FCD LGAIM0058-00 USER INSTRUCTIONS Digital Positioner 3200MD 3200MD Digital LGENIM0059-09 12/13 Installation Operation Maintenance PositionerSafety Manual Installation, Operation and Maintenance Instructions
User instructions - Digital Positioner 3200MD LGENIM0059-08 10/13 Contents 1 2 4 5 6 7 8 2 Terms Concerning Safety General Information 3.1 Unpacking 3.2 Storage 3.3 Pre-installation Inspection Logix 3200MD Positioner Overview 4.1 Specifications 4.2 Positioner Operation 4.3 Detailed Sequence of Positioner Operations Mounting and Installation 5.1 Mounting to Valtek Linear Mark One Valves 5.2 Mounting to Standard Valtek Rotary Valves 5.3 Optional Valtek Rotary Mounting Procedure 5.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 1 Terms Concerning Safety The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instructions to highlight particular dangers and/ or to provide additional information on aspects that may not be readily apparent. DANGER: Indicates that death, severe personal injury and/or substantial property damage will occur if proper precautions are not taken.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 2. Inspect the solenoid and positioner soft goods and replace as necessary. 4 Logix 3200MD Positioner Overview The Logix 3200MD digital positioner is a two-wire 4-20 mA input digital valve positioner. The positioner is configurable through the local user interface. The Logix 3200MD utilizes the HART protocol to allow twoway remote communications with the positioner.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Table VII: Hazardous Area Certifications North America (FM/CSA) Flame Proof SIRA 03ATEX1387 II 2 GD Ex d IIB+H2 T5 IP65 Ex tD A21 IP65 T95˚C (Ta =-40°C to +80°C) T5 (Ta = -40˚C to +80C Explosion Proof Class I, Div 1, Groups B,C,D DIP Class II, III, Div 1 Groups E,F,G Class I, Zone 1, Ex d IIB+H2 (CSA Only) T5 Tamb = -40˚C ≤ Ta ≤ +80˚C (CSA Only) T6 Tamb = -40˚C ≤ Ta ≤ +60˚C Type 4X Intrinsically Safe SIRA 03ATEX2299X II 1 GD Ex ia IIC
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 4.2 Positioner Operation The Logix 3200MD positioner is an electric feedback instrument. Figure 1 shows a Logix 3200MD positioner installed on a doubleacting linear actuator for air-to-open action. The Logix 3200MD 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.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Figure 2: System Positioning Algorithm Air Supply Control Algorithm Sensor Inner-Loop Output Pmax Pmin Gmult 4-20 mA (Analog Mode) Command In (Digital Mode) Linear Mode Characterization Soft Limits MPC CONTROL COMMAND Deviation + - I Integration Summer Inner Loop Offset The piezo valve pressure modulator controls the air pressure under a diaphragm by means of a piezo beam bender.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Figure 3: Linear Mark One Control Valve Mounting Logix 3200IQ Positioner Bracket Bolts Bracket Locknut Washer Follower Arm Positioner Bolts Nut Nut Lock Washer Nut Stem Clamp Follower Pin Take-off Arm Bolts Metal Washers 5 Mounting and Installation 5.1 Mounting to Valtek Linear Mark One Valves 4. Screw one mounting bolt into the hole on the yoke mounting pad nearest the cylinder.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 • 3⁄8" socket with extension ! 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.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 the A/D feedback values were exceeded and the arm must be adjusted away from the positioners limits. Return to step 2 and rotate the arm back approximately 10 degrees. The pin should extend approximately 1⁄16" past the take-off arm. When properly adjusted, securely tighten the bracketing bolts. Orienting the Take-off Arm for Final Lock Down ! NOTE: Remember to remove the air supply before re-adjusting 1.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 1. Using a ½" open-end wrench and two 5⁄16-18 x ½" bolts, attach bracket to actuator transfer case pads. Leave bracket loose to allow for adjustment. 2. Using four ¼-20 x ½" bolts and a 7⁄16" open-end wrench, fasten positioner to universal bracket, using the four-hole pattern that locates the positioner the farthest from the valve. Rotate positioner 90 degrees from normal so gauges are facing upward. 3.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 6 Wiring and Grounding Guidelines (See Figure 6) 6.1 WARNING: This product has electrical conduit connections in either thread sizes ½" NPT or M20 which appear identical but are not interchangeable. Housings with M20 threads are stamped with the letters M20 above the conduit opening. Forcing dissimilar threads together will damage equipment, cause personal injury and void hazardous location certifications.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 The voltage 12.5 VDC is greater than the required 10.0 VDC; therefore, this system will support the Logix 3200MD digital positioner. The Logix 3200MD positioner has a worst case input resistance equivalent to 500 Ω at a 20 mA input current. WARNING: Never connect a voltage source directly across the positioner terminals. This could cause permanent circuit board damage.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 In order to calculate the maximum network capacitance, use the following formula: Figure 8: Local User Interface LEDs 65 Cnetwork (μF) ≤ (R - 0.0032 barrier + Rwire + 390) DIP Switch Block Equation 2 Jog Buttons 65 Cnetwork (μF) ≤ R(R - 0.0032 Example: = 300 Ω barrier barrier + Rwire + 390) Rwire = 50 Ω Example: = 22 300pFΩ= 0.000022 μF CRcable barrier = foot foot Rwire = 50 Ω 65 22 pF ==0.000022 = - 0.0032 0.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Figure 9: Default Custom Characterization Table VIII: Characteristic Curve Data % Command % Control Command =% % Control Command =% Linear Custom Custom 0 0 0 0 Linear 5 0.62 5 8.66 100 10 1.35 10 16.24 90 15 2.22 15 23.17 80 20 3.25 20 30.11 25 4.47 25 35.31 70 30 5.91 30 40.51 60 35 7.63 35 45.42 50 40 9.66 40 50.34 45 12.07 45 54.40 50 14.92 50 58.47 40 30 55 18.31 55 62.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Off Off forces the positioner to use one of the factory preset tuning sets determined by the rotary “Gain” selector switch. Settings “A” through “H” are progressively higher gain predefined tuning sets. The Gain selector switch can be adjusted at any time to modify the tuning parameters. ! NOTE: With Autotune on “E” is the default adjustable GAIN selector switch setting for all actuator sizes.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 7.6 Local Control of Valve Position 7.10 Logix 3200MD Status Condition Local control of valve position can be done from the user interface by holding both jog buttons while then simultaneously pressing the quick cal button for 3 seconds. The and buttons can then be used to position the valve. While in this mode the LED‘s will flash a YGYY (yellow-green-yellow-yellow) sequence.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Table X: Logix 3200MD Status Condition Codes Blink Code GGGG GGGY GGYG GGYY NORMAL OPERATION indicates normal, healthy operation MPC ACTIVE MODE (user set) indicates that tight shutoff (MPC) is active. The command is beyond the user set limit for tight shutoff feature. This is a normal condition for all valves when closed. The factory default setting triggers this at command signals below 1%.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Blink Code **YYGR **YYYG **YYYY **YRGG **YRGY **YRGR YRYG YRRY **YRRR RGGY Description Recommendations SUPPLY PRESSURE HIGH WARNING indicates the positioner has determined that the supply pressure is above the user set warning limit. Regulate the supply pressure at the positioner below the maximum limit recommended for your actuator. Recalibrate pressure sensors. Check the pressure sensor board connections.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Blink Code RGGR RGYG RGYY RGRR RYYG **RRGG **RRGY **RRGR RRYG RRYR RRRY RRRR 20 Description INNER LOOP OFFSET TIME OUT ALARM indicates that during calibration the Inner Loop Offset value did not settle. This could result in less accurate positioning. Recommendations Repeat the stroke calibration to get a more accurate ILO value.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 8 Maintenance and Repair 8.1 Driver Module Assembly The driver module assembly moves the spool valve by means of a differential pressure across its diaphragm. Air is routed to the driver module from the regulator through a flexible hose. A barbed fitting connects the flexible hose to the driver module assembly. Wires from the driver module assembly connect the hall effect sensor and the piezo valve modulator to the main PCB assembly.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 9. Remove the plastic board cover by removing the three retaining screws. (See Figure 14.) 25. Carefully slide the spool into the connecting clip on the top of the driver module assembly. 10. Disconnect the flexible tubing from the barbed fitting at the driver 26. Carefully slide the block over the spool, using the machined surface of the housing base as a register (Figure 13). Slide the 11.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 8.2 Regulator The regulator reduces the pressure of the incoming supply air to a level that the driver module can use. 8.3 Checking or Setting Internal Regulator Pressure To replace the regulator, refer to Figures 11 and 15 and proceed as outlined below. The following tools are required: To check or set the internal regulator pressure, refer to Figure 16 and proceed as outlined below.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 8. Once the regulator pressure is set, tighten the set screw retaining nut on the top of the regulator, remove the air supply to the positioner, remove the barbed tee, and reconnect the flexible tubing from the regulator to the barbed fitting on the side of the driver module. 9. Install the plastic board cover. Insert the three retaining screws through the plastic cover into the threaded boss and tighten evenly, using a Phillips screwdriver.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 8.6 Stem Position Sensor The position feedback assembly transmits valve positions information to the processor. This is accomplished by means of a rotary position sensor that connects to the valve stem through a feedback linkage. To provide for accurate tracking of the pin in the slot, the follower arm is biased against one side of the slot with a rotary spring.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 8.7 Main PCB Assembly The main printed circuit board (PCB) assembly contains the circuit board and processor that perform control functions of the positioner. The main PCB is to be replaced as a unit. None of the components on the main PCB are serviceable. Replacing Main PCB Assembly Removing the Pressure Sensor Board To replace the pressure sensor board, refer to Figures 11, 15 and 25 and proceed as outlined below.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 6. Install the plastic board cover. Insert the three retaining screws through the plastic cover into the threaded boss and tighten evenly, using a Phillips screwdriver. Do not overtighten. 11. Feed the wires on the back of the new customer user interface board through the passageway into the main chamber of the housing. 7. Reinstall all covers. 12. Set the customer interface board in place and secure with three screws (See Figure 6). 8.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 9 Optional Hardware 9.1 Vented Design Figure 20: Spool Cover Vent 3⁄8" NPT x 3⁄8" Swagelok Tube Fitting (See Figures 19 and 20) A standard Logix 3200MD 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.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 9.3 4-20 mA Analog Output Board The Logix 3200MD digital positioner can be supplied to provide an analog feedback signal of the stem position. This option can also be retrofitted in the field. The 4-20 mA analog output board is wired in series with a 12.5 to 40 VDC power supply (See Figure 23). This position feedback option has the following features and specifications: • Does not interfere with positioner operation.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 10 Requirements for Safety Integrity This section provides information and additional user responsibilities in order to meet Safety Integrity Level 2 (SIL 2) per IEC 61508 Parts 1-3. 10.1 Fail Safe State The fail safe state for the Logix 3200MD positioner: • Fail Safe State 1: The spool valve is at less than 5% of full stroke such that Output (Port) 1 is venting and Output (Port) 2 is open to supply pressure.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 10.5 Maximum Achievable SIL 10.9 Required Configuration Settings The Flowserve 3200MD 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) configurations.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 10.11 Lifetime Limits The expected lifetime of the Flowserve 3200MD Positioner is approximately 10 years. The reliability data listed the FMEDA report is only valid for this period. The failure rates of the Flowserve 3200MD 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.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 Figure 24: Exploded Drawing 2 3 4 5 11 42 6 12 43 13 7 9 14 44 45 46 40 47 36 15 39 41 38 49 8 10 17 50 16 48 51 37 52 18 53 1 26 54 25 24 19 55 20 56 29 33 32 21 30 28 34 27 22 23 35 31 33
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 11 34 Parts List Item No. Part Item No.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 12 Logix 3200MD Spare Parts Kits Item No. See Figure 25 for item numbers. Item No. Description Quantity Kit 2: Driver Module Assembly -40° to 80°C Kit, P/N 199786.999.000 16 Pressure Regulator 1 17 Screw, Regulator to Housing 4 33 Driver Module Assembly 1 34 Hex Barbed Fitting w/ Captive O-ring 1 36 Screw, Driver to Housing 1 37 Nylon Washer 1 Kit 3: Spool Assembly Valve Kit, P/N 199787.999.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 13.2 Logix O.E.M. Mounting Kits Brand Model Size Mounting Kit Masoneilan (Rotary Actuators) Table XI: Logix O.E.M. Mounting Kits (continued) 33 B 173298 Brand Model Size 30 34 40 50 657 & 667 Fisher 60 Mounting Kit 213905 141410 0.5" – 1.5" stroke 171516 0.5" – 1.5" stroke 171517 2" stroke 171516 0.5" – 1.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 14 Frequently Asked Questions 5 percent. At 5 percent, the spool will be driven fully open or fully closed, depending on the air action of the valve, in order to provide full actuator Q: My DCS uses 24 VDC, can I run a Logix 3200MD? saturation and tight shutoff. The positioner will maintain full saturation below A: A DCS output current card does run from 24 VDC but the card regulates 5 percent command signal.
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 15 How to Order Certifications NAMUR 316 Stainless Steel (VDI/VDE 3845) -N6 ½" NPT M20 Four-way (Double-Acting) Three-way (Single-Acting) Three-way Purge (Single Acting) not for use with natural gas (used to purge spring side of actuator with instrument air) Four-way Vented (Double-Acting) Three-way Vented (Single-Acting) -E -M -04 -03 -34 -3P -4V -3V Gauges SS with brass internals, psi (bar/kPa) (Valtek Standard) SS with SS intern
User Instructions - Digital Positioner 3200MD LGENIM0059-09 12/13 16 Troubleshooting Failure No LED is blinking Erratic communications Unit does not respond to analog commands Valve position reading is not what is expected Position is driven fully open or closed and will not respond to command Sticking or hunting operation of the positioner Probable Cause Corrective Action Current source below 3.6 mA without AO card or 3.7 mA with AO card Verify current source is outputting at least 3.
FCD LGENIM0059-09 12/13 To find your local Flowserve representative please use the Sales Support Locator System found at: www.flowserve.com/contact.htm or call USA 801 489-8611 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.
