Valtek Logix 1200e/1210e Digital Positioner

Transcription

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 accessories. Refer to the appropriate instructions when this
information is needed.
WARNING: To avoid possible injury to personnel 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 maintenance procedures other than outlined could
drastically affect performance and be hazardous to personnel and equipment, and may
void existing warranties.
V ltek SKU 138430
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 warranted.
Valve and Instrumentation Storage
Procedures
Storage
Control valve packages (a control valve and its instrumentation) can be safely stored in an enclosed building that affords environmental protection; heating is
not required. Control valve packages must be stored
on suitable skids, not directly on the floor. The storage
location must also be free from flooding, dust, dirt, etc.
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 installation. 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 following steps:
1. Replace the pressure-balanced plug O-rings.
2. Inspect the solenoid and positioner soft goods and
replace as necessary.
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Table of Contents
General 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 Positioner
on Valtek Mark One Control Valve
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Flowserve Corpor tion V ltek Control Prod cts Tel USA 801 489 8611
Unpacking
Logix 1200e Positioner Overview
1. While unpacking the Logix 1200e positioner, check
the packing list against the materials received. Lists
describing the system and accessories are
included in each shipping container.
The Logix 1200e digital positioner is a two-wire,
4-20 mA input, digital valve positioner. The Logix
1200e positioner also utilizes the HART protocol to
allow two-way remote communications with the positioner. The Logix 1200e positioner can control both
double and single-acting actuators with linear and
rotary mountings. Start up current must be at least
3.5 mA but once started, the Logix 1200e digital positioner operates with a signal as low as 2.8 mA. Below
2.8 mA, the operation and communication are suspended.
2. When lifting the system from the shipping container, position lifting straps to avoid damage to
mounted accessories. Systems with valves up to
six inches may be lifted by actuator lifting ring. On
larger systems, lift unit using lifting straps or hooks
through the yoke legs and outer end of body.
WARNING: When lifting a valve/actuator assembly with lifting straps, be aware the center of
gravity may be above the lifting point. Therefore, support must be given to prevent the
valve/actuator from rotating. Failure to do so
can cause serious injury to personnel or damage to nearby equipment.
3. In the event of shipping damage, contact the shipper immediately.
4. Should any problem arise, contact a Flowserve
Flow Control Division representative.
Since the positioner is insensitive to supply pressure
changes and can handle supply pressures from 30 to
150 psig, a supply regulator is usually not required;
however, in applications where the supply pressure is
higher than the maximum actuator pressure rating a
supply regulator is required to lower the pressure to
the actuator’s maximum rating (not to be confused
with operating range). An air filter is required for all
applications due to the close clearances in the spool.
NOTE: The air supply must conform to ISA Standard
ISA 7.0.01 (a dew point at least 18 degrees Fahrenheit
below ambient temperature, particle size below five
microns – one micron recommended – and oil content
not to exceed one part per million).
Specifications
Table III: Physical Specifications
Table 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 operating
current
2.8 mA
Maximum voltage
40.0 VDC
Table II: SoftTools Suite Software Specifications
Computer
Minimum Pentium processor running Windows 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 Filter
May be required in conjunction with some
DCSs
HART MUX
MTL 4840 system
Operating
Temperature Range
-40° F to +185° F
(-40° C to +85° C)
Housing
Cast, powder-painted aluminum,
stainless steel
Weight
8.3 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 Proof
FM/CSA Class 1, Div 1, Groups B, C, D
CENELEC EExd IIB+H2 T5, IP-65
Non-incendive
FM/CSA Class 1, Div 2, Groups A, B, C,
D; CENELEC IIC Exn, T6,BS 6941,
IP-65, T
Intrinsically Safe
FM/CSA Class 1, Div 1, Groups A, B, C,
D; CENELEC EExib, T4 & T5, IP-65
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.
Digital Position
Algorithm
Collector Board
Pressure Sensor
Air-to-open
Configuration
Flame Arrestors
Spool Valve
Air Supply
LED
Display
Exhaust
OUTPUT 1
OUTPUT 2
Main PCB Tray
Exhaust
Ribbon Cable
Flame
Arrestor
Flame Arrestor
Filter
Stem Position Sensor
Regulator
Hall Effect Sensor
Electromagnetic Coil
Nozzle
Orifice
Flapper
Figure 1: Logix 1200e Digital Positioner Schematic
Positioner Operation
The Logix 1200e positioner is an electric feedback
instrument. Figure 1 shows a Logix 1200e positioner
installed on a double-acting actuator for air-to-open
action. Positioning is based on a balance of two signals: one proportional to the command input signal
and the other proportional to the valve stem position.
The supply pressure for the positioner pressure modulator is tapped off the main supply. Next it passes
through an internal pressure regulator that regulates it
to approximately 22 psig. The air then passes through
an orifice that restricts the flow and air consumption.
The pressure modulator further controls the air to
6-10 psig, when operating current is applied, using a
spring-diaphragm flapper that is attracted by an electromagnet to a nozzle. A temperature compensated
hall effect sensor mounted on a circuit board senses
the spool valve position. The hall effect sensor and circuitry create an inner feedback loop, which determines
how much current to send to the electromagnet for a
desired spool valve position. The electro-magnet in
the feedback loop varies the nozzle-flapper spacing,
which regulates the output pressure to 6-10 psig, proportional to the digital position algorithm.
When the command and stem position signals are
equal, the system will be in equilibrium and the valve
stem will be in the position called for by the command
signal. If these opposing signals are not equal, the
spool valve will move up (or down) and, by means of
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the pressure modulator, change output pressures and
flow rate. This will cause the actuator piston to move
until the signal of the position sensor equalizes with
the command signal.
Detailed Sequence of Positioner
Operations
The detailed sequence of positioner operations is as
follows: An increase in the command signal causes
the modulator pressure to increase, pushing the spool
assembly upward from its equilibrium position. This
opens the spool valve ports, supplying air to Output 1
and exhausting air from Output 2. This causes the
actuator piston to move upward.
The upward motion of the piston is transmitted back to
the positioner through the stem position feedback linkage, changing proportionally to the valve stem position. The piston continues to stroke upward until the
stem position signal of the sensor increases sufficiently to counter the signal being sent to the control
algorithm. At this point, the spool is at its equilibrium
position as the pressures in the cylinder stabilize and
the air flow to the actuator decreases. The positioner
will then make small null adjustments to fine-tune the
desired position and compensate for changes in
dynamic loading.
A decrease in the command signal reverses the
described actions, causing a proportional downward
movement of the actuator piston and stem.
Logix 1000 Series Positioner
Vented-design Conversion
A standard Logix 1000 series positioner is vented
directly to the atmosphere. When supply air is substituted with sweet natural gas, the following changes
and considerations must be met. Piping must be used
to route the exhausted natural gas to a safe environment. This piping system may cause some positioner
back pressure in the main chamber (from modulator)
and spool chambers (from actuator). This increase in
pressure is due to restrictions caused by piping losses
from the pipe and fittings
Two chambers must be vented on the Logix 1000
series positioners: the main housing chamber and the
spool valve chamber (Figures 1 and 2). The main
chamber vent is located on the backside of the positioner (see Figure 1). There is a small, silver-colored
cover (item 24, SKU 10097867), protecting the vent
which must be removed and can be discarded.
A fitting may now be threaded into the 1/8-inch NPT
hole and tubing/piping attached.
NOTE: On rotary products, the mounting bracket covers the main housing vent. An adequate size access
hole must be drilled in the bracket at the time of
assembly to allow access to the main housing vent.
Maximum Allowable Housing
Back Pressure
1 psi (0.07 bar)
NPT x 1⁄4-inch
Swagelok Tube Fitting
1⁄4-inch
1⁄4-inch
FNTP x
MNPT Reducer
1⁄8-inch
Figure 3: Main Housing Vent
The maximum allowable back pressure from the collection 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 rise
above 2.0 psi (0.14 bar).
If this occurs the weather seal boot (SKU 130884),
found on the early versions of the Logix 1000 positioner, identified by the diagonal window in the main
cover, must be checked for proper sealing, as overpressure will move the seal out of place. (See
Figure 4). Damage will not occur to the seal, only seal
alignment will be affected. A typical sign of boot leakage is a dramatic deterioration of positioner performance. To correct the seal, remove the driver module
and simply re-align back into its groove. If back pressure of 3.5 psi (0.24 bar) is reached, total valve control
will be lost.
Field Terminations
HART Connection
Terminals
4-20 mA Feedback
Terminals (optional)
Housing EARTH
Terminal
Seal Boot
Shielded
Cable
Connect Shield at Source Ground
4-20 mA Current Source
Figure 2: Field Termination
Figure 4: Seal on Modulator
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will cause problems with overshoot but permanent
damage will not occur until pressures exceed 20 psi
(1.4 bar).
Tubing Positioner to Actuator
Maximum Allowable
spool Back Pressure
8 psi (0.55 bar)
3
/8-inch NPT x 3/8-inch
Swagelok Tube Fitting
Proper tubing orientation is critical for the positioner to
function 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 to
the bottom side of the actuator. The Output 2 port of
the positioner manifold is tubed to the top side of the
actuator. For air-to-close valves the above configuration is reversed.
For single-acting actuators Output 1 port is always
tubed to the actuator regardless of air action. Output 2
port must be plugged.
WARNING: This product has electrical conduit
connections in either thread sizes 0.5-inch NPT or
M20 which appear identical but are not interchangeable. Forcing dissimilar threads together
will damage equipment, cause personal injury and
void hazardous location certifications. Conduit fittings must match equipment housing threads
before installation. If threads do not match, obtain
suitable adapters or contact a Flowserve office.
Wiring and Grounding Guidelines
Input Cable Shielding (Figure 2)
Customer Connection
3/8-inch Tubing
Figure 5: Spool Cover Vent
The spool valve chamber has two parts: the spool
valve cover, (item 9, SKU 130811) and spool valve
shroud (item 10, SKU 130825). The spool valve cover
is replaced by SKU 10134649 for early versions of the
Logix 1000 positioner or SKU 10160335 for later versions (identified by the 1200e or the round window in
the main cover). This new cover has a 3/8-inch NPT
hole where tubing/piping must be attached. The spool
valve shroud is discarded and not replaced with anything. The maximum allowable back pressure while
stroking the valve is 8 psi (0.55 bar). Higher pressures
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The input loop current signal to the Logix 1200e digital
positioner should be in shielded cable. Shields must
be tied to a ground at only one end of the cable to provide a place for environmental electrical noise to be
removed from the cable. In general, shield wire should
be connected at the source.
Grounding Screw
The green grounding screw, located inside the termination cap, should be used to provide the unit with an
adequate and reliable earth ground reference. This
ground should be tied to the same ground as the electrical conduit. Additionally, the electrical conduit should
be earth grounded at both ends of its run.
The green grounding screw must not be used to
terminate signal shield wires.
Figure 6: Compliance Voltage
Compliance Voltage (Figure 6)
Cable Requirements
Output compliance voltage refers to the voltage limit
that can be provided by the current source. A current
loop system consists of the current source, wiring
resistance, barrier resistance (if present), and the
Logix 1200e positioner impedance. The Logix 1200e
digital positioner requires that the current loop system
allows for a 12.0 VDC drop across the positioner at
maximum loop current. The 12.0 VDC drop across the
Logix 1200e positioner terminals is generated by the
positioner from the 4-20 mA loop current input.
The Logix 1200e digital positioner utilizes the HART
Communication protocol. This communication signal
is superimposed on the DC 4-20 mA current signal.
The two frequencies used by the HART protocol are
1200e Hz and 2200 Hz. In order to prevent distortion
of the HART communication, cable capacitance and
cable length restrictions must be calculated. The cable
length must be limited if the capacitance is too high.
Selecting a cable with lower capacitance/foot rating
will allow longer cable runs. In addition to the cable
capacitance, the network resistance also affects the
allowable cable length.
CAUTION: Never connect a voltage source directly
across the positioner terminals. This could cause
permanent circuit board damage.
In order to calculate the maximum network capacitance, use the following formula.
Determine if the loop will support the Logix 1200e digital positioner by performing the following calculation.
Voltage = Compliance Voltage (@Current )
- Current *(R +R )
MAX
MAX
barrier
65
C network ( µF ) ≤ -------------------------------------------------------------- – 0.0032
( R barrier + R wire + 390 )
Example: R
barrier
= 300 Ω
wire
The calculated voltage must be greater than 12 VDC
in order to support the Logix 1200e digital positioner.
R = 50 Ω
wire
22ρF
0.000022µF
C cable = -------------- = -------------------------------foot
foot
Example: DCS Compliance Voltage = 19 V
R
barrier
= 300 Ω
65
--------------------------------------- – 0.0032 = 0.08µF = C network ( µF ) ( Max )
300 + 50 + 390
R = 25 Ω
wire
CURRENT
MAX
= 20 mA
C network ( µF )
Max Cable Length = ---------------------------------C network
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 digital positioner. The Logix 1200e positioner has an
input resistance equivalent to 625 Ω at a 20 mA input
current.
0.08µF
Max Cable Length = ----------------------------------------------0.000022µF ⁄ foot
To control cable resistance, No. 24 AWG cable should
be used for runs less than 5000 feet. For cable runs
longer than 5000 feet, No. 20 AWG cable should be
used.
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Collector Board
Pressure
Modulator
Connection
Hall Sensor
Connection
O-ring
Driver Module
Assembly
Minimum Pressure
Set Screw (factory
calibrated)
Install orifice before driver
module is in housing
Position wires to
the rear of Modulator
Hall Sensor Connector
Pressure Modulator Connector
Figure 7: Driver Module Assembly
Driver Module Assembly
The driver module assembly moves the spool valve by
means of differential pressures on its diaphragm. Air is
routed to the module from the regulator through a
hose that connects to the assembly through a hose
barb with an integral orifice. Wires from the module
connect the hall effect sensor and the pressure modulator coil to the collector board.
Driver Module Assembly Replacement
To replace the driver module assembly, refer to
Figure 7, 8, 9, 11, 20 and proceed as outlined below.
The following tools are required:
Flat plate/bar about 1/8-inch thick
Phillips 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), using
flat bar/plate in slot.
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4. Remove the spool valve cover by removing the
screw and sliding the cover assembly backwards
until the tab is clear of the slot. Removing the sheet
metal cap, hydrophobic filter, or O-ring from this
assembly is not necessary (Figure 11).
5. Being careful not to lose the nylon washer, remove
the Phillips-head screw that attaches the driver
module to the main housing (Figure 8).
6. Remove the spool valve block by removing the two
Phillips-head screws and carefully sliding the block
off the spool (Figure 8).
CAUTION: The spool (extending from the driver
assembly) is easily damaged. Use extreme caution when handling the spool and spool valve
block.
7. Carefully remove spool by sliding end of spool out
of connecting clip. Excessive force may bend
spool.
8. Remove main cover.
Housing
Spool Valve Block
opening. This will allow the driver module to thread
out without tangling or cutting the wires.
12. Grasp the driver module pressure modulator cap
to rotate the entire driver module. Turn it counter
clockwise to remove. After it is threaded out, carefully retract the driver module from the housing.
13. Take new driver module, and verify that the O-ring
is in place. Lay the wires back and along modulator as shown in Figure 7, and hold in place by
hand.
Spool
Spool Valve
Screws
Nylon
Gaskets
Driver to
Housing Screws
Figure 8: Spool and Block
Orifice
14. Gently direct the driver module into the housing
bore. Turn the driver module clockwise to thread it
into the housing. Continue rotating the module
until it bottoms out.
15. Once the threads are fully engaged, rotate the
driver module counter clockwise until the flat on
the driver module and the flat on the housing are
aligned. This will align the screw holes for the next
step.
16. Verify that nylon gasket is in the counter bore in
the driver module retaining screw hole as shown in
Figure 8.
17. Insert a driver-to-housing screw into the driver
housing through the counter-bored hole in positioner main housing. Tighten with a phillips screwdriver.
18. Feed the driver module wires into the main chamber of the housing, and connect them to the collector board.
19. Verify that the three O-rings are in the counterbores on the machined platform where the spool
valve block is to be placed (Figure 20).
20. Carefully slide the spool into the connecting clip of
the driver module assembly.
Driver
Module
Cover
Figure 9: Driver Module Orifice
9. Remove the tubing from the orifice in the driver
module assembly (Figure 9).
21. Carefully slide the block over the spool, using the
machined surface of the housing base as a register (Figure 8). Slide the block toward the driver
module until the two retaining holes line up with
the threaded holes in the base.
22. Install two spool-valve screws and tighten securely
with a Phillips screwdriver.
10. Remove the two wiring connections that link the
driver module assembly to the collector board.
23. Slide the spool valve cover assembly over the
spool valve until the tang engages into housing
slot. Install spool valve cover screw and tighten
securely.
11. Feed the wires back through the housing so they
extend backward, out toward the driver module
24. Thread main cover and driver module cover into
the main housing.
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Spool Valve
To replace the spool valve, refer to Figure 8, 10 & 11
and proceed as outlined below.
until the tab is clear of the slot. It is not necessary
to remove the sheet metal cap, hydrophobic filter,
or O-ring from this assembly (Figure 11).
4. Remove the spool valve block by removing the two
phillips-head screws and carefully sliding the block
off the spool (Figure 8).
CAUTION: Spool (extending from driver assembly) is easily damaged. Use extreme caution
when handling spool and spool valve block.
5. Grasp the bottom of the regulator and unscrew it
from the interface plate.
6. Verify that the O-rings are in place on the base of
the new regulator and thread it into the hole in
interface plate.
7. Install four screws to fasten the collector board into
the housing. Replace the four wire connections.
8. Attach the flexible tubing to the orifice.
9. Re-install all covers.
O-ring
Hydrophobic
Filter
5. Carefully remove spool by sliding end of spool out
of connecting clip. Excessive force may bend the
spool.
6. Verify that the three O-rings are in the counterbores on the machined platform where the new
spool valve block is to be placed (Figure 20).
7. Careful slide the spool into the connecting clip of
the driver module assembly.
machined surface of the housing base as a register
(Figure 8). Slide the block toward the driver module
until the two retaining holes line up with the
threaded holes in the base.
9. Install two spool-valve screws and tighten securely
with a phillips screwdriver.
10. Slide the spool valve cover assembly over the
spool valve until the tang engages into housing
slot. Install the spool valve cover screw and tighten
securely.
Regulator
The regulator reduces the pressure of the incoming
supply air to a level that the driver module can use.
Replacing Regulator
3. Remove the main cover.
4. Remove the four wire connections from the collector board. Next remove the four screws that fasten
the collector board to the housing.
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Spool
Valve
Cover
Spool
Valve Shroud
Figure 10: Spool Valve Cover Assembly
Spool Valve Cover
The spool valve cover incorporates a coalescing filter
element in a two-piece cover. This protects the spool
valve chamber from moisture and provides a low back
pressure vent for exhaust air from the spool valve.
Replacing Filter in Spool Valve Cover
3. Remove the spool cover by removing the screw
and sliding the cover assembly backwards until the
tab is clear of the slot. The sheet metal cover may
be removed and cleaned with a brush or by blowing
out with compressed air (Figure 11).
4. Remove the O-ring from around hydrophobic filter
element and set aside (Figure 10).
5. Remove the molded filter element by pulling
straight out of chamber cover vent piece.
6. Install O-ring into base of chamber cover vent piece
as shown in Figure 10.
7. Place new molded filter element into the chamber
cover vent piece. This element provides part of the
track 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 by
setting it on the ramp and sliding it until the tab seats
in the slot (Figure 11) and secure with No. 8-32
screw.
Main PCB Assembly
The main PCB assembly contains the circuit board
and processor that perform control functions of the
positioner. The board is encapsulated in a tray with a
protective silicon coating. This module can be easily
replaced if necessary. None of the components inside
the tray are serviceable. This module is to be replaced
as a unit.
Replacing Main PCB Assembly (Figure 12)
3. Remove the main cover and disconnect the ribbon
cable from the collector board.
CAUTION: To avoid damaging any components,
exercise caution by gently raising the locking
tab to release the ribbon cable.
4. Remove the PCB assembly by removing the three
No. 6-32 screws and lifting the tray out of housing.
Spool Valve Cover
5. Place the new PCB assembly on the bosses inside
the positioner housing.
Screw
Figure 11: Spool Valve Cover Assembly
6. Insert three No. 6-32 screws through the tray into
the threaded bosses and tighten evenly, using a
phillips screwdriver. Do not overtighten.
7. Reconnect the ribbon cable to the collector board
Ribbon Cable
Main PCB
Assembly
Screws (3)
Figure 12: Main PCB Assembly
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Collector Board
The collector board assembly provides a central routing for all electronic connections in the positioner, linking the pressure modulator coil, hall effect sensor and
field inputs to the main electronics. The collector board
assembly also provides for mounting of the pressure
sensors used in the advanced model.
NOTE: The two screws through the stiffener plate
are longer.
5. Tighten all four screws.
6. Connect the main ribbon from the electronics tray.
7. Reconnect wiring to the collector board.
Field Terminations
Removing Collector Board (Figure 20)
The customer interface board provides a connection
point inside the explosion proof housing for all hookups to positioner. While the board is not likely to experience a failure, it can easily be replaced.
3. Remove the main cover and disconnect the wiring to
the collector board. Each cable has its own unique
connector to prevent mistakes in reconnecting.
Replacing Customer Interface Board
(Figure 2 & 20)
4. Remove the four No. 8-32 screws holding the
collector board to the housing.
5. Remove the collector board.
3. Remove the main cover and disconnect the customer interface cable from collector board.
Replacing Collector Board
4. Remove the customer interface cover and the three
No. 8-32 screws.
NOTE: A Logix 120X (standard model) cannot be
upgraded to a Logix 1210e (advanced model) by
changing out the collector board. The Logix 120X and
Logix 1210e use different positioner housings.
1. Advanced collector board only – Verify that pressures sensors are in place on back of collector
board, and that the two O-rings are in place.
2. Set collector board assembly in place.
3. Advanced collector boards require a stiffener plate
above the pressure sensors (Figure 20).
4. Insert four No. 8-32 screws through the collector
board into the threaded holes of the housing.
44 12
5. Remove customer interface board, carefully pulling
wiring through bore.
6. Verify that the O-ring is in place in the counter bore
in the positioner housing.
7. Feed wiring through passageway into main chamber of housing.
8. Set the circuit board in place and secure with three
No. 8-32 screws.
9. Connect customer interface cable to collector
board.
10. Replace covers.
Stem Position Sensor
The position feedback assembly transmits valve position information to the processor. This is accomplished
by means of a rotary position sensor that connects to
the valve stem through a feedback linkage. To provide
for accurate tracking of the pin in the slot, the follower
arm is biased against one side of the slot with a rotary
spring. This spring also automatically moves the position feedback assembly to its limit in the unlikely event
of failure of any component in the linkage.
Housing
Stem Position
Sensor
Sensor
Cable
8. Route wires along the position sensor and reconnect 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
box wrench
3/8-inch open-end wrench
7/16-inch
1. Remove washer and nut first from follower pin
assembly. Insert pin into the appropriate hole in follower arm, based on stroke length. The stroke
lengths are stamped next to their corresponding
holes in the follower arms. Make sure the
unthreaded end of the pin is on the stamped side of
the arm. Reinsert lock washer and tighten nut to
complete follower arm assembly.
2. Slide the double-D slot in the follower arm assembly over the flats on the position feedback shaft in
the back of the positioner. Make sure the arm is
pointing toward the customer interface side of the
positioner. Slide lock washer over the threads on
the shaft and tighten down the nut.
Bearing
Stem Position
Sensor Dot
3. Align the bracket with the three outer mounting
holes on the positioner. Fasten with 1/4-inch bolts.
Feedback Shaft
Figure 13: Stem Position Sensor
Orientation
Stem Position Sensor Replacement
(Figure 13, 20)
3. Remove the main cover and disconnect rotary
position sensor wires from collector board.
4. Remove the two screws from rotary position sensor
and remove the sensor from the housing.
5. Turn position sensor shaft until the dot on the slot is
oriented with the wires on the pot (Figure 13).
6. Insert the position sensor into the shaft with wires
pointing toward the main PCB assembly. Turn the
position sensor clockwise until bolting slots align
with the housing screw holes and the wires on the
sensor 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.
4. Screw mounting bolt into the hole on the yoke
mounting pad nearest the cylinder. Stop when the
bolt is approximately 3/16-inch from being flush with
mounting pad.
5. Slip the large end of teardrop shaped mounting
hole in the back of the positioner/bracket assembly
over mounting bolt. Slide the small end of teardrop
under mounting bolt and align the lower mounting
holes.
6. Insert lower mounting bolt and tighten bolting.
7. Slide appropriate pin slot on the take-off arm, based
on stroke length, over follower arm pin. The appropriate stroke lengths are stamped by each pin slot.
8. Position the take-off arm mounting slot against the
stem clamp mounting pad. Apply Loctite 222 to
take off arm bolting and insert through washers into
stem clamp. Torque to 120 in-lbs.
9. Center the take-off arm on the rolling sleeve of the
follower pin.
10. Align take-off arm with top plane of the stem clamp
and tighten bolting.
44 13
Logix 1200 Positioner
Bracket Bolts
Bracket
Locknut
Washer
Follower
Arm
Positioner
Bolts
Nut
Nut
Lock Washer
Nut
Follower Pin
Stem Clamp
Take-off Arm
Bolts
Metal
Washers
Figure 14: Linear Mark One Control Valve Mounting
Standard Rotary Mounting Procedure
(See Figure 15)
The standard rotary mounting applies to valve/actuator assemblies that do not have mounted volume tanks
or handwheels. The standard mounting uses a linkage
directly coupled to the valve shaft. This linkage has
been designed to allow for minimal misalignment
between the positioner and the actuator. The tools
required for the following procedure are:
5/32
allen wrench
end wrench
7/16-inch end wrench
3/8-inch socket with extension
3/16 nutdriver
1/2-inch
1. Fasten spline lever adapter to splined lever using
two No. 6 x 0.50-inch self tapping screws.
2. Slide take-off arm assembly onto spline lever
adapter shaft. Insert screw with star washer
through take-off arm and add second star washer
and nut. Tighten nut with socket so arm is lightly
snug on shaft but still able to rotate. This will be
tightened after linkage is correctly oriented.
44 14
3. Attach follower arm to positioner feedback shaft
using the star washer and No. 10-32 nut.
NOTE: Arm will point up when feedback shaft is in
the free position.
4. Using four 0.25-20 x 0.50 L. bolts, fasten positioner
to universal bracket using appropriate hole pattern
(stamped on bracket).
5. Using a 1/2-inch end wrench and two 0.3125-18 x
0.50 L. bolts, attach bracket to actuator transfer
case pad. Leave these bolts slightly loose until final
adjustments are made.
6. Rotate take-off arm so the follower pin will slide into
its slot. Adjust bracket position noting the engagement of the follower pin and the take-off arm slot.
The pin should extend approximately 1/16-inch past
take-off arm. When properly adjusted, securely
tighten 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 side
of the Actuator.
Positioner Bolts 1/4-20 (4)*
Bracket Bolts 5/16-18 (2) (not shown)
Take off Arm, Rotary
Lock Washer (2)
Bolt No.10-32
Nut No.10-32
Logix 1200
Digital Positioner
Self Tapping Screws (2)
Spline Lever Adapter
Nut No.10-32
Lock Washer
Follower Arm
* Located in appropriate
hole pattern as indicated on
bracket. (25, 50, 100/200)
Figure 15: Standard Rotary Mounting
2. OUTPUT 2 port of the manifold to the topside of
the actuator.
3. With supply pressure off, rotate the follower arm in
the same direction the shaft would rotate upon a
loss of supply pressure. When the mechanical stop
of the follower arm (positioner) is reached, rotate
back approximately 15 degrees.
4. Hold the take-off arm in place; tighten the screw of
the take-off arm.
NOTE: The take-off arm should be snug enough to
hold the follower arm in place but allow movement
when pushed.
8. Press the Quick-Cal button for 5 to 10 seconds or
until positioner begins to move. The positioner will
now perform a stroke calibration.
9. If the calibration was successful the green LED will
blink and the valve will be in control mode. Continue with step 10. If calibration failed the A/D feedback values were exceeded and the arm must be
adjusted away from the positioners limits. Return to
step 3 and back off approximately 10 degrees.
NOTE: Remember to remove the air supply before
re-adjusting take-off-arm.
10. Tighten the nut on the take-off arm. The socket
head screw of the take-off arm must be tight,
about 40 in-lbs.
5. Connect regulated air supply to appropriate port in
manifold.
NOTE: If the take-off arm slips, the positioner must
be re-calibrated.
6. Remove main cover and locate DIP switches and
Quick-Cal button
WARNING: Failure to follow this procedure will
result in positioner and/or linkage damage.
Check air-action and stroke carefully before
lockdown of take-off arm to spline lever
adapter.
7. Refer to sticker on main board tray and set DIP
switches accordingly
44 15
Tripper
Tripper Clamp
Bracket Bolts 5/16-18 (2)
Ball Joint Ends
Follower Arm
Bolts (2)
Rotate Positioner 90°
Locknuts (2)
*Tie Rod
Mounting Bolts
1
/4-20 (4)
Nut No. 10-32
Lock Washer
* Tie Rod must be cut to desired length
Figure 16: Optional Rotary Mounting
Optional Rotary Mounting Procedure
The optional rotary mounting applies to valve/actuator
assemblies that are equipped with mounted volume
tanks or handwheels. The optional mounting uses a
four-bar linkage coupled to the valve shaft. The following tools are required:
3/8-inch
box wrench
7/16-inch
1/2-inch
box wrench
box wrench
1. Using a 1/2-inch box end wrench and two 0.3125-18
x 0.50 L. bolts, attach bracket to actuator transfer
case pads. Leave bracket loose to allow for
adjustment.
2. Using four 0.25-20 x 0.50 L. bolts and a 7/16-inch
box wrench, fasten positioner to universal bracket,
using the four-hole pattern that locates the positioner the farthest from the valve. Rotate positioner
44 16
90 degrees from normal so gauges are facing
upward.
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 two
0.25-20 L. bolts and two 0.25-20 locknuts. Leave
tripper loose on shaft until final adjustment.
5. Thread ball joint linkage end to tripper and tighten
(Thread locking compound such as Loctite is recommended to prevent back threading). Adjust
length of tie rod so follower arm and tripper rotate
parallel to each other (the rod must be cut to the
desired length). Connect other ball joint end to follower 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.
WARNING: If rotating in wrong direction, serious damage will occur to the positioner and/or
linkage. Check air action and stroke direction
carefully.
LED Indicators
The Logix 1200e has three LED indicators that are visible through a window in the main cover. Only one LED
will blink at any given time. Each LED has a different
color to convey basic information about the positioner
status. Green indicates that the positioner is operating
normally. Yellow indicates that a ‘customer defined
limit’ or ‘alert’ has been reached. Red indicates that an
error condition exists. The HART hand held communicator, ValTalk or SoftTools PC software must be used
to determine the specific reason for a yellow or red
LED status.
During stroke and actuator calibration, no LED will
blink. After calibration is complete, the green LED indicates that the calibration was completed successfully.
If the yellow or red LED blinks after a calibration process, a warning or error was detected and the HART
communication to the device must be used to identify
the specific calibration error.
NOTE: If the LED indicator changes from green to yellow after a calibration process, the user may have set
a 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, the
Logix 1200e has a Quick-Cal feature that performs a
stroke calibration and allows basic operation of the
positioner. The Quick-Cal routine applies full supply
pressure to the upper and lower mechanical limits to
determine the valve stroke. Valve systems without
mechanical stops must use the ValTalk or SoftTools
software to manually calibrate the valve.
WARNING: The calibration routines are only to be
used on systems which have mechanical stops.
The calibration routines apply full supply pressure
to determine stroke length and may cause damage
to the valve, actuator or positioner.
NOTE: The Quick-Cal operation retains all previously
configured information except for the three DIP switch
settings and stroke parameters. The settings of
ATO/ATC, Linear/Rotary, Linear/Custom and stroke
parameters are overridden and rest to the DIP switch
settings when the Quick-Cal button is used. If the
device is being installed for the first time, factory
default parameters are used.
The Quick-Cal button and DIP switch settings are
located on the collector board inside the main housing
chamber as shown in Figure 17.
Quick-Cal DIP Switch
Quick-Cal Button
Figure 17: Quick-Cal Button
WARNING: Accessing this function requires
removal of the main cover. The user must take all
precautions if this operation is performed in explosion-proof areas.
Make the appropriate configuration settings, using the
DIP switches on the collector board. ATO/ATC selects
air-to-open or air-to-close (this is determined by the
mechanical
tubing
of
the
actuator). The
LIN_VALV/ROT_VALV button allows the user to select
linear or rotary feedback linkage. The LIN_VALV
switch enables the feedback potentiometer to utilize
the entire resolution through a maximum of 60
degrees rotation (45 degrees is typical). The
ROT_VALV switch increases the rotation of the potentiometer up to 105 degrees (90 degrees is typical).
Thus a long stroke sliding stem valve may require this
dip switch to be set on ROT_VALV if the stroke rotates
the feedback potentiometer more than 60 degrees.
The LIN/CUSTOM option allows selection of linear or
custom control characterization. If Custom is
selected, the positioner activates custom characterization. If the device is being installed for the first time,
the default custom characterization is equal percent.
However, if a custom curve has been previously
loaded, the previous curve will be used. The DIP
switch settings are only read after the Quick-Cal button is pressed for 5 seconds; otherwise, the settings
do not have any effect. The DIP switch settings will
override any previous configuration done using HART
communications. Press the Quick-Cal button for five
to ten seconds. If the button is released before five
seconds have elapsed, no action will be taken. After
approximately five seconds, the positioner will begin a
44 17
stroke calibration. Release the Quick-Cal button once
calibration has started. The positioner will automatically stroke the valve. The stroke sequence will be to
the extremes (open to close), to the mid stroke, then
to the signal position. No LED will blink during this
process.
Rotate Stem Position Sensor slowly
NOTE: If Quick-Cal is interrupted during calibration
the mode of the positioner may stay in digital, requiring
HART communications to place it back into analog.
If calibration was successful, upon completion the
green LED will blink and the valve will be in control
mode. If the yellow LED blinks immediately after a
stroke calibration, this usually indicates that the valve
did not stroke. Check the air supply and cable connections. If a calibration error occurred, the red LED will
blink. The cause of a red LED is generally a stem position linkage/feedback sensor alignment problem. For
linear linkage, the active electrical feedback angle is
65 degrees. For rotary linkage, the active electrical
feedback angle is 95 degrees. The red LED indicates
that the mechanical travel is not centered within the
electrical sensor travel. If a red LED is blinking after a
stroke calibration, loosen the feedback sensor mounting screws as shown in Figure 18. Turn the stem position sensor slowly while watching the LED indicators.
Try small movements, both clockwise and counterclockwise. If the yellow LED begins to blink, the feedback sensor has been correctly moved into range.
Tighten the feedback sensor mounting screws and
repeat the Quick-Cal procedure. If the LED remains
red 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 clamp
and take-off arm height.
NOTE: If the stroke calibration stops in the closed
position, the error occurred when the position
sensor/linkage was at closed position. If the stroke
calibration stops in the open position, the error
occurred when position sensor/linkage was at the
open position. No calibration parameters are saved if
an error occurs. If the power to the positioner is
removed, the unit will power-up with the previous
configuration parameters. A successful calibration will
save parameters.
If the valve does not stroke after pressing the QuickCal button, this may be an indication that the internal
regulator pressure and/or the driver module minimum
pressure is low. Refer to the following instructions to
check and set the internal regulator and minimum
pressure settings.
NOTE: Ensure that all linkages are tight and correctly
mounted before attempting to calibrate. Loose or
incorrectly mounted linkage will cause calibration failure and difficulty in troubleshooting.
44 18
Stem Position
Sensor Mounting Screws (2)
Figure 18: Stem Position Sensor
Adjustment
Checking or Setting Internal Regulator Pressure
The tools and equipment used in the next procedure
are from indicated vendors.
2. Disconnect the air supply from the positioner.
3. Remove the main cover and the 1/16 inch flexible
tubing from the driver module orifice.
4. Obtain a barbed tee (Pneumadyne part No. SBF16T or equivalent) and two pieces of 1/16 inch flexible tubing, a few inches in length each.
5. Connect the 1/16 inch flexible tubing, found in the
positioner, to the barbed tee. Using one of the new
flexible tubing pieces connect the barbed tee to the
orifice. Connect the remaining tee port to a 0 to 30
psi pressure gauge.
6. Reconnect the air supply to the positioner and read
the internal regulator pressure on the 0 to 30
gauge. The internal pressure should be set to 21.5
±0.5 psi. If adjustment in needed, scrape off the silicon compound covering the screw. Then adjust the
regulator pressure by turning the setscrew on top
of the regulator with a small screwdriver.
7. Once the regulator pressure is set, remove the air
supply to the positioner, remove the barbed tee,
and reconnect the positioner's flexible tubing to the
orifice.
8. Reconnect air supply to positioner.
No. 10-32 Extension
(Clippard Part No. 15010)
Minimum Pressure
Test Port
5. Remove the No. 10-32 x 0.016 orifice and gasket
(Figure 9) from the driver module using a 1/2-inch
nut driver. Take care to not misplace the gasket.
6. Screw in the 10-32 extension followed by the 10-32
x swivel elbow.
7. Direct the swivel elbow so the minimum pressure
test port is accessible.
1
No.10-32 x /16
Barb
8. Screw a No. 10-32 x 1/16-inch barb fitting into the
test port, and screw the No. 10-32 x 0.016 orifice
into the end of the elbow as shown.
9. Connect the tubing from the internal regulator output port to the orifice.
10. Using some 1/16-inch flexible tubing, connect a 0
to 30 psi gauge to the minimum pressure set port.
No.10-32 x .016
Orifice
Pressure from Internal
Regulator to be tubed to
this orifice
No.10-32 x Swivel
TEE (Pneumadyne
Part No. SFL-10)
Figure 19: Driver Module Minimum
Pressure Check
Checking or Setting the Driver Module Minimum
Pressure
11. Once the gauge is connected, reapply the positioner air supply. The minimum pressure should
now be registering on the gauge and must be 3.8
to 4.2 psi. If the minimum pressure is not correct,
take a 9/64 allen wrench and turn the minimum
pressure set screw located at the bottom of the
driver module (Figure 7) until the pressure is in the
range indicated. Cycle the positioner air supply
several times and recheck the minimum pressure
and re-adjust, if necessary, to ensure that the
pressure has settled within the range specified.
12. When the pressure is set, remove the air supply.
Refer to Figure 19, proceed as follows:
2. Disconnect power from the positioner.
3. Remove the main cover and remove the 1/16 flexible tubing from the orifice.
4. Obtain a No. 10-32 x swivel elbow (Pneumadyne
part No. SFL-10 or equivalent) and a No. 10-32
extension (Clippard part No. 15010 or equivalent).
13. Remove the No. 10-32 x 1/16 barb and orifice from
the swivel elbow and then remove swivel elbow
and extension.
14. Replace the orifice and gasket as shown in
Figure 9 and reconnect the 1/16 inch flexible tubing
from the internal regulator output port to the orifice.
Reconnect the positioner air supply and power.
The positioner should now be ready to calibrate.
44 19
PROTOCOL
Selection
HART
1
ns
ec
tio
nn
ial
ec
Sp
tio
n
Op
Co
Ac
uit
nd
Co
ial
os
rtif
ic
De ation
sig
s
Sh n Ve
aft
rsi
on
Ce
ter
Ma
gn
Dia
Pr
oto
co
l
tic
s
tio
ns
LOGIX 1200 Model Numbers
e
Code
*2
DIAGNOSTICS
Selection
Standard
Advanced
Code
*0
1
MATERIAL
Selection
Aluminum, Valtek (White Paint)
Stainless Steel, Valtek (No Paint)
Aluminum, Automax (Black Paint)
Aluminum, Automax (Food Grade White Paint)
Aluminum, Accord (Black Paint)
Aluminum, Automax (Food Grade White Paint)
CERTIFICATIONS
Selection
Explosion proof EEx d IIB + H2 (CENELEC SCS)
Nonincendive Class I, Div. 2, (Factory Mutual), Class I, Div. 2 (CSA)
Explosion proof Class I, Div. 1, Groups B,C,D Intrinsically Safe Class I,
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)
General Purpose
SHAFT
Selection
DD Shaft
NAMUR
CONDUIT CONNECTIONS
Selection
1/2” NPT
M20
ACTION
Selection
4 way
3 way
4 way Vented
3 way Vented
SPECIAL OPTIONS
Selection
No Specials
4-20 mA Position Feedback
Note:
44 20
*Product Default Value
Code
*0
1
2
3
4
5
Code
07
08
10
13
14
Code
*Blank
N
Code
*Blank
M
Code
*Blank
3
V
W
Code
*Blank
F
1 = Logix Product Line
Item
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Part
Housing Logix 1200 Positioner
Main Housing Cover
O-ring, Main Housing Cover
LED Display Window
O-ring, Window
2
Washer, Seal ring
Retaining Ring
Screw, Anti-Rotation
Spool Valve Cover
Spool Valve Shroud
Hydrophobic Filter,
Spool Valve Chamber
O-ring, Spool Valve Cover
8
Screw, Spool Valve Cover
Driver Module Cover
13
O-ring, Driver Module
Cover
10
Regulator, 5 to 30 psi
(Includes O-ring)
Internal Filter
O-ring, interface plate to
housing seal
Screw, interface plate to
housing (4)
Interface Plate
Orifice, Barbed Fitting
Flexible Tubing
Hex Barbed Fitting
W/Captive O-ring
Main vent cover
Screw, Main vent Cover
Customer Interface Cover
44
O-ring, Customer Interface
Cover
29
28.
29.
30.
31.
32.
33.
34.
35.
36.
Screw, Anti-Rotation
Pressure Gauge, 0-160 psi (2)
Customer Interface Board
Screw, Customer Interface Bboard (3)
O-ring, Customer Interface Board
Grounding Screw (2)
Main PCB Assembly
Screw, Main PCB Assembly (3)
Collector Board Assembly
(Standard / Advanced Model)
37. O-ring, Sensor to Housing (2)
38. Collector Board Stiffener (Advanced only)
39. Screw, Pressure Sencors to Housing
(2 Advanced only)
5
16
6
9
7
3
19
21
4
11
12
39
18
36
38
17
40
20
43
41
44
42
37
35
48
47
49
34
51
57
27
50
46
26
31
32
52
1
53
54
30
33
55
28
25
56
22
45
24
23
15
14
*Aluminum or Stainless Steel
40. Screw, Collector Board to Housing
(4 Standard - 2 Advanced)
41. Spool Valve Block
42. Spool Valve
43. Screw, Spool Valve to Housing (2)
44. O-ring, Spool Valve (3)
45. Driver Module Assembly
46. Nylon Washer (1)
47. Screw, Driver to Housing (1)
48. Stem Position Sensor
49. Screw, Potentiometer to Housing (2)
50. Metal washers (2)
51. Screw, Spring to Feedback Shaft
52. Feedback Shaft
53. O-ring, Feedback Shaft
54. Bearing
55. Torsion Spring
56. E-ring
57. Air Screens
Figure 20: Exploded View
44 21
Available Spare Part Kits for Logix 1200e digital postioner
Kit 1 – Driver Module Assembly
SKU 10130943
Item No.
45
47
46
23
16
Kit 5 – Advanced Collector Board Assembly
SKU 10130946
Description
Driver module
Screw, driver to housing
Nylon washer
Orifice barbed fitting and gasket
Regulator and captive O-ring(s)
Quantity
1
1
1
1
1
Item No.
36
37
38
39
40
Description
Spool valve Block
Spool valve
Screw, spool valve to housing
O-ring, spool valve
Item No.
30
31
32
33
Quantity
1
1
2
3
Description
Customer interface board
Screw, customer interface board
O-ring, customer interface board
Grounding screw
Quantity
1
3
1
1
Kit 7 – Main PCB Assembly
SKU 10130948
Kit 3 – Soft Goods Kit
SKU 10130944
Item No.
3
15
27
32
37
44
53
5
18
12
17
Quantity
1
2
1
2
2
Kit 6 – Customer Interface Assembly
SKU 10130947
Kit 2 – Spool Valve Kit
SKU 10130950
Item No.
41
42
43
44
Description
Collector board
O-ring, sensor to housing
Collector board stiffener
Screw, pressure sensors to housing
Screw, collector board to standoffs
Description
O-ring, main housing cover
O-ring, driver module cover
O-ring, customer interface cover
O-ring, customer interface board
O-ring, pressure sensor to housing
O-ring, spool valve
O-ring, feedback shaft
O-ring, main cover window
O-ring, interface plate
O-ring, spool valve cover
Internal filter
Item No.
Description
34
Main PCB assembly
35
Screw, main PCB assembly
Quantity
1
1
1
1
2
3
1
1
1
1
1
Kit 8 – Regulator
SKU 10070875
Item No.
Description
6
Regulator and captive O-ring(s)
Quantity
1
Kit 9 – Stem Position Sensor
SKU 10061643
Item No.
Description
48
Stem position sensor
Kit 4 – Standard Collector Board Assembly
SKU 10130945
Item No.
Description
36
Collector board
40
Screw, collector board
Quantity
1
3
Quantity
1
HART Filter
SKU 10079944
Quantity
1
4
4-20 mA Position Feedback Kit
SKU 10125599
Table VI: Valtek Linear Mounting Kits
50 Square-inch*
25 Square-inch
Spud
Standard
Handwheel
Standard
Handwheel
2.00
10067289
10067368
10091897
10067368
10067316
10067384
100-200 Square-inch
Standard
Handwheel
10067329†
10067384
2.88
10067329
10067386
3.38
10067351
10067389
4.75
10067351
10067389
2.62
* 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
Table VII: Valtork Rotary Mounting Kits*
25 Square-inch
50 Square-inch
100-200 Square-inch
Shaft Diameter
Standard
Optional
Standard
Optional
Optional
0.44
10067418
10067527
1006790
0.63
10067418
10067565
1006790
10067573
10067502
0.75
10067418
10067569
10067490
10067574
10067502
0.88
10067418
10067572
10067490
10067575
10067502
1.12
10067418
10067490
10067580
10067502
10067616
1.50
10067418
10067490
10067502
10067617
1.75
10067418
10067490
10067502
10067618
Standard
10067502
10067615
* 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
Table VIII: Logix Mounting Kits (Continued)
Mounting Kit
50
60
1250
L – M5-.8 Metric Bolting
10124070
0.5 – 1.5-in. stroke
10124085
2-in. stroke
10124070
0.5 – 1.5-in. stroke
10124085
2-in. stroke
Notes
Example: NK313A
Kits designed for the following O.E.M.'s
Air-torque
AT Series AT0 — AT6
SNA
Series
SNA3 — SNA2000
N Series
N250. 300
225
R Series
R2 — R5
450
RPC
Series
RP — TPC11000
70
10124086
80
10124087
4-in. stroke
1052
33
657-8
40
Bettis
10124203
Rotary
10126736
EL-O-Matic
Neles
RC
10124060
RD
10131247
Foxboro
Slid-Std
10131247
10119289
R314
10094495
10406329
E25 — E350
P Series
P35 — P4000
XL Series XL45 — XL4580
Unitorq
M Series
Worcester
39 Series 2539 — 4239
VST-VA3R
17-in. dia. 10126736
M20 — M2958
0.75 – 1.5-in. Std
HD
9
11
37
NAMUR Mounting Kits
Prefix
NK – NAMUR Accessory Mounting Kit
Bracket Option
28 – 20mm Pinion x 80mm Bolt Spacing
12-in. dia. 10126736
Masoneilan (Linear Actuators)
Automax
SNA115
G2009-M11 — G3020-M11
E Series
Hytork
VSL-VA1D
Valtek
Trooper
G Series
Honeywell
10126255
Linear
Automax
10125818
675
Automax
Mounting Kit
B – 10-32 UNF Bolting
10100780
40
657 & 667
Size
A – 10-24 UNC Bolting
30
34
Model
Bolt Option
Fisher
38
10124594
13
10124593
18
10125747
24
10126826
11
10125402
13
10125401
15
10140783
18
10125747*
24
10126826
44 23
Table VIII: Logix Mounting Kits (Continued)
Model
Size
Mounting Kit
Masoneilan (Linear Actuators, cont.)
25
10125644
50
10125645
100
10125646
6
10124595
16
10126752
47
B
10125702
48
B
10125702
“D” Domotor
200
71 Domotor
vided between the supplies powering the Logix
unit and the analog output board.
• Available for explosion-proof and safe applications
(CSA, FM).
Specifications
Potentiometer Range
of Rotation
40° to 95°
Power Supply Range
12.5 to 40 VDC
(24V DC typical)
10127467
Maximum Load
Resistance (ohms)
(Supply Voltage - 12.5) / 0.02
71-2057AB-D
10129359
Current Signal Output 4-20 mA
71-40413BD
10129461
Linearity
88
Masoneilan (Rotary Actuators)
33
B
10125542
4
35
6
10125542
7
70
10
10125542
1.0% F.S.
Repeatability
0.25% F.S.
Hysteresis
1.0% FS
Operating
Temperature
-40° to 185° F
(-40° to 85° C)
Ambient
Temperature
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 Supply
Effects
Out put signal change is less than
0.05% FS when supply voltage is
varied between 12.5 and 40 VDC
Vanguard
37/64
10127426
* Adjustable Mounting kit 10126736 may be needed if
handwheels are used.
4 to 20 mA Analog Output Retrofit
General Information
The Logix 1200e digital positioner/controller can be
retrofitted to provide an analog feedback signal of the
stem position. This position feedback option has the
following features and specifications:
• Does not interfere with positioner operation.
+
–
+
–
• Zero and span adjustments of the feedback signal
are independent of the positioner and can be
adjusted manually.
• Output follows actual position of valve, including all
failure modes of positioner except loss of power. An
output of 3.15 mA is transmitted with loss of power
to the analog output board.
Position Feedback
Current Loop
(Logix Output)
R Load
–
12.5 to
40 VDC
Power
Supply
+
• Immune to RFI/EMI disturbances.
• Can be retrofitted in the field.
CAUTION: Because the analog output board
shares common signals with the Logix internal
circuitry, the two units cannot be powered by
the same external power supply or by power
supplies that share a common reference.Galvanic isolation of at least 50 VDC must be pro-
44 24
Positioner Command
Current Loop
(Logix Input)
–
4 to 20 mA
Current Source
+
CAUTION: Isolated power sources required.
Figure 21: Analog Output Board Power
Span Adjustment
Zero Adjustment
DIR/REV Switch
Potentiometer
Connections
Terminal Board
Connection
Control
Board
Connection
Figure 22: 4-20 mA Analog Output Board
Calibration
To calibrate the Logix 1200e or 1200e digital positioner equipped with analog output, follow the procedure outlined below:
1. Wire the position transmitter in series with a 12.5 to
40 VDC power supply and a milliamp meter.
CAUTION: Do not apply a voltage greater than
40 volts to transmitter terminals or the circuit
will be damaged.
2. Be certain the direct/reverse switch is set to provide
the desired output signal action. In the DIR position, a counterclockwise rotation of the potentiometer shaft (when looking at the label side of the
potentiometer) will cause the output signal to
increase. In the REV position, a clockwise stem
rotation causes the signal to increase. Perform a
stroke calibration whenever the direct/reverse
switch is changed.
WARNING: Keep hands, hair, clothing, etc.
away from moving parts when operating the
valve. Failure to do so can cause serious injury.
3. Stroke the valve to the close position.
4. Referring to Figure 22, adjust the zero adjusting
screw with a small, flathead screwdriver until the
meter reads 4 mA DC.
5. Stroke the valve to the open position.
6. Adjust the span adjusting screw until the meter
reads 20 mA DC.
7. Stroke the valve to the closed position and recheck
the meter for 4 mA DC. Some fine tuning of the calibration may be required. Repeat steps 3 through 7
until 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 Logix
digital positioner has a circular window in the main
cover (as opposed to a diagonal, oblong window in the
earlier model). To retrofit Logix digital positioner to 420 mA analog output, use the following procedure:
1. Remove the main cover (Figure 29).
2. Remove the lower and middle screws holding the
control board in place; discard these screws.
3. Place the analog output board on the lower portion
of the control board and secure with the two longer
screws (6 x 32 1.25-in.) provided (Figure 33).
4. Unplug the orange/red/brown or brown/red/orange
three-wire-set from the collector board.
5. Plug the orange/red/brown or brown/red/orange
three-wire-set into the correct receiver in the analog output board (Figure 26).
6. Plug the three-wire set from the analog output
board into the receiver on the collector board (that
previously had held the orange/red/brown or
brown/red/orange wire-set).
44 25
7. Connect the blue/yellow two-wire-set from the user
interface board to the remaining receiver on the
analog output board (Figure 27).
NOTE: On some boards both set of wires are
red/black but have different connectors - only one
set will be able to be plugged into the analog output
board.
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 Logix
digital positioner has an oblong, diagonal window (as
opposed to a circular window in the newer model). To
retrofit an existing Logix digital positioner to 4-20 mA
analog output, use the following procedure:
1. Remove the main cover and the user interface
cover from the Logix unit (Figure 29).
2. Disconnect the ribbon cable that connects the control board from the collector board.
3. Remove the three screws holding the control board
in 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 interface board to the collector board.
9. Feed the user interface two-wire-sets in the housing, placing the wires in the trough at the bottom of
the housing. Connect the red/black two-wire-set to
the collector board where the old user interface
wire-set was connected. Pull the new blue/yellow
feedback two-wire-set so that it is next to the
red/black two-wire-set on the collector board.
NOTE: With some boards both sets of wires are
red/black but have different connectors. The feedback wire-set will be connected later to the analog
output board.
10. Carefully replace the control board, ensuring that
the clear pressure hose found inside the Logix unit
is not pinched.
11. Place the analog output board on the lower portion
of the control board and secure with the two longer
screws provided. Secure the top of the control
board with the original shorter screw (Figure 33).
12. Connect the control board ribbon cable to the collector board.
13. Unplug the orange/red/brown or brown/red/orange
wire set from the collector board.
14. Plug the orange/red/brown or brown/red/orange
wire set into the correct receiver in the analog output board.
15. Plug the three-wire-set from the analog output
board into the receiver on the collector board that
previously held the orange / red / brown or brown /
red / orange three-wire-set.
7. Install the new user interface board with its two
connectors inserted into the cavity of the housing.
Make sure the O-ring is between the user interface
board and the housing (Figure 32).
16. Connect the blue/yellow two-wire-set from the user
interface board to the remaining receiver on the
analog output board. NOTE: With some boards,
both two-wire-sets are red/black but have different
connectors - only one set will be able to be plugged
into the analog output board. Complete the installation by placing the Quick-Cal sticker on the control
board can and the user interface sticker in the user
interface cover (Figures 14 and 15).
8. Install the three screws to secure the user interface
into the housing. Tighten to hand-tight.
17. Replace the main cover and the user interface
cover.
6. Remove the three screws holding the user interface
board in place. Save these screws as well as the
O-ring that goes between the user interface board
and the housing (Figure 31).
44 26
Figure 23: Logix 1200e Positioner with
Circular Window Design
Figure 26: Installation of Three-wire-set to
Analog Output Board
Figure 24: Logix Positioner with
Cover Removed
Figure 27: Completed Installation of
Analog Output Board
Figure 25: Installation of
Analog Output Board
44 27
Diagonal Window Design
Figure 31: Removal of
Old User Interface Board
Cover Removed
Figure 32: Installation of
New User Interface Board
Figure 30: Removal of Control Board
Figure 33: Installation of Analog Output
44 28
Figure 34: Sticker Application
Figure 35: Completed Installation of
Analog Output Board and
User Interface Board
44 29
Troubleshooting
Introduction
With the analog source, the 4-20 mA signal is converted to a percentage. During loop calibration, the
signals corresponding to 0 percent and 100 percent
are defined.
This guide is designed to assist the user in troubleshooting the Logix™ 1200e digital positioner. The
Logix 1200e positioner is a two-wire, HART communication-based device, and is used in conjunction with
ValTalk™ and SoftTools™ software or the HART 275
handheld communicator. As part of this troubleshooting guide, a number of recommendations are provided, which should improve operation and allow for
accurate configuration.
At this point, the command value is passed through a
characterization/limits modifier block. The positioner
no longer uses cams or other mechanical means to
characterize the output of the positioner. This function
is performed by the software, which allows for user
adjustment in the field.
The positioner has two basic modes: Linear and Custom characterization. In the Linear mode, the command signal is passed straight through to the control
algorithm in a 1:1 transfer. If Custom characterization
is enabled, the command source is mapped to a new
output curve through a 21-point, user-defined curve. In
addition, two user-defined features, Soft Limits and
MPC (Minimum Position Cutoff), may affect the final
command signal. The actual command being used to
position the stem is called Control Command. The
Control Command is the actual positioning command
after any characterization or user limits have been
evaluated.
Theory of Operation
NOTE: Variable names found in Figure 18 are used in
ValTalk and SoftTools software and can be found in
the Measured Values Status screen.
The Logix 1200e digital positioner receives power
from the two-wire, 4-20 mA input signal. However,
since this positioner utilizes HART communications,
two sources can be used for the command signal:
analog or digital. With the analog source, the 4-20 mA
signal is used for the command source. With the digital
source, the level of the input 4-20 mA signal is ignored
and a digital signal (sent via HART) is used as the
command source. The command source can be
accessed with ValTalk or SoftTools software, or the
HART 275 communicator.
The Logix 1200e positioner uses a two-stage, stempositioning algorithm. The two stages are comprised
of an inner-loop, spool control and an outer-loop stem
position control. Referring to Figure 18, the stem position sensor provides a measurement of the stem
movement. The Control Command is compared
against the Stem Position. If any deviation exists, the
control algorithm sends a signal to the inner-loop control to move the spool up or down, depending on the
Whether in analog or a digital source, 0 percent is
always defined as the valve’s closed position and 100
percent is always defined as the valve’s open position.
Tubed ATO
Air Supply
Control
Algorithm
Command
Source
4–20
(Analog Mode)
Analog
Digital
Command in
(Digital mode)
Linear Mode
Characterization
Soft Limits
MPC
Control
+
Deviation
Command
Pmax
Pmin
Gmult
Integration Summer
Inner Loop Offset
Inner-Loop
Hall Sensor
Output
Sensor
Modulator
Coil Current
D/A Output
Percentage
Inner Loop
Spool Control
Stem
Position
Sensor
Position
44 30
deviation. The inner-loop then quickly adjusts the
spool position. At that point, the actuator pressures
change and the stem begins to move. The stem movement reduces the deviation between Control Command and Stem Position. This process continues until
the deviation goes to zero. The control algorithm is
both proportional and integral. (This algorithm will be
further explained later in this guide.)
The following detailed example explains the control
function:
Given:
Unit is in Analog command source
Custom characterization is disabled
(therefore characterization is Linear)
Soft limits and MPC are disabled
Valve has zero deviation with a present input
signal of 12 mA
Loop calibration: 4 mA = 0% command, 20
mA = 100% command
Actuator is tubed ATO (Air-to-Open)
Given these conditions, 12 mA represents a Command Source of 50 percent. Custom characterization
is disabled, so the Command Source is passed 1:1 to
the Control Command. Since zero deviation exists, the
Stem Position is also at 50 percent. With the stem at
the desired position, the spool valve will be positioned
so that no airflow is allowed to either side of the actuator. This is commonly called the null or balanced spool
position.
At this point, change the input signal from 12 mA to 16
mA. The positioner sees this as a Command Source
of 75 percent. With Linear characterization, the Control Command becomes 75 percent. Deviation is the
difference between Control Command and Stem Position, i.e. Deviation = 75% - 50%= +25%, where 50 percent is the present stem position. With a positive
deviation, the control algorithm sends a signal to move
the spool up from its present position. As the spool
moves up, the supply air is applied to the bottom of the
actuator and air is exhausted from the top of the actuator. This new pressure differential causes the stem to
start moving towards the desired position of 75 percent. As the stem moves, the Deviation begins to
decrease. The control algorithm begins to reduce the
spool opening. This process continues until the Deviation goes to zero. At this point, the spool will return to
its null or balanced position. Stem movement stops
and the desired stem position is now achieved.
One important parameter is now introduced – the
inner loop offset. Referring to Figure 18, a number
designated as the Inner Loop Offset is added to the
output of the control algorithm. For the spool to remain
in its null or balanced position, the control algorithm
must output a non-zero spool command. This is the
purpose of the inner loop offset. The value of this number is equivalent to the signal that must be sent to the
spool position control to bring it to a null position with
zero deviation. This parameter is important for proper
control and will be discussed further in the Control and
Tuning section.
Mounting and Installation
Air Supply Requirements
NOTE: The Logix 1200e positioner requires an external air filter (preferably the Valtek coalescing air filter).
The air supply must conform to ISA Standard S7.3 (a
dew point at least 18° F/10° C below ambient temperature, particle size below 5-microns and oil content not
to exceed one part per million); however, filtering for 1micron particle size is recommended. For a model with
advanced diagnostics (Logix 121X), the internal pressure sensors are rated for continuous operation up to
150 psig (10.3 barg).
Electrical Wiring
First, verify the polarity when making the field termination connection. The Logix 1200e positioner is reverse
polarity protected. With a 4-20 mA source connected,
verify that the positioner’s LED is blinking to determine
if the electronics are running. Only one LED will blink
at any given time. Remember the 4-20 mA input current signal must be greater than 3.5 mA to power-up
the Logix 1200e positioner. Never connect a voltage
source directly across the Logix 1200e terminals. The
current must always be limited for 4-20 mA operation.
NOTE: The Logix 1200e positioners carries an intrinsically safe barrier rating of 125 mA. Currents up to 125
mA will not damage the device.
Frequently Asked Questions
Q: My DCS uses 24 VDC. Can I run a Logix 1200e
positioner?
A: A DCS output current card does run from 24 VDC
but the card regulates the actual current output. However, if the 24 VDC were applied directly across the
terminals, nothing would limit the current and the
Logix 1200e field termination board could be damaged. The important point to remember is that it does
not matter what the current source voltage supply is
as long as the current is limited in the 4-20 mA range.
44 31
Q: I accidentally placed a voltage supply across the
Logix 1200e positioner. How do I know if I damaged
something?
A: The typical failure in an over-current situation is a
short circuit. Your loop current will be maintained but
the Logix 1200e control board will receive no power.
With power removed from the Logix 1200e positioner,
use an ohmmeter to measure the ohms across the terminals. If the reading indicates a short (close to zero
ohms), the field termination board must be replaced.
Make sure the positive lead is on the ‘+’ terminal and
negative lead is on the ‘-’ terminal when measuring the
resistance.
Q: What is the input resistance of the Logix 1200e
positioner?
A: The Logix 1200e positioner does not have a simple
resistive input. When measuring the voltage across
the Logix 1200e positioner, it only varies slightly when
the current is changed from 4 mA to 20 mA (11.7 VDC
to 12 VDC nominal). This is because the Logix 1200e
positioner is an active device. For the Logix 1200e
positioner, effective resistance is commonly referred
to. (Effective resistance is the resistance at a given
current.) To explain further:
Effective Resistance = (Terminal Voltage)/Current
For example, at 20 mA: Effective resistance = 12
VDC/0.02 A = 600 Ω
The Logix 1200e positioner has a specification of 600
Ω @ 20 mA.
NOTE: One cannot measure across the terminals of
an unpowered Logix 1200e positioner and find the
effective resistance.
Air Action
Air-to-open and air-to-close are determined by the
actuator tubing and not the software. When air-action
selection is chosen during configuration, that selection
tells the control which way the actuator is tubed. Verify
that the actuator tubing is correct prior to a stroke calibration. The top output port is called Output 1. It
should be tubed to the side of the actuator that must
receive air to begin the correct action. For example, for
an air-to-open linear actuator, Output 1 should be
tubed to the bottom of the actuator.
Linear vs. Rotary
The positioner has two configuration settings: Linear
and Rotary. For better resolution, stem position sensor
gains are adjusted based on the linkage angle of rotation. The linear setting allows for linkage rotation up to
65°. The rotary setting allows for linkage rotation up to
44 32
95°. These settings only determine the angle of sensor rotation and do not affect control parameters.
If a positioner is set to linear configuration and a red
LED blinks after calibration, the most common cause
is the sensor movement was greater than 65°. This
can occur if the roller pin was placed in the wrong hole
on the follower arm or the stem clamp is placed too
high on the actuator stem. The take-off arm should
always be level with the stem clamp on linear
mountings.
The Logix 1200e positioner has an electrical measurement range of 95°. That is, the electronics will sense
stem position over a 95° range. With a rotary valve, the
typical rotation is 90°. When connecting a Logix 1200e
positioner to a rotary valve, the 90° valve rotation is
centered within the 100° electrical range. If mechanical movement falls outside the electrical measurement
range, the positioner can have a dead band at one end
of travel in which valve movement cannot be sensed.
Q: How do I know if the rotary linkage is centered
within the 95° electrical range?
A: The slot in the take-off arm has enough clearance
around the roller pin to move the follower arm slightly.
Move the valve to the fully closed position. At this position, move the follower arm within the slot clearance. If
the valve does not respond by making an adjustment,
linkage adjustment is necessary. Repeat this test at
the fully open position.
To adjust the stem position linkage, use the Logix variable number 2. This can be viewed as A/D feedback in
the Measured Value screen in ValTalk software or the
Hall pot sensor A/D value in the Condition screen
under View Variables in SoftTools TechCheck. It can
also be viewed from the HART 275 communicator in
the Status/Technician menu. With the valve in its
mechanical fail position (no pressure applied), slightly
move the follower arm while watching variable number
2. If the number does not change, the arm is not centered in the electrical range. (The number will jump
one or two counts due to noise at a fixed position and
should not be considered a change. It should move
greater than 10 to 20 counts if the linkage is centered
correctly.) If necessary, rotate the take-off arm or feedback sensor to bring the linkage in range.
NOTE: Due to the speed of HART communication,
allow two to three seconds for the display to update
after each adjustment.
This procedure is only necessary on a rotary mounting. For linear mountings, the red LED will blink if 65°
travel is exceeded. Refer to the Calibration section for
further information on stroke calibration errors.
Calibration
Quick-Cal Function
The Quick-Cal™ function is a method by which the
valve can be stroke calibrated without using ValTalk or
SoftTools software or the HART 275 communicator.
NOTE: This feature is provided to allow stroke calibration in the event a HART interface is not available. This
allows the valve to be placed in operation. However,
full configuration can only be accomplished through
ValTalk, SoftTools or the HART 275 handheld communicator.
The Quick-Cal function only affects the stroke calibration parameters. Any previous configuration or stored
information is not affected. If the positioner loop current has not been calibrated in the field, it defaults to a
loop calibration of 4 mA being a 0 percent command
and 20 mA being a 100 percent command. This cannot be changed without HART interface. If the loop
has been calibrated in the field, these settings will not
be affected by the Quick-Cal function.
Regarding the Linear vs. Custom DIP switch setting: If
the third Quick-Cal DIP switch is set to Linear, the
transfer characteristic from 4-20 mA input signal to
Control Command will be 1:1. If the DIP switch is set
to Custom, custom characterization will be enabled.
The factory custom characterization curve is equal
percent. If the characterization curve has been modified in the field, the modified curve will be used.
NOTE: The DIP switch settings only become effective
if the Quick-Cal button is pressed for five seconds. If
the Quick-Cal function is not used, the DIP switch settings have no effect on positioner operation.
Command 0% Calibration Flag
During loop calibration, the Logix 1200e positioner
checks if the value read with the current at the desired
0 percent command level is within range. This error
normally indicates that the loop current was set above
21 mA during this part of the calibration procedure.
(See How to Clear Flags section on page X.)
Command 100% Calibration Flag
During loop calibration, the Logix 1200e positioner
checks if the value read with the current at the desired
100 percent command level is within range. This error
normally indicates that the loop current was set above
21 mA during this part of the calibration procedure.
(See How to Clear Flags section on page X.)
Position 0% Calibration Flag
During stroke calibration, the Logix 1200e positioner
checks if the linkage is placing the stem position sensor in range. If the valve stroke causes stem position
measurement to move out of range in the closed position, a Position 0% flag will be generated. The valve
stem will stop in the closed position and the red LED
will blink. The linkage must then be adjusted to bring
the sensor in range. (See How to Clear Flags section
on page X.)
NOTE: The Logix 1200e positioner has a special LED
indication. If the linkage is out of range, the LEDs can
be used as an adjustment guide. The LED will change
from red to yellow when the linkage is brought into
range. Refer to Stroke Calibration Section.
Position 100% Calibration Flag
During stroke calibration, the Logix 1200e positioner
checks if the linkage is placing the stem position sensor in range. If the valve stroke causes stem position
measurement to move out of range in the open position, a Position 100% flag will be generated. The valve
stem will stop in the open position and the red LED will
blink. Linkage must be adjusted to bring the sensor in
range. (See How to Clear Flags section on page X.)
NOTE: The Logix 1200e positioner has a special LED
indication. If the linkage is out of range, the LEDs can
be used as an adjustment guide. The LED will change
from red to yellow when the linkage is brought into
range. Refer to Stroke Calibration section.
Command Span Flag
Command span is a check during loop calibration to
verify that the input signal changed between a 0 percent reading and a 100 percent reading. The most
common cause for a Command Span flag is forgetting
to change the current source when asked to set the
100 percent current level. Clear a Command Span
Flag by performing a Command calibration correctly.
Position Span Flag
Position span is a check during stroke calibration to
verify that the valve stem moved. The algorithm waits
to detect if no movement is detected when the valve is
automatically stroked open. Although the algorithm
waits for valve movement, if a large actuator (size 200
or 300) is run at low pressures, it may not detect
movement and stop with a Position Span Error. Anything that could prevent the valve from stroking will
generate a Position Span Error (no supply pressure or
malfunctioning spool valve). Clear a Position Span flag
signal by correcting the problem that is preventing the
valve to stroke and re-calibrate the stroke.
44 33
Control and Tuning
Setting P+I Parameters
Using ValTalk or SoftTools software, default tuning
parameters can be selected: Factory A, Factory B, etc.
(with Factory A beginning at the smallest actuator size
and the lowest gain settings). Using the Advanced
option, one can set individual tuning parameters. The
software manuals outline the procedure to adjust
these tuning parameters; however, a few key points
are mentioned below.
Maximum Gain, Minimum Gain, and Gain Multiplier:
These three parameters are related by the following
formulas:
Proportional Gain = Maximum Gain - |deviation| x
Gain Multiplier
If Proportional Gain < Minimum Gain, then Proportional Gain = Minimum Gain
tion, it can add overshoot as well as cause the
positioner to hunt if too large. The recommendation is
that maximum and minimum gains be adjusted while
leaving Integral Gain fixed at 10. Integration is disabled below a stem position of 5 percent and above a
stem position of 95 percent. This is to prevent integration windup from calibration shifts due to lower pressure or a damaged seat, which may prevent fully
closing the valve.
The Integral Summer within the Logix 1200e positioner is clamped at +20.00% and -20.00%. If the integration summer (Variable No.15 in ValTalk or SoftTools
software) is fixed at +20% or -20%, it usually indicates
a control problem. Some reasons for a clamped integration summer are listed below:
• Stroke calibration incorrect
• Any failure which prevents stem position movement,
such as stuck spool, handwheel override, low
pressure
• Incorrect inner loop offset
• Loss of air supply on a fail in place actuator
Writing a zero to Integral Gain will clear the Integration
Summer. The Integral Gain can then be returned to its
original value.
Proportional Gain
Maximum Gain
Gain Multiplier
(Determines Slope)
Minimum Gain
Small Steps
Large Steps
| deviation |
Figure 19: Logix 1200e Proportional Gain
This algorithm allows for quicker response to smaller
steps yet stable control for large steps. Setting the
Gain Multiplier to zero or Max Gain = Min Gain results
in a typical fixed proportional gain.
The higher the Gain Multiplier, the smaller the required
deviation before the gain increases. Default values
upon 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 Valtek
actuator sizes.
The Integral Gain is used primarily for deviations due
to temperature drift within the inner loop spool control.
The factory default value is 10. Although higher numbers can speed the time it takes to reach zero devia44 34
Referring to Figure 1 under Theory of Operation, three
control numbers are summed to drive the inner loop
spool position control: proportional gain, integral summer, and inner loop offset. Inner Loop Offset is the
parameter that holds the spool in the ‘null’ or ‘balance’
position with a control deviation of zero. This value is
written by the factory during production and is a function of the mechanical and electrical spool sensing tolerances. However, if the driver module assembly is
replaced or if the software Reset is performed, adjusting this value may be necessary. The method outlined
below should be used to adjust the Inner Loop Offset:
NOTE: Logix 1200e positioners with embedded code
(revision 0.2 and higher) will automatically calculate
this value during a stroke calibration.
ValTalk and SoftTools Software
1. From the Advanced Tuning Screen send a 50 percent command using 4-20 mA signal or digital mode.
NOTE: Digital mode must be set in Instrument Status screen prior to entering Advanced Tuning
screen.
2. Allow the position to stabilize.
3. Record the D/A output % reading (displayed on the
upper right hand side). This number will vary
slightly; therefore, estimate an average over a brief
period of time.
4. Write this number to the Inner Loop Offset.
SoftTools TechCheck Software
1. From the Custom Tuning screen, select the Adjust
ILO button.
2. Allow the position to stabilize.
3. Write the value shown for D/A Average to Inner
Loop Offset.
NOTE: The actuator must not be saturated (D/A output = 0) while setting the Inner Loop Offset.
HART 275 Handheld Communicator
1. Send a 50 percent command using 4-20 mA signal
or 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 100 percent. 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 used
on the readings obtained from command and stem
position sampling. This filter is internal to the positioner software and is not associated with the external
HART filter. This parameter setting should remain at
0.5.
Spool Valve
The spool valve is a four-way directional valve with
precision features to provide optimal control and lowair consumption. To help prevent a malfunction of the
spool valve, the positioner supply air must conform to
ISA Standard S7.3 (a dew point at least 18 degrees
below ambient temperature, particle size below 5microns, oil content not to exceed one part per million). The standard Valtek coalescing filter is highly
recommended to help meet these requirements.
Small particles, oil that has varnished, corrosion, ice,
burrs, and extreme wear could cause the spool valve
to act abnormally. If the spool valve is suspected of
sticking, check it by performing the following procedure:
1. Make sure the valve is bypassed or in a safe
condition.
until the tab is clear of the slot.
4. Inspect the coalescing filter element in the spool
valve cover for signs of oil, water and debris that
may have come from the air supply. (A clean filter is
white.)
5. Remove the two Phillips-head screws holding the
spool valve to the housing. Inspect the free movement of the spool by carefully sliding the block up
and down on the spool about 0.25 inches (6 mm).
The block should slide on the spool with no resistance. Carefully remove the block from the spool,
ensuring it is removed concentric with the spool.
6. Inspect the block and spool for oil, water, debris
and wear. If oil, water and/or debris are found, the
spool and block can be cleaned with a non-residue
cleaner, lint-free cloth and soft-bristle brush. If wear
is found, replace the driver module assembly or
spool valve. Refer to Spool Valve and/or Driver
Module sections.
7. Before re-assembly, verify the three O-rings are
correctly placed in the counter-bores on the
machined platform where the spool valve block is
to be placed.
machined surface of the housing base as a register. Slide the block toward the driver module until
the two retaining holes line up with the threaded
holes in the base. If resistance is still encountered,
re-clean both parts or replace the driver module
assembly or spool valve.
HART Communication
Current Source Interference
HART communication superimposes two frequencies
(1200e Hz and 2200 Hz) on the DC 4-20 mA current
signal. Some current sources (DCS or 4-20 mA calibrator) can interfere with the HART signal. This may
prevent communication with ValTalk or SoftTools software or the HART 275 handheld communicator. Intermittent communication may also be the result of a
HART incompatible current source. In this case, a filter
is necessary between the current source and Logix
1200e positioner to allow HART communication.
Valtek HART Filter (VHF)
Figure 20 & Figure 21
Flowserve offers a filter (Valtek part no. 10079944)
that must be used on each 4-20 mA line if the current
source interferes with communication. The filter does
not affect the DC current but prevents the source from
affecting the HART frequencies. The filter comes in a
DIN rail mount package.
44 35
NOTE: This filter is not rated for use in hazardous
areas. It should be located between the current source
and the barrier in intrinsically safe applications.
• Rochester Instrument Systems (RIS) CL-4002
• Unomat UPS-I
HART Modem
The HART modem is a device that connects to the
serial communications port of a computer. This
modem converts the RS-232 COM port signals to the
HART signal. A HART modem is required to use
ValTalk software, and is optional in SoftTools since a
MUX can be used in its place. The HART modem
takes power from the RS-232 COM port lines. If using
a laptop computer that is operating on its internal
battery, HART communication may become erratic as
the batteries begin to lose their charge. This is due to
a reduction in HART modem power. At this point,
recharge the batteries or apply AC adapter power to
correct the problem.
Connections
Figure 20: HART VHF Filter
Q: How do I know if I need a VHF?
A: If the current source is interfering with communication, it will affect the ValTalk or SoftTools software and
the HART 275 handheld communicator. If the positioner communicates to ValTalk software or the HART
275 handheld communicator when using one current
source (for example, a 4-20 mA current calibrator) and
not the DCS, it indicates a filter is necessary with that
current source. Some 4-20 mA calibrators that work
without a filter are listed below. If one of these is available, try to connect with ValTalk or SoftTools software
or the HART 275 handheld communicator again. If
communications are established while using one of
these sources, but fails on the original source, a filter
is needed.
The following handheld 4-20 mA calibrators do not
require a filter:
When using ValTalk or SoftTools software or the HART
275 handheld communicator, the leads can be connected anywhere across the 4-20 mA current signal.
The leads are not polarity sensitive. When using a filter, the connection must be made between the filter
output and the Logix 1200e positioner (Figure 21).
Cabling
Because HART protocol uses frequencies of 1200e
Hz and 2200 Hz to communicate, cable type and
length must be considered. High capacitance/foot
cable or long runs can cause erratic communication.
Refer to instructions for correct cable requirements.
Intrinsically Safe Barriers
When selecting an intrinsically safe barrier, make sure
the barrier is HART-compatible. Although the barrier
will pass the loop current and allow normal positioner
control, if not compatible, it may prevent HART
communication.
• Altek Model 334
Figure 21: HART VFH Filter Schematic
44 36
Alarms
Introduction
The Logix 1200e positioner has several internal
alarms that monitor electronics operation. An internal
alarm causes the red LED to blink. Alarms can be
viewed in the Alarm screen of ValTalk software, View
Alert display (by right-clicking on the alarm LED in the
lower right-hand corner of any screen), Alert Details
button with SoftTools TechCheck, or by using the Hot
Key with the HART 275 handheld communicator.
‘Alarms’ differ from ‘alerts’ in that the action of the
positioner may be erratic during the alarm conditions,
while alerts warn a predefined, user-configured condition has occurred that may require service in the near
future. Alarms cause the red LED to blink, while alerts
cause the yellow LED to blink.
12-bit A/D Reference Alarm
The Logix 1200e positioner utilizes a 12-bit analog-todigital (A/D) converter to acquire command and stem
position readings. If the precision reference used by
the A/D drifts outside rated tolerances, the 12-bit A/D
Reference Alarm will become active. A reference error
will cause change in calibration and control readings.
If a continuous 12-bit A/D Reference Alarm exists, the
main PCB assembly must be replaced. Refer to spare
parts kit numbers section.
1.23 V Reference Alarm
The 1.23 V Reference is used by the inner loop spool
position control. If it drifts outside normal tolerances,
the 1.23 V Reference Alarm will become active. If a
continuous 1.23 V Reference Alarm exists, the main
PCB assembly must be replaced. Refer to spare parts
kit numbers section.
12 bit D/A Alarm
The Logix 1200e positioner utilizes a 12-bit digital-toanalog (D/A) converter to send a control signal from
the micro-controller to the inner loop spool positioning
circuit. The output of the D/A converter is independently measured to verify correct operation. A 12-bit
D/A Alarm indicates the D/A may be malfunctioning. If
a continuous 12-bit D/A Alarm exists, the main PCB
assembly must be replaced.
Temperature Alarm
The main PCB assembly contains an ambient
temperature sensor. If the ambient temperature
reading moves outside the operating range (-40° F to
185° F/-40° C to 85° C), the Temperature alarm
becomes active and the red LED blinks. If this alarm is
present and the ambient temperature reading is
incorrect, the main PCB assembly must be replaced.
Refer to spare parts kit numbers section.
Hall Sensor Alarm
As described in the Theory of Operation, the Logix
1200e positioner incorporates an inner loop, spoolpositioning stage. A hall sensor is used for spool control. If the electronics sense a problem with the sensor,
the Hall Sensor Alarm becomes active. Two common
reasons for a Hall Sensor Alarm are a loose or missing cable connection to the Collector Board Assembly
or a broken wire. In the rare event that the actual hall
sensor is defective, the driver module assembly must
be replaced. Refer to spare parts kit numbers section.
Modulator Current Alarm
The pressure modulator is an electro-pneumatic
device that takes a current signal from the electronics
control and generates a pressure that moves the
spool. The Logix 1200e positioner is a loop-powered
device that must run on very low power. During operation, the pressure modulator current is monitored. If
the current draw is not within acceptable parameters
for the given control mode, the Modulator Current
Alarm becomes active and the red LED blinks. The
magnitude of Modulator Coil Current can be viewed as
Variable No. 97 in the Instrument Status screen (ValTalk software), the Condition screen under View Variables (SoftTools TechCheck software) or in the
Status/Technician screen (HART 275 handheld communicator). Listed below are some reasons for a Modulator Current Alarm:
• Pressure modulator minimum pressure too low
• Clogged or restricted orifice
• Malfunctioning or missing cable connection to collector board assembly
• Stuck or sticky spool
• Internal air leaks from tubing, orifice gasket or pressure modulator
44 37
Board Current Alarm
The Logix 1200e positioner is a loop-powered device,
which must run on very low power. During operation,
the current draw of the electronics is monitored. If current draw is excessive and would prevent operation at
3.7 mA, the Board Current Alarm becomes active and
the red LED blinks. The most common cause is a
failed main PCB assembly. If the electronics’ current
draw is excessive, the Logix 1200e positioner will most
likely operate at higher currents (12 mA and above)
but may lose power at lower currents. This error
requires that the main PCB be replaced. Refer to
spare parts kit numbers section.
EEPROM Checksum Alarm
Configuration data is stored in EEPROM. When power
is lost, configuration information is retrieved from
EEPROM and operation resumes. A check is done by
the micro-controller after a power-up to make sure
data saved in EEPROM has not been corrupted. The
checksum is a number that is calculated based on
configuration data. It is also saved in EEPROM every
time data is stored. After a power-up, if this number
does not match the data in memory, an EEPROM
Checksum Alarm is generated and the red LED blinks.
If this occurs, turn off the power to the Logix 1200e
positioner, followed by turning on the power. If the
error does not clear, try saving the configuration data
again using ValTalk or SoftTools software, or a HART
275 handheld communicator. If the previous configuration has not been saved, reset the device and re-configure. If these steps still do not clear the error, the
main PCB assembly must be replaced. Refer to spare
parts kit numbers section.
Pressure Alarms
NOTE: Pressure alarms are only available on models
with advanced diagnostics (Logix 121X).
Advanced diagnostic models add top, bottom and supply pressure sensors on more current models (Logix
1210e) the supply sensor is not included, instead,
supply is calculated using the other pressure sensors.
These sensor readings and alarms are only accessible from ValTalk or SoftTools software, or a HART 275
handheld communicator when the configuration has
been set to Advanced.
The Loss of Pressure Alarm becomes active when the
supply pressure is near the minimum positioner operating pressure of 30 psig (2.1 barg). If the LEDs alternate between red and green, the supply pressure may
44 38
be at the limit threshold. This alarm is meant to alert
the user to low supply pressure as well as complete
loss of pressure.
Both the top and bottom sensors are checked during
actuator calibration. If a calibration reading appears to
be out of range, the appropriate alarm will become
active. The pressure sensors are located on the collector board assembly.
Alerts
MPC (Minimum Position Cutoff)
The Minimum Position Cutoff (MPC) or tight shutoff
feature of the Logix 1200e positioner allows the user
to control the level at which the command signal
causes full actuator saturation in the closed position.
This feature can be used to guarantee actuator saturation in the closed position or prevent throttling around
the seat at small command signal levels. This features
defaults to 1% from the factory (which means it is
enabled).
NOTE: The positioner automatically adds a 1 percent
hysteresis value to the MPC setting to prevent jumping
in and out of saturation when the command is close to
the MPC setting.
Q: I set the MPC at 5 percent. How will the positioner
operate?
A: Assume the present command signal is at 50 percent. If the command signal is decreased, the positioner will follow the command until it reaches 5
percent. At 5 percent, the spool will be driven in order
to provide full actuator saturation. The positioner will
maintain full saturation below 5 percent command signal. Now, as the command increases, the positioner
will remain saturated until the command reaches 6
percent. (Remember the 1 percent hysteresis value
added by the positioner). At this point, the stem position will follow the command signal.
Q: I have MPC set to 3 percent but the valve will not
go below 10 percent.
A: Check to see if the lower soft limit is enabled. The
lower soft limit must be less than or equal to 0 percent
for the MPC to become active. If a positive lower soft
limit is written, this limit will take priority over the MPC
feature.
Soft Limits
Unlike position alerts, soft limits prevent the stem position from moving below or above the configured limits.
If the command signal is trying to drive the position
past one of the limits, the yellow LED will blink but the
stem position will remain at the set limit.
Q: Will soft limits prevent the valve from going to its fail
position?
A: No.
Position Alerts
Position alerts notify the user the valve has traveled
past a configured limit. The default settings are -10
percent and 110 percent, which are outside normal
travel and therefore disabled. Position alerts only
notify the user a limit has been exceeded and do not
limit stem movement. Position alerts will cause the yellow LED to blink.
and added to the travel accumulator. From this new
position, dead band high and low limits are again calculated.
For example, the Logix 1200e positioner has a default
dead band configuration of 20 percent. The valve has
a 4-inch (10 cm) linear stroke. When the valve first
powers up, the command signal is 50 percent. The
unit will calculate a high travel threshold of 70 percent
(50 percent present position plus 20 percent dead
band) and a low travel threshold of 30 percent (50 percent present position minus 20 percent dead band).
As long as the stem position remains greater than 30
percent and less than 70 percent, no additions are
made to the travel accumulator. At this point, assume
the stem position moves to 80 percent, which is outside the present dead band. The Logix 1200e positioner calculates the stem movement and adds this
number to the travel accumulator.
80% (present position) – 50% (previous) =
30% movement x 4-inch stroke = 1.2 inches
Cycle Counter
The cycle counter is another means of monitoring
valve travel. Unlike the travel accumulator, the stem
position must do two things to count as a cycle: 1)
exceed the cycle counter dead band and 2) change
direction. A cycle counter limit can also be written into
the positioner. If this limit is exceeded, the yellow LED
blinks. The cycle counter must be reset to begin a new
count sequence. This must be done after the alert has
been triggered to reset the alert. Do this by clicking on
the reset button in ValTalk or SoftTools software in the
configuration section of the software. With the HART
275 handheld communicator, resetting is accomplished by choosing Configure (3) Cycle/Travel Inf. (9),
Cycle/Travel, Cycle Information (2), Reset Cycle
Counter (4).
Therefore, 1.2 inches (3 cm) is added to the travel
accumulator. New dead band thresholds of 100 percent (80 percent present position plus 20 percent
dead band) and 60 percent (80 percent present position minus 20 percent dead band) are calculated. This
process continues as the stem position moves
throughout its stroke range.
The travel accumulator will need to be reset to begin a
new count sequence. This must be done after the alert
has been triggered to reset the alert. Do this by clicking on the reset button in ValTalk or SoftTools software
(in the Configuration section of the software) With the
HART 275 handheld communicator, resetting is
accomplished by choosing Configure (3) Cycle/Travel
Inf. (9), Cycle/Travel, Travel Information (2), Reset
Travel Accumulator (4).
Travel Accumulator
Position Deviation
The travel accumulator is similar to an automobile
odometer and sums the total valve movement. Using
the user-defined stroke length and travel dead band,
the Logix 1200e positioner keeps a running total of
valve movement. When the positioner first powers up,
high and low dead band limits are calculated around
the present position. When the stem position exceeds
the travel dead band, the movement from the center of
the dead band region to the new position is calculated
If the stem position differs from the control command
by a certain amount for a given length of time, the yellow LED blinks to signify excess deviation. The trip
point and settling times are set from the Configuration
screen of ValTalk and SoftTools software. It is set in
the HART 275 handheld communicator under Configure (3), Position Alerts (9), Deviation Deadband (3)
and Time (4).
44 39
Advanced Features
Standard vs. Advanced Diagnostics
The Logix 1200e digital positioner is available with
either standard or advanced diagnostics. The model
with advanced diagnostics adds top, bottom and supply on more current models (Logix 1210e) the supply
sensor is not included, instead, supply is calculated
using the other pressure sensors. This allows for more
diagnostic calculations such as loss of pressure, friction, advanced signatures, and troubleshooting.
Stroke Length
Stroke length is used by the travel accumulator. When
the stroke length and units are set, the length is used
to determine the total travel accumulated. The travel
accumulator will have the units associated with stroke.
Example: Stroke length is set to 4.0 inches (10 cm). If
the valve is moved from 0 percent to 100 percent, 4
inches will be added to the travel accumulator. The
travel accumulator units will be inches. If stroke length
is 90 degrees for a rotary, the travel accumulator will
now have units of degree. A 0 percent to 100 percent
stroke will add 90 to the travel accumulator.
NOTE: Stroke length is not set or used during calibration.
Q: Can I upgrade from a model with standard diagnostics to advanced diagnostics?
Answer: Yes, but only with the earlier model (the
model characterized by an oblong LED window). The
most current model (1200e, characterized by a round
LED window) cannot be upgraded. A new advanced
collector board assembly can be purchased. Simply
replace the standard collector board with the
advanced collector board. All connectors on the collector board are keyed and unique for easy cable reconnection. Using ValTalk or SoftTools software, or the
HART 275 handheld communicator, configure the
positioner for Advanced Diagnostics and perform an
actuator pressure calibration.
Temperature and Pressure Units
The desired temperature and pressure units can be
set during configuration. Once set, all readings will be
displayed in the desired units.
Custom Characterization
Custom characterization can be thought of as a ‘soft
CAM.’ The user can define a characterization curve
using 21-points. The control will linearly interpolate
between points. Points do not have to be equally
spaced, which will allow more definition at critical
curve areas.
The Logix 1200e positioner has two modes: Linear
and Custom Characterization. Linear is a straight 1:1
mapping of command to control command and does
not use the 21-point curve definition. When Custom
Characterization is disabled, the positioner is automatically in Linear mode. If custom characterization is
enabled, the Logix 1200e positioner uses the 21-point
user defined curve.
Q: Is there a default custom characterization curve?
A: Yes. The Logix 1200e positioner comes with a factory default equal-percent curve as shown in Table III
44 40
.
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
NOTE: Custom characterization points can only be
entered by using ValTalk or SoftTools software. The
HART 275 handheld communicator will only allow the
user to enable or disable the currently stored custom
characterization.
Table IV: Troubleshooting Logix 1200e 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 1. Actuator is tubed for wrong air
input signal
action
1. See Air Action on page 44-32.
1. See Spool Valve on page 44-35.
1. Spool is stuck
Unit does not respond to analog 4-20
mA command
1. Unit is in digital command mode 1. See Theory of Operation on
page 44-30.
1. Error occurred during calibration
1. See Calibration on page 44-33.
44 41
Failure or Problem
Probable Cause(s)
Refer to Section(s)
Calibration
Red LED blinks after a Quick-Cal oper- 1. Positioner configured for Linear
ation. Valve stays in fully open or
operation, but mounted on a
closed position.
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 1. See Quick-Cal Function on
calibration (low or no air supply)
page 44-33. or 44-16.
Rotary valve has a dead band at the
fully open or closed position
1. Mechanical travel is not centered within the electrical measurement 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. See Command 100% Calibration Flag on page 44-33.
1. Current source changed
between two values
Control and Tuning
Valve will not saturate at closed position
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. See Advanced Features on
page 44-40.
Sticking or hunting operation of the
positioner
1. Contamination of spool valve
assembly
1. MPC not enabled
1. See Air Supply Requirements
on page 44-31. See Spool Valve
on page 44-35.
1. Incorrect adjustment of P+I setting
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.
1. Current source problem; May
need HART filter
1. See Current Source Interference on page 44-35.
1. Modem connection not operating correctly
1. See HART Modem on
page 44-36.
1. HART module not enabled in
ValTalk software
1. In Options, select HART protocol
HART Communication
Will not communicate
HART 275 communicator indicates
Generic after it connects to positioner
44 42
1. Handheld not programmed with 1. Contact Flowserve Flow ConValtek DD
trol Division's Houston facility at
281.479.9500.
Failure or Problem
Erratic communications
Probable Cause(s)
1. Maximum cable length or
impedance exceeded
Refer to Section(s)
1. See HART Communication on
page 44-35.
1. HART modem not receiving
enough power. (laptop batteries
low)
1. Interference with I.S. barrier
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. See Hall Sensor Alarm on
page 44-37.
1. Sensor may be damaged
Modulator Current
1. Modulator minimum pressure
may be too low
1. See Modulator Current Alarm
on page 44-37.
1. Clogged orifice
1. Bad cable connection
EEPROM checksum
1. Error when reading non-volatile 1. See EEPROM Checksum Alarm
memory storage
on page 44-38.
Multiple Internal Flags
1. Bad micro-controller on main
PCB assembly
1. Replace main PCB assembly
1. Modulator coil current may be
too high
1. See Modulator Current Alarm
on page 44-37.
LEDs
LED alternates between Green and
Red in normal operation
1. Supply pressure may be close
to minimum of 30 psig (2.1 barg)
No LED blinks during calibration
1. Normal operation
1.
Yellow LED is blinking but valve position 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. See MPC (Minimum Position
Cutoff) on page 44-38.
1. 1% hysteresis around MPC setpoint being considered
44 43
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended
function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety 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 purchaser/user must therefore assume the ultimate responsibility for the proper sizing and selection, installation, operation and maintenance of Flowserve products. The purchaser/user should
read 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 connection 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 a
guarantee 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 product. Because Flowserve is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should
any question arise concerning these provisions, the purchaser/user should contact Flowserve Corporation at any of its worldwide operations or offices.
For more information, contact:
For more information about Flowserve and its products,
contact www.flowserve.com or call USA 972 443 6500
Manufacturing Facilities
Quick Response Centers
1350 N. Mt. Springs Prkwy.
Springville, UT 84663
Telephone 801 489 8611
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45141 Essen, Germany
Telephone (49) 2 01 89 19 5
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5114 Railroad Street
Deer Park, TX 77536 USA
1300 Parkway View Drive
Pittsburgh, PA 15205 USA
Alläe du Quartz 1
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Switzerland
Telephone (41) 32 925 9700
Facsimile (41) 32 926 5422
104 Chelsea Parkway
Boothwyn, PA 19061 USA
FCD VLAIM044 04c© 2000 Flowserve Corpor tion Flowserve Corpor tion V ltek Control Prod cts Tel USA 801 489 8611

Valtek Logix 1200e/1210e Digital Positioner

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