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Valtek SKU 138430 44-1 Valtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Valtek ® Logix ® 1200e digital positioners. Series 1000 is the term used for all the positioners herein; however, specific numbers indicate features specific to a model (i.e. Logix 1200e indicates that the positioner uses HART ® protocol). Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating, or performing any maintenance on the valve. Separate Valtek Flow Control Products Installation, Operation, Maintenance instructions cover the valve (such as IOM 1 or IOM 27) and actuator (such as IOM 2 or IOM 31) portions of the system and other acces- sories. Refer to the appropriate instructions when this information is needed. WARNING: Standard industry safety practices must be adhered to when working on this or any process control product. Specifically, personal protective and lifting devices must be used as war- ranted. Valve and Instrumentation Storage Procedures Storage Control valve packages (a control valve and its instru- mentation) can be safely stored in an enclosed build- ing 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. Pre-installation Inspection If a valve control package has been stored for more than one year, inspect one actuator by disassembling it per the appropriate Installation, Operation, and Maintenance Instructions (IOM) prior to valve installa- tion. If O-rings are out-of-round, deteriorated, or both, they must be replaced and the actuator rebuilt. All actuators must then be disassembled and inspected. If the actuator O-rings are replaced, complete the follow- ing steps: 1. Replace the pressure-balanced plug O-rings. 2. Inspect the solenoid and positioner soft goods and replace as necessary. WARNING: To avoid possible injury to person- nel or damage to valve parts, users must strictly adhere to WARNING and CAUTION notes. Modifying this product, substituting non-factory or inferior parts, or using mainte- nance procedures other than outlined could drastically affect performance and be hazard- ous to personnel and equipment, and may void existing warranties.
45

Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

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Page 1: Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

Valtek Logix 1200e/1210eDigital Positioner

GENERAL INFORMATION

The following instructions are designed to assist inunpacking, installing and performing maintenance asrequired on Valtek® Logix® 1200e digital positioners.Series 1000 is the term used for all the positionersherein; however, specific numbers indicate featuresspecific to a model (i.e. Logix 1200e indicates that thepositioner uses HART® protocol). Product users andmaintenance personnel should thoroughly review thisbulletin prior to installing, operating, or performing anymaintenance on the valve.

Separate Valtek Flow Control Products Installation,Operation, Maintenance instructions cover the valve(such as IOM 1 or IOM 27) and actuator (such as IOM2 or IOM 31) portions of the system and other acces-sories. Refer to the appropriate instructions when thisinformation is needed.

WARNING: Standard industry safety practicesmust be adhered to when working on this or anyprocess control product. Specifically, personalprotective and lifting devices must be used as war-ranted.

Valve and Instrumentation Storage ProceduresStorage

Control valve packages (a control valve and its instru-mentation) can be safely stored in an enclosed build-ing that affords environmental protection; heating isnot required. Control valve packages must be storedon suitable skids, not directly on the floor. The storagelocation must also be free from flooding, dust, dirt, etc.

Pre-installation Inspection

If a valve control package has been stored for morethan one year, inspect one actuator by disassemblingit per the appropriate Installation, Operation, andMaintenance Instructions (IOM) prior to valve installa-tion. If O-rings are out-of-round, deteriorated, or both,they must be replaced and the actuator rebuilt. Allactuators must then be disassembled and inspected. Ifthe actuator O-rings are replaced, complete the follow-ing steps:

1. Replace the pressure-balanced plug O-rings.

2. Inspect the solenoid and positioner soft goods andreplace as necessary.

WARNING: To avoid possible injury to person-nel or damage to valve parts, users muststrictly adhere to WARNING and CAUTIONnotes. Modifying this product, substitutingnon-factory or inferior parts, or using mainte-nance procedures other than outlined coulddrastically affect performance and be hazard-ous to personnel and equipment, and mayvoid existing warranties.

Valtek SKU 138430 44-1

Page 2: Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

Table of ContentsGeneral Information ................................................... 1

Valve and Instrumentation Storage Procedures .... 1

Logix 1200e Positioner Overview............................... 3

Specifications............................................................. 3

Positioner Operation................................................... 4

Detailed Sequence of Positioner Operations......... 4

Logix 1000 Series Positioner Vented-design Conversion ................................................................. 5

Tubing Positioner to Actuator ................................ 6

Wiring and Grounding Guidelines.......................... 6

Available Spare Part Kits for Logix 1200e digital postioner .............................................................. 22

4 to 20 mA Analog Output Retrofit....................... 24

General Information ............................................. 24

Calibration............................................................ 25

Troubleshooting........................................................ 30

Introduction .......................................................... 30

Theory of Operation............................................. 30

Mounting and Installation..................................... 31

Calibration............................................................ 33

Control and Tuning .............................................. 34

HART Communication ......................................... 35

Alarms.................................................................. 37

Alerts.................................................................... 38

Advanced Features .................................................. 40

Logix 1200e Digital Positioneron Valtek Mark One Control Valve

44-2 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Page 3: Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

Unpacking

1. While unpacking the Logix 1200e positioner, checkthe packing list against the materials received. Listsdescribing the system and accessories areincluded in each shipping container.

2. When lifting the system from the shipping con-tainer, position lifting straps to avoid damage tomounted accessories. Systems with valves up tosix inches may be lifted by actuator lifting ring. Onlarger systems, lift unit using lifting straps or hooksthrough the yoke legs and outer end of body.

WARNING: When lifting a valve/actuator assem-bly with lifting straps, be aware the center ofgravity may be above the lifting point. There-fore, support must be given to prevent thevalve/actuator from rotating. Failure to do socan cause serious injury to personnel or dam-age to nearby equipment.

3. In the event of shipping damage, contact the ship-per immediately.

4. Should any problem arise, contact a FlowserveFlow Control Division representative.

Logix 1200e Positioner OverviewThe Logix 1200e digital positioner is a two-wire,4-20 mA input, digital valve positioner. The Logix1200e positioner also utilizes the HART protocol toallow two-way remote communications with the posi-tioner. The Logix 1200e positioner can control bothdouble and single-acting actuators with linear androtary mountings. Start up current must be at least3.5 mA but once started, the Logix 1200e digital posi-tioner operates with a signal as low as 2.8 mA. Below2.8 mA, the operation and communication are sus-pended.

Since the positioner is insensitive to supply pressurechanges and can handle supply pressures from 30 to150 psig, a supply regulator is usually not required;however, in applications where the supply pressure ishigher than the maximum actuator pressure rating asupply regulator is required to lower the pressure tothe actuator’s maximum rating (not to be confusedwith operating range). An air filter is required for allapplications due to the close clearances in the spool.

NOTE: The air supply must conform to ISA StandardISA 7.0.01 (a dew point at least 18 degrees Fahrenheitbelow ambient temperature, particle size below fivemicrons – one micron recommended – and oil contentnot to exceed one part per million).

SpecificationsTable I: Electrical Specifications

Power supply Two-wire, 4-20 mA 12.0 VDC

Compliance voltage 12.0 VDC

Effective resistance 625 Ω @ 20 mA

Communications HART Protocol

Minimum required start-up current

3.5 mA

Minimum operatingcurrent

2.8 mA

Maximum voltage 40.0 VDC

Table II: SoftTools Suite Software Specifications

Computer

Minimum Pentium processor running Win-dows 95 or NT, 16-MB total memory (32-MB recommended), 20-MB available hard disk space, one CD-ROM drive

HART Modem RS-232 Modem or PCMCIA card

HART FilterMay be required in conjunction with some DCSs

HART MUX MTL 4840 system

Table III: Physical Specifications

Operating Temperature Range

-40° F to +185° F(-40° C to +85° C)

HousingCast, powder-painted aluminum, stainless steel

Weight8.3 pounds (3.9 kg) aluminum 20.5 pounds (9.3 kg) stainless steel

Table IV: Positioner Specifications

Dead band <0.1% full scale

Repeatability < 0.05% full scale

Linearity< 0.5% (rotary), < 0.8% (sliding stem) full scale

Air Consumption at < 0.3 SCFM (0.5 Nm3/hr)@60 psig (4 barg)

Table V: Hazardous Area Certifications

Explosion ProofFM/CSA Class 1, Div 1, Groups B, C, D CENELEC EExd IIB+H2 T5, IP-66

Non-incendiveFM/CSA Class 1, Div 2, Groups A, B, C, D; CENELEC IIC Exn, T6,BS 6941,IP-66, T

Intrinsically SafeFM/CSA Class 1, Div 1, Groups A, B, C, D; CENELEC EExib, T4 & T5, IP-66

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-3

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.

Positioner OperationThe Logix 1200e positioner is an electric feedbackinstrument. Figure 1 shows a Logix 1200e positionerinstalled on a double-acting actuator for air-to-openaction. Positioning is based on a balance of two sig-nals: one proportional to the command input signaland the other proportional to the valve stem position.

The supply pressure for the positioner pressure modu-lator is tapped off the main supply. Next it passesthrough an internal pressure regulator that regulates itto approximately 22 psig. The air then passes throughan orifice that restricts the flow and air consumption.

The pressure modulator further controls the air to6-10 psig, when operating current is applied, using aspring-diaphragm flapper that is attracted by an elec-tromagnet to a nozzle. A temperature compensatedhall effect sensor mounted on a circuit board sensesthe spool valve position. The hall effect sensor and cir-cuitry create an inner feedback loop, which determineshow much current to send to the electromagnet for adesired spool valve position. The electro-magnet inthe feedback loop varies the nozzle-flapper spacing,which regulates the output pressure to 6-10 psig, pro-portional to the digital position algorithm.

When the command and stem position signals areequal, the system will be in equilibrium and the valvestem will be in the position called for by the commandsignal. If these opposing signals are not equal, thespool valve will move up (or down) and, by means of

the pressure modulator, change output pressures andflow rate. This will cause the actuator piston to moveuntil the signal of the position sensor equalizes withthe command signal.

Detailed Sequence of Positioner Operations

The detailed sequence of positioner operations is asfollows: An increase in the command signal causesthe modulator pressure to increase, pushing the spoolassembly upward from its equilibrium position. Thisopens the spool valve ports, supplying air to Output 1and exhausting air from Output 2. This causes theactuator piston to move upward.

The upward motion of the piston is transmitted back tothe positioner through the stem position feedback link-age, changing proportionally to the valve stem posi-tion. The piston continues to stroke upward until thestem position signal of the sensor increases suffi-ciently to counter the signal being sent to the controlalgorithm. At this point, the spool is at its equilibriumposition as the pressures in the cylinder stabilize andthe air flow to the actuator decreases. The positionerwill then make small null adjustments to fine-tune thedesired position and compensate for changes indynamic loading.

A decrease in the command signal reverses thedescribed actions, causing a proportional downwardmovement of the actuator piston and stem.

Figure 1: Logix 1200e Digital Positioner Schematic

O

Hall Effect Sensor

Electro magnetic Coil

Nozzle Flapper

Digital Position Algorithm

Spool Valve

Flame Arrestors

Collector BoardPressure Sensor

Air Supply

LEDDisplay

Orifice

ExhaustOUTPUT 1

OUTPUT 2

Exhaust

FlameArrestor

Stem Position Sensor

Air-to-openConfiguration

Main PCB Tray

Ribbon Cable

Flame Arrestor

Filter

Regulator

44-4 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Logix 1000 Series Positioner Vented-design Conversion

A standard Logix 1000 series positioner is venteddirectly to the atmosphere. When supply air is substi-tuted with sweet natural gas, the following changesand considerations must be met. Piping must be usedto route the exhausted natural gas to a safe environ-ment. This piping system may cause some positionerback pressure in the main chamber (from modulator)and spool chambers (from actuator). This increase inpressure is due to restrictions caused by piping lossesfrom the pipe and fittings

Two chambers must be vented on the Logix 1000series positioners: the main housing chamber and thespool valve chamber (Figures 1 and 2). The mainchamber vent is located on the backside of the posi-tioner (see Figure 1). There is a small, silver-coloredcover (item 24, SKU 10097867), protecting the ventwhich must be removed and can be discarded.

A fitting may now be threaded into the 1/8-inch NPThole and tubing/piping attached.

NOTE: On rotary products, the mounting bracket cov-ers the main housing vent. An adequate size accesshole must be drilled in the bracket at the time ofassembly to allow access to the main housing vent.

The maximum allowable back pressure from the col-lection device on the main housing vent is 1.0 psi(0.07 bar). Vent flow rate is 244 standard in3/min.

WARNING: The back pressure must never riseabove 2.0 psi (0.14 bar).

If this occurs the weather seal boot (SKU 130884),found on the early versions of the Logix 1000 posi-tioner, identified by the diagonal window in the maincover, must be checked for proper sealing, as over-pressure will move the seal out of place. (SeeFigure 4). Damage will not occur to the seal, only sealalignment will be affected. A typical sign of boot leak-age is a dramatic deterioration of positioner perfor-mance. To correct the seal, remove the driver moduleand simply re-align back into its groove. If back pres-sure of 3.5 psi (0.24 bar) is reached, total valve controlwill be lost.

Figure 2: Field Termination

Field Terminations

HAR T ConnectionTerminals

4-20 mA FeedbackTerminals (optional)

Housing EARTHTerminal

Connect Shield at Source Ground

4-20 mA Current Source

ShieldedCable

Figure 3: Main Housing Vent

Figure 4: Seal on Modulator

Maximum Allowable HousingBack Pressure1 psi (0.07 bar)

1 4-inch NPT x 4-inchSwagelok Tube Fitting

14-inch FNTP x 8-inchMNPT Reducer

1

1

Seal Boot

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-5

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The spool valve chamber has two parts: the spoolvalve cover, (item 9, SKU 130811) and spool valveshroud (item 10, SKU 130825). The spool valve coveris replaced by SKU 10134649 for early versions of theLogix 1000 positioner or SKU 10160335 for later ver-sions (identified by the 1200e or the round window inthe main cover). This new cover has a 3/8-inch NPThole where tubing/piping must be attached. The spoolvalve shroud is discarded and not replaced with any-thing. The maximum allowable back pressure whilestroking the valve is 8 psi (0.55 bar). Higher pressures

will cause problems with overshoot but permanentdamage will not occur until pressures exceed 20 psi(1.4 bar).

Tubing Positioner to Actuator

Proper tubing orientation is critical for the positioner tofunction correctly and have the proper failure mode.Refer to Figure 1 and note that for air-to-open valves,the Output 1 port of the positioner manifold is tubed tothe bottom side of the actuator. The Output 2 port ofthe positioner manifold is tubed to the top side of theactuator. For air-to-close valves the above configura-tion is reversed.

For single-acting actuators Output 1 port is alwaystubed to the actuator regardless of air action. Output 2port must be plugged.

WARNING: This product has electrical conduitconnections in either thread sizes 0.5-inch NPT orM20 which appear identical but are not inter-changeable. Forcing dissimilar threads togetherwill damage equipment, cause personal injury andvoid hazardous location certifications. Conduit fit-tings must match equipment housing threadsbefore installation. If threads do not match, obtainsuitable adapters or contact a Flowserve office.

Wiring and Grounding Guidelines

Input Cable Shielding (Figure 2)

The input loop current signal to the Logix 1200e digitalpositioner should be in shielded cable. Shields mustbe tied to a ground at only one end of the cable to pro-vide a place for environmental electrical noise to beremoved from the cable. In general, shield wire shouldbe connected at the source.

Grounding Screw

The green grounding screw, located inside the termi-nation cap, should be used to provide the unit with anadequate and reliable earth ground reference. Thisground should be tied to the same ground as the elec-trical conduit. Additionally, the electrical conduit shouldbe earth grounded at both ends of its run.

The green grounding screw must not be used toterminate signal shield wires.

Figure 5: Spool Cover Vent

Maximum Allowablespool Back Pressure8 psi (0.55 bar)

3/8-inch NPT x 3/8-inch Swagelok Tube Fitting

Customer Connection 3/8-inch Tubing

44-6 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Compliance Voltage (Figure 6)

Output compliance voltage refers to the voltage limitthat can be provided by the current source. A currentloop system consists of the current source, wiringresistance, barrier resistance (if present), and theLogix 1200e positioner impedance. The Logix 1200edigital positioner requires that the current loop systemallows for a 12.0 VDC drop across the positioner atmaximum loop current. The 12.0 VDC drop across theLogix 1200e positioner terminals is generated by thepositioner from the 4-20 mA loop current input.

CAUTION: Never connect a voltage source directlyacross the positioner terminals. This could causepermanent circuit board damage.

Determine if the loop will support the Logix 1200e dig-ital positioner by performing the following calculation.

Voltage = Compliance Voltage (@CurrentMAX) - CurrentMAX*(Rbarrier+Rwire)

The calculated voltage must be greater than 12 VDCin order to support the Logix 1200e digital positioner.

Example: DCS Compliance Voltage = 19 V

Rbarrier = 300 Ω

Rwire = 25 Ω

CURRENTMAX = 20 mA

Voltage = 19 V - 0.020 A*(300 Ω + 25 Ω)

= 12.5 V

The voltage 12.5 V is greater than the required 12.0 V;therefore, this system will support the Logix 1200e dig-ital positioner. The Logix 1200e positioner has aninput resistance equivalent to 625 Ω at a 20 mA inputcurrent.

Cable Requirements

The Logix 1200e digital positioner utilizes the HARTCommunication protocol. This communication signalis superimposed on the DC 4-20 mA current signal.The two frequencies used by the HART protocol are1200e Hz and 2200 Hz. In order to prevent distortionof the HART communication, cable capacitance andcable length restrictions must be calculated. The cablelength must be limited if the capacitance is too high.Selecting a cable with lower capacitance/foot ratingwill allow longer cable runs. In addition to the cablecapacitance, the network resistance also affects theallowable cable length.

In order to calculate the maximum network capaci-tance, use the following formula.

Example: Rbarrier = 300 Ω

Rwire = 50 Ω

To control cable resistance, No. 24 AWG cable shouldbe used for runs less than 5000 feet. For cable runslonger than 5000 feet, No. 20 AWG cable should beused.

Figure 6: Compliance Voltage

Cnetwork µF( ) 65Rbarrier Rwire 390+ +( )

-------------------------------------------------------------- 0.0032–≤

Ccable22ρFfoot

--------------0.000022µF

foot--------------------------------= =

65300 50 390+ +--------------------------------------- 0.0032– 0.08µF Cnetwork µF( ) Max( )= =

Max Cable LengthCnetwork µF( )

Cnetwork-----------------------------------=

Max Cable Length 0.08µF0.000022µF foot⁄-----------------------------------------------=

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-7

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Driver Module Assembly

The driver module assembly moves the spool valve bymeans of differential pressures on its diaphragm. Air isrouted to the module from the regulator through ahose that connects to the assembly through a hosebarb with an integral orifice. Wires from the moduleconnect the hall effect sensor and the pressure modu-lator coil to the collector board.

Driver Module Assembly Replacement

To replace the driver module assembly, refer toFigure 7, 8, 9, 11, 20 and proceed as outlined below.The following tools are required:

Flat plate/bar about 1/8-inch thickPhillips screwdriver

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the driver module cover (Figure 9), usingflat bar/plate in slot.

4. Remove the spool valve cover by removing thescrew and sliding the cover assembly backwardsuntil the tab is clear of the slot. Removing the sheetmetal cap, hydrophobic filter, or O-ring from thisassembly is not necessary (Figure 11).

5. Being careful not to lose the nylon washer, removethe Phillips-head screw that attaches the drivermodule to the main housing (Figure 8).

6. Remove the spool valve block by removing the twoPhillips-head screws and carefully sliding the blockoff the spool (Figure 8).

CAUTION: The spool (extending from the driverassembly) is easily damaged. Use extreme cau-tion when handling the spool and spool valveblock.

7. Carefully remove spool by sliding end of spool outof connecting clip. Excessive force may bend spool.

8. Remove main cover.

Figure 7: Driver Module Assembly

Collector Board

PressureModulatorConnection

Hall SensorConnection

O-ring

Driver ModuleAssembly

Minimum PressureSet Screw (factorycalibrated)

Position wires tothe rear of Modulator

Install orifice before drivermodule is in housing

Hall Sensor Connector

Pressure Modulator Connector

44-8 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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9. Remove the tubing from the orifice in the drivermodule assembly (Figure 9).

10.Remove the two wiring connections that link thedriver module assembly to the collector board.

11.Feed the wires back through the housing so theyextend backward, out toward the driver module

opening. This will allow the driver module to threadout without tangling or cutting the wires.

12.Grasp the driver module pressure modulator cap torotate the entire driver module. Turn it counterclockwise to remove. After it is threaded out, care-fully retract the driver module from the housing.

13.Take new driver module, and verify that the O-ringis in place. Lay the wires back and along modulatoras shown in Figure 7, and hold in place by hand.

14.Gently direct the driver module into the housingbore. Turn the driver module clockwise to thread itinto the housing. Continue rotating the module untilit bottoms out.

15.Once the threads are fully engaged, rotate thedriver module counter clockwise until the flat on thedriver module and the flat on the housing arealigned. This will align the screw holes for the nextstep.

16.Verify that nylon gasket is in the counter bore in thedriver module retaining screw hole as shown inFigure 8.

17.Insert a driver-to-housing screw into the driverhousing through the counter-bored hole in posi-tioner main housing. Tighten with a phillips screw-driver.

18.Feed the driver module wires into the main cham-ber of the housing, and connect them to the collec-tor board.

19.Verify that the three O-rings are in the counter-bores on the machined platform where the spoolvalve block is to be placed (Figure 20).

20.Carefully slide the spool into the connecting clip ofthe driver module assembly.

21.Carefully slide the block over the spool, using themachined surface of the housing base as a register(Figure 8). Slide the block toward the driver moduleuntil the two retaining holes line up with thethreaded holes in the base.

22.Install two spool-valve screws and tighten securelywith a Phillips screwdriver.

23.Slide the spool valve cover assembly over the spoolvalve until the tang engages into housing slot.Install spool valve cover screw and tighten securely.

24.Thread main cover and driver module cover intothe main housing.

Figure 8: Spool and Block

Figure 9: Driver Module Orifice

Spool ValveScrews

Ny lonGaskets

Driver toHousing Screws

Spool

Spool Valve BlockHousing

DriverModul eCover

Orifice

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-9

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Spool Valve

To replace the spool valve, refer to Figure 8, 10 & 11and proceed as outlined below.

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the spool valve cover by removing thescrew and sliding the cover assembly backwardsuntil the tab is clear of the slot. It is not necessaryto remove the sheet metal cap, hydrophobic filter,or O-ring from this assembly (Figure 11).

4. Remove the spool valve block by removing the twophillips-head screws and carefully sliding the blockoff the spool (Figure 8).

CAUTION: Spool (extending from driver assem-bly) is easily damaged. Use extreme cautionwhen handling spool and spool valve block.

5. Carefully remove spool by sliding end of spool outof connecting clip. Excessive force may bend thespool.

6. Verify that the three O-rings are in the counter-bores on the machined platform where the newspool valve block is to be placed (Figure 20).

7. Careful slide the spool into the connecting clip ofthe driver module assembly.

8. Carefully slide the block over the spool, using themachined surface of the housing base as a register(Figure 8). Slide the block toward the driver moduleuntil the two retaining holes line up with thethreaded holes in the base.

9. Install two spool-valve screws and tighten securelywith a phillips screwdriver.

10.Slide the spool valve cover assembly over the spoolvalve until the tang engages into housing slot.Install the spool valve cover screw and tightensecurely.

Regulator

The regulator reduces the pressure of the incomingsupply air to a level that the driver module can use.

Replacing Regulator

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the main cover.

4. Remove the four wire connections from the collec-tor board. Next remove the four screws that fastenthe collector board to the housing.

5. Grasp the bottom of the regulator and unscrew itfrom the interface plate.

6. Verify that the O-rings are in place on the base ofthe new regulator and thread it into the hole ininterface plate.

7. Install four screws to fasten the collector board intothe housing. Replace the four wire connections.

8. Attach the flexible tubing to the orifice.

9. Re-install all covers.

Spool Valve Cover

The spool valve cover incorporates a coalescing filterelement in a two-piece cover. This protects the spoolvalve chamber from moisture and provides a low backpressure vent for exhaust air from the spool valve.

Replacing Filter in Spool Valve Cover

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the spool cover by removing the screwand sliding the cover assembly backwards until thetab is clear of the slot. The sheet metal cover maybe removed and cleaned with a brush or by blowingout with compressed air (Figure 11).

4. Remove the O-ring from around hydrophobic filterelement and set aside (Figure 10).

5. Remove the molded filter element by pullingstraight out of chamber cover vent piece.

6. Install O-ring into base of chamber cover vent pieceas shown in Figure 10.

Figure 10: Spool Valve Cover Assembly

O-ring

Hyd rophobicFilter

SpoolValveCover

SpoolValve Shroud

44-10 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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7. Place new molded filter element into the chambercover vent piece. This element provides part of thetrack to secure the O-ring installed in the last step.

8. Place spool valve shroud onto spool valve cover.

9. Place the spool valve cover assembly in place bysetting it on the ramp and sliding it until the tab seatsin the slot (Figure 11) and secure with No. 8-32screw.

Main PCB Assembly

The main PCB assembly contains the circuit boardand processor that perform control functions of thepositioner. The board is encapsulated in a tray with aprotective silicon coating. This module can be easilyreplaced if necessary. None of the components insidethe tray are serviceable. This module is to be replacedas a unit.

Replacing Main PCB Assembly (Figure 12)

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the main cover and disconnect the ribboncable from the collector board.

CAUTION: To avoid damaging any components,exercise caution by gently raising the lockingtab to release the ribbon cable.

4. Remove the PCB assembly by removing the threeNo. 6-32 screws and lifting the tray out of housing.

5. Place the new PCB assembly on the bosses insidethe positioner housing.

6. Insert three No. 6-32 screws through the tray intothe threaded bosses and tighten evenly, using aphillips screwdriver. Do not overtighten.

7. Reconnect the ribbon cable to the collector boardFigure 11: Spool Valve Cover Assembly

Figure 12: Main PCB Assembly

Ribbon Cable

Screws (3)

Main PCB Assembly

Screw Spool Valve Cover

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-11

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Collector Board

The collector board assembly provides a central rout-ing for all electronic connections in the positioner, link-ing the pressure modulator coil, hall effect sensor andfield inputs to the main electronics. The collector boardassembly also provides for mounting of the pressuresensors used in the advanced model.

Removing Collector Board (Figure 20)

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the main cover and disconnect the wiring tothe collector board. Each cable has its own uniqueconnector to prevent mistakes in reconnecting.

4. Remove the four No. 8-32 screws holding thecollector board to the housing.

5. Remove the collector board.

Replacing Collector Board

NOTE: A Logix 120X (standard model) cannot beupgraded to a Logix 1210e (advanced model) bychanging out the collector board. The Logix 120X andLogix 1210e use different positioner housings.

1. Advanced collector board only – Verify that pres-sures sensors are in place on back of collectorboard, and that the two O-rings are in place.

2. Set collector board assembly in place.

3. Advanced collector boards require a stiffener plateabove the pressure sensors (Figure 20).

4. Insert four No. 8-32 screws through the collectorboard into the threaded holes of the housing.

NOTE: The two screws through the stiffener plateare longer.

5. Tighten all four screws.

6. Connect the main ribbon from the electronics tray.

7. Reconnect wiring to the collector board.

Field Terminations

The customer interface board provides a connectionpoint inside the explosion proof housing for all hook-ups to positioner. While the board is not likely to expe-rience a failure, it can easily be replaced.

Replacing Customer Interface Board(Figure 2 & 20)

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the main cover and disconnect the cus-tomer interface cable from collector board.

4. Remove the customer interface cover and the threeNo. 8-32 screws.

5. Remove customer interface board, carefully pullingwiring through bore.

6. Verify that the O-ring is in place in the counter borein the positioner housing.

7. Feed wiring through passageway into main cham-ber of housing.

8. Set the circuit board in place and secure with threeNo. 8-32 screws.

9. Connect customer interface cable to collectorboard.

10.Replace covers.

44-12 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Stem Position Sensor

The position feedback assembly transmits valve posi-tion information to the processor. This is accomplishedby means of a rotary position sensor that connects tothe valve stem through a feedback linkage. To providefor accurate tracking of the pin in the slot, the followerarm is biased against one side of the slot with a rotaryspring. This spring also automatically moves the posi-tion feedback assembly to its limit in the unlikely eventof failure of any component in the linkage.

Stem Position Sensor Replacement(Figure 13, 20)

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the power and air supply to the unit.

3. Remove the main cover and disconnect rotaryposition sensor wires from collector board.

4. Remove the two screws from rotary position sensorand remove the sensor from the housing.

5. Turn position sensor shaft until the dot on the slot isoriented with the wires on the pot (Figure 13).

6. Insert the position sensor into the shaft with wirespointing toward the main PCB assembly. Turn theposition sensor clockwise until bolting slots alignwith the housing screw holes and the wires on thesensor protrude over the main PCB assembly tray.

7. Carefully center position sensor on the shaft bore,insert and tighten the screws. Do not over tighten.

8. Route wires along the position sensor and recon-nect to collector board.

Mounting to Linear Mark One Valves(See Figure 14)

The tools required for the following procedure are:

9/16-inch open-end wrench 7/16-inch box wrench 3/8-inch open-end wrench

1. Remove washer and nut first from follower pinassembly. Insert pin into the appropriate hole in fol-lower arm, based on stroke length. The strokelengths are stamped next to their correspondingholes in the follower arms. Make sure theunthreaded end of the pin is on the stamped side ofthe arm. Reinsert lock washer and tighten nut tocomplete follower arm assembly.

2. Slide the double-D slot in the follower arm assem-bly over the flats on the position feedback shaft inthe back of the positioner. Make sure the arm ispointing toward the customer interface side of thepositioner. Slide lock washer over the threads onthe shaft and tighten down the nut.

3. Align the bracket with the three outer mountingholes on the positioner. Fasten with 1/4-inch bolts.

4. Screw mounting bolt into the hole on the yokemounting pad nearest the cylinder. Stop when thebolt is approximately 3/16-inch from being flush withmounting pad.

5. Slip the large end of teardrop shaped mountinghole in the back of the positioner/bracket assemblyover mounting bolt. Slide the small end of teardropunder mounting bolt and align the lower mountingholes.

6. Insert lower mounting bolt and tighten bolting.

7. Slide appropriate pin slot on the take-off arm, basedon stroke length, over follower arm pin. The appro-priate stroke lengths are stamped by each pin slot.

8. Position the take-off arm mounting slot against thestem clamp mounting pad. Apply Loctite 222 totake off arm bolting and insert through washers intostem clamp. Torque to 120 in-lbs.

9. Center the take-off arm on the rolling sleeve of thefollower pin.

10.Align take-off arm with top plane of the stem clampand tighten bolting.

Figure 13: Stem Position Sensor Orientation

Sensor Cable

Feedback Shaft

Housing Stem PositionSensor

BearingStem PositionSensor Dot

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-13

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Standard Rotary Mounting Procedure(See Figure 15)

The standard rotary mounting applies to valve/actua-tor assemblies that do not have mounted volume tanksor handwheels. The standard mounting uses a linkagedirectly coupled to the valve shaft. This linkage hasbeen designed to allow for minimal misalignmentbetween the positioner and the actuator. The toolsrequired for the following procedure are:

5/32 allen wrench 1/2-inch end wrench 7/16-inch end wrench3/8-inch socket with extension3/16 nutdriver

1. Fasten spline lever adapter to splined lever usingtwo No. 6 x 0.50-inch self tapping screws.

2. Slide take-off arm assembly onto spline leveradapter shaft. Insert screw with star washerthrough take-off arm and add second star washerand nut. Tighten nut with socket so arm is lightlysnug on shaft but still able to rotate. This will betightened after linkage is correctly oriented.

3. Attach follower arm to positioner feedback shaftusing the star washer and No. 10-32 nut.

NOTE: Arm will point up when feedback shaft is inthe free position.

1. Using four 0.25-20 x 0.50 L. bolts, fasten positionerto universal bracket using appropriate hole pattern(stamped on bracket).

2. Using a 1/2-inch end wrench and two 0.3125-18 x0.50 L. bolts, attach bracket to actuator transfercase pad. Leave these bolts slightly loose until finaladjustments are made.

3. Rotate take-off arm so the follower pin will slide intoits slot. Adjust bracket position noting the engage-ment of the follower pin and the take-off arm slot.The pin should extend approximately 1/16-inch pasttake-off arm. When properly adjusted, securelytighten the bracketing bolts.

Orienting the Take-off Arm for Final Lock Down

Tube positioner to valve in the following manner:

1. OUTPUT 1 port of the manifold to the bottom sideof the Actuator.

Figure 14: Linear Mark One Control Valve Mounting

Logix 1200 Positioner

PositionerBolts

Nut

Lock Washer

Nut

Follower Pin

Take-off Arm

Bolts

Stem Clamp

Bracket Bolts

BracketLocknutWasher

FollowerArm

Nut

MetalWashers

44-14 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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2. OUTPUT 2 port of the manifold to the topside ofthe actuator.

3. With supply pressure off, rotate the follower arm inthe same direction the shaft would rotate upon aloss of supply pressure. When the mechanical stopof the follower arm (positioner) is reached, rotateback approximately 15 degrees.

4. Hold the take-off arm in place; tighten the screw ofthe take-off arm.

NOTE: The take-off arm should be snug enough tohold the follower arm in place but allow movementwhen pushed.

5. Connect regulated air supply to appropriate port inmanifold.

6. Remove main cover and locate DIP switches andQuick-Cal button

7. Refer to sticker on main board tray and set DIPswitches accordingly

8. Press the Quick-Cal button for 5 to 10 seconds oruntil positioner begins to move. The positioner willnow perform a stroke calibration.

9. If the calibration was successful the green LED willblink and the valve will be in control mode. Con-tinue with step 10. If calibration failed the A/D feed-back values were exceeded and the arm must beadjusted away from the positioners limits. Return tostep 3 and back off approximately 10 degrees.

NOTE: Remember to remove the air supply beforere-adjusting take-off-arm.

10.Tighten the nut on the take-off arm. The sockethead screw of the take-off arm must be tight, about40 in-lbs.

NOTE: If the take-off arm slips, the positioner mustbe re-calibrated.

WARNING: Failure to follow this procedure willresult in positioner and/or linkage damage.Check air-action and stroke carefully beforelockdown of take-off arm to spline leveradapter.

Figure 15: Standard Rotary Mounting

Positioner Bolts 1/4-20 (4)*

Bracket Bolts 5/16-18 (2) (not shown)

* Located in appropriatehole pattern as indicated onbracket. (25, 50, 100/200)

Take off Arm, RotaryLock Washer (2)Bolt No.10-32Nut No.10-32

Self Tapping Screws (2)

Spline Lever Adapter

Nut No.10-32Lock Washer

Follower Arm

Logix 1200Digital Positioner

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-15

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Optional Rotary Mounting Procedure

The optional rotary mounting applies to valve/actuatorassemblies that are equipped with mounted volumetanks or handwheels. The optional mounting uses afour-bar linkage coupled to the valve shaft. The follow-ing tools are required:3/8-inch box wrench 7/16-inch box wrench

1/2-inch box wrench

1. Using a 1/2-inch box end wrench and two 0.3125-18x 0.50 L. bolts, attach bracket to actuator transfercase pads. Leave bracket loose to allow foradjustment.

2. Using four 0.25-20 x 0.50 L. bolts and a 7/16-inchbox wrench, fasten positioner to universal bracket,using the four-hole pattern that locates the posi-tioner the farthest from the valve. Rotate positioner

90 degrees from normal so gauges are facingupward.

3. Attach follower arm to positioner feedback shaft,using the star washer and No. 10-32 nut.

4. Attach tripper and tripper clamp to shaft, using two0.25-20 L. bolts and two 0.25-20 locknuts. Leavetripper loose on shaft until final adjustment.

5. Thread ball joint linkage end to tripper and tighten(Thread locking compound such as Loctite is rec-ommended to prevent back threading). Adjustlength of tie rod so follower arm and tripper rotateparallel to each other (the rod must be cut to thedesired length). Connect other ball joint end to fol-lower arm using a star washer and a No. 10-32 nut.

6. Tighten bracket and tripper bolting.

7. Check for proper operation, note direction of rotation.

Figure 16: Optional Rotary Mounting

Tripper

Tripper Clamp

Bo lts (2)

Locknuts (2)

*Tie Rod

Nut No. 10-32 Lock Washer

Bracket Bo lts 5/16-18 (2)

Ball oint Ends

Follower Arm

Rotate Positioner 90°

Mounting Bo lts1/4-20 (4)

Tie Rod must be cut to desired length

44-16 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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WARNING: If rotating in wrong direction, seri-ous damage will occur to the positioner and/orlinkage. Check air action and stroke directioncarefully.

LED Indicators

The Logix 1200e has three LED indicators that are vis-ible through a window in the main cover. Only one LEDwill blink at any given time. Each LED has a differentcolor to convey basic information about the positionerstatus. Green indicates that the positioner is operatingnormally. Yellow indicates that a ‘customer definedlimit’ or ‘alert’ has been reached. Red indicates that anerror condition exists. The HART hand held communi-cator, ValTalk or SoftTools PC software must be usedto determine the specific reason for a yellow or redLED status.

During stroke and actuator calibration, no LED willblink. After calibration is complete, the green LED indi-cates that the calibration was completed successfully.If the yellow or red LED blinks after a calibration pro-cess, a warning or error was detected and the HARTcommunication to the device must be used to identifythe specific calibration error.

NOTE: If the LED indicator changes from green to yel-low after a calibration process, the user may have seta warning limit (position alert, cycle counter alert,etc.). Use HART communications to monitor status.

Stroke Calibration using the Quick-Cal Button

For cases when the HART hand held communicator,ValTalk or SoftTools PC software is not available, theLogix 1200e has a Quick-Cal feature that performs astroke calibration and allows basic operation of thepositioner. The Quick-Cal routine applies full supplypressure to the upper and lower mechanical limits todetermine the valve stroke. Valve systems withoutmechanical stops must use the ValTalk or SoftToolssoftware to manually calibrate the valve.

WARNING: The calibration routines are only to beused on systems which have mechanical stops.The calibration routines apply full supply pressureto determine stroke length and may cause damageto the valve, actuator or positioner.

NOTE: The Quick-Cal operation retains all previouslyconfigured information except for the three DIP switchsettings and stroke parameters. The settings ofATO/ATC, Linear/Rotary, Linear/Custom and strokeparameters are overridden and rest to the DIP switchsettings when the Quick-Cal button is used. If thedevice is being installed for the first time, factorydefault parameters are used.

The Quick-Cal button and DIP switch settings arelocated on the collector board inside the main housingchamber as shown in Figure 17.

WARNING: Accessing this function requiresremoval of the main cover. The user must take allprecautions if this operation is performed in explo-sion-proof areas.

Make the appropriate configuration settings, using theDIP switches on the collector board. ATO/ATC selectsair-to-open or air-to-close (this is determined by themechanical tubing of the actuator). TheLIN_VALV/ROT_VALV button allows the user to selectlinear or rotary feedback linkage. The LIN_VALVswitch enables the feedback potentiometer to utilizethe entire resolution through a maximum of 60degrees rotation (45 degrees is typical). TheROT_VALV switch increases the rotation of the poten-tiometer up to 105 degrees (90 degrees is typical).Thus a long stroke sliding stem valve may require thisdip switch to be set on ROT_VALV if the stroke rotatesthe feedback potentiometer more than 60 degrees.The LIN/CUSTOM option allows selection of linear orcustom control characterization. If Custom isselected, the positioner activates custom character-ization. If the device is being installed for the first time,the default custom characterization is equal percent.However, if a custom curve has been previouslyloaded, the previous curve will be used. The DIPswitch settings are only read after the Quick-Cal but-ton is pressed for 5 seconds; otherwise, the settingsdo not have any effect. The DIP switch settings willoverride any previous configuration done using HARTcommunications. Press the Quick-Cal button for five toten seconds. If the button is released before five sec-onds have elapsed, no action will be taken. Afterapproximately five seconds, the positioner will begin a

Figure 17: Quick-Cal Button

Quick-Cal DIP Switch

Quick-Cal Button

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-17

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stroke calibration. Release the Quick-Cal button oncecalibration has started. The positioner will automati-cally stroke the valve. The stroke sequence will be tothe extremes (open to close), to the mid stroke, thento the signal position. No LED will blink during thisprocess.

NOTE: If Quick-Cal is interrupted during calibrationthe mode of the positioner may stay in digital, requiringHART communications to place it back into analog.

If calibration was successful, upon completion thegreen LED will blink and the valve will be in controlmode. If the yellow LED blinks immediately after astroke calibration, this usually indicates that the valvedid not stroke. Check the air supply and cable connec-tions. If a calibration error occurred, the red LED willblink. The cause of a red LED is generally a stem posi-tion linkage/feedback sensor alignment problem. Forlinear linkage, the active electrical feedback angle is65 degrees. For rotary linkage, the active electricalfeedback angle is 95 degrees. The red LED indicatesthat the mechanical travel is not centered within theelectrical sensor travel. If a red LED is blinking after astroke calibration, loosen the feedback sensor mount-ing screws as shown in Figure 18. Turn the stem posi-tion sensor slowly while watching the LED indicators.Try small movements, both clockwise and counter-clockwise. If the yellow LED begins to blink, the feed-back sensor has been correctly moved into range.Tighten the feedback sensor mounting screws andrepeat the Quick-Cal procedure. If the LED remainsred even after moving the full length of the sensor slot,verify the following items are correctly set:LIN_VALV/ROT_VALV DIP switch setting, stem clampand take-off arm height.

NOTE: If the stroke calibration stops in the closedposition, the error occurred when the positionsensor/linkage was at closed position. If the strokecalibration stops in the open position, the erroroccurred when position sensor/linkage was at theopen position. No calibration parameters are saved ifan error occurs. If the power to the positioner isremoved, the unit will power-up with the previousconfiguration parameters. A successful calibration willsave parameters.

If the valve does not stroke after pressing the Quick-Cal button, this may be an indication that the internalregulator pressure and/or the driver module minimumpressure is low. Refer to the following instructions tocheck and set the internal regulator and minimumpressure settings.

NOTE: Ensure that all linkages are tight and correctlymounted before attempting to calibrate. Loose orincorrectly mounted linkage will cause calibration fail-ure and difficulty in troubleshooting.

Checking or Setting Internal Regulator Pressure

The tools and equipment used in the next procedureare from indicated vendors.

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect the air supply from the positioner.

3. Remove the main cover and the 1/16 inch flexibletubing from the driver module orifice.

4. Obtain a barbed tee (Pneumadyne part No. SBF-16T or equivalent) and two pieces of 1/16 inch flexi-ble tubing, a few inches in length each.

5. Connect the 1/16 inch flexible tubing, found in thepositioner, to the barbed tee. Using one of the newflexible tubing pieces connect the barbed tee to theorifice. Connect the remaining tee port to a 0 to 30psi pressure gauge.

6. Reconnect the air supply to the positioner and readthe internal regulator pressure on the 0 to 30gauge. The internal pressure should be set to 21.5±0.5 psi. If adjustment in needed, scrape off the sil-icon compound covering the screw. Then adjust theregulator pressure by turning the setscrew on topof the regulator with a small screwdriver.

7. Once the regulator pressure is set, remove the airsupply to the positioner, remove the barbed tee,and reconnect the positioner's flexible tubing to theorifice.

8. Reconnect air supply to positioner.

Figure 18: Stem Position Sensor Adjustment

Rotate Stem Position Sensor slol

Stem PositionSensor Mounting Screws (2)

44-18 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Page 19: Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

Checking or Setting the Driver Module Minimum Pressure

Refer to Figure 19, proceed as follows:

1. Make sure valve is bypassed or in a safe condition.

2. Disconnect power from the positioner.

3. Remove the main cover and remove the 1/16 flexi-ble tubing from the orifice.

4. Obtain a No. 10-32 x swivel elbow (Pneumadynepart No. SFL-10 or equivalent) and a No. 10-32extension (Clippard part No. 15010 or equivalent).

5. Remove the No. 10-32 x 0.016 orifice and gasket(Figure 9) from the driver module using a 1/2-inchnut driver. Take care to not misplace the gasket.

6. Screw in the 10-32 extension followed by the 10-32x swivel elbow.

7. Direct the swivel elbow so the minimum pressuretest port is accessible.

8. Screw a No. 10-32 x 1/16-inch barb fitting into thetest port, and screw the No. 10-32 x 0.016 orificeinto the end of the elbow as shown.

9. Connect the tubing from the internal regulator out-put port to the orifice.

10.Using some 1/16-inch flexible tubing, connect a 0 to30 psi gauge to the minimum pressure set port.

11.Once the gauge is connected, reapply the posi-tioner air supply. The minimum pressure shouldnow be registering on the gauge and must be 3.8 to4.2 psi. If the minimum pressure is not correct, takea 9/64 allen wrench and turn the minimum pressureset screw located at the bottom of the driver mod-ule (Figure 7) until the pressure is in the range indi-cated. Cycle the positioner air supply several timesand recheck the minimum pressure and re-adjust, ifnecessary, to ensure that the pressure has settledwithin the range specified.

12.When the pressure is set, remove the air supply.

13.Remove the No. 10-32 x 1/16 barb and orifice fromthe swivel elbow and then remove swivel elbow andextension.

14.Replace the orifice and gasket as shown inFigure 9 and reconnect the 1/16 inch flexible tubingfrom the internal regulator output port to the orifice.Reconnect the positioner air supply and power. Thepositioner should now be ready to calibrate.

Figure 19: Driver Module Minimum Pressure Check

Minimum PressureTest Port

No.10-32 x 1/16

Ba rb

No.10-32 x SwivelTEE (PneumadynePart No. SFL-10)

No.10-32 x .016Orifice

Pressure from InternalRegulator to be tubed tothis orifice

No. 10-32 Extension(Clippard Part No. 15010)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-19

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LOGIX 1200 Model Numbers

PROTOCOL

Selection CodeHART *2

DIAGNOSTICSSelection CodeStandard *0Advanced 1

MATERIALSelection CodeAluminum, Valtek (White Paint) *0Stainless Steel, Valtek (No Paint) 1Aluminum, Automax (Black Paint) 2Aluminum, Automax (Food Grade White Paint) 3Aluminum, Accord (Black Paint) 4Aluminum, Automax (Food Grade White Paint) 5

CERTIFICATIONSSelection CodeExplosion proof EEx d IIB + H2 (CENELEC SCS) 07Nonincendive Class I, Div. 2, (Factory Mutual), Class I, Div. 2 (CSA) 08Explosion proof Class I, Div. 1, Groups B,C,D Intrinsically Safe Class I, 10

Div. 1, Groups A thru G (FM, CSA) FM Nonincendive. CSA Class I,Div. 2 Class I, Zone 1, Group IIB + H2 and Exia Class 1, Zone 0,Group IIC (CSA ONLY)

Intrinsically Safe EEx ib, Nonincendive EEx n (CENELEC SCS) 13General Purpose 14

SHAFTSelection CodeDD Shaft *BlankNAMUR N

CONDUIT CONNECTIONSSelection Code1/2” NPT *BlankM20 M

ACTIONSelection Code4 way *Blank3 way 34 way Vented V3 way Vented W

SPECIAL OPTIONSSelection CodeNo Specials *Blank4-20 mA Position Feedback F

Prot

ocol

Diag

nosti

cs

1

Mate

rial

Certi

ficati

ons

Shaft

Cond

uit C

onne

ction

sAc

tion

Spec

ial O

ption

s

Note: *Product Default Value 1 = Logix Product Line

e

Desig

n Ve

rsion

44-20 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Figure 20: Exploded View

44

30

2

43

37

38 36

34

35

33

3231

29

27 26

2825

24

23

22

19 21

18

20

17

16

15

14

11

12

9

10

13

8

7

6

5

1

56

55

53

54

52

51

50

48

49

46

47

45

4443

42

41

40

39

Aluminum or Stainless Steel

ItemNo. Par t1. Housing Logix 1200 Positioner2. Main Housing Cover3. O-ring, Main Housing Cover4. LED Display Window5. O-ring, Window6. Washer, Seal ring7. Retaining Ring8. Screw, Anti-Rotation9. Spool Valve Cover

10. Spool Valve Shroud11. Hyd rophobic Filter,

Spool Valve Chamber12. O-ring, Spool Valve Cover13. Screw, Spool Valve Cover14. Driver Module Cover15. O-ring, Driver Module

Cover16. Regu lator, 5 to 30 psi

(I ncludes O-ring)17. Internal Filter18. O-ring, interface plate to

housing se al19. Screw, interface plate to

housing (4)20. Interface Plate21. Orifice, Barbed Fitting22. Flexi ble Tubing23. Hex Barbed Fitting

W/Captive O-ring24. Main vent cover25. Screw, Main vent Cover26. Customer Interface Cover27. O-ring, Customer Interface

Cover

28. Screw, Anti-Rotation29. Pressure Gauge , 0-160 psi (2)30 . Customer Interface Board31. Screw, Customer Interface Bboard (3)32. O-ring, Customer Interface Board33 . Grounding Screw (2)34. Main PCB Assembly35. Screw, Main PCB Assembly (3)36. Collector Board Assembly

(Standard / Advanced Model)37. O-ring, Sensor to Housing (2)38. Collector Board Stiff ener (Advanced only)39. Screw, Pressure Sencors to Housing

(2 Advanced only)

40. Screw, Collector Board to Housing(4 Standard - 2 Advanced)

41. Spool Valve Block42. Spool Valve43. Screw, Spool Valve to Housing (2)44. O-ring, Spool Valve (3)45. Driver Module Assembly46. Nyl on Washer (1)47. Screw, Driver to Housing (1)48. Stem Position Sensor49. Screw, Potentiometer to Housing (2)50. Metal washers (2)51. Screw, Spring to Feedback Shaft52. Feedback Shaft53. O-ring, Feedback Shaft54. Bearing55 . Torsion Spring56. E-ring

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-21

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Available Spare Part Kits for Logix 1200e digital postioner

HART FilterSKU 10079944

4-20 mA Position Feedback KitSKU 10125599

Kit 1 – Driver Module AssemblySKU 10130943Item No. Description Quantity

45 Driver module 147 Screw, driver to housing 146 Nylon washer 1

23 Orifice barbed fitting and gasket 116 Regulator and captive O-ring(s) 1

Kit 2 – Spool Valve KitSKU 10130950Item No. Description Quantity

41 Spool valve Block 142 Spool valve 143 Screw, spool valve to housing 2

44 O-ring, spool valve 3

Kit 3 – Soft Goods KitSKU 10130944Item No. Description Quantity

3 O-ring, main housing cover 115 O-ring, driver module cover 127 O-ring, customer interface cover 1

32 O-ring, customer interface board 137 O-ring, pressure sensor to housing 244 O-ring, spool valve 3

53 O-ring, feedback shaft 15 O-ring, main cover window 1

18 O-ring, interface plate 1

12 O-ring, spool valve cover 117 Internal filter 1

Kit 4 – Standard Collector Board AssemblySKU 10130945Item No. Description Quantity

36 Collector board 140 Screw, collector board 4

Kit 5 – Advanced Collector Board AssemblySKU 10130946Item No. Description Quantity

36 Collector board 137 O-ring, sensor to housing 238 Collector board stiffener 1

39 Screw, pressure sensors to housing 240 Screw, collector board to standoffs 2

Kit 6 – Customer Interface AssemblySKU 10130947

Item No. Description Quantity30 Customer interface board 131 Screw, customer interface board 3

32 O-ring, customer interface board 133 Grounding screw 1

Kit 7 – Main PCB AssemblySKU 10130948

Item No. Description Quantity34 Main PCB assembly 135 Screw, main PCB assembly 3

Kit 8 – RegulatorSKU 10070875Item No. Description Quantity

6 Regulator and captive O-ring(s) 1

Kit 9 – Stem Position SensorSKU 10061643Item No. Description Quantity

48 Stem position sensor 1

Table VI: Valtek Linear Mounting Kits

25 Square-inch 50 Square-inch* 100-200 Square-inch

Spud Standard Handwheel Standard Handwheel Standard Handwheel

2.00 10067289 10067368 10091897 10067368

2.62 10067316 10067384 10067329† 10067384

2.88 10067329 10067386

3.38 10067351 10067389

4.75 10067351 10067389

* A 50 square-inch, 2.00 spud with live loading requires kit number 10067301.† Live loading is not available on a 100 square-inch, 2.62 spud.

44-22 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Table VII: Valtork Rotary Mounting Kits*

25 Square-inch 50 Square-inch 100-200 Square-inch

Shaft Diameter Standard Optional Standard Optional Standard Optional

0.44 10067418 10067527 1006790 10067502

0.63 10067418 10067565 1006790 10067573 10067502

0.75 10067418 10067569 10067490 10067574 10067502

0.88 10067418 10067572 10067490 10067575 10067502 10067615

1.12 10067418 10067490 10067580 10067502 10067616

1.50 10067418 10067490 10067502 10067617

1.75 10067418 10067490 10067502 10067618

* Standard: All Rotary Valves with Standard Accessories (End of Shaft Mount)Optional: All Rotary Valves with Handwheels or Volume Tanks (Linkage Design)

Table VIII: Logix Mounting Kits

Model Size Mounting Kit

Fisher

657 & 667

30

1010078034

40

5010124070 0.5 – 1.5-in. stroke

10124085 2-in. stroke

6010124070 0.5 – 1.5-in. stroke

10124085 2-in. stroke

70 101240864-in. stroke

80 10124087

1250

225

10125818450

675

1052 33 10124203 Rotary

657-8 40 10126736

Neles

RC 10124060

RD 10131247

Foxboro

Slid-Std 10126255

Linear 10131247

Valtek

Trooper 10119289 0.75 – 1.5-in. Std

Automax

Automax R314 10094495 HD

SNA115 10406329

NAMUR Mounting Kits

Prefix

NK – NAMUR Accessory Mounting Kit

Bracket Option

28 – 20mm Pinion x 80mm Bolt Spacing

38 – 38mm Pinion x 80mm Bolt Spacing

313 – 30mm Pinion x 80mm Bolt Spacing

513 – 50mm Pinion x 130mm Bolt Spacing

Bolt Option

A – 10-24 UNC Bolting

B – 10-32 UNF Bolting

L – M5-.8 Metric Bolting

Notes

Example: NK313A

Kits designed for the following O.E.M.'s

Air-torque AT Series AT0 — AT6

Automax

SNA Series

SNA3 — SNA2000

N Series N250. 300

R Series R2 — R5

BettisRPC Series

RP — TPC11000

G Series G2009-M11 — G3020-M11

EL-O-MaticE Series E25 — E350

P Series P35 — P4000

Hytork XL Series XL45 — XL4580

Unitorq M Series M20 — M2958

Worcester 39 Series 2539 — 4239

Honeywell

VST-VA3R 17-in. dia. 10126736

VSL-VA1D 12-in. dia. 10126736

Masoneilan (Linear Actuators)

37

910124594

11

13 10124593

18 10125747

24 10126826

38

11 10125402

13 10125401

15 10140783

18 10125747*

24 10126826

Table VIII: Logix Mounting Kits (Continued)

Model Size Mounting Kit

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-23

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4 to 20 mA Analog Output Retrofit

General InformationThe Logix 1200e digital positioner/controller can beretrofitted to provide an analog feedback signal of thestem position. This position feedback option has thefollowing features and specifications:

• Does not interfere with positioner operation.

• Zero and span adjustments of the feedback signalare independent of the positioner and can beadjusted manually.

• Output follows actual position of valve, including allfailure modes of positioner except loss of power. Anoutput of 3.15 mA is transmitted with loss of powerto the analog output board.

• Immune to RFI/EMI disturbances.

• Can be retrofitted in the field.

CAUTION: Because the analog output boardshares common signals with the Logix internalcircuitry, the two units cannot be powered bythe same external power supply or by powersupplies that share a common reference.Gal-vanic isolation of at least 50 VDC must be pro-

vided between the supplies powering the Logixunit and the analog output board.

• Available for explosion-proof and safe applications(CSA, FM).

Masoneilan (Linear Actuators, cont.)

71 Domotor

25 10125644

50 10125645

100 10125646

886 10124595

16 10126752

47 B 10125702

48 B 10125702

“D” Domotor 200 10127467

71-2057AB-D 10129359

71-40413BD 10129461

Masoneilan (Rotary Actuators)

33 B 10125542

35

4

101255426

7

70 10 10125542

Vanguard

37/64 10127426

* Adjustable Mounting kit 10126736 may be needed if handwheels are used.

Table VIII: Logix Mounting Kits (Continued)

Model Size Mounting Kit

Figure 21: Analog Output Board Power

Specifications

Potentiometer Range of Rotation

40° to 95°

Power Supply Range12.5 to 40 VDC(24V DC typical)

Maximum LoadResistance (ohms)

(Supply Voltage - 12.5) / 0.02

Current Signal Output 4-20 mA

Linearity 1.0% F.S.

Repeatability 0.25% F.S.

Hysteresis 1.0% FS

OperatingTemperature

-40° to 185° F(-40° to 85° C)

AmbientTemperature

For a 100° F (38° C) change in ambient temperature, maximum zero shift is 0.4% FS, maximum span shift is 0.7% FS

Power SupplyEffects

Out put signal change is less than 0.05% FS when supply voltage is varied between 12.5 and 40 VDC

Positioner CommandCurrent Loop (Logix Input)

Position FeedbackCurrent Loop (Logix Output)

+ – –+

RLoad

4 to 20 mACurrent Source

12.5 to 40 VDCPower Supply

+

+

CAUTION: Isolated power sources required.

44-24 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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CalibrationTo calibrate the Logix 1200e or 1200e digital posi-tioner equipped with analog output, follow the proce-dure outlined below:

1. Wire the position transmitter in series with a 12.5 to40 VDC power supply and a milliamp meter.

CAUTION: Do not apply a voltage greater than40 volts to transmitter terminals or the circuitwill be damaged.

2. Be certain the direct/reverse switch is set to providethe desired output signal action. In the DIR posi-tion, a counterclockwise rotation of the potentiome-ter shaft (when looking at the label side of thepotentiometer) will cause the output signal toincrease. In the REV position, a clockwise stemrotation causes the signal to increase. Perform astroke calibration whenever the direct/reverseswitch is changed.

WARNING: Keep hands, hair, clothing, etc.away from moving parts when operating thevalve. Failure to do so can cause serious injury.

3. Stroke the valve to the close position.

4. Referring to Figure 22, adjust the zero adjustingscrew with a small, flathead screwdriver until themeter reads 4 mA DC.

5. Stroke the valve to the open position.

6. Adjust the span adjusting screw until the meterreads 20 mA DC.

7. Stroke the valve to the closed position and recheckthe meter for 4 mA DC. Some fine tuning of the cal-ibration may be required. Repeat steps 3 through 7until satisfied.

Retrofitting to a Logix 1200e Digital Positioner (with Circular Window in the Main Cover)

As shown in Figure 23, the newer model of the Logixdigital positioner has a circular window in the maincover (as opposed to a diagonal, oblong window in theearlier model). To retrofit Logix digital positioner to 4-20 mA analog output, use the following procedure:

1. Remove the main cover (Figure 29).

2. Remove the lower and middle screws holding thecontrol board in place; discard these screws.

3. Place the analog output board on the lower portionof the control board and secure with the two longerscrews (6 x 32 1.25-in.) provided (Figure 33).

4. Unplug the orange/red/brown or brown/red/orangethree-wire-set from the collector board.

5. Plug the orange/red/brown or brown/red/orangethree-wire-set into the correct receiver in the ana-log output board (Figure 26).

6. Plug the three-wire set from the analog outputboard into the receiver on the collector board (thatpreviously had held the orange/red/brown orbrown/red/orange wire-set).

Figure 22: 4-20 mA Analog Output Board

Span Adjustment

Zero Adjustment

DIR/REV Switch

PotentiometerConnections

Control BoardConnection

Terminal BoardConnection

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-25

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7. Connect the blue/yellow two-wire-set from the userinterface board to the remaining receiver on theanalog output board (Figure 27).

NOTE: On some boards both set of wires arered/black but have different connectors - only oneset will be able to be plugged into the analog outputboard.

8. Replace the main cover.

Retrofitting to a Logix Digital Positioner(with Diagonal Window in the Main Cover)

As shown in Figure 28, the earlier model of the Logixdigital positioner has an oblong, diagonal window (asopposed to a circular window in the newer model). Toretrofit an existing Logix digital positioner to 4-20 mAanalog output, use the following procedure:

1. Remove the main cover and the user interfacecover from the Logix unit (Figure 29).

2. Disconnect the ribbon cable that connects the con-trol board from the collector board.

3. Remove the three screws holding the control boardin place. Discard two of the screws.

4. Remove the control board from the Logix unit (Figure 30).

5. Disconnect the cable that goes from the user inter-face board to the collector board.

6. Remove the three screws holding the user interfaceboard in place. Save these screws as well as theO-ring that goes between the user interface boardand the housing (Figure 31).

7. Install the new user interface board with its twoconnectors inserted into the cavity of the housing.Make sure the O-ring is between the user interfaceboard and the housing (Figure 32).

8. Install the three screws to secure the user interfaceinto the housing. Tighten to hand-tight.

9. Feed the user interface two-wire-sets in the hous-ing, placing the wires in the trough at the bottom ofthe housing. Connect the red/black two-wire-set tothe collector board where the old user interfacewire-set was connected. Pull the new blue/yellowfeedback two-wire-set so that it is next to thered/black two-wire-set on the collector board.NOTE: With some boards both sets of wires arered/black but have different connectors. The feed-back wire-set will be connected later to the analogoutput board.

10.Carefully replace the control board, ensuring thatthe clear pressure hose found inside the Logix unitis not pinched.

11.Place the analog output board on the lower portionof the control board and secure with the two longerscrews provided. Secure the top of the controlboard with the original shorter screw (Figure 33).

12.Connect the control board ribbon cable to the col-lector board.

13.Unplug the orange/red/brown or brown/red/orangewire set from the collector board.

14.Plug the orange/red/brown or brown/red/orangewire set into the correct receiver in the analog out-put board.

15.Plug the three-wire-set from the analog outputboard into the receiver on the collector board thatpreviously held the orange / red / brown or brown /red / orange three-wire-set.

16.Connect the blue/yellow two-wire-set from the userinterface board to the remaining receiver on theanalog output board. NOTE: With some boards,both two-wire-sets are red/black but have differentconnectors - only one set will be able to be pluggedinto the analog output board. Complete the installa-tion by placing the Quick-Cal sticker on the controlboard can and the user interface sticker in the userinterface cover (Figures 14 and 15).

17.Replace the main cover and the user interfacecover.

44-26 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Figure 23: Logix 1200e Positioner with Circular Window Design

Figure 24: Logix Positioner withCover Removed

Figure 25: Installation ofAnalog Output Board

Figure 26: Installation of Three-wire-set to Analog Output Board

Figure 27: Completed Installation of Analog Output Board

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-27

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Figure 28: Logix Positioner withDiagonal Window Design

Figure 29: Logix Positioner withCover Removed

Figure 30: Removal of Control Board

Figure 31: Removal ofOld User Interface Board

Figure 32: Installation ofNew User Interface Board

Figure 33: Installation of Analog Output

44-28 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Figure 34: Sticker Application Figure 35: Completed Installation of Analog Output Board and

User Interface Board

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-29

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Troubleshooting

IntroductionThis guide is designed to assist the user in trouble-shooting the Logix™ 1200 digital positioner. The Logix1200 positioner is a two-wire, HART communication-based device, and is used in conjunction with Val-Talk™ and SoftTools™ software or the HART 275handheld communicator. As part of this troubleshoot-ing guide, a number of recommendations are pro-vided, which should improve operation and allow foraccurate configuration.

Theory of OperationNOTE: Variable names found in Figure 18 are used inValTalk software and can be found in the MeasuredValues Status screen.

The Logix 1200 digital positioner receives power fromthe two-wire, 4-20 mA input signal. However, since thispositioner utilizes HART communications, two sourcescan be used for the command signal: analog or digital.With the analog source, the 4-20 mA signal is used forthe command source. With the digital source, the levelof the input 4-20 mA signal is ignored and a digital sig-nal (sent via HART) is used as the command source.The command source can be accessed with ValTalk orSoftTools software, or the HART 275 communicator.

Whether in analog or a digital source, 0 percent isalways defined as the valve’s closed position and 100percent is always defined as the valve’s open position.With the analog source, the 4-20 mA signal is con-

verted to a percentage. During loop calibration, thesignals corresponding to 0 percent and 100 percentare defined.

At this point, the command value is passed through acharacterization/limits modifier block. The positionerno longer uses cams or other mechanical means tocharacterize the output of the positioner. This functionis performed by the software, which allows for useradjustment in the field.

The positioner has two basic modes: Linear and Cus-tom characterization. In the Linear mode, the com-mand signal is passed straight through to the controlalgorithm in a 1:1 transfer. If Custom characterizationis enabled, the command source is mapped to a newoutput curve through a 21-point, user-defined curve. Inaddition, two user-defined features, Soft Limits andMPC (Minimum Position Cutoff), may affect the finalcommand signal. The actual command being used toposition the stem is called Control Command. TheControl Command is the actual positioning commandafter any characterization or user limits have beenevaluated.

The Logix 1200 positioner uses a two-stage, stem-positioning algorithm. The two stages are comprisedof an inner-loop, spool control and an outer-loop stemposition control. Referring to Figure 18, the stem posi-tion sensor provides a measurement of the stemmovement. The Control Command is comparedagainst the Stem Position. If any deviation exists, thecontrol algorithm sends a signal to the inner-loop con-trol to move the spool up or down, depending on thedeviation. The inner-loop then quickly adjusts the

StemPositionSensor

Tubed ATO

Sensor

Air Supply

ModulatorCoil Current

Inner LoopSpool Control

Inner-LoopHall Sensor

Output

ControlAlgorithm

Deviation

Position

Pmax

Pmin

Gmult

Integration Summer

Inner Loop Offset

AnalogDigital

CommandSource

Command in(Digital mode)

+Control

Command

4–20(Analog Mode)

Linear ModeCharacterizationSoft LimitsMPC

D/A OutputPercentage

44-30 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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spool position. At that point, the actuator pressureschange and the stem begins to move. The stem move-ment reduces the deviation between Control Com-mand and Stem Position. This process continues untilthe deviation goes to zero. The control algorithm isboth proportional and integral. (This algorithm will befurther explained later in this guide.)

The following detailed example explains the controlfunction: Given:

Unit is in Analog command sourceCustom characterization is disabled (therefore characterization is Linear)Soft limits and MPC are disabledValve has zero deviation with a present input signal of 12 mALoop calibration: 4 mA = 0% command, 20 mA = 100% commandActuator is tubed ATO (Air-to-Open)

Given these conditions, 12 mA represents a Com-mand Source of 50 percent. Custom characterizationis disabled, so the Command Source is passed 1:1 tothe Control Command. Since zero deviation exists, theStem Position is also at 50 percent. With the stem atthe desired position, the spool valve will be positionedso that no airflow is allowed to either side of the actua-tor. This is commonly called the null or balanced spoolposition.

At this point, change the input signal from 12 mA to 16mA. The positioner sees this as a Command Sourceof 75 percent. With Linear characterization, the Con-trol Command becomes 75 percent. Deviation is thedifference between Control Command and Stem Posi-tion, i.e. Deviation = 75% - 50%= +25%, where 50 per-cent is the present stem position. With a positivedeviation, the control algorithm sends a signal to movethe spool up from its present position. As the spoolmoves up, the supply air is applied to the bottom of theactuator and air is exhausted from the top of the actu-ator. This new pressure differential causes the stem tostart moving towards the desired position of 75 per-cent. As the stem moves, the Deviation begins todecrease. The control algorithm begins to reduce thespool opening. This process continues until the Devia-tion goes to zero. At this point, the spool will return toits null or balanced position. Stem movement stopsand the desired stem position is now achieved.

One important parameter is now introduced – theinner loop offset. Referring to Figure 18, a numberdesignated as the Inner Loop Offset is added to theoutput of the control algorithm. For the spool to remain

in its null or balanced position, the control algorithmmust output a non-zero spool command. This is thepurpose of the inner loop offset. The value of this num-ber is equivalent to the signal that must be sent to thespool position control to bring it to a null position withzero deviation. This parameter is important for propercontrol and will be discussed further in the Control andTuning section.

Mounting and Installation

Air Supply RequirementsNOTE: The Logix 1200 positioner requires an externalair filter (preferably the Valtek coalescing air filter).

The air supply must conform to ISA Standard S7.3 (adew point at least 18° F/10° C below ambient tempera-ture, particle size below 5-microns and oil content notto exceed one part per million); however, filtering for 1-micron particle size is recommended. For a model withadvanced diagnostics (Logix 121X), the internal pres-sure sensors are rated for continuous operation up to150 psig (10.3 barg).

Electrical WiringFirst, verify the polarity when making the field termina-tion connection. The Logix 1200 positioner is reversepolarity protected. With a 4-20 mA source connected,verify that the positioner’s LED is blinking to determineif the electronics are running. Only one LED will blinkat any given time. Remember the 4-20 mA input cur-rent signal must be greater than 3.5 mA to power-upthe Logix 1200 positioner. Never connect a voltagesource directly across the Logix 1200 terminals. Thecurrent must always be limited for 4-20 mA operation.

NOTE: The Logix 1200 positioners carries an intrinsi-cally safe barrier rating of 125 mA. Currents up to 125mA will not damage the device.

Frequently Asked Questions

Q: My DCS uses 24 VDC. Can I run a Logix 1200positioner?

A: A DCS output current card does run from 24 VDCbut the card regulates the actual current output. How-ever, if the 24 VDC were applied directly across theterminals, nothing would limit the current and theLogix 1200 field termination board could be damaged.The important point to remember is that it does notmatter what the current source voltage supply is aslong as the current is limited in the 4-20 mA range.

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-31

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Q: I accidentally placed a voltage supply across theLogix 1200 positioner. How do I know if I damagedsomething?

A: The typical failure in an over-current situation is ashort circuit. Your loop current will be maintained butthe Logix 1200 control board will receive no power.With power removed from the Logix 1200 positioner,use an ohmmeter to measure the ohms across the ter-minals. If the reading indicates a short (close to zeroohms), the field termination board must be replaced.Make sure the positive lead is on the ‘+’ terminal andnegative lead is on the ‘-’ terminal when measuring theresistance.

Q: What is the input resistance of the Logix 1200positioner?

A: The Logix 1200 positioner does not have a simpleresistive input. When measuring the voltage acrossthe Logix 1200 positioner, it only varies slightly whenthe current is changed from 4 mA to 20 mA (11.7 VDCto 12 VDC nominal). This is because the Logix 1200positioner is an active device. For the Logix 1200 posi-tioner, effective resistance is commonly referred to.(Effective resistance is the resistance at a given cur-rent.) To explain further:

Effective Resistance = (Terminal Voltage)/Current

For example, at 20 mA: Effective resistance = 12VDC/0.02 A = 600 Ω

The Logix 1200 positioner has a specification of 600 Ω@ 20 mA.

NOTE: One cannot measure across the terminals ofan unpowered Logix 1200 positioner and find theeffective resistance.

Air ActionAir-to-open and air-to-close are determined by theactuator tubing and not the software. When air-actionselection is chosen during configuration, that selectiontells the control which way the actuator is tubed. Verifythat the actuator tubing is correct prior to a stroke cali-bration. The top output port is called Output 1. Itshould be tubed to the side of the actuator that mustreceive air to begin the correct action. For example, foran air-to-open linear actuator, Output 1 should betubed to the bottom of the actuator.

Linear vs. RotaryThe positioner has two configuration settings: Linearand Rotary. For better resolution, stem position sensorgains are adjusted based on the linkage angle of rota-tion. The linear setting allows for linkage rotation up to65°. The rotary setting allows for linkage rotation up to

95°. These settings only determine the angle of sen-sor rotation and do not affect control parameters.

If a positioner is set to linear configuration and a redLED blinks after calibration, the most common causeis the sensor movement was greater than 65°. Thiscan occur if the roller pin was placed in the wrong holeon the follower arm or the stem clamp is placed toohigh on the actuator stem. The take-off arm shouldalways be level with the stem clamp on linearmountings.

The Logix 1200 positioner has an electrical measure-ment range of 95°. That is, the electronics will sensestem position over a 95° range. With a rotary valve,the typical rotation is 90°. When connecting a Logix1200 positioner to a rotary valve, the 90° valve rotationis centered within the 100° electrical range. If mechan-ical movement falls outside the electrical measure-ment range, the positioner can have a dead band atone end of travel in which valve movement cannot besensed.

Frequently Asked Questions

Q: How do I know if the rotary linkage is centeredwithin the 95° electrical range?

A: The slot in the take-off arm has enough clearancearound the roller pin to move the follower arm slightly.Move the valve to the fully closed position. At this posi-tion, move the follower arm within the slot clearance. Ifthe valve does not respond by making an adjustment,linkage adjustment is necessary. Repeat this test atthe fully open position.

To adjust the stem position linkage, use the Logix vari-able number 2. This can be viewed as A/D feedback inthe Measured Value screen in ValTalk software or theHall pot sensor A/D value in the Condition screenunder View Variables in SoftTools TechCheck. It canalso be viewed from the HART 275 communicator inthe Status/Technician menu. With the valve in itsmechanical fail position (no pressure applied), slightlymove the follower arm while watching variable number2. If the number does not change, the arm is not cen-tered in the electrical range. (The number will jumpone or two counts due to noise at a fixed position andshould not be considered a change. It should movegreater than 10 to 20 counts if the linkage is centeredcorrectly.) If necessary, rotate the take-off arm or feed-back sensor to bring the linkage in range.

NOTE: Due to the speed of HART communication,allow two to three seconds for the display to updateafter each adjustment.

This procedure is only necessary on a rotary mount-ing. For linear mountings, the red LED will blink if 65°travel is exceeded. Refer to the Calibration section forfurther information on stroke calibration errors.

44-32 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Calibration

Quick-Cal FunctionThe Quick-Cal™ function is a method by which thevalve can be stroke calibrated without using ValTalk orSoftTools software or the HART 275 communicator.

NOTE: This feature is provided to allow stroke calibra-tion in the event a HART interface is not available. Thisallows the valve to be placed in operation. However,full configuration can only be accomplished throughValTalk, SoftTools or the HART 275 handheld commu-nicator.

The Quick-Cal function only affects the stroke calibra-tion parameters. Any previous configuration or storedinformation is not affected. If the positioner loop cur-rent has not been calibrated in the field, it defaults to aloop calibration of 4 mA being a 0 percent commandand 20 mA being a 100 percent command. This can-not be changed without HART interface. If the loophas been calibrated in the field, these settings will notbe affected by the Quick-Cal function.

Regarding the Linear vs. Custom DIP switch setting: Ifthe third Quick-Cal DIP switch is set to Linear, thetransfer characteristic from 4-20 mA input signal toControl Command will be 1:1. If the DIP switch is setto Custom, custom characterization will be enabled.The factory custom characterization curve is equalpercent. If the characterization curve has been modi-fied in the field, the modified curve will be used.

NOTE: The DIP switch settings only become effectiveif the Quick-Cal button is pressed for five seconds. Ifthe Quick-Cal function is not used, the DIP switch set-tings have no effect on positioner operation.

Command 0% Calibration FlagDuring loop calibration, the Logix 1200 positionerchecks if the value read with the current at the desired0 percent command level is within range. This errornormally indicates that the loop current was set above21 mA during this part of the calibration procedure.(See How to Clear Flags section on page X.)

Command 100% Calibration FlagDuring loop calibration, the Logix 1200 positionerchecks if the value read with the current at the desired100 percent command level is within range. This errornormally indicates that the loop current was set above21 mA during this part of the calibration procedure.(See How to Clear Flags section on page X.)

Position 0% Calibration FlagDuring stroke calibration, the Logix 1200 positionerchecks if the linkage is placing the stem position sen-sor in range. If the valve stroke causes stem positionmeasurement to move out of range in the closed posi-tion, a Position 0% flag will be generated. The valvestem will stop in the closed position and the red LEDwill blink. The linkage must then be adjusted to bringthe sensor in range. (See How to Clear Flags sectionon page X.)

NOTE: The Logix 1200 positioner has a special LEDindication. If the linkage is out of range, the LEDs canbe used as an adjustment guide. The LED will changefrom red to yellow when the linkage is brought intorange. Refer to Stroke Calibration Section.

Position 100% Calibration FlagDuring stroke calibration, the Logix 1200 positionerchecks if the linkage is placing the stem position sen-sor in range. If the valve stroke causes stem positionmeasurement to move out of range in the open posi-tion, a Position 100% flag will be generated. The valvestem will stop in the open position and the red LED willblink. Linkage must be adjusted to bring the sensor inrange. (See How to Clear Flags section on page X.)

NOTE: The Logix 1200 positioner has a special LEDindication. If the linkage is out of range, the LEDs canbe used as an adjustment guide. The LED will changefrom red to yellow when the linkage is brought intorange. Refer to Stroke Calibration section.

Command Span FlagCommand span is a check during loop calibration toverify that the input signal changed between a 0 per-cent reading and a 100 percent reading. The mostcommon cause for a Command Span flag is forgettingto change the current source when asked to set the100 percent current level. Clear a Command SpanFlag by performing a Command calibration correctly.

Position Span FlagPosition span is a check during stroke calibration toverify that the valve stem moved. The algorithm waitsto detect if no movement is detected when the valve isautomatically stroked open. Although the algorithmwaits for valve movement, if a large actuator (size 200or 300) is run at low pressures, it may not detectmovement and stop with a Position Span Error. Any-thing that could prevent the valve from stroking willgenerate a Position Span Error (no supply pressure ormalfunctioning spool valve). Clear a Position Span flagsignal by correcting the problem that is preventing thevalve to stroke and re-calibrate the stroke.

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Control and Tuning

Setting P+I ParametersUsing ValTalk or SoftTools software, default tuningparameters can be selected: Factory A, Factory B, etc.(with Factory A beginning at the smallest actuator sizeand the lowest gain settings). Using the Advancedoption, one can set individual tuning parameters. Thesoftware manuals outline the procedure to adjustthese tuning parameters; however, a few key pointsare mentioned below.

Maximum Gain, Minimum Gain, and Gain Multiplier:These three parameters are related by the followingformulas:

Proportional Gain = Maximum Gain - |deviation| xGain Multiplier

If Proportional Gain < Minimum Gain, then Propor-tional Gain = Minimum Gain

This algorithm allows for quicker response to smallersteps yet stable control for large steps. Setting theGain Multiplier to zero or Max Gain = Min Gain resultsin a typical fixed proportional gain.

The higher the Gain Multiplier, the smaller the requireddeviation before the gain increases. Default valuesupon initiating a RESET are Maximum Gain = 2.0,Minimum Gain = 1.0, and Gain Multiplier = 0.05.These values will allow stable control on all Valtekactuator sizes.

The Integral Gain is used primarily for deviations dueto temperature drift within the inner loop spool control.The factory default value is 10. Although higher num-bers can speed the time it takes to reach zero devia-

tion, it can add overshoot as well as cause thepositioner to hunt if too large. The recommendation isthat maximum and minimum gains be adjusted whileleaving Integral Gain fixed at 10. Integration is dis-abled below a stem position of 5 percent and above astem position of 95 percent. This is to prevent integra-tion windup from calibration shifts due to lower pres-sure or a damaged seat, which may prevent fullyclosing the valve.

The Integral Summer within the Logix 1200 positioneris clamped at +20.00% and -20.00%. If the integrationsummer (Variable No.15 in ValTalk or SoftTools soft-ware) is fixed at +20% or -20%, it usually indicates acontrol problem. Some reasons for a clamped integra-tion summer are listed below:

• Stroke calibration incorrect

• Any failure which prevents stem position movement,such as stuck spool, handwheel override, lowpressure

• Incorrect inner loop offset

• Loss of air supply on a fail in place actuator

Writing a zero to Integral Gain will clear the IntegrationSummer. The Integral Gain can then be returned to itsoriginal value.

Referring to Figure 1 under Theory of Operation, threecontrol numbers are summed to drive the inner loopspool position control: proportional gain, integral sum-mer, and inner loop offset. Inner Loop Offset is theparameter that holds the spool in the ‘null’ or ‘balance’position with a control deviation of zero. This value iswritten by the factory during production and is a func-tion of the mechanical and electrical spool sensing tol-erances. However, if the driver module assembly isreplaced or if the software Reset is performed, adjust-ing this value may be necessary. The method outlinedbelow should be used to adjust the Inner Loop Offset:

NOTE: Logix 1200 positioners with embedded code(revision 0.2 and higher) will automatically calculatethis value during a stroke calibration.

ValTalk Software1. From the Advanced Tuning Screen send a 50 per-

cent command using 4-20 mA signal or digital mode.

NOTE: Digital mode must be set in Instrument Sta-tus screen prior to entering Advanced Tuningscreen.

2. Allow the position to stabilize.

3. Record the D/A output % reading (displayed on theupper right hand side). This number will varyslightly; therefore, estimate an average over a briefperiod of time.

Figure 19: Logix 1200 Proportional Gain

Small Steps Large Steps

deviation

Minimum Gain

Maximum Gain

Pro

po

rtio

nal

Gai

n

Gain Multiplier(Determines Slope)

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4. Write this number to the Inner Loop Offset.

SoftTools TechCheck Software

1. From the Custom Tuning screen, select the AdjustILO button.

2. Allow the position to stabilize.

3. Write the value shown for D/A Average to InnerLoop Offset.

NOTE: The actuator must not be saturated (D/A out-put = 0) while setting the Inner Loop Offset.

HART 275 Handheld Communicator

1. Send a 50 percent command using 4-20 mA signalor digital mode.

2. Proceed to the Status/Technician menu.

3. Locate the D/A Output Voltage.

4. Divide this number by 2.5 V and multiple by 100percent. Example: D/A Output Voltage = 1.25 V.Therefore: 1.25 V/2.5 V x 100% = 0.5 x 100% =50%.

5. Write this percentage value to the Inner Loop Offset.

Digital Filter

This parameter controls a noise reduction filter usedon the readings obtained from command and stemposition sampling. This filter is internal to the posi-tioner software and is not associated with the externalHART filter. This parameter setting should remain at0.5.

Spool ValveThe spool valve is a four-way directional valve withprecision features to provide optimal control and low-air consumption. To help prevent a malfunction of thespool valve, the positioner supply air must conform toISA Standard S7.3 (a dew point at least 18 degreesbelow ambient temperature, particle size below 5-microns, oil content not to exceed one part per mil-lion). The standard Valtek coalescing filter is highlyrecommended to help meet these requirements.

Small particles, oil that has varnished, corrosion, ice,burrs, and extreme wear could cause the spool valveto act abnormally. If the spool valve is suspected ofsticking, check it by performing the following proce-dure:

1. Make sure the valve is bypassed or in a safecondition.

2. Disconnect the power and air supply to the unit.

3. Remove the spool valve cover by removing thescrew and sliding the cover assembly backwardsuntil the tab is clear of the slot.

4. Inspect the coalescing filter element in the spoolvalve cover for signs of oil, water and debris thatmay have come from the air supply. (A clean filter iswhite.)

5. Remove the two Phillips-head screws holding thespool valve to the housing. Inspect the free move-ment of the spool by carefully sliding the block upand down on the spool about 0.25 inches (6 mm).The block should slide on the spool with no resis-tance. Carefully remove the block from the spool,ensuring it is removed concentric with the spool.

6. Inspect the block and spool for oil, water, debrisand wear. If oil, water and/or debris are found, thespool and block can be cleaned with a non-residuecleaner, lint-free cloth and soft-bristle brush. If wearis found, replace the driver module assembly orspool valve. Refer to Spool Valve and/or DriverModule sections.

7. Before re-assembly, verify the three O-rings arecorrectly placed in the counter-bores on themachined platform where the spool valve block is tobe placed.

8. Carefully slide the block over the spool, using themachined surface of the housing base as a regis-ter. Slide the block toward the driver module untilthe two retaining holes line up with the threadedholes in the base. If resistance is still encountered,re-clean both parts or replace the driver moduleassembly or spool valve.

HART Communication

Current Source InterferenceHART communication superimposes two frequencies(1200 Hz and 2200 Hz) on the DC 4-20 mA currentsignal. Some current sources (DCS or 4-20 mA cali-brator) can interfere with the HART signal. This mayprevent communication with ValTalk or SoftTools soft-ware or the HART 275 handheld communicator. Inter-mittent communication may also be the result of aHART incompatible current source. In this case, a filteris necessary between the current source and Logix1200 positioner to allow HART communication.

Valtek HART Filter (VHF) Figure 20 & Figure 21Flowserve offers a filter (Valtek part no. 10079944)that must be used on each 4-20 mA line if the currentsource interferes with communication. The filter doesnot affect the DC current but prevents the source fromaffecting the HART frequencies. The filter comes in aDIN rail mount package.

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NOTE: This filter is not rated for use in hazardousareas. It should be located between the current sourceand the barrier in intrinsically safe applications.

Frequently Asked Questions

Q: How do I know if I need a VHF?

A: If the current source is interfering with communica-tion, it will affect the ValTalk or SoftTools software andthe HART 275 handheld communicator. If the posi-tioner communicates to ValTalk software or the HART275 handheld communicator when using one currentsource (for example, a 4-20 mA current calibrator) andnot the DCS, it indicates a filter is necessary with thatcurrent source. Some 4-20 mA calibrators that workwithout a filter are listed below. If one of these is avail-able, try to connect with ValTalk or SoftTools softwareor the HART 275 handheld communicator again. Ifcommunications are established while using one ofthese sources, but fails on the original source, a filteris needed.

The following handheld 4-20 mA calibrators do notrequire a filter:

• Altek Model 334

• Rochester Instrument Systems (RIS) CL-4002

• Unomat UPS-I

HART ModemThe HART modem is a device that connects to theserial communications port of a computer. Thismodem converts the RS-232 COM port signals to theHART signal. A HART modem is required to useValTalk software, and is optional in SoftTools since aMUX can be used in its place. The HART modemtakes power from the RS-232 COM port lines. If usinga laptop computer that is operating on its internalbattery, HART communication may become erratic asthe batteries begin to lose their charge. This is due toa reduction in HART modem power. At this point,recharge the batteries or apply AC adapter power tocorrect the problem.

ConnectionsWhen using ValTalk or SoftTools software or the HART275 handheld communicator, the leads can be con-nected anywhere across the 4-20 mA current signal.The leads are not polarity sensitive. When using a fil-ter, the connection must be made between the filteroutput and the Logix 1200 positioner (Figure 21).

CablingBecause HART protocol uses frequencies of 1200 Hzand 2200 Hz to communicate, cable type and lengthmust be considered. High capacitance/foot cable orlong runs can cause erratic communication. Refer toinstructions for correct cable requirements.

Intrinsically Safe BarriersWhen selecting an intrinsically safe barrier, make surethe barrier is HART-compatible. Although the barrierwill pass the loop current and allow normal positionercontrol, if not compatible, it may prevent HARTcommunication.

Figure 20: HART VHF Filter

Figure 21: HART VFH Filter Schematic

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Alarms

IntroductionThe Logix 1200 positioner has several internal alarmsthat monitor electronics operation. An internal alarmcauses the red LED to blink. Alarms can be viewed inthe Alarm screen of ValTalk software, View Alert dis-play (by right-clicking on the alarm LED in the lowerright-hand corner of any screen), Alert Details buttonwith SoftTools TechCheck, or by using the Hot Keywith the HART 275 handheld communicator. ‘Alarms’differ from ‘alerts’ in that the action of the positionermay be erratic during the alarm conditions, whilealerts warn a predefined, user-configured conditionhas occurred that may require service in the nearfuture. Alarms cause the red LED to blink, while alertscause the yellow LED to blink.

12-bit A/D Reference AlarmThe Logix 1200 positioner utilizes a 12-bit analog-to-digital (A/D) converter to acquire command and stemposition readings. If the precision reference used bythe A/D drifts outside rated tolerances, the 12-bit A/DReference Alarm will become active. A reference errorwill cause change in calibration and control readings.If a continuous 12-bit A/D Reference Alarm exists, themain PCB assembly must be replaced. Refer to spareparts kit numbers section.

1.23 V Reference AlarmThe 1.23 V Reference is used by the inner loop spoolposition control. If it drifts outside normal tolerances,the 1.23 V Reference Alarm will become active. If acontinuous 1.23 V Reference Alarm exists, the mainPCB assembly must be replaced. Refer to spare partskit numbers section.

12 bit D/A AlarmThe Logix 1200 positioner utilizes a 12-bit digital-to-analog (D/A) converter to send a control signal fromthe micro-controller to the inner loop spool positioningcircuit. The output of the D/A converter is indepen-dently measured to verify correct operation. A 12-bitD/A Alarm indicates the D/A may be malfunctioning. Ifa continuous 12-bit D/A Alarm exists, the main PCBassembly must be replaced.

Temperature AlarmThe main PCB assembly contains an ambienttemperature sensor. If the ambient temperaturereading moves outside the operating range (-40° F to185° F/-40° C to 85° C), the Temperature alarmbecomes active and the red LED blinks. If this alarm ispresent and the ambient temperature reading isincorrect, the main PCB assembly must be replaced.Refer to spare parts kit numbers section.

Hall Sensor AlarmAs described in the Theory of Operation, the Logix1200 positioner incorporates an inner loop, spool-posi-tioning stage. A hall sensor is used for spool control. Ifthe electronics sense a problem with the sensor, theHall Sensor Alarm becomes active. Two common rea-sons for a Hall Sensor Alarm are a loose or missingcable connection to the Collector Board Assembly or abroken wire. In the rare event that the actual hall sen-sor is defective, the driver module assembly must bereplaced. Refer to spare parts kit numbers section.

Modulator Current AlarmThe pressure modulator is an electro-pneumaticdevice that takes a current signal from the electronicscontrol and generates a pressure that moves thespool. The Logix 1200 positioner is a loop-powereddevice that must run on very low power. During opera-tion, the pressure modulator current is monitored. Ifthe current draw is not within acceptable parametersfor the given control mode, the Modulator CurrentAlarm becomes active and the red LED blinks. Themagnitude of Modulator Coil Current can be viewed asVariable No. 97 in the Instrument Status screen (Val-Talk software), the Condition screen under View Vari-ables (SoftTools TechCheck software) or in theStatus/Technician screen (HART 275 handheld com-municator). Listed below are some reasons for a Mod-ulator Current Alarm:

• Pressure modulator minimum pressure too low

• Clogged or restricted orifice

• Malfunctioning or missing cable connection to col-lector board assembly

• Stuck or sticky spool

• Internal air leaks from tubing, orifice gasket or pres-sure modulator

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Board Current AlarmThe Logix 1200 positioner is a loop-powered device,which must run on very low power. During operation,the current draw of the electronics is monitored. If cur-rent draw is excessive and would prevent operation at3.7 mA, the Board Current Alarm becomes active andthe red LED blinks. The most common cause is afailed main PCB assembly. If the electronics’ currentdraw is excessive, the Logix 1200 positioner will mostlikely operate at higher currents (12 mA and above)but may lose power at lower currents. This errorrequires that the main PCB be replaced. Refer tospare parts kit numbers section.

EEPROM Checksum AlarmConfiguration data is stored in EEPROM. When poweris lost, configuration information is retrieved fromEEPROM and operation resumes. A check is done bythe micro-controller after a power-up to make suredata saved in EEPROM has not been corrupted. Thechecksum is a number that is calculated based onconfiguration data. It is also saved in EEPROM everytime data is stored. After a power-up, if this numberdoes not match the data in memory, an EEPROMChecksum Alarm is generated and the red LED blinks.If this occurs, turn off the power to the Logix 1200positioner, followed by turning on the power. If theerror does not clear, try saving the configuration dataagain using ValTalk or SoftTools software, or a HART275 handheld communicator. If the previous configura-tion has not been saved, reset the device and re-con-figure. If these steps still do not clear the error, themain PCB assembly must be replaced. Refer to spareparts kit numbers section.

Pressure AlarmsNOTE: Pressure alarms are only available on modelswith advanced diagnostics (Logix 121X).

Advanced diagnostic models add top, bottom and sup-ply pressure sensors on more current models (Logix1210e) the supply sensor is not included, instead,supply is calculated using the other pressure sensors.These sensor readings and alarms are only accessi-ble from ValTalk or SoftTools software, or a HART 275handheld communicator when the configuration hasbeen set to Advanced.

The Loss of Pressure Alarm becomes active when thesupply pressure is near the minimum positioner oper-ating pressure of 30 psig (2.1 barg). If the LEDs alter-nate between red and green, the supply pressure may

be at the limit threshold. This alarm is meant to alertthe user to low supply pressure as well as completeloss of pressure.

Both the top and bottom sensors are checked duringactuator calibration. If a calibration reading appears tobe out of range, the appropriate alarm will becomeactive. The pressure sensors are located on the col-lector board assembly.

Alerts

MPC (Minimum Position Cutoff)The Minimum Position Cutoff (MPC) or tight shutofffeature of the Logix 1200 positioner allows the user tocontrol the level at which the command signal causesfull actuator saturation in the closed position. This fea-ture can be used to guarantee actuator saturation inthe closed position or prevent throttling around theseat at small command signal levels. This featuresdefaults to 1% from the factory (which means it isenabled).

NOTE: The positioner automatically adds a 1 percenthysteresis value to the MPC setting to prevent jumpingin and out of saturation when the command is close tothe MPC setting.

Frequently Asked Questions

Q: I set the MPC at 5 percent. How will the positioneroperate?

A: Assume the present command signal is at 50 per-cent. If the command signal is decreased, the posi-tioner will follow the command until it reaches 5percent. At 5 percent, the spool will be driven in orderto provide full actuator saturation. The positioner willmaintain full saturation below 5 percent command sig-nal. Now, as the command increases, the positionerwill remain saturated until the command reaches 6percent. (Remember the 1 percent hysteresis valueadded by the positioner). At this point, the stem posi-tion will follow the command signal.

Q: I have MPC set to 3 percent but the valve will notgo below 10 percent.

A: Check to see if the lower soft limit is enabled. Thelower soft limit must be less than or equal to 0 percentfor the MPC to become active. If a positive lower softlimit is written, this limit will take priority over the MPCfeature.

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Soft LimitsUnlike position alerts, soft limits prevent the stem posi-tion from moving below or above the configured limits.If the command signal is trying to drive the positionpast one of the limits, the yellow LED will blink but thestem position will remain at the set limit.

Q: Will soft limits prevent the valve from going to its failposition?

A: No.

Position AlertsPosition alerts notify the user the valve has traveledpast a configured limit. The default settings are -10percent and 110 percent, which are outside normaltravel and therefore disabled. Position alerts onlynotify the user a limit has been exceeded and do notlimit stem movement. Position alerts will cause the yel-low LED to blink.

Cycle CounterThe cycle counter is another means of monitoringvalve travel. Unlike the travel accumulator, the stemposition must do two things to count as a cycle: 1)exceed the cycle counter dead band and 2) changedirection. A cycle counter limit can also be written intothe positioner. If this limit is exceeded, the yellow LEDblinks. The cycle counter must be reset to begin a newcount sequence. This must be done after the alert hasbeen triggered to reset the alert. Do this by clicking onthe reset button in ValTalk or SoftTools software in theconfiguration section of the software. With the HART275 handheld communicator, resetting is accom-plished by choosing Configure (3) Cycle/Travel Inf. (9),Cycle/Travel, Cycle Information (2), Reset CycleCounter (4).

Travel AccumulatorThe travel accumulator is similar to an automobileodometer and sums the total valve movement. Usingthe user-defined stroke length and travel dead band,the Logix 1200 positioner keeps a running total ofvalve movement. When the positioner first powers up,high and low dead band limits are calculated aroundthe present position. When the stem position exceedsthe travel dead band, the movement from the center ofthe dead band region to the new position is calculated

and added to the travel accumulator. From this newposition, dead band high and low limits are again cal-culated.

For example, the Logix 1200 positioner has a defaultdead band configuration of 20 percent. The valve hasa 4-inch (10 cm) linear stroke. When the valve firstpowers up, the command signal is 50 percent. Theunit will calculate a high travel threshold of 70 percent(50 percent present position plus 20 percent deadband) and a low travel threshold of 30 percent (50 per-cent present position minus 20 percent dead band).As long as the stem position remains greater than 30percent and less than 70 percent, no additions aremade to the travel accumulator. At this point, assumethe stem position moves to 80 percent, which is out-side the present dead band. The Logix 1200 posi-tioner calculates the stem movement and adds thisnumber to the travel accumulator.

80% (present position) – 50% (previous) =

30% movement x 4-inch stroke = 1.2 inches

Therefore, 1.2 inches (3 cm) is added to the travelaccumulator. New dead band thresholds of 100 per-cent (80 percent present position plus 20 percentdead band) and 60 percent (80 percent present posi-tion minus 20 percent dead band) are calculated. Thisprocess continues as the stem position movesthroughout its stroke range.

The travel accumulator will need to be reset to begin anew count sequence. This must be done after the alerthas been triggered to reset the alert. Do this by click-ing on the reset button in ValTalk or SoftTools software(in the Configuration section of the software) With theHART 275 handheld communicator, resetting isaccomplished by choosing Configure (3) Cycle/TravelInf. (9), Cycle/Travel, Travel Information (2), ResetTravel Accumulator (4).

Position DeviationIf the stem position differs from the control commandby a certain amount for a given length of time, the yel-low LED blinks to signify excess deviation. The trippoint and settling times are set from the Configurationscreen of ValTalk and SoftTools software. It is set inthe HART 275 handheld communicator under Config-ure (3), Position Alerts (9), Deviation Deadband (3)and Time (4).

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-39

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Advanced Features

Standard vs. Advanced DiagnosticsThe Logix 1200 digital positioner is available witheither standard or advanced diagnostics. The modelwith advanced diagnostics adds top, bottom and sup-ply on more current models (Logix 1210e) the supplysensor is not included, instead, supply is calculatedusing the other pressure sensors. This allows for morediagnostic calculations such as loss of pressure, fric-tion, advanced signatures, and troubleshooting.

Frequently Asked Questions

Q: Can I upgrade from a model with standard diagnos-tics to advanced diagnostics?

Answer: Yes, but only with the earlier model (themodel characterized by an oblong LED window). Themost current model (1200e, characterized by a roundLED window) cannot be upgraded. A new advancedcollector board assembly can be purchased. Simplyreplace the standard collector board with theadvanced collector board. All connectors on the col-lector board are keyed and unique for easy cable re-connection. Using ValTalk or SoftTools software, or theHART 275 handheld communicator, configure thepositioner for Advanced Diagnostics and perform anactuator pressure calibration.

Temperature and Pressure UnitsThe desired temperature and pressure units can beset during configuration. Once set, all readings will bedisplayed in the desired units.

Stroke LengthStroke length is used by the travel accumulator. Whenthe stroke length and units are set, the length is usedto determine the total travel accumulated. The travelaccumulator will have the units associated with stroke.

Example: Stroke length is set to 4.0 inches (10 cm). Ifthe valve is moved from 0 percent to 100 percent, 4inches will be added to the travel accumulator. Thetravel accumulator units will be inches. If stroke lengthis 90 degrees for a rotary, the travel accumulator willnow have units of degree. A 0 percent to 100 percentstroke will add 90 to the travel accumulator.

NOTE: Stroke length is not set or used during calibration.

Custom CharacterizationCustom characterization can be thought of as a ‘softCAM.’ The user can define a characterization curveusing 21-points. The control will linearly interpolatebetween points. Points do not have to be equallyspaced, which will allow more definition at criticalcurve areas.

The Logix 1200 positioner has two modes: Linear andCustom Characterization. Linear is a straight 1:1 map-ping of command to control command and does notuse the 21-point curve definition. When Custom Char-acterization is disabled, the positioner is automaticallyin Linear mode. If custom characterization is enabled,the Logix 1200 positioner uses the 21-point userdefined curve.

Frequently Asked Questions

Q: Is there a default custom characterization curve?

A: Yes. The Logix 1200 positioner comes with a fac-tory default equal-percent curve as shown in Table III

44-40 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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.

NOTE: Custom characterization points can only beentered by using ValTalk or SoftTools software. TheHART 275 handheld communicator will only allow the

user to enable or disable the currently stored customcharacterization.

Table III: Equal Percentage Curve Data

% Command

% Control Command

0 0.00

5 1.00

10 2.00

15 3.00

20 4.00

25 5.24

30 6.47

35 8.02

40 9.57

45 11.86

50 14.15

55 17.54

60 20.93

65 25.94

70 30.95

75 38.36

80 45.77

85 55.66

90 67.68

95 82.31

100 100.00

Table IV: Troubleshooting Logix 1200 Digital Positioner (1 of 3)

Failure or Problem Probable Cause(s) Refer to Section(s)

Mounting and Installation

LED does not blink 1. 4-20 mA input polarity may be reversed

1. 4-20 mA input level may be too low

1. Calibration is in process

1. See Electrical Wiring on page 44-31. or Wiring and Grounding guidelines on page 44-6.

1. See overview on page 44-4.

1. See Calibration on page 44-33..

Valve moves in wrong direction with no input signal

1. Actuator is tubed for wrong air action

1. Spool is stuck

1. See Air Action on page 44-32.

1. See Spool Valve on page 44-35.

Unit does not respond to analog 4-20 mA command

1. Unit is in digital command mode

1. Error occurred during calibration

1. See Theory of Operation on page 44-30.

1. See Calibration on page 44-33.

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Calibration

Red LED blinks after a Quick-Cal oper-ation. Valve stays in fully open or closed position.

1. Positioner configured for Linear operation, but mounted on a rotary actuator

1. Feedback linkage out of range

1. See Quick-Cal Function on page 44-33.

1. See Stem Position Sensor on page 44-12.

Yellow LED blinks after a Quick-Cal operation

1. Valve did not fully stroke during calibration (low or no air supply)

1. See Quick-Cal Function on page 44-33. or 44-16.

Rotary valve has a dead band at the fully open or closed position

1. Mechanical travel is not cen-tered within the electrical mea-surement range.

1. See Linear vs. Rotary on page 44-32. or Stem Position Sensor on page 44-12.

Red LED after loop current calibration 1. Applied Current is greater than 21 mA

1. Current source changed between two values

1. See Command 100% Calibra-tion Flag on page 44-33.

Control and Tuning

Valve will not saturate at closed posi-tion

1. MPC may need to be enabled 1. See MPC (Minimum Position Cutoff) on page 44-38.

Valve will not travel below or above a certain limit

1. Soft limits not enabled

1. MPC not enabled

1. See Advanced Features on page 44-40.

Sticking or hunting operation of the positioner

1. Contamination of spool valve assembly

1. Incorrect adjustment of P+I set-ting

1. See Air Supply Requirements on page 44-31. See Spool Valve on page 44-35.

1. See Setting P+I Parameters on page 44-34.

Large initial deviation. Only present on initial power-up.

1. Inner loop offset not correct 1. See Setting P+I Parameters on page 44-34.

Stem position movement is not linear with command

1. Custom characterization not enabled

1. See Custom Characterization on page 44-40.

HART Communication

Will not communicate 1. Current source problem; May need HART filter

1. Modem connection not operat-ing correctly

1. HART module not enabled in ValTalk software

1. See Current Source Interfer-ence on page 44-35.

1. See HART Modem on page 44-36.

1. In Options, select HART proto-col

HART 275 communicator indicates Generic after it connects to positioner

1. Handheld not programmed with Valtek DD

1. Contact Flowserve Flow Con-trol Division's Houston facility at 281.479.9500.

Table IV: Troubleshooting Logix 1200 Digital Positioner (2 of 3)

Failure or Problem Probable Cause(s) Refer to Section(s)

44-42 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

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Erratic communications 1. Maximum cable length or impedance exceeded

1. HART modem not receiving enough power. (laptop batteries low)

1. Interference with I.S. barrier

1. See HART Communication on page 44-35.

Alarms

Temperature 1. Ambient temperature has exceeded electronics ratings

1. See Temperature Alarm on page 44-37.

Hall sensor 1. Cable may have bad connection

1. Sensor may be damaged

1. See Hall Sensor Alarm on page 44-37.

Modulator Current 1. Modulator minimum pressure may be too low

1. Clogged orifice

1. Bad cable connection

1. See Modulator Current Alarm on page 44-37.

EEPROM checksum 1. Error when reading non-volatile memory storage

1. See EEPROM Checksum Alarm on page 44-38.

Multiple Internal Flags 1. Bad micro-controller on main PCB assembly

1. Replace main PCB assembly

LEDs

LED alternates between Green and Red in normal operation

1. Modulator coil current may be too high

1. Supply pressure may be close to minimum of 30 psig (2.1 barg)

1. See Modulator Current Alarm on page 44-37.

No LED blinks during calibration 1. Normal operation 1.

Yellow LED is blinking but valve posi-tion is fine

1. User-defined limit may have been reached; check alarm screen

1. See Alerts on page 44-38.

Red LED is blinking on advanced model, even though positioner has pressure

1. Pressure below 30 psi (2.1 bar) 1. See Pressure Alarms on page 44-38.

Advanced Features

Will not display pressure readings 1. Configuration not set to Advanced

1. See Standard vs. Advanced Diagnostics on page 44-40.

MPC will not function 1. Lower soft limit >= 0%.

1. 1% hysteresis around MPC set-point being considered

1. See MPC (Minimum Position Cutoff) on page 44-38.

Table IV: Troubleshooting Logix 1200 Digital Positioner (3 of 3)

Failure or Problem Probable Cause(s) Refer to Section(s)

Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611 44-43

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44-44 Flowserve Corporation, Valtek Control Products, Tel. USA 801 489 8611

Page 45: Valtek Logix 1200e/1210e Digital Positioner - Flowservewater.flowserve.com/.../Products/Flowcontrol/Logix/LGAIM0044.pdfValtek Logix 1200e/1210e Digital Positioner GENERAL INFORMATION

FCD VLAIM044-04c© 2000 Flowserve Corporation. Flowserve Corporation, Valtek Control Products, Tel. 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 intendedfunction 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 vari-ety of industrial service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The pur-chaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products. The purchaser/user shouldread and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in con-nection with the specific application.

While the information and specifications presented in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as aguarantee of satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this prod-uct. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Shouldany question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of its worldwide operations or offices.

For more information about Flowserve and its products,contact www.flowserve.com or call USA 972 443 6500 For more information, contact:

Manufacturing Facilities

1350 N. Mt. Springs Prkwy.Springville, UT 84663Telephone 801 489 8611Facsimile 801 489 3719

1300 Parkway View DrivePittsburgh, PA 15205 USATelephone 412 787 8803Facsimile 412 787 1944

Manderscheidstr. 1945141 Essen, GermanyTelephone (49) 2 01 89 19 5Facsimile (49) 2 01 891 9600

Alläe du Quartz 1CH-2300 La Chaux-de-FondsSwitzerlandTelephone (41) 32 925 9700Facsimile (41) 32 926 5422

Quick Response Centers

5114 Railroad StreetDeer Park, TX 77536 USATelephone 281 479 9500Facsimile 281 479 8511

104 Chelsea ParkwayBoothwyn, PA 19061 USATelephone 610 497 8600Facsimile 610 497 6680