalibrate the
Logix 500+ positioner to restore operation.
flowserve.com
Figure 28: MFC Analog Output Circuit
22
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5.3.2
Discrete Output
Low
1.2 mA > output >
0.1 mA
(typically 0.5 mA)
For DO function, wire the MFC in series with a 8 to 40
VDC power supply, including a method to determine the
current such as a resistor. Or use a NAMUR switch
amplifier made for this purpose. In DO configuration, the
card is a NAMUR switch.
Less than 0.1 mA
MFC (DI)
When configured as a DO, current will remain high until
the user-defined condition (an alarm) is active, and then
drop low when tripped. See Figure 29.
8 VDC
Minimum
MFC
Figure 29: MFC Discrete Output Circuit
5.3.3
Discrete Input
For the DI function, wire the MFC in series with a 0 to 40
VDC power supply. Keep the voltage low under normal
circumstances. Raise the voltage to create a tripped
input state. See Figure 30.
Figure 30: MFC Discrete Input Circuit
Table 14: Auxiliary Card Status
Card
Condition
Status
Indication
Multi-Function Card
Monitoring Position
(typical 4-20mA )
Output
(mA)
Less than 8 V on
AO terminals.
No Loop
Power
High
output > 2.1 mA
(520MD+ typically
3 mA)
(510+ typically 7
mA)
1Nominal
MFC (AO)
MFC (DO)
flowserve.com
23
Low
(input < 2.5 VDC)
High
(input > 8.0 VDC)
0Tripped
No Loop
Power
1Nominal
0Tripped
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5.4
V to I Card Connections
The V to I card is used if powering the positioner using a
voltage generator is desired. The card requires a
voltage input and converts the voltage to a current
suitable for powering the positioner. The positioner can
still communicate via a HART interface on the voltage
lines.
Figure 32: V to I Card Circuit
NOTE: When using the V to I card, digital position
control is recommended.
Controlling position by
changing the voltage may result in lack of position
linearity and accuracy.
Wire the V to I card according to Figure 32: V to I Card
Circuit. Connect the voltage input to the V to I card
terminal. Connect the red wire from the V to I card to the
positive terminal on the main board 4-20 mA input
connector. Connect the black wire from the V to I card
to the negative terminal on the main board 4-20 mA
input connector.
Current to the positioner can be approximated by the
formula in Equation 4.
Equation 4
O=
Figure 33: V to I Card installed
PQRRST UVSW XYZ[Y ]^ S UVSW XY
5B5
Example
Supply Voltage = 24 V
Terminal Voltage = 10 V
O=
24 − 10
= 20 &'
696
Figure 31: V to I Card
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24
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5.5
Limit Switches
Limit switches provide an independent verification of the
position of the feedback shaft. Wire the limit switches
according to Table 15: Limit Switch Connections. For
more information, see Table 7: Limit Switch
Specifications on page 75. See Figure 34.
Table 15: Limit Switch Connections
Terminal (See Figure 34)
Switch
1
2
3
4
5
6
NC
NO
C
NC
NO
C
+
+
-
+
+
-
Mechanical
Cherry DG 13-B2RA
1 & 4 NC
LS1
Figure 34: Limit Switch Board
LS2
Reed
Hamlin 59165-1-S-00-C
+
NO
-
+
LS1
LS2
Inductive Sensor
P&F NJ2-V3-N
NAMUR NC
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Proximity
P&F SJ2-S1N
NAMUR NO
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Proximity
P&F SJ2-SN
NAMUR NC
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Sensor
P&F NBB2-V3-E2
PNP NO
BN
General Purpose Only Vcc+
BU
LS1
flowserve.com
BK
BN
SW+ Vcc+
BU
BK
-
SW+
LS2
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5.6
Remote Mount
The remote mount option can be used where excessive
vibration or environmental factors prevent the placement
of a positioner directly on the valve. Wire the remote
mount board according to Table 16: Remote Mount Card
Connections. For more information, see Table 6:
Remote Mount Specifications on page 75.
Table 16: Remote Mount Card Connections
Terminal (See Figure 35:
Remote Mount Board)
From Remote Mount
A
Red
B
White
C
Black
Figure 35: Remote Mount Board
5.7
Connections for Intrinsically Safe
Operation
See section 21 HAZARDOUS AREA CERTIFICATIONS
for entity parameters and control drawing reference.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
6 STARTUP
6.1
6.2
Quick Start Instructions
Local User Interface Overview
Once the positioner is installed, adjusting the DIP switch
settings and performing a Quick-Cal function will
typically get the positioner working properly. This simple
procedure takes only seconds for most valves.
The Logix 500+ local user interface allows the user to
calibrate, configure the basic operation, and tune the
response of the positioner without additional tools or
configurators. See Figure 36.
1
Using the Configuration Switches, select the
desired configuration.
•
2
Hold the Quick-Cal button for 3 seconds. This will
initiate a stroke calibration.
•
After the stroke calibration is complete, the positioner is
ready for control.
•
CAUTION: During the QUICK-CAL operation the
valve may stroke unexpectedly. Notify proper personnel
that the valve will stroke, and make sure the valve is
properly isolated.
•
•
Card Slot 2
Card Slot 1
Configuration Switches (8) – Used to set basic
configuration. See explanations in section 26.3
Configuration Switch Settings.
Interface Buttons – Used to calibrate the positioner,
perform special functions and navigate the display
menu.
o ►QUICK-CAL / ACCEPT
o ▲Up
o ▼Down
o ◄Back
Selectable GAIN Switch (Rotary) – Used to
manually fine-tune the performance.
LED Indicators (Red, Yellow, and Green) – Indicate
status, alarms and warnings.
Display (Optional) – Provides a full menu of detailed
information and configuration options.
Display
HART
4-20 mA
Input
LED Status
Lights
QUICK-CAL/
ACCEPT Button
Configuration
Switches
Selectable
GAIN Switch
BACK
Button
Figure 36: Local User Interface
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UP Button
DOWN Button
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
6.3
Configuration Switch Settings
Before placing the unit in service, set the Configuration
Switches to the desired control options.
NOTE: The Configuration Switch settings are
activated only by performing a Stroke calibration
(pressing the “QUICK-CAL” button for 3 seconds).
However, the Configuration Switch settings may be
edited from the DTM or Handheld at any time.
6.3.1
Air Action Switch
This must be set to match the configuration of the
valve/actuator mechanical tubing connection since the
tubing determines the air action of the system.
If Single Acting (Poppet) Relay
ATO - Increasing pressure from Port B (labeled “Y1”)
causes the valve to open.
ATC - Increasing pressure from Port B (labeled “Y1”)
causes the valve to close.
If Double Acting (Spool) Relay
ATO - Increasing pressure from Port A (labeled “Y1”)
causes the valve to open.
ATC - Increasing pressure from Port A (labeled “Y1”)
causes the valve to close.
6.3.2
Actuator Switch
This must be set to match the configuration of the
actuator and is used in some diagnostics.
Double - Select Double when both sides of the actuator
are pressurized.
Single - Select Single when only one side of the actuator
is pressurized.
6.3.3
Signal at Closed Switch
Normally this will be set to 4 mA for an Air-To-Open
actuator configuration, and 20 mA for Air-To-Close.
4 mA - Selecting 4 mA will make the valve close when
the signal is low (4 mA) and open when the signal is high
(20 mA).
20 mA - Selecting 20 mA will make the valve close when the
signal is high (20 mA) and open when the signal is low (4
mA).
closes with a 20 mA signal, the AO will show a 20 mA signal
at closed.
6.3.4
The Characterization Switch allows a better match between
the input command and the actual fluid flow through the
valve. This feature is typically used with valves that have
non-linear flow characteristics. The positioner makes a
correction by applying an adjustment to the input command
according to a characterization curve.
Linear - Select Linear if the actuator position should be
directly proportional to the command input signal. (For most
rotary valves, this setting gives an =% Cv characteristic due
to their inherent =% characteristics.)
Other - Select Other if one of the pre-set characterization
curves or a custom curve is desired. The default will be the
Custom curve which is populated with a standard 30:1 equal
percent rangeability curve which generally opens less than
the input command. To select one of the other curve options,
use the LCD menu, a Handheld or the ValveSight DTM. To
modify the Custom curve, use the DTM. See section 28.3.6
Configuration (Characterization) for more information.
6.3.5
Auto Tune Switch
This switch controls whether the positioner will automatically
tune itself during the stroke calibration (Quick-Cal), or use
preset tuning parameters.
On - Selecting On enables an auto tune feature that will
automatically determine the positioner gain settings. The
automatic tuning will be based on response parameters
measured during the latest Quick-Cal. The valve response is
a combination of these response parameters and the current
position of the Selectable GAIN Switch.
Off - Selecting Off forces the positioner to use one of the
factory preset tuning sets determined by the Selectable GAIN
Switch. Settings “B” through “J” are progressively higher
predefined tuning sets.
Selecting “A” on the Selectable Gain Switch during a QuickCal allows the user to use and preserve manually adjusted
gains. See section 26.4 Stroke Calibration for more details.
NOTE: The gain switch is live meaning that regardless of
the Auto Tune selection, the gain settings can be adjusted at
any time during operation by changing the selectable GAIN
switch position. See Figure 37.
NOTE: When using an Analog Output (AO) function of
the Multi-Function Card, the AO signal corresponds with the
Signal At Closed selection. If the valve closes with a 4 mA
signal, the AO will show a 4 mA signal at closed. If the valve
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Characterization Switch
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
6.4
Figure 37: Selectable GAIN Switch
6.3.6
Quick Calibration Switch
This switch selects between Auto and Jog calibration modes.
Auto - Use the Auto setting if the fully opened position of the
valve has a mechanical stop. This is typical for most valves.
In Auto mode during a stroke calibration (Quick-Cal), the
positioner will fully close the valve and register the 0%
position, then fully open the valve to register the 100%
position.
Jog - Use the Jog setting if the fully opened position of the
valve has no hard stop, but needs to be set manually. In Jog
mode during a stroke calibration (Quick-Cal), the positioner
will fully close the valve and register the 0% position, then
wait for the user to move the valve to the 100% open position
using the ▲Up and ▼Down buttons.
Press the
►ACCEPT/QUICK-CAL button to accept the 100% location.
Stroke Calibration
The ►ACCEPT/QUICK-CAL button is used to initiate an
automatic stroke calibration.
The stroke calibration
determines the closed (0%) and open (100%) positions of the
valve and gathers information about the response of the
valve (such as valve stroke time) in order to determine the
gains. The gains are then set automatically. After a stroke
calibration, the positioner is ready to control.
To perform a Quick-Cal, first ensure the Quick Calibration
Switch is set to Auto or Jog as appropriate. Press and hold
the ►ACCEPT/QUICK-CAL button for approximately 3
seconds. This will initiate the automatic stroke calibration.
While the calibration is in progress, the LED lights will flash
status codes indicating the calibration progress. See section
37.3 Status Code Descriptions for an explanation of the
status code sequences.
The initial calibration of extremely large or very small
actuators may require several calibration attempts. The
positioner adapts to the actuator performance and begins
each calibration where the last attempt ended. On an initial
installation it is recommended that after the first successful
calibration that one more calibration be completed for
optimum performance.
6.4.1
Quick Calibration Switch – Jog
See section 26.4 Stroke Calibration for more details.
6.3.7
Valve Stability Switch
This switch adjusts the position control algorithm of the
positioner for use with low-friction control valves or highfriction automated valves.
Lo Friction - Placing the switch to Lo Friction optimizes the
response for low friction, high performance control valves.
This setting provides for optimum response times when used
with most low friction control valves.
Hi Friction - Placing the switch to the right optimizes the
response for valves and actuators with high friction levels.
This setting slightly slows the response and will normally stop
limit cycling that can occur on high friction valves. See
section 28.3.7 Configuration (Pressure Control) for more
details.
NOTE: This option is more effective on with Advanced or
Pro diagnostic levels.
6.3.8
Spare Switch
If special features have been purchased they may be
controlled by this switch. See associated documentation for
more details.
Set the Quick Calibration Switch to Jog if the valve/actuator
assembly has no internal mechanical stop at the fully open
position. In this case, follow these instructions:
1
Press and hold the ►ACCEPT/QUICK-CAL button for
approximately 3 seconds.
This will initiate the jog stroke calibration. The positioner will
then close the valve and set the zero position. The zero
position is automatically always set at the valve seat. At this
point the LED‘s will flash in a sequence of G-R-R-R (greenred-red-red) which indicates that the user must use the jog
keys to manually position the valve to approximately 100%.
2
3
Use the up and down keys to position the valve at
approximately 100% open.
Press the ►ACCEPT/QUICK-CAL button to proceed.
No more user actions are required while the calibration
process is completed. When the lights return to a sequence
that starts with a green light the calibration is complete.
The jog calibration process will only allow the user to set the
span.
If an elevated zero is needed a handheld or
ValveSight DTM are required.
6.4.2
Tuning Options
Quick-Cal Custom Gains - This is typically the fastest way to
achieve ideal gains. Set the Auto Tune Configuration Switch
to On and the Selectable GAIN Switch to “E”. Then perform
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
a Quick-Cal.
During the Quick-Cal, custom tuning
parameters will be determined based on measured response
parameters. The gains can then be fine-tuned by adjusting
the Selectable GAIN Switch. Selecting “D” “C” or “B” will
progressively provide a more stable response. Selecting “F”
through “J” will progressively provide a more active response.
In most cases selecting “E” will give the best results. This is
the default setting for all actuator sizes. Raising or lowering
the Selectable GAIN Switch setting is a function of the
positioner/valve response to the control signal, and is not
actuator size dependent.
Standard Preset Gains - If standard, preset gains are
desired, set the Auto Tune Configuration Switch to Off. After
performing a Quick-Cal, use the Selectable GAIN switch to
the desired level (“B” – “J”). The standard, preset gain
settings are not affected by Quick-Cal.
It may be necessary to set the gain switch BEFORE the
Quick Cal. Very fast stroking valves may need to be at lower
gains and very slow stroking valves may need to be at higher
gains.
Custom Manual Gains - To set gains manually, set the
selectable GAIN switch to “A”. Changing the switch from “B”
to “A” will write the standard “B” settings into the “A”
parameters, allowing a starting point for modification.
Similarly, changing the switch from “J” to “A” will write the
standard “J” settings into the “A” parameters. Custom tuning
values can then be entered using the Display Menu, a
Handheld or ValveSight DTM. With the Selectable GAIN
Switch set to “A”, the tuning will not be modified during a
Quick-Cal.
6.4.3
Aborting a Quick-Cal
The Quick-Cal can be aborted at any time by briefly pressing
the ◄ BACK button. In this case, the previous settings will
be retained.
6.4.4
On Line Stroke Calibration Adjustments
At times an adjustment to the calibration is desired, but the
process cannot be interrupted. The stroke calibration can be
adjusted with minimal valve movement. Contact your local
Field Service Technician for more information.
6.5
Analog Output (AO) Calibration
The Analog Output (position feedback) function of the MultiFunction Card can be configured calibrated using the DTM or
LCD. Ensure the card is installed, the positioner recognizes
the card, and it is configured to be an AO.
The DTM AO calibration wizard is found here:
Configuration / Card Slot 1 (or 2) / Multi-Function Card /
Analog Output Calibration.
The LCD AO calibration features are found here:
Card 1 (or Card 2) / Multi-Function Card / Config/Cal
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
7 POSITIONER FUNCTIONS (No
Display Required)
The following features can be performed using the local
interface.
No display is required for these features.
Additional features are offered with the use of a display,
Handheld or DTM.
NOTE: In order to prevent unintentional adjustments of
the configuration, tuning, or control of the valve, the Tamper
Lock feature may be used. This is set in the DTM and
disables the buttons and menus except for the ability to view
the status of the positioner. When locked, the positioner may
be temporarily unlocked by entering a PIN. (An LCD is
required to enter the PIN.) Or, the positioner can be
unlocked from the DTM.
7.1
Live Manual Tuning (Adjusting the
Gain)
Use the Selectable GAIN Switch to adjust the gain at any
time during operation. This adjustment takes effect
immediately. For faster response select settings above “E”
(F-J). For more stable response, select settings below “E”
(B-D). See Figure 36: Local User Interface on page 98.
7.2
valve information will also be lost and need to be restored. A
factory reset will always reset the command source to analog
4-20 mA.
NOTE: Once the Multi-Function Card (MFC) type has
been configured, the type selection will still remain after a
factory reset.
CAUTION: Performing a factory reset may result in the
inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and make
sure the valve is properly isolated.
7.5
The version number of the embedded code may be checked
at any time except during a calibration. To see the major
version number, hold the ▲Up button. This will not alter the
operation of the unit other than to change the blink sequence
to 3 blinks indicating the major version number. Holding the
▼Down button will give the minor version number without
affecting operation. The version codes are interpreted
according to the following table:
Table 17: Viewing Version Numbers
First
Blink Color
G
G
G
G
G
G
G
G
G
Y
Y
Y
Y
Y
Y
Y
Y
Y
R
R
R
R
R
R
R
R
R
Local Control Of Valve Position
To manually adjust the position of the valve regardless of the
input command (analog or digital), press and hold the ▲Up,
▼Down and ◄ BACK buttons for about 3 seconds. The
▲Up, ▼down buttons can then be used to position the valve.
While in this mode the LED‘s will flash a GRRY (green-redred-yellow) sequence. To exit the local control mode and
return to normal operation, briefly press the ►
ACCEPT/QUICK-CAL button.
CAUTION: When operating using local control of the
valve, the valve will not respond to external commands.
Notify proper personnel that the valve will not respond to
remote command changes, and make sure the valve is
properly isolated.
7.3
Command Source Reset
Performing a command source reset will reset the command
source to analog if it has been inadvertently left in digital
mode. This is done by holding down both the ▲Up and
▼Down
buttons,
then
briefly
pressing
the
►ACCEPT/QUICK-CAL button.
7.4
Factory Reset
To perform a factory reset, hold ► ACCEPT/QUICK-CAL
button while applying power. All of the internal variables
including calibration will be reset to factory defaults. The
positioner must be re-calibrated after a factory reset. Tag
names and other user configured limits, alarm settings, and
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Viewing Version Numbers
31
Second
Blink Color
G
G
G
Y
Y
Y
R
R
R
G
G
G
Y
Y
Y
R
R
R
G
G
G
Y
Y
Y
R
R
R
Third
Blink Color
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
Version
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
For example, if holding the ▲Up button gave a G-G-R code,
and holding the ▼Down gave a Y-Y-G code then the
resulting version number would be 2.12.
7.6
Analog Input Calibration
The Analog Input Calibration allows the user to define the mA
current that will designate the 0% and 100% commands.
This is done by holding down both the ◄ BACK and the
►ACCEPT/QUICK-CAL button for about 3 seconds. The
blink code should change to GRYG. Adjust the input current
to correspond with the 0% position (usually 4 mA). Briefly
press the ►ACCEPT/QUICK-CAL button. The blink code
should change to GRYY. Adjust the input current to
correspond with the 100% position (usually 20 mA). Briefly
press the ►ACCEPT/QUICK-CAL button.
7.7
Select and Calibrate Analog Output
To change the Multi-Function Card to the Analog Output
function and calibrate, hold down both the ◄ BACK and the
▲Up button for about 3 seconds. The blink code should
change to GYRG. If desired, adjust the output current for the
0% position by pressing the ▲Up or ▼Down button. Briefly
press the ►ACCEPT/QUICK-CAL button. The blink code
should change to GYRY. If desired, adjust the output current
for the 100% position by pressing the ▲Up or ▼Down
button. Briefly press the ►ACCEPT/QUICK-CAL button.
7.8
Select Discrete Output
The Discrete Output mode generates a high current of about
7 mA in the normal state. When the Position Deviation alarm
is tripped, the output changes to 0.5 mA.
To change the Multi-Function Card to the Discrete Output
function, hold down both the ◄ BACK and the ▼Down
button for about 3 seconds. The blink code should change to
GRYR. Briefly press the ►ACCEPT/QUICK-CAL button.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
8 POSITIONER FUNCTIONS (LCD
Display)
The optional LCD display provides a variety of useful
information and functions. The Main View shows important
information using icons and scrolling status lines. Using the
directional buttons (▼▲►◄) to navigate the menu, the user
can view detailed information perform commonly used
functions. See Figure 38.
NOTE: The LCD backlight may change brightness during
use. This is normal. The backlight uses any residual power
not used by other functions of the circuitry. When current
supply is low (4mA) the light will appear darker. When
current supply is high (20mA) the light will appear brighter.
8.1
Main Display View
The main view provides an instant display of important status
parameters: Position, Final Command, Scrolling Status
Message, Current Alarm Status and Status Icons.
8.1.1
DIP Switch Override – This indicates that the Configuration
(DIP) Switches do not reflect the actual configuration of the
positioner. This can happen if a Configuration Switch is
changed after a Quick-Cal, or if the configuration is was
changed from the DTM. Performing a Quick-Cal will reset
the configuration to what the Configuration Switches show,
which may not be desirable in this case. Ensure the
Configuration Switches are set properly before performing a
Quick-Cal.
8.1.3
Current Alarm Status
The Current Alarm Status area shows the highest priority
alarm, warning, alert or status indication. This matches the
code indicated by the flashing LEDs.
8.1.4
Status Icons
Status icons continuously show the state of the features and
modes.
Table 18: Status Icons
Position and Command
Icon Location
The current Position and Command are always shown. This
shows the Final Command which has been adjusted
according to a Characterization Curve, MPC, or Soft Limits
that have been applied and should match the Position.
Icon
Icon Meaning
Standard
Upgrade Level
Advanced upgrade
Pro upgrade
8.1.2
Scrolling Status Messages
The Scrolling Status Message provides the following
information as applicable:
Date and Time – The date and time format is adjustable.
See Section 28.3.9 Configuration (Set Time and Date) for
more information.
Ambient Temperature – This is the temperature inside the
positioner.
Supply Pressure – The supply pressure is available with
Advanced and Pro upgrades.
Friction – This is calculated when the valve moves. Friction
is available with the Pro upgrade.
Actuation Ratio – This is the amount of available force used
to move the valve.
Pneumatic Leak – This is leak beyond normal air
consumption. Pneumatic Leak is available with the Pro
upgrade.
Training Percent Complete – Training tracks key parameters
for a period of time. This data can be used to set more
meaningful Alarm and Warning limits. Training will begin
automatically after 24 hours of continuous operation and end
after 90 days of positioner operation. Or use the DTM to
initialize this function. The training status will show only if
training has occurred.
Training Hours Remaining - This shows the hours left in the
training session if training is currently in progress.
Auxiliary Card 1 Status - This shows the type of card in
auxiliary card slot 1.
Auxiliary Card 2 Status - This shows the type of card in
auxiliary card slot 2.
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Analog command mode
Command
Source
Digital command mode
Out of service
Training in progress
Training Mode
Training complete
(blank)
Training not started
Pressure control locked
Pressure
Control
(blank)
HART
Communicatio
ns
(blank)
Pressure control not locked
HART communication currently in
progress
Burst mode in progress
No HART communication currently
in progress
CST ramping up
Continuous
Stroke Test
(CST)
CST ramping down
CST holding steady
(blank)
CST not activated
Upgrade Level Icons - The upgrade levels provide increased
functionality beginning at none, then Standard, Advanced
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
and finally Pro. These levels also correspond to the model
numbers 510+, 520MD+, 521MD+ and 522MD+ respectively.
A 510+ positioner has limited diagnostics and cannot be
upgraded. A Standard (520MD+) has positioner positionbased diagnostics and can be upgraded to a 521MD+ in the
field. An Advanced (521MD+) positioner includes pressure
sensor functions and can be upgraded to a 522MD+ in the
field.
A Pro (522MD+) positioner includes the pressure
sensor functions along with full diagnostic capabilities and is
fully upgraded.
Command Source Icons – The positioner is in Analog
Command mode if it is using the 4-20 mA signal to control
the location of the valve. In Digital Command mode, the
positioner ignores the 4-20 command and responds to the
position command given through HART. In Out Of Service
mode, the positioner is performing a calibration, signature,
partial stroke test or is in a factory reset state.
Training Mode Icons – The positioner can keep track of
several key data parameters for a period of time specified by
the user. This data can be viewed while setting alarm limits
to make them more meaningful. For example, if supply
pressure cycles every day from 5 bar to 4 bar in normal
operation, this information will be displayed where the supply
pressure warning limits are set. Seeing that the supply
typically drops to 4 bar, the user can then set the supply
pressure low warning to a value below 4 bar. See the DTM
User Manual for more information.
Pressure Control – When the position of the valve gets very
close to the commanded position, the positioning algorithm
will change to pressure control. This means the pressures
will be held constant (locked), improving the stability of the
valve position. 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%, the pressure “locks”. This value can be adjusted using
the Display Menu or DTM. See section 28.3.7 Configuration
(Pressure Control).
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HART Communications Icons – When the positioner is
sending or receiving data via the HART communication
protocol, the icon will be displayed. During burst mode, a
pulsating heart icon will be displayed.
Continuous Stroke Test (CST) – For valves that are normally
held at a constant position for extended periods of time, the
Continuous Stroke Test can provide assurance that the valve
is still responsive. When CST is on, the positioner will cause
a very small amount of valve movement.
From this
movement, the positioner can find information about the
health of the valve, actuator and positioner.
This is not
recommended for valves intended for high accuracy or
stability.
To achieve the CST function, the positioner adds a small
deviation to the command. The deviation is ramped at a rate
of 0.05%/second up to 5%. However, the instant the valve
moves, the ramp reverses and begins to grow in the opposite
direction. So, with low friction, the actual movement will be
quite small. If the valve does not move by the time the
deviation equals 5%, a counter will start. After 5 consecutive
failed attempts to move, the CST warning will appear. The
ramp rate, maximum limit, and frequency of the CST can be
adjusted using the DTM.
8.1.5
Adjusting the Display Contrast
To adjust the display contrast, hold the ◄ Back button for 3
seconds. Use the ▲Up and ▼ Down buttons to adjust the
contrast. Use the ►ACCEPT/QUICK-CAL to accept the
settings.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
8.2
Menu Overview
Status
Command (mA)
Command (%)
Position (%)
2
PS (Supply Pressure)
2
PA (Port A Pressure)
2
PB (Port B Pressure)
3
Friction
3
Actuation Ratio
3
Pneumatic Leak
Temperature
Valve Cycles
Valve Travel (%)
Card 1 Value
1
Card 2 Value
Alerts and Alarms
Current Alarms (Prioritized)
Event History
Last Event
2nd Event
3rd Event
*
*
*
32nd Event
1
Air Flow Units
1
Actuator Area Units
1
Date Format
Number Format
LCD Orientation
1
Burst Mode
ON/OFF
Positioner Revs
SW Rev
Bld Date
Bld Time
HW Rev
CPU Rev
HART Ver
Card 1
Card 2
Factory Reset
1
Aux Card 1 (or Card 2 )
No Card: “No Card”
Multi-Function Card
Not Configured
Set as AO Card
Set as DO Card
1
Set as DI Card
Config/Cal
If Not Configured – “No Configuration Allowed”
If AO
Set 0%
Set 100%
If DO – “Use DTM”
1
If DI
Set to No Action
Set to Trigger PST
Set to Command Override
Set Command Point
1
Partial Stroke Test
Start
Last Result
Calibration
Stroke/Quick Calibration
1
Pressure Sensor Calibration
1
Friction Calibration
1
Triple Calibration
Command Input Calibration
1
Calibration Dates
Configuration
Positioner Tuning
Characterization
Pressure Control
Soft Limits & Shutoff
High Soft Limit
Low Soft Limit
Upper Position Shutoff
Lower Position Shutoff
1
Set Date & Time
User Preferences
All Units
1
Pressure Units
1
Force Units
Temperature Units
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Language
English
German
French
Spanish
Portuguese
Russian
Turkish
Italian
1 Not available with 510+.
2 Requires 520MD+ Advanced positioner upgrade.
3 Requires 520MD+ Pro positioner upgrade.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
The LCD display is an available option with the 510+ and
520MD+ models.
For example, if the Multi-Function Card (MFC) was in slot 1,
configured as an analog output (AO), and giving 12.34 mA,
the display would show “AO 1 12.34mA”. If no card is in the
slot, the display will show “No Card”.
8.3.1
For more information about auxiliary card status, see Table
14: Auxiliary Card Status.
8.3
Menu Features
Status
►Status
►Command (mA)
►Command (%)
►Position (%)
2
►PS (Supply Pressure)
2
►PA (Port A Pressure)
2
►PB (Port B Pressure)
3
►Friction
►Actuation Ratio3
3
►Pneumatic Leak
►Temperature
►Valve Cycles
►Valve Travel (%)
►Card 1 Value
1
►Card 2 Value
1 Not available with 510+
2 Requires 520MD+ Advanced positioner upgrade.
3 Requires 520MD+ Pro positioner upgrade.
The Status menu is used to view information about the
configuration and operation of the system.
Command displays the final command in mA.
Command displays the final command in %.
Position displays the valve position in %.
PS displays the supply pressure.
PA displays the pressure in port A. This is the primary port if
using a poppet-style relay module.
PB displays the pressure in port B. This is the primary port if
using a spool-style relay module.
Friction displays the friction of the actuator/valve assembly.
Actuation Ratio displays the force required to actuate the
valve as a percentage of the total force available. The value
is an estimate of the force that would be required to move the
valve to the end of travel, fully compressing the actuator
spring(s).
Pneumatic Leak is an estimate of leak in addition to regular
air consumption.
Temperature displays the temperature inside the positioner.
Valve Cycles are counted each time the positioner changes
direction. The movement must be beyond a dead-band
window. This window is set to 0.5% as a default, but can be
changed using the DTM.
Valve Travel is counted in small increments every time the
valve moves beyond the dead-band window. The travel is
displayed in % of full stroke.
Card 1 Value shows the configuration and status of the
auxiliary card in slot 1. A tripped state is represented by a 0.
A nominal state is represented by a 1.
Card 2 Value shows the configuration and status of the
auxiliary card in slot 2. A tripped state is represented by a 0.
A nominal state is represented by a 1.
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8.3.2
Alerts and Alarms
►Alerts and Alarms
►Current Alarms (Prioritized)
►Event History
►Last Event
►2nd Event
►3rd Event
*
*
*
►32nd Event
The Alerts and Alarms menu shows current and past alarms,
warnings, alerts, and calibrations.
Current Alarms displays all events that are actively sounding.
Event History displays past 32 events including alarms,
warnings, alerts, and calibrations. The event that occurred
most recently is displayed first (event 32) with later events
recorded below. Each event has a time stamp and shows if it
was turning on or off.
8.3.3
Partial Stroke Test
1
►Partial Stroke Test
►Start
►Last Result
1 Not available with 510+
The Partial Stroke Test (PST) menu provides the user the
ability to start a PST and see the results of the latest PST.
CAUTION: Performing a Partial Stroke Test will result in
valve movement and the inability to operate the valve until
the test is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated if
required by plant procedures.
Start allows the user to initialize the (PST).
Last Result shows “Pass” or “Fail” from the last PST attempt.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
8.3.4
Calibration
►Calibration
►Stroke/Quick Calibration
1
►Pressure Sensor Calibration
1
►Friction Calibration
1
►Triple Calibration
►Command Input Calibration
1
►Calibration Dates
1 Not available with 510+
The Calibration menu allows the user to calibrate the
positioner’s sensors. The positioner can accurately control
with only a Quick-Cal. Typically this is all that is needed. A
friction calibration is recommended if the positioner has been
upgraded to Pro diagnostics. See section 26 STARTUP for
more details.
CAUTION: Performing a calibration may result in valve
movement and the inability to operate the valve until the
calibration is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated
before proceeding.
Stroke/Quick Calibration starts an automatic calibration of the
position feedback sensor. The stroke calibration determines
the closed (0%) and open (100%) positions of the valve and
gathers information about the response of the valve (such as
valve stroke time) in order to determine the gains. The gains
are then set automatically. After a stroke calibration, the
positioner is ready to control.
(ADC) that corresponds to 4 mA.) Then press the
►ACCEPT/QUICK-CAL button to set the value. Press the
▼Down button to move to “Set 100%”. Set the command
input current to 12 mA. (The display will show a high ADC to
correspond to 12 mA.) Again press the ►ACCEPT/QUICKCAL button to set the value. Select the ◄Back Button to
exit.
Signal At Closed = 20mA Example:
If the desired signal at closed is 20 mA, first set the Signal at
Closed DIP switch to 20 mA. Then perform a stroke
calibration by pressing the ►ACCEPT/QUICK-CAL button for
more than 3 seconds. This registers the DIP switch settings.
Then, in the Command Input Calibration menu, when the
display shows “Set 0%” it is expecting the lowest current
value. Set the input current to 4 mA. For “Set 100%”, it is
looking for the highest current value. Set the input current to
20 mA. After accepting theses values, the positioner will
interpret the 20 mA input as 0% valve position and the 4 mA
input as 100%.
Calibration Dates lists the most recent date of each
calibration.
NOTE: To calibrate the Analog Output, see section 31
MULTI-FUNCTION CARD.
8.3.5
►Configuration
►Positioner Tuning
►P-Gain Open
►I-Gain Open
►D-Gain Open
►P-Gain Close
►I-Gain Close
►D-Gain Close
►Open Stroke Time
►Close Stroke Time
►Minimum Open Time
►Minimum Close Time
►Gain Set
See section 26.4 Stroke Calibration for more details.
Pressure Sensor Calibration starts an automatic calibration of
the pressure sensors. The pressure sensors are calibrated
at the factory and typically will not need calibration. Use this
feature if new pressure sensors are installed. If desired,
configure the positioner to use the most recent pressure
calibration values after a factory reset. To do this, write a 1
to variable 104 using the Edit Variables page of the
ValveSight DTM.
Friction Calibration starts an automatic calculation of total
system friction. This also determines the spring rate and
other values critical to the Pro diagnostic functions.
NOTE: Friction forces may change quickly when a valve
is first placed into service.
Triple Calibration performs Stoke, Pressure and Friction
calibrations in one step.
Command Input Calibration is used to adjust the input range.
Set the lowest current (Set 0%) and the highest current (Set
100%) that will be used. The default input range is 4 to 20
mA. The “Set 0%” value must be lower than the “Set 100%
value.
Split Range Example:
A split range is easily configured. For example, a 4 to 12 mA
signal can be set to correspond to a 0 to 100% stroke. When
the display shows “Set 0%”, set the command input current
to 4 mA. (The display will show a low Analog to Digital Count
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Configuration (Positioner Tuning)
The Configuration – Positioner Tuning menu allows the user
to manually adjust individual tuning parameters. All tuning
parameters are automatically set to optimal values during
Quick-Cal. Typically a Quick-Cal is all that is needed for
positioner tuning. See section 26 STARTUP for more details.
CAUTION: Adjusting the tuning parameters will affect
the responsiveness of the valve and could cause rapid
changes to the valve position. Notify proper personnel that
the valve may stroke, and make sure the valve is properly
isolated before proceeding.
P-Gain, I-Gain and D-Gain are the proportional, integral, and
differential elements of the feedback algorithm. These gains
are different for the opening and closing directions because
typically responsiveness is different in each direction.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
NOTE: Only those with specific training in PID tuning
algorithms should attempt to adjust the tuning by manually
changing the PID values.
Open Stroke Time is the fastest time it took the valve to
stroke from 0% to 100% during Quick-Cal.
Close Stroke Time is the fastest time it took the valve to
stroke from 100% to 0% during Quick-Cal.
Minimum Open Time and Minimum Close Time (Speed
Limits) are used to prevent the valve from moving too quickly.
This can be used when the process is sensitive to rapid flow
or pressure changes. This shows the time (in seconds) that
the positioner will allow the valve to travel a full stroke. This
speed limit applies to smaller movements of the valve too.
For example, if the Minimum Open Time were set to 20
seconds, and the command was changed from 40% to 50%,
the positioner would move the valve at a constant rate, taking
2 seconds to complete the move. If the Minimum Close Time
was set to 0, and the command was changed from 50% back
to 40%, the positioner would make the move as quickly as
possible.
The default values are 0 seconds, meaning the positioner will
move the valve as quickly as possible.
Gain Set with Dual selected, applies independent gains in the
open and closing directions (default). With Single selected,
the most conservative gains found during calibration are
applied in both the open and closing directions.
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8.3.6
Configuration (Characterization)
►Configuration
►Characterization
►MaxFlo Linear
►MaxFlo Equal %
►Valdisk Linear
►Valdisk Equal %
►ShearStream Linear
►ShearStream Equal %
►Custom
The Configuration – Characterization menu allows the user to
change the characterization of the command. This allows a
better match between the input command and the actual fluid
flow through the valve. This feature is typically used with
valves that have non-linear flow characteristics.
The
positioner makes a correction by applying an adjustment to
the input command according to a characterization curve.
The table below shows the available characterization curve
options. Each point of the Custom curve can be adjusted
using the ValveSight DTM. See Figure 39.
To view the characterization curve options, set the
Characterization switch “Other” before performing a QuickCal. Otherwise, the only option available is “Linear”. If a
Quick-Cal is not possible, use the ValveSight DTM to select
the curve.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Table 19: Characteristic Curve Data
Final Command
Command
Input
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
75.0
80.0
85.0
90.0
95.0
100.0
Characterizatio
n DIP set to
“Linear”
Characterization
DIP set to
“Other”
Linear
MaxFlo
Linear
MaxFlo
=%
Valdisk
Linear
Valdisk
=%
ShearStream
Linear
ShearStream
=%
Custom
(Default)
(Linear =%)
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
55.00
60.00
65.00
70.00
75.00
80.00
85.00
90.00
95.00
100.00
0.00
6.50
11.60
16.20
20.50
24.60
28.50
32.40
36.20
40.00
43.80
47.60
51.50
55.50
59.50
63.80
68.20
73.00
78.40
85.00
100.00
0.00
1.00
2.00
3.00
4.40
5.80
7.40
9.30
11.20
13.50
16.10
19.10
22.40
26.20
30.60
35.70
41.70
48.90
57.70
69.20
100.00
0.00
13.00
20.00
26.25
32.10
37.50
42.60
47.40
51.80
56.00
60.00
63.60
67.20
70.60
73.90
77.20
81.30
84.00
87.80
92.10
100.00
0.00
4.00
6.00
7.80
9.30
11.50
14.00
16.50
19.30
22.50
26.00
30.00
34.70
39.60
45.10
51.30
57.80
64.80
72.50
81.30
100.00
0.00
25.00
35.00
44.00
50.20
55.50
60.20
64.30
68.00
71.50
74.70
77.70
80.50
83.20
85.90
88.40
90.80
93.20
95.50
97.80
100.00
0.00
8.00
14.00
17.00
21.00
24.00
27.50
31.50
35.50
39.50
43.90
48.10
52.80
57.40
62.40
67.50
72.90
78.60
84.70
91.20
100.00
0.00
0.62
1.35
2.22
3.25
4.47
5.91
7.63
9.66
12.07
14.92
18.31
22.32
27.08
32.71
39.40
47.32
56.71
67.84
81.03
100.00
point-by point. To modify the Custom curve, use the
ValveSight DTM.
100
Linear
90
MaxFlo
Linear
MaxFlo =%
Final Command
80
70
60
Valdisk
Linear
Valdisk =%
50
40
30
ShearStream
Linear
ShearStream
=%
Custom
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Command Input
Figure 39: Characterization Curves
Select the appropriate curve as required by the process
design.
Custom - Select Custom for a standard 30:1 linear equal
percent rangeability curve. The curve may be customized
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CAUTION: Changing the characterization curve may
cause the valve to move suddenly. Notify proper personnel
that the valve may stroke and if required, make sure the
valve is properly isolated before proceeding.
8.3.7
Configuration (Pressure Control)
►Configuration
►Pressure Control
►Window
The Configuration (Pressure Control) menu allows the user
to change the size of the pressure control window. This
window becomes active when the Valve Stability Switch is
set to “Hi”.
The Valve Stability Switch optimizes the
response for valves and actuators with high friction levels.
When set to “Hi”, it slightly slows the response and will
normally stop limit cycling that can occur on high friction
valves.
Window - When the position of the valve gets within the
pressure control window, the positioning algorithm will
change to pressure control. This means the pressures will
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
be held constant (locked), improving the stability of the valve
position.
8.3.8
Configuration (Soft Limits and Shutoff)
►Configuration
►Soft Limits & Shutoff
►High Soft Limit
►Low Soft Limit
►Upper Position Shutoff
►Lower Position Shutoff
Set Time and Date – Use the ▲Up and ▼Down buttons to
set the time and date. The format of the time and date is
displayed above the input fields.
8.3.10 Configuration (User Preferences)
►Configuration
►User Preferences
►All Units
1
►Pressure Units
1
►Force Units
►Temperature Units
1
►Air Flow Units
1
►Actuator Area Units
1
►Date Format
►Number Format
►LCD Orientation
Soft Limits allows the user to limit the movement of the valve.
Shutoff allows the user to tightly shut the valve with all
available force.
High Soft Limit and Low Soft Limit - This feature is used to
simulate physical blocks on the valve that restrict movement
past a set point. Once the Soft Limit is set, the positioner will
not attempt to move the valve position (final command)
beyond the set point, regardless of the analog or digital
command input signal.
CAUTION: Changing the Soft Limits may limit the
movement of the valve. The valve may not shut or open fully.
NOTE: Removing power to below 3.6 mA will still cause
the valve to move to the de-energized state regardless of the
Soft Limits.
Upper Position Shutoff and Lower Position Shutoff - This
feature, (also called Minimum Position Cutoff or MPC) is
used to tightly close or open the valve. It is used when a
tight seal is needed or when debris or friction may otherwise
interfere with complete closure.
When the valve is
commanded past the Shutoff points, the pilot relay will direct
full supply pressure to the appropriate port, applying all
available force to close (or open) the valve. The Shutoff
points apply to the Final Command.
CAUTION: Changing the Shutoff limits may cause the
valve to fully open or fully close after the command passes a
set limit.
Though Shutoff and Soft Limit features should not be used
together, if both are set, the greater of the two settings will
take precedence at the closed end; and the lesser of the two
settings will take precedence at the open end.
8.3.9
Configuration (Set Time and Date)
►Configuration
1
►Set Date & Time
1 Not available with 510+
The User Preferences menu allows the user to format how
information is displayed.
The following table shows the available options. By default
the positioner is set to show information in International
System (SI) units. To change all units to North American
(English), make the selection under All Units. Each selection
can also be changed individually.
Table 20: User Preference Options
International
North
Units/Format
System (SI)
American
(Default)
(English)
All Units
SI
North American
-
Pressure
bar
PSI
kg/cm2,
kPa
N
lbf
kg
degrees C
degrees F
-
Force
Temperature
Air Flow
slph
scfm
slpm,
Nm3/hr
Actuator Area
cm2
in2
-
Date Format
Day.Mon.Year
Mon/Day/Year
-
Comma
Decimal Point
-
Number
LCD Orientation – Use this selection to turn the turn the
display upside down (180 degrees). Use this feature when
the positioner is mounted upside down.
1 Not available with 510+
The positioner has an internal clock. The clock allows time
and date information to be stored with alarms and other
events. The clock does not account for daylight savings.
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Other
Options
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
8.3.11 Configuration (Burst Mode)
►Configuration
1
►Burst Mode
►On/Off
CAUTION: Performing a factory reset may result in the
inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and make
sure the valve is properly isolated.
8.3.14 Card 1 (or Card 2)
1 Not available with 510+
Burst Mode continuously transmits HART information.
Two slots are available for auxiliary cards. The MultiFunction Card (MFC) can be configured for analog output
(AO), Discrete Input (DI) and Discrete Output (DO).
On/Off – Use this feature to turn burst mode on and off.
8.3.12 Configuration (Positioner Revs)
►Configuration
► Positioner Revs
► SW Rev
► Bld Date
► Bld Time
► HW Rev
► CPU Rev
1
► HART Ver
► Card 1
► Card 2
NOTE: With Logix 510+, only Card 1 is available with
either AO or limited DO function.
►Card 1 (or Card 2)
►No Card
No Card – This is displayed when no card is present in the
slot.
1
►Aux Card 1 (or Card 2 )
►Multi-Function Card
►Not Configured
►Set as AO Card
►Set as DO Card
1
►Set as DI Card
►Config/Cal
►If Not Configured – “No Configuration Allowed”
►If AO
►Set 0%
►Set 100%
►If DO – “Use DTM”
1
►If DI
►Set to No Action
►Set to Trigger PST
►Set to Command Override
►Set Command Point
1 Not available with 510+
Positioner revisions are shown in this menu.
SW Rev –The revision of the embedded software.
Bld Date –The date of the embedded software build.
Bld Time –The time of day of the embedded software build.
HW Rev –The revision of the main board.
CPU Rev – The revision of the CPU.
HART Ver –The revision of the HART protocol (5, 6, or 7).
Card 1 – The software revision on Card 1.
Card 2 – The software revision on Card 2.
1 Not available with 510+
8.3.13 Configuration (Factory Reset)
►Configuration
► Factory Reset
At times, it may be convenient to reset all of the variables to
a default state. In this case, perform a Factory Reset.
Factory Reset – Use this feature to reset all variables to their
factory default state. All of the internal variables including
calibration will be reset to factory defaults. The positioner
must be re-calibrated after a factory reset. Tag names and
other user configured limits, alarm settings, and valve
information will also be lost and will need to be restored. A
factory reset will always reset the command source to analog
4-20 mA.
NOTE: Once the Multi-Function Card (MFC) type has
been configured, the type selection will still remain after a
factory reset.
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Multi-Function Card – This is displayed when a MultiFunction Card is present in the slot. Configuration options
follow. See section 31 MULTI-FUNCTION CARD for more
information. On entering the MFC menu, the menu item
below will be highlighted indicating the current MFC function.
To set the function, select the function and select Accept.
Not Configured – The MFC is not configured for any function
by default. The configuration must be set by using the
following functions.
Set as AO Card – Use this feature to set the MFC as an
analog output card.
Set as DO Card – Use this feature to set the MFC as a
discrete output card. A 510+ will only trigger off of the
Position Deviation alarm.
Set as DI Card – Use this feature to set the MFC as a
discrete input card.
Config/Cal – Use this feature to further configure the MFC.
The menu items below this level will change according to the
MFC configuration type selected.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
If Not Configured
No Configuration Allowed – Because the card type has not
been selected, no configuration options are available.
If Set As AO Card
Set 0% - Set the current (mA) that will correspond to the
0% (closed) valve position.
Set 100% - Set the current (mA) that will correspond to the
100% (open) valve position.
9 HART COMMUNICATION
The Logix 520MD+ series positioners use the HART
communication
protocol
specified
by
the
HART
Communication Foundation.
9.1
ValveSight DTM
NOTE: The AO calibration values are required to match
the “Signal At Closed” configuration switch on the positioner.
For example, if the switch is set to 4 mA, the “Set 0%” current
must be less than the “Set 100%” current.
Flowserve Corporation has produced a custom Device Type
Manager (DTM) for the Logix 520MD+ digital positioners to
support the ValveSight diagnostics platform.
If Set As DO Card
Use DTM – The DO is highly configurable. Use the
ValveSight DTM to set the function of the DO. When used
with the 510+, DO is not configurable and triggers only off
the Position Deviation alarm.
The DTM contains a high level “Dashboard” view of the
system health and status information. See Figure 40. It also
contains comprehensive user-friendly interfaces for control
and reporting of alarms, of-line and on-line diagnostic tests,
calibrations and system configurations.
If Set As DI Card
Set to No Action – Use this option if only an
acknowledgement of the DI state is desired.
Set to Trigger PST – Use this option to initiate a partial
stroke test when the DI state goes high.
Set to Command Override - Use this option to override the
analog or digital command input to move the valve to a set
position as long as the DI state remains high.
Set Command Point – Use this feature to set the override
position.
The position is a final command (not
characterized). Tight Shutoff settings and Soft Limits will
still apply.
The ValveSight DTM is available from a Flowserve
representative or from www.valvesight.com.
8.3.15 Language
► Language
►English
►German
►French
►Spanish
►Portuguese
►Russian
►Turkish
►Italian
Figure 40: ValveSight DTM Dashboard
9.2
HART 375/475 Handheld
Communicator
The display menu is available in several languages.
To navigate directly to the language menu, select the
following sequence of buttons: ▲Up , ▲Up, ►QUICK-CAL /
ACCEPT.
The Logix 520MD+ digital positioner supports and is
supported by the HART 375/475 Handheld Communicator.
The Device Description (DD) files can be obtained from the
HART Communication Foundation or from your Flowserve
representative.
9.3
Changing HART Versions
The Logix 520MD+ positioner comes standard with the
HART 6 communication protocol. Follow this procedure to
change to HART 5 or 7.
1
2
flowserve.com
42
Remove the outer cover.
Remove the inner cover by removing the 6 inner cover
retaining screws.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
CAUTION: Observe precautions
electrostatically sensitive devices.
3
4
for
handling
With a clean, non-conductive instrument, change the
position of DIP switch according to Figure 41: HART
DIP Switch.
After changing the DIP switch, the
positioner will immediately recognize the new HART
communication protocol.
Replace the covers.
9.4
Burst Mode
Burst Mode is available with a handheld device. In the
handheld, select the Burst Mode feature under the
Configuration Menu. Variables that are transmitted in burst
mode are shown in the table below.
Table 21: Default HART Parameters for Burst Mode
HART
Variable
Primary
Secondary
Tertiary
Quaternary
Data Description
4-20 Command (%)
Final Command (%)
Purchased with Standard Diagnostics:
Temperature (C)
Purchased with Advanced or Pro Diagnostics:
Supply Pressure (bar)
Valve Position (%)
NOTE: These variable assignments are reestablished
during a factory reset. A field upgrade will not change the
tertiary variable.
NOTE: The DTM will not function while the positioner is in
Burst Mode.
Figure 41: HART DIP Switch
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Table 15: Logix 500+ and ValveSight DTM Features
10 MODEL FEATURES
10.2 Valvesight DTM Diagnostic Levels
The DTM is not required for the positioner to function, but the
graphical capabilities of the DTM allow for a richer interface
and additional functionality, including viewing the dashboard,
charts, annunciator panel, test comparisons, and data logs
and printing reports.
The DTM also comes in two versions: “Basic” and
“Advanced”.
•
The “Basic” DTM provides an intuitive, easy-to-use user
interface to the positioner.
It includes calibration,
configuration, auxiliary card information and off-line
diagnostic tests. A dashboard gives a quick view of
important information.
•
The “Advanced” DTM provides a view of the positioner’s
full health analysis and interfaces to all of the
positioner’s “Pro” diagnostic functionality.
It is generally wise to use the Advanced DTM with the
Advanced and Pro positioners.
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Logix 522MD+ (Pro)
ValveSight Advanced
Logix 521MD+ (Advanced)
The Logix 520MD+ digital positioners have three levels of
diagnostics, “Standard”, “Advanced”, and “Pro”.
•
“Standard” diagnostics provide complete safety and
position-related diagnostics and data.
•
“Advanced” diagnostics provide additional pressure
data.
•
“Pro” diagnostics enhance the off-line tests with
additional force data, and provide powerful on-line
monitoring capabilities including friction, data logging
functions,
and
comprehensive
system
health
information.
Logix 520MD+ (Standard)
10.1 MD+ Positioner Diagnostic Levels
Positioner
Logix 510+
The Logix 520MD+ digital positioners include –
•
HART communication.
•
a DTM for viewing and controlling advanced features.
•
Additional diagnostics depending on the diagnostic level
chosen.
ValveSight Basic
The Logix 510+ digital positioner includes –
•
the QUICK-CAL feature that allows the positioner to be
calibrated at the push of one button.
•
limited diagnostics that monitor position, the pilot relay
and electronics.
•
an 8-DIP configuration switch for flexible set-up.
•
a 10-position gain selector switch is also included for
quick adjustments to responsiveness.
•
an LCD option provides a dashboard for viewing current
status and a complete menu for viewing and configuring
detailed settings.
•
up to two auxiliary cards for analog output (AO), discrete
input (DI) and discrete output (DO) functions.
DTM
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Hardware
Quick Calibration Button
3-LED Indicator
4-DIP Configuration
8-DIP Configuration
10-Position Gain Adjustment Switch
LCD Display Option
2 Auxiliary Cards (AO, DO, DI options)
X
X
X
1 Auxiliary Card (AO, DO optoins)
Limit Switch Option
Remote Mount Option
Humidity Sensor
Teminal Voltage < 10.0 V
X
Teminal Voltage < 6.0 V
SIL 3
Software
HART Communication
X
X
X
X
X
Off-Line Diagnostics
(Ramp Test, Step Test, HDRL, Partial
Stroke Test)
X
X
X
X
X
On-Line Data Monitor
(Monitor and Save Sensor Data)
X
X
X
X
X
Time Stamped Alarms
X
X
X
X
X
X
X
Pressure Sensor Data
(Supply, Port A, Port B)
X
On-Line Pro Diagnostics
(Force, Actuation, Pneumatic Leak,
Continuous Stroke Testing, etc.)
X
X
Health Evaluation
(Valve, Positioner, Actuator and
Control)
X
X
Training
(Determines Typical Behavior)
X
X
Data Logging
(High Speed Internal Data Capture)
X
X
Long-Term Trend Logging
(14 parameters over 15 years)
X
X
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
11 MULTI-FUNCTION CARD
The optional Multi-Function Card (MFC) can be configured to
act as an Analog Output, Discrete Output, or Discrete Input.
Up to two MFCs may be installed at one time.
NOTE: With Logix 510+, only Card 1 is available with
either AO or limited DO function.
MFCs are immune to RFI/EMI
certifications in section 21.
disturbances.
The MFC configured as an AO does not interfere with
positioner operation.
NOTE: The AO signal corresponds with the Signal At
Closed configuration switch setting. If the valve closes with
a 4 mA signal, the AO will show a 4 mA signal when closed.
If the valve closes with a 20 mA signal, the AO will show a 20
mA signal when closed.
See
11.2 Discrete Output (DO)
Table 22: Multi-Function Card CrossReferences
Information
Analog
Output
Specifications
Electronic
Connections
IOM Section
20.4
Analog Output
25.3
Multi-Function Card (AO,
Page
74
DO, DI)
93
Table 14: Auxiliary Card Status
94
Configuration
28.3.14
112
Certifications
21
Hazardous Area
Certifications
Status
Card 1 (or Card 2)
77
Use the Discrete Output function of the MFC to indicate a
variety of conditions such as alarms, warnings, position
limits, etc. Alarms that are masked will not cause the DO to
trip. The current is normally high, and drops low when one of
the pre-configured states occurs.
Configuration of the discrete output signal is done using the
ValveSight DTM or push-buttons. To change the MultiFunction Card to the Discrete Output function using the
buttons, see section 27.7.
With Logix 510+, the DO function may be selected using
push buttons, but will be limited to trip on the deviation alarm
only.
The MFC configured as a DO does not interfere with
positioner operation.
The MFC DO complies with DIN 19234 standard. For
specific current limits, see Table 14: Auxiliary Card Status.
11.3 Discrete Input (DI)
Use the Discrete Input function of the MFC to signal the
positioner to begin a partial stroke test, or move to a
predefined position as long as the signal remains.
Supply a low voltage (or no voltage) to indicate a normal
state. Raise the voltage to indicate the tripped state.
Configuration of the discrete output signal is done using the
display menu, a HART handheld Communicator, or the
ValveSight DTM .
Figure 42: Multi-Function Card
For specific voltage limits, see Table 14: Auxiliary Card
Status.
11.1 Analog Output (AO)
Configure the MFC as an Analog Output device to produce a
4-20 mA signal that corresponds to the position of the valve.
Output follows actual position of valve, including all failure
modes of positioner except loss of power. An output of < 1.0
mA is transmitted when the positioner loses power.
Calibration of the analog output signal is performed using the
display menu, a HART handheld communicator, or the
ValveSight DTM or push-buttons. To change the MultiFunction Card to the Analog Output function and calibrate
using the buttons, see section 27.7.
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NOTE: When 2 cards are configured as DI at the same
time, where both are configured to override the position
command, the card in slot 1 will take priority regardless of the
order in which the override commands are triggered.
CAUTION: During the use of the Discrete Input function,
the valve may stroke unexpectedly. Follow internal
procedures, ensuring that the configured movement of the
valve (performing a PST or moving to a set-point) is allowed.
Notify proper personnel that the valve will stroke, and make
sure the valve is properly isolated if required.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
12 V TO I CARD
13 LIMIT SWITCHES
The optional V to I card allows the use of a DC voltage
source (e.g. 24 Volts) to power the positioner. This is
typically for on/off emergency shut-down valves.
The
positioner is left in digital mode and the position is
commanded by the DTM or Hand-Held. The positioner can
receive commands via HART. Partial stroke tests can be
performed via HART commands. Reducing the voltage to
below 10 volts causes the positioner to shut down and go to
the fail safe position.
The V to I card is immune to RFI/EMI disturbances. See
certifications in section 21.
Section
Page
13.2 Limit Switch Types
V to I Card
Specification
s
20.8
Certifications
21
Hazardous Area
Certifications
77
25.4
95
Electronic
Connections
Safety
Function
Ordering
Limit
Switches
The Logix 500+ digital positioner can be equipped with a limit
switch unit. The unit has two main parts, the electrical switch
board and the vane. The switch board is connected to the
Inner cover. The vane connects to the feedback shaft which
extends through the positioner and moves with the valve.
The vane can hold a cam or ferromagnetic device. As the
shaft rotates, the pick-up switch LS1 or LS2 is activated. The
switching point can be adjusted.
Four types of Limit Switches can be used with the Logix
500+.
Table 23: V to I Card Cross-References
Information
13.1 Limit Switch Operation
V to I Board Specifications
V to I Card Connections
35
Integrity
39.2
Requirements for Safety
Spare Parts Kits
75
119
144
Mechanical switches are triggered by the use of a
mechanical cam and followers. See Figure 44: Limit
Switches.
Reed switches are triggered by a magnetic force.
physical contact occurs.
No
Inductive Slot switches are triggered when the sensor detects
a ferromagnetic vane inserted between the coils.
No
physical contact occurs.
Inductive switches are triggered when the sensor detects a
ferromagnetic vane approaching the coils in the switch. No
physical contact occurs.
Table 24: Limit Switch Cross-References
Information
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46
Page
Electronic
Specifications
20.7
Certifications
21
Hazardous Area
Certifications
77
25.5
96
Electronic
Connections
Install or Adjust
the Limit Switch
Ordering Limit
Switches
Figure 43: V to I Card
Section
Limit Switch Specifications
Limit Switches
75
36.4
Installing a Limit Switch
121
39.2
Spare Parts Kits
144
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
14 REMOTE MOUNT
14.1 Remote Mount Opereation
The remote mount option can be used where excessive
vibration or environmental factors prevent the placement of a
positioner directly on the valve.
The remote mount unit consists of just the feedback
mechanism enclosed in a sturdy container. This assembly is
mounted to the valve/actuator assembly. The actuator tubing
and feedback signals are routed some distance to the
positioner. Tubing is connected to the positioner. The
feedback signal wires are connected to a remote mount
board installed in the Logix 500+ positioner. See Figure
45: Remote Mount Board.
Table 25: Remote Mount Cross-References
Figure 44: Limit Switches
Information
Section
Page
Electronic
Specifications
20.6
Electronic
Connections
25.6
Remote Mount
97
39.2
Spare Parts Kits
144
38.1
Positioner Dimensions
141
Ordering a
Remote Mount
Board
Ordering a
Remote Mount
Device
Remote Mount Specifications
75
For more information on the remote mount option, see Logix
Remote Mount Option user instructions, FCD LGENIM0001.
Figure 45: Remote Mount Board
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
15 REQUIREMENTS FOR SAFETY
INTEGRITY
A typical** response time for the poppet relay to move to a
fail-safe state due to a sudden command change was found
to be 0.10 s at 22 C, 0.23 s at -40 C and .13 s at 85 C.
This section provides information and additional user
responsibilities in order to meet up to Safety Integrity Level 3
(SIL 3) per IEC 61508.
**Tests were with 60 PSI (4.1 bar) supply pressure.
The safety function of the positioner is to go to the fail-safe
state (vent air from the actuator) given a low power condition
to the 4 to 20 mA input terminal.
15.1 Fail Safe State
The fail safe state for a positioner with a three-way (SingleActing), Poppet Style Relay is when the relay valve is at less
than 5% of full stroke such that output port B (Y1) is venting.
The fail safe state for a positioner with a three-way (SingleActing), Spool Style Relay is when the relay valve is at less
than 5% of full stroke such that output port A (Labeled Y1) is
venting.
The fail safe state for a positioner with a four-way (DoubleActing), Spool Style Relay is when the relay valve is at less
than 5% of full stroke such that output port A (labeled Y1) is
venting and port A (labeled Y2) is open to supply pressure.
NOTE: The fail safe states above represent the fail safe state
of the positioner. The valve fail safe state may be different
depending on spring configuration and tubing. Ensure the
valve fail-safe state is appropriate for your application.
15.2 Safety Function
The Logix 520MD+ positioner moves to fail-safe state upon
the removal of analog input power (less than 3.6 mA)
NOTE: If using the V to I card, less than 10 Volts at the V to I
card terminals will produce a current less than 3.6 mA.
15.3 Fail Safe State Response Time
Test to find the final valve assembly response time to ensure
it meets application-specific requirements. Response times
will vary widely with actuator size, the use of boosters, stroke
length, starting position, fail-safe direction, tubing size, supply
pressure, and temperature. The air flow capacity also affects
the response time. See section 20.2 Pneumatic Output for
air flow capacity.
A typical* response time for the spool relay to move to a failsafe state due to a sudden command change was found to
be 0.06 seconds. (The response time was 0.50 s at -40C
and .35 s at 85C.)
NOTE: During the stroke calibration (Quick-Cal), valve stroke
times are measured and recorded in the positioner. To view
them, see tuning parameters on the positioner menu or in the
DTM.
15.4 Positioner Model Selection and
Specification
Any Logix 520MD+ positioner can be used for up to SIL 3
applications as stated above.
15.5 Installation
Ensure installation of the positioner is properly performed
according to this manual. Ensure tubing is configured to the
actuator so that the fail-safe state of the positioner matches
the desired fail-safe state of the valve.
15.6 Required Configuration Settings
The following user settable options must be properly
configured for the individual application in order to provide
the designed safety integrity for that application.
•
Calibrate the analog input (command). The fail safe state
of the valve must correspond to the analog input
command at less than 3.6 mA.
•
It is recommended to lock the local interface to prevent
unintended adjustments of the settings by an
unauthorized user.
15.7 Maximum Achievable SIL
The Flowserve 520MD+ Valve Positioner covered by this
safety manual is suitable for use in low demand mode of
operation Safety Integrity Functions (SIF) up to SIL 2 in
simplex (1oo1) and SIL 3 in redundant (1oo2) configurations.
The achieved SIL for a particular SIF needs to be verified by
PFDAVG calculation for the entire SIF including the failure
rates of the associated sensors and valves that are also part
of the SIF.
For details, contact your Flowserve representative for Failure
Mode, Effects, and Diagnostics Analysis (FMEDA) report
number 520+ is FLO 11-02-062 R001 for Logix 520MD+.
15.8 Reliability data
The time for the valve to move to from 50% to 0% under the
same conditions was found to be 0.22 s. Friction in this case
was 49.5 lbs (220 N).
For reliability data, a detailed Failure Mode, Effects, and
Diagnostics Analysis (FMEDA) report has been prepared and
is available from Flowserve with all failure rates and failure
modes for use in SIL verification. See FMEDA report number
FLO 11-02-062 R001 for Logix 520MD+.
*Tests were with a 25 inch double acting Mark 1 actuator, 0.75 inch (19 mm)
stroke, ambient temperature 74°F (23.3 °C), 60 PSI (4.1 bar) supply, quarter
inch tubing, starting at 50% open, moving to fully closed. Friction was
calculated with a bi-directional ramp test at a rate of 10 seconds/100%.
NOTE: The failure rates of the associated sensors, logic
solver, valves and actuators need to be accounted for in the
Safety Instrumented Function (SIF) level PFDAVG calculation.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
15.9 Lifetime limits
The expected lifetime of the Flowserve 520MD+ Positioner is
approximately 10 years. The reliability data listed the FMEDA
report is only valid for this period. The failure rates of the
Flowserve 520MD+ Valve Positioner may increase sometime
after this period. Reliability calculations based on the data
listed in the FMEDA report for lifetimes beyond 10 years may
yield results that are too optimistic, i.e. the calculated Safety
Integrity Level may not be achieved.
logic solver. If PST has been implemented then no additional
failure modes will be detected by the proof test. Failure
modes not covered include possible valve sticking in the
travel range not tested and leaking of the valve seat for fail
closed valves.
Steps for Proof Test
Step Action
1. Bypass the safety PLC or take other appropriate action to
avoid a false trip.
15.10 Proof Testing
2. Set the analog input command to less than 3.6 mA.
3. Ensure that the attached valve is fully in the safe state
(defined by application) and has moved to that position
within the allowed time. This will test for all failures that
could prevent the closure of the valve, including electronic
and mechanical faults, as well as valve faults.
The objective of proof testing when used in low demand
mode of operation is to detect failures within the Flowserve
520MD+ Valve Positioner and its associated sensors and
actuators that may not be detected by the normal selfdiagnostics. Of main concern are undetected failures that
prevent the safety instrumented function from performing its
intended function.
4. Inspect the 520MD+ Valve Positioner for any visible
damage or contamination and ensure the follower arm has
sufficient spring bias if applicable.
The frequency of the proof tests (or the proof test interval) is
to be determined in the reliability calculations for the safety
instrumented functions for which the Flowserve 520MD+
Valve Positioner is applied. The actual proof tests must be
performed at least as frequently as specified in the
calculation in order to maintain required safety integrity of the
safety instrumented function.
The following tests need to be specifically executed when a
proof test is performed. The results of the proof test need to
be documented and this documentation should be part of a
plant safety management system.
NOTE: Positioner failures that are detected should be
reported to Flowserve.
To perform the proof testing, an LCD display or HART
communicator such as a 375 Handheld or software such as
ValveSight DTM for Logix 520MD+ are required.
Steps for Partial Stroke Test (PST)
5. Check the errors generated by accessing the Alerts and
Alarms menu on the LCD or the Alarm Annunciator in the
DTM or other HART system using command 48.
6. Remove the bypass from the safety PLC or otherwise
restore normal operation.
When the tests listed above are executed, a proof test
coverage of 95% for the 520MD+ can be claimed if PST has
not been implemented as a diagnostic. To be considered as
a diagnostic the PST has to be implemented in a SIL rated
logic solver. If PST has been implemented, then no additional
failure modes will be detected by the proof test. Failure
modes not covered include possible leaking of the valve seat
for fail closed valves.
15.11 Maintenance
Follow routine maintenance. See section 36.1 Scheduled
Maintenance.
Step Action
1. Verify the control loop is ready for valve movement in the
amount set for the PST.
2. Execute the PST via the LCD menu, DD, or DTM.
3. View the results of the PST via the LCD menu, DD, or
DTM.
4. Check the errors generated by accessing the Alerts and
Alarms menu on the LCD menu, DD, or the Alarm
Annunciator in the DTM or other HART system using
command 48.
When the tests listed above are executed, a proof test
coverage of 95% for the 520MD+ can be claimed if PST has
not been implemented as a diagnostic. To be considered as
a diagnostic the PST has to be implemented in a SIL rated
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15.12 Repair and replacement
In the unlikely event that the Flowserve 520MD+ Valve
Positioner fails, the failure should be reported to Flowserve.
Replace faulty components according to section 36 of this
manual or return the positioner to Flowserve for service.
With experience and the right parts, repair times for any
component can be less than an hour, however a 24 hour
mean time to repair should be assumed for safety availability
calculations.
15.13 Training Requirements
Activities specified in this manual shall be performed by a
service technician trained in the installation and maintenance
of process instrumentation. See section 1.4 Qualified
Personnel.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
16 MAINTENANCE AND REPAIR
The kits listed in section 39.2 Spare Parts Kits can be
replaced by a technician trained in positioner function and
handling of static sensitive devices.
CAUTION: Depressurize the positioner before servicing.
CAUTION: Use eye protection.
CAUTION: When touching the circuit boards, observe
precautions for handling electrostatically sensitive devices.
16.1 Scheduled Maintenance
The supply gas filter(s) should be scheduled for regular
maintenance as required to maintain supply gas quality. If
contamination is found in the filter, the inside of the positioner
should be visually inspected for contamination.
If
contamination is found in the positioner, the positioner should
be replaced.
16.2 Required Tools and Equipment
The Logix 500+ digital positioner has modular components
that can be replaced using the tools shown in Figure 46.
Figure 46: Tools for Positioner Maintenance
The spool, block and manifold of the double acting relay can
be cleaned using acetone, a soft cotton cloth and cotton
swabs.
Connections to the limit switch are independent of other
connections to the positioner. See Figure 47.
For electrical connection diagrams, see Table 15: Limit
Switch Connections. For electrical specifications, see Table
7: Limit Switch Specifications.
DANGER: For units installed in hazardous areas special
installation cautions and procedures are required. The
installation of hazardous location electrical equipment must
comply with the procedures contained in the certificates of
conformance. Country specific regulations may apply.
Electrical safety is determined only by the power supply
device. (Positioner operation with limited voltage only).
Installation
1
Remove the outer cover.
2
Place the limit switch board (1) onto the Inner cover (2)
and secure it with 3 mounting screws (3).
3
Install vane assembly (4) and secure with 2 screws (5).
Adjusting Switches
1
Loosen the two screws on the vane (5).
2
Stroke the valve to the first switching position.
3
Set the switching point of the limit switch by adjusting
the lower vane for the lower switch (LS2).
4
Stroke the valve to the second switching position (LS1).
5
Set the switching point of the limit switch by adjusting
the vane for the upper switch.
6
Tighten the two screws on the vane (5).
7
Attach wires to terminals. .
8
Check the two switching points and repeat the
adjustment steps 1 to 6, if necessary.
9
Replace the outer cover.
16.3 Torque Specification for Screws
Table 26: Torque Specification for Screws
Outer Cover (4 Screws)
1.7 N-m (15 in-lb)
Limit Switch (3 Screws)
0.56 N-m (5 in-lb)
Limit Switch Vane (2 Screws)
0.34 N-m (3 in-lb)
Inner Cover (6 Screws)
0.34 N-m (3 in-lb)
LCD (4 Screws)
0.34 N-m (3 in-lb)
Main Board (2 Screws)
0.34 N-m (3 in-lb)
Pressure Board ( 6 Screws)
0.68 N-m (6 in-lb)
Double Acting Relay Block ( 2 Screws)
0.56 N-m (5 in-lb)
Double Acting Relay manifold (2 Screws)
0.56 N-m (5 in-lb)
Single Acting Relay (2 Screws)
0.56 N-m (5 in-lb)
Main PCB, MFC, V to I & Limit switch
terminal connections.
0.5 – 0.6 N-m (4-5 in-lb)
16.4 Installing a Limit Switch
The Logix 500+ digital positioner can be equipped with an
additional limit switch unit. Part of the switching unit attaches
to the feedback shaft. The sensors attach to the inner cover.
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50
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Figure 47: Limit Switch
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51
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
16.5 Replacing the LCD Board
16.6 Replacing an Auxiliary Card
The LCD board connects to the main board providing
additional functionality at the local user interface.
Up to two auxiliary cards can be installed at a time. Each
communicates independently to the main processor, though
only one cable is used to connect both cards. See Figure 50.
Removal
1
Make sure the valve is bypassed or in a safe condition.
2
Disconnect power to the positioner.
3
Remove the inner cover by removing the 6 inner cover
retaining screws. See Figure 48.
4
Unscrew the 4 screws holding the LCD Board in place.
See Figure 49.
5
Gently pry the locking feature on the connector with a
small flat screwdriver and separate the connector from
the main board. Be careful not to pull the cable, as this
may cause damage to the cable.
Installation
1
Connect the LCD Board to the Main Board using the
cable. Ensure the connector’s locking features engage.
2
Align the LCD Board with the 4 stand-offs on the main
board.
3
Screw the LCD Board to the 4 stand-offs.
4
Replace the Inner Cover.
NOTE: The LCD backlight may change brightness during
use. This is normal. The backlight uses any residual power
not used by other functions of the circuitry. When current
supply is low (4mA) the light will appear darker. When
current supply is high (20mA) the light will appear brighter.
Removal
1
Make sure the valve is bypassed or in a safe condition.
2
Disconnect the power to the positioner.
3
Remove the main cover.
4
Disconnect the two wire connection from the side of the
Card.
5
Unscrew and remove the auxiliary card clips.
6
Gently slide the card from the slot. (If two cards are
present, remove both cards from the slots.)
7
Gently pry the locking feature on the connector with a
small flat screwdriver and separate the connector from
the card. Be careful not to pull the cable, as this may
cause damage to the cable.
8
Replace the second card (if present) back into the slot.
9
Replace the auxiliary card clips.
Installation
1
Make sure the valve is bypassed or in a safe condition.
2
Disconnect the power to the unit.
3
Remove the main cover.
4
Unscrew and remove the auxiliary card clips.
5
If a card is present, gently slide the card from the slot to
access the internal connector.
6
Connect the card to the main board using the internal
connector cable.
Ensure the connector’s locking
features engage.
7
Gently slide the card(s) into the slot(s).
CAUTION: Ensure proper circuitry is used before
connecting cables to the auxiliary card. See section 25
ELECTRICAL CONNECTIONS for more information.
8
9
10
Route the external cable through the electrical conduit
ports in the base and connect the external cable to the
auxiliary card. See Figure 42: Multi-Function Card.
Replace the auxiliary card clips.
Reinstall the main cover.
Figure 50: Auxiliary Card
Figure 48: Inner Cover
Figure 49: LCD
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
16.7 Replacing a Main Board
Removal
1
Make sure the valve is bypassed or in a safe condition.
2
Remove the outer cover.
3
Disconnect the power to the positioner.
4
Remove the inner cover. See Figure 48: Inner Cover
above.
5
Disconnect the power cable to the main board.
6
Disconnect the auxiliary card cable if present. See
Figure 50: Auxiliary Card on page 124.
7
Disassemble the switch mechanism if present.
8
Remove the inner cover by removing the 6 retaining
screws. See Figure 48: Inner Cover.
9
Remove the screws from the main circuit board. See
Figure 51: Main Board Screws.
10 Gently lift the main board rotating the bottom up while
keeping the top in place.
11 Disconnect the pressure sensor board cable, the hall
sensor cable, the piezo cable and the feedback cable.
(Use a small flat screwdriver to pry the locking features
and carefully separate the connector from the main
board. Be careful not to pull the cable, as this may
cause damage to the cable.) See Figure 52.
2
3
Installation
1
Place the pressure sensor O-rings in the three holes.
2
Cover the O-rings with the pressure sensor board.
3
Insert the 6 screws. Tighten until the pressure sensor
board makes firm contact with the base.
Calibration
1
Initiate a Pressure or Triple Calibration from the LCD or
DTM.
2
To calibrate the supply pressure sensor 0 value,
disconnect the supply air. Go to Edit Variables. Write
the value from variable 74 (PS ADC Count) to variable
71. (PS ADC Count at 0 psi). Reconnect the supply air.
3
To keep the calibration values even after a Factory
Reset, write a 1 to Variable 104.
Figure 53: Pressure Sensor Board
Installation
1
Place the main board on the positioner base with the 420 mA input on the same side as the electronic access
ports.
2
Lift the main board rotating the bottom (configuration
switches) upwards while keeping the top in place.
3
Connect the pressure sensor board cable, the hall
sensor cable, and the feedback cable. Ensure the
connector’s locking features engage.
4
Place the main board on the positioner base, ensuring
the cables are clear of the feedback gears. Insert the
two retaining screws.
5
Replace the inner cover by inserting the 6 retaining
screws.
6
Calibrate.
Figure 51: Main Board Screws
Figure 52: Main Board Connectors
16.8 Replacing the Pressure Sensor
Board
Removal
1
Remove the main board.
See procedure above.
(Disconnecting the hall sensor and feedback cables is
not required.)
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Unscrew the 6 screws holding the pressure sensor
board in place. See Figure 53.
Remove the pressure sensor board.
53
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
16.9 Cleaning and Replacing a Double
Acting Pilot Relay
Removal
1
Remove the Main Board. See procedure above.
2
Fully loosen the 2 spool block screws. By squeezing
the two screws toward each other, grip the spool block
and pull it straight out. Take care to slide the spool
straight out of the spool seat to avoid bending the spool
or damaging the clip spring. The small clip spring
should remain attached to the spool.
3
Remove the first manifold gasket.
4
Remove the 2 manifold screws.
5
Remove the manifold assembly.
6
Remove the second manifold gasket and manifold Oring.
Cleaning
1
Using acetone and a cotton cloth wipe down the block
and manifold.
2
Use cotton swabs to reach inside air passage ways.
3
Dry components thoroughly.
Figure 55: Double Acting Relay Assembly
CAUTION: Follow precautions on acetone label and MSDS.
Figure 56: Clip Spring Orientation
Installation
1
Place the manifold gasket and manifold O-ring into the
base.
2
Place the manifold assembly.
3
Place the 2 manifold screws.
4
Place the manifold gasket.
5
Ensure the spool is oriented properly in the block.
Ensure the clip spring is oriented properly on the spool.
(See 126-Figure 56.) Holding the block level, slide the
spool/block/clip spring assembly onto the manifold
ensuring the proper placement of the spool and clip
spring into the piston slot and tighten the 2 spool block
screws.
6
Reassemble the main board and covers and calibrate.
16.10 Replacing a Single Acting Pilot Relay
Refer to Figure 57.
Removal
1
Remove the Main Board. See procedure above.
2
Remove the two relay assembly screws.
3
Remove the single acting relay.
4
Remove the supply plug screw and O-ring.
5
Remove the Manifold gasket.
Installation
1
Place the Manifold gasket.
2
Place the supply plug O-ring and screw.
3
Place the single acting relay.
4
Place the two relay assembly screws.
5
Reassemble the main board and covers and calibrate.
Figure 57: Single Acting Relay Assembly
Figure 54: Inserting the Double Acting Block Assembly
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
17 TROUBLESHOOTING
17.1 Troubleshooting Guide
Table 27: Troubleshooting Guide
Failure
Probable Cause
Corrective action
No LED is blinking.
1. Current source too low.
2. Voltage of current source is too low.
3. Incorrect wiring polarity.
1. Verify current source supplies at least 3,8 mA.
2. Verify voltage source supplies at least 10VDC.
3. Check wiring for correct polarity.
Erratic communications.
1. Current source bandwidth not
limited to 25Hz.
2. Maximum cable length or cable
impedance exceeded.
3. HART modem connected to PC RS232 port not receiving enough power
4. Interference with I.S. barrier.
5. Current source stripping (filtering)
HART signal.
1. Maximum allowable current source rate of change is
924 mA per second.
2. Check cable size, length and capacitance. See
Section 25 ELECTRICAL CONNECTIONS.
3. Verify laptop battery is not low.
4. Must use HART compatible I.S. barrier.
5. Use a 250Ω resistor and a 22 µF capacitor to create
a HART filter according to the following schematic.
Unit does not respond
to analog commands.
1. The positioner is in digital
command mode.
2. An error occurred during
calibration.
1.
2.
Valve position reading
is not what is
expected.
1. Stem position sensor mounting
is off 180 degrees.
2. Stroke not calibrated
3. Tight shutoff MPC (Minimum
position cutoff) is active.
4. Custom characterization or soft
stops are active.
1.
2.
3.
4.
Position is driven fully
open or closed and will
not respond to
command.
1.
2.
1.
2.
3.
3.
4.
5.
6.
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Stroke is not calibrated.
Inner-loop hall sensor is not
connected.
Wrong air action was entered in
software.
Actuator tubing is backward.
Electro-pneumatic
converter is
malfunctioning.
Control parameter inner-loop
offset is too high/low.
55
4.
5.
6.
Switch to analog command mode using the
procedure outlined in Section 27.3
Command Source Reset, use the
ValveSight DTM, or use a handheld
communicator.
Check Status Codes. Correct calibration
error. Recalibrate.
Reposition the sensor.
Perform a Stroke calibration (Quick-Cal).
Verify Tight Shutoff settings.
Verify custom characterization or soft-stop limits.
Perform stroke calibration (Quick-Cal)
Verify hardware connections.
Check ATO (Air-to-open) and ATC (Air-to-Close)
settings. Recalibrate using Quick-Cal to apply
settings.
Verify ATO/ATC actuator tubing.
Replace electro-pneumatic converter.
Adjust inner-loop and see if proper control
resumes.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Sticking or hunting
operation of the positioner
1.
2.
3.
4.
Contamination of the electropneumatic converter.
Control tuning parameters not
correct.
Packing friction is high.
Spool valve is corroded or dirty.
1.
2.
3.
4.
LCD backlight flickering or
dim.
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1.
The backlight uses any residual
1.
power not used by other functions of
the circuitry.
56
Check air supply for proper filtering and meeting
ISA specifications ISA-7.0.01.
Lower proportional gain settings.
Enable the stability DIP switch on the local
interface and recalibrate. If problem persists,
adjust pressure control window with handheld
communicator or ValveSight and recalibrate.
Disassemble and clean spool valve.
Fluctuations in the LCD backlight are normal. No
action required.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
17.2 Status Code Index
NOTE: Not all status codes are available with all positioner models.
Table 28: Status Code
Index
Cmd Frequency ALM
RYGY
Pilot Response WRN
YRGG
Stroke Cal Req
RGRG
Cmd Frequency WRN
YGYR
Pilot Travel WRN
YGGY
Stroke Shift
RGRY
CST Failed WRN
YGRY
Pneumatic Leak WRN
YRYR
Stroke Span Decrease
RGRY
Code
DI Cmd Override
GRGR
Position < ADC Range
RGGY
Stroke Span Increase
RGRY
A/O Cal in Prog
GRGY
Digital Cmd Mode
GGYY
Position > ADC Range
RGGY
Supply Press Hi WRN
YYGR
A/O Range Small
RGYR
Driver Module ALM
RRYR
Position Limit Alert
YGGG
Supply Press Lo ALM
RYYG
Actuation Ratio WRN
YYYY
Factory Reset State
RGRR
Position Range Small
RGGY
Supply Press Lo WRN
YYYG
Actuator Cycles WRN
YGGY
Feedback Cal Change
RGRY
Position Shift WRN
YYGY
Temperature High WRN
YYGG
Actuator Travel WRN
YGGY
Feedback Cal Error
RGGY
Power ON
GGGG
Temperature Low WRN
YYGG
Air Supply Humid WRN
YYRY
Feedback Linkage ALM
RRYG
Press Board Fail WRN
RYRY
Temperature WRN
YYGG
Air Supply Icing WRN
YYRR
Friction Cal in Prog
GRGY
Pressure Cal in Prog
GRGY
Tight Shut Off Mode
GGGY
Analog In < ADC Range
RGGG
Friction Cal Req
GYYY
Pressure Cal Req
GYYG
Valve Can't Move ALM
RYGG
Analog In > ADC Range
RGGG
Friction High ALM
RRGR
Psn Amplitude ALM
RYGR
Valve Can't Open ALM
RYGG
Analog In Cal Error
RGGG
Friction High WRN
YRGR
Psn Amplitude WRN
YGYY
Valve Can't Shut ALM
RYGG
Analog In Cal in Prog
GRGY
Friction Low ALM
RRGY
Psn Control ALM
RYGR
Valve Cycles WRN
YGGY
Analog In Range Small
RGGG
Friction Low WRN
YRGY
Psn Control WRN
YGYY
Valve Cycles WRN
YGGY
Backlash ALM
RRYY
ILO Time Out
RGGR
Psn Deviation ALM
RRRR
Valve Travel WRN
YGGY
Backlash WRN
YRYY
Initializing
GGYR
Psn Frequency ALM
RYGR
Bellows Cycles WRN
YGGY
Jog Cal Set 100% Pos
GRRR
Psn Frequency WRN
YGYY
Bellows Travel WRN
YGGY
Jog Cmd Mode
GRRY
Psn High Limit Alert
YGGG
Calibration in Progress
GRGY
Local Interface Off
GGYG
Psn Low Limit Alert
YGGG
Card 1 Error
RYYR
Low Battery WRN
YRRG
Psn Sensor Fail ALM
RYRG
Card 1 Fail WRN
RYYR
Main Board Fail WRN
RYRR
PST Failed WRN
YGRR
Card 1 No Loop Pwr
RYYR
Memory Error WRN
YYYR
PST Scheduled
GYYR
Card 1 WRN
RYYR
No Motion Time Out
RGYY
Setting ILO
GRGY
Card 2 Error
RYYY
Opened Too Far WRN
YYGY
Settle Time Out
RGYG
Card 2 Fail WRN
RYYY
Piezo Volts ALM
RRRY
Signature or PST
GRGG
Card 2 No Loop Pwr
RYYY
Piezo Volts High ALM
RRRY
Soft Stop Alert
GYGY
Card 2 WRN
RYYY
Piezo Volts High WRN
YRRY
Soft Stop High Alert
GYGY
Closed Too Far WRN
YYGY
Piezo Volts Low ALM
RRRY
Soft Stop Low Alert
GYGY
Cmd Amplitude ALM
RYGY
Piezo Volts Low WRN
YRRY
Software Error WRN
YYRG
Cmd Amplitude WRN
YGYR
Piezo Volts WRN
YRRY
Spring Fail WRN
YRRR
Cmd Control ALM
RYGY
Pilot Cycles WRN
YGGY
Squawk Mode
GGRR
YGYR
Pilot Response ALM
RRGG
Stroke Cal in Prog
GRGY
Status
Description
Cmd Control WRN
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
17.3 Status Code Descriptions
NOTE: Not all status codes are available with all
positioner models.
GGGG
●●●●
both the UP and DOWN buttons and briefly pressing the
QUICK-CAL/ACCEPT button.
GGYR
●●●●
INITIALIZING
POWER ON
Description: The positioner has powered up and is displaying
a blink sequence 3 times.
Description: No issues.
Possible Solutions: Wait for 3 blink sequences to complete.
Possible Solutions: Not applicable.
GGGY
●●●●
TIGHT SHUT OFF MODE
Description: (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.
GGYG
●●●●
LOCAL INTERFACE OFF
Description: 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.
GGYY
●●●●
DIGITAL COMMAND MODE
Description: 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 by holding
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GGRR
●●●●
SQUAWK MODE
Description: 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 turned off remotely.
3) More than one hour has passed since the command was
issued.
GYGY
●●●●
SOFT STOP HIGH LIMIT ALERT
SOFT STOP LOW LIMIT ALERT
Description: The Final Command would move the valve
beyond the user-set Soft Limit, but the internal software is
holding the position at the limit. The function is similar to a
mechanical limit stop except it is not active if the unit is unpowered.
Possible Solutions: If more travel is needed, reset the Soft
Limits. If not, adjust the Final Command signal back into the
specified range.
GYYG
●●●●
PRESSURE CALIBRATION REQUIRED
Description: 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.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
●●●●
GYYY
FRICTION CALIBRATION REQUIRED
Description: 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.
●●●●
GYYR
PARTIAL STROKE TEST SCHEDULED
Description: 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.
GRGG
●●●●
Description: 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 DTM.
GRRY
●●●●
JOG COMMAND MODE
Description: The positioner has been placed in a local
override mode where the valve can only be stroked using the
UP and DOWN buttons. 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 QUICK-CAL/ACCEPT button.
GRRR ●●●●
JOG CALIBRATION SET 100% POSITION
Description: During a jog calibration, the unit is waiting for the
user to manually adjust the valve position to the desired
100% open position.
SIGNATURE OR PARTIAL STROKE TEST IN PROGRESS
Description: 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.
GRGY
●●●●
STROKE CALIBRATION IN PROGRESS
SETTING INNER LOOP OFFSET
PRESSURE CALIBRATION IN PROGRESS
FRICTION CALIBRATION IN PROGRESS
ANALOG OUTPUT CALIBRATION IN PROGRESS
COMMAND INPUT CALIBRATION IN PROGRESS
Description: A calibration sequence is in progress. The inner
loop offset is an important step of the stroke calibration.
Possible Solutions: The calibration can be canceled from the
corresponding calibration page of the DTM, from the
handheld, or by briefly pressing the BACK button.
GRGR
●●●●
Possible Solutions: Use the Up and Down buttons on the
positioner to adjust the valve to the desired fully open
position. The QUICK-CAL/ACCEPT button to accept.
YGGG ●●●●
POSITION HIGH LIMIT ALERT
POSITION LOW LIMIT ALERT
Description: The position has reached or is exceeding a user
defined position limit. This is similar to a limit switch
indicator.
Possible Solutions: Set the limit to a higher (or lower) value if
more travel is needed, or adjust the command signal back in
the specified range.
YGGY ●●●●
ACTUATOR CYCLES WARNING
ACTUATOR TRAVEL WARNING
BELLOWS CYCLES WARNING
BELLOWS TRAVEL WARNING
PILOT RELAY CYCLES WARNING
PILOT RELAY TRAVEL WARNING
VALVE CYCLES WARNING
VALVE TRAVEL WARNING
DI COMMAND OVERRIDE
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Description: The cycle or travel limit of the valve, actuator,
bellows or pilot relay has been exceeded. Each cycle
represents two reversals of the direction of valve movement.
The cycle counting criterion and count limit (for the valve,
actuator and bellows) are set by the user to track the usage
of the valve assembly.
Possible Solutions: Follow routine procedures for
maintenance when the limit is reached. For example valve
inspection may include checking the packing tightness, and
checking linkages for wear, misalignment, and tightness.
Bellows inspection may include checking bellows for cracking
or leaking. Actuator inspection may include checking the
actuator seals and lubrication. Relay inspection may include
checking for high air consumption and signs of wear on the
spool. After maintenance, reset the travel accumulator.
YGYY ●●●●
POSITION AMPLITUDE WARNING
POSITION FREQUENCY WARNING
Description: The amplitude or frequency of the position signal
is above the warning limit. The positioner is controlling the
position of the valve with large or 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.
YGYR ●●●●
COMMAND AMPLITUDE WARNING
COMMAND FREQUENCY WARNING
Description: The amplitude or frequency of the command
signal is above the warning limit. This could mean the
control loop has larger swings or is oscillating faster than
desirable.
Possible Solutions: Verify the limits are set at an appropriate
level. Review the control loop parameters and equipment.
Adjust as necessary.
YGRY ●●●●
CONTINUOUS STROKE TEST FAILED WARNING
Description: During the continuous stroke test, the valve did
not move after 5 consecutive attempts. 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.
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YGRR ●●●●
PARTIAL STROKE TEST FAILED WARNING
Description: Measured times or forces during the last partial
stroke test did not pass the criteria set by the user. 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.
YYGG ●●●●
TEMPERATURE HIGH WARNING
TEMPERATURE LOW WARNING
Description: The temperature of the internal electronics has
exceeded the manufacturer set limits of -40°C (-40°F) to
85°C (176°F). Low temperature may inhibit responsiveness
and accuracy. 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. Heat the
positioner if needed. If the temperature reading is in error,
replace the main board.
YYGY ●●●●
VALVE CLOSED TOO FAR WARNING
VALVE OPENED TOO FAR WARNING
Description: While the valve was in use, it closed or 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.
YYGR ●●●●
SUPPLY PRESSURE HIGH WARNING
Description: The supply pressure is above the user set
warning limit. 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.
YYYG ●●●●
SUPPLY PRESSURE LOW WARNING
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Description: The supply pressure is below the user set
warning limit. 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).
YYRR ●●●●
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.
Description: 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.
YYYY ●●●●
YRGG ●●●●
ACTUATION RATIO WARNING
Description: The force required to control the system is close
to the maximum available force. 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.
YYYR ●●●●
MEMORY ERROR WARNING
Description: 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 WARNING AIR SUPPLY ICING
WARNING
Possible Solutions: Ensure supply gas is clean and dry.
Check and clean the regulator filter.
PILOT RELAY RESPONSE WARNING
Description: The pilot relay is sticking or slow to respond.
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.
YRGY ●●●●
FRICTION LOW WARNING
SOFTWARE ERROR WARNING
Description: The friction has passed below the user set limit.
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.
Description: There has been a watch dog time out, stack
overflow warning, or CPU usage warning.
Possible Solutions: Check for packing leak.
replace the valve packing.
Possible Solutions: If the problem persists, perform a factory
reset. If it still persists, reprogram or replace the main board.
YRGR ●●●●
YYRG ●●●●
Tighten or
FRICTION HIGH WARNING
YYRY ●●●●
AIR SUPPLY HUMID WARNING
Description: The supply gas has high relative humidity which
can lead to condensation on electronic components and
failure of electronic functions.
Description: The valve and actuator friction has passed the
user set limit. 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: Ensure supply gas is clean and dry.
Check and clean the regulator filter.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
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.
This may prevent the proper failure position upon loss of
signal/power. This condition may occur briefly on an air-toclose valve that is held for long periods of time in the closed
position, or an air-to-open valve held in the open position.
YRYY ●●●●
YRRR ●●●●
BACKLASH WARNING
SPRING UNABLE TO FAIL SAFE WARNING
Description: The amount of detected backlash has passed
the user set warning limit. This may affect valve stability.
Description: Upon loss of air supply, the valve may not move
to the fail-safe position. 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: Check the stem and actuator for loose
components.
YRYR ●●●●
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.
PNEUMATIC LEAK WARNING
Possible Solutions: Repair or replace actuator spring. Check
for high friction. Reduce process load.
Description: The positioner has detected a leak in the
actuation assembly. Leakage from the actuator can cause
decreased
responsiveness
and
excessive
air/gas
consumption.
RGGG ●●●●
Possible Solutions: Repair pneumatic leaks at the tubing
junctions and actuator seals.
Check spool valve for
excessive wear.
YRRG ●●●●
LOW BATTERY WARNING
Description: The battery for the real time clock is low. 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.
YRRY ●●●●
PIEZO VOLTAGE HIGH WARNING
PIEZO VOLTAGE LOW WARNING
Description: If the voltage to the piezo is too high, 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. If the
voltage to the piezo is too low, the piezo may be damaged.
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COMMAND INPUT BELOW ADC RANGE
COMMAND INPUT ABOVE ADC RANGE
COMMAND INPUT RANGE TOO SMALL
Description: During Command Loop Calibration, the signal
was out of the Analog to Digital Converter (ADC) range, or
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 and between 10 and 4085 ADC.
Possible Solutions: Recalibrate making sure to use valid
command signal values.
RGGY ●●●●
POSITION RANGE TOO SMALL
POSITION SENSOR ABOVE ADC RANGE
POSITION SENSOR BELOW ADC RANGE
Description: During calibration, the range of motion of the
position feedback arm was too small for optimum
performance or the feedback sensor moved beyond its range
of operation.
Possible Solutions: Check for loose linkages. Adjust the
positioner mounting. Adjust the feedback pin back into range.
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 QUICK-CAL/ACCEPT button
acknowledges a small range and the positioner will operate
using the short stroke calibration if otherwise a good
calibration.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
RGGR ●●●●
INNER LOOP OFFSET TIME OUT
Description: 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.
RGYG ●●●●
SETTLE TIME OUT
Description: 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.
RGYY ●●●●
NO MOTION TIME OUT
Description: 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.
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.
RGYR ●●●●
ANALOG OUTPUT RANGE TOO SMALL
Description: 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.
RGRG ●●●●
STROKE CALIBRATION REQUIRED
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Description: 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 failsafe position until a
calibration is successfully completed.
Possible Solutions: Perform a Stroke Calibration (QUICKCAL) 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.
RGRY ●●●●
STROKE SHIFT
Description: 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.
STROKE SPAN DECREASE
Description: 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.
STROKE SPAN INCREASE
Description: The 0% and 100% valve positions are farther
apart compared to the last stroke calibration. This could
indicate seat wear.
Possible Solutions: Ensure the feedback linkage is not bent
and the positioner is mounted securely.
If the feedback
potentiometer is over-rotated, repeat the stroke calibration
until the Stroke Shift error is no longer present. Inspect valve
or schedule valve for inspection. This notification can be
cleared by briefly pressing the QUICK-CAL/ACCEPT button.
RGRR ●●●●
FACTORY RESET STATE
Description: The positioner is in factory reset state.
Calibration is required to enable control.
Possible Solutions: Perform a Stroke Calibration (QUICKCAL).
RYGG ●●●●
VALVE CAN'T OPEN ALARM
VALVE CAN'T SHUT ALARM
Description: Pressure has been applied (or removed) to open
or shut the valve, but the valve is not moving. 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
63
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
external or internal mechanical obstruction, loosen the
packing, clean the stem, repair or replace the actuator, repair
the valve if galling is suspected.
Description: Auxiliary Card 2 has no loop current.
RYGY ●●●●
Possible Solutions: MFC: Check auxiliary loop wiring and
ensure adequate compliance voltage and current. Check
auxiliary card connection to the main board. Replace card if
condition persists.
COMMAND AMPLITUDE ALARM
COMMAND FREQUENCY ALARM
Description: The amplitude or frequency of the command
signal is above the alarm limit. This could mean the control
loop has larger or faster swings than desirable.
RYYR ●●●●
AUX CARD 1 ERROR
Description: Auxiliary Card 1 has an electrical problem.
Possible Solutions: Verify the limits are set at an appropriate
level. Review the control loop parameters and equipment.
Adjust as necessary.
AUX CARD 1 FAILURE WARNING
Description: Auxiliary Card 1 is not communicating.
RYGR ●●●●
AUX CARD 1 NO LOOP POWER
POSITION AMPLITUDE ALARM
POSITION FREQUENCY ALARM
Description: Auxiliary Card 1 has no loop current.
Description: The amplitude or frequency of the position signal
is above the alarm limit. The positioner is controlling the
position of the valve with large or rapid corrections.
Possible Solutions: MFC: Check auxiliary loop wiring and
ensure adequate compliance voltage and current. Check
auxiliary card connection to the main board. Replace card if
condition persists.
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.
RYRG ●●●●
POSITION SENSOR FAILURE ALARM
RYYG ●●●●
SUPPLY PRESSURE LOW ALARM
Description: The feedback arm may be disconnected from
the valve assembly or the sensor has failed.
Description: The supply pressure is below the user set
warning limit. 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: Check the feedback arm linkage.
Recalibrate. If the problem persists return the unit for repair.
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.
PRESSURE SENSOR BOARD FAILURE WARNING
RYYY ●●●●
AUX CARD 2 ERROR
RYRY ●●●●
Description: 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.
RYRR ●●●●
MAIN BOARD ELECTRONIC FAILURE WARNING
Description: Auxiliary Card 2 has an electrical problem.
AUX CARD 2 FAILURE WARNING
Description: Auxiliary Card 2 is not communicating.
AUX CARD 2 NO LOOP POWER
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Description: 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.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Possible Solutions: Fix broken linkage or adjust feedback
arm until full motion is within the range of the POT.
RRGG ●●●●
PILOT RELAY RESPONSE ALARM
Description: The pilot relay is sticking or extremely slow to
respond. This affects the responsiveness, increases the
chance of limit cycling and excessive air consumption. The
pilot relay consists of the driver module assembly with piezo
(I-P relay) which is coupled to the spool valve or poppet.
Delayed response can be caused by a partially clogged piezo
or debris, oil, corrosion, or ice on the spool, or low supply
pressure.
RRYY ●●●●
BACKLASH ALARM
Description: The amount of detected backlash has passed
the user set alarm limit. This may affect valve stability.
Possible Solutions: Check the stem and actuator for loose
components.
Possible Solutions: Check response of the valve. If OK,
adjust Pilot Relay Response limits. Check the supply
pressure.
Check the spool or poppet for debris, oil,
corrosion, ice on the spool. Clean or replace the spool
assembly. Replace the piezo or driver module assembly.
Maintain a clean, water-free air/gas supply.
RRYR ●●●●
RRGY ●●●●
Possible Solutions: Check the internal wiring connections.
Replace the pilot relay.
DRIVER MODULE ALARM
Description: The pilot relay can't open, the pilot relay can't
shut, or the Hall sensor circuit has failed.
FRICTION LOW ALARM
Description: The friction has passed below the user set limit.
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 a packing leak.
replace the valve packing.
Tighten or
RRRY ●●●●
PIEZO VOLTAGE HIGH ALARM
Description: The voltage driving the piezo is above the alarm
limit. This could indicate an error with the relay or the main
board. The positioner may still be functioning, but have
reduced performance under some circumstances.
RRGR ●●●●
PIEZO VOLTAGE LOW ALARM
FRICTION HIGH ALARM
Description: The voltage to the piezo is too low. 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.
Description: The valve and actuator friction has passed the
user set limit. 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.
RRYG ●●●●
FEEDBACK LINKAGE ALARM
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.
RRRR ●●●●
POSITION DEVIATION ALARM
Description: The difference between the command and the
actual position has been greater than the user-set limit for
longer than a user-set 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.
Description: The feedback linkage is broken or the position
feedback POT is out of range.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
17.4 Help From Flowserve
17.4.1 Phone Support
Over-the-phone troubleshooting is often available for
positioner issues. Should your positioner be experiencing
problems, or if you have questions that are not answered by
this manual, feel free to call your local sales representative or
a Quick Response Center (QRC). See the back cover of this
manual for contact details.
17.4.2 Returning the 500+ Positioner for Service
If troubleshooting is unable to solve the problem, the unit
may be returned. Please follow the steps below.
1. Request a Return Goods Authorization (RGA) form.
An RGA form will be e-mailed to you to accompany
the unit being returned.
2. Remove all fittings, brackets, filters, feedback arms,
etc. from the unit before packaging.
3. If the unit was operated with a gas other than clean
air, please include the related MSDS with the return.
4. Complete the RGA form. Write any specific issues
with the positioner you would like us to evaluate.
Please include the customer name and contact
information
5. When packaging, please secure the unit in a
method that will insure it will reach our facility
undamaged (the weight of positioners will often
settle through packing peanuts and pop large air
packets).
6. Please insert a copy of the completed RGA form
inside the package and write the RGA number on
the outside of the package. Send the unit to the
address at the bottom of the form.
If the cause of the unit failure is found to be a manufacturing
defect and the unit is within the warranty period (18 months
from manufacture) it will be repaired free of charge. If no
problem is found with the unit and the unit is still under
warranty, a fee for the evaluation will be required. If the
cause of the unit failure is not covered under the warranty a
fee will be charged for the evaluation and a quote will be
provided showing the cost of the repair. If the customer
decides to purchase a new positioner, the evaluation fee will
be waved.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
18 POSITIONER DIMENSIONS
18.1 Positioner Dimensions
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
19 HOW TO ORDER
19.1 Positioners
Table 29: 500+ Positioner Configurations
Description
Logix 500+ Series
Analog Only; 8-DIP Set-Up with LCD Option; Limited Diagnostics
Code
Example
5
5
10+
HART; 8-DIP Set-Up with LCD Option; Standard (Basic Functionality) 1, 2
20MD+
HART; 8-DIP Set-Up with LCD Option; Advanced (With Pressure Sensing) 1, 2
21MD+
HART; 8-DIP Set-Up with LCD Option; Pro (With Full ValveSight Diagnostics) 1
22MD+
General Purpose
22MD+
Selection
Base Model
Communication
and
Diagnostics
14
Intrinsically Safe, North America, IP66, Class I, Div 1 Groups A-D T4/T6
Intrinsically Safe, North America, IP66, Class I, Zone 0, AEx ia IIC T4/T6 Ga
Intrinsically Safe, North America IP66, Class I, Zone 0, Ex ia IIC T4/T6 Ga
Non-Incendive, North America, IP65, Class I, Div 2, Groups A-D T4/T6
Non-Sparking, North America, IP65, Class I, Zone 2 AEx nA IIC T4/T6 Gc
Non-Sparking, North America, IP65, Class I, Zone 2 Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to
+45°C)
Dust Ignition, North America, IP65, Zone 21, AEx tb IIIC T100°C Db (Ta=-52°C to +85°C) NEMA Type 4X
37
IECEx FMG 12.0001X, IP66, Ex ia IIC T4/T6 Ga
IECEx FMG 12.0001X, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
IECEx FMG 12.0001X, IP65, Ex tb IIIC T100°C Db (Ta=-52°C to +85°C)
37
ATEX FM15ATEX0002X II 3 G, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 1 G, IP66, Ex ia IIC T4/T6 Ga ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
Certifications
ATEX FM12ATEX0009X II 2 D, IP65, Ex tb IIIC T 100°C Db (Ta=-52°C to +85°C)
Intrinsically Safe, North America, IP66, Class I, Div 1 Groups A-D T4/T6
Intrinsically Safe, North America, IP66, Class I, Zone 0, AEx ia IIC T4/T6 Ga
Intrinsically Safe, North America IP66, Class I, Zone 0, Ex ia IIC T4/T6 Ga
Non-Incendive, North America, IP65, Class I, Div 2, Groups A-D T4/T6
Non-Sparking, North America, IP65, Class I, Zone 2 AEx nA IIC T4/T6 Gc
Non-Sparking, North America, IP65, Class I, Zone 2 Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to
+45°C)
Dust Ignition, North America, IP65, Zone 21, AEx tb IIIC T100°C Db (Ta=-52°C to +85°C) NEMA Type 4X
42 8
ATEX FM15ATEX0002X II 3 G, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 1 G, IP66, Ex ia IIC T4/T6 Ga ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 2 D, IP65, Ex tb IIIC T 100°C Db (Ta=-52°C to +85°C)
TR CU, Russia, IP66, Ex ia IIC T4/T6 (510+: [email protected]=-52°C to +85°C, [email protected]=-52°C to +45°C)
TR CU, Russia, IP66, Ex ia IIC T4/T6 (520MD+ Double Acting Relay: [email protected]=-56°C to +85°C, [email protected]=-56°C to +45°C)
44
TR CU, Russia, IP66, Ex ia IIC T4/T6 (520MD+ Single Acting Relay: [email protected]=-63°C to +85°C, [email protected]=-63°C to +45°C)
2
Mounting: M8 x 1.25, Pneumatics: G1/4", Conduit: M20 x 1.5, Vents G1/4"
3
D - 316 Stainless Steel Shaft (Valtek Standard)
D
NAMUR - 316 Stainless Steel Shaft (VDI/VDE 3845)
R
Three-way (Single-Acting), Poppet Style Relay
1
Three-way (Single-Acting), Spool Style Relay
2
Four-way (Double-Acting), Spool Style Relay
3
No Indicator
0
Flat Indicator
F
Domed Indicator
D
No special options
0
Chinese Configuration6
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68
0
Special Options
1
Mounting: M8 x 1.25, Pneumatics: 1/4" NPTF, Conduit: M20 x 1.5, Vents 1/4" NPTF
F
Position Indicator
A
Mounting: 5/16" 18 UNC, Pneumatics: 1/4" NPTF, Conduit: 1/2" NPTF, Vents 1/4" NPTF
1
Action
B
Aluminum - Black Base with Black Cover (Accord)
D
Feedback Shaft
Y
Aluminum - Black Base with Black Cover (Automax)
1
Threaded
Connections
W
Aluminum - Black Base with Yellow Cover
W
Housing
-
Positioner Configuration
Aluminum - Black Base with White Cover
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Selection
No Manifold
0
Gauge Manifold - Aluminum (required for gauges)
GM
0
Nickel Plated with Brass Internals, psi (bar/kPa)
1
Nickel Plated with Brass Internals. psi (kg/cm2 )
2
SS with SS Internals. psi (bar/kPa)
3
SS with SS Internals. psi (kg/cm2 )
4
UCC Press Test Plug, 1/8" NPT
A
Valve, Tank, Schrader 645A
B
0
LCD
1
Slot 1 - No Card
0
Slot 1 - Multi-Function Card 3,7
Slot 1 - V to I Card
1
6
2
0
Slot 2 - Multi-Function Card 3,6
1
No Switches
0
Mechanical Limit Switch 4
1
Reed Switch
2
3
Slot Type NAMUR Sensor, P+F SJ2 S1N 8
4
Slot Type NAMUR Sensor, P+F SJ2 SN 8
5
Namur V3 type proximity switch, P+F NBB2-V3-E2 4
6
Remote Mount Feedback 5
7
HART 6 standard. Can be configured as HART 5 or HART 7 in the field.
Can be upgraded to 521MD+ or 522 MD+ in the field.
Can be configured as Analog Output, Discrete Output or Discrete Input in the field. Slot 2 available only after slot 1 is filled
Only available for general purpose (certification option 14).
Includes adapter board (installed in the positioner) and the low profile remote mount unit (which may be shipped separately).
Only available with the 520MD+ model.
MFC for 510+ in slot 1 only. This MFC may be configured as AO or DO with limited functionality. Only available with LCD option.
Certification code 42 should only be used when limit switch codes 3,4 and 5 are selected.
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69
3
Namur V3 type proximity switch, P+F NJ2-V3-N 8
0
Slot 2 - No Card
1
2
3
4
5
6
7
8
1
Limit Switches or
Remote Mount
No LCD
1
Auxiliary Card Slot
2
-
Auxiliary Card Slot
1
1
No Gauges
Optional Electronic Add-Ins
Display
Example
GM
Pressure Gauges
Code
-
Manifold
Description
Optional Mechanical Add-Ins
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
19.2 Spare Parts Kits
Table 29: Spare Parts Kits
Ref.
Description
Part-no.
Cover:
Yellow
Black
White
283450.999.000
283451.999.000
283452.999.000
8
Boards:
510+ Main
520MD+ Main
LCD
Pressure Sensor
Multi-Function Card (Slot1)
Multi-Function Card (Slot2)
V to I Card (Slot 1)
331625.999.000
283453.999.000
283454.999.000
283455.999.000
283456.999.000
314887.999.000
331725.999.000
10
11
12
Pilot Relay Module:
Single Acting (Poppet)
Double or Single Acting (Spool)
Pneumatic Restrictor
283458.999.000
283459.999.000
291750.999.000
13
14
15
16
17
18
Limit Switches:
Mechanical Switch*
Reed Switch
P&F SJ2-SN*
P&F SJ2-S1N*
P&F NJ2-V3-N*
P&F NBB2-V3-2N*
291751.999.000
291752.999.000
291753.999.000
291754.999.000
291755.999.000
291755.999.000
1
2
3
4
5
6
7
Figure 58: Spare Parts Kits
* Only available for general purpose (certification option 14).
NOTE: Multi-function cards and limit switches may be
purchased as upgrades and installed after the initial
purchase of the positioner. In this case, the positioner label
must be modified to reflect the change.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Gage Blocks,
a stem position sensor provides a
measurement of the stem movement. The Final Command is
compared against the Stem Position. If any deviation exists,
the control algorithm sends a signal to the inner-loop control
to move the relay in a direction, depending upon the
deviation. The inner-loop then quickly adjusts the spool
position. The actuator pressures change and the stem
begins to move. The stem movement reduces the deviation
between Final Command and Stem Position. This process
continues until the deviation goes to zero.
19.3 Inner Loop
The inner-loop controls the position of the relay valve by
means of a driver module. The driver module consists of a
temperature-compensated hall-effect sensor and a Piezo
valve pressure modulator.
The Piezo valve pressure
modulator controls the air pressure under a diaphragm by
means of a Piezo beam bender. The Piezo beam deflects in
response to an applied voltage from the inner-loop
electronics. As the voltage to the Piezo valve increases, the
Piezo beam bends, closing off against a nozzle causing the
pressure under the diaphragm to increase. As the pressure
under the diaphragm increases or decreases, the spool or
poppet valve moves up or down respectively. The Hall Effect
sensor transmits the position of the spool or poppet back to
the inner-loop electronics for control purposes.
•
•
•
Valve has zero deviation with a present input signal of
12 mA.
Loop calibration: 4 mA = 0% command, 20 mA = 100%
command.
Actuator is tubed and positioner is configured air-toopen.
Given these conditions, 12 mA represents a Command
source of 50 percent. Custom characterization is disabled so
the command source is passed 1:1 to the Final Command.
Since zero deviation exists, the stem position is also at 50
percent. With the stem at the desired position, the spool
valve will be at a middle position that balances the pressures
above and below the piston in the actuator. This is commonly
called the null or balanced spool position.
Assume the input signal changes from 12 mA to 16 mA. The
positioner sees this as a command source of 75 percent.
With Linear characterization, the Final Command becomes
75 percent. Deviation is the difference between Final
Command and Stem Position: Deviation = 75% - 50% =
+25%, where 50 percent is the present stem position. With
this positive deviation, the control algorithm sends a signal to
move the spool up from its present position. As the spool
moves, the supply air is applied to the bottom of the actuator
and air is exhausted from the top of the actuator. This new
pressure differential causes the stem to start moving towards
the desired position of 75 percent. As the stem moves, the
Deviation begins to decrease. The control algorithm begins to
reduce the spool opening. This process continues until the
Deviation goes to zero. At this point, the spool will be back in
its null or balanced position. Stem movement will stop and
the desired stem position is now achieved.
19.5 Inner Loop Offset
The position of the spool (or poppet) at which the pressures
are balanced, holding the valve position in a steady state, is
called the Inner Loop Offset. The controlling algorithm uses
this value as a reference in determining the Piezo voltage.
This parameter is important for proper control and is
optimized and set automatically during stroke calibration.
Figure 2: Principles of Operation of Logix 500+
19.4 Detailed Sequence
Operations
of
Positioner
A more detailed example explains the control function. See
Figure 3. Assume the unit is configured as follows:
•
•
•
Unit is in Analog command source.
Custom characterization is
disabled
characterization is Linear).
No soft limits enabled. No MPC set.
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(therefore
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
10
1
11
12
2
13
14
3
21
4
22
5
23
6
24
7
25
26
8
9
15
1 - Piezo Assembly
2 - Block
3 - Spool
4 - Regulator Assembly
5 - Piezo Cable
6 - Hall Sensor Cable
7 - Auxiliary Card
8 - Main Board
9 - 4-20 mA Input
16
17
10- Hall Sensor Assembly
11- Exhaust
12- Port B
13- Supply Pressure
14- Pressure Sensor Board
18
19
20
15- Supply In
16- Pressure Sensor Cable
17- Feedback Cable
18- Exhaust
19- Port A
20- Feedback Potentiometer
Figure 3: Logix 500+ Digital Positioner Schematic
(Double Acting Relay - Air To Open)
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73
21- Actuator Housing
22- Spring
23- Piston
24- Stem
25- Yoke
26- Take-Off Arm
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
20 SPECIFICATIONS
20.3 Air Supply
20.1 Input Signal
Table 3: Air Supply
Table 1: Input Signal
Positioner Alone
or with
Multi-Function Card
Power Supply
Two-wire, 4-20 mA
10.0 VDC plus line losses (Logix 520MD+)
6.0 VDC plus line losses (Logix 510+)
Input Signal Range
4 - 20 mA
Compliance Voltage
10.0 VDC @ 20 mA (Logix 520MD+)
6.0 VDC @ 20 mA (Logix 510+)
Effective Resistance
500 Ω @ 20 mA Typical
Minimum Input
Pressure
1.5 Bar (22 PSI)
Maximum Input
Pressure
Single Acting Relay – 6.2 Bar (90 PSI)
Double Acting Relay – 10.3 Bar (150 PSI)
Air Supply Quality
The air supply must be free from moisture,
oil and dust by conforming to the ISA
7.0.01 standard. (A dew point at least 18
degrees Fahrenheit below ambient
temperature, particle size below five
microns—one micron recommended—and
oil content not to exceed one part per
million).
Operating Humidity
0 - 100% non-condensing
Acceptable Supply
Gasses
Minimum Required
Operating Current
3.8 mA
Maximum Shut-down
Current
3.6 mA
Power Interruption
Time Limit
Power-up time
After power has been applied for at least 10
seconds, a 60 ms power interruption will not
cause the positioner to reset.
Air, sweet natural gas, nitrogen and CO2
are acceptable supply gasses.
Sour natural gas is not acceptable.
For Type nA and Type tb installation only
air or inert gas may be connected to the air
supply inlet.
Air Consumption
Time from application of power to begin
controlling valve < 1.0 second.
Communications
Single Acting Relay –
0.069 Nm³/h @ 1.5 bar
(0.041 SCFM @ 22 PSI)
0.082 Nm³/h @ 4.1 bar
(0.050 SCFM @ 60 PSI)
Double Acting Relay –
0.297 Nm³/h @ 1.5 bar
(0.175 SCFM @ 22 PSI)
0.637 Nm³/h @ 4.1 bar
(0.375 SCFM @ 60 PSI)
HART protocol (Logix 520MD+ only)
20.2 Pneumatic Output
Table 2: Pneumatic Output
Output Pressure
Range
0 to 100% of air supply pressure.
Output Air Capacity
Single Acting Relay –
9.06 Nm³/h @ 1.5 bar
(5.33 SCFM @ 22 PSI)
20.8 Nm³/h @ 4.1 bar
(12.2 SCFM @ 60 PSI)
20.4 Analog Output – Multi-Function Card
Double Acting Relay –
14.3 Nm³/h @ 1.5 bar
(8.44 SCFM @ 22 PSI)
30.6 Nm³/h @ 4.1 bar
(18.0 SCFM @ 60 PSI)
Primary Output Ports Single Acting Relay – Port B
(Port is pressurized in Double Acting Relay – Port A
energized state. Port
is exhausted upon loss
of power.)
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Table 4: 4 to 20 mA Analog Output Specification
For entity parameters, see section 21 HAZARDOUS AREA
CERTIFICATIONS.
Power Supply Range
10.0 to 40 VDC, (24 VDC Typical)
Current Signal Output
4 to 20 mA
Linearity
1.0% F.S.
Repeatability
0.25% F.S.
Hysteresis
1.0% F.S.
Operating Temperature
-52 to 85°C (-61.6 to 185°F)
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
20.5 Stroke Output
20.8 V to I Board Specifications
Table 5: Stroke Output
Table 8: V to I Board Specifications
Feedback shaft
Rotation
Min 15°, Max 90°
45° recommended for linear applications.
Board Input
Voltage
Resulting Current
Shut-Off Voltage
10 VDC
~0 mA
Working Voltage
19 - 26 VDC
~12 to 24 mA
20.6 Remote Mount Specifications
Table 6: Remote Mount Specifications
For entity parameters, see section 21 HAZARDOUS AREA
CERTIFICATIONS.
Use only with Logix® Remote
Remote Mount Device
Mount Option device.
20.9 Positioner Performance
Characteristics
Table 9: Performance Characteristics
Better than or equal to the following values on a 25 square inch
Mark I actuator.
Max Cable and Tube Distance
30.5 m (100 ft)
Resolution
≤ 0.25%
Operating Temperature
-52 to 85°C (-61.6 to 121°F)
Linearity
+/-1.25%
Repeatability
≤ 0.25%
Hysteresis
≤ 1.0%
20.7 Limit Switch Specifications
Table 7: Limit Switch Specifications
For entity parameters, see section 21 HAZARDOUS AREA
CERTIFICATIONS.
Switch
Specifications
Mechanical
Cherry DG 13-B(X)RA
NO and/or NC
General Purpose Only
Load Current:
Voltage:
Temperature:
3/2 AAC/ADC
125/30 VAC/VDC
-25 to +85 °C
(-13 °F to 185 °F)
Reed
Hamlin 59050-030
NO
Load Current:
Voltage:
Temperature:
500 mA
200VDC
-40 to +105 °C
(-40 °F to 221 °F)
Inductive Sensor
P&F NJ2-V3-N
NAMUR NC -3
Load Current:
Inductive Proximity
P&F SJ2-S1N
NAMUR NO-4
Load Current:
Voltage:
Temperature:
Voltage:
Temperature:
Plate: ≤ 1 mA;
No Plate: ≥ 3 mA
Nominal 8.2 VDC
-25 °C to 100 °C
(-13 °F to 212 °F)
Plate: ≤ 1 mA;
No Plate: ≥ 3 mA
5-25 VDC
(Nominal 8 VDC)
-25 °C to 100 °C
(-13 °F to 212 °F)
Deadband
≤ 0.3%
Sensitivity
≤ 0.25%
Stability
≤ 0.4%
Long term drift
≤ 0.5%
Supply Pressure Effect
≤ 0.2%
NOTE: Performance tested according to ISA 75.13.
20.10 Physical Specifications
Table 10: Physical Specifications
For dimensions, see section 38 POSITIONER .
Housing Material
Cast, powder-painted aluminum
EN AC-AlSi12(Fe)
Soft Goods
Fluorosilicone
Weight of Base
Positioner Without
Accessories
With Single Acting Relay
1.76 kg (3,88 lb)
With Double Acting Relay
1.88 kg (4.14 lb)
20.11 Temperature
Inductive Proximity
P&F SJ2-SN
NAMUR NC-5
Load Current:
Voltage:
Temperature:
Inductive Sensor
P&F NBB2-V3-E2
PNP NO
General Purpose Only
Load Current:
Voltage:
Temperature:
flowserve.com
Plate: ≤ 1 mA;
No Plate: ≥ 3 mA
5-25 VDC
(Nominal 8 VDC)
-40 °C to 100 °C
(-40 °F to 212 °F)
0…100 mA
10...30 VDC
-25 °C to 70 °C
(-13 °F to 158 °F)
Table 11: Temperature
Operating Temperature -52 to 85°C (-61.6 to 185°F)
Range
Transport and Storage
Range
-52 to 85°C (-61.6 to 185°F)
NOTE: Reduced performance possible at low
temperatures.
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20.12 ValveSight DTM Software
Specifications
Table 12: ValveSight DTM Software Specifications
Computer
Minimum Pentium processor running
Windows 2000, XP, Server 2003, Server
2003 R2, Server 2008 (32-bit & 64-bit
Versions), Server 2008 R2 (32-bit & 64-bit
Versions), and 7 (32-bit & 64-bit Versions).
Memory: >64MB Available HARD Disk
Space : >64MB
Ports
1 minimum available with 8 maximum
possible. (Can also communicate via
serial, PCMCIA and USB connections)
HART Modem
RS-232,
PCMCIA card, or
USB
HART Filter
May be required in conjunction with some
DCS hardware.
HART MUX
MTL 4840/ELCON 2700, P&F K System
HART Multiplexer
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21 HAZARDOUS AREA CERTIFICATIONS
DANGER: Certifications listed on the positioner are correct for that positioner. Before using the information on this
page, ensure the certifications on the positioner label match the certifications on this page.
Table 13: Logix 500+ Series Hazardous Locations Information
ATEX
Intrinsically Safe
FM12ATEX0009X
II 1 G
Ex ia IIC T4/T6 Ga IP66
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
North America (cFMus)
Type ‘n’
FM15ATEX0002X
II 3 G
Ex nA IIC T4/T6 Gc IP65
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
Type ‘t’
II 2 D
FM12ATEX0009X
Ex tb IIIC T100˚C Db IP65
Tamb = -52˚C ≤ Ta ≤ +85˚C
Intrinsically Safe
Class I, Div 1, Groups A,B,C,D
Class I, Zone 0, AExia IIC T4/T6 Ga
Class I, Zone 0, Ex ia IIC T4/T6 Ga
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
NEMA Type 4X, IP66
Non-Incendive
Class I, Div 2, Groups A,B,C,D,
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
NEMA Type 4X, IP65
Type ‘n’
Class 1, Zone 2, AEx nA IIC T4/T6 Gc
Class 1, Zone 2, Ex nA IIC T4/T6 Gc
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
NEMA Type 4X, IP65
Type ‘t’
Zone 21, AEx tb IIIC T100˚C Db IP65
Tamb = -52˚C ≤ Ta ≤ +85˚C
Entity
Parameters
4-20
Input/
V to I
MFC
Ui (Vdc)=
30
Limit Switches
-02
-03
-04
-05
30
10.6
16
16
16
Remote
Mount
Entity
Parameters
4-20
Input/
V to I
MFC
Vo = 5V
Ui (Vdc)=
30
Limit Switches
-02
-03
-04
-05
30
10.6
16
16
16
Remote
Mount
Vo = 5V
Ii (mA)=
100
100
29.7
25
25
25
Io = 79mA
Ii (mA)=
100
100
29.7
25
25
25
Io = 79mA
Pi (mW)=
800
800
79
34
34
34
Po = 129mW
Pi (mW)=
800
800
79
34
34
34
Po = 129mW
Ci (nF)=
0
0
1
40
60
30
Co = 2uF
Ci (nF)=
0
0
1
40
30
30
Co = 2uF
Li (µH)=
47
0
1
50
100
100
Lo = 100uH
Li (µH)=
47
0
1
50
100
100
Lo = 100uH
IECEx
Intrinsically Safe
FMG 12.0001X
Ex ia IIC T4/T6 Ga IP66
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
Notes
Type ‘n’
FMG 12.0001X
Ex nA IIC T4/T6 Gc IP65
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
Type ‘t’
FMG 12.0001X
Ex tb IIIC T100˚C Db IP65
Tamb = -52˚C ≤ Ta ≤ +85˚C
Entity
Parameters
4-20
Input/
V to I
MFC
Limit
Switches
-02
Remote
Mount
Ui (Vdc)=
30
30
10.6
Vo = 5V
Ii (mA)=
100
100
29.7
Io = 79mA
Pi (mW)=
800
800
79
Po = 129mW
Ci (nF)=
0
0
1
Co = 2uF
Li (µH)=
47
0
1
Lo = 100uH
•
Reference installation drawing # 291780
Warning!
•
Limit Switch options -01 and -06 are not rated for use in hazardous areas for
ATEX and North America (cF Mus). Limit Switch options -01, -03, -04, -05 and
-06 are not rated for use in hazardous areas for IECEx. Select these options
only when installing in non-explosive atmospheres.
•
Covers must be properly installed in order to maintain environmental ratings.
Special Conditions for Safe Use:
•
The equipment must be installed in such a manner as to minimize the risk of
impact or friction with other metal surfaces.
•
To avoid possibility of static discharge clean only with a damp Cloth
•
For Intrinsically Safe installations the positioner must be connected to suitably
rated intrinsically safe equipment, and must be installed in accordance with
applicable intrinsically safe installation standards.
•
Substitution of components may impair Intrinsic Safety.
•
Use appropriately rated cable insulation at higher temperatures.
•
For type ‘nA’ and Type ‘tb’ installation only air or inert gas may be connected to
the air supply inlet.
•
Provisions shall be made externally to provide transient overvoltage protection
to a level not to exceed 140% of the peak rated input voltage.
Conditions spéciales pour une utilisation en toute sécurité:
•
Le matériel doit être installé de sorte à réduire au minimum le risque de choc ou de frottement avec d'autres surfaces métalliques.
•
Pour éviter les risques de décharge d'électricité statique Nettoyez uniquement avec un chiffon humide
•
Pour les installations en sécurité intrinsèque, le positionneur doit être connecté à un équipement sécurité intrinsèque convenablement qualifié, et doit être installé conformément aux normes
d'installation sécurité intrinsèque applicables.
Assessed to the following ATEX standards: EN 60079-0:2012, , EN 60079-11:2012, EN 60079-15:2010, EN 60079-26:2007, EN 60079-31:2014, EN60529:1991+A1:2000
Assessed to the following IECEx standards: IEC 60079-0:2011, IEC 60079-11:2011, IEC 60079-15:2010, IEC 60079-31:2013, IEC 60079-26:2006.
Assessed to the following US standards: Class 3600 :2011,Class 3610 :2010, FM 3611, Class 3810 :2005, ANSI/NEMA 250 :2008, ANSI/IEC 60529 :2004, ANSI/ISA 60079-0
:2013 ANSI/ISA 60079-1 :2009, ANSI/ISA 60079-11:2011, ANSI/ISA 60079-15:2012,ANSI/ISA 60079-31:2013.
Assessed to the following CAN standards: CSA C22.2 No.0.4, CSA C22.2 No. 0.5, CSA C22.2 No.60529, CSA C22.2 60079-0, CSA C22.2 60079-1,CSA C22.2 No. 157, CSA
C22.2 No.213,CSA No. 60079-11, CSA C22.2 No. 60529.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
22 STORAGE AND UNPACKING
22.1 Storage
22.4 Labels
FLOWSERVE Control valve packages (a control valve
and its instrumentation) are typically well protected from
corrosion. Nevertheless FLOWSERVE products must
be stored in a clean, dry environment such as an
enclosed building that affords environmental protection.
Heating is not required. Control valve packages must be
stored on suitable skids, not directly on the floor. The
storage location must also be free from flooding, dust,
dirt, etc. Plastic caps are fitted to protect the flange faces
and positioner ports to prevent the ingress of foreign
materials. These caps should not be removed until the
valve or positioner is actually mounted into the system.
Verify that the labels match the intended application.
Note: Mark checkbox next to hazardous area information for
protection method Logix 500MD+ is installed to.
Pressure
Rating
Hazardous
Area
Information
If FLOWSERVE products (especially sealing materials)
have been in storage for longer periods check these for
corrosion or deterioration before using these products.
Fire protection for FLOWSERVE products must be
provided by the end user.
22.2 Unpacking
While unpacking the valve and/or Logix 500MD+
positioner, check the packing list against the materials
received. Lists describing the system and accessories
are included in each shipping container.
Figure 4: Certification Label
In the event of shipping damage, contact the shipper
immediately. Should any problems arise, contact a
Flowserve Flow Control Division representative.
22.3 Pre-installation Inspection
Model Code
When installing a positioner, verify the shaft has not
been damaged and that the plugs and cover are in
place. The plugs keep debris and moisture from
damaging the internal components of the positioner. If
the positioner has been contaminated, clean the
positioner components gently with a soft damp cloth.
Some components may be removed for better access.
See section 36 MAINTENANCE AND REPAIR. When
cleaning a Double Acting Relay (Spool and Block) take
care not to bend or force the spool. A Single Acting
Relay may be removed, but do not disassembled the
relay. Check connectors to ensure that no debris is
present. Port screens can be removed with a flat
screwdriver for access to internal passages.
Optional
Hardware
Diagnostics
Figure 5: Model Code Label
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
23 MOUNTING AND INSTALLING
23.1 Mounting to Mark One Linear
Valves
16
Insert the lower mounting bolt and tighten the
bolting.
17
Position the take-off arm mounting slot against the
stem clamp mounting pad. Apply Loctite 222 to the
take-off arm bolting and insert through washers into
stem clamp. Leave bolts loose.
To mount a Logix 500+ positioner to a Valtek linear Mark
One valve, refer to Figure 6: Mounting to Mark I Linear
Valves and proceed as outlined below.
11
12
18
Slide the appropriate pin slot of the take-off arm,
based on stroke length, over the follower arm pin.
The appropriate stroke lengths are stamped by
each pin slot.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
Remove washer and nut from follower pin
assembly. Insert pin into the appropriate hole in
follower arm, based on stroke length. The stroke
lengths are stamped next to their corresponding
holes in the follower arms. Make sure the
unthreaded end of the pin is on the stamped side of
the arm. Reinstall lock washer and tighten nut to
complete follower arm assembly.
Slide the slot in the follower arm assembly over the
flats on the position feedback shaft in the back of
the positioner. Make sure the arm is pointing
toward the side of the positioner with ports A, B,
and Supply. Slide the lock washer over the threads
on the shaft and tighten down the nut.
13
Align the bracket with the three outer mounting
holes on the positioner. Fasten with 1/4" bolts.
14
Screw one mounting bolt into the hole on the yoke
mounting pad nearest the cylinder. Stop when the
bolt is approximately 3⁄16" from being flush with
mounting pad.
15
Slip the large end of the teardrop shaped mounting
hole in the back of the positioner/bracket assembly
over the mounting bolt. Slide the small end of the
teardrop under the mounting bolt and align the
lower mounting hole.
19
Center the take-off arm on the rolling sleeve of the
follower pin.
20
Align the take-off arm with the top plane of the
stem clamp and tighten bolting. Torque to 120 in-lb.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve. If mounted incorrectly, a
stroke calibration error will occur and the indicator lights
will blink a RGGY code indicating the position sensor
has gone out of range on one end of travel or the travel
is too small. Reposition the feedback linkage or rotate
the position sensor to correct the error.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature in the Custom Characterization
page of the DTM.
Bracket
Positioner
Feedback
Shaft
Follower
Arm
Follower
Pin
Take-Off
Arm Pin Slot
Take-Off
Arm
Figure 6: Mounting to Mark I Linear Valves
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79
Stem
Clamp
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Linear
18
To mount a Logix 500+ positioner to a FlowTop linear
actuator and valve (with direct mounting / integrated
tubing), refer to Figure 7 and proceed as outlined below.
Assemble the take-off pin to the take-off plate and
mount the take-off plate to the valve stem using the
two screws. Adjust the follower pin to match the
correct location as indicated on the follower arm’s
embossed scale.
19
Place the actuator O-ring.
20
Place the positioner on the actuator, ensuring the
take-off pin is inside the follower arm slot. Adjust
the follower arm as needed.
23.2 Mounting
Valves
to
FlowTop
NOTE: Because the integral mounting uses the
alternate pneumatic port, the positioner must have a
poppet style, single acting relay. This is indicated in the
model code with a “1” in the highlighted location:
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
521MD+14-W1ED1F0-GM2-1103
21
Use the actuator screws to secure the positioner in
place.
Ensure positioner O-ring surface is clean. Then
install the O-ring, and FlowTop mounting block
using the positioner screws.
22
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
Attach the follower arm to the feedback shaft using
the follower arm nut.
23
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
24
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
15
Remove the FlowTop port plug screw. Plug port B.
16
17
Refer to Figure 8: FlowTop Mounting.
Positioner Screws
FlowTop Mounting Bracket
Positioner O-ring
Spacer
FlowTop Port
Port B
Follower Arm
Feedback Shaft
Follower Arm Nut
Figure 7: FlowTop Mounting Bracket
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
26
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
27
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
28
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature on the Custom Characterization
page of the DTM.
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
Actuator Screws
Actuator O-ring
Take-Off Pin
Take-Off Plate
Take-Off Plate Screws
Figure 8: FlowTop Mounting
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Valtek
20
Using four 1/4-20 x 1/2" bolts, fasten positioner to
universal bracket using appropriate hole pattern
(stamped on bracket).
The standard rotary mounting applies to Valtek
valve/actuator assemblies that do not have mounted
volume tanks or hand-wheels. The standard mounting
uses a linkage directly coupled to the valve shaft. This
linkage has been designed to allow for minimal
misalignment between the positioner and the actuator.
Refer to Figure 10 through Figure 12.
21
Using a ½” end wrench and two 5/16-18 X ½” bolts,
attach bracket to actuator transfer case pad.
Leave these bolts slightly loose until final
23.3 Mounting to
Rotary Valves
Standard
16
Fasten the spline lever adapter to the splined lever
using two 6 x 1/2" self-tapping screws.
17
Slide the take-off arm onto the spline lever adapter
shaft, orienting the arm to the current valve
position. Insert the screw with star washer through
the take-off arm and add the second star washer
and nut and tighten.
Feedback Shaft
Follower Arm
Universal
Bracket
Figure 9: Valtek Rotary Follower Arm
adjustments are made.
22
Spline
Lever
Adapter
Rotate follower arm so the follower pin will slide
into the slot on the take-off arm. Over-rotate the
follower arm if needed so the arm moves freely
through the intended travel.
Take-Off
Arm
Assembly
Figure 10: Valtek Rotary Take-Off Arm
18
Attach follower arm to positioner feedback shaft
using the star washer and 10-32 nut.
19
Rotate the follower arm so the follower pin will slide
into the slot on the take-off arm. Adjust the bracket
position as needed noting the engagement of the
follower pin and the take-off arm slot. The pin
should extend approximately 2 mm past the takeoff arm. When properly adjusted, securely tighten
the bracketing bolts
flowserve.com
Figure 11: Valtek Rotary Mounting
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
82
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
23
Adjust the bracket position as needed noting the
engagement of the follower pin and the take-off
arm slot. The pin should extend approximately
1⁄16" past the take-off arm. When properly
adjusted, securely tighten the bracketing bolts.
24
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
25
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
26
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
27
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
28
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
29
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: If mounted properly, the follower arm should
be horizontal when the valve is at 50% stroke and
should move approximately ±30° from horizontal over
the full stroke of the valve.
NOTE: To virtually eliminate non-linearity, use the
Linearization feature on the Custom Characterization
page of the DTM.
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
30
Figure 12: Valtek Rotary Final Orientation
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
23.4 Mounting
Valves
12
to
MaxFlo
15
Rotary
Slide the take-off arm onto the shaft. Insert the
screw with star washer through the take-off arm
and add the second star washer and nut. Tighten
nut with socket so arm is lightly snug on the shaft
but still able to rotate. This will be tightened after
linkage is correctly oriented. Refer to figures Figure
Rotate the follower arm so the take-off pin will slide
into the slot on the follower arm. Adjust the bracket
position as needed noting the engagement of the
follower pin and the take-off arm slot. The pin
should extend approximately 2 mm past the takeoff arm. When properly adjusted, securely tighten
the bracketing bolts.
Take-Off Arm
Take-Off Pin
Figure 15: MaxFlo Assembly
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
Figure 13: MaxFlo Take-Off Arm
13 through Figure 16.
13
Attach the mounting plate to the positioner using 4
screws.
14
Attach follower arm to positioner feedback shaft.
Mounting Plate
Feedback Shaft
Follower Arm
Figure 16: MaxFlo Connection
Figure 14: MaxFlo Follower Arm
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16
84
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
17
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
23.5 Mounting to Rotary
(AutoMax) Valves
18
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
11
Attach the mounting plate to the positioner using 4
screws. See Figure 17.
19
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
12
Rotate the feedback shaft to match the orientation
of the receiver on the actuator.
20
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
21
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
13
Mount the positioner onto the actuator using the
washers and nuts. See Figure 18.
14
22
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, the
feedback values were exceeded and the arm must
be adjusted away from the positioner’s limits.
Rotate the feedback shaft so that the full free travel
of the feedback shaft is in the range of the actuator
movement. Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
15
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
16
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
17
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
18
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
19
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
20
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, remove
power from the positioner, disconnect the air, and
remove the positioner from the actuator. Rotate
the feedback shaft so that the full free travel of the
feedback shaft is in the range of the actuator
movement.
Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NAMUR
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Figure 17: AutoMax Bracket
Figure 18: AutoMax Assembly
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
23.6 Mounting to a Linear NAMUR
Pneumatic Actuator
The mounting of a rod actuator kit and actuator
(according to IEC 534 part 6) is described in the
following example. Refer to Figure 19.
15
Mount the follower arm by unscrewing the lock nut
for the follower arm attachment. Place the follower
arm on the shaft at the back of the positioner and
fasten it with the lock nut. The follower pin should
point away from the positioner.
16
Attach the stem clamp bracket to the stem clamp
and fasten it with two hexagon socket screws and
lock washers.
17
Attach the take-off arm to the stem clamp bracket
and fasten it with a hexagon socket caps crew and
a washer.
CAUTION: Maximum torque 0,25 Nm (0,18 ft-lbs).
18
To mount the positioner, adjust the actuator to midstroke.
19
Pre-assemble the mounting bracket on the left
actuator leg and hand-tighten the two U-bolts, nuts
and lock-washers.
20
Attach the positioner to the pre-assembled
mounting bracket and fasten it with two hexagon
screws and two lock washers. Check that the
follower pin is inserted in the slot of the take-off
arm and the follower arm is positioned parallel to
the take-off arm.
21
Tighten all screws and nuts.
24
Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
25
Refer to sticker on main board cover and set DIP
switches accordingly. See section 26 STARTUP.
26
Press the QUICK-CAL/ACCEPT button for three to
four seconds or until the positioner begins to move.
The positioner will now perform a stroke calibration.
27
If the calibration was successful the green LED will
blink GGGG or GGGY and the valve will be in
control mode.
28
If calibration fails, as indicated by a RGGY blink
code, retry the calibration. If it still fails, remove
power from the positioner, disconnect the air, and
remove the positioner from the actuator. Rotate
the feedback shaft so that the full free travel of the
feedback shaft is in the range of the actuator
movement.
Optionally, continue to attempt the
calibration. Each calibration attempt adjusts the
acceptable limits and it should pass eventually.
CAUTION: Remember to remove the air supply
before re-adjusting take-off arm.
NOTE: The feedback shaft has a clutch mechanism
that allows for over-rotation of the shaft for easy
adjustments.
NOTE: A slight unsymmetrical mounting increases
the linearity deviation but does not affect the
performance of the device.
Follower
Arm
NOTE: Depending on the actuator size and stroke it
may be necessary to flip the take-off arm (Figure 3) by
180° and attach it to the opposite side of the stem clamp
bracket.
22
Connect regulated air supply to appropriate port in
manifold. See section 24 TUBING.
23
Connect the power to the 4-20 mA terminals. See
section 25 ELECTRICAL CONNECTIONS.
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Take Off
Arm
Follower
Pin
Stem
Clamp
Figure 19: Mounting to a Linear Actuator
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
24 TUBING
After mounting has been completed, tube the positioner
to the actuator using the appropriate compression fitting
connectors.
For best performance, use 10 mm (3/8
inch) tubing for 645 square cm (100 square inch)
actuators or larger. See Figure 24 below.
S
B (Y2)
A (Y1)
24.1 Determine Air Action
Spool Relay
The port labeled “Y1” delivers air when an air supply is
present and the relay is energized. (For positioners with
double acting relays, this is port A. For positioners with
single acting relays, this is port B.) Typically, the port
labeled “Y1” should be tubed to the pneumatic side of
the actuator (the side that would result in the air
compressing the actuator spring). When tubed this way,
the spring is designed to return the valve to the fail safe
state should supply air or power to the unit fail.
Figure 20: Linear, Double Acting, Air to Open
Tube the port labeled “Y1” to the side of the actuator that
must receive air to begin moving away from the fail safe
state.
Example: Rotary Double-Acting Actuators
For a rotary actuator, the “Y1” port of the positioner
manifold is tubed to the far side of the actuator. The “Y2”
port of the positioner manifold is tubed to the side of the
actuator closer to the transfer case. This tubing
convention is followed regardless of air action. On rotary
actuators, the transfer case orientation determines the
air action. See Figure 21.
If air from “Y1” should open the valve, set the Air Action
configuration switch on the positioner to Air-to-Open,
otherwise set it to Air-to-Close.
The Air-to-Open and Air-to-Close selection is determined
by the actuator tubing, not the software. When air action
selection is made during configuration, the selection tells
the control which way the actuator has been tubed.
.
If the valve is double acting, port the valve labeled “Y2”
to the other side of the actuator.
DANGER: Proper tubing orientation is critical for the
positioner to function correctly and have the proper
failure mode.
Example: Tubing Linear Double-Acting Actuators
S
B (Y2)
A (Y1)
For a linear air-to-open actuator, the “Y1” port of the
positioner is tubed to the bottom side of the actuator
(closest to the valve). The “Y2” port of the positioner is
tubed to the top side of the actuator. See Figure 20. For
a linear air-to-close actuator the tubing configuration is
reversed.
Spool Relay
Figure 21: Rotary, Double Acting, Air to Open
Example: Tubing Single-acting Actuators
For single-acting actuators, the “Y1” port is always tubed
to the pneumatic side of the actuator regardless of air
action. If a double acting (spool style) relay is installed in
the positioner, plug port B (Y2). If a single acting poppet style relay is installed, plug port A (Y2) as in
Figure 22. Or, port A may be used for purging. See
Purging Single Acting Actuators below.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
natural gas, piping must be used to route the exhausted
natural gas to a safe environment.
The housing chamber exhaust port is located on the
backside of the positioner. The actuator exhaust port is
located on the bottom of the positioner. Both ports are
tapped with either ¼ NPTF or G ¼ threads and covered
with a protective cap. To control vented gas, remove the
caps and connect the necessary tubing/piping to these
ports. See Figure 23: Exhaust Vents.
S
B (Y1)
A (Y2) Plug
This piping system may cause some positioner back
pressure. Back pressure in the housing chamber is from
the modulator and regulator. Back pressure in the
exhaust port is from the actuator.
Poppet Relay
The maximum allowable back pressure from the housing
chamber is 0.14 barg (2.0 PSIG). For flow rates, see
section 20.3 Air Supply.
The maximum allowable back pressure from the exhaust
port is 0.55 barg (8.0 PSIG) for double acting relays and
is 0.14 barg (2.0 PSIG) for single acting relays. Higher
pressure may result in decreased performance. For
output flow rates, see section 20.2 Pneumatic Output.
Figure 22: Linear, Single Acting, Air to Open
24.2 Connect Supply Port
CAUTION: The back pressure in the main housing
must never rise above 0.14 barg (2.0 PSIG). This could
cause the positioner to become unresponsive under
some circumstances
The positioner ports are threaded with either G ¼ or ¼
NPTF as indicated on the housing.
In order to maintain the recommended air quality, a
coalescing filter should always be installed in the supply
gas line. An air filter is highly recommended for all
applications where dirty air is a possibility. The positioner
passage ways are equipped with small filters, which
remove medium and coarse size dirt from the
pressurized air. If necessary, they are easily accessible
for cleaning.
A supply regulator is recommended if the customer will
be using the diagnostic features of the Logix 500+ but is
not required. In applications where the supply pressure
is higher than the maximum actuator pressure rating a
supply regulator is required to lower the pressure to the
actuator’s maximum rating.
Housing
Chamber
Exhaust
(0.14 barg Max)
Actuator
Exhaust
(0.55 barg Max)
24.3 Purging Single Acting Actuators
Figure 23: Exhaust Vents
Purging allows the non-pressurized side of a single
acting actuator to fill with exhaust gas instead of
atmospheric air.
This configuration helps prevent
corrosion
of
actuator
components
in
harsh
environments. When a single acting relay is used, a
special procedure can be performed to configure the
positioner to purge properly using port A. Contact your
local Flowserve Representative for more information
regarding the purging option.
.
24.4 Vented Design
A standard Logix 500+ positioner is vented directly to the
atmosphere. When supply air is substituted with sweet
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Port
Poppet
Style
Relay
(Single
Acting)
Spool
Style
Relay
(Double
Acting)
Spool
Style
Relay
(Single
Acting)
S
Supply
Supply
Supply
B
Y1
Y2
(Plug)
A
(Plug)
Y1
Y1
Figure 24: Pneumatic Connections
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25 ELECTRICAL CONNECTIONS
25.1 Electrical Terminals
Limit Switch
Terminals 1-6
Auxiliary Cards
Slot 2 Slot 2 +
Slot 1 +
Slot 1 –
HART 4-20 mA
Input +
Input –
Housing EARTH
Terminal
Internal
External
NOTE: Tighten
all terminals 0.5 – 0.6 Nm
Figure 25: Terminal Diagram
25.2 Command Input (4-20 mA)
Connection
Equation 1
Available Voltage = Controller Voltage @Current
Current
× R
+ R!
The Logix 500+ is reverse polarity protected, however,
verify polarity when making field termination connection.
Wire 4-20 mA current source to the input terminal
labeled “HART 4-20mA INPUT”. Tighten using 0.5 to 0.6
Nm torque. See Figure 25: Terminal Diagram.
Depending on the current source, a HART filter may be
required. See 37.1 Troubleshooting Guide.
Current "
R
R!
25.2.1 Compliance Voltage
= 20&'
= 300)
= 25)
Available Voltage = 19 V − 0.020 A × 300) + 25)
Output compliance voltage refers to the voltage limit the
current source can provide. A current loop system
consists of the current source, wiring resistance, barrier
resistance (if present), and the Logix 500+ impedance.
The Logix 500+ requires that the current loop system
allow for a 10 VDC drop across the positioner at
maximum loop current. The operating current range is
from 3.8 to 24 mA.
Available Voltage = 12.5 V
The available voltage (12.5 V) is greater than the
required voltage (10.0 V) therefore; this system will
support the Logix 500+. The Logix 500+ has an input
resistance equivalent to 500 Ω at a 20 mA input current.
CAUTION: The current must always be limited for
4-20 mA operation. Never connect a voltage source
directly across the Logix 500+ terminals. This could
cause permanent circuit board damage.
In order to determine if the loop will support the Logix
500+, perform the calculation in the following equation.
The Available Voltage must be greater than 10VDC in
order to support the Logix 500+. Also, see Table 1:
Input Signal.
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#
−
91
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
4-20 mA
Current
Source
Controller
Voltage
Barrier
(If Present)
Wire
R
R
+
Compliance 10
Voltage
VDC
-
Logix
520MD+
Current
Figure 26: Compliance Voltage
25.2.2 Cable Requirements
Max Cable Length =
The Logix 520MD+ digital positioner utilizes the HART
Communication protocol. This communication signal is
superimposed on the 4-20 mA current signal. The two
frequencies used by the HART protocol are 1200 Hz and
2200 Hz. In order to prevent distortion of the HART
communication signal, cable capacitance and cable
length restrictions must be calculated. The cable length
must be limited if the capacitance is too high. Selecting a
cable with lower capacitance/foot rating will allow longer
cable runs. In addition to the cable capacitance, the
network resistance also affects the allowable cable
length. See Figure 26.
Max Cable Length = 1111 &
To control cable resistance, 24 AWG cable should be
used for runs less than 5000 feet. For cable runs longer
than 5000 feet, 20 AWG cable should be used.
The input loop current signal to the Logix 520MD+ digital
positioner should be in shielded cable. Shields must be
tied to a ground at only one end of the cable to provide a
place for environmental electrical noise to be removed
from the cable. In general, shield wire should be
connected at the source, not at the positioner.
In order to calculate the maximum network capacitance,
use the following formula:
25.2.3 Intrinsically Safe Barriers
Equation 2
C.
/!0 1
μF ≤
5678
9:;<<=>< ? [email protected]=<>?AB78
− 0.0032
When selecting an intrinsically safe barrier, make sure
the barrier is HART compatible. Although the barrier will
pass the loop current and allow normal positioner
control, if not compatible, it may prevent HART
communication.
Example:
= 300) (if present)
R
R!
C.
0.08 μF
ML
. 000072
&
25.2.4 Grounding and Conduit
= 50)
/!0 1
μF ≤
5678
A77C? 67C?AB78
The grounding terminals, located by the electrical
conduit ports should be used to provide the unit with an
adequate and reliable earth ground reference. This
ground should be tied to the same ground as the
electrical conduit. Additionally, the electrical conduit
should be earth grounded at both ends of its run.
− 0.0032= 0.08 μF
In order to calculate the maximum cable length, use the
following formula:
Equation 3
Max Cable Length =
C. /!0
CH I
NOTE: The grounded screw must not be used to
terminate signal shield wires. Shield wires should be
terminated only at the signal source.
1
This product has electrical conduit connections in either
thread sizes 1/2" NPTF or M20x1.5 which appear
identical but are not interchangeable. The thread size is
indicated on the side of the positioner near the conduit
Example:
CH
I
KL
ML
= 72
= .000072
&
&
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
connections. Conduit fittings must match equipment
housing threads before installation. If threads do not
match, obtain suitable adapters or contact a Flowserve
representative. See Figure 27: Conduit and Grounding.
25.3 Multi-Function Card (AO, DO, DI)
The Multi-Function Card can act as an Analog Output
(AO), a Discrete Output (DO), or a Discrete Input (DI).
Connections to the Multi-Function Card are made
directly to the card terminals. For detailed information
about voltage and current limits, see Table 14: Auxiliary
Card Status below.
Conduit
Thread Size
Grounding
Terminals
See section 31 MULTI-FUNCTION CARD for more
information.
Electrical
Conduit
Connections
25.3.1 Analog Output
For AO function wire the MFC in series with a 10 to 40
VDC power supply, including a method to determine the
current. When configured as an AO, the current will
follow the valve position. See Figure 28.
Figure 27: Conduit and Grounding
25.2.5 Electromagnetic Compatibility
The Logix 500+ digital positioner has been designed to
operate correctly in electromagnetic (EM) fields found in
typical industrial environments. Care should be taken to
prevent the positioner from being used in environments
with excessively high EM field strengths (greater than 10
V/m). Portable EM devices such as hand-held two-way
radios should not be used within 30 cm of the device.
10 VDC
to
40 VDC
Voltage
Source
Ensure proper wiring and shielding techniques of the
control lines, and route control lines away from
electromagnetic sources that may cause unwanted
electrical noise. An electromagnetic line filter can be
used to further eliminate noise (FLOWSERVE Part
Number 10156843).
MFC
In the event of a severe electrostatic discharge near the
positioner, the device should be inspected to ensure
correct operability. It may be necessary to recalibrate the
Logix 500+ positioner to restore operation.
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Figure 28: MFC Analog Output Circuit
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25.3.2 Discrete Output
Table 14: Auxiliary Card Status
Card
For DO function, wire the MFC in series with a 8 to 40
VDC power supply, including a method to determine the
current such as a resistor. Or use a NAMUR switch
amplifier made for this purpose. In DO configuration, the
card is a NAMUR switch.
Condition
Status
Indication
Multi-Function Card
Monitoring Position
(typical 4-20mA )
Output
(mA)
Less than 8 V on
AO terminals.
No Loop
Power
High
output > 2.1 mA
(520MD+ typically
3 mA)
(510+ typically 7
mA)
1Nominal
Low
1.2 mA > output >
0.1 mA
(typically 0.5 mA)
0Tripped
MFC (AO)
When configured as a DO, current will remain high until
the user-defined condition (an alarm) is active, and then
drop low when tripped. See Figure 29.
Switch Amp
MFC (DO)
8 VDC
Minimum
1 kΩ
Typical
Less than 0.1 mA
MFC (DI)
MFC
Figure 29: MFC Discrete Output Circuit
25.3.3 Discrete Input
For the DI function, wire the MFC in series with a 0 to 40
VDC power supply. Keep the voltage low under normal
circumstances. Raise the voltage to create a tripped
input state. See Figure 30.
0 VDC
to
40 VDC
Voltage
Source
Discrete Input
Voltage Loop
(Logix Input)
MFC
Figure 30: MFC Discrete Input Circuit
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94
Low
(input < 2.5 VDC)
High
(input > 8.0 VDC)
No Loop
Power
1Nominal
0Tripped
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25.4 V to I Card Connections
The V to I card is used if powering the positioner using a
voltage generator is desired. The card requires a
voltage input and converts the voltage to a current
suitable for powering the positioner. The positioner can
still communicate via a HART interface on the voltage
lines.
V to I Voltage Loop
(Logix Input)
Main
Board
4-20mA
Input
NOTE: When using the V to I card, digital position
control is recommended.
Controlling position by
changing the voltage may result in lack of position
linearity and accuracy.
+
-
6 to 30 VDC
Voltage Source
50 Ω
HART
Handheld
Black
Red
Wire the V to I card according to Figure 32: V to I Card
Circuit. Connect the voltage input to the V to I card
terminal. Connect the red wire from the V to I card to the
positive terminal on the main board 4-20 mA input
connector. Connect the black wire from the V to I card
to the negative terminal on the main board 4-20 mA
input connector.
~696 Ω
MFC
Current to the positioner can be approximated by the
formula in Equation 4.
Equation 4
Figure 32: V to I Card Circuit
O=
PQRRST UVSW XYZ[Y ]^ S UVSW XY
5B5
Example
Supply Voltage = 24 V
Terminal Voltage = 10 V
O=
24 − 10
= 20 &'
696
Terminals
+ -
Figure 33: V to I Card installed
Figure 31: V to I Card
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25.5 Limit Switches
LS1
Limit switches provide an independent verification of the
position of the feedback shaft. Wire the limit switches
according to Table 15: Limit Switch Connections. For
more information, see Table 7: Limit Switch
Specifications on page 75. See Figure 34.
Table 15: Limit Switch Connections
LS2
Terminal (See Figure 34)
Switch
Terminals
1
2
3
4
5
6
NC
NO
C
NC
NO
C
+
+
-
+
+
-
Mechanical
Cherry DG 13-B2RA
1 & 4 NC
LS1
Figure 34: Limit Switch Board
LS2
Reed
Hamlin 59165-1-S-00-C
+
NO
-
+
LS1
LS2
Inductive Sensor
P&F NJ2-V3-N
NAMUR NC
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Proximity
P&F SJ2-S1N
NAMUR NO
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Proximity
P&F SJ2-SN
NAMUR NC
BN
BU
BN
BU
+
-
+
-
LS1
LS2
Inductive Sensor
P&F NBB2-V3-E2
PNP NO
BN
General Purpose Only Vcc+
BU
LS1
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BK
BN
SW+ Vcc+
BU
BK
-
SW+
LS2
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
25.6 Remote Mount
The remote mount option can be used where excessive
vibration or environmental factors prevent the placement
of a positioner directly on the valve. Wire the remote
mount board according to Table 16: Remote Mount Card
Connections. For more information, see Table 6:
Remote Mount Specifications on page 75.
Table 16: Remote Mount Card Connections
Terminal (See Figure 35:
Remote Mount Board)
From Remote Mount
A
Red
B
White
C
Black
Terminals
Figure 35: Remote Mount Board
25.7 Connections for Intrinsically Safe
Operation
See section 21 HAZARDOUS AREA CERTIFICATIONS
for entity parameters and control drawing reference.
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26 STARTUP
26.1 Quick Start Instructions
26.2 Local User Interface Overview
Once the positioner is installed, adjusting the DIP switch
settings and performing a Quick-Cal function will
typically get the positioner working properly. This simple
procedure takes only seconds for most valves.
The Logix 500+ local user interface allows the user to
calibrate, configure the basic operation, and tune the
response of the positioner without additional tools or
configurators. See Figure 36.
3
Using the Configuration Switches, select the
desired configuration.
•
4
Hold the Quick-Cal button for 3 seconds. This will
initiate a stroke calibration.
•
After the stroke calibration is complete, the positioner is
ready for control.
•
CAUTION: During the QUICK-CAL operation the
valve may stroke unexpectedly. Notify proper personnel
that the valve will stroke, and make sure the valve is
properly isolated.
•
•
Card Slot 2
Card Slot 1
Configuration Switches (8) – Used to set basic
configuration. See explanations in section 26.3
Configuration Switch Settings.
Interface Buttons – Used to calibrate the positioner,
perform special functions and navigate the display
menu.
o ►QUICK-CAL / ACCEPT
o ▲Up
o ▼Down
o ◄Back
Selectable GAIN Switch (Rotary) – Used to
manually fine-tune the performance.
LED Indicators (Red, Yellow, and Green) – Indicate
status, alarms and warnings.
Display (Optional) – Provides a full menu of detailed
information and configuration options.
Display
HART
4-20 mA
Input
LED Status
Lights
QUICK-CAL/
ACCEPT Button
Configuration
Switches
Selectable
GAIN Switch
BACK
Button
Figure 36: Local User Interface
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UP Button
DOWN Button
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
26.3 Configuration Switch Settings
Before placing the unit in service, set the Configuration
Switches to the desired control options.
NOTE: The Configuration Switch settings are
activated only by performing a Stroke calibration
(pressing the “QUICK-CAL” button for 3 seconds).
However, the Configuration Switch settings may be
edited from the DTM or Handheld at any time.
26.3.1 Air Action Switch
This must be set to match the configuration of the
valve/actuator mechanical tubing connection since the
tubing determines the air action of the system.
If Single Acting (Poppet) Relay
ATO - Increasing pressure from Port B (labeled “Y1”)
causes the valve to open.
ATC - Increasing pressure from Port B (labeled “Y1”)
causes the valve to close.
If Double Acting (Spool) Relay
ATO - Increasing pressure from Port A (labeled “Y1”)
causes the valve to open.
ATC - Increasing pressure from Port A (labeled “Y1”)
causes the valve to close.
26.3.2 Actuator Switch
This must be set to match the configuration of the
actuator and is used in some diagnostics.
Double - Select Double when both sides of the actuator
are pressurized.
Single - Select Single when only one side of the actuator
is pressurized.
26.3.3 Signal at Closed Switch
Normally this will be set to 4 mA for an Air-To-Open
actuator configuration, and 20 mA for Air-To-Close.
4 mA - Selecting 4 mA will make the valve close when
the signal is low (4 mA) and open when the signal is high
(20 mA).
20 mA - Selecting 20 mA will make the valve close when the
signal is high (20 mA) and open when the signal is low (4
mA).
closes with a 20 mA signal, the AO will show a 20 mA signal
at closed.
26.3.4 Characterization Switch
The Characterization Switch allows a better match between
the input command and the actual fluid flow through the
valve. This feature is typically used with valves that have
non-linear flow characteristics. The positioner makes a
correction by applying an adjustment to the input command
according to a characterization curve.
Linear - Select Linear if the actuator position should be
directly proportional to the command input signal. (For most
rotary valves, this setting gives an =% Cv characteristic due
to their inherent =% characteristics.)
Other - Select Other if one of the pre-set characterization
curves or a custom curve is desired. The default will be the
Custom curve which is populated with a standard 30:1 equal
percent rangeability curve which generally opens less than
the input command. To select one of the other curve options,
use the LCD menu, a Handheld or the ValveSight DTM. To
modify the Custom curve, use the DTM. See section 28.3.6
Configuration (Characterization) for more information.
26.3.5 Auto Tune Switch
This switch controls whether the positioner will automatically
tune itself during the stroke calibration (Quick-Cal), or use
preset tuning parameters.
On - Selecting On enables an auto tune feature that will
automatically determine the positioner gain settings. The
automatic tuning will be based on response parameters
measured during the latest Quick-Cal. The valve response is
a combination of these response parameters and the current
position of the Selectable GAIN Switch.
Off - Selecting Off forces the positioner to use one of the
factory preset tuning sets determined by the Selectable GAIN
Switch. Settings “B” through “J” are progressively higher
predefined tuning sets.
Selecting “A” on the Selectable Gain Switch during a QuickCal allows the user to use and preserve manually adjusted
gains. See section 26.4 Stroke Calibration for more details.
NOTE: The gain switch is live meaning that regardless of
the Auto Tune selection, the gain settings can be adjusted at
any time during operation by changing the selectable GAIN
switch position. See Figure 37.
NOTE: When using an Analog Output (AO) function of
the Multi-Function Card, the AO signal corresponds with the
Signal At Closed selection. If the valve closes with a 4 mA
signal, the AO will show a 4 mA signal at closed. If the valve
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26.4 Stroke Calibration
More
Responsive
More
Stable
Figure 37: Selectable GAIN Switch
26.3.6 Quick Calibration Switch
This switch selects between Auto and Jog calibration modes.
Auto - Use the Auto setting if the fully opened position of the
valve has a mechanical stop. This is typical for most valves.
In Auto mode during a stroke calibration (Quick-Cal), the
positioner will fully close the valve and register the 0%
position, then fully open the valve to register the 100%
position.
Jog - Use the Jog setting if the fully opened position of the
valve has no hard stop, but needs to be set manually. In Jog
mode during a stroke calibration (Quick-Cal), the positioner
will fully close the valve and register the 0% position, then
wait for the user to move the valve to the 100% open position
using the ▲Up and ▼Down buttons.
Press the
►ACCEPT/QUICK-CAL button to accept the 100% location.
The ►ACCEPT/QUICK-CAL button is used to initiate an
automatic stroke calibration.
The stroke calibration
determines the closed (0%) and open (100%) positions of the
valve and gathers information about the response of the
valve (such as valve stroke time) in order to determine the
gains. The gains are then set automatically. After a stroke
calibration, the positioner is ready to control.
To perform a Quick-Cal, first ensure the Quick Calibration
Switch is set to Auto or Jog as appropriate. Press and hold
the ►ACCEPT/QUICK-CAL button for approximately 3
seconds. This will initiate the automatic stroke calibration.
While the calibration is in progress, the LED lights will flash
status codes indicating the calibration progress. See section
37.3 Status Code Descriptions for an explanation of the
status code sequences.
The initial calibration of extremely large or very small
actuators may require several calibration attempts. The
positioner adapts to the actuator performance and begins
each calibration where the last attempt ended. On an initial
installation it is recommended that after the first successful
calibration that one more calibration be completed for
optimum performance.
26.4.1 Quick Calibration Switch – Jog
See section 26.4 Stroke Calibration for more details.
26.3.7 Valve Stability Switch
This switch adjusts the position control algorithm of the
positioner for use with low-friction control valves or highfriction automated valves.
Lo Friction - Placing the switch to Lo Friction optimizes the
response for low friction, high performance control valves.
This setting provides for optimum response times when used
with most low friction control valves.
Hi Friction - Placing the switch to the right optimizes the
response for valves and actuators with high friction levels.
This setting slightly slows the response and will normally stop
limit cycling that can occur on high friction valves. See
section 28.3.7 Configuration (Pressure Control) for more
details.
NOTE: This option is more effective on with Advanced or
Pro diagnostic levels.
26.3.8 Spare Switch
If special features have been purchased they may be
controlled by this switch. See associated documentation for
more details.
Set the Quick Calibration Switch to Jog if the valve/actuator
assembly has no internal mechanical stop at the fully open
position. In this case, follow these instructions:
4
Press and hold the ►ACCEPT/QUICK-CAL button for
approximately 3 seconds.
This will initiate the jog stroke calibration. The positioner will
then close the valve and set the zero position. The zero
position is automatically always set at the valve seat. At this
point the LED‘s will flash in a sequence of G-R-R-R (greenred-red-red) which indicates that the user must use the jog
keys to manually position the valve to approximately 100%.
5
6
Use the up and down keys to position the valve at
approximately 100% open.
Press the ►ACCEPT/QUICK-CAL button to proceed.
No more user actions are required while the calibration
process is completed. When the lights return to a sequence
that starts with a green light the calibration is complete.
The jog calibration process will only allow the user to set the
span.
If an elevated zero is needed a handheld or
ValveSight DTM are required.
26.4.2 Tuning Options
Quick-Cal Custom Gains - This is typically the fastest way to
achieve ideal gains. Set the Auto Tune Configuration Switch
to On and the Selectable GAIN Switch to “E”. Then perform
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
a Quick-Cal.
During the Quick-Cal, custom tuning
parameters will be determined based on measured response
parameters. The gains can then be fine-tuned by adjusting
the Selectable GAIN Switch. Selecting “D” “C” or “B” will
progressively provide a more stable response. Selecting “F”
through “J” will progressively provide a more active response.
In most cases selecting “E” will give the best results. This is
the default setting for all actuator sizes. Raising or lowering
the Selectable GAIN Switch setting is a function of the
positioner/valve response to the control signal, and is not
actuator size dependent.
Standard Preset Gains - If standard, preset gains are
desired, set the Auto Tune Configuration Switch to Off. After
performing a Quick-Cal, use the Selectable GAIN switch to
the desired level (“B” – “J”). The standard, preset gain
settings are not affected by Quick-Cal.
It may be necessary to set the gain switch BEFORE the
Quick Cal. Very fast stroking valves may need to be at lower
gains and very slow stroking valves may need to be at higher
gains.
Custom Manual Gains - To set gains manually, set the
selectable GAIN switch to “A”. Changing the switch from “B”
to “A” will write the standard “B” settings into the “A”
parameters, allowing a starting point for modification.
Similarly, changing the switch from “J” to “A” will write the
standard “J” settings into the “A” parameters. Custom tuning
values can then be entered using the Display Menu, a
Handheld or ValveSight DTM. With the Selectable GAIN
Switch set to “A”, the tuning will not be modified during a
Quick-Cal.
26.4.3 Aborting a Quick-Cal
The Quick-Cal can be aborted at any time by briefly pressing
the ◄ BACK button. In this case, the previous settings will
be retained.
26.4.4 On Line Stroke Calibration Adjustments
At times an adjustment to the calibration is desired, but the
process cannot be interrupted. The stroke calibration can be
adjusted with minimal valve movement. Contact your local
Field Service Technician for more information.
26.5 Analog Output (AO) Calibration
The Analog Output (position feedback) function of the MultiFunction Card can be configured calibrated using the DTM or
LCD. Ensure the card is installed, the positioner recognizes
the card, and it is configured to be an AO.
The DTM AO calibration wizard is found here:
Configuration / Card Slot 1 (or 2) / Multi-Function Card /
Analog Output Calibration.
The LCD AO calibration features are found here:
Card 1 (or Card 2) / Multi-Function Card / Config/Cal
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27 POSITIONER FUNCTIONS (No
Display Required)
The following features can be performed using the local
interface.
No display is required for these features.
Additional features are offered with the use of a display,
Handheld or DTM.
NOTE: In order to prevent unintentional adjustments of
the configuration, tuning, or control of the valve, the Tamper
Lock feature may be used. This is set in the DTM and
disables the buttons and menus except for the ability to view
the status of the positioner. When locked, the positioner may
be temporarily unlocked by entering a PIN. (An LCD is
required to enter the PIN.) Or, the positioner can be
unlocked from the DTM.
27.1 Live Manual Tuning (Adjusting the
Gain)
Use the Selectable GAIN Switch to adjust the gain at any
time during operation. This adjustment takes effect
immediately. For faster response select settings above “E”
(F-J). For more stable response, select settings below “E”
(B-D). See Figure 36: Local User Interface on page 98.
valve information will also be lost and need to be restored. A
factory reset will always reset the command source to analog
4-20 mA.
NOTE: Once the Multi-Function Card (MFC) type has
been configured, the type selection will still remain after a
factory reset.
CAUTION: Performing a factory reset may result in the
inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and make
sure the valve is properly isolated.
27.5 Viewing Version Numbers
The version number of the embedded code may be checked
at any time except during a calibration. To see the major
version number, hold the ▲Up button. This will not alter the
operation of the unit other than to change the blink sequence
to 3 blinks indicating the major version number. Holding the
▼Down button will give the minor version number without
affecting operation. The version codes are interpreted
according to the following table:
Table 17: Viewing Version Numbers
First
Blink Color
G
G
G
G
G
G
G
G
G
Y
Y
Y
Y
Y
Y
Y
Y
Y
R
R
R
R
R
R
R
R
R
27.2 Local Control Of Valve Position
To manually adjust the position of the valve regardless of the
input command (analog or digital), press and hold the ▲Up,
▼Down and ◄ BACK buttons for about 3 seconds. The
▲Up, ▼down buttons can then be used to position the valve.
While in this mode the LED‘s will flash a GRRY (green-redred-yellow) sequence. To exit the local control mode and
return to normal operation, briefly press the ►
ACCEPT/QUICK-CAL button.
CAUTION: When operating using local control of the
valve, the valve will not respond to external commands.
Notify proper personnel that the valve will not respond to
remote command changes, and make sure the valve is
properly isolated.
27.3 Command Source Reset
Performing a command source reset will reset the command
source to analog if it has been inadvertently left in digital
mode. This is done by holding down both the ▲Up and
▼Down
buttons,
then
briefly
pressing
the
►ACCEPT/QUICK-CAL button.
27.4 Factory Reset
To perform a factory reset, hold ► ACCEPT/QUICK-CAL
button while applying power. All of the internal variables
including calibration will be reset to factory defaults. The
positioner must be re-calibrated after a factory reset. Tag
names and other user configured limits, alarm settings, and
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Second
Blink Color
G
G
G
Y
Y
Y
R
R
R
G
G
G
Y
Y
Y
R
R
R
G
G
G
Y
Y
Y
R
R
R
Third
Blink Color
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
G
Y
R
Version
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
For example, if holding the ▲Up button gave a G-G-R code,
and holding the ▼Down gave a Y-Y-G code then the
resulting version number would be 2.12.
27.6 Analog Input Calibration
The Analog Input Calibration allows the user to define the mA
current that will designate the 0% and 100% commands.
This is done by holding down both the ◄ BACK and the
►ACCEPT/QUICK-CAL button for about 3 seconds. The
blink code should change to GRYG. Adjust the input current
to correspond with the 0% position (usually 4 mA). Briefly
press the ►ACCEPT/QUICK-CAL button. The blink code
should change to GRYY. Adjust the input current to
correspond with the 100% position (usually 20 mA). Briefly
press the ►ACCEPT/QUICK-CAL button.
27.7 Select and Calibrate Analog Output
To change the Multi-Function Card to the Analog Output
function and calibrate, hold down both the ◄ BACK and the
▲Up button for about 3 seconds. The blink code should
change to GYRG. If desired, adjust the output current for the
0% position by pressing the ▲Up or ▼Down button. Briefly
press the ►ACCEPT/QUICK-CAL button. The blink code
should change to GYRY. If desired, adjust the output current
for the 100% position by pressing the ▲Up or ▼Down
button. Briefly press the ►ACCEPT/QUICK-CAL button.
27.8 Select Discrete Output
The Discrete Output mode generates a high current of about
7 mA in the normal state. When the Position Deviation alarm
is tripped, the output changes to 0.5 mA.
To change the Multi-Function Card to the Discrete Output
function, hold down both the ◄ BACK and the ▼Down
button for about 3 seconds. The blink code should change to
GRYR. Briefly press the ►ACCEPT/QUICK-CAL button.
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28 POSITIONER FUNCTIONS (LCD
Display)
The optional LCD display provides a variety of useful
information and functions. The Main View shows important
information using icons and scrolling status lines. Using the
directional buttons (▼▲►◄) to navigate the menu, the user
can view detailed information perform commonly used
functions. See Figure 38.
NOTE: The LCD backlight may change brightness during
use. This is normal. The backlight uses any residual power
not used by other functions of the circuitry. When current
supply is low (4mA) the light will appear darker. When
current supply is high (20mA) the light will appear brighter.
28.1 Main Display View
The main view provides an instant display of important status
parameters: Position, Final Command, Scrolling Status
Message, Current Alarm Status and Status Icons.
DIP Switch Override – This indicates that the Configuration
(DIP) Switches do not reflect the actual configuration of the
positioner. This can happen if a Configuration Switch is
changed after a Quick-Cal, or if the configuration is was
changed from the DTM. Performing a Quick-Cal will reset
the configuration to what the Configuration Switches show,
which may not be desirable in this case. Ensure the
Configuration Switches are set properly before performing a
Quick-Cal.
28.1.3 Current Alarm Status
The Current Alarm Status area shows the highest priority
alarm, warning, alert or status indication. This matches the
code indicated by the flashing LEDs.
28.1.4 Status Icons
Status icons continuously show the state of the features and
modes.
Table 18: Status Icons
28.1.1 Position and Command
Icon Location
The current Position and Command are always shown. This
shows the Final Command which has been adjusted
according to a Characterization Curve, MPC, or Soft Limits
that have been applied and should match the Position.
Upgrade Level
Icon
Icon Meaning
Standard
Advanced upgrade
Pro upgrade
28.1.2 Scrolling Status Messages
The Scrolling Status Message provides the following
information as applicable:
Date and Time – The date and time format is adjustable.
See Section 28.3.9 Configuration (Set Time and Date) for
more information.
Ambient Temperature – This is the temperature inside the
positioner.
Supply Pressure – The supply pressure is available with
Advanced and Pro upgrades.
Friction – This is calculated when the valve moves. Friction
is available with the Pro upgrade.
Actuation Ratio – This is the amount of available force used
to move the valve.
Pneumatic Leak – This is leak beyond normal air
consumption. Pneumatic Leak is available with the Pro
upgrade.
Training Percent Complete – Training tracks key parameters
for a period of time. This data can be used to set more
meaningful Alarm and Warning limits. Training will begin
automatically after 24 hours of continuous operation and end
after 90 days of positioner operation. Or use the DTM to
initialize this function. The training status will show only if
training has occurred.
Training Hours Remaining - This shows the hours left in the
training session if training is currently in progress.
Auxiliary Card 1 Status - This shows the type of card in
auxiliary card slot 1.
Auxiliary Card 2 Status - This shows the type of card in
auxiliary card slot 2.
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Analog command mode
Command
Source
Digital command mode
Out of service
Training in progress
Training Mode
Training complete
(blank)
Training not started
Pressure control locked
Pressure
Control
(blank)
HART
Communicatio
ns
(blank)
Pressure control not locked
HART communication currently in
progress
Burst mode in progress
No HART communication currently
in progress
CST ramping up
Continuous
Stroke Test
(CST)
CST ramping down
CST holding steady
(blank)
CST not activated
Upgrade Level Icons - The upgrade levels provide increased
functionality beginning at none, then Standard, Advanced
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
and finally Pro. These levels also correspond to the model
numbers 510+, 520MD+, 521MD+ and 522MD+ respectively.
A 510+ positioner has limited diagnostics and cannot be
upgraded. A Standard (520MD+) has positioner positionbased diagnostics and can be upgraded to a 521MD+ in the
field. An Advanced (521MD+) positioner includes pressure
sensor functions and can be upgraded to a 522MD+ in the
field.
A Pro (522MD+) positioner includes the pressure
sensor functions along with full diagnostic capabilities and is
fully upgraded.
Command Source Icons – The positioner is in Analog
Command mode if it is using the 4-20 mA signal to control
the location of the valve. In Digital Command mode, the
positioner ignores the 4-20 command and responds to the
position command given through HART. In Out Of Service
mode, the positioner is performing a calibration, signature,
partial stroke test or is in a factory reset state.
Training Mode Icons – The positioner can keep track of
several key data parameters for a period of time specified by
the user. This data can be viewed while setting alarm limits
to make them more meaningful. For example, if supply
pressure cycles every day from 5 bar to 4 bar in normal
operation, this information will be displayed where the supply
pressure warning limits are set. Seeing that the supply
typically drops to 4 bar, the user can then set the supply
pressure low warning to a value below 4 bar. See the DTM
User Manual for more information.
Pressure Control – When the position of the valve gets very
close to the commanded position, the positioning algorithm
will change to pressure control. This means the pressures
will be held constant (locked), improving the stability of the
valve position. 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%, the pressure “locks”. This value can be adjusted using
the Display Menu or DTM. See section 28.3.7 Configuration
(Pressure Control).
HART Communications Icons – When the positioner is
sending or receiving data via the HART communication
protocol, the icon will be displayed. During burst mode, a
pulsating heart icon will be displayed.
Continuous Stroke Test (CST) – For valves that are normally
held at a constant position for extended periods of time, the
Continuous Stroke Test can provide assurance that the valve
is still responsive. When CST is on, the positioner will cause
a very small amount of valve movement.
From this
movement, the positioner can find information about the
health of the valve, actuator and positioner.
This is not
recommended for valves intended for high accuracy or
stability.
To achieve the CST function, the positioner adds a small
deviation to the command. The deviation is ramped at a rate
of 0.05%/second up to 5%. However, the instant the valve
moves, the ramp reverses and begins to grow in the opposite
direction. So, with low friction, the actual movement will be
quite small. If the valve does not move by the time the
deviation equals 5%, a counter will start. After 5 consecutive
failed attempts to move, the CST warning will appear. The
ramp rate, maximum limit, and frequency of the CST can be
adjusted using the DTM.
28.1.5 Adjusting the Display Contrast
To adjust the display contrast, hold the ◄ Back button for 3
seconds. Use the ▲Up and ▼ Down buttons to adjust the
contrast. Use the ►ACCEPT/QUICK-CAL to accept the
settings.
Final Command
Position
Status Icon
Scrolling Status
Message
Current Alarm
Status
Figure 38: Display Main View
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28.2 Menu Overview
Status
Command (mA)
Command (%)
Position (%)
2
PS (Supply Pressure)
2
PA (Port A Pressure)
2
PB (Port B Pressure)
3
Friction
3
Actuation Ratio
3
Pneumatic Leak
Temperature
Valve Cycles
Valve Travel (%)
Card 1 Value
1
Card 2 Value
Alerts and Alarms
Current Alarms (Prioritized)
Event History
Last Event
2nd Event
3rd Event
*
*
*
32nd Event
1
Air Flow Units
1
Actuator Area Units
1
Date Format
Number Format
LCD Orientation
1
Burst Mode
ON/OFF
Positioner Revs
SW Rev
Bld Date
Bld Time
HW Rev
CPU Rev
HART Ver
Card 1
Card 2
Factory Reset
1
Aux Card 1 (or Card 2 )
No Card: “No Card”
Multi-Function Card
Not Configured
Set as AO Card
Set as DO Card
1
Set as DI Card
Config/Cal
If Not Configured – “No Configuration Allowed”
If AO
Set 0%
Set 100%
If DO – “Use DTM”
1
If DI
Set to No Action
Set to Trigger PST
Set to Command Override
Set Command Point
1
Partial Stroke Test
Start
Last Result
Calibration
Stroke/Quick Calibration
1
Pressure Sensor Calibration
1
Friction Calibration
1
Triple Calibration
Command Input Calibration
1
Calibration Dates
Configuration
Positioner Tuning
Characterization
Pressure Control
Soft Limits & Shutoff
High Soft Limit
Low Soft Limit
Upper Position Shutoff
Lower Position Shutoff
1
Set Date & Time
User Preferences
All Units
1
Pressure Units
1
Force Units
Temperature Units
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Language
English
German
French
Spanish
Portuguese
Russian
Turkish
Italian
1 Not available with 510+.
2 Requires 520MD+ Advanced positioner upgrade.
3 Requires 520MD+ Pro positioner upgrade.
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The LCD display is an available option with the 510+ and
520MD+ models.
For example, if the Multi-Function Card (MFC) was in slot 1,
configured as an analog output (AO), and giving 12.34 mA,
the display would show “AO 1 12.34mA”. If no card is in the
slot, the display will show “No Card”.
28.3.1 Status
For more information about auxiliary card status, see Table
14: Auxiliary Card Status.
28.3 Menu Features
►Status
►Command (mA)
►Command (%)
►Position (%)
2
►PS (Supply Pressure)
2
►PA (Port A Pressure)
2
►PB (Port B Pressure)
3
►Friction
►Actuation Ratio3
3
►Pneumatic Leak
►Temperature
►Valve Cycles
►Valve Travel (%)
►Card 1 Value
1
►Card 2 Value
1 Not available with 510+
2 Requires 520MD+ Advanced positioner upgrade.
3 Requires 520MD+ Pro positioner upgrade.
The Status menu is used to view information about the
configuration and operation of the system.
Command displays the final command in mA.
Command displays the final command in %.
Position displays the valve position in %.
PS displays the supply pressure.
PA displays the pressure in port A. This is the primary port if
using a poppet-style relay module.
PB displays the pressure in port B. This is the primary port if
using a spool-style relay module.
Friction displays the friction of the actuator/valve assembly.
Actuation Ratio displays the force required to actuate the
valve as a percentage of the total force available. The value
is an estimate of the force that would be required to move the
valve to the end of travel, fully compressing the actuator
spring(s).
Pneumatic Leak is an estimate of leak in addition to regular
air consumption.
Temperature displays the temperature inside the positioner.
Valve Cycles are counted each time the positioner changes
direction. The movement must be beyond a dead-band
window. This window is set to 0.5% as a default, but can be
changed using the DTM.
Valve Travel is counted in small increments every time the
valve moves beyond the dead-band window. The travel is
displayed in % of full stroke.
Card 1 Value shows the configuration and status of the
auxiliary card in slot 1. A tripped state is represented by a 0.
A nominal state is represented by a 1.
Card 2 Value shows the configuration and status of the
auxiliary card in slot 2. A tripped state is represented by a 0.
A nominal state is represented by a 1.
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28.3.2 Alerts and Alarms
►Alerts and Alarms
►Current Alarms (Prioritized)
►Event History
►Last Event
►2nd Event
►3rd Event
*
*
*
►32nd Event
The Alerts and Alarms menu shows current and past alarms,
warnings, alerts, and calibrations.
Current Alarms displays all events that are actively sounding.
Event History displays past 32 events including alarms,
warnings, alerts, and calibrations. The event that occurred
most recently is displayed first (event 32) with later events
recorded below. Each event has a time stamp and shows if it
was turning on or off.
28.3.3 Partial Stroke Test
1
►Partial Stroke Test
►Start
►Last Result
1 Not available with 510+
The Partial Stroke Test (PST) menu provides the user the
ability to start a PST and see the results of the latest PST.
CAUTION: Performing a Partial Stroke Test will result in
valve movement and the inability to operate the valve until
the test is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated if
required by plant procedures.
Start allows the user to initialize the (PST).
Last Result shows “Pass” or “Fail” from the last PST attempt.
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28.3.4 Calibration
►Calibration
►Stroke/Quick Calibration
1
►Pressure Sensor Calibration
1
►Friction Calibration
1
►Triple Calibration
►Command Input Calibration
1
►Calibration Dates
1 Not available with 510+
The Calibration menu allows the user to calibrate the
positioner’s sensors. The positioner can accurately control
with only a Quick-Cal. Typically this is all that is needed. A
friction calibration is recommended if the positioner has been
upgraded to Pro diagnostics. See section 26 STARTUP for
more details.
CAUTION: Performing a calibration may result in valve
movement and the inability to operate the valve until the
calibration is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated
before proceeding.
Stroke/Quick Calibration starts an automatic calibration of the
position feedback sensor. The stroke calibration determines
the closed (0%) and open (100%) positions of the valve and
gathers information about the response of the valve (such as
valve stroke time) in order to determine the gains. The gains
are then set automatically. After a stroke calibration, the
positioner is ready to control.
See section 26.4 Stroke Calibration for more details.
Pressure Sensor Calibration starts an automatic calibration of
the pressure sensors. The pressure sensors are calibrated
at the factory and typically will not need calibration. Use this
feature if new pressure sensors are installed. If desired,
configure the positioner to use the most recent pressure
calibration values after a factory reset. To do this, write a 1
to variable 104 using the Edit Variables page of the
ValveSight DTM.
Friction Calibration starts an automatic calculation of total
system friction. This also determines the spring rate and
other values critical to the Pro diagnostic functions.
NOTE: Friction forces may change quickly when a valve
is first placed into service.
Triple Calibration performs Stoke, Pressure and Friction
calibrations in one step.
Command Input Calibration is used to adjust the input range.
Set the lowest current (Set 0%) and the highest current (Set
100%) that will be used. The default input range is 4 to 20
mA. The “Set 0%” value must be lower than the “Set 100%
value.
Split Range Example:
A split range is easily configured. For example, a 4 to 12 mA
signal can be set to correspond to a 0 to 100% stroke. When
the display shows “Set 0%”, set the command input current
to 4 mA. (The display will show a low Analog to Digital Count
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(ADC) that corresponds to 4 mA.) Then press the
►ACCEPT/QUICK-CAL button to set the value. Press the
▼Down button to move to “Set 100%”. Set the command
input current to 12 mA. (The display will show a high ADC to
correspond to 12 mA.) Again press the ►ACCEPT/QUICKCAL button to set the value. Select the ◄Back Button to
exit.
Signal At Closed = 20mA Example:
If the desired signal at closed is 20 mA, first set the Signal at
Closed DIP switch to 20 mA. Then perform a stroke
calibration by pressing the ►ACCEPT/QUICK-CAL button for
more than 3 seconds. This registers the DIP switch settings.
Then, in the Command Input Calibration menu, when the
display shows “Set 0%” it is expecting the lowest current
value. Set the input current to 4 mA. For “Set 100%”, it is
looking for the highest current value. Set the input current to
20 mA. After accepting theses values, the positioner will
interpret the 20 mA input as 0% valve position and the 4 mA
input as 100%.
Calibration Dates lists the most recent date of each
calibration.
NOTE: To calibrate the Analog Output, see section 31
MULTI-FUNCTION CARD.
28.3.5 Configuration (Positioner Tuning)
►Configuration
►Positioner Tuning
►P-Gain Open
►I-Gain Open
►D-Gain Open
►P-Gain Close
►I-Gain Close
►D-Gain Close
►Open Stroke Time
►Close Stroke Time
►Minimum Open Time
►Minimum Close Time
►Gain Set
The Configuration – Positioner Tuning menu allows the user
to manually adjust individual tuning parameters. All tuning
parameters are automatically set to optimal values during
Quick-Cal. Typically a Quick-Cal is all that is needed for
positioner tuning. See section 26 STARTUP for more details.
CAUTION: Adjusting the tuning parameters will affect
the responsiveness of the valve and could cause rapid
changes to the valve position. Notify proper personnel that
the valve may stroke, and make sure the valve is properly
isolated before proceeding.
P-Gain, I-Gain and D-Gain are the proportional, integral, and
differential elements of the feedback algorithm. These gains
are different for the opening and closing directions because
typically responsiveness is different in each direction.
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NOTE: Only those with specific training in PID tuning
algorithms should attempt to adjust the tuning by manually
changing the PID values.
Open Stroke Time is the fastest time it took the valve to
stroke from 0% to 100% during Quick-Cal.
Close Stroke Time is the fastest time it took the valve to
stroke from 100% to 0% during Quick-Cal.
Minimum Open Time and Minimum Close Time (Speed
Limits) are used to prevent the valve from moving too quickly.
This can be used when the process is sensitive to rapid flow
or pressure changes. This shows the time (in seconds) that
the positioner will allow the valve to travel a full stroke. This
speed limit applies to smaller movements of the valve too.
For example, if the Minimum Open Time were set to 20
seconds, and the command was changed from 40% to 50%,
the positioner would move the valve at a constant rate, taking
2 seconds to complete the move. If the Minimum Close Time
was set to 0, and the command was changed from 50% back
to 40%, the positioner would make the move as quickly as
possible.
The default values are 0 seconds, meaning the positioner will
move the valve as quickly as possible.
Gain Set with Dual selected, applies independent gains in the
open and closing directions (default). With Single selected,
the most conservative gains found during calibration are
applied in both the open and closing directions.
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28.3.6 Configuration (Characterization)
►Configuration
►Characterization
►MaxFlo Linear
►MaxFlo Equal %
►Valdisk Linear
►Valdisk Equal %
►ShearStream Linear
►ShearStream Equal %
►Custom
The Configuration – Characterization menu allows the user to
change the characterization of the command. This allows a
better match between the input command and the actual fluid
flow through the valve. This feature is typically used with
valves that have non-linear flow characteristics.
The
positioner makes a correction by applying an adjustment to
the input command according to a characterization curve.
The table below shows the available characterization curve
options. Each point of the Custom curve can be adjusted
using the ValveSight DTM. See Figure 39.
To view the characterization curve options, set the
Characterization switch “Other” before performing a QuickCal. Otherwise, the only option available is “Linear”. If a
Quick-Cal is not possible, use the ValveSight DTM to select
the curve.
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Table 19: Characteristic Curve Data
Final Command
Command
Input
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
75.0
80.0
85.0
90.0
95.0
100.0
Characterizatio
n DIP set to
“Linear”
Characterization
DIP set to
“Other”
Linear
MaxFlo
Linear
MaxFlo
=%
Valdisk
Linear
Valdisk
=%
ShearStream
Linear
ShearStream
=%
Custom
(Default)
(Linear =%)
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.00
55.00
60.00
65.00
70.00
75.00
80.00
85.00
90.00
95.00
100.00
0.00
6.50
11.60
16.20
20.50
24.60
28.50
32.40
36.20
40.00
43.80
47.60
51.50
55.50
59.50
63.80
68.20
73.00
78.40
85.00
100.00
0.00
1.00
2.00
3.00
4.40
5.80
7.40
9.30
11.20
13.50
16.10
19.10
22.40
26.20
30.60
35.70
41.70
48.90
57.70
69.20
100.00
0.00
13.00
20.00
26.25
32.10
37.50
42.60
47.40
51.80
56.00
60.00
63.60
67.20
70.60
73.90
77.20
81.30
84.00
87.80
92.10
100.00
0.00
4.00
6.00
7.80
9.30
11.50
14.00
16.50
19.30
22.50
26.00
30.00
34.70
39.60
45.10
51.30
57.80
64.80
72.50
81.30
100.00
0.00
25.00
35.00
44.00
50.20
55.50
60.20
64.30
68.00
71.50
74.70
77.70
80.50
83.20
85.90
88.40
90.80
93.20
95.50
97.80
100.00
0.00
8.00
14.00
17.00
21.00
24.00
27.50
31.50
35.50
39.50
43.90
48.10
52.80
57.40
62.40
67.50
72.90
78.60
84.70
91.20
100.00
0.00
0.62
1.35
2.22
3.25
4.47
5.91
7.63
9.66
12.07
14.92
18.31
22.32
27.08
32.71
39.40
47.32
56.71
67.84
81.03
100.00
point-by point. To modify the Custom curve, use the
ValveSight DTM.
100
Linear
90
MaxFlo
Linear
MaxFlo =%
Final Command
80
70
60
Valdisk
Linear
Valdisk =%
50
40
30
ShearStream
Linear
ShearStream
=%
Custom
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Command Input
Figure 39: Characterization Curves
Select the appropriate curve as required by the process
design.
Custom - Select Custom for a standard 30:1 linear equal
percent rangeability curve. The curve may be customized
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CAUTION: Changing the characterization curve may
cause the valve to move suddenly. Notify proper personnel
that the valve may stroke and if required, make sure the
valve is properly isolated before proceeding.
28.3.7 Configuration (Pressure Control)
►Configuration
►Pressure Control
►Window
The Configuration (Pressure Control) menu allows the user
to change the size of the pressure control window. This
window becomes active when the Valve Stability Switch is
set to “Hi”.
The Valve Stability Switch optimizes the
response for valves and actuators with high friction levels.
When set to “Hi”, it slightly slows the response and will
normally stop limit cycling that can occur on high friction
valves.
Window - When the position of the valve gets within the
pressure control window, the positioning algorithm will
change to pressure control. This means the pressures will
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
be held constant (locked), improving the stability of the valve
position.
28.3.8 Configuration (Soft Limits and Shutoff)
►Configuration
►Soft Limits & Shutoff
►High Soft Limit
►Low Soft Limit
►Upper Position Shutoff
►Lower Position Shutoff
Soft Limits allows the user to limit the movement of the valve.
Shutoff allows the user to tightly shut the valve with all
available force.
High Soft Limit and Low Soft Limit - This feature is used to
simulate physical blocks on the valve that restrict movement
past a set point. Once the Soft Limit is set, the positioner will
not attempt to move the valve position (final command)
beyond the set point, regardless of the analog or digital
command input signal.
CAUTION: Changing the Soft Limits may limit the
movement of the valve. The valve may not shut or open fully.
NOTE: Removing power to below 3.6 mA will still cause
the valve to move to the de-energized state regardless of the
Soft Limits.
Upper Position Shutoff and Lower Position Shutoff - This
feature, (also called Minimum Position Cutoff or MPC) is
used to tightly close or open the valve. It is used when a
tight seal is needed or when debris or friction may otherwise
interfere with complete closure.
When the valve is
commanded past the Shutoff points, the pilot relay will direct
full supply pressure to the appropriate port, applying all
available force to close (or open) the valve. The Shutoff
points apply to the Final Command.
CAUTION: Changing the Shutoff limits may cause the
valve to fully open or fully close after the command passes a
set limit.
Though Shutoff and Soft Limit features should not be used
together, if both are set, the greater of the two settings will
take precedence at the closed end; and the lesser of the two
settings will take precedence at the open end.
28.3.9 Configuration (Set Time and Date)
►Configuration
1
►Set Date & Time
Set Time and Date – Use the ▲Up and ▼Down buttons to
set the time and date. The format of the time and date is
displayed above the input fields.
28.3.10 Configuration (User Preferences)
►Configuration
►User Preferences
►All Units
1
►Pressure Units
1
►Force Units
►Temperature Units
1
►Air Flow Units
1
►Actuator Area Units
1
►Date Format
►Number Format
►LCD Orientation
1 Not available with 510+
The User Preferences menu allows the user to format how
information is displayed.
The following table shows the available options. By default
the positioner is set to show information in International
System (SI) units. To change all units to North American
(English), make the selection under All Units. Each selection
can also be changed individually.
Table 20: User Preference Options
International
North
Units/Format
System (SI)
American
(Default)
(English)
All Units
SI
North American
-
Pressure
bar
PSI
kg/cm2,
kPa
N
lbf
kg
degrees C
degrees F
-
Force
Temperature
Air Flow
slph
scfm
slpm,
Nm3/hr
Actuator Area
cm2
in2
-
Date Format
Day.Mon.Year
Mon/Day/Year
-
Comma
Decimal Point
-
Number
LCD Orientation – Use this selection to turn the turn the
display upside down (180 degrees). Use this feature when
the positioner is mounted upside down.
1 Not available with 510+
The positioner has an internal clock. The clock allows time
and date information to be stored with alarms and other
events. The clock does not account for daylight savings.
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Other
Options
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28.3.11 Configuration (Burst Mode)
►Configuration
1
►Burst Mode
►On/Off
CAUTION: Performing a factory reset may result in the
inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and make
sure the valve is properly isolated.
28.3.14 Card 1 (or Card 2)
1 Not available with 510+
Burst Mode continuously transmits HART information.
Two slots are available for auxiliary cards. The MultiFunction Card (MFC) can be configured for analog output
(AO), Discrete Input (DI) and Discrete Output (DO).
On/Off – Use this feature to turn burst mode on and off.
28.3.12 Configuration (Positioner Revs)
►Configuration
► Positioner Revs
► SW Rev
► Bld Date
► Bld Time
► HW Rev
► CPU Rev
1
► HART Ver
► Card 1
► Card 2
1 Not available with 510+
Positioner revisions are shown in this menu.
SW Rev –The revision of the embedded software.
Bld Date –The date of the embedded software build.
Bld Time –The time of day of the embedded software build.
HW Rev –The revision of the main board.
CPU Rev – The revision of the CPU.
HART Ver –The revision of the HART protocol (5, 6, or 7).
Card 1 – The software revision on Card 1.
Card 2 – The software revision on Card 2.
28.3.13 Configuration (Factory Reset)
►Configuration
► Factory Reset
At times, it may be convenient to reset all of the variables to
a default state. In this case, perform a Factory Reset.
Factory Reset – Use this feature to reset all variables to their
factory default state. All of the internal variables including
calibration will be reset to factory defaults. The positioner
must be re-calibrated after a factory reset. Tag names and
other user configured limits, alarm settings, and valve
information will also be lost and will need to be restored. A
factory reset will always reset the command source to analog
4-20 mA.
NOTE: Once the Multi-Function Card (MFC) type has
been configured, the type selection will still remain after a
factory reset.
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NOTE: With Logix 510+, only Card 1 is available with
either AO or limited DO function.
►Card 1 (or Card 2)
►No Card
No Card – This is displayed when no card is present in the
slot.
1
►Aux Card 1 (or Card 2 )
►Multi-Function Card
►Not Configured
►Set as AO Card
►Set as DO Card
1
►Set as DI Card
►Config/Cal
►If Not Configured – “No Configuration Allowed”
►If AO
►Set 0%
►Set 100%
►If DO – “Use DTM”
1
►If DI
►Set to No Action
►Set to Trigger PST
►Set to Command Override
►Set Command Point
1 Not available with 510+
Multi-Function Card – This is displayed when a MultiFunction Card is present in the slot. Configuration options
follow. See section 31 MULTI-FUNCTION CARD for more
information. On entering the MFC menu, the menu item
below will be highlighted indicating the current MFC function.
To set the function, select the function and select Accept.
Not Configured – The MFC is not configured for any function
by default. The configuration must be set by using the
following functions.
Set as AO Card – Use this feature to set the MFC as an
analog output card.
Set as DO Card – Use this feature to set the MFC as a
discrete output card. A 510+ will only trigger off of the
Position Deviation alarm.
Set as DI Card – Use this feature to set the MFC as a
discrete input card.
Config/Cal – Use this feature to further configure the MFC.
The menu items below this level will change according to the
MFC configuration type selected.
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If Not Configured
No Configuration Allowed – Because the card type has not
been selected, no configuration options are available.
If Set As AO Card
Set 0% - Set the current (mA) that will correspond to the
0% (closed) valve position.
Set 100% - Set the current (mA) that will correspond to the
100% (open) valve position.
29 HART COMMUNICATION
The Logix 520MD+ series positioners use the HART
communication
protocol
specified
by
the
HART
Communication Foundation.
29.1 ValveSight DTM
NOTE: The AO calibration values are required to match
the “Signal At Closed” configuration switch on the positioner.
For example, if the switch is set to 4 mA, the “Set 0%” current
must be less than the “Set 100%” current.
Flowserve Corporation has produced a custom Device Type
Manager (DTM) for the Logix 520MD+ digital positioners to
support the ValveSight diagnostics platform.
If Set As DO Card
Use DTM – The DO is highly configurable. Use the
ValveSight DTM to set the function of the DO. When used
with the 510+, DO is not configurable and triggers only off
the Position Deviation alarm.
The DTM contains a high level “Dashboard” view of the
system health and status information. See Figure 40. It also
contains comprehensive user-friendly interfaces for control
and reporting of alarms, of-line and on-line diagnostic tests,
calibrations and system configurations.
If Set As DI Card
Set to No Action – Use this option if only an
acknowledgement of the DI state is desired.
Set to Trigger PST – Use this option to initiate a partial
stroke test when the DI state goes high.
Set to Command Override - Use this option to override the
analog or digital command input to move the valve to a set
position as long as the DI state remains high.
Set Command Point – Use this feature to set the override
position.
The position is a final command (not
characterized). Tight Shutoff settings and Soft Limits will
still apply.
The ValveSight DTM is available from a Flowserve
representative or from www.valvesight.com.
28.3.15 Language
► Language
►English
►German
►French
►Spanish
►Portuguese
►Russian
►Turkish
►Italian
Figure 40: ValveSight DTM Dashboard
29.2 HART 375/475 Handheld
Communicator
The display menu is available in several languages.
To navigate directly to the language menu, select the
following sequence of buttons: ▲Up , ▲Up, ►QUICK-CAL /
ACCEPT.
The Logix 520MD+ digital positioner supports and is
supported by the HART 375/475 Handheld Communicator.
The Device Description (DD) files can be obtained from the
HART Communication Foundation or from your Flowserve
representative.
29.3 Changing HART Versions
The Logix 520MD+ positioner comes standard with the
HART 6 communication protocol. Follow this procedure to
change to HART 5 or 7.
5
6
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113
Remove the outer cover.
Remove the inner cover by removing the 6 inner cover
retaining screws.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
CAUTION: Observe precautions
electrostatically sensitive devices.
29.4 Burst Mode
Burst Mode is available with a handheld device. In the
handheld, select the Burst Mode feature under the
Configuration Menu. Variables that are transmitted in burst
mode are shown in the table below.
Table 21: Default HART Parameters for Burst Mode
HART
Variable
Primary
Secondary
Tertiary
Quaternary
Data Description
4-20 Command (%)
Final Command (%)
Purchased with Standard Diagnostics:
Temperature (C)
Purchased with Advanced or Pro Diagnostics:
Supply Pressure (bar)
Valve Position (%)
NOTE: These variable assignments are reestablished
during a factory reset. A field upgrade will not change the
tertiary variable.
HART 5
1234
HART DIP Switch
HART 6
(default)
1234
8
handling
With a clean, non-conductive instrument, change the
position of DIP switch according to Figure 41: HART
DIP Switch.
After changing the DIP switch, the
positioner will immediately recognize the new HART
communication protocol.
Replace the covers.
HART 7
1234
7
for
NOTE: The DTM will not function while the positioner is in
Burst Mode.
Figure 41: HART DIP Switch
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Table 15: Logix 500+ and ValveSight DTM Features
30 MODEL FEATURES
30.2 Valvesight DTM Diagnostic Levels
The DTM is not required for the positioner to function, but the
graphical capabilities of the DTM allow for a richer interface
and additional functionality, including viewing the dashboard,
charts, annunciator panel, test comparisons, and data logs
and printing reports.
The DTM also comes in two versions: “Basic” and
“Advanced”.
•
The “Basic” DTM provides an intuitive, easy-to-use user
interface to the positioner.
It includes calibration,
configuration, auxiliary card information and off-line
diagnostic tests. A dashboard gives a quick view of
important information.
•
The “Advanced” DTM provides a view of the positioner’s
full health analysis and interfaces to all of the
positioner’s “Pro” diagnostic functionality.
It is generally wise to use the Advanced DTM with the
Advanced and Pro positioners.
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Logix 522MD+ (Pro)
ValveSight Advanced
Logix 521MD+ (Advanced)
The Logix 520MD+ digital positioners have three levels of
diagnostics, “Standard”, “Advanced”, and “Pro”.
•
“Standard” diagnostics provide complete safety and
position-related diagnostics and data.
•
“Advanced” diagnostics provide additional pressure
data.
•
“Pro” diagnostics enhance the off-line tests with
additional force data, and provide powerful on-line
monitoring capabilities including friction, data logging
functions,
and
comprehensive
system
health
information.
Logix 520MD+ (Standard)
30.1 MD+ Positioner Diagnostic Levels
Positioner
Logix 510+
The Logix 520MD+ digital positioners include –
•
HART communication.
•
a DTM for viewing and controlling advanced features.
•
Additional diagnostics depending on the diagnostic level
chosen.
ValveSight Basic
The Logix 510+ digital positioner includes –
•
the QUICK-CAL feature that allows the positioner to be
calibrated at the push of one button.
•
limited diagnostics that monitor position, the pilot relay
and electronics.
•
an 8-DIP configuration switch for flexible set-up.
•
a 10-position gain selector switch is also included for
quick adjustments to responsiveness.
•
an LCD option provides a dashboard for viewing current
status and a complete menu for viewing and configuring
detailed settings.
•
up to two auxiliary cards for analog output (AO), discrete
input (DI) and discrete output (DO) functions.
DTM
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Hardware
Quick Calibration Button
3-LED Indicator
4-DIP Configuration
8-DIP Configuration
10-Position Gain Adjustment Switch
LCD Display Option
2 Auxiliary Cards (AO, DO, DI options)
X
X
X
1 Auxiliary Card (AO, DO optoins)
Limit Switch Option
Remote Mount Option
Humidity Sensor
Teminal Voltage < 10.0 V
X
Teminal Voltage < 6.0 V
SIL 3
Software
HART Communication
X
X
X
X
X
Off-Line Diagnostics
(Ramp Test, Step Test, HDRL, Partial
Stroke Test)
X
X
X
X
X
On-Line Data Monitor
(Monitor and Save Sensor Data)
X
X
X
X
X
Time Stamped Alarms
X
X
X
X
X
X
X
Pressure Sensor Data
(Supply, Port A, Port B)
X
On-Line Pro Diagnostics
(Force, Actuation, Pneumatic Leak,
Continuous Stroke Testing, etc.)
X
X
Health Evaluation
(Valve, Positioner, Actuator and
Control)
X
X
Training
(Determines Typical Behavior)
X
X
Data Logging
(High Speed Internal Data Capture)
X
X
Long-Term Trend Logging
(14 parameters over 15 years)
X
X
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31 MULTI-FUNCTION CARD
The optional Multi-Function Card (MFC) can be configured to
act as an Analog Output, Discrete Output, or Discrete Input.
Up to two MFCs may be installed at one time.
NOTE: With Logix 510+, only Card 1 is available with
either AO or limited DO function.
MFCs are immune to RFI/EMI
certifications in section 21.
disturbances.
The MFC configured as an AO does not interfere with
positioner operation.
NOTE: The AO signal corresponds with the Signal At
Closed configuration switch setting. If the valve closes with
a 4 mA signal, the AO will show a 4 mA signal when closed.
If the valve closes with a 20 mA signal, the AO will show a 20
mA signal when closed.
See
31.2 Discrete Output (DO)
Table 22: Multi-Function Card CrossReferences
Information
IOM Section
Analog
Output
Specifications
Electronic
Connections
20.4
Analog Output
25.3
Multi-Function Card (AO,
Page
74
DO, DI)
93
Table 14: Auxiliary Card Status
94
Configuration
28.3.14
112
Certifications
21
Hazardous Area
Certifications
Status
Card 1 (or Card 2)
77
Use the Discrete Output function of the MFC to indicate a
variety of conditions such as alarms, warnings, position
limits, etc. Alarms that are masked will not cause the DO to
trip. The current is normally high, and drops low when one of
the pre-configured states occurs.
Configuration of the discrete output signal is done using the
ValveSight DTM or push-buttons. To change the MultiFunction Card to the Discrete Output function using the
buttons, see section 27.7.
With Logix 510+, the DO function may be selected using
push buttons, but will be limited to trip on the deviation alarm
only.
The MFC configured as a DO does not interfere with
positioner operation.
MultiFunction
Card
The MFC DO complies with DIN 19234 standard. For
specific current limits, see Table 14: Auxiliary Card Status.
31.3 Discrete Input (DI)
Use the Discrete Input function of the MFC to signal the
positioner to begin a partial stroke test, or move to a
predefined position as long as the signal remains.
Supply a low voltage (or no voltage) to indicate a normal
state. Raise the voltage to indicate the tripped state.
Configuration of the discrete output signal is done using the
display menu, a HART handheld Communicator, or the
ValveSight DTM .
Figure 42: Multi-Function Card
For specific voltage limits, see Table 14: Auxiliary Card
Status.
31.1 Analog Output (AO)
Configure the MFC as an Analog Output device to produce a
4-20 mA signal that corresponds to the position of the valve.
Output follows actual position of valve, including all failure
modes of positioner except loss of power. An output of < 1.0
mA is transmitted when the positioner loses power.
Calibration of the analog output signal is performed using the
display menu, a HART handheld communicator, or the
ValveSight DTM or push-buttons. To change the MultiFunction Card to the Analog Output function and calibrate
using the buttons, see section 27.7.
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NOTE: When 2 cards are configured as DI at the same
time, where both are configured to override the position
command, the card in slot 1 will take priority regardless of the
order in which the override commands are triggered.
CAUTION: During the use of the Discrete Input function,
the valve may stroke unexpectedly. Follow internal
procedures, ensuring that the configured movement of the
valve (performing a PST or moving to a set-point) is allowed.
Notify proper personnel that the valve will stroke, and make
sure the valve is properly isolated if required.
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32 V TO I CARD
33 LIMIT SWITCHES
The optional V to I card allows the use of a DC voltage
source (e.g. 24 Volts) to power the positioner. This is
typically for on/off emergency shut-down valves.
The
positioner is left in digital mode and the position is
commanded by the DTM or Hand-Held. The positioner can
receive commands via HART. Partial stroke tests can be
performed via HART commands. Reducing the voltage to
below 10 volts causes the positioner to shut down and go to
the fail safe position.
The V to I card is immune to RFI/EMI disturbances. See
certifications in section 21.
Section
Page
33.2 Limit Switch Types
V to I Card
Specification
s
20.8
Certifications
21
Hazardous Area
Certifications
77
25.4
95
Electronic
Connections
Safety
Function
Ordering
Limit
Switches
The Logix 500+ digital positioner can be equipped with a limit
switch unit. The unit has two main parts, the electrical switch
board and the vane. The switch board is connected to the
Inner cover. The vane connects to the feedback shaft which
extends through the positioner and moves with the valve.
The vane can hold a cam or ferromagnetic device. As the
shaft rotates, the pick-up switch LS1 or LS2 is activated. The
switching point can be adjusted.
Four types of Limit Switches can be used with the Logix
500+.
Table 23: V to I Card Cross-References
Information
33.1 Limit Switch Operation
V to I Board Specifications
V to I Card Connections
35
Integrity
39.2
Requirements for Safety
Spare Parts Kits
75
119
144
Mechanical switches are triggered by the use of a
mechanical cam and followers. See Figure 44: Limit
Switches.
Reed switches are triggered by a magnetic force.
physical contact occurs.
No
Inductive Slot switches are triggered when the sensor detects
a ferromagnetic vane inserted between the coils.
No
physical contact occurs.
Inductive switches are triggered when the sensor detects a
ferromagnetic vane approaching the coils in the switch. No
physical contact occurs.
V to I Card
Table 24: Limit Switch Cross-References
Information
Page
Electronic
Specifications
20.7
Certifications
21
Hazardous Area
Certifications
77
25.5
96
Electronic
Connections
Install or Adjust
the Limit Switch
Ordering Limit
Switches
Figure 43: V to I Card
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Section
117
Limit Switch Specifications
Limit Switches
75
36.4
Installing a Limit Switch
121
39.2
Spare Parts Kits
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34 REMOTE MOUNT
34.1 Remote Mount Opereation
Terminals
The remote mount option can be used where excessive
vibration or environmental factors prevent the placement of a
positioner directly on the valve.
Vane
Limit
Switches
Figure 44: Limit Switches
The remote mount unit consists of just the feedback
mechanism enclosed in a sturdy container. This assembly is
mounted to the valve/actuator assembly. The actuator tubing
and feedback signals are routed some distance to the
positioner. Tubing is connected to the positioner. The
feedback signal wires are connected to a remote mount
board installed in the Logix 500+ positioner. See Figure
45: Remote Mount Board.
Table 25: Remote Mount Cross-References
Information
Section
Page
Electronic
Specifications
20.6
Electronic
Connections
25.6
Remote Mount
97
39.2
Spare Parts Kits
144
38.1
Positioner Dimensions
141
Ordering a
Remote Mount
Board
Ordering a
Remote Mount
Device
Remote Mount Specifications
75
For more information on the remote mount option, see Logix
Remote Mount Option user instructions, FCD LGENIM0001.
Terminals
Figure 45: Remote Mount Board
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35 REQUIREMENTS FOR SAFETY
INTEGRITY
A typical** response time for the poppet relay to move to a
fail-safe state due to a sudden command change was found
to be 0.10 s at 22 C, 0.23 s at -40 C and .13 s at 85 C.
This section provides information and additional user
responsibilities in order to meet up to Safety Integrity Level 3
(SIL 3) per IEC 61508.
**Tests were with 60 PSI (4.1 bar) supply pressure.
The safety function of the positioner is to go to the fail-safe
state (vent air from the actuator) given a low power condition
to the 4 to 20 mA input terminal.
35.1 Fail Safe State
The fail safe state for a positioner with a three-way (SingleActing), Poppet Style Relay is when the relay valve is at less
than 5% of full stroke such that output port B (Y1) is venting.
The fail safe state for a positioner with a three-way (SingleActing), Spool Style Relay is when the relay valve is at less
than 5% of full stroke such that output port A (Labeled Y1) is
venting.
The fail safe state for a positioner with a four-way (DoubleActing), Spool Style Relay is when the relay valve is at less
than 5% of full stroke such that output port A (labeled Y1) is
venting and port A (labeled Y2) is open to supply pressure.
NOTE: The fail safe states above represent the fail safe state
of the positioner. The valve fail safe state may be different
depending on spring configuration and tubing. Ensure the
valve fail-safe state is appropriate for your application.
35.2 Safety Function
The Logix 520MD+ positioner moves to fail-safe state upon
the removal of analog input power (less than 3.6 mA)
NOTE: If using the V to I card, less than 10 Volts at the V to I
card terminals will produce a current less than 3.6 mA.
35.3 Fail Safe State Response Time
Test to find the final valve assembly response time to ensure
it meets application-specific requirements. Response times
will vary widely with actuator size, the use of boosters, stroke
length, starting position, fail-safe direction, tubing size, supply
pressure, and temperature. The air flow capacity also affects
the response time. See section 20.2 Pneumatic Output for
air flow capacity.
A typical* response time for the spool relay to move to a failsafe state due to a sudden command change was found to
be 0.06 seconds. (The response time was 0.50 s at -40C
and .35 s at 85C.)
NOTE: During the stroke calibration (Quick-Cal), valve stroke
times are measured and recorded in the positioner. To view
them, see tuning parameters on the positioner menu or in the
DTM.
35.4 Positioner Model Selection and
Specification
Any Logix 520MD+ positioner can be used for up to SIL 3
applications as stated above.
35.5 Installation
Ensure installation of the positioner is properly performed
according to this manual. Ensure tubing is configured to the
actuator so that the fail-safe state of the positioner matches
the desired fail-safe state of the valve.
35.6 Required Configuration Settings
The following user settable options must be properly
configured for the individual application in order to provide
the designed safety integrity for that application.
•
Calibrate the analog input (command). The fail safe state
of the valve must correspond to the analog input
command at less than 3.6 mA.
•
It is recommended to lock the local interface to prevent
unintended adjustments of the settings by an
unauthorized user.
35.7 Maximum Achievable SIL
The Flowserve 520MD+ Valve Positioner covered by this
safety manual is suitable for use in low demand mode of
operation Safety Integrity Functions (SIF) up to SIL 2 in
simplex (1oo1) and SIL 3 in redundant (1oo2) configurations.
The achieved SIL for a particular SIF needs to be verified by
PFDAVG calculation for the entire SIF including the failure
rates of the associated sensors and valves that are also part
of the SIF.
For details, contact your Flowserve representative for Failure
Mode, Effects, and Diagnostics Analysis (FMEDA) report
number 520+ is FLO 11-02-062 R001 for Logix 520MD+.
35.8 Reliability data
The time for the valve to move to from 50% to 0% under the
same conditions was found to be 0.22 s. Friction in this case
was 49.5 lbs (220 N).
For reliability data, a detailed Failure Mode, Effects, and
Diagnostics Analysis (FMEDA) report has been prepared and
is available from Flowserve with all failure rates and failure
modes for use in SIL verification. See FMEDA report number
FLO 11-02-062 R001 for Logix 520MD+.
*Tests were with a 25 inch double acting Mark 1 actuator, 0.75 inch (19 mm)
stroke, ambient temperature 74°F (23.3 °C), 60 PSI (4.1 bar) supply, quarter
inch tubing, starting at 50% open, moving to fully closed. Friction was
calculated with a bi-directional ramp test at a rate of 10 seconds/100%.
NOTE: The failure rates of the associated sensors, logic
solver, valves and actuators need to be accounted for in the
Safety Instrumented Function (SIF) level PFDAVG calculation.
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35.9 Lifetime limits
The expected lifetime of the Flowserve 520MD+ Positioner is
approximately 10 years. The reliability data listed the FMEDA
report is only valid for this period. The failure rates of the
Flowserve 520MD+ Valve Positioner may increase sometime
after this period. Reliability calculations based on the data
listed in the FMEDA report for lifetimes beyond 10 years may
yield results that are too optimistic, i.e. the calculated Safety
Integrity Level may not be achieved.
35.10 Proof Testing
The objective of proof testing when used in low demand
mode of operation is to detect failures within the Flowserve
520MD+ Valve Positioner and its associated sensors and
actuators that may not be detected by the normal selfdiagnostics. Of main concern are undetected failures that
prevent the safety instrumented function from performing its
intended function.
The frequency of the proof tests (or the proof test interval) is
to be determined in the reliability calculations for the safety
instrumented functions for which the Flowserve 520MD+
Valve Positioner is applied. The actual proof tests must be
performed at least as frequently as specified in the
calculation in order to maintain required safety integrity of the
safety instrumented function.
The following tests need to be specifically executed when a
proof test is performed. The results of the proof test need to
be documented and this documentation should be part of a
plant safety management system.
NOTE: Positioner failures that are detected should be
reported to Flowserve.
To perform the proof testing, an LCD display or HART
communicator such as a 375 Handheld or software such as
ValveSight DTM for Logix 520MD+ are required.
Steps for Partial Stroke Test (PST)
logic solver. If PST has been implemented then no additional
failure modes will be detected by the proof test. Failure
modes not covered include possible valve sticking in the
travel range not tested and leaking of the valve seat for fail
closed valves.
Steps for Proof Test
Step Action
1. Bypass the safety PLC or take other appropriate action to
avoid a false trip.
2. Set the analog input command to less than 3.6 mA.
3. Ensure that the attached valve is fully in the safe state
(defined by application) and has moved to that position
within the allowed time. This will test for all failures that
could prevent the closure of the valve, including electronic
and mechanical faults, as well as valve faults.
4. Inspect the 520MD+ Valve Positioner for any visible
damage or contamination and ensure the follower arm has
sufficient spring bias if applicable.
5. Check the errors generated by accessing the Alerts and
Alarms menu on the LCD or the Alarm Annunciator in the
DTM or other HART system using command 48.
6. Remove the bypass from the safety PLC or otherwise
restore normal operation.
When the tests listed above are executed, a proof test
coverage of 95% for the 520MD+ can be claimed if PST has
not been implemented as a diagnostic. To be considered as
a diagnostic the PST has to be implemented in a SIL rated
logic solver. If PST has been implemented, then no additional
failure modes will be detected by the proof test. Failure
modes not covered include possible leaking of the valve seat
for fail closed valves.
35.11 Maintenance
Follow routine maintenance. See section 36.1 Scheduled
Maintenance.
Step Action
1. Verify the control loop is ready for valve movement in the
amount set for the PST.
2. Execute the PST via the LCD menu, DD, or DTM.
3. View the results of the PST via the LCD menu, DD, or
DTM.
4. Check the errors generated by accessing the Alerts and
Alarms menu on the LCD menu, DD, or the Alarm
Annunciator in the DTM or other HART system using
command 48.
When the tests listed above are executed, a proof test
coverage of 95% for the 520MD+ can be claimed if PST has
not been implemented as a diagnostic. To be considered as
a diagnostic the PST has to be implemented in a SIL rated
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35.12 Repair and replacement
In the unlikely event that the Flowserve 520MD+ Valve
Positioner fails, the failure should be reported to Flowserve.
Replace faulty components according to section 36 of this
manual or return the positioner to Flowserve for service.
With experience and the right parts, repair times for any
component can be less than an hour, however a 24 hour
mean time to repair should be assumed for safety availability
calculations.
35.13 Training Requirements
Activities specified in this manual shall be performed by a
service technician trained in the installation and maintenance
of process instrumentation. See section 1.4 Qualified
Personnel.
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36 MAINTENANCE AND REPAIR
Pressure Board ( 6 Screws)
0.68 N-m (6 in-lb)
The kits listed in section 39.2 Spare Parts Kits can be
replaced by a technician trained in positioner function and
handling of static sensitive devices.
Double Acting Relay Block ( 2 Screws)
0.56 N-m (5 in-lb)
Double Acting Relay manifold (2 Screws)
0.56 N-m (5 in-lb)
Single Acting Relay (2 Screws)
0.56 N-m (5 in-lb)
Main PCB, MFC, V to I & Limit switch
terminal connections.
0.5 – 0.6 N-m (4-5 in-lb)
CAUTION: Depressurize the positioner before servicing.
CAUTION: Use eye protection.
36.4 Installing a Limit Switch
CAUTION: When touching the circuit boards, observe
precautions for handling electrostatically sensitive devices.
36.1 Scheduled Maintenance
The supply gas filter(s) should be scheduled for regular
maintenance as required to maintain supply gas quality. If
contamination is found in the filter, the inside of the positioner
should be visually inspected for contamination.
If
contamination is found in the positioner, the positioner should
be replaced.
36.2 Required Tools and Equipment
The Logix 500+ digital positioner has modular components
that can be replaced using the tools shown in Figure 46.
Philips Screwdriver #2
________
Philips Screwdriver #1
________
Slot Screwdriver (≤ 3.5mm)
________
2.5 mm Hex Key
________
2.0 mm Hex Key
________
Figure 46: Tools for Positioner Maintenance
The spool, block and manifold of the double acting relay can
be cleaned using acetone, a soft cotton cloth and cotton
swabs.
The Logix 500+ digital positioner can be equipped with an
additional limit switch unit. Part of the switching unit attaches
to the feedback shaft. The sensors attach to the inner cover.
Connections to the limit switch are independent of other
connections to the positioner. See Figure 47.
For electrical connection diagrams, see Table 15: Limit
Switch Connections. For electrical specifications, see Table
7: Limit Switch Specifications.
DANGER: For units installed in hazardous areas special
installation cautions and procedures are required. The
installation of hazardous location electrical equipment must
comply with the procedures contained in the certificates of
conformance. Country specific regulations may apply.
Electrical safety is determined only by the power supply
device. (Positioner operation with limited voltage only).
Installation
4
Remove the outer cover.
5
Place the limit switch board (1) onto the Inner cover (2)
and secure it with 3 mounting screws (3).
6
Install vane assembly (4) and secure with 2 screws (5).
Adjusting Switches
10 Loosen the two screws on the vane (5).
11 Stroke the valve to the first switching position.
12 Set the switching point of the limit switch by adjusting
the lower vane for the lower switch (LS2).
13 Stroke the valve to the second switching position (LS1).
14 Set the switching point of the limit switch by adjusting
the vane for the upper switch.
15 Tighten the two screws on the vane (5).
16 Attach wires to terminals. .
17 Check the two switching points and repeat the
adjustment steps 1 to 6, if necessary.
18 Replace the outer cover.
36.3 Torque Specification for Screws
Table 26: Torque Specification for Screws
Outer Cover (4 Screws)
1.7 N-m (15 in-lb)
Limit Switch (3 Screws)
0.56 N-m (5 in-lb)
Limit Switch Vane (2 Screws)
0.34 N-m (3 in-lb)
Inner Cover (6 Screws)
0.34 N-m (3 in-lb)
LCD (4 Screws)
0.34 N-m (3 in-lb)
Main Board (2 Screws)
0.34 N-m (3 in-lb)
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
5
4
3
1
2
Figure 47: Limit Switch
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36.5 Replacing the LCD Board
The LCD board connects to the main board providing
additional functionality at the local user interface.
Removal
6
Make sure the valve is bypassed or in a safe condition.
7
Disconnect power to the positioner.
8
Remove the inner cover by removing the 6 inner cover
retaining screws. See Figure 48.
9
Unscrew the 4 screws holding the LCD Board in place.
See Figure 49.
10 Gently pry the locking feature on the connector with a
small flat screwdriver and separate the connector from
the main board. Be careful not to pull the cable, as this
may cause damage to the cable.
Installation
5
Connect the LCD Board to the Main Board using the
cable. Ensure the connector’s locking features engage.
6
Align the LCD Board with the 4 stand-offs on the main
board.
7
Screw the LCD Board to the 4 stand-offs.
8
Replace the Inner Cover.
NOTE: The LCD backlight may change brightness during
use. This is normal. The backlight uses any residual power
not used by other functions of the circuitry. When current
supply is low (4mA) the light will appear darker. When
current supply is high (20mA) the light will appear brighter.
Inner
Cover
Screws
Inner
Cover
Screws
Figure 48: Inner Cover
Figure 49: LCD
36.6 Replacing an Auxiliary Card
Up to two auxiliary cards can be installed at a time. Each
communicates independently to the main processor, though
only one cable is used to connect both cards. See Figure 50.
Removal
10 Make sure the valve is bypassed or in a safe condition.
11 Disconnect the power to the positioner.
12 Remove the main cover.
13 Disconnect the two wire connection from the side of the
Card.
14 Unscrew and remove the auxiliary card clips.
15 Gently slide the card from the slot. (If two cards are
present, remove both cards from the slots.)
16 Gently pry the locking feature on the connector with a
small flat screwdriver and separate the connector from
the card. Be careful not to pull the cable, as this may
cause damage to the cable.
17 Replace the second card (if present) back into the slot.
18 Replace the auxiliary card clips.
Installation
11 Make sure the valve is bypassed or in a safe condition.
12 Disconnect the power to the unit.
13 Remove the main cover.
14 Unscrew and remove the auxiliary card clips.
15 If a card is present, gently slide the card from the slot to
access the internal connector.
16 Connect the card to the main board using the internal
connector cable.
Ensure the connector’s locking
features engage.
17 Gently slide the card(s) into the slot(s).
CAUTION: Ensure proper circuitry is used before
connecting cables to the auxiliary card. See section 25
ELECTRICAL CONNECTIONS for more information.
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18
19
20
Route the external cable through the electrical conduit
ports in the base and connect the external cable to the
auxiliary card. See Figure 42: Multi-Function Card.
Replace the auxiliary card clips.
Reinstall the main cover.
Figure 50: Auxiliary Card
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36.7 Replacing a Main Board
Removal
12 Make sure the valve is bypassed or in a safe condition.
13 Remove the outer cover.
14 Disconnect the power to the positioner.
15 Remove the inner cover. See Figure 48: Inner Cover
above.
16 Disconnect the power cable to the main board.
17 Disconnect the auxiliary card cable if present. See
Figure 50: Auxiliary Card on page 124.
18 Disassemble the switch mechanism if present.
19 Remove the inner cover by removing the 6 retaining
screws. See Figure 48: Inner Cover.
20 Remove the screws from the main circuit board. See
Figure 51: Main Board Screws.
21 Gently lift the main board rotating the bottom up while
keeping the top in place.
22 Disconnect the pressure sensor board cable, the hall
sensor cable, the piezo cable and the feedback cable.
(Use a small flat screwdriver to pry the locking features
and carefully separate the connector from the main
board. Be careful not to pull the cable, as this may
cause damage to the cable.) See Figure 52.
Installation
7
Place the main board on the positioner base with the 420 mA input on the same side as the electronic access
ports.
8
Lift the main board rotating the bottom (configuration
switches) upwards while keeping the top in place.
9
Connect the pressure sensor board cable, the hall
sensor cable, and the feedback cable. Ensure the
connector’s locking features engage.
10 Place the main board on the positioner base, ensuring
the cables are clear of the feedback gears. Insert the
two retaining screws.
11 Replace the inner cover by inserting the 6 retaining
screws.
12 Calibrate.
Figure 52: Main Board Connectors
36.8 Replacing the Pressure Sensor
Board
Removal
4
Remove the main board.
See procedure above.
(Disconnecting the hall sensor and feedback cables is
not required.)
5
Unscrew the 6 screws holding the pressure sensor
board in place. See Figure 53.
6
Remove the pressure sensor board.
Installation
4
Place the pressure sensor O-rings in the three holes.
5
Cover the O-rings with the pressure sensor board.
6
Insert the 6 screws. Tighten until the pressure sensor
board makes firm contact with the base.
Calibration
4
Initiate a Pressure or Triple Calibration from the LCD or
DTM.
5
To calibrate the supply pressure sensor 0 value,
disconnect the supply air. Go to Edit Variables. Write
the value from variable 74 (PS ADC Count) to variable
71. (PS ADC Count at 0 psi). Reconnect the supply air.
6
To keep the calibration values even after a Factory
Reset, write a 1 to Variable 104.
Figure 51: Main Board Screws
Figure 53: Pressure Sensor Board
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
36.9 Cleaning and Replacing a Double
Acting Pilot Relay
Removal
7
Remove the Main Board. See procedure above.
8
Fully loosen the 2 spool block screws. By squeezing
the two screws toward each other, grip the spool block
and pull it straight out. Take care to slide the spool
straight out of the spool seat to avoid bending the spool
or damaging the clip spring. The small clip spring
should remain attached to the spool.
9
Remove the first manifold gasket.
10 Remove the 2 manifold screws.
11 Remove the manifold assembly.
12 Remove the second manifold gasket and manifold Oring.
Cleaning
4
Using acetone and a cotton cloth wipe down the block
and manifold.
5
Use cotton swabs to reach inside air passage ways.
6
Dry components thoroughly.
Figure 55: Double Acting Relay Assembly
CAUTION: Follow precautions on acetone label and MSDS.
MSDS.
Figure 56: Clip Spring Orientation
Installation
7
Place the manifold gasket and manifold O-ring into the
base.
8
Place the manifold assembly.
9
Place the 2 manifold screws.
10 Place the manifold gasket.
11 Ensure the spool is oriented properly in the block.
Ensure the clip spring is oriented properly on the spool.
(See 126-Figure 56.) Holding the block level, slide the
spool/block/clip spring assembly onto the manifold
ensuring the proper placement of the spool and clip
spring into the piston slot and tighten the 2 spool block
screws.
12 Reassemble the main board and covers and calibrate.
36.10 Replacing a Single Acting Pilot Relay
Refer to Figure 57.
Removal
6
Remove the Main Board. See procedure above.
7
Remove the two relay assembly screws.
8
Remove the single acting relay.
9
Remove the supply plug screw and O-ring.
10 Remove the Manifold gasket.
Installation
6
Place the Manifold gasket.
7
Place the supply plug O-ring and screw.
8
Place the single acting relay.
9
Place the two relay assembly screws.
10 Reassemble the main board and covers and calibrate.
Figure 57: Single Acting Relay Assembly
Figure 54: Inserting the Double Acting Block Assembly
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
37 TROUBLESHOOTING
37.1 Troubleshooting Guide
Table 27: Troubleshooting Guide
Failure
Probable Cause
Corrective action
No LED is blinking.
4. Current source too low.
5. Voltage of current source is too low.
6. Incorrect wiring polarity.
4. Verify current source supplies at least 3,8 mA.
5. Verify voltage source supplies at least 10VDC.
6. Check wiring for correct polarity.
Erratic communications.
6. Current source bandwidth not
limited to 25Hz.
7. Maximum cable length or cable
impedance exceeded.
8. HART modem connected to PC RS232 port not receiving enough power
9. Interference with I.S. barrier.
10. Current source stripping (filtering)
HART signal.
6. Maximum allowable current source rate of change is
924 mA per second.
7. Check cable size, length and capacitance. See
Section 25 ELECTRICAL CONNECTIONS.
8. Verify laptop battery is not low.
9. Must use HART compatible I.S. barrier.
10. Use a 250Ω resistor and a 22 µF capacitor to create
a HART filter according to the following schematic.
Unit does not respond
to analog commands.
3. The positioner is in digital
command mode.
4. An error occurred during
calibration.
3.
4.
Valve position reading
is not what is
expected.
5. Stem position sensor mounting
is off 180 degrees.
6. Stroke not calibrated
7. Tight shutoff MPC (Minimum
position cutoff) is active.
8. Custom characterization or soft
stops are active.
1.
2.
3.
4.
Position is driven fully
open or closed and will
not respond to
command.
7.
8.
7.
8.
9.
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Stroke is not calibrated.
Inner-loop hall sensor is not
connected.
9. Wrong air action was entered in
software.
10. Actuator tubing is backward.
11. Electro-pneumatic
converter is
malfunctioning.
12. Control parameter inner-loop
offset is too high/low.
127
Switch to analog command mode using the
procedure outlined in Section 27.3
Command Source Reset, use the
ValveSight DTM, or use a handheld
communicator.
Check Status Codes. Correct calibration
error. Recalibrate.
Reposition the sensor.
Perform a Stroke calibration (Quick-Cal).
Verify Tight Shutoff settings.
Verify custom characterization or soft-stop limits.
Perform stroke calibration (Quick-Cal)
Verify hardware connections.
Check ATO (Air-to-open) and ATC (Air-to-Close)
settings. Recalibrate using Quick-Cal to apply
settings.
10. Verify ATO/ATC actuator tubing.
11. Replace electro-pneumatic converter.
12. Adjust inner-loop and see if proper control
resumes.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Sticking or hunting
operation of the positioner
5.
6.
7.
8.
Contamination of the electropneumatic converter.
Control tuning parameters not
correct.
Packing friction is high.
Spool valve is corroded or dirty.
5.
6.
7.
8.
LCD backlight flickering or
dim.
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2.
The backlight uses any residual
2.
power not used by other functions of
the circuitry.
128
Check air supply for proper filtering and meeting
ISA specifications ISA-7.0.01.
Lower proportional gain settings.
Enable the stability DIP switch on the local
interface and recalibrate. If problem persists,
adjust pressure control window with handheld
communicator or ValveSight and recalibrate.
Disassemble and clean spool valve.
Fluctuations in the LCD backlight are normal. No
action required.
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
37.2 Status Code Index
NOTE: Not all status codes are available with all positioner models.
Table 28: Status Code
Index
Cmd Frequency ALM
RYGY
Pilot Response WRN
YRGG
Stroke Cal Req
RGRG
Cmd Frequency WRN
YGYR
Pilot Travel WRN
YGGY
Stroke Shift
RGRY
CST Failed WRN
YGRY
Pneumatic Leak WRN
YRYR
Stroke Span Decrease
RGRY
Code
DI Cmd Override
GRGR
Position < ADC Range
RGGY
Stroke Span Increase
RGRY
A/O Cal in Prog
GRGY
Digital Cmd Mode
GGYY
Position > ADC Range
RGGY
Supply Press Hi WRN
YYGR
A/O Range Small
RGYR
Driver Module ALM
RRYR
Position Limit Alert
YGGG
Supply Press Lo ALM
RYYG
Actuation Ratio WRN
YYYY
Factory Reset State
RGRR
Position Range Small
RGGY
Supply Press Lo WRN
YYYG
Actuator Cycles WRN
YGGY
Feedback Cal Change
RGRY
Position Shift WRN
YYGY
Temperature High WRN
YYGG
Actuator Travel WRN
YGGY
Feedback Cal Error
RGGY
Power ON
GGGG
Temperature Low WRN
YYGG
Air Supply Humid WRN
YYRY
Feedback Linkage ALM
RRYG
Press Board Fail WRN
RYRY
Temperature WRN
YYGG
Air Supply Icing WRN
YYRR
Friction Cal in Prog
GRGY
Pressure Cal in Prog
GRGY
Tight Shut Off Mode
GGGY
Analog In < ADC Range
RGGG
Friction Cal Req
GYYY
Pressure Cal Req
GYYG
Valve Can't Move ALM
RYGG
Analog In > ADC Range
RGGG
Friction High ALM
RRGR
Psn Amplitude ALM
RYGR
Valve Can't Open ALM
RYGG
Analog In Cal Error
RGGG
Friction High WRN
YRGR
Psn Amplitude WRN
YGYY
Valve Can't Shut ALM
RYGG
Analog In Cal in Prog
GRGY
Friction Low ALM
RRGY
Psn Control ALM
RYGR
Valve Cycles WRN
YGGY
Analog In Range Small
RGGG
Friction Low WRN
YRGY
Psn Control WRN
YGYY
Valve Cycles WRN
YGGY
Backlash ALM
RRYY
ILO Time Out
RGGR
Psn Deviation ALM
RRRR
Valve Travel WRN
YGGY
Backlash WRN
YRYY
Initializing
GGYR
Psn Frequency ALM
RYGR
Bellows Cycles WRN
YGGY
Jog Cal Set 100% Pos
GRRR
Psn Frequency WRN
YGYY
Bellows Travel WRN
YGGY
Jog Cmd Mode
GRRY
Psn High Limit Alert
YGGG
Calibration in Progress
GRGY
Local Interface Off
GGYG
Psn Low Limit Alert
YGGG
Card 1 Error
RYYR
Low Battery WRN
YRRG
Psn Sensor Fail ALM
RYRG
Card 1 Fail WRN
RYYR
Main Board Fail WRN
RYRR
PST Failed WRN
YGRR
Card 1 No Loop Pwr
RYYR
Memory Error WRN
YYYR
PST Scheduled
GYYR
Card 1 WRN
RYYR
No Motion Time Out
RGYY
Setting ILO
GRGY
Card 2 Error
RYYY
Opened Too Far WRN
YYGY
Settle Time Out
RGYG
Card 2 Fail WRN
RYYY
Piezo Volts ALM
RRRY
Signature or PST
GRGG
Card 2 No Loop Pwr
RYYY
Piezo Volts High ALM
RRRY
Soft Stop Alert
GYGY
Card 2 WRN
RYYY
Piezo Volts High WRN
YRRY
Soft Stop High Alert
GYGY
Closed Too Far WRN
YYGY
Piezo Volts Low ALM
RRRY
Soft Stop Low Alert
GYGY
Cmd Amplitude ALM
RYGY
Piezo Volts Low WRN
YRRY
Software Error WRN
YYRG
Cmd Amplitude WRN
YGYR
Piezo Volts WRN
YRRY
Spring Fail WRN
YRRR
Cmd Control ALM
RYGY
Pilot Cycles WRN
YGGY
Squawk Mode
GGRR
YGYR
Pilot Response ALM
RRGG
Stroke Cal in Prog
GRGY
Status
Description
Cmd Control WRN
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
37.3 Status Code Descriptions
NOTE: Not all status codes are available with all
positioner models.
GGGG
●●●●
both the UP and DOWN buttons and briefly pressing the
QUICK-CAL/ACCEPT button.
GGYR
●●●●
INITIALIZING
POWER ON
Description: The positioner has powered up and is displaying
a blink sequence 3 times.
Description: No issues.
Possible Solutions: Wait for 3 blink sequences to complete.
Possible Solutions: Not applicable.
GGGY
●●●●
TIGHT SHUT OFF MODE
Description: (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.
GGYG
●●●●
LOCAL INTERFACE OFF
Description: 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.
GGYY
●●●●
DIGITAL COMMAND MODE
Description: 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 by holding
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GGRR
●●●●
SQUAWK MODE
Description: 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 turned off remotely.
3) More than one hour has passed since the command was
issued.
GYGY
●●●●
SOFT STOP HIGH LIMIT ALERT
SOFT STOP LOW LIMIT ALERT
Description: The Final Command would move the valve
beyond the user-set Soft Limit, but the internal software is
holding the position at the limit. The function is similar to a
mechanical limit stop except it is not active if the unit is unpowered.
Possible Solutions: If more travel is needed, reset the Soft
Limits. If not, adjust the Final Command signal back into the
specified range.
GYYG
●●●●
PRESSURE CALIBRATION REQUIRED
Description: 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.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
●●●●
GYYY
FRICTION CALIBRATION REQUIRED
Description: 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.
●●●●
GYYR
PARTIAL STROKE TEST SCHEDULED
Description: 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.
GRGG
●●●●
Description: 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 DTM.
GRRY
●●●●
JOG COMMAND MODE
Description: The positioner has been placed in a local
override mode where the valve can only be stroked using the
UP and DOWN buttons. 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 QUICK-CAL/ACCEPT button.
GRRR ●●●●
JOG CALIBRATION SET 100% POSITION
Description: During a jog calibration, the unit is waiting for the
user to manually adjust the valve position to the desired
100% open position.
SIGNATURE OR PARTIAL STROKE TEST IN PROGRESS
Description: 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.
GRGY
●●●●
STROKE CALIBRATION IN PROGRESS
SETTING INNER LOOP OFFSET
PRESSURE CALIBRATION IN PROGRESS
FRICTION CALIBRATION IN PROGRESS
ANALOG OUTPUT CALIBRATION IN PROGRESS
COMMAND INPUT CALIBRATION IN PROGRESS
Description: A calibration sequence is in progress. The inner
loop offset is an important step of the stroke calibration.
Possible Solutions: The calibration can be canceled from the
corresponding calibration page of the DTM, from the
handheld, or by briefly pressing the BACK button.
GRGR
●●●●
Possible Solutions: Use the Up and Down buttons on the
positioner to adjust the valve to the desired fully open
position. The QUICK-CAL/ACCEPT button to accept.
YGGG ●●●●
POSITION HIGH LIMIT ALERT
POSITION LOW LIMIT ALERT
Description: The position has reached or is exceeding a user
defined position limit. This is similar to a limit switch
indicator.
Possible Solutions: Set the limit to a higher (or lower) value if
more travel is needed, or adjust the command signal back in
the specified range.
YGGY ●●●●
ACTUATOR CYCLES WARNING
ACTUATOR TRAVEL WARNING
BELLOWS CYCLES WARNING
BELLOWS TRAVEL WARNING
PILOT RELAY CYCLES WARNING
PILOT RELAY TRAVEL WARNING
VALVE CYCLES WARNING
VALVE TRAVEL WARNING
DI COMMAND OVERRIDE
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Description: The cycle or travel limit of the valve, actuator,
bellows or pilot relay has been exceeded. Each cycle
represents two reversals of the direction of valve movement.
The cycle counting criterion and count limit (for the valve,
actuator and bellows) are set by the user to track the usage
of the valve assembly.
Possible Solutions: Follow routine procedures for
maintenance when the limit is reached. For example valve
inspection may include checking the packing tightness, and
checking linkages for wear, misalignment, and tightness.
Bellows inspection may include checking bellows for cracking
or leaking. Actuator inspection may include checking the
actuator seals and lubrication. Relay inspection may include
checking for high air consumption and signs of wear on the
spool. After maintenance, reset the travel accumulator.
YGYY ●●●●
POSITION AMPLITUDE WARNING
POSITION FREQUENCY WARNING
Description: The amplitude or frequency of the position signal
is above the warning limit. The positioner is controlling the
position of the valve with large or 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.
YGYR ●●●●
COMMAND AMPLITUDE WARNING
COMMAND FREQUENCY WARNING
Description: The amplitude or frequency of the command
signal is above the warning limit. This could mean the
control loop has larger swings or is oscillating faster than
desirable.
Possible Solutions: Verify the limits are set at an appropriate
level. Review the control loop parameters and equipment.
Adjust as necessary.
YGRY ●●●●
CONTINUOUS STROKE TEST FAILED WARNING
Description: During the continuous stroke test, the valve did
not move after 5 consecutive attempts. 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.
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YGRR ●●●●
PARTIAL STROKE TEST FAILED WARNING
Description: Measured times or forces during the last partial
stroke test did not pass the criteria set by the user. 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.
YYGG ●●●●
TEMPERATURE HIGH WARNING
TEMPERATURE LOW WARNING
Description: The temperature of the internal electronics has
exceeded the manufacturer set limits of -40°C (-40°F) to
85°C (176°F). Low temperature may inhibit responsiveness
and accuracy. 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. Heat the
positioner if needed. If the temperature reading is in error,
replace the main board.
YYGY ●●●●
VALVE CLOSED TOO FAR WARNING
VALVE OPENED TOO FAR WARNING
Description: While the valve was in use, it closed or 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.
YYGR ●●●●
SUPPLY PRESSURE HIGH WARNING
Description: The supply pressure is above the user set
warning limit. 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.
YYYG ●●●●
SUPPLY PRESSURE LOW WARNING
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Description: The supply pressure is below the user set
warning limit. 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).
YYRR ●●●●
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.
Description: 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.
YYYY ●●●●
YRGG ●●●●
ACTUATION RATIO WARNING
Description: The force required to control the system is close
to the maximum available force. 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.
YYYR ●●●●
MEMORY ERROR WARNING
Description: 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 WARNING AIR SUPPLY ICING
WARNING
Possible Solutions: Ensure supply gas is clean and dry.
Check and clean the regulator filter.
PILOT RELAY RESPONSE WARNING
Description: The pilot relay is sticking or slow to respond.
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.
YRGY ●●●●
FRICTION LOW WARNING
SOFTWARE ERROR WARNING
Description: The friction has passed below the user set limit.
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.
Description: There has been a watch dog time out, stack
overflow warning, or CPU usage warning.
Possible Solutions: Check for packing leak.
replace the valve packing.
Possible Solutions: If the problem persists, perform a factory
reset. If it still persists, reprogram or replace the main board.
YRGR ●●●●
YYRG ●●●●
Tighten or
FRICTION HIGH WARNING
YYRY ●●●●
AIR SUPPLY HUMID WARNING
Description: The supply gas has high relative humidity which
can lead to condensation on electronic components and
failure of electronic functions.
Description: The valve and actuator friction has passed the
user set limit. 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: Ensure supply gas is clean and dry.
Check and clean the regulator filter.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
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.
This may prevent the proper failure position upon loss of
signal/power. This condition may occur briefly on an air-toclose valve that is held for long periods of time in the closed
position, or an air-to-open valve held in the open position.
YRYY ●●●●
YRRR ●●●●
BACKLASH WARNING
SPRING UNABLE TO FAIL SAFE WARNING
Description: The amount of detected backlash has passed
the user set warning limit. This may affect valve stability.
Description: Upon loss of air supply, the valve may not move
to the fail-safe position. 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: Check the stem and actuator for loose
components.
YRYR ●●●●
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.
PNEUMATIC LEAK WARNING
Possible Solutions: Repair or replace actuator spring. Check
for high friction. Reduce process load.
Description: The positioner has detected a leak in the
actuation assembly. Leakage from the actuator can cause
decreased
responsiveness
and
excessive
air/gas
consumption.
RGGG ●●●●
Possible Solutions: Repair pneumatic leaks at the tubing
junctions and actuator seals.
Check spool valve for
excessive wear.
YRRG ●●●●
LOW BATTERY WARNING
Description: The battery for the real time clock is low. 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.
YRRY ●●●●
PIEZO VOLTAGE HIGH WARNING
PIEZO VOLTAGE LOW WARNING
Description: If the voltage to the piezo is too high, 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. If the
voltage to the piezo is too low, the piezo may be damaged.
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COMMAND INPUT BELOW ADC RANGE
COMMAND INPUT ABOVE ADC RANGE
COMMAND INPUT RANGE TOO SMALL
Description: During Command Loop Calibration, the signal
was out of the Analog to Digital Converter (ADC) range, or
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 and between 10 and 4085 ADC.
Possible Solutions: Recalibrate making sure to use valid
command signal values.
RGGY ●●●●
POSITION RANGE TOO SMALL
POSITION SENSOR ABOVE ADC RANGE
POSITION SENSOR BELOW ADC RANGE
Description: During calibration, the range of motion of the
position feedback arm was too small for optimum
performance or the feedback sensor moved beyond its range
of operation.
Possible Solutions: Check for loose linkages. Adjust the
positioner mounting. Adjust the feedback pin back into range.
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 QUICK-CAL/ACCEPT button
acknowledges a small range and the positioner will operate
using the short stroke calibration if otherwise a good
calibration.
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RGGR ●●●●
INNER LOOP OFFSET TIME OUT
Description: 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.
RGYG ●●●●
SETTLE TIME OUT
Description: 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.
RGYY ●●●●
NO MOTION TIME OUT
Description: 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.
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.
RGYR ●●●●
ANALOG OUTPUT RANGE TOO SMALL
Description: 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.
RGRG ●●●●
STROKE CALIBRATION REQUIRED
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Description: 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 failsafe position until a
calibration is successfully completed.
Possible Solutions: Perform a Stroke Calibration (QUICKCAL) 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.
RGRY ●●●●
STROKE SHIFT
Description: 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.
STROKE SPAN DECREASE
Description: 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.
STROKE SPAN INCREASE
Description: The 0% and 100% valve positions are farther
apart compared to the last stroke calibration. This could
indicate seat wear.
Possible Solutions: Ensure the feedback linkage is not bent
and the positioner is mounted securely.
If the feedback
potentiometer is over-rotated, repeat the stroke calibration
until the Stroke Shift error is no longer present. Inspect valve
or schedule valve for inspection. This notification can be
cleared by briefly pressing the QUICK-CAL/ACCEPT button.
RGRR ●●●●
FACTORY RESET STATE
Description: The positioner is in factory reset state.
Calibration is required to enable control.
Possible Solutions: Perform a Stroke Calibration (QUICKCAL).
RYGG ●●●●
VALVE CAN'T OPEN ALARM
VALVE CAN'T SHUT ALARM
Description: Pressure has been applied (or removed) to open
or shut the valve, but the valve is not moving. 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
135
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
external or internal mechanical obstruction, loosen the
packing, clean the stem, repair or replace the actuator, repair
the valve if galling is suspected.
Description: Auxiliary Card 2 has no loop current.
RYGY ●●●●
Possible Solutions: MFC: Check auxiliary loop wiring and
ensure adequate compliance voltage and current. Check
auxiliary card connection to the main board. Replace card if
condition persists.
COMMAND AMPLITUDE ALARM
COMMAND FREQUENCY ALARM
Description: The amplitude or frequency of the command
signal is above the alarm limit. This could mean the control
loop has larger or faster swings than desirable.
RYYR ●●●●
AUX CARD 1 ERROR
Description: Auxiliary Card 1 has an electrical problem.
Possible Solutions: Verify the limits are set at an appropriate
level. Review the control loop parameters and equipment.
Adjust as necessary.
AUX CARD 1 FAILURE WARNING
Description: Auxiliary Card 1 is not communicating.
RYGR ●●●●
AUX CARD 1 NO LOOP POWER
POSITION AMPLITUDE ALARM
POSITION FREQUENCY ALARM
Description: Auxiliary Card 1 has no loop current.
Description: The amplitude or frequency of the position signal
is above the alarm limit. The positioner is controlling the
position of the valve with large or rapid corrections.
Possible Solutions: MFC: Check auxiliary loop wiring and
ensure adequate compliance voltage and current. Check
auxiliary card connection to the main board. Replace card if
condition persists.
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.
RYRG ●●●●
POSITION SENSOR FAILURE ALARM
RYYG ●●●●
SUPPLY PRESSURE LOW ALARM
Description: The feedback arm may be disconnected from
the valve assembly or the sensor has failed.
Description: The supply pressure is below the user set
warning limit. 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: Check the feedback arm linkage.
Recalibrate. If the problem persists return the unit for repair.
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.
PRESSURE SENSOR BOARD FAILURE WARNING
RYYY ●●●●
AUX CARD 2 ERROR
RYRY ●●●●
Description: 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.
RYRR ●●●●
MAIN BOARD ELECTRONIC FAILURE WARNING
Description: Auxiliary Card 2 has an electrical problem.
AUX CARD 2 FAILURE WARNING
Description: Auxiliary Card 2 is not communicating.
AUX CARD 2 NO LOOP POWER
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Description: 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.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Possible Solutions: Fix broken linkage or adjust feedback
arm until full motion is within the range of the POT.
RRGG ●●●●
PILOT RELAY RESPONSE ALARM
Description: The pilot relay is sticking or extremely slow to
respond. This affects the responsiveness, increases the
chance of limit cycling and excessive air consumption. The
pilot relay consists of the driver module assembly with piezo
(I-P relay) which is coupled to the spool valve or poppet.
Delayed response can be caused by a partially clogged piezo
or debris, oil, corrosion, or ice on the spool, or low supply
pressure.
RRYY ●●●●
BACKLASH ALARM
Description: The amount of detected backlash has passed
the user set alarm limit. This may affect valve stability.
Possible Solutions: Check the stem and actuator for loose
components.
Possible Solutions: Check response of the valve. If OK,
adjust Pilot Relay Response limits. Check the supply
pressure.
Check the spool or poppet for debris, oil,
corrosion, ice on the spool. Clean or replace the spool
assembly. Replace the piezo or driver module assembly.
Maintain a clean, water-free air/gas supply.
RRYR ●●●●
RRGY ●●●●
Possible Solutions: Check the internal wiring connections.
Replace the pilot relay.
DRIVER MODULE ALARM
Description: The pilot relay can't open, the pilot relay can't
shut, or the Hall sensor circuit has failed.
FRICTION LOW ALARM
Description: The friction has passed below the user set limit.
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 a packing leak.
replace the valve packing.
Tighten or
RRRY ●●●●
PIEZO VOLTAGE HIGH ALARM
Description: The voltage driving the piezo is above the alarm
limit. This could indicate an error with the relay or the main
board. The positioner may still be functioning, but have
reduced performance under some circumstances.
RRGR ●●●●
PIEZO VOLTAGE LOW ALARM
FRICTION HIGH ALARM
Description: The voltage to the piezo is too low. 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.
Description: The valve and actuator friction has passed the
user set limit. 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.
RRYG ●●●●
FEEDBACK LINKAGE ALARM
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.
RRRR ●●●●
POSITION DEVIATION ALARM
Description: The difference between the command and the
actual position has been greater than the user-set limit for
longer than a user-set 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.
Description: The feedback linkage is broken or the position
feedback POT is out of range.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
37.4 Help From Flowserve
37.4.1 Phone Support
Over-the-phone troubleshooting is often available for
positioner issues. Should your positioner be experiencing
problems, or if you have questions that are not answered by
this manual, feel free to call your local sales representative or
a Quick Response Center (QRC). See the back cover of this
manual for contact details.
37.4.2 Returning the 500+ Positioner for Service
If troubleshooting is unable to solve the problem, the unit
may be returned. Please follow the steps below.
7. Request a Return Goods Authorization (RGA) form.
An RGA form will be e-mailed to you to accompany
the unit being returned.
8. Remove all fittings, brackets, filters, feedback arms,
etc. from the unit before packaging.
9. If the unit was operated with a gas other than clean
air, please include the related MSDS with the return.
10. Complete the RGA form. Write any specific issues
with the positioner you would like us to evaluate.
Please include the customer name and contact
information
11. When packaging, please secure the unit in a
method that will insure it will reach our facility
undamaged (the weight of positioners will often
settle through packing peanuts and pop large air
packets).
12. Please insert a copy of the completed RGA form
inside the package and write the RGA number on
the outside of the package. Send the unit to the
address at the bottom of the form.
If the cause of the unit failure is found to be a manufacturing
defect and the unit is within the warranty period (18 months
from manufacture) it will be repaired free of charge. If no
problem is found with the unit and the unit is still under
warranty, a fee for the evaluation will be required. If the
cause of the unit failure is not covered under the warranty a
fee will be charged for the evaluation and a quote will be
provided showing the cost of the repair. If the customer
decides to purchase a new positioner, the evaluation fee will
be waved.
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
38 POSITIONER DIMENSIONS
38.1 Positioner Dimensions
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
39 HOW TO ORDER
39.1 Positioners
Table 29: 500+ Positioner Configurations
Description
Logix 500+ Series
Analog Only; 8-DIP Set-Up with LCD Option; Limited Diagnostics
Code
Example
5
5
10+
HART; 8-DIP Set-Up with LCD Option; Standard (Basic Functionality) 1, 2
20MD+
HART; 8-DIP Set-Up with LCD Option; Advanced (With Pressure Sensing) 1, 2
21MD+
HART; 8-DIP Set-Up with LCD Option; Pro (With Full ValveSight Diagnostics) 1
22MD+
General Purpose
22MD+
Selection
Base Model
Communication
and
Diagnostics
14
Intrinsically Safe, North America, IP66, Class I, Div 1 Groups A-D T4/T6
Intrinsically Safe, North America, IP66, Class I, Zone 0, AEx ia IIC T4/T6 Ga
Intrinsically Safe, North America IP66, Class I, Zone 0, Ex ia IIC T4/T6 Ga
Non-Incendive, North America, IP65, Class I, Div 2, Groups A-D T4/T6
Non-Sparking, North America, IP65, Class I, Zone 2 AEx nA IIC T4/T6 Gc
Non-Sparking, North America, IP65, Class I, Zone 2 Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to
+45°C)
Dust Ignition, North America, IP65, Zone 21, AEx tb IIIC T100°C Db (Ta=-52°C to +85°C) NEMA Type 4X
37
IECEx FMG 12.0001X, IP66, Ex ia IIC T4/T6 Ga
IECEx FMG 12.0001X, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
IECEx FMG 12.0001X, IP65, Ex tb IIIC T100°C Db (Ta=-52°C to +85°C)
37
ATEX FM15ATEX0002X II 3 G, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 1 G, IP66, Ex ia IIC T4/T6 Ga ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
Certifications
ATEX FM12ATEX0009X II 2 D, IP65, Ex tb IIIC T 100°C Db (Ta=-52°C to +85°C)
Intrinsically Safe, North America, IP66, Class I, Div 1 Groups A-D T4/T6
Intrinsically Safe, North America, IP66, Class I, Zone 0, AEx ia IIC T4/T6 Ga
Intrinsically Safe, North America IP66, Class I, Zone 0, Ex ia IIC T4/T6 Ga
Non-Incendive, North America, IP65, Class I, Div 2, Groups A-D T4/T6
Non-Sparking, North America, IP65, Class I, Zone 2 AEx nA IIC T4/T6 Gc
Non-Sparking, North America, IP65, Class I, Zone 2 Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to
+45°C)
Dust Ignition, North America, IP65, Zone 21, AEx tb IIIC T100°C Db (Ta=-52°C to +85°C) NEMA Type 4X
42 8
ATEX FM15ATEX0002X II 3 G, IP65, Ex nA IIC T4/T6 Gc ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 1 G, IP66, Ex ia IIC T4/T6 Ga ([email protected]=-20°C to +85°C, [email protected]=-52°C to +45°C)
ATEX FM12ATEX0009X II 2 D, IP65, Ex tb IIIC T 100°C Db (Ta=-52°C to +85°C)
TR CU, Russia, IP66, Ex ia IIC T4/T6 (510+: [email protected]=-52°C to +85°C, [email protected]=-52°C to +45°C)
TR CU, Russia, IP66, Ex ia IIC T4/T6 (520MD+ Double Acting Relay: [email protected]=-56°C to +85°C, [email protected]=-56°C to +45°C)
44
TR CU, Russia, IP66, Ex ia IIC T4/T6 (520MD+ Single Acting Relay: [email protected]=-63°C to +85°C, [email protected]=-63°C to +45°C)
2
Mounting: M8 x 1.25, Pneumatics: G1/4", Conduit: M20 x 1.5, Vents G1/4"
3
D - 316 Stainless Steel Shaft (Valtek Standard)
D
NAMUR - 316 Stainless Steel Shaft (VDI/VDE 3845)
R
Three-way (Single-Acting), Poppet Style Relay
1
Three-way (Single-Acting), Spool Style Relay
2
Four-way (Double-Acting), Spool Style Relay
3
No Indicator
0
Flat Indicator
F
Domed Indicator
D
No special options
0
Chinese Configuration6
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140
0
Special Options
1
Mounting: M8 x 1.25, Pneumatics: 1/4" NPTF, Conduit: M20 x 1.5, Vents 1/4" NPTF
F
Position Indicator
A
Mounting: 5/16" 18 UNC, Pneumatics: 1/4" NPTF, Conduit: 1/2" NPTF, Vents 1/4" NPTF
1
Action
B
Aluminum - Black Base with Black Cover (Accord)
D
Feedback Shaft
Y
Aluminum - Black Base with Black Cover (Automax)
1
Threaded
Connections
W
Aluminum - Black Base with Yellow Cover
W
Housing
-
Positioner Configuration
Aluminum - Black Base with White Cover
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Selection
No Manifold
0
Gauge Manifold - Aluminum (required for gauges)
GM
0
Nickel Plated with Brass Internals, psi (bar/kPa)
1
Nickel Plated with Brass Internals. psi (kg/cm2 )
2
SS with SS Internals. psi (bar/kPa)
3
SS with SS Internals. psi (kg/cm2 )
4
UCC Press Test Plug, 1/8" NPT
A
Valve, Tank, Schrader 645A
B
0
LCD
1
Slot 1 - No Card
0
Slot 1 - Multi-Function Card 3,7
Slot 1 - V to I Card
1
6
2
0
Slot 2 - Multi-Function Card 3,6
1
No Switches
0
Mechanical Limit Switch 4
1
Reed Switch
2
3
Slot Type NAMUR Sensor, P+F SJ2 S1N 8
4
Slot Type NAMUR Sensor, P+F SJ2 SN 8
5
Namur V3 type proximity switch, P+F NBB2-V3-E2 4
6
Remote Mount Feedback 5
7
HART 6 standard. Can be configured as HART 5 or HART 7 in the field.
Can be upgraded to 521MD+ or 522 MD+ in the field.
Can be configured as Analog Output, Discrete Output or Discrete Input in the field. Slot 2 available only after slot 1 is filled
Only available for general purpose (certification option 14).
Includes adapter board (installed in the positioner) and the low profile remote mount unit (which may be shipped separately).
Only available with the 520MD+ model.
MFC for 510+ in slot 1 only. This MFC may be configured as AO or DO with limited functionality. Only available with LCD option.
Certification code 42 should only be used when limit switch codes 3,4 and 5 are selected.
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141
3
Namur V3 type proximity switch, P+F NJ2-V3-N 8
0
Slot 2 - No Card
1
2
3
4
5
6
7
8
1
Limit Switches or
Remote Mount
No LCD
1
Auxiliary Card Slot
2
-
Auxiliary Card Slot
1
1
No Gauges
Optional Electronic Add-Ins
Display
Example
GM
Pressure Gauges
Code
-
Manifold
Description
Optional Mechanical Add-Ins
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
39.2 Spare Parts Kits
Table 29: Spare Parts Kits
Ref.
Description
Part-no.
Cover:
Yellow
Black
White
283450.999.000
283451.999.000
283452.999.000
8
Boards:
510+ Main
520MD+ Main
LCD
Pressure Sensor
Multi-Function Card (Slot1)
Multi-Function Card (Slot2)
V to I Card (Slot 1)
331625.999.000
283453.999.000
283454.999.000
283455.999.000
283456.999.000
314887.999.000
331725.999.000
10
11
12
Pilot Relay Module:
Single Acting (Poppet)
Double or Single Acting (Spool)
Pneumatic Restrictor
283458.999.000
283459.999.000
291750.999.000
13
14
15
16
17
18
Limit Switches:
Mechanical Switch*
Reed Switch
P&F SJ2-SN*
P&F SJ2-S1N*
P&F NJ2-V3-N*
P&F NBB2-V3-2N*
291751.999.000
291752.999.000
291753.999.000
291754.999.000
291755.999.000
291755.999.000
1
2
3
4
5
6
7
* Only available for general purpose (certification option 14).
NOTE: Multi-function cards and limit switches may be
purchased as upgrades and installed after the initial
purchase of the positioner. In this case, the positioner label
must be modified to reflect the change.
Figure 58: Spare Parts Kits
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Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
39.3 Gage Blocks
Table 31: Gage Block (Aluminum - ¼ G)
Table 30: Gage Block (Aluminum - ¼ NPT)
Gage
Internal
Material
Pressure
Units
Relay
No.
Gages
Part-no.
Gage
Internal
Material
Pressure
Units
N/A
N/A
N/A
0
291759.999.000
N/A
N/A
PSI
(Bar/kPa)
Brass
PSI
(kg/cm2)
PSI
(Bar/kPa)
Stainless
Steel
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
2
307318.999.000
2
325205.999.000
3
291760.999.000
2
307319.999.000
2
325206.999.000
3
291761.999.000
2
307320.999.000
2
325207.999.000
3
291762.999.000
PSI
(Bar/kPa)
Brass
PSI
(kg/cm2)
PSI
(Bar/kPa)
Stainless
Steel
Relay
No.
Gages
Part-no.
N/A
0
325223.999.000
2
325070.999.000
2
325209.999.000
3
325213.999.000
2
325214.999.000
2
325215.999.000
3
325216.999.000
2
325071.999.000
2
325210.999.000
3
325217.999.000
2
325218.999.000
2
325219.999.000
3
325220.999.000
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
Single
Acting
Poppet
Single
Acting
Spool
Double
Acting
Spool
2
307321.999.000
2
325208.999.000
3
291763.999.000
UCC Pressure Test Plug
0
325211.999.000
UCC Pressure Test Plug
0
325221.999.000
Schrader 645A
0
325212.999.000
Schrader 645A
0
325222.999.000
PSI
(kg/cm2)
flowserve.com
PSI
(kg/cm2)
143
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
39.4 VDI/VDE 3847 Mounting Blocks
Table 32: VDI/VDE 3847 Mounting Block (Aluminum)
Relay
Type
No. Gage Internal
Pressure Units
Gages
Material
Part-no.
Poppet
0
N/A
N/A
307308.999.000
Poppet
2
Brass
PSI (Bar/kPa)
307309.999.000
Poppet
2
Brass
PSI (kg/cm2)
307310.999.000
Poppet
2
Stainless
PSI (Bar/kPa)
307311.999.000
Poppet
2
Stainless
PSI (kg/cm2)
307312.999.000
Spool
0
N/A
N/A
307313.999.000
Spool
3
Brass
PSI (Bar/kPa)
307314.999.000
Spool
3
Brass
PSI (kg/cm2)
307315.999.000
Spool
3
Stainless
PSI (Bar/kPa)
307316.999.000
Spool
3
Stainless
PSI (kg/cm2)
307317.999.000
39.5 Mounting Kits
Table 33: Mounting Kits
Description
Part-no.
Shaft Converter - D to NAMUR
314586.999.000
Direct Mount – 500MD+
(IEC 534 part 6 FlowTop, Kämmer KA, Kämmer
KP, and standard NAMUR linear valves)
307303.999.000
flowserve.com
144
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
INDEX
A
Minimum Open Time · 45
Mounting · 15
Mounting Kits · 82
Multi-Function Card · 10, 29, 48, 52, 53
Actuation Ratio · 40, 43, 67, 71
Air Action Switch · 35
Air Supply · 10
Analog Output · 10, 52
Auto Tune Switch · 35
Auxiliary Card · 30, 40, 59
N
C
Outer Loop · 7
Calibration · 36, 37, 42, 44, 52, 67, 68, 69, 72, 73
Characterization · 35, 45
Command Source Reset · 38
Compliance Voltage · 27
Configuration Switch Settings · 35
Continuous Stroke Test · 41
D
NAMUR AutoMax Valves · 21
O
P
Partial Stroke Test · 42, 43, 51, 69
Performance · 11
Pneumatic Leak · 40, 43, 51, 67
Positioner Dimensions · 77
Pressure Control · 36, 41, 46
Pressure Sensor Board · 61
Date and Time · 40, 47
Diagnostic Features · 51
DIP Switch Override · 40
Discrete Input · 52
Discrete Output · 52
Display Contrast · 41
Double Acting Relay · 26, 62
Q
E
S
Electrical Connections · 27
Event History · 42, 43
Safety · 5
Shutoff · 47
Signal at Closed Switch · 35
Single Acting Relay · 26, 63
Soft Limits · 47
Spare Parts · 5, 80
Specifications · 10
Status Code · 37, 67, 68
Status Icons · 40
Status Messages · 40
Stroke Calibration · 34, 37
Stroke Time · 45
F
Factory Reset · 38, 48
FloTop Linear Valves · 16
Friction · 36, 40, 41, 42, 43, 44, 67, 69, 70, 72, 73, 74
H
Handheld Communicator · 49
HART · 5, 6, 10, 12, 41, 48, 49, 56
Hazardous Area Certifications · 13
I
Quick Calibration Switch · 36
Quick-Cal · 34
R
Remote Mount · 11, 33, 54
Repair · 57
T
Inner Loop · 7
Installation · 15
L
Language · 49
LCD Board · 59
LCD Menu · 40
Limit Switch · 11, 32, 33, 53, 57
Local Control Of Valve Position · 38
Local User Interface · 34
M
Main Board · 61
Maintenance · 14, 57
Mark One Linear Valves · 15
MaxFlo Rotary Valves · 20, 23
Minimum Close Time · 45
flowserve.com
Temperature · 10, 11, 40, 42, 43, 47, 67
Training · 40
Troubleshooting · 27, 65
Tubing · 24
Tuning · 38, 44
V
Valtek Rotary Valves · 18
Valve Action Switch · 35
Valve Cycles · 43, 67
Valve Stability Switch · 36
Valve Travel · 43, 67
ValveSight DTM · 12, 49
Vented Design · 25
Version Numbers · 38, 48
145
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
flowserve.com
146
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
500+ Installation, Operation, Maintenance,
and Safety Manual
Description
Date
Rev
Initial Draft
Updated for review.
Update for exida review.
Added Additional detail, filled out the blank sections.
Sent for Field Trials
Updates from Field Trial – Added mounting.
Updated for Certifications – Safety and Hazardous Area cert sections.
Updated for Certifications
Updated for Certifications
For Rio Tinto Production Run
Updated Hazardous Area Cert to remove some certs until we can pass.
Added Screw Torque Specification Table
May 17, 2011
July 11, 2011
August 31, 2011
September 30, 2011
November 4, 2011
December 2, 2011
January 15, 2012
March 6, 2012
March 16, 2012
May 28, 2012
July 6, 2012
A
B
C
D
E
F
G
H
J
00
01
Updated Hazardous Area Certs, How To Order, Spare Parts Kits, and
added diagrams to the Tubing section.
Updated How To Order. Removed Safety DO card info. Added note
about DI priority. Added warning to follow certs listed on positioner.
Added note to check positioner for hazardous area certs. Added HART
parameters for burst mode. Changed Danger to Caution for unexpected
valve movement. Added reference to ISA 75.13 for testing performance.
Updated figure with two different MFCs. Added linear NAMUR
mounting example. Updated the mounting kit.
Updated MFC DO specifications in section 7.3 Added remote mount
sections 2.6, 7.5, 15 and 20.1. Added sections 20.3 (Gage Block) and
20.4 (VDI/VDE). Added QR code.
Updated the D-NAMUR shaft kit number. Added date to revision
number. Added typical tripped DO value of 0.5 mA. Fixed temperature
typo: 185F. Updated SIL section 16.
Added number for MFC 2 kit. Removed 5 Bar max for natural gas
supply. Add Hazardous location information for MFC. Updated IP rating
to page 10.
Added 505 and 510. Changed document title to 500+. Updated
hazardous area section. Updated How to Order section.
02
03
04
February 12, 2013
05
March 21, 2013
06
May 30, 2013
07
October 10, 2013
08
November 13, 2013
09
Updated hazardous area section. Updated How to Order section.
November 13, 2013
10
Removed statements telling user he could update Stroke Speed. Updated
table 11 with additional computer compatibility information. Updated
table 8 hardware requirements. Added references to figures. Updated title
to include 520MD+ 510+ and 505+ per Mikes’ request. Added Gain Set in
menu.
September 14, 2014
11
flowserve.com
147
Logix® 520MD+ and 510+ Digital Positioners FCD LGENIM0105-16 8/15
Reformatted to 8.5 x 11 paper. Updated gage block tables in how to
order section. Removed 505+ information. Added label description in
section 4. Added table of figures. Added V to I card information in
several sections including section 3.
November 10, 2014
12
Added Ex nA / Ex tb ratings , new special condition of safe use and
standards assessed to certifications page section 3. Add torque values
for terminal connections section 7, 18.3. Added additional acceptable
supply gases to section 2.3. Inserted new images into figures 6, 8, 11, 15
and 18. Changed the cover photo. Inserted cover photo into figures 20,
21, 22 and 24. Updated model table to show more certification detail.
Remove the retaining clips off of figures 25, 42, 43, 44, 48 and 50.
Corrected Figure 3.
March 12, 2015
13
Changed Table 1 in Section 2.1 (Power supply, Input Signal Range,
Compliance Voltage and Communications).
April 14, 2015
14
Added Hazardous Location Certification Code 42
June 26, 2015
15
Added Hazardous Location Certification Code 44
August 25, 2015
16
Revision History
Approvals (Signatures required for changes to Section 3)
Name
Signature
Date
Kent Woolf (author)
Ken Beatty
Jeff Taylor
Steve Christiansen
Doug Forman
Distribution
Name
Function
Doug Forman
Nate Higbee
Dave Nagel
Ed Silva
Mike Yost
Sulav Shakya
Karlin Wilkes
Edwin Hordijk
Thye Chin Boo
Ricardo Tozzi
Craig Larsen
Mike Waier
Dmitry Gerasimov
Darren
Engineering
Engineering
Engineering
Engineering
Engineering
Engineering
Marketing
Sales
Sales
Sales
Sales
Sales
Russian Translation
Russian Translation
flowserve.com
148
Rev

• 2, Flowserve Logix 520MD+ User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 2 Field Trial Version – Printed October 28, 2011 CONTENTS 1 GENERAL INFORMATION …………………………… 3 1.1 U SING T HIS D OCUMENT ……………………………………………………3 1.2 T ERMS C ONCERNING S AFETY ………………………………………………3 1.3 P ROTECTIV…

• 1, Flowserve Logix 520MD+ Logix® 520MD+ Series Installation Operation Maintenance Safety Manual Digital Positioner FCD LGENIM0105-00
  …

• 15, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 15 Field Trial Version – Printed October 28, 2011 6.5 Pneumatic Terminals Figure 6: Pneumatic Connections Port Single Acting Poppet Style Relay Double Acting Spool Style Relay Supply B Y1 Y2 A Y1
  …

• 50, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 50 Field Trial Version – Printed October 28, 2011 18 POSITIONER DIMENTIONS 18.1 Positioner Dimensions Figures here…
  …

• 42, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 42 Field Trial Version – Printed October 28, 2011 17.2 Status Code Index Table 22: Status Code Index Description Status Code A/O Cal in Prog GRGY A/O Range Small RGYR Actuation Ratio WRN YYYY Actuator Cycles WRN YGGY Actuator Travel WRN YGGY Air Supply Humid WRN YYRY Air Supply Icing WRN YYRR Analog In < ADC…

• 11, Flowserve Logix 520MD+ User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 11 Field Trial Version – Printed October 28, 2011 5.2 Mounting Positioner to Flow-Top Linear Valves Text here…
  …

• 17, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 17 Field Trial Version – Printed October 28, 2011 Figure 8: HART Filter Figure 9: Compliance Voltage 7.4 Cable Requirements The Logix 520MD+ digital positioner utilizes the HART Communication protocol. This communication signal is superimposed on the 4-20 mA current si…

• 36, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 36 Field Trial Version – Printed October 28, 2011 15 SAFETY DO CARD 15.1 Safety DO Function The optional Safety Discrete Output Card (Safety DO) provides a way for the user to detect errors that are critical to the ability of the system to move to a safe state sh…

• 33, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 33 Field Trial Version – Printed October 28, 2011 12 DIAGNOSTIC FEATURES 12.1 Positioner Diagnostic Levels The Logix 520MD+ digital positioners have three levels of diagnostics, “Standard”, “Advanced”, and “Pro”. • “Standard” diagnostics provide complete position- related diagnostics and data. …

• 22, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 22 Field Trial Version – Printed October 28, 2011 While the calibration is in progress, the LED lights will flash status codes indicating the calibration progress. See section 17.3 Status Code Descriptions for an explanation of the status code sequences. The initial calibration of extremely large or …

• 19, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 19 Field Trial Version – Printed October 28, 2011 7.9 Safety Discrete Output (Safety DO) The Safety Discrete Output (Safety DO) provides a relay- style, open or closed circuit. Connections to the Multi- Function Card are made directly to the card terminals. Wire the Safety DO in series with a p…

• 12, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 12 Field Trial Version – Printed October 28, 2011 5.3 Mounting Positioner to Standard Valtek Rotary Valves Text here…
  …

• 30, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 30 Field Trial Version – Printed October 28, 2011 used to tightly close or open the valve. It is used when a tight seal is needed or when debris or friction may otherwise interfere with complete closure. When the valve is commanded past the Shutoff points, the pilot rela…

• 13, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 13 Field Trial Version – Printed October 28, 2011 5.4 Mounting Positioner to NAMUR Rotary Valves Text here…
  …

• 40, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 40 Field Trial Version – Printed October 28, 2011 Figure 30: Double Acting Relay Assembly Figure 31: Clip Spring Orientation 16.8 Replacing a Single Acting Pilot Relay Removal 1 Remove the Main Board. See procedure above. 2 Remove the two relay assembly screws. 3 Re…

• 18, User Instructions — Logix® 520MD+ Series Digital Positioner FCD LGENIM0105-00 © Flowserve Corporation 18 Field Trial Version – Printed October 28, 2011 Figure 10: Conduit and Grounding 7.6 Electromagnetic Compatibility The Logix 520MD+ digital positioner has been designed to operate correctly in electromagnetic (EM) fields found in typical industrial environments. Care should be taken…

• Page 1
  USER INSTRUCTIONS Logix 520MD+ and 510+ Installation ® Digital Positioners Operation Maintenance FCD LGENIM0105-15-AQ – (05/16) Experience In Motion…

• Page 2: Table Of Contents

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Contents 6 Tubing 6.1 Determine Air Action 6.2 Connect Supply Port 6.3 Purging Single Acting Actuators 1 General Information 6.4 Vented Design 1.1 Using This Document 7 Electrical Connections 1.2 Terms Concerning Safety 7.1 Electrical Terminals 1.3 Protective Clothing…

• Page 3
  18.10 Replacing A Single Acting Pilot Relay 19 Troubleshooting 19.1 Troubleshooting Guide 19.2 Status Code Index 19.3 Status Code Descriptions 19.4 Help From Flowserve 20 Positioner Dimensions 20.1 Positioner Dimensions 21 How To Order 21.1 Positioners 21.2 Spare Parts Kits 21.3 Gage Blocks…
• Page 4
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Figure 15: Maxflo Assembly Figure 16: Maxflo Connection Figure 17: Automax Bracket Figure 18: Automax Assembly Figure 19: Mounting To A Linear Actuator Figure 20: Linear, Double Acting, Air To Open Figure 21: Rotary, Double Acting, Air To Open Figure 22: Linear, Single Acting, Air To Open Figure 23: Exhaust Vents…

• Page 5: General Information

  520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® General Information 1.3 Protective Clothing Flowserve positioners use high pressure gas to operate. Use eye 1.1 Using This Document protection when working around pressurized equipment. Follow proper Product users and maintenance personnel should thoroughly review procedures for working with natural gas if it is used.

• Page 6: Service / Repair

  The Logix 500+ receives power from the two-wire, 4-20 mA input Flowserve will not accept deliveries if a certificate has not been signal. However, since this positioner utilizes HART communications, provided (a form can be obtained from Flowserve).

• Page 7: Command Input And Final Command

  The Final Command is compared against the Stem Position. If any deviation exists, the control algorithm sends a signal to the inner-loop control to move the relay in a direction, depending upon the deviation. flowserve.com…

• Page 8: Detailed Sequence Of Positioner Operations

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Assume the input signal changes from 12 mA to 16 mA. The position- er sees this as a command source of 75 percent. With Linear charac- terization, the Final Command becomes 75 percent. Deviation is the difference between Final Command and Stem Position: Deviation = 75% — 50% = +25%, where 50 percent is the present stem position.

• Page 9: Figure 3: Logix 500+ Digital Positioner Schematic

  Pressure Sensor Cable Regulator Assembly Feedback Cable Piezo Cable Exhaust Hall Sensor Cable Port A Auxiliary Card Feedback Potentiometer Main Board Actuator Housing 4-20 mA Input Spring Hall Sensor Assembly Piston Exhaust Stem Port B Yoke Supply Pressure Take-Off Arm flowserve.com…

• Page 10: Specifications

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® SPECIFICATIONS 2.3 Air Supply Table 3: Air Supply 2.1 Input Signal Minimum Input Pressure 1.5 Bar (22 PSI) Table 1: Input Signal Maximum Input Pressure Single Acting Relay – 6.2 Bar (90 PSI) Positioner Alone or with Multi-Function Card Double Acting Relay –…

• Page 11: Stroke Output

  NAMUR NC-5 -40 °C to 100 °C Temperature (-40 °F to 212 °F) Load Current 0…100 mA Inductive Sensor Voltage 10…30 VDC P&F NBB2-V3-E2 PNP NO -25 °C to 70 °C Temperature General Purpose Only (-13 °F to 158 °F) flowserve.com…

• Page 12: Valvesight Dtm Software Specifications

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 2.12 ValveSight DTM Software Specifications Table 12: ValveSight DTM Software Specifications Minimum Pentium processor running Windows 2000, XP, Server 2003, Server 2003 R2, Server 2008 (32-bit & 64-bit Computer Versions), Server 2008 R2 (32-bit &…

• Page 13: Hazardous Area Certifications

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® HAZARDOUS AREA CERTIFICATIONS DANGER: Certifications listed on the positioner are correct for that positioner. Before using the information on this page, ensure the certifications on the positioner label match the certifications on this page. Table 13: Logix 500+ Series Hazardous Locations Information ATEX North America (cFMus)

• Page 14: Storage And Unpacking

  Verify that the labels match the intended application. 4.1 Storage NOTE: Mark checkbox next to hazardous area information for Flowserve Control valve packages (a control valve and its instrumen- protection method Logix 500MD+ is installed to. tation) are typically well protected from corrosion. Nevertheless Flow- serve products must be stored in a clean, dry environment such as an enclosed building that affords environmental protection.

• Page 15: Mounting And Installing

  Slip the large end of the teardrop shaped mounting hole in the back of the positioner/bracket assembly over the mounting bolt. Slide the small end of the teardrop under the mounting bolt and align the lower mounting hole. Figure 6: Mounting to Mark I Linear Valves flowserve.com…

• Page 16: Mounting To Flowtop Linear Valves

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 5.2 Mounting to FlowTop Linear Valves Assemble the take-off pin to the take-off plate and mount the take-off plate to the valve stem using the two screws. Adjust the To mount a Logix 500+ positioner to a FlowTop linear actuator and follower pin to match the correct location as indicated on the valve (with direct mounting / integrated tubing), refer to Figure 7 and…

• Page 17: Figure 8: Flowtop Mounting

  Optionally, con- tinue to attempt the calibration. Each calibration attempt adjusts the acceptable limits and it should pass eventually. Actuator Screws Actuator O-Ring Take-Off Pin Take-Off Plate Take-Off Plate Screws Figure 8: FlowTop Mounting flowserve.com…

• Page 18: Mounting To Standard Valtek Rotary Valves

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 5.3 Mounting to Standard Valtek Rotary Valves Using a ½” end wrench and two 5/16-18 X ½” bolts, attach bracket to actuator transfer case pad. Leave these bolts slightly The standard rotary mounting applies to Valtek valve/actuator assem- loose until final adjustments are made.

• Page 19: Figure 12: Valtek Rotary Final Orientation

  14. If the calibration was successful the green LED will blink GGGG NOTE: To virtually eliminate non-linearity, use the Linearization or GGGY and the valve will be in control mode. feature on the Custom Characterization page of the DTM. Figure 12: Valtek Rotary Final Orientation flowserve.com…

• Page 20: Mounting To Maxflo Rotary Valves

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 5.4 Mounting to MaxFlo Rotary Valves Slide the take-off arm onto the shaft. Insert the screw with star washer through the take-off arm and add the second star washer and nut.

• Page 21: Mounting To Rotary Namur (Automax) Valves

  See Figure 18. Connect regulated air supply to appropriate port in manifold. See section 6 TUBING. Connect the power to the 4-20 mA terminals. See section 7 ELECTRICAL CONNECTIONS. Remove main cover and locate DIP switches and QUICK-CAL/ ACCEPT button. flowserve.com…

• Page 22: Figure 17: Automax Bracket

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Figure 17: AutoMax Bracket Figure 18: AutoMax Assembly…

• Page 23: Mounting To A Linear Namur Pneumatic Actuator

  Connect the power to the 4-20 mA terminals. See section 7 ELECTRICAL CONNECTIONS. 10. Remove main cover and locate DIP switches and QUICK-CAL/ ACCEPT button. 11. Refer to sticker on main board cover and set DIP switches accordingly. See section 8 STARTUP. flowserve.com…

• Page 24: Tubing

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® TUBING After mounting has been completed, tube the positioner to the actu- ator using the appropriate compression fitting connectors. For best performance, use 10 mm (3/8 inch) tubing for 645 square cm (100 square inch) actuators or larger.

• Page 25: Connect Supply Port

  When a single acting relay is used, a special procedure can be performed to configure the positioner to purge properly using port A. Contact your local Flowserve Representative for more information regarding the purging option. 6.4 Vented Design A standard Logix 500+ positioner is vented directly to the atmosphere.

• Page 26: Figure 24: Pneumatic Connections

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Spool Style Spool Style Relay Port Relay Relay (Single Acting) (Double Acting) (Single Acting) Supply Supply Supply (Plug) (Plug) Figure 24: Pneumatic Connections…

• Page 27: Electrical Connections

  Never connect a voltage source directly across the the calculation in the following equation. The Available Voltage must Logix 500+ terminals. This could cause permanent circuit board be greater than 10VDC in order to support the Logix 500+. Also, see damage. Table 1: Input Signal. flowserve.com…

• Page 28: Figure 26: Compliance Voltage

  The thread size is indicated on the side of the positioner near the conduit connections. Conduit fittings must match equipment housing threads before installation. If threads do not match, obtain suitable adapters or contact a Flowserve representative. See Figure 27: Con- duit and Grounding.

• Page 29: Multi-Function Card (Ao, Do, Di)

  An electromagnetic line filter can be used to further eliminate noise (Flowserve Part Number 10156843). In the event of a severe electrostatic discharge near the positioner, the device should be inspected to ensure correct operability.

• Page 30: Figure 29: Mfc Discrete Output Circuit

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 7.3.2 Discrete Output Table 14: Auxiliary Card Status Card Condition Status Indication For DO function, wire the MFC in series with a 8 to 40 VDC power Multi-Function Card supply, including a method to determine the current such as a resis- Monitoring Position (typical 4-20mA ) Output (mA)

• Page 31: To I Card Connections

  Equation 4 (Supply Voltage-Terminal Voltage) Figure 32: V to I Card Circuit Example Supply Voltage = 24 V Terminal Voltage = 10 V (24-10) = 20 mA Figure 33: V to I Card installed Figure 31: V to I Card flowserve.com…

• Page 32: Limit Switches

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 7.5 Limit Switches Limit switches provide an independent verification of the position of the feedback shaft. Wire the limit switches according to Table 15: Limit Switch Connections. For more information, see Table 7: Limit Switch Specifications on page 11.

• Page 33: Remote Mount

  Table 16: Remote Mount Card Connections Terminal (See Figure 35: Remote Mount Board) From Remote Mount White Black Figure 35: Remote Mount Board 7.7 Connections for Intrinsically Safe Operation See section 3 HAZARDOUS AREA CERTIFICATIONS for entity parameters and control drawing reference. flowserve.com…

• Page 34: Startup

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® STARTUP 8.2 Local User Interface Overview The Logix 500+ local user interface allows the user to calibrate, 8.1 Quick Start Instructions configure the basic operation, and tune the response of the positioner Once the positioner is installed, adjusting the DIP switch settings and without additional tools or configurators.

• Page 35: Configuration Switch Settings

  At Closed selection. If the valve closes with a 4 mA signal, the AO will show a 4 mA signal at closed. If the valve closes with a 20 mA signal, the AO will show a 20 mA signal at closed. flowserve.com…

• Page 36: Stroke Calibration

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® termine the gains. The gains are then set automatically. After a stroke More More calibration, the positioner is ready to control. Stable Responsive To perform a Quick-Cal, first ensure the Quick Calibration Switch is set to Auto or Jog as appropriate.

• Page 37: Analog Output (Ao) Calibration

  The DTM AO calibration wizard is found here: Configuration / Card Slot 1 (or 2) / Multi-Function Card / Analog Output Calibration. The LCD AO calibration features are found here: Card 1 (or Card 2) / Multi-Function Card / Config/Cal flowserve.com…

• Page 38: Positioner Functions (No Display Required)

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® POSITIONER FUNCTIONS NOTE: Once the Multi-Function Card (MFC) type has been con- figured, the type selection will still remain after a factory reset. (No Display Required) CAUTION: Performing a factory reset may result in the inability to operate the valve until reconfigured properly.

• Page 39: Analog Input Calibration

  0.5 mA. To change the Multi-Function Card to the Discrete Output function, hold down both the ,BACK and the Down button for about 3 seconds. The blink code should change to GRYR. Briefly press the .ACCEPT/QUICK-CAL button. flowserve.com…

• Page 40: Positioner Functions (Lcd Display)

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 10 POSITIONER FUNCTIONS Auxiliary Card 1 Status — This shows the type of card in auxiliary card slot 1. Auxiliary Card 2 Status — This shows the type of card in auxiliary card slot 2. (LCD Display) DIP Switch Override –…

• Page 41: Figure 38: Display Main View

  Down buttons to adjust the contrast. Use the (locked), improving the stability of the valve position. The point at .ACCEPT/QUICK-CAL to accept the settings. which the pressure control is locked depends on the Valve Stability Figure 38: Display Main View flowserve.com…

• Page 42: Menu Overview

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 10.2 Menu Overview Temperature Units Status Air Flow Units Command (mA) Actuator Area Units Command (%) Date Format Position (%) Number Format PS (Supply Pressure) LCD Orientation PA (Port A Pressure) Burst Mode PB (Port B Pressure) ON/OFF…

• Page 43: Menu Features

  0.5% as a default, but can be changed using the DTM. Last Result shows “Pass” or “Fail” from the last PST attempt. Valve Travel is counted in small increments every time the valve moves beyond the dead-band window. The travel is displayed in % of full stroke. flowserve.com…
• Page 44
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 10.3.4 Calibration “Set 0%”, set the command input current to 4 mA. (The display will show a low Analog to Digital Count (ADC) that corresponds to 4 mA.) .Calibration Then press the .ACCEPT/QUICK-CAL button to set the value.
• Page 45
  (default). With Single selected, the most con- servative gains found during calibration are applied in both the open and closing directions. 10.3.6 Configuration (Characterization) .Configuration .Characterization .MaxFlo Linear .MaxFlo Equal % .Valdisk Linear .Valdisk Equal % .ShearStream Linear .ShearStream Equal % .Custom flowserve.com…

• Page 46: Figure 39: Characterization Curves

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Table 19: Characteristic Curve Data Final Command Characterization Characterization DIP set to “Other” DIP set to “Linear” Command Custom Input Shear-Stream Linear MaxFlo Linear MaxFlo =% Valdisk Linear Valdisk =% Shearstream=% (Default) Linear…

• Page 47
  The clock does not account for daylight savings. Set Time and Date – Use the Up and Down buttons to set the time and date. The format of the time and date is displayed above the input fields. flowserve.com…
• Page 48
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 10.3.11 Configuration (Burst Mode) CAUTION: Performing a factory reset may result in the inability to operate the valve until reconfigured properly. Notify proper .Configuration .Burst Mode personnel that the valve may stroke, and make sure the valve is .On/Off properly isolated.

• Page 49: Hart Communication

  “Set 100%” current. on-line diagnostic tests, calibrations and system configurations. If Set As DO Card The ValveSight DTM is available from a Flowserve representative or Use DTM – The DO is highly configurable. Use the ValveSight DTM from www.valvesight.com.

• Page 50: Burst Mode

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 11.4 Burst Mode CAUTION: Observe precautions for handling electrostatically sensitive devices. Burst Mode is available with a handheld device. In the handheld, se- lect the Burst Mode feature under the Configuration Menu. Variables With a clean, non-conductive instrument, change the position that are transmitted in burst mode are shown in the table below.

• Page 51: Model Features

  • The “Advanced” DTM provides a view of the positioner’s full health analysis and interfaces to all of the positioner’s “Pro” diagnostic functionality. It is generally wise to use the Advanced DTM with the Advanced and Pro positioners. flowserve.com…

• Page 52: Multi-Function Card

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 13 MULTI-FUNCTION CARD 13.2 Discrete Output (DO) Use the Discrete Output function of the MFC to indicate a variety of The optional Multi-Function Card (MFC) can be configured to act as conditions such as alarms, warnings, position limits, etc.

• Page 53: To I Card

  Electronic Specifications 2.7 Limit Switch Specifications Certifications Hazardous Area Certifications Electronic Connections 7.5 Limit Switches Install or Adjust the Limit Switch 18.4 Installing a Limit Switch Ordering Limit Switches 21.2 Spare Parts Kits Figure 43: V to I Card flowserve.com…

• Page 54: Remote Mount

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 16 REMOTE MOUNT 16.1 Remote Mount Operation Terminals The remote mount option can be used where excessive vibration or environmental factors prevent the placement of a positioner directly on the valve. The remote mount unit consists of just the feedback mechanism enclosed in a sturdy container.

• Page 55: Requirements For Safety Integrity

  NOTE: If using the V to I card, less than 10 Volts at the V to I card terminals will produce a current less than 3.6 mA. The Flowserve 520MD+ Valve Positioner covered by this safety manual 17.3 Fail Safe State Response Time…

• Page 56: Lifetime Limits

  10 years. The reliability data listed the FMEDA report is only valid Steps for Proof Test for this period. The failure rates of the Flowserve 520MD+ Valve Posi- tioner may increase sometime after this period. Reliability calculations Step Action…

• Page 57: Maintenance And Repair

  0.56 N-m (5 in-lb) Double Acting Relay manifold (2 Screws) 0.56 N-m (5 in-lb) Single Acting Relay (2 Screws) 0.56 N-m (5 in-lb) Main PCB, MFC, V to I & Limit switch terminal 0.5 – 0.6 N-m (4-5 in-lb) connections. flowserve.com…

• Page 58: Figure 47: Limit Switch

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Figure 47: Limit Switch…

• Page 59: Replacing The Lcd Board

  Connect the card to the main board using the internal connector cable. Ensure the connector’s locking features engage. Gently slide the card(s) into the slot(s). CAUTION: Ensure proper circuitry is used before connecting cables to the auxiliary card. See section 7 ELECTRICAL CONNECTIONS for more information. flowserve.com…

• Page 60: Figure 50: Auxiliary Card

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Route the external cable through the electrical conduit ports in the base and connect the external cable to the auxiliary card. See Figure 42: Multi-Function Card. Replace the auxiliary card clips. 10.

• Page 61: Replacing A Main Board

  Replace the inner cover by inserting the 6 retaining screws. To keep the calibration values even after a Factory Reset, write a Calibrate. 1 to Variable 104. Pressure Main Sensor Board Screws Screws Figure 53: Pressure Sensor Board Figure 51: Main Board Screws flowserve.com…

• Page 62: Cleaning And Replacing A Double Acting Pilot Relay

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 18.9 Cleaning & Replacing a Double Acting Pilot Relay Removal Remove the Main Board. See procedure above. Fully loosen the 2 spool block screws. By squeezing the two screws toward each other, grip the spool block and pull it straight out.

• Page 63: Replacing A Single Acting Pilot Relay

  Remove the Manifold gasket. Installation Place the Manifold gasket. Place the supply plug O-ring and screw. Figure 55: Double Acting Relay Assembly Place the single acting relay. Place the two relay assembly screws. Reassemble the main board and covers and calibrate. flowserve.com…

• Page 64: Figure 57: Single Acting Relay Assembly

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® Relay Assembly Screws (2) Single Acting Relay Supply Plug Screw & O-Ring Manifold Gasket Base Figure 57: Single Acting Relay Assembly…

• Page 65: Troubleshooting

  Spool valve is corroded or dirty. recalibrate. Disassemble and clean spool valve The backlight uses any residual power not used by Fluctuations in the LCD backlight are normal. No action LCD backlight flickering or dim. other functions of the circuitry. required. flowserve.com…

• Page 66
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 19.2 Status Code Index NOTE: Not all status codes are available with all positioner models. Table 28: Status Code Index Description Status Code Feedback Cal Error RGGY Psn Amplitude WRN YGYY A/O Cal in Prog GRGY…

• Page 67: Status Code Index

  4-20 mA signal by using a handheld, the Dashboard page of the DTM, or performing a manual Command Reset. Perform the Com- mand Reset by holding both the UP and DOWN buttons and briefly pressing the QUICK-CAL/ACCEPT button. flowserve.com…

• Page 68
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® ..GYYY GRGR FRICTION CALIBRATION REQUIRED DI COMMAND OVERRIDE Description: No friction calibration has been performed since the last Description: The Multi-Function Card has been configured as a Discrete factory reset.
• Page 69
  This could mean the control loop has larger calibration. swings or is oscillating faster than desirable. Possible Solutions: Verify the limits are set at an appropriate level. Re- view the control loop parameters and equipment. Adjust as necessary. flowserve.com…
• Page 70
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® ..YYGR YYRG SUPPLY PRESSURE HIGH WARNING SOFTWARE ERROR WARNING Description: The supply pressure is above the user set warning limit. Description: There has been a watch dog time out, stack overflow Supply pressure that exceeds the maximum rating on the actuator can warning, or CPU usage warning.
• Page 71
  Possible Solutions: Recalibrate making sure to use valid command could be caused by rapidly power cycling the positioner. signal values. 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. flowserve.com…
• Page 72
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® ..RGGY RGYR POSITION RANGE TOO SMALL ANALOG OUTPUT RANGE TOO SMALL POSITION SENSOR ABOVE ADC RANGE Description: During an Analog Output Calibration the difference POSITION SENSOR BELOW ADC RANGE between the milliamp signal at 0% and the milliamp signal at 100% Description: During calibration, the range of motion of the position was too small.
• Page 73
  RYRG POSITION SENSOR FAILURE ALARM Description: The feedback arm may be disconnected from the valve assembly or the sensor has failed. Possible Solutions: Check the feedback arm linkage. Recalibrate. If the problem persists return the unit for repair. flowserve.com…
• Page 74
  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® ..RYRY RRGR PRESSURE SENSOR BOARD FAILURE WARNING FRICTION HIGH ALARM Description: One or more pressure sensors may have failed. Description: The valve and actuator friction has passed the user set limit.
• Page 75
  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. flowserve.com…

• Page 76: Help From Flowserve

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 19.4 Help From Flowserve 19.4.1 Phone Support Over-the-phone troubleshooting is often available for positioner is- sues. Should your positioner be experiencing problems, or if you have questions that are not answered by this manual, feel free to call your local sales representative or a Quick Response Center (QRC).

• Page 77: Positioner Dimensions

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 20 Positioner Dimensions 20.1 Positioner Dimensions flowserve.com…

• Page 78: How To Order

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 21 HOW TO ORDER 21.1 Positioners Table 29: 500+ Positioner Configurations Selection Description Code Example Base Model Logix 500+ Series Analog Only; 8-DIP Set-Up with LCD Option; Limited Diagnostics Communication HART;…

• Page 79
  MFC for 510+ in slot 1 only. This MFC may be configured as AO or DO with limited functionality. Only available with LCD option. When limit switch codes 3, 4 and 5 are selected, only certification codes 14 and 42 should be used flowserve.com…

• Page 80: Spare Parts Kits

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 21.2 Spare Parts Kits Table 29: Spare Parts Kits Ref. Description Part-no. Cover: Yellow 283450.999.000 Black 283451.999.000 White 283452.999.000 Board: 505+ Main 331625.999.000 520MD+ Main 283453.999.000 283454.999.000 Pressure Sensor 283455.999.000 Multi-Function Card (Slot1) 283456.999.000…

• Page 81: Gage Blocks

  307321.999.000 Acting 325218.999.000 Poppet Poppet Single Single (kg/cm2) Acting 325208.999.000 (kg/cm2) Acting 325219.999.000 Spool Spool Double Double Acting 291763.999.000 Acting 325220.999.000 Spool Spool UCC Pressure Test Plug 325211.999.000 UCC Pressure Test Plug 325221.999.000 Schrader 645A 325212.999.000 Schrader 645A 325222.999.000 flowserve.com…

• Page 82: Vdi/Vde 3847 Mounting Blocks

  Logix 520MD+ and 510+ Digital Positioners FCD LGENIM0105-15-AQ – 05/16 ® 21.4 VDI/VDE 3847 Mounting Blocks Table 32: VDI/VDE 3847 Mounting Block (Aluminum) Relay Gage Internal Pressure Units Part-no. Type Gages Material Poppet 307308.999.000 Poppet Brass PSI (Bar/kPa) 307309.999.000 Poppet Brass PSI (kg/cm2) 307310.999.000…

• Page 83
  Version Numbers · 38, 48 73, 74 Pressure Sensor Board · 61 Handheld Communicator · 49 Quick Calibration Switch · 36 HART · 5, 6, 10, 12, 41, 48, 49, 56 Quick-Cal · 34 Hazardous Area Certifications · 13 flowserve.com…
• Page 84
  Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide India 560 066 variety of industrial service conditions.

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