OPERATION AND MAINTENANCE MANUAL 394A5056 PV02-SSFV Flowserve Mark One Valve Flowserve Actutator Flowserve Logix 3200MD Positioner SMC Filter Regulator @ GE Power Generation GENERAL ELECTRIC COMPANY mi 1/6/08 ii/ejos 39445056FLOWSERVE USER INSTRUCTIONS Valtek Mark One and Installation Mark Two Control Valves Operation Maintenance 39445056 tae eed— FLOWSERVE User instructions - Mark One - VLENIM0001-01 07.07 —— Contents 1 General Information 2 Unpacking 3, Installation 4 Quick Check 5. Valve Maintenance 6. Disassembly and Inspection 7. ‘Assembly and Installation 8. Severe Service Trim Options 84 CavControl 82. ChannelStream 33. MegaStream 84. Stealth 86. TigerTooth Figures Figure 1 ~ Mark One Control Valve Body Assembly Figure 2 — Pressure Balanced Mark One Control Valve Body Assembly Figure 3. ~ Exploded View Mark One Body Assembly Figure 4 — Soft Seat Assembly Figure Actuator Stem / Stem Clamp Alignment Figure 6 ~ Mark One with CavControl Trim Body Assembly Figure 7 ~Mark One with ChannelStream Trim Body Assembly Figure 8 ~ Mark One with MegaStream Trim Body Assembly Figure 9 — Mark One with Stealth Trim Body Assembly Figure 10 Mark One with TigerTooth Trim Body Assembly Tables Table | ~ Common Lubricants Table Il - Suggested Bonnet Botting Torque Values Table Ill ~ Troubleshooting Chart Tee 7 394A5056 A 70- FLOWSERVE — rr 12. > © General Information Using The following instructions are designed to assist in Unpacking, installing and performing maintenance a required on Flowserve products. Product users ‘and maintenance personnel should thoroughly review this bulletin prior to unpacking, installing, operat- ing, or performing any maintenance. In most cases, Flowserve valves, actuators and accessories are de~ signed for specific applications (e.g. with regard to medium, pressure, and temperature). For this reason, they should not be used in other applications without first contacting the manufacturer. The product Instal- lation, Operation, and Maintenance Instructions pro- vides important additional safety information. Applicability The following instructions are applicable to the main~ tenance and installation of Flowserve Valtek Mark One ‘and Two contiol valves. These instructions cannot claim to cover all details ofall possible product varia- tions, nor can they provide information for every pos- sible example of installation, operation or maintenance, This means that the instructions normally include only the directions to be followed by qualified personal us- ing the product for its defined purpose. If there are any Uncertainties in this respect, particularly in the event cof missing product-related information, clarification must be obtained via the appropriate Flowsorve sales office. All Flowserve User Manuals are available at ‘ww flowserve.com, Terms Concerning Safety The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instructions to highlight par- ticular dangers and/or to provide additional information ‘on aspects that may not be readily apparent. DANGER: Indicates that death, severe personal injury and/or substantial property damage will ccur if proper precautions are not taken. WARNING: Indicates that death, severe personal injury and/or substantial property damage can occur if proper precautions are nol taken. CAUTION: Indicates that minor personal injury and/or property damage can occur it proper precautions are not taken, NOTE: Indicates and provides additional technical in- formation, which may not be obvious, even to qualified personnel User instructions - Mark One - VLENIMO001-01 07.07 13.2. 16. 16. 17. Compliance with other notes, which may not be partic- ularly emphasized, with regard to transport, assembly, operation and maintenance and with regard to techni= cal documentation (e.g, in the operating instructions, product documentation, or on the product itself) is essential, in order to avoid faults, which can directly or indirectly cause severe personal injury or property damage. Protective Clothing DANGER: Flowserve products are often used in prob- lematic applications (¢.g. under extremely high pres sures with dangerous, toxic or corrosive mediums). When performing service, inspection, or repair opera- tions, alvays ensure that the valve and actuator are ddepressutized and that the valve has been cleaned and is free from harmful substances. In such cases, pay particular attention to personal protection (e.g. protec- tive clothing, gloves, glasses etc.) Qualified Personnel Qualified personne! are people who, on account oftheir training, experience and instruction and their know- edge of relevant standatds, specifications, accident prevention regulations and operating conditions, have been authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers. Contact your local Flowserve representation for a schedule of train- ing schools. Spare Parts Use only Flowserve original spare parts. Flowserve cannot accept responsibilty for any damages that oc- cour from using spare parts or fastening materials from other manufactures. If Flowserve products (especially sealing materials) have been on store for long periods of time check them for corrasion or deterioration be- fore putting them into use. Service / Repair To avoid possible injury to personne! or damage to Products, safety terms must be strictly adhered to. Modifying this product, substituting non-factory parts, or using maintenance procedures other than those outlined in these Installation, Operation, and Mainte- ance Instructions could drastically affect perform- ance, be hazardous to personnel and equipment, and may void existing warranties. Between the actuator and the valve there are moving parts. To avoid injury, Flowserve provides pinch-point-protection in the form of cover plates, especially where side-mounted posi eo] 394A5056 A ‘at70— FLOWSERVE User instructions ~ Mark One - VLENIMO0O1-01 07.07 —— Upper Guide Plu cen (iam #87) Upper Packing (item # 83) . Packing Spacers Body Bolting (item # 94-99), (tem 3 108/114) Lower Packing Bonnet Flange {Item # 83) (itm # 70 | ' Lower Guide Bonnet (item # 83) (tem #40) Bonnet Gasket (item #58) Body (itom #1) Seat Ring Seat (item #20) peeney Seat Gasket (item #55) DTG = Figure 1: Mark One Control Valve Body Assembly an ‘sor- FLOWSERVE — 1.8. 22, 23, 24, tioners are fitted. If these plates are removed for in- spection, service or repair special atention is required, Ater completing work the cover plates must be re- fitted. Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use, all recognized regulations for safety ‘and good engineering practices must be followed. WARNING: Before products are returned to Flowserve {or repair or service, Flowserve must be provided with 2 certificate that confirms that the product has been decontaminated and is clean, Flowserve will not ac- cept deliveries if a cleaning certificate has not been provided. Return authorization is also required before parts are returned. Contact your local Flowserve rep- resentative to obtain return authorization. Storage In many cases, Flowserve products are manufactured from stainless steel, Products nat manufactured from stainless steel are provided with an epoxy resin coat ing. This means that Flowserve products are well Protected from corrosion. Nevertheless, Flowserve Products must be stored adequately in a clean, dry environment, Plastic caps or plywood protectors are fitted to help protect the flange faces and prevent the ingress of foreign materials. These caps should not be removed until the valve Is actually mounted into the system, Unpacking While unpacking the valve, check the packing list against the materials received. Lists describing the valve and accessories are included in each shipping container. When lifting the valve from shipping container, use straps through the yoke legs, or the fiting lugs at- tached to the body bolting for valves over four inch, athe adjusting screw for valves four inch and under. Take cae to position liting straps to avoid damage to the tubing, mounted accessories, or stroke plate WARNING: When lifting a valve be aware that the cen- tre of gravity may be above the ling point. There- fore, support must be given to prevent the valve from rotating. Failure to do so can cause serious injury to personnel and damage to the valve and nearby equip- ment. Contact your shipper immediately if there is shipping damage. Should any problem arse, call your Flowserve repre- sentative A - 34 3.2, 33, 34, 38, 36 ay. User instructions - Mark One - VLENIMO001-01 07.07 Installation DANGER: Before installation check the purchase or der number, serial number, and/or the tag number to ensure that the valve and actuator being installed are correct forthe intended application WARNING: The maximum air supply for most Valtek cylinder actuators is 150 psi (10.3 bar), In some cas- es, the air supply must be limited to less than 150 psi (10.3 bar). This is indicated on a sticker found near the upper air port on the actuator cylinder. An air regulator should be installed to ensure the supply pressure docs not exceed the actuator design pres- sure indicated on the sticker, CAUTION: Do not insulate extensions that are pro- vided for hot or cold services. CAUTION: On valves equipped with air filters, the air filter must point down to perform properly. NOTE: Selecting the proper fastener material is the responsibility of the customer. Typically, the supplier does not know what the valve service conditions or environment may be. Flowserve's standard body bolt ing material is B7/2H. 88/8 (stainless steel) is optional {or applications more than 800° F / 425° C and with stainless steel or alloy body valves. The customer therefore must consider the material's resistance to stress corrosion cracking in addition to general cor- rosion. As with ary mechanical equipment, periodic Inspection and maintenance is required, For more information about fastener materials, contact your Flowserve representative. Pipelines must be correctly aligned to ensure that the valve is not fitted under tension, Fire protection must be provided by the user. Before installing the valve, clean the line of dirt, weld- ing chips, scale and other foreign material. Whenever possible, the valve should be installed in an upright position. Vertical instalation permits easier valve maintenance. This is also important for cryo- genic applications to keep the packing isolated from the flowing medium, permitting the packing tempera ‘ure to remain close to ambient temperature Be sure to provide proper overhead clearance for the actuator to allow for disassembly of the plug from the valve body. Refer to the appropriate actuator User Instructions for proper clearances. Actuator User In- structions are available at wwvwflowserve.com. Double-check flow direction to be sure the valve is installed correctly. Flow direction is indicated by the arrow attached to the body. It welding the valve into the line, use extreme care to avoid excess heat buildup in the valve. Tee 394A5056 A Bat 70=, FLOWSERVE Se User instructions - Mark One - VLENIMO001-01 07.07 38, 3.9, 44 Figure 2: Pressure Balanced Mark One Control Valve Body Assembly It the valve has separable end flanges, verify that the half rings are installed on the valve body before bolting the valve inta the line WARNING: Failure to install half rings on the valve body can cause serious personal injury. Connect the air supply and instrument signal lines. Throttling control valves are equioped with a valve po- sitioner. Refer to the appropriate positioner bulletin for connections, maximum air supplies, and maintenance instructions. An air filter should be installed before the positioner. All connections must be free of leaks. CAUTION: On valves equipped with air fters, the air filter must point dovin to perform propery, uick-check Prior to start-up, check the control valve by following these steps: Stroke the valve and observe the plug position indica~ tor on the stem clamp compared to the stroke indica 42. 43, 44, tor plate, The plug should change position in a smooth linear fashion, NOTE: Due to excessive friction a dry graphite packing can cause the plug stem to move in a jerky fashion Lubrication of graphite packing will provide smoother stroking. Lubrication can be done by using a bonnet lubricator or by liberally coating each packing ring by hand during installation. Please refer to Table | for ists of common lubricants, WARNING: Keep hands, hair and clothing away from all moving parts when operating the valve. Failure to do so can cause serious injury. Check for full stroke by making appropriate instrument signal changes. Check all air connections for leaks. Check packing box bolting for the correct adjustment. Refer to the packing installation manual for specific, details on maintaining the style of packing supplied CRATRONONSER cam 3945056 Ta7O]- FLOWSERVE — A 45, 5A 52. 53. CAUTION: Do not overtighten packing. This can cause excessive packing wear, high stem friction that may impede plug movement and can damage the packing. Over-tightening packing will not improve the stem seal unless the packing has been previously damaged. Damaged packing should be replaced. Make sure the valve falls in the correct direction in case of air fallure. This is done by turning off the air supply and observing the failure direction Valve Maintenance Atleast once every six months, check for proper oper= ation by following the preventative maintenance steps outlined below. These steps can be performed while the valve is in-line and, in some cases, without inter- rupting service. If an internal problem is suspected, refer to Section 6, Valve Disassembly and Inspection. Look for signs of gasket leakage through the end flang- es and bonnet. Re-torque flange and bonnet boting (i required), Refer to Table Il for bonnet bot torque val- ues Examine the valve for damage caused by corrosive ‘umes or process drippings. Ciean valve and repaint areas of severe oxidation Check packing box bolting for proper tightness and packing leakage. I packing leakage is noticed, packing maintenance is required. Refer to the packing installa- tion manual (document number VLAIMO40) for specit- ic details on maintaining the style of packing supplied. CAUTION: Do not overtighten packing. This can cause excessive packing wear and high stem friction that may impede stem movement. Packing that is tight- ened too tight wil typically not seal correctly. User instructions - Mark One - VLENIMO001-01 07.07 NOTE: Due to excessive tition a dry graphite packing can cause the plug stem to move in a jerky fashion. Lubrication of graphite packing wil provide smoother stroking, Lubrication can be done by using @ bonnet lubricator or by liberally coating each packing rng by hand during instalation, Please refer to Table Ifor lst of common lubricants. W& WARNING: Keep hands, hair and clothing away trom all moving parts when operating the valve, Failure to do so can cause serious injury. 5.7. Make sure positioner linkage and stem clamp are se- cutely fastened Ifthe tem clamp is lose, check plug thread! engagement (refer to the *Reassernbly and In- stalltion” section forthe corect procedure on align- ing the plug with the seat). Tighten stem clamp nut NOTE: Reter to the appropriate User Manuals when adjusting postioners and providing maintenance to actuators Curent User Manuals ar avail at wav towserv.com 58. _Veity that the takeott arm and follower arm are not binding a either end ofthe stroke, The follower arm attached to the positioner should be free to move slightly when the valve i at both ends ofthe stroke 59. Ensure all accessories, brackets and bolting are se- cutely fastened 5.10. If possible, remove air supply and observe actuator for correct fai-ste action 5.11. Checkrubber actuator bellows for spits, cuts or wea. 5.12. Spray a soap solution around the actuator cylinder te- taining ring and actuator stem guide to check for ar leaks through te O-rings, $13, Clean any dirt and other foreign materia rom the plug stem, 55. It the valve is supplied with a lubricator fitting, check +4. fan arfilter is supplied, check and replace cartidge lubricant suoply and add lubricant if necessary. See necessary, Drain any moisture accumulated in the alr Table | for common lubricants filter, 5.6. Itpossible, stroke the valve and check for smaoth full stroke operation, Unsteady stem movement could in- dicate an internal valve problem, Table I: Common Packing Lubricants Lubricant Manufacturer [Temperature Range | Application Description °F “C Krytox® [1 DuPont 510560 |-2010 285 | Fluorinated general purpose grease; handles common liquids and gasses; good lubricity in harsh mediums; nonfiammable, chemically inert; will nt harm plastic or metal parts GP460 [Acheson Colloids |32to 1000 [OtoS40 | Graphite in petrolatum: high pressure; anti-galing: graphite Company remains above 600°F / 316°C 725 Chesterton 32t0 2600 [0101425 | Nickel, Aluminum and graphite in oll suspension;provides protection with an ultra-thin coating of nickel particles C= ee] 39445056 a o170=, FLOWSERVE —— User instructions - Mark One - VLENIMO001-01 07.07 Gland Flange (hemo) Bonnet Flange (hem 970}, Upper Packing Aer #88) Lower Packing (tem 48) Giand Botting 14108, 117) I —— & Yoke Clamp Bolts (hems 76,1071 Bonnet Gasket (tm #58) Seat Retainer ‘hem 230) Seat Gasket (tem #5) Upper cue oe. “tem #87) —i Packing Spacers tn 8 eee a | a Bonet pug tm = seat Ring iene a re Body Figure 3: Exploded View Mark One Body Assembly 3945056 30r70- FLOWSERVE — 6. 64, 62. 63. 63.1 63.2, 633. 63.4. 64. 65. Valve Disassembly To disassemble the valve body, refer to Figures 1, 2 and 3 then proceed as follows: WARNING: Depressurize line to atmospheric pressure and drain all fluids before working on the valve. Failure ‘to do so can cause serious injury. If valve is ar-to-open, apply air under the piston to lift the plug off the seat before taking the valve apart. if valve is air-to-close, proceed to step 6.3 Remove the bonnet flange bolting and lift actuator, bonnet and plug out of the valve. Once removed, the actuator, bonnet and plug assembly (called the top works) should be lowered and blocked to prevent rall- ing during the disassembly of the top works. WARNING: Danger exists in removing the actuator, bonnet and plug, especially if a pressure balanced plug is used. The pressure balanced sleeve may stick to the plug and fall during disassembly, causing pos~ sible serious injury and damage to the valve or nearby equipment. If sleeve is observed sticking to the plug, steps 63.1 to 6.3.4 should be consulted, CAUTION: Heavy actuators may require a hoist. Lift the valve with the yoke legs using a lifting strap and a hoist, Great care should be taken to lift the actuator and plug straight out of the body to avoid damage to the plug and seat. Ifthe slaeve is observed sticking to the plug during Temoval, fully extend the plug by applying air above the piston, allowing the sleeve to remain in the body and the bonnet to rise above the body. In the gap between the top of the sleeve and the bot- tam of the bonnet, place wooden blocking of equal thickness in at least three places. The wooden blocks ‘must not extend in far enough that they interfere with plug movement. The plug must be allowed to stroke Up to the bonnet. By applying air below the piston, retract the plug unti ‘the plug head is freed from the sleeve. Once the plug is free from the sleeve, remove the plug and bonnet assembly from the body. Lift the pressure balanced sleeve out of the valve body using ltting points on the top ofthe sleeve. NOTE: In many small Mark One valves, the seat re- tainer and pressure balancer sleeve are one and the same part. In larger valves, there are separate pres- sure balancer sleeves and seat retainers Lift retainer, seat ring and gaskets free of the body. Care must be taken not to damage the gasket surfaces in the body when the gaskets are removed. Valves with soft seats (see figure 4) require the seat Ting to be inspected and possibly disassembled Check to see that seating surfaces on the plug and seat assemblies are free of damage. If the seat insert is worn, remove it from the assembly. Since the plug 66. 67. 68. 69. User instructions - Mark One - VLENIMO001-01 07.07 seating surface does not come in contact with the seat insert retainer, itis not necessary to correct any mi- nor damage to that part. The plug seating surface can be re-machined to a 30 degree angle. Lapping is not required when proper reassembly procedures are fol- lowed Loosen the stem clamp and unscrew the plug from the actuator stom, WARNING: Danger exists when working with large valves and heavy parts. Take care to properly sup- port large parts to avoid damage to the parts of nearby equipment or personnel. Remove the packing gland bolting, yoke clamps and Femove the actuator. Ifthe seat surfaces need re-machining, both surfaces ‘on plug and seat ring must be reworked. The seat angle on the plug is 30 degrees (36 degrees for Cav- Control and ChannelStream valves); the seat ring, 33 ‘degraes. Lapping is nat necessary if proper assembly procedures are followed GAUTION: If ro-machining, protect the stem while turing. Ensure concentration ofthe seat surface with the plug stem (or outside diameter of the seat ring, if machining the seat), To replace packing or change the packing box con- figuration, push out packing, spacer and guides from underneath the bonnet with a dowel around 0,13 inch (8.3 mm) larger in diameter than the plug stem. Table Il: Suggested Bonnet Bolting Torque Values BoltStud Material inches) | _carbon Stee! Stainless Steel ftibs [Nm | ftlbs Nm 58 80 10s | 50 68 3i4 s40_[ 190 | 90 122 78 zo | 312 | 150 203 1 350 475 | 220 298 1ie_| 50 | 6 | 330 m7 1a_| 730990 | 460 24 13 | 930 | 1342 | 630 854 tv2_| 1320 | 1790 | 340 1139 tse_| 1710 | 2318 | 1080 1464 taa_| 2170 | 2042 | 1400 1898 17 | 2700_[ 3661 | 1700 2305; 2 3a50_[ 4542 | 2100 2847 394A5056 10 of 70=, FLOWSERVE Se Soft Seat Retainer Soft Set —__ Seat ing Figure 4: Soft Seat Assembly a4 Wrong Correct Figure 5: Actuator Stem / Stem Clamp Alignment User instructions - Mark One - VLENIMO001-01 07.07 6.10. en - 7 72. Tret70 WARNING: For valves equipped with separable end flanges, do nat machine body gasket surfaces. Ma- chining could cause failure of the separable flange lip causing end gasket leakage and valve failure CAUTION: When using separable end flanges and spiral wound gaskets, use gaskets with outer backup rings. Failure to do so could result in excess stress in some applications, Check to see the seating surfaces on both the seat ring and plug are free of damage to ensure tight shutoff Make sure the gasket surfaces on the seat ring, bonnet and body are clean and undamaged. Examine the plug stem and bonnet bore for scoring, scratches, pitting or other damage Refer to the appropriate actuator User Manual for de~ tailed instructions on actuators, Assembly and Installation NOTE: Separate User Manuals with instructions on as- sembling actuators, positioners and other equipment can be found on wwwwflowserve,com. Review any rel evant User Manual before proceeding NOTE: It is recommended that all soft goods are re- placed when rebuilding Mark One and Two control valves. Soft goods include gaskets, pressure balanced seals, soft seat inserts, quide liners and packing seats. Replacing these parts helps to ensure proper function- ing of the control valve. ‘To reassemble the valve body, refer to figures 1, 2 and 6 thru 9 and proceed as follows: It the packing has been removed, refer to the ap- propriate packing User Manual (document number \VLAIMO040) and reinstall the packing and lower guide exactly as shown. Make sure at least 1/8 inch is left at the top of the packing box for the top quide to sit into the bonnet. Different packing spacers permit 2 wide variety of packing configurations, such as twin seal and vacuum-pressure packing, CAUTION: Valves with extended bonnets or metal bellows seals must not have lower packing installed. Instead, lower packing rings should be installed with the upper set. Lower packing installed in extended bonnets or metal bellows seal valves will diminish the integrity of the packing assembly. NOTE: Guide liners should be replaced each time the valve packing is replaced. Do not rebuild the valve without the correct guide liners. 7.3. Revinsert the plug stem into the packing box, being caraful not to score the plug stem or the guides. Rein- stall pressure balanced seals if required 7.4, Tum actuator back onto the plug, without turning the 7» lug inside the bonnet. Make sure the gland flange and bonnet flange are in place before engaging the plug 39445056 A stem and actuator stem threads. The gland flange- FLOWSERVE — 75. 76. >> - 77. 78. 73. 794 79.2. chamfer must be face down towards the valve body. Leave approximately three to four plug stem threads exposed. Attach yoke clamp and gland flange batting For valves with a2-inch spud, be sure the half rings are in place between the yoke and bonnet. Firmiy tighten yoke clamp bolting. The packing box nuts should be just over finger tight NOTE: Do not allow the gland flange to contact and gall the polished plug stem, Install new bonnet and seat gaskets with the bevelled edge up for Teflon gaskets, Insert the seat ring into the body with the step side down. When the seat ring is properly in place it will ‘tum easily in the body. Place the seat retainer into the body with the thin end of the cathedral window down. Most retainers have an arrow pointing up to verity cor- rect installation. For pressure balanced valves, install the pressure balanced sleeve gasket. Ensure that se- vere service retainers are correctly indexed by turning the retainer in the body. Correctly aligned retainers. should turn easily CAUTION: Instaling seat retainers upside down can damage the contral valve parts. CAUTION: Seat rings, retainers and pressure balanced sleeves must be installed squarely into the body to ‘unction correctly. To check to make sure the parts are installed correctly, rotate these parts a litle by hand. ‘The parts should rotate freely without binding, NOTE: When the seat retainer has only two ports, one ofthe two ports should be aligned with the upper port of the body. Place air under the actuator piston on ait-to-open valves to retract the plug, Lower the plug and bonnet squarely into the body. Be careful not to scratch or gal the plug as it enters the body. To properly align the seat ring and plug, frst bring the bonnet bolting to finger-tightness. With pneumatic actuators, apply air pressure above the piston to seat the plug in the seat ring. Proceed to step 7.10. With electric or hydraulic actuators, move the actua- tor stem down until it is completely extended, Next, retract the actuator stem 1/8 inch (3.2 mm). Install the stem clamp onto the plug stem and actuator stem and tighten the associated bolting. Mave the actuator stem completely dovin. Adjust actuator limit switches according to the actuator’s operating manual. The ac ‘uator limit switches will need to be readjusted once the body bolting has been tightened NOTE: Step 7.10 applies only o valves with pneumatic actuators. If an electric or hydraulic actuator is used, return the plug to the mid-stroke position and proceed to tighten, A 7.10, ma 742, 748, 744, 745. User instructions - Mark One - VLENIMO001-01 07.07 CAUTION: Failure to return the plug toa mid-stroke po- sition (electric or hydraulic operators only) will cause damage to the actuator and / or the valve during the bonnet tightening sequence. This is due to the inability of most electric / hydraulic actuators to accommodate the 1/16 inch / 1.60 mm back-drive during the tighten- ing sequence. For airto-close valves, skip this step and go to step 7.11. For airto-open valves, check for proper plug seating as follows: When proper seating occurs, the bonnet flange will be forced up against the finger-tight body bolting with such force that it will be impossi- ble to move the flange. f proper seating does not oc~ cur, the bonnet flange can be wigled with light hand force for small valves and light wrench force for larger valves. Should this occur, place air under the actua~ tor piston and retract the actuator to approximate mid- stroke position. Turn the plug out of the actuator plug stem one additional thread and repeat above seating procedure. When the bonnet flange becomes tight against the finger-tight body bolting, the plug is prop- erly seated. If necessary, repeat abave procedure until proper seating occurs. ‘Stroke the valve open and closed several times to center the seat ring, Retract the plug (open position) Begin tightening the bonnet flange bolting in a manner that will Keep the bonnet flange square / parallel with the body. Tighten the first bolt 1/6 turn, or one nut fat, en tighten the bolt directly opposite 1/6 turn and so fn around the flange. Firmly tighten all bolts evenly and completely to compress the bonnet gasket and to seat the bonnet. Torque the bonnet bolts to the sug- torque values in Table Il. The bonnet will seat metal to metal with the body when the bonnet bolts are correctly torqued into place Apply air over the piston to seat the plug. For all thrat- tling valves, adjust the stem clamp so that with full n= strument signal to the positioner the full signal scribe line on the positioner cam points to the centre of the cam roller bearing, CAUTION: Make sure the slots of the stem clamp are perpendicular to the bolting. See Figure 5. NOTE: For on / off valves, the bottom of the stem clamp should simply be lined up with the bottom of actuator stem + 1/16 inch (1.8 mm), Tighten the stem clamp bolting. Proper tightness is, important since this adjustment secures the actuator stem to the plug stem. Adjust the stroke plate so the stem clamp points to the “closed” position. It the valve has been taken out of the line, make sure the flow arrow indicates proper flow direction upon reinstallation ‘Adjust and test al cessori 394A5056 A Tat 70=, FLOWSERVE Se User instructions - Mark One - VLENIMO001-01 07.07 Figure 6 Mark One with CavControl Trim Body Assembly 8. 81, aA 812 8.2. 8.21. 8.22. 8.23. 3.24. 8244 3.2.4.2 8.2.43. Figure 7 Mark One with ChannelStream Trim Body Assembly 3945056 x 13 of 70 AN Severe Service Trim Options CcavControl CavContol replaces the standard Mark One retainer witha drilled, stepped-hole retainer, see Figure 6, The plug and bonnet have dimensional differences from the standard Mark One design. Assembly and disas: ‘sembly of the valve follows the standard procedures. CavControl retainers, plugs and seats should be ex- amined for excessive cavitation damage when disas- ‘sembled. Holes in the retainer should be checked for worn or eroded surfaces. Check for plugged holes in the retainer. Plugs and retainer mating surfaces should be examined for damage. Repair and replace ment af damaged pats is critical to maintaining eavi- tation resistance CAUTION: To function properly, CavControl is always installed flow over ChannelStream ChannelStream replace the standard retainer with multiple sleeves pinned together, see Figure 7. The plug, seat ring, and bonnet have dimensional difter- ences trom the standard Mark One design. Assembly and disassembly of the valve follows the standard procedures, ChannelSteam retainers, plugs and seats should be examined for excessive cavitation damage when disassembled, The inner holes inthe retainer should be checked for wear or erosion, evidence of ero- sion should require that the retainer is disassembled. Plugs and retainer mating surfaces should be exam- ined for damage. Repair and replacement of damaged pars is critical to maintaining cavitation resistance. CChannelStream retainers shouldbe cleaned of debris whenever the vale is opened. Use the follaving steps if the retainer must be dis- assembled to clean or inspect for damage. Channel- Stream retainers in pressure classes 900 and higher cannot be disassembled in the field. Contact your lo: cal Flowserve representative for service options. Carefully grind away the small bead welds located on the assembly pins near the top of the retainer. This wil loosen the pins which hold the retainer together. Using a punch, locate the hole in the retainer opposite the pin and drive each pin out ofthe retainer The retainer can now be inspected for damage or cleaned Reassemble the retainer sleeves and reinstall the pins making sure to leave an open hole opposite each pin ‘so that the pin can be driven out in the future. Apply a ‘small (1/8 inch) bead of weld to each pin to hold it in place. NOTE: Do not weld more than the approved 1/8 inch. Excessive heat from the bead welds that are too large can disturb critical retainer tolerances, Use an appro- priate weld rod which i compatible with the retainer material. uncertain, contac the factory. CAUTION: To function properiy, ChannelStream is al- ways installed flow over—~ FLOWSERVE User instructions - Mark One - VLENIMO001-01 07.07 — 4.3. MegaStream 8.3.1. MegaStream replaces the standard Mark One retainer witha driled hole retainer, see Figure 8. The plug and bonnet are typically identical to the standard Mark One design. Assembly and disassembly of the valve follows the standard procedures. 8.3.2. MegaStream retainers, plugs and seats should be ex- amined for damage when disassembled, Holes in the retainer should be checked for worn or eraded sur- faces. Check for plugged holes in the retainer. Mutt- stage MegaStream retainers cannot be disassembled Ax Resa and replacement of damaged partis erica to maintaining noise contro CAUTION: To function properly, MegaStream is al \ways installed flow under. Figure 8 Mark One with MegaStream Trim Body Assembly 8.4. Stealth 8.4.1. _ Stealth replaces the standard Mark One retainer with a braised, stacked-disk retainer, see Figure 9. Several of the parts, including the plug, seat ring and bon- net have dimensional differences from the standard Mark One design. Assembly and disassembly of the valve follows the standard procedures. 8.4.2. Stealth retainers, plugs and seats should be exam- ined for damage when disassembled. Holes in the retainer should be checked for worn or eraded sur- faces. Check for plugged holes inthe retainer. Stealth Ax ites cannot be disassembled. Repatr and re- placement of damaged parts is citcal to maintaining noise control, CAUTION: With rare exception, to function properly, Stealth is always installed flow under. 84.3 When reinstalling Stealth retainers, care must be given to orientating the retainer correctly. Stealth re- tainers have an arrow that must be aligned with the valve outlet Figure 9 EDATRONONEET = Mark One with Stealth Trim Body Assembly. 39445056 A Tr ato=, FLOWSERVE Se Figure 10 Mark One with TigerTooth Trim Body Assembly User instructions - Mark One - VLENIMO001-01 07.07 TigerTooth TigerTooth replaces the standard Mark One retainer with @ welded or pinned, stacked-disk retainer, see Figure 10. Several ofthe parts, including the plug, seat ring and bonnet have dimensional differences from the standard Mark One design. Assembly and disas- sembly ofthe valve follows the standard procedures. TigerToth retainers, plugs and seats should be ex- amined for damage when disassembled. The retainer should be checked for worn or eroded surfaces. Check for debris lodged in the retainer. Pinned TigerTooth retainers can be disassembled and cleaned. Care should be taken when reassembling to stack up the discs in the same order Each disc has been etched with a number for that purpose. Welded TigerTooth retainers should not be disassembled outside @ quali- fied service centre, Repair and replacement of dam aged parts is critical to maintaining noise andor cavi- tation control CAUTION: With rare exception, to function properly, TigerToath is always installed flow under. EDATRONONEET = 39445056 & Isat 70- FLOWSERVE — User instructions - Mark One - VLENIMO001-01 07.07 Table III: Troubleshooting Chart Problem Probable Cause Corrective Action Siem motion | 1. Overtightened packing 1. Adjust the packing box nuts to slightly over finger tight impeded 2. Service temperature is beyond | 2. Reconfirm service conditions and contact factory operating limits of trim design Inadequate air supply ‘3. Check for leaks in air supply or instrument signal system; tighten loose connections and replace leaky lines Maltunctioning positioner 4. Refer to positioner User Instructions, Excessive seat leakage Improperly tightened bonnet 1. Refer to step 7.11 Assembly and Installation section for correct tightening procedure Worn or damaged seat ring 2, Disassemble valve and replace ar repair seat ring Worn or damaged seat or bon net gasket Inadequate actuator thrust Incorrectly adjusted plug 4. Check for adequate air supply to actuator; if air supply is adequate, recon- | 5 Reter to steps 7.9 0 7.11 Assembly and Installation section for corect 3. Disassemble and replace gaskets firm service conditions and contact factory plug adjustment Improper flow direction 6, Refer to original specifications or contact factory Improper handwheel adjust- ‘ment acting as alimit-stop 7. Adjust handwheel until plug seats properly Worn or damaged pressure balanced seals Inadequate air supply pressure 19. Check for leaks in alr ‘supply or instrument signal system; tighten loose 8, Disassemble and replace pressure balanced seals, connections and replace leaky lines Inadequate flow Improper plug adjustment, limiting stroke 1. Refer to steps 7.9 to 7.11 Assembly and Installation section for correct plug adjustment Maltunctioning positioner 2, Refer to positioner maintenance instructions Service conditions exceed trim design capacity 3, Verify service conditions and consult factory 4, Incorrect actuator stroke 4 Verily actuator stroke 5 Inadequate air supply pressure ‘5, Check for leaks in air supply or instrument signal system; tighten loose connections and replace leaky lines Plug slams ‘incorrect plug adjustment al- 2 lowing improper cushion of air between actuator piston and yoke Inadequate air supply 3.Trim sized too large for flow rate 2, Check air supply to actuator; repair leaks and remove any restrictions in 43. Verity the service conditions and actuator sizing, install reduced trim 1. Refer to steps 7.9 to 7.11 Assembly and Installation section for correct plug adjustment supply line Valve does not fallin correct position 1 Incorrect flow direction 1. Reconfirm direction and, if necessary, correct flow direction through valve 2 Incorrect actuator fal direction 2, Consult actuator User Manual and change fail direction CATERER = 39405056 Tsar 70—~ FLOWSERVE User instructions - Mark One - VLENIMO001-01 07.07 ee Flowserve Worldwide Flowserve Faw Control Division Flowserve Pte Lis 1350 tt Springs Parkway 12 Tuas Avenue 20 Spragila, UP 84663 Shngapore 638624 usa Singapore Phone: 801489 3611 Prone: 656879 2900, 201 4893718 Fax: 956862 4840, Flowserve Austral Pty Lid Flowserve de Venezuela 1a Damare Dive Zona nds A 68. Scoresby Veoria 3178 No. 1498-155 Zon Industrial I ‘stala Maracabo, Zula 1082 Phone: 61 (3) 9759 3300, Venectela Fax, 61 (8) 8759 3307 Phone: 58261 736,771 Fa 58261 726.1912 Flowserve (usta) GmbH Contra Vaves Vila Oparaton Flowserve comeration Kasernengasse POBox 208 00 vilach 1 Khabar 31852 Ssterrsich ‘Saul Arabia Phone. 43 (0) 4242 41181 0 Phone: 9660857 3146 Fave 43 (0) 4242 41181 90 Fax 9665 4815276 Flowserve india Contls Put i Flowsenve Plot 4, TA’Road #8 EPIP Whiefld Unt 1, 12Dtector Roaa Bangalore, Karaka, 360066 Spartan Ext? Inala Kampton Pare Phone: 91 80 40146700 Gauteng 1613 Fac 8120 28410286, South Ain Phone: 27 (0) 11 923 7300, Fa 270) 11 9746420 00 VLEUIMOOOT-0f 07.07 (Replaces AIC. 00) Noss, Bays Ron vt - ” Suh ndistral Bark, Suzhou sJangsu Proving, PS. 215021, representatv hina To find your local Flowserve representative please use the Chin 512.6288 4720 Sales Support Locator System found a: Fax, 86512 6268 8796 wovwAlowserve.comieontact htm orcall USA 801 489-8611 Flowserve Regional Flowserve Canada Corp. Flowserve Flow Control oad ath Ste ‘ule Response Center monn, Alera TEP 1K6 5114 Raloas Steet Cana Deer Park Texas 77396 Phone: 780-149-4850, Usa Fae 760-448-851 Phone: 281 4799500, St ape ty iis i te ic Yn Fo 281 479 8517 soo Flowserve Flow Control sce i ac el wth : {uk Response Cont Flowserve Flow Control oe : 104 Chalsea Parkuay (ui Response Center Boothuyn, Pennsyvania 2820 W, Carina! Orv Pheri concn terre mir USA feaumnt Texas 77705 ” serena Phone: 610487 8600, Usa Son achat eaten Fax 610497 6680 Pane: 409 842 6600 srl sah Fae 409 8405213, 394A5056 Oe 117 of 70— FLOWSERVE SS Installation, Operation, Maintenance Instructions Valtek Spring Cylinder Linear Actuators GENERAL INFORMATION The following instructions are designed to assist in installing, troubleshooting and servicing Valtek spring cylinder actuators. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating or disassembling the actuator. Separate installation, operation and maintenance instructions cover additional features (such as hand- wheels, limit stops, fail-safe systems or limit switches), This publication does not contain information on Flowserve positioners. Refer to the appropriate instal- lation operation and maintenance instructions for installing, maintaining, troubleshooting, calibrating and operating Flowserve positioners. To avoid possible injury to personnel or dam- age to valve parts, WARNING and CAUTION notes must be strictly followed. Modifying this product, substituting non-factory or inferior parts or using maintenance procedures other than outlined could drastically affect perfor- mance, void product warranties and be hazard- ous to personnel and equipment. WARNING: Standard industry safety practices must be followed when working on this or any process control product. Specifically, personal protection and lifting devices must be used as, warranted. Valtek No, 49012 Unpacking While unpacking the actuator, check packing listagainst, materials received, Lists describing the actuator and accessories are included in each shipping container. 1. Position the lifting straps and hoist to avoid damage to the tubing and mounted accessories when lifting the actuator from the shipping container. WARNING: When lifting an actuator with lifting straps through the yoke legs, be aware the center of gravity may be above the lifting point. Therefore, support must be given to prevent the actuator from rotating or causing serious injury to personnel or damage to nearby equipment. 2. Contact your shipper immediately in the event of shipping damage. 3. Contact your Flowserve representative for any problems, Installation Prior to installation, make sure adequate overhead clearance for the actuators provided to allow for proper, removal from the valve body and for proper mainte- nance. Refer to Table 1 NOTE: if the actuator is attached to a valve body assembly, see Installation, Operation, Maintenance In- structions 1 for overhead clearg ‘394A5056 A Cc 18,0707Table 1: Overhead Clearance for Disassembly ‘Actuator Size Minimum Clearance 25 6 inches 50 8 inches 100,200,300 200; inch 400,500,600 Sinches 4. Connect the air supply and instrument signal air lines to the two appropriately marked connections ‘on the positioner. Since both the cylinder and positioner are suitable for 150 psi air supply, an air regulator should not be used unless the supply ‘exceeds 150 psi, NOTE: In some cases, air supply must be limited to 100 psi rather than 150 psi; this will be indicated by a sticker found near the upper air port on the cylinder. WARNING: To avoid personal injury or eq ment damage, do not exceed recommended ‘supply pressure. 2. Installation of an air filter on the supply line is recommended, 3, Usea soap solution to make sure all air connections are leak free. MAINTENANCE Atleast once every six months, check for proper opera- tion by following the preventative maintenance steps outlined below. These steps can be performed while the actuator is in service and, in some cases, without interrupting service. Ifan internal problem is suspected with the actuator, refer to the "Disassembly and Reas- sembly" section. 1. Examine the actuator for damage caused by corro- sive fumes and process drippings. 2, Clean the actuator and repaint any areas of severe oxidation. 3. If possible, stroke the actuator and check for smooth, full-stroke operation. WARNING: To avoid serious injury, keephands, hair and clothing away from all moving parts while operating the actuator. 4, Make sure positioner mounting bolts, inkage and stem clamp are securely fastened, 5. Ensure all accessories, brackets and associated bolting are securely fastened. 6. Ifpossible, remove air supply and observe actuator for correct fail-safe action. 7. Check rubber bellows for wear. 8, Spray soap solution around the cylinder retaining fing, the adjusting screw and the lower actuator stem bushing to check for air leaks through the O-rings and gasket. 9. Clean any ditt or foreign material from the actuator stem 10. If an air filter is supplied, check and replace cartridge as necessary, DISASSEMBLY AND REASSEMBLY Disassembling the Actuator Referto Figures 1 through 5 to disassemble the cylinder actuator. 1. Shut off air supply. If actuator is installed on a Flowserve valve, remove the valve per Installation Operation, Maintenance Instructions 1 WARNING: To avoid serious injury, depressur- ize the line to atmospheric pressure and drain all fluids before working on the actuator. 2. Disconnect all tubing. Remove stem clamp and stem bellows from the actuator stem 3, Relieve spring compression completely by remov- ing the adjusting screw. Remove adjusting screw gasket from adjusting screw. CAUTION: Do not use a screwdriver or bar to turn the adjusting screw; instead, use a wrench on the flats of the screw. WARNING: To avoid serious personal injury, relieve the spring compression before further disassembly. The cylinder could possibly fly off the yoke when removing the cylinder retaining ring. 4, Remove the cylinder retaining ring from the groove at the base of the cylinder by using two screw- drivers. Insert one screwdriver in siot found in the ring and pry the ring from the groove. Use the other screwdriver to help work the ring out ofthe cylinder groove. 5. Pull the cylinder off the yoke and piston; some ‘O-ring resistance may be felt. WARNING: To avoid serious personal injury, do not use air pressure to remove the cylinder. The cylinder could possibly fly off the yoke. 6. For heavy-duty spring designs using a spring cap (see Figure 4), remove the spring cap and cap ‘O-ring from the cylinder. 7. For air-to-retract configurations, remove the spring(s) and spring button for cleaning andinspec- tion (see Figures 1, 3and 5). Remove the actuator stem locknut and slide the piston and stem spacer off the actuator stem. The spring guide should be removed when using heavy-duty spring designs, NOTE: The dual, heavy-duty spring configuration (Figure 3) has two springs, one inside the other. Remove both springs during this step. 22 39405056 ve Corporation, Valtek Control Products, Tel. USA 801 489 8641 i970(ttom No, 248) Spring Button (tom N9.227) Adjusting Screw Gasket (“YY ‘Adjusting Screw {tom No. 210) cylinder (Item No. 202) Actuator Stem Locknut (tem No. 348) (ttom No. 272) Piston— (tiem No. 225) Upper Stem Bushing— (tem No. 253) ‘Actuator Stem O-ring —~ (tem No. 275) Lower Stem Bushing (item No. 254) ‘Stem Clamp Bolting (tom No. 240/345) Stem Clamp. (tem No. 249), ‘Spring (tiem No. 228) ~ Stem Spacer {tiem No. 223), Piston O-ring (tem No. 271) Yoke O-ring (tiem No. 274) ~ Cylinder Retaining Ring (tem No. 256) “~~ Actuator Stem ret NY ‘Stem Bellows. (tom No. 247), ‘Stroke Plat {tem No. 213) Figure 1: Air-to-retract Cylinder Actuator NOTE: item numbers correspond directly to actuator’ bill of material. Refer to it for specific part numbers. Yoke (Item No, 201) For air-to-extend configurations, slowly loosen and, remove the actuator stem locknut. Be certain the piston follows the stem locknut up the actuator stem and does not bind on the actuator stem. Remove the actuator stem locknut, spring button, piston, spring and stem spacer. WARNING: To avoid personal injury, be certain the spring force is completely relieved before removing actuator stem locknut. Flowserve Corporation, Vatsk Contro! Products, Tel. USA 801 489 8611 8. Remove the piston O-ring, piston stem O-ring and yoke O-ring, 9. Remove the actuator stem O-ring NOTE: The upper and lower stem bushings are pressed into the yoke. Removal of the bushings to replace the actuator stem O-ring is unnecessary. 10. Use appropriately sized press to push worn or damaged bushings out of yoke. 39005056 A 2 of 10Adjusting Screw Gasket-— (tom No. 248), —— Adjusting Screw (tem No. 210) _-~ Actuator Stem Locknut (item No, 348) cylinder: (tem No. 202) Piston (item No, 225) ‘Spring Button— {tem No. 227) Piston O-ring —~ (tom No. 271) Piston Stem O-ring (tom No. 272) ‘Spring Stem Spacer {tem No, 228) Actuator Stem O-ring L-—~ ttem No. 275) Yoke O-ring (tom No. 274) — cylinder Retaini {tem No 229) Upper Stem Bushing ~~ (ttam No. 253), Lower Stem Bushing: (liom No. 254) ‘Stem Clamp Bolting: {Wom No. 240/348) ‘Stem Clamp- (tem No, 258) ‘Actuator Stem (ttem No. 211), Stem Bellows {tom No, 247) Stroke Plate (item No, 213), yoke {tom No 249), {ttom No, 201) Figure 2: Air-to-extend Cylinder Actuator NOTE: Item numbers correspond directly to actuators bil of material, Refer toi for specific part numbers. Reassembling the Actuator To reassemble the cylinder actuator, refer to Figures 1 through 5: 1. AllO-rings should be replaced. New O-rings should be lubricated with a silicone lubricant (Dow Corning 55M or equivalent). Silicone O-rings must be lubri- cated with Magnalube-G lubricant or equivalent. Do not use silicone lubricant on silicone O-rings. 2, Thoroughly clean all internal parts before beginning assembly. Lubricate cylinder wall with silicone lubricant, 3. Lubricate the outside of the replacement bushings ifthe stem bushings have been removed. Press a new lower stem bushing into the actuator stem bore 24 Flowserve Corporation, Vltek Contol in the yoke until it bottoms out. Press the upper stem bushing into the bore until itis flush with the top of the yoke (refer to Figures 1 or 2), . Replace the actuator stem O-ring and yoke O-ring. Reassemble the piston, piston stem O-ring and stem spacer on the actuator stem according to the proper ait-action (refer to either Figure 1 or 2) Replace the piston O-ring, Alt-to-extend configura tions require the spring button to be stored under actuator stem locknut. Tighten the locknut firmly. NOTE: When reassembling heavy-duty, spring- design actuators, the spring guide must be first inserted under the actuator stem locknut (see Figures 3 and 4). EDR 39005056 AAdjusting Screw Gasket ——__ (tem No, 248), Outer Spring — ———Adjusting Screw (item No, 210), cylinder (tem No, 228) (item No, 202) Inner Spring~——___ (tem No, 230) Actuator Stem Locknut. (tom No. 348) Piston Stem O-ri (item No. 272) Spring Button (item No. 227) Spring Guide (iter No, 328) _ Piston O-ring (item No. 271) Piston ——— (tem No, 225) _— Yoke O-ring (item No, 274) Upper Stem Bushing ~ (tam No, 253) Actuator Stem O-ring (tom No. 275) Cylinder Retaining Ring (iter No. 256) ‘Actuator Stem (item No, 219), ‘Stem Clamp Belting (tem No, 240/345) a - "—~ Stem Bellows {tem No, 247) Stroke Plate (item No. 213) —~Yoke Stem Clamp ~ (tem Ne. 249), (item No. 208) Figure 3: Dual-spring Cylinder Actuator NOTE: Item numbers correspond directly to actuators bil of material, Refer toi for specific part numbers. 6. For air-to-extend configurations, place the spring under the piston and insert the actuator stem through the yoke, being careful not to pinch the actuator stem O-ring or gall the stem and stem bushings, For air-to-retract configurations, insert the actuator stem through the yoke and place the spring(s) and spring button above the piston. 7. Replace the cap O-ring and install the spring cap in the cylinder when using heavy-duty spring designs using spring caps (see Figure 4), 8. Install the cylinder, making sure the yoke is pushed deeply enough into the cylinder to aliow the cylinder retaining ring to be installed. Care should be taken not to scar or cut the piston and yoke O-rings. Flowserve Corporation, Vatsk Contro! Products, Tel. USA 801 489 8611 9. Reinsert the cylinder retaining ring by until itsnaps. inplace. Use ahammerand dri punch to lightly tap the retaining ring in the groove. WARNING: To avoid personal injury, the cylin- der retaining ring must be solidly in place. The cylinder could possibly fly off when pressur- ed. Be careful not to pinch or cut fingers on the square edges of the retaining ring during stallation. 10. Reinstall the adjusting screw using anew adjusting screw gasket. NOTE: Be certain the hole in the spring button is directly centered under the adjusting screw hole in the cylinder on air-to-retract configurations. ‘394A5056 A 22 of 70Adjusting Screw Gasket —__ ‘Adjusting Screw (tem No, 210) (tom No, 248), ——— Spring Cap Spring Button (om No, 227), Cap O-ring—_ (Wem No, 270) Actuator Stem Locknut (iter No, 348) Piston Stem O-ring: (item No, 272), Piston—_ (tern No, 225) —~ (tem No. 325) _ Spring (tom No. 228) _— Cylinder fam No, 202) ‘Spring Guide tem No. 328) Piston O-ring (tom No. 271) Yoke O-ring Upper Stem Bushing ~ (item No, 274) (iter No, 253), Actuator Stem O-ring ———— (iter No, 275) Lower Stem Bushing— (ier No. 254) Cylinder Retaining Ring (tom No. 258) “Actuator Stem (tem No. 211) ‘Stem Bellows Stem Clamp Bolting ~ (or No. 240/245), Stem Clamp (tem No, 247) ~~ Stroke Plate ~ (item No, 253) ~ (ter No. 249), ™ Yoke Figure 4: Cap-spring Cylinder Actuator NOTE: item numbers correspond directly to actuators bill of material, Refer to it for specific part numbers (tem No, 201) 11. Tighten the adjusting screw enough to provide an air seal with the gasket. Do not overtighten. 12, Reinstall the stem bellows and stem clamp. NOTE: To ensure maximum clamping strength when installing the stem clamp, make sure the stem clamp bolting is perpendicular to one of the slots ‘machined into the actuator stem. 13. Apply air over the piston, Tighten the stem clamp bolting with the stem clamp adjusted to point at the closed position of the stroke indicator plate. NOTE: if the actuator is installed on a Flowserve valve, refer to Installation, Operaton, Mainto- nance Instructions 1 for correct plug stem thread engagement. 14, Reconnect tubing, supply and signal lines. 26 Reversing the Air-action To change the air action from air-to-retract to air-to extend, or vice versa, refer to Figures 1, 2 or 5: NOTE: Heavy-duty spring actuators are not reversible. 1. Disassemble the actuator according to the "Disas- sembling the Actuator’ section. 2. For air-to-retract action, reassemble the actuator with stem spacer and spring button over the piston. 3. For airto-extend action, reassemble with spring and stem spacer below the piston and with the spring button stored above the piston. 4. Reassemble the actuator according to the "Reas- sembling the Actuator” section, 5. The positioner must also be reversed. See the appropriate positioner maintenance instructions, [S94AS056 page 23 of 70 Flowserve Corporation, Valtsk Control ProbeLifting Ring (ier. 209), ‘Adjusting Serew Adjusting Serew Gasket (aa, 248 Cytindor tem 202) ‘Actuator Stam Lock Nut (ta. 348) Spring Button—_ =a e= Spring Button — itonne 22 ato. |e Semone ND pro. RETRACT stem spacer . . EXTEND hentia Pion Piston Oxving ——_ Piston Stem 0 ae benno 27 Crome 72) ‘Stem Spacer coe e Piston Stem O-ring. Actuator Stem — oem 2, Upper Stem Bushing ‘Actuator Stem O-ring Lower Stam Bushing - Yoke O-ring — (tema 215, Yous (hem, 208) Stroke Plate (remna. 213) Cylinder Retaining Ring vom No. 286) ‘stem Clamp Stem Bellows — /. Stem Clamp Bolt Figure 5: Exploded View, Spring Cylinder Actuator NOTE: item numbers correspond directly to actuator's bil of material, Refer to it for specific part numbers. ‘Storm Clamp Nut (tem 3) i Flowserve Corporation, Vatsk Contro! Products, Tel. USA 801 489 8611 394as0s6 EETroubleshooting Problem Probable Cause Corrective Action High air consumption or | 1. Leaks in the air supply or instru- | 1, Tighten connections and replace any leakage ment signal system leaking lines 2. Maifunctioning positioner 2. Refer to appropriate positioner maintenance bulletin 3. Leaks through O-rings or adjusting | 3. Replace O-rings or gasket screw gasket ‘Actuator does not move to | 1. Air pressure in cylinder not venting | 1. Refer to appropriate positioner {ail position upon loss. because of faulty positioner maintenance bulletin of air supply pressure 2. Spring failure 2. Replace spring 3. Internal valve problem 3. Refer to valve's maintenance bulletin Jerky or sticking 41. Insufficient air supply pressure | 1. Check air supply and any filters or ‘stem travel regulators; check for leaking O-rings 2. Unlubricated cylinder wall 2. Lubricate cylinder wall with silicone lubricant 3. Wom or damaged stem bushings | 3. Check actuator stem for damage’ replace actuator stem, O-ring, and sstem bushings, if necessary 4, Improperly assembled spring 4. Disassemble actuator and check cylinder and piston for damage; reassemble actuator correctly 5. Internal valve problem 5. Refer to valve's maintenance instructions Flowserve Corporation has established industry leadership in the design and manufacture af ts products. When properly selected, this Flowserve produc s designed to perform is intended function safely during ks usefl fe. However, the purchaser or user af Flowserve products should be aware that Flowserve products might be used in numeraus applications under @ wide variety of industrial service Conditions, Although Flowserve can (and often dass) provide general guidelines, t cannot provide specific data and warnings forall possible applications, The purchaserluser must therefora assume tne utimate responsiblity forthe prope sizing and selection, installa- tion, operation and maintonance af Flowsorve products. The purchaserlusar should read and understand the Installation Operation Maintenance (ION) instructions included with the product, and ain is employees and contracors inthe safe use of Flowserve products in connection wits the spectc application. ‘While the information and specificaions presented in this iterature are beloved to be accurate, they are supplied fr informative purposes only and shoule not be considered cerified 0” as a guarantee of salsfacory results by reliance thereon. Nothing contained herein isto be construed as a warranty or quarante, express or implied, rogarding any mattor with respect to this product. Because Flowsorve Is continually improving and upgrading is product design, the specications, dimensions and information contained herein are subject to thhange without naice. Should any question arse concerning these provisions, the purchaserluser sould contact Flowserve Corporation at any of ts worldwide operations or ofices For more information about Flowserve and ts products, For more infarmation, contact contact wivw.owserve.com or call USA 972 443 6500, Regional Headquarters ‘Quick Response Centers 1350 N. ML. Springs Prawy. 5114 Railroad Streot Springville, UT 84063 Door Park, TX 77536 USA Phone 80% 489 8611 Phone 28% 479 9500 Facsimile 801 489 3719 Facsimile 261 479 6511 42 Tas Avenue 20 104 Chelsea Parkway Republic of Signapore 638824 Boothwyn, PA 19081 USA, Phone (65) 862 3332 Phone 810 497 8600, Facsimile (5) 862 4940 Facsimile 610 497 6680, 12, av. du Québeo, BP. 645 1300 Parkway View Drive 91965, Courtaboeuf Cedex, France Pittsburgh, PA 15205 USA Phone (38 1) 60 92 32 TGEDERINGNNEER Ter Facsimile (33 1) 60 92: ‘ows and Valk we aad Vr ol Fosazve Capo 39445056 A FCO VLAIM002-15 ©1999 Flowserve Corporation. Flawserve Corporation, Vatek Contrl 25 of 70FLOWSERVE USER INSTRUCTIONS — Digital Positioner 3200MD Installation Operation Maintenance 394A5056 (ae eT=, FLOWSERVE ——— Contents User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 1._Terms Concerming Safety 38 Maintenance and Repair 2 2 General Information 3 8.1 Diver Module Assembly a Unpacking and Storage 3 82_Reguator 23 3.1_Unpacking 3 '83__Checking or Setting Iteral Regulater Pressure 24 32 Storage 3 84 Spool Vale 25 3.3 _Presnstalaion Inspection 3 85 Spool Valve Cover 25 ‘© Logix 3200M0 Positioner Overview 4 'B6 Stem Position Sensor 26 441 Spectiations 4 87 MainPOB Assembly a 42 Positioner Operation 8 88 Pressure Sensor Board 7 “43 _ Detaled Sequence of Positioner Operations 7 ‘89 Customer interface Board 28 5 Mounting and instalation 8 3 _Oplional Hardware 23 5:1_ Mounting to Valtek Linear Mark One Val 3 9.1 Vented Design 2 '52_ Mounting to Standard Valiek Rotary Valves 3 9.2 HART Modem 30 ‘53 Optional Valtek Rotary Mounting Procedure 1 934-20 mA Analog Output Board 30 ‘54 Tubing Postoner to Actuator 110 Parts List 2 Wiring and Grounding Guidelines ¥2 11 Logix200M0 Spare Pats Kis 4 &1_420mA Command Input Wiring 13 12 Logix3200M0 Mounting Kis 3 %2__Grounding Screw 13 2.1 Valtek Mounting Kits 35 3 _Complance Voltage 13 422, Log 0M. Mounting Kis 36 Cable Requirements 3 323. NAMUR Accessory Mounting KitPart Numbers 38 5 _Intrnsically Sate Bariers 14 18 Frequently Askod Quostions a7 7 Startup 14 14 Howto Ordor 38 7.4 Logie3200M Local Interface 14 15 Troubleshooting 38 7.2__Infial DIP Switch Settings Operation 4 7.3 Operation of Configuration DIP Switch Setings 15 74 Setup ofthe Cal Dip-Swith fr the Quik Calibration operating mode, 16 75__QUICK-CAL Operation % 7.6 Local control of valve postion v7 77_ Factory Reset v7 7.8_Gommand Reset 7 73 7 7.40, Logix 3200MD Status Condition 7 7.AT_VaiveS gt Configuration and Dagnostc Sofware and HART 876 Handheld Communicator 8 Tee 39445056 A TT}- FLOWSERVE ——— 1 Terms Concerning Safety “The stay terms DANGER, WARNING, CRUTION and NOTE ae used in thse insvuctons to hghohtpartizular angers and! orto provide atonal intormation on aspects hat may not be realy apparent (6° DANGER: Indicates that death, severe personal injury and or substantial property damage will occur if proper precau- tions ae not taken, xe WARNING: Indicates that death, severe personal injury and ‘or substantial property éamage can occur i proper precau- tions are not taken, & WARNING: Substitution of components may impair intrinsic safety. ‘A CAUTION: Indicates that minor personal injury andlor prop- erty damage can occur i proper precautions are not taken, NOTE: indicates and provides ational technical information, which ‘may not be very obvious eve to qualified personnel, Compl ance with other, not particulary emphasized notes, with regard to ‘anspor, assembly, operation and maintenance and with regard to technical documentation (eg, inthe operating instruction, product documentation or on the product seis essential, In arder to avoid faults, which in themselves might directly or indirect cause severe personal injury or property damage. 2 — General Information The folowing instructions ate designe oasstin unpack, inslling and peroring maintenance a required on Vat Log® S200MD data ostoners.Sres 300s the tem used forall the postoneshurn; however, sect mumbrsindeate features ‘peat mad (Logi 3200 inst that the postone as HART®pratoel, See Logix 3200MD Mod Number able inthis manual fora breakdown of spec model numbers. Product users and malstnance personnel shoul thoroughly reve ths buletin prior‘ instling, peating, or performing any maintenance onthe vate ‘Separate Vatek Flow Control Products Installation, Operation, Maintenance instructions cover the valve (such as |OM 1 or IOM 27) and actuator (such as OM 2 or 1OM 31) portions of the system and other accessories. Rete tothe appropiate instructions when ths Information is needed, To avoid possible injury to personnel or damage to valve pats, WARNING and CAUTION notes must be stity followed. Modifying ‘his product, substituting nonfactory part or using maintenance User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 procedures other than outined could drastically affect performance and be hazardous to personnel and equipment, and may void exit ing warrants. WARNING: Standard industry safety practices must be adhered to ‘when working on this or any process control product. Specialy petsonal protective and liting devices must be used as warranted 3 Unpacking and Storage 3.1. Unpacking 4. While unpacking the Logix 3200MD pos'tione, check the sacking ist against the materials received. ists desriting the system and accessories are included in each shipping container 2 When lting the system from the shipping conainr, postion ittng straps to avoid damage to mounted accessories, Systems wth valves upto six inches may be ited by actuator iting ring On larger systems, it unit using iting straps or hooks through the yoke legs and outer end of body. WARNING: When iting a valve/actuator assembly with liting strap, be aware the centr of gravity may be above the iting point. Therefore, support must be glen to prevent the valefactuatr from rotting, Faure to do so can cause serous injury to personnel or damage to nearby equipment 3. Inthe event of shipping damage, contact the shioper immediatly. 4. Should any problems arse, contact a Flowserve Flow Control Division representative. 3.2 Storage Control valve packages (a control valve and its instrumentation) can be safely stored in an enclosed building tat affords enviran- ‘mental protection; heating isnot required. Control valve packages must be stored on suitable skids, not diecty on te floor. The storage location must also be fee from flooding, dust, dit, ete 3.3 Pre-installation Inspection Ir a valve control package has been stored for more than one year, inspect one actuator by disassembling It per the appropriate Insta lation, Operation, and Maintenance Instructions ((OM) prior to valve instalation, O-rings are outof-ound, deteriorated, or both, they must be replaced andthe actuator rebul. All actuators must then be disassembled and inspected. the actuator O-rings are replaced, complete the following steps: SECA 3945056 25070=, FLOWSERVE ——— 1. Replace the pressure-balance plug O-tings. 2. Inspect the solenoid and positioner soft goods and replace as necessary. 4 Logix 3200MD Positioner Overview ‘The Logix 3200M0 digital postioner is atwo-wire 4-20 mA input digtal valve postioner. The positioner is configurable through the local user interface, The Logix $200MD uilizes the HART protocl to allow two= \way remote communications with the positioner The Logix 3200MD posiloner can control bath double- and single-actng actuators with linear or rotary mountings. The positioners completely powered by the 4-20 mA input signal. Start up current must beat least 3.6 mA without AO card or 3.85 mA with AO card 44 Specifications comsomy | wowine2ma Peover Supay 10.0 t0 30.0 voe oov0e @20ma 49506 207A pla {420 whan HART communication ste ART rte 3.85 mAh AD boars s00v0e Gomptanee Voge etactve Resistance Communications Diu Operating urea aimum Vaage Tabet: VaiveSight Suite Software Specifications User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 Minimum Perum processor running Windows 85, computer | N20, XP. 32 NB taal memory (4 MB recon " mended, 30 MB avai hard isk space, CD-ROM Pars 7 ri aalabe with & maximum posse, (oan also commmuizate via PMGIA and USB connections) HART Modem | RS-282/POMCIAcaraUSB ~ May be required in conjuneton with some DOS HART iter [haraware HART MUX | MTL aBA0/ELGON 2700 Table: Environmental Conditions Standard Operating Temperature Range Low “anspor and Soren? to 75 (to 0° Temperature Range 40" 0 TBF (0106070) Operating Hmiy 0 100% nor-condensng| "te: The ar supp must conform to ISA Standard ISA 7001 (a dew ont at as 18 dares Farenbet beiw ambient omperature particle Sz below fie mcrons—one micron recomrmended—and ol content not to exceed one part pe mon) Table V: Physical Specifications Housing ateal | Gast powder-pained aluminum, ste ta Soft Goods | Buna-N/Porsieone 13 pounds (48k) aluminum Wit 205 pounds (83h) stars tel Table v: Positioner Spectcations Deadband De fl Repestabiy 0.05% ful sea Lineoty <8 (lay, 8%, lng stm fill sale Ar Consumption | <0. SOFA (0 Nir) 60 psi (é bara) ‘Air Capaty 12 SOF 60 psi A bara} (027 OH) Tee 394A5056 A DoT- FLOWSERVE ——— Table Vl: Hazardous Area Certifications User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 ed a Co Entity Param carer ee oe cope BOD ao foe S Nothoptcatio |T67,., <=60%0 New SCD oxupaero Tasca Class | I Il, Div 4, Groups AB,¢,0 | Ymax = 90 Volts Class 1, Zone 0, AEX ia lIC oe S oomw Jones rc = tone’ ra, vena “10 Ci = 30ni T8T aX gout Bese Gens De, Grins 60 oe et is, 2 Sonny 10 ore = So Tat, < =80% Tyee ee ea 5 10 Cass I, D2, Groups AB.C,D | NotRequired Tat, 5 =80% ‘ee Caio Foret ow | Bk nxneqice —|rscr=-4otco ancy] es | smn 2) Xx | eealtc 1 = soon Tati are 85C) | ogg : zo Tove 282 Mnectoew eee ATEX he a ec eee sere SSeS amen Ter. wee Tara St Wie IECEx Exia tic = 100mA, miami] 2 réc.socwsese) | es a2 Som Baissea Faroe = oo [ease Net Roures retarcens+00o) | os | amma. > racy Sat a (en) reewrceme+sre) | 08 ci 14 (40°C $ Tas + 85°C) (Pos Bs noe waRwins: 1 In arder to maintain the explosionpraofcertficaions de nat remave or loosen covers during operation, 2.To avoid the passibity of stale d'scnarge clean ony with a damp cloth 5. The postoner mut be connactd osutabe rated nrnialy sale equipment, and must be istaled in accordance wth intnsicaly safe instalation standards [3S4A5056 page 30 of 70 5—~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ Table Vi-4 0 20 mA Analog Output Spsctcatins the command source. The command source canbe acessed with “FuanRung fRotbon [495° a Sit Softwa the HART 375 communicator, or oter host Power Supay Range T2si040VOG, avo Dpian SONNE mum Loa Resta oh) | (Sup vokage-12.5)7 0.02 Whether in Analog or Digital Source, OY is alnays defined asthe Curent Signal Output 42018 valve closed poston and 100% is always defined asthe valve open Uneaiy| [hones position. In Analog Source, the 4-20 mA signal is converted toa Repeatability [o2sres percentage, During loop calibration, the signals corresponding to Histeresis [homes (0% and 100% are defined Operating Temperature [40° 176% 40" ac The input signal in percent passes through a characterization’ limits moter block. The positioner no longer uses CAMS or other hanial means to characterize the output ofthe positioner. This, 4.2 Positioner Operation ‘unaion is dane in software, whieh allows for i-he-fld customer “he Logix 3200M0 postianaris an elect feedback nstumant. adjustment. The postiongr has tre basi modes: Linear Equal Figte 1 shows Logic 3200M0 posting instaled ona duble-_Petent -%) and Custom characterization. In Linear mode, the inpt ‘etn near actuator fr aisto-openatn, signals pated saigt through tthe convo lgoti na: trans. In Equal Percent -) made, the input signal is mapped to The LogixS200MD resees power om the Wowie, 420mA Lata st vargeabily ch eae If act santereaton input signal. However, since tis positioner utlizes HART com- ‘munications, two sources can be used forthe command signal: ‘Analog and Digital. n Analog source, the 4-20 mA signals used for the command source. In Digital source, the level ofthe input 4-20 mA signa is ignored and a digital signal, sont via HART, is used as is enabled, the input signal's mapped to ether a default =% output curve ora custom, user-defined 21-point output curve. The custom user-defined 21-point output curve is defined using a handheld or ValveSight software. In adition, two user-defined features, Soft Lim its and MPC (Minimum Position Cutoff), may affect the fina input Figure 1: Logix 3200M0 Digital Positioner Schematic (aito-open configuration) \ \, Sears a j a o a fo , = ~ ie 8 ew a ’ en" — 3945056 A 31 of 70 |- FLOWSERVE ——— Figure 2: System Positioning Algorithm ann | (pe \7 signal. The actual command being used to postion the stem, after any characterization ot user limits have been evaluted is called the onto! Command, The Logix 3200MD uses a two-stage, stem-positoning algorithm The two stages consist ofan inne-loop, spool contra and an outer= loop, stam postion control. Referring again to Figur 1,2 position sensor provides a measurement ofthe stem movement. The Control Commands compared against the Stem Position. If any deviation exists, the control algorithm sends a signal to the ine-loop contro o move te spool up or down, depending upon ‘the deviation, The inner-ioop then quicky adjusts the spool position, The actuator pressures change andthe stem begins to move, The stom movement reduces the devietion between Control Command and Stem Peston. This process continues untl the deviation goes toe. The inne-loop controls the position af the spool valve by means of driver module. The ativer module consists of a tamperature-com pensated hal effect sensor and a piezo valve pressure modulator Tho piezo valve pressure modulator controls the alr pressure under a diaphragm by means ofa piezo beam bender. The piezo beam detects in response to an applied voltage from the innet-loopelac- tronics. As the voltage tothe piezo valve increases, the piezo beam bends, closing off against a nozzle causing the pressure under the diaphragm to increase. As the pressure under the daphragm increases or decreases, the spool valve maves up or down respec tively. The hal effect sensor transmits the postion ofthe spool back ‘tothe inne-4oopeletrones for control purposes. 4.3 Detailed Sequence of Positioner Operations A more detailed example explains the contol function, Assume the Units configured as follows * Unitis in Analog command source. User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 DS < Dame | + Custom characterization is cisabled (therefore characterization is Linear + No soft limits enablee, No MPC set. + Valve has zero deviation witha present input signal of 12 mA, + Loop calibration: 4 mA. mand. ‘command, 20 mA = 100% com- + Actuator is tubed and positioners configured air ‘pen Given these conditions, 12 mA represents a Command source of ‘50 percent. Custom characterization cisabled so the Command source is passed 1-1 to the Controf Command. Since zero deviation nists, the Stem Position is aiso at 50 percent. With the stem at the Rotate Positioner 80° Mounting Batts ¥-20 (4) Cees er A 394A5056 3570- FLOWSERVE ——— 2 With supply pressure of, rotate the follower arm inthe same direction the shaft would rotate upon aloss of supply pressure When the mechanical stop of the follower arm (positioner) is reached, rotate back approximately 15 degrees. 3, Hole the take-off arm in plac; tghton the seraw ofthe take-off NOTE: Te take-off arm shouldbe snug enough to hold the fo lowor am in place but allow movement when pushed 4. Gonnect regulated ar supply to appropriate port in manifold 5, Remove main cover and locate DIP switches and QUICK-CAL button. 6, Refer to sticker on main board cover and set DIP switches accordingly. (A more detailed explanation ofthe DIP switch settings is given in Section 7, “Startup.") 7. Press the QUICK-CAL button for three to four seconds or nti the positioner begins to move. The positioner will now Performa stroke calibration 8. Ifthe calibration was successful the green LED vil lnk GGG ‘or {&GY and the valve wil be n control mode, Continue with step 9 I calibration falled, a indicated by a RGGY blink code, the AD feedback values were exceeded and the arm must be adjusted avay trom the positioners limits. Return to step 2 and Fotate the arm back approximately 10 degrees. NOTE: Remember to remove the alr supply before take-off am. sting 8. Tighten the nut onthe take-off arm, The socket head screw of the take-off arm must be ight, about 40 in NOTE: It the take-off arm sips, the postioner must be recalibrate. WARNING: Failure to follow this procedure will result In positioner and/or linkage damage. Check al-ation and stroke carefuly before lockdown of take-off arm to spline lover adapter. 5.3 Optional Valtek Rotary Mounting Procedure (see Figure 5) The optional rotary mounting applies to Valtek valve/actuato assem- bis that ar equipped with mounted volume tanks or handwheels. User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 ‘The optional mounting uses a four-bar linkage coupled tothe valve shaft. The folowing tools ae required: + W open-end wrench +s oper-end wrench + open-end wrench 1. Using @ 4" open-end wrench and two He-18 x’ bak, attach bracket to actuator transfer case pads. Leave bracket lose to allow for adjustmont 2. Using four %-20% 4" bolts and a open-end wrench, aston positioner to universal bracket, using the four-hoe patter that locates the positioner the farthest from the valve Rotate posi- tioner 90 degrees fram narmal so gauges are facing upward, 3, Attach follower arm to positioner feedback shaft, using the star ‘washer and 10-82 nut 4, Attach tipper and trpper clamp to vale shat using two %-20 bolts and two 4-20 locknuts. Leave tipper lose on shaft until final adjustment ‘5. Thread ballin linkage end to tripper and tighten (thread locking compound suchas Loctite is recommended to prevent back threading). Adjust the length o trod so follower arm and trpper rotate paral to each other the rod must be cut tothe esied length). Connect the other ball ont end to follower arm using a star washer and a 10:32 nut 6, Tighten bracket an tripper bong 7. Check for proper operation, note direction of rotation & WARNING: If rotating in wrong direction, serious dam- age wll occur tothe positioner and/or linkage. Check air action and stroke direction carefully before itating operation 5.4 Tubing Positioner to Actuator The Logix 3200MD digtal positioner i insensitive to supply pres- ‘sure changes and can handle supply pressures from 30 to 150 psig ‘A supply regulator i recommended i the customer wl be using the diagnostic features ofthe Logix 3200MD but isnot required. In applications where te supply pressures higher than the maximum actuator pressure rating a supoly reguatrisrequted to lower the pressure tothe actuato’s maximum rating (not to be contused with EDATRONONEET =r 39445056 A=, FLOWSERVE ——— operating range). An ai iter is highly recommended forall applica tions where ay aris a possibility NOTE: The air supply must confarm to ISA Standard ISA7.0.01 (a dow point at least 18°F below ambiont temperature, particle size below five mizrons—one mieron recammended—and oll content not to exceed one part per milion). ‘Arto-open and atto-lose are determined by the actuator tubing, not the software. When aration selection is made during con- figuration, thal selection tls the contal wich way the actuator has been tubed. The top output ports called Output ft should be tubed tothe side ofthe actuator that must receive air to begin the correct action on increasing signal. Verity that tubing is corect prior toa stroke calibration. Proper ting orientation is ertcal forthe postioner to function correctly and have the proper failure Reler to Figure 1 and folow te instructions below Linear Double-acting Actuators Fora linear air-to-open actuator, the Output 1 port of the positioner manifold is tubed tothe bottom side ofthe actuator. ‘The Output 2 port ofthe positioner manifolds tubed tothe top ‘ide of the actuator. Fora linear air-to-close actuator the above configuration is reversed. Rotary Double-actng Actuators Fora rotary actuator, the Output 1 port ofthe positioner manifold is tubed tothe bottom side ofthe actuator. The Output 2 port of the positioner manifold is tubed to the top sie ofthe actuator. This tubing convention is followed regardless of air action, On rotary actuators, the transfer case orientation determines the ai action Single-actng Actuators For single-actng actuators, the Output 1 ports aways tubed tothe pneumatic side ofthe actuator regardless of ar action. The Output 2 port must be plugges. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 6 — Wiring and Grounding Guidelines (see Figures) © WARNING: This product has electrical conduit connections in either thread sizes ¥° NPT or M20 which appear identical but are notinterchangeable. Housings with M20 threads are stamped with the letters M20 above the conduit opening. Forcing dissimilar threads together will damage equipment, cause petsonal injury and void hazardous location cetti- cations. Conduit fitings must match equipment housing ‘threads betore instalation I threads do not match, obtain suitable adopters or contact a Flowseve representative LH | Haar Terminals Figure 6: Fed Termination =F 420 mA Feedback ferminas(Opona) Housing EARTH Tein Feit wht Terminators Connee hid at Source (round 4-20 mA Caet Soure [20a Gurert Source ECARD =r 39445056 nN +37 of 70- FLOWSERVE ——— 6.1 4-20 mA Command Input Wiring Very polarity when making td termination connection. The Logix 3200 is reverse polaiy protected, Wire 4-20 mA current source to ‘the input terminal labeled 4-20 mA Input on the user interface board (see Figure 6). Never connect a votage source directly across the Log 3200MD terminals. The current must avays be ited for 4-20 mA operation. Minimum operating cutentis 3.6 mA. The input loop curent signal to the Logix 8200MD algal pastoner should be in shielded cable, Shields must be tied to a ground at only ‘ne and of the cable to provide a place for environmental electrical noise tobe removed from the cable. In general, shield wire should be connected atthe source NOTE: The Logix 3200MD positioner caries an intrinsically safe bar- Fier rating of 100 mA. Input currents should not exceed 100 mA, 6.2 Grounding Screw The gteen grounding screw, located inside the termination cap, should be used to provide the unit with an adequate and rlabie earth ground reference This ground shouldbe ted tothe same ‘round as the electrical cond Aditional, the electrical condut should be earth grounded at both ends ofits run, ‘& WARNING: The groon grounding screw must not be used to terminate signal shield wires 6.3 Compliance Voltage (see Figure 7) ‘Output compliance voltage refers to the voltage limit that ean be provided by the current source, A curent loop system consists of the cutent source, wiring resistance, barir resistance present), and the Log 3200MD positioner impedance. The Logix 3200MD digital positioner requires tat the current loop system allows for 10.0 VDC drop across the positioner at maximum loop cutent. The 10.0 VDC drop across the Logix 3200MD positioner terminals is generated by the positioner from the 4-20 mA loop current input Figure 7: Compliance Votage User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 The actual voltage atthe terminals varies trom 8.8 to 10.0 VDC depending onthe curent mA signal, HART communications, and ambient temperature $. WARNING: Never connect a voltage source directly across the positioner terminals, This could cause permanent circuit board damage. Determine if the loop wil support the Logix 3200MD dig posi- tioner by performing the following calulation, Voltage = Compliance Voltage (@Curert...) Current. et Ra) Equation ‘The calculated votage must be greater than 10 VDC inorder to saely support the Logix 2200MD digital positioner. Example: GS Compliance Voltage = 18 VDC Bue = 200.0 n= 250 Curent, = 20 mA Voltage = 19 VDC ~0.020 A- (200.0 + 25 0) 25 V0C The voltage 12.5 VOG is greater than the required 10.0 VDG; there- fore, his system wil support the Logi 2200MD digital poston. ‘The Log 3200MD positioner has a worst case input resistance equivalent to $00 0 ata 20 mA input current 6.4 Cable Requirements ‘The Logxx 3200MD cigital positioner uriizes the HART Commu- nication protocol, This communication signal is superimposed ‘onthe 4-20 mA current signal. The two frequencies used by the HART protocol are 1200 Hz and 2200 Hz In order to prevent E DATRONONGET = 39445056 a ee]=, FLOWSERVE ——— distortion of the HART communication signa, cable capacitance and cable length restrictions must be calculated, The cable length must be limited it the capacitance is too high. Selecting a cable vith lower capacitance/fot rating will alow longer cable runs. In addition to the cable capacitance, the network resistance also affects the allowable cable length. In order to calelate the maximum network capacitance, use the following formal Comma WAYS | RT Rev BUH} ~ 910082 | Fauaton2 Brampl! Ry. = 3000 Ry = 500 Can = 22pF - 0.000022 uF a a 65 (800 + 50+ 380) | 0.0082 = 0.08 UF = Coanena (Hf) conse Msi cae Langh = eG — =n To control cable resistance, 24 AWG cable shouldbe used for runs less than $000 feet. For cable runs longer than 5000 feet, 20 AWG cable should be used 6.5 __Intrinsically Safe Barriers ‘When selecting an intrinsically safe bari, make sure the bari is HART compatible. Athough the barier will pass the loop current and alow normal positioner control, if nat compatile, i may prevent HART communication. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 7 ~~ Startup 7.1 Logix 3200MD Local Interface Operation The Logi 3200MD local userintertace allows the user to conigue the basic operation o he positioner, tune the response, and calibrate the positioner withovt additonal tools o eonfigurators. The Local Interface consists ofa quik calibration button for automatic zet0 and span setting, alongwith two jog buttons for spanning vale: tuatrs with no fied interral stop inthe open poston, Ther is also a switch block containing 8 switches. Six ofthe switches are forbasic configuration settings and one i for calibration option. Thotais also a gain selector swtch for adusting the postionar ain sotings. For iniaton of he operational stats o alarm conditions there are also 8 LEDs onthe local user ntertace Figure 8: Local User Interface eas 7.2 Betore placing the unit in service, set the dip-switehes inthe Config raion and Cal boxes to the desired contro options. Fora detailed Aescription a each dlp-sutchseltng, see sections 182 Initial DIP Switch Settings NOTE: The switch settings in the Configuration box are activated only by pressing the "Quick Cal” button, except Auto-tuneadjust- ‘ments that can be made at anytime Eee] 39485056 i 9 of 70,- FLOWSERVE ——— 7.3 Operation of Configuration DIP Switch Settings The ist 7 Dip Switches ae for basic configuration Ait Aetion This must beset to match the configuration ofthe vale/actuator ‘mechanical twing connection and spring locaton since these deter- mine the ar action ofthe system, ‘ATO (ainto-open) Select ATO if increasing output pressure fram the positioner port ts tube sot il cause the valve to open [ATC (airto-lose) _Selact ATC it increasin output pressure from ‘the positioner port ts tubed soit wl cause the ave to cose Signal at Closed Normal this wil be set to 4 mA fr an Aito-open actuator, and 20 mA or an Ai-to-close actuator configuration. mA Selecting 4 mA will make the vale fly closed when the signals 4 mA and fully open when th signal is 20 mA 20 mA Selecting 20 mA will make the vale full closed wien ‘the signal is 20 mA and fully open when the signalis 4 mA, Pos. Characterization Linear Select the actuator position should be directly proportional tothe input signal. (Due to ther inherent =% char acteristics, this setting give an =% Cy character'stic for most rotary valves) Optional Selectif another characteristic is desired whichis set in conjunction vith the next switch, labeled Optional Pos, Chat Optional Pos. Characterization Ifthe Pos, Characterization switch is set to optional then this switch is active with the folowing options: ‘The =% option wil characterize the actutor response tothe input signal based ona standard 80-1 equal percent rangabilty curve Custom If Customs selected, te positioner willbe charac terized to a custom table that must be set-up using a properly configured HART 275 handheld or other host software. The Detauit setting fo this curve is modified quick open, (also used for a linear Ov characteristic for most rotary valves) Table Vil: Characteristic Curve Data or 7 Command Fre: eta cut Crctatin | | | a ee oo ae a ae saat ew * 0 40 966 40 4 n Ce a : [ie ° | | oes at * a a a ° 5 ‘5671 5 550 ° + =e O10 2 mw so wo 1) ww 10 = ea senna eo or [or Saas User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 A “ao TO ]=, FLOWSERVE ——— ‘Auto Tune This switch controls whether the positioner wil auto tune itself or use preset tuning parameters. (On On enables an auto tune feature that wll automatically determine the positioner gain settings based on the current postion of the selectable “Gain” switch setting and response patameters measured during th lst Quick-Cal, The gain switch is ive meaning the setings can be adjusted at any time by changing the selectable gan switch position, (Note that there is small black arrow indicating the selection. The lots NOT in the indicator) Figure 10: Adjustable GAIN Switch It the selectable GAIN switch is sotto“ withthe auto tune switch on, progressively lower gai settings will be used based on response parameters measured during the lst ‘uick-caL. It the adjustable GAIN selector suite s set to", "6", or withthe auto tune switch on, progressively higher gain setings ill be calculated and used based on response parameters measured during the last QUICK-CAL Iv the selectable GAIN site is set to “A" the tuning will not be modified with a QUICK-CAL.. Use this setting if custom tuning Will be done using @ handheld or other Flowserve software Off Offforces the positioner to use one ofthe factory preset tuning sets determined by the rotary “Gain” selector ‘witch. Settings “A” through “H” are progressively higher gain predefined tuning sets. The Gain selector switch can be adjusted at any ime to modify the tuning parameters NOTE: With Autotune on “E” Is the default adjustable GAIN selactor switch setting for all actuator sizes. Raising or lowering the gain setting isa function ofthe posiionerNalve response to the control signal, and isnot actuator size dependent. Spare Switeh If special features have been purchased they may be controlled ty this switch, Soe special documentation for more details Stability Switeh This switch adjusts te postion control algorithm of the posioner {or use with low-tition contro valves or high-ition automated valves. Placing the switch tothe let optimizes the response for low friction high performance control vales. This setting provides [S94A5056 page 41 of 70 User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 for optimum response times when used with most lw fiction control vaives Placing the switch tothe right optimizes the response for valves and actuators with igh fiction levels. Ths setting slightly slows the response and will normally stop limit cycling that can occur on high friction valves. NOTE: This option is more effective on advanced units with the optional pressure sensors installed 7.4 — Setup of the Cal Dip-Switch for the Quick Calibration operating mode. The eighth DIP switch selects between two calbration options, The function of th Cal DIP switch is descrived below, ‘Auto Select Autoif the valvelactuator assembiy has an internal stop inthe open postion. In Auto mode the positioner vil fully close the vale and register the 0% positon and then open the valve tothe stop to restr the 100% positon when performing a selcaliraton, See detailed instructions in the next section on how to perform an auto positioner calibration ‘Jog Select Jog't the valvalactuator assembly has no calora- tion stop inthe open postion. In the Jog made the positioner wil fully close te value for the 0% position and then walt forthe User tose the open postion using the Jog buttons abel with the up and down arrows. See the detailed instructions in the next section on how to perform a manual calbation using the Jog” buttons. & WARNING: During the QUICK-CAL operation the valve ‘may stroke unexpectedly. Not proper personnel that ‘the valve wil stroke, and make sure the vale is properly isolated 7.5 QUICK-CAL Operation The QUICK-CAL button is used to locally inate acalbration ofthe positioner Pressing and holding the QUICK:CAL button for ap Proximately3 seconds wil inate the calibration. A QUICK-CAL can be aborted at any time by briefly pressing the QUICK-CAL button and the previous settings wil be retained. the Quick calbration switch (be careful not to confuse with the ‘QUICK-CAL button) i set to Auto andthe valveactuator assem- by has the necessary internal stops the calbration will complata alomaticaly. While th calibration i in progress you wll notice a setias of ferent lights flashing indicating the calibration progress. When te lights return toa sequence that starts whh a green light the calibration is complete. (see the table X for an explanation ofthe various light sequences) The ntl calibration of extremely large or very small actuators may equire several calibration attempts. The positioner adapts to the actuator performance and begins each~_~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ callration where the lat attempt ended. Onan intial instalation it is recommended that after the frst successtul calibration that one ‘more calibration be completed for optimum performance. lt the Quick calibration switch is set to Jog, the calibration will Intaly close the valve then cause a small jump in the valve position. The jog calibration process wil only allow the user to ‘manually set the span; zero position is automatically aways set at the seat, If an elevated zero is needed a handheld or other PC based configuration software is required, When performing jag callration the LED's wl lsh ina sequence of -6-Y-R (yellow-green-yellov-red) which indicates thatthe user must use the jog keys to manually position the valve to approximately 100%. When the valve is approximately 100% open press both the and buttons simultaneously to proceed to the next step. The valve will hen stoke and then watt while flashing the ¥-G-V-R sequence agai, allowing the user to adjust the valve position a second time to exactly 100% using the jog buttons. When the stems properly positioned press both the. and buttons simultaneously again ta register the 100% position and proceed [No more user actions are required while the calibration process. is completed. When the ights return toa sequence that starts vith a green ight the calibration is complete. (see the appendix for an explanation ofthe various light sequences) 7.6 — Local control of valve position Local contro of valve position can be done from the user interface by holding both jog buttons while then simutaneously pressing the quick cal button for 3 seconds. The aand ¥ buttons can then be used to postion the valve, While inthis ‘mode the LED's wil lash a YGVY (yellow-green-yellow-yellow) sequence, To ext the local control mode and return to normal ‘operation, briefly press the quick-Cal button © WARNING: When operating using local control of the valve, ‘the valve wil nat respond to external commands. Notily proper personnel that the valve wil not respond to remate ‘ommand changes, and make sure the valve is properly Isolated 7.7 Factory Reset To perform a factory reset, hold QUICK-CAL button while applying power and all ofthe internal varables including calloration willbe reset to factory defauits. The postioner must be e-calbrated afler a factory reset. Tag names and other user configured limits, alarm sittings, and valve information wil aso be lst and need tobe restored & WARNING: Performing a factory reset may result in the inability to operate the valve untl reconfigured propery Notity proper personnel that the valve may stroke, and make ‘sure the valve is propery isolated, 7.8 Command Reset erforming a command reset wil reset the command source to analog It has been inadvertently left in digltal mode. This is done ‘while a QUICK-CAL is in process by holding down both the a. and ‘A. buttons while briefly pressing the QUICK-CAL button, A new ‘QUICK-CAL must be done ater reseting 7.9 Version number checking ‘The version number ofthe embedded code may be checked at any time except during a calibration by holding down the button, This will not alter the operation ofthe unt other than to change the Dlink sequence to 3 blinks indicating the major version number, Holding the button wil give the minor version number without affecting operation. The version codes are interpreted by adding up the numbers assigned according to the following table Table X: Version number checking Per ames bal Value im io Green ° ° ° yelow | 8 |S 1 Red 18 6 z For example if holding the button gave aG-6- code, and holding the W button gave a ¥-¥-G code then the resuiting version number would be (0+0+2) (94340) or version 2.12. 7.10 Logix 3200MD Status Condition ‘The blink codes used to convey the status ofthe Logix 32000 digital positioner are described inthe folowing table. In genera, any sequence starting witha green ight flashing first is normal ‘operating made and indicates that there are no internal problems, Some clagnostic satus results are only avaliable withthe Advanced ‘or Pro diagnostics option EDATRONONEET =r 394A5056 A "42 of 70]=, FLOWSERVE ——— Table X: Logix 320040 Status Condon Codes User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 ry ae ny (GGG _| NORMAL OPERATION indcstes normal, heathy operaton {GEGY [MPC ACTIVE MODE (users) ndicts that Vaht suo (MPC) igh shut not desired revel the Vg shut fs to he comet is active, The command is beyond the ser slit fr tignt | values or aust th command signal inside of the spcied MF huto feature. This is anormal contion fr all vas whan | See OTM scree: Configuation/CustomiPostion Cul tlosed. The factory deat setting tiggars this at command si nals below 1%. Ths indication may also occur on 3 way ahs at both ands of travel ite high MPC valu as een se. {GEVG | LOCAL INTERFACE DISABLED/ENABLED wien OISABLED, iv | flaca conta ls desir hon ta lozal trace must be reanabiod tleales PC settnare has buen used ta dbl he acl inertace, | ram the remote stare, See DTM scree: Coniguain/Babc Lac This ce is only aresent fora shor time when the Quick Gal ntertace. buon is presse. {GEVY [DIGITAL COMMAND SOURCE indicates a HART signals ded [A manual Command Source Rese proved to change he command lo change be positon command and te analog 4:20 mA put [back o analog contol mode from the aa intrface i PC or hand ald signals ignored configurator is po avaiable. This is dane while a QUICK-CAL isin ao ass by holding own both the Jog butons (up and down) whi briy Dressing the QUICK-CAL button. Araw QUICK-CAL must be done ater reseting. Soe DTM scren: Dashboard ‘EGRR | SQUAWK MODE ON/OFF [user sei] When ON. ti indeatesa | This mode ie canceled the Qukcal bun sly pressed. the user has se the pastone to ash a special sequence so that | Squawk madeis selected again remote, or more than ne hour as canbe visual locale passed since the command was sued, See DTM seraen. Configuration! Custom ‘B¥GG__| POSITION LINTT ALERT (user se indicates the poston as Reset the inacatar friar Wavls needed or adjust he comand signal reached ovis excoedin aust defied uper ot loner postion |ackin te spcted range. See DTM screen: ConiguationGustomiPo- indeator sir ta mt ste indcato, ston Cue. Ths nazar can be doles, {¥GY _ | SOFT STOP LIMIT ALERT (user se) indicates the units bang [Reset the im more ravls needed or asst he comand signal commanded to exceed a. user deine upper or lower positon |backin he spectied ange. See DTM sereen: Coniquraion/CustonySon limit and the inal softwares holding the positon atthe mit. | Limi. The functions sila to a mechanal mit stop except tis not sce he unt s un-powered {REG | CYCLES or TRAVEL LIMIT ALERT (user st indicates that one of For vive accumustors ndatons follow routine procedures for ‘the cele or ave ints has been exceeded, The eter and | maintenance when the limits reached suchas checking he packing count mitre se bythe user to track he usage of the vale. | tighness and checking nkages for wear, misalignment, nd tightness. Ther are accumuotars for total ve travel. total va cycles, | Aer maintenance, reset the yee accurulitor. See DTM sean: Heath {otal spoo vale travel anatotl spool valve cycles. Flowsere_|Sats/Postoner Heath, This intr canbe disabled, For spool vale supplis software can identity the specif it that hasbeen | accumulators inspect for hgh ar consumption and signs of west. See reached [DTM seren: Heath StatusPositoner Heath. This indicator canbe deabee ‘YaGY | SIGNATURE IN PROGRESS MODE inccates that atest has been_| Signatures can only be canceled by owserv supplied stare, See inate by Fowsere suppbed sotare DTM seren: agnosis "YaGR | INITIALIZING MODE cisplys a bink sequence 8 ines when te | Wai or power up to compete units powering up. YYEYE | CALIBRATION I$ IN PROGRESS indcsesacalratonispo- | Local calbraton may be caowed by rely pushing the quckel buon, ess. Calibrations such as stoke may be ined localy wth | Remote eabratons can only be canceled by te sofware, the GuickCl Button or tematey. Other calbratios forthe n= Puls and ouput or orssure sensors ae onl ited rote YEY¥ | JOG COMMAND STATE ndistes the unt hasbeen pacedin a Corl he valve using the og batons. This mode may be eancsed by incl override mode where the vive can ony be stoked using [bry pushing the quikal burton the two local joa buts. YYEYR | JOG CALIBRATION STATE indicates that ung ajog calbraon, Use the buitors on the postoner toads te valve tothe dered fly ‘the units waking forthe user to manual aus the vate post | open poston. See the explanation of Jog Calta inthe Quick Za ‘ono the desired 100% open postion section of main document for operation. ‘YG POSITIONER TEMPERATURE WARNING (ser st) indicates the | Regulate the temperature of the postione. the temperature reading is rons have exceeded a temperature iit. The in~ |in error, replace the main board. See OTM scree: Heath Status/Posto ‘um int ofthe ectrongs ad the dau setngs 20°F (40°C) |ner Heath. Thi indleator ean be disabled. Law temperature may hibit responsiveness ana accuracy. The rns and deat sting is 15°F (85°). igh temperature may litte of he postoner ‘YWEY | PRESSURE OUT OF RANGE WARNING inials tha during a | Adjust he soply pressure toa proper value (0-180 pig) so the pos press ort Tw foo smal for optimum performance, tioner can propery calibrate te sensors, Then recalibrate, Bri push the quie-cal button to acknowdge this canton and te positioner wil operate using te current shor stroke clan values vai 39405056 “43 of 70- FLOWSERVE ——— User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 smmendatlons ‘SUPPLY PRESSURE HIGH WARNING indicate the postioner | Regulate the sul pressure a the pastone below he maximum mit, has dotermines thal the supply pressure is above the user at | recommended for your acuatr. Racalate pressure sensor. Check warning kt the pressure sensor board connections. Reglaceocessure sensor boar itnncessry. See DTM soren: Heath StausActator Heath. This indeator can beable, ‘YW | SUPPLY PRESSURE LOW WAANING (user st) indieals atthe |Reguate te supoly assure a th poslonar above 30 PSI 21 supply pressures below the user set waring it Low supely_| ar). Recalbrate pressure sensors. Ensure sytem aga Supls ressure can cause p0ar valve response or postoner lure. | adequate. Repair kinke supply tubing. Check the pressure sensor board ‘Toe minimum ecommended supply pressure is 30 PSI 2.1 az) |eomection an replace pressure sensor board necessary. Check or {or proper operation. The unt wil fal at ss than agprximatey | poeumatc leaks inthe actuator and actuator bing. See DTM sree: 17 PSL(-2 ars). Low suppy pressure indications ean also be | Heath Sttus/Actuator Heath. This inscator can be disable caused by neurite 'YW¥Y | ACTUATION RATIO WARNING (user sai) ndctes «deceased |Tncrease he supply pres. Reduce be rtion, Check he aby ofthe sytem to actuate the va itis based onthe rato_| spring. Resize the actuator. Adjust user set its. See DTM of avalabe fore to required fore to actuate. tis atcted by the |Health StetusRetuator Heath, Ths idieator canbe asabe, process lad ction, sring fre, and avaible supply pressure 'YREG | PILOT RELAY RESPONSE WARNING (user et) inceates at [Cheek esponse ofthe val. FOK adust Plat Rely Response its ie pl reli sticking or slow fo respond. This afcts the | Check supply oressure. Check the spoo for debris, cl, corrosion, ce responsiveness, increases he chance of it oycling and onthe spool. Clean or repiace the spool assembly Replace the piezo ‘excessive ar consumption, The piot lis par ofthe inner | or driver module assembly. Maintin clean, waters aivass supp loop an consist ofthe crver module assembly wit piezo (+P _|See DTM screen: Heath Siats/Psitoner Healt. This indir canbe ralay) whichis coupled to he spool valve, The value ofthis | isabad indicator coresponde with inner loop lag, layed response can because bya paral clogged piezo or debris, i, coresion, ot lee onthe sala ow supply pressure 'YRGY FRICTION LOW WARRING (user sal) incase Ton Fas | Low fiction is uualy an indeabon of moropey aged pacing or sels passed below the user sel ni inthe va and actuator See OTH screen: Healy Satsaive Heath, This indeator canbe disables. "YRGR | PNEUMATIC LEAK WARRING ( Repair preumati laksa te tubing nels and actor seal Ensure ‘ner has detected a leak n he austin assembly. Leakage rom | proper suply pressure, See OTM screen Health Status/Atuator Keath ‘he actuator can cause deceased responsiveness and excessive | This indator canbe diab alga consumption. Low suppypressute can alse tigger his ating 'YAVG | FRICTION AIGH WARNING (user se cates the vahe/actstor | Deerine fie tons sigicanty trong wih the valve contol. ‘tition has passed the user set int. gh ftion ean cause oop_| ol consider increasing the rion waming Lit, Consider the fokoving ‘zllaions. poor poston eatl ely mation, ovave sticking, |t0 reduce ition: Stoke the vat clear of bul p. Clear ay extral IRean be eased by uld-up rom the prose onthe etn tim or | mechaiealobstucton, loosen the packng, clean the stm, rapa oe stat by 2aling Bean or quides inthe vate and actuator | lace the acuato. Highly acai fiction or vr ky ave! cn inate Gling of the tim or stm, exassvlythtened packing Inkages, | ital galing. Repro place interal vale components. See OTN rote vlvelatstr mechani isu. screen Heath Statisivlve Health. This neato canbe dsl 'YARY ELECTRONIC INABILITY TO FAIL SAFE WARNING indicates that [I ala persit or more than 20 minutes, the Piezo assembly is daa the plezo ray be Gamage. This may prevent the prope tale | ged and should be replaced. This indcator can be sable. poston upon loss of signalpawer. This condition may occur Pity ana arose vale that shed for long periods ot ime Inthe closed poston oF and arto-pen ve hein the open positon. ‘YRRR | PNEUMATIC INABILITY TO FAIL SAFE WARRING dicate hat [Check Tor high ston. Repair or plac actuator spring. Reduce po upon oss of ar suppy the valve may not maveto te ti-ste | cess load. This indicator can be csbled poston, The sping slne is nat adequate to overcome the ‘rion and process load inthe system. The system i relying on reumatc fore to actat inthe crcton the spring is pushing ‘he tlsale spring may have fied ort was nt sized propery {or the application. Ficlon or process lad may have increase 'RGGY | FEEDBACK READING PROBLEM DURING CALIBRATION ALARM | Check or loose linkages andor adust the Toedback pao a postion Indias that during calbraon, the ange of motion of the post | loser tothe follower arm pivot a eeate a larger angle o ation ‘91 Feedback am was too smal for optimum pecformanc, othe back rotation sess than 15 degrees forte Iola va travel poston sensor was au of range re. Bray pushing the quckcal buon acknowledges ths fandion an he postoner wll operat sing the cure shat stroke alain if oherwisea good calbraton the condtion doesnot iar ‘then adjust he postonr mounting nkage or feedback gtentiometer ‘ta mow the positon sensor back into ange then estar the calibra on. This eor ma be cleared by bry pushing the quik-cal button, whch lores the pstone ta ue the parameters rom te lst 20d a SERIE = ‘394A5056 ‘OFT=, FLOWSERVE ——— ere User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 ee 'RGGR | INNER LOOP OFFSET TIME OUT ALARM during eaitraton tne | Repet the eroke calration te get more acurate LO value. To Inner Loop Oise vale did nt settle, This could result nls [proceed using te lse accurate ILO value, this error maybe cleared by curate postoning Bri pushing the guikea button, Laverng the gai seling maybe the actuators unstable during the cabration. Gan seins canbe ahysiealy austed on te deve, A lower ter represents wer gah RGVG | NON-SETTLE TIME OUT ALARM indiaes that Gung calbraton, [Check orloose inkages ora loose posona sensor. This ero may be the postion feedback sensors nat sete, cleared by brety pushing the quckcal btn, which wil force te p> stoner o use the parameters fom the st good calibration, Ths erat may appear on some vy smal actuators during the inal calbration Recalibating may cler te robiem. RGVY | NO MOTION TIME OUT ALARM indicates at during ealaton, [Check inkages and ar supply to ake sure he systems propery co there was na main ofthe acuator based onthe crrent stoke | nected. Ifthe ime out occured Because the actuate very large then time configuration. simply rey the duck cal andthe osidoner wit automaticaly adjust for larger actuator by doubing the tine alowed for movement. Ths eror may be cleared by bry pushing te quick-cal button, whic wl force | Ie postoner to sete paamaers rom heat 900d carton, RGRR | FACTORY RESET STATE ndicats th uithas nada factory rset |Calbrate. Prope Valvsight operation wll equre stroke, actuator. and has not yt bee clbrated. The unit il not espond to | trettoneatbation tobe complete, This indeator can be disabled commands and wil remain in he faste poston unt a ela Lon is succesful completed TRYVG | SUPPLY PRESSURE LOW ALARIM (user se) mais thatthe | Regulate the supply pressure a the psibaner above 30 PSI 27 supp pressure is blow the user et alarm im. Low supply bar. Recalrate pressure sensors. Ensure system ags supp is Dressure can cause poor ave response or postoner allure. | adequate, Repair kinked suply tubing. Check the pressure sensor board The minimum recommended supply pressure is 80 PS 21 bar) [connection an replace pressure sensor boat if necessary, Check for for proper operation, Te unt wil fal at ss than approximately | pneumatic less in he actuator and atustor tung. See OTM 17 PSI(12 bas}, Low supply pressure indications can also be | Health StatusActuatr Heath, ‘cause by pneumatic ak TARGG PILOT RELAY RESPONSE ALARM (use st) ndesles thatthe [Check response ofthe vale, OK, ads Plot Relay Response ims Pict lai ticking or extremal iow to respond. Tis tlc |Check ne suppy pressure, Check he spool for deb, ol coosion, the responsiveness, increases th chance of iit eyeing and |e onthe saa. Clan or replace the spool asemaly. Replace he piezo cessive ar consumption, The plat relay consist ofthe atver| er driver module assem, Maintain a clan, water-re agae S40. ‘module assembly with piezo (-P ray) whic 's coupled to _| See DTM screa: Heath Status/Posioner Heath. This inleatr canbe the spool vave, Delayed ratponce canbe caused by apart, | disabled ‘logged piezo or debris ol, corrosion. o athe spo aw supp pressure. TRREY FRICTION LOW ALARW users irdeates th Welon has [Cheek ora packing ak Than or replace he ve packing. See OTM assed below the user set limi. The arm indicates amore | seren: Meath StatusValve Heath. Ths indicator can be csbled, vere condton than the waa, TRRGR FRICTION HIGH ALARM use at indeaae te vaelacuaor [Dalarna fe intone eignieanyIaranng wh he vale conta fiction has patted the use se it.The alarm indeales a mre | faa, eansider increasing the tan waning lt. Consider the severe condton than the warning. High rection can cause loap | folowing to reduce tction: Stroke the vat claro bulld-up. Cea ‘clans, poor postion contro, jrky mation, or valve stckig. | any external mechanial obstruction, loosen te packing, clan the stem, ean be eased by bulup trom the process onthe stem, tim [repair or replace the actuator. High leaized frietion or very jerky travel sat, by fling bearing o guides inthe valve and actua--—_|canindeate intemal galing. Repair or replace internal vive componen- tor galing of the vim or stem excessively tightened packing, |. See DTW screen Hath Sttus/Valve Hea This indator can be Linkages, or other vaveactuator mechanical sues. sabes, FRRVG PIEZO VOLTAGE ALARM idestos te orton ofthe cult Bard | ihe units funcorng and entoing replace the peo, Wit does nat that drives the ez is ba, of iezo vas ses bad opette replace te main cult board_ This ndcator can be disabled. TRRVR PILOT RELAY POSITION LIMIT ALARM indicates he plot lay [Check for adequate sul oessure. Ahall sensor probe may be {spool appears tobe ed at limit ands nat responding. This |lared by brety pushing the quckcl button, which wil force the ‘ould be duet ow supply pressure, ahall sensrtatis out |pastionerto use he parameter rom the last vad calration. Check the of ealbraton,abroken piezo, stuck scl, ora wre connection | intermal wing hamesss for good connections. Check the spool ave problem. for sickng problems. ifthe postione stil doesnot operate replace the | 5, srivr module assembly andor spac assem TARRY ELECTRONICS ERROR OR ALARM indiestes the ternal data ror may st clear wth time. If er persis, cycle power and cor was nat update correct, This may atlect the funtion ofthe [plete a Quek-Cal. Ite eror sil persists, Check internal wiring ané Postionerin varous ways or nota al. This ean be eaused whan [connectors for elec! shots or opens. Ina problems ae found and {intermittent operation occurs when connecting power alan persists, replace the main cicut bard TARAR | POSITION DEVIATION ALARM (users) inceates te Gerence | Review active alarms and warnings tnd root causes os alarm, S22 btiween the eommand andthe actual poston hasbeen greater than the users limit for longer than a users time OTM screen: Alerts/Command Deviton. This instr canbe disabled EDATNONONBET 394A5056- FLOWSERVE ——— 7.11 ValveSight Configuration and Diagnostic Software and HART 375 Handheld Communicator Flowserve Corporation has writen custom configuration and diagnasti software forthe Logix 3200MD algtl posioner called ValveSight This software is available from a Flowserve representa- tive. The Logix 8200MD digital positioner supports and is supported by the HART 375 Handheld Communicator The Device Description (00) fe andthe manval ited below can be obtained from the HART Communication Foundation or from your Flowservereprasen- tative. For mor information please see the folowing guide + Product Manual forthe HART Communicator. Diagnostic features such as the datalog, signature tess, and ramp tests are performed using the ValveSight software. Certain clbra- tion features such as loop calibration, analog output cabration, and actuator pressure sensor ealirations are performed using the HART 8375 Handhelé Communicator or using diagnostic software such as Valveight. 8 — Maintenance and Repair 8.1 Driver Module Assembly The diiver module assembly moves the spool valve by means ofa differential pressure across its diaphragm. Ais routed to the driver module trom the regulator through a flexible hose. A barbed fiting connects the flexible hose tothe driver module assembly. Wires from the driver module assembly connect the hall effect sensor andthe piezo valve modulator to the main PCB assembly Driver Module Assembly Replacement To replace the diver module assembly, refer to Figures 11-18 and 25, and proceed as outined below. The following toos are required + Flat plate o bar aboutV" thick + Philips screwdriver + nutariver & WARNING: Observe precautions for handling electrostati- cally senstve devices. 1. Make sure the vale is bypassed or in a safe condition 2. Disconnect the power and air supply to the unit User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 Remove the diver module cover (Figute 14), using alt bar or plate inthe slot to tun the cover. Remove the spoo! valve cover by removing the screw and sid- ing the cover assembly backwards until theta is clear ofthe sat (Figure 12). The sheot metal cap, hydrophobic fier, and ‘ting should be removed withthe spool valve cover, tis not necessary to take these parts out ofthe spool valve cover Being careful not to lose the nylon washer, remove the Philips wad sorew that attaches the diver module to the main housing (Figure 13), WARNING: Spoo! (extending from the driver module assembly) Is easily damaged, Use extreme caution when handling spool and spool valve black. Do not handle the spool by the machined portions of spool. The toer- ances betwen the block and spool are extremely tight. Contamination in the block or an the spool may cause the spoo! to hang, Figuro 11: Driver Module Assombly Presa ans Bosrd Replat parece Bear rnncton f tease, Pare Nessie ‘em Paton Wino Drveenese sera on Op tore Dr Moses esa Psi Masstr Conner Ha sensor Connector Figure 12: Spool Valve Cover Assembly ‘Spool Vatve Cover EDATRONONEET =r 394A5056 aA aot 70=, FLOWSERVE ——— 2 Figure 13: Spool and Block Heusing | orveeto Nylon Housing Serew Spool vane Serew Figure 14: river Module Barbed Fiting Barbed Fiting Diver Module Gaver 6, Remove the spool valve block by removing the two rilips-nead screns and careful sliding the block afte spool (Fgure 13). 7. Carefully remove the spoo by sing the end ofthe spool out of the connection clip Excessive force may bend spool 8. Remove the main cover 8. Remove the plastic board cover by removing te thre retaining sorews (see Figure 14). 10, Disconnect the fexietubin from the barbed fiting tthe Arvor module assembly (soe Figure 14), 11, Use the nutarver to remove the barbed fiting from the driver module assembly, 12, Unplug the two wiring connections that ink the diver module assembly to the main POB assembly 39445056 A P27 oF 70 13. 4 16. 17 19 20, a. 2 2 2 26 26. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 Foed the two wires onthe driver module back int the driver ‘module compartment so that they stick ou the driver module ‘opening (see Figure 11). This wil alow the driver module to thread out without tangling or cuting the wires. Grasp the base of the driver module and tum it counterclockwise to remove, After is threaded out, carefully retract the driver ‘module from the housing Remove the barbed fing trom the side ofthe new ctver mod le using the 4 nutdriver Vert thatthe O-ring i in place on the top of the new driver ‘module. Lay the wire back along the side ofthe diver module as shown in Figure 11 and hold the wires in positon by hand, Gently inser the driver module into the driver module compart: ‘ment inthe housing, Tun the diver module clockwise to thread itinto the housing. Continue rotating the diver module until it bottoms out ‘Once the driver module has bottomed out so that the threads ly engaged, rotate the diver module counter clockwise ntl the flat on the driver module and the flat on the housing are aligned. This wll align the screw hole forthe next step. Verity thatthe nylon gaskets inthe counter bore inthe driver ‘module retaining screw hole as shown in Figure 13. Insert a drvar-to-housing serew nto the driver housing through ine counterhored hole in positioner main housing. Tighten with a Philips screwdriver, Reach through the main compartment into the driver module compartment ofthe postioner and install the barbed fing on ide ofthe diver module using the Y nutdiver. NOTE: Do not mx the barbed iting with those trom older Logi positioners. Older models contain orifices that wil not work in ine Logi 3200MD model. Orifice ar brass-colored, barbed fitings ae sivercolred Reconnect the flexible tube coring from the regulator to the barbed tng Feed the driver module wes into the main chamber ofthe hous Ing, and connect them tothe main PCB Assembly. Verity thatthe three O-ings aren the counterbores on the ‘machined platform where the spool valve block's tobe placed (Figure 25), Carefuly slide the spool into the connecting clip on the top of the driver module assembly Careful slide the biock over the spool, sing the machined surface ofthe housing base as a register (Figure 13). Slide the- FLOWSERVE ——— 27. 28 28, 30. Figure 1: Main PCB Assembly Nain Pow Retaining serous Regulator Pressure Sensor Board block toward the driver module until the two retaining holes line up with the threaded holes in the base Install two spoot-vale screws and tighten securely wit a Phi lips screwdtiver (see Figure 13), Slide the spool valve cover assembiy over the spool valve uti ‘the tang engages into the housing sot. Install spool vave cover screw and tighten securely (see Figure 12) Install the plastic board cover. Insert the thre retaining screw ‘through the plastic cover into the threaded boss and tighten evenly, using a Philips screwdriver. Do not ovetighten (see Figure 15). Reconnect power and ar supply tothe positioner and perform a stroke calibration, Reinstal all covers. Cee er 39405056 A [as oF 70 User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 RtaningScres 8.2 Regulator ‘The regulator reduces the pressure ofthe incoming supply ar to @ loval thatthe crver module can use, Replacing Regulator To replace the reguator, refer to Figures 11 and 15 and proceed as ‘outined below. The following tools are required + Philips screwdriver + ve nutdriver ‘$ WARNING: Observe precautions for handing eectrostat- caly sensitive devices. 1. Make sure vate is bypassed orn ste condition 2. Disconnect the power andar supply to the unit 3. Remove the main cover. 4. Remove the plastic board cover by removing the three retaining screws (soe Figur 15), Ey=, FLOWSERVE ——— 4 5. Remove the ve wire connections from the main PCB assembly (six wire connections fhe unit is equipped withthe 4-20 mA analog output option), 6. Remove the retaining screw trom the main PCB assembly and lit the main PCB out af the housing 7. Remove the four screws from the regulator base, Verify that as regulator is removed, the Oring and fier remain in the counter bore (please see Figure 11), '8. Remove tubing and barbed fing from the regulator base, 9. Install barbed fiting and tubing tothe new reguatr. 10, Very O-ing and fier are inthe counterbor. Install new regula for using 8-32 x" serews NOTE: Do nat mix the regulator with those from older Logix po- stioners. Older models contain regulators with different settings that wll not workin the Logix 3200MD mode. The regulator pressure setting is printed on the tp ofthe regulator. The Logix ‘320MD regulators setto 17.4 psig. 11, Install the main PGB int the housing, Insert the etlning screw ‘through the board into the threaded boss and ight evenly, using a Philips screwdriver Do not overtighten, 12, Reinstall the tve wite connections (six wie connections i the units equipped withthe 4-20 mA analog autput option), 13, Instalthe plastic board cover. Insert the thee retaining screws ‘through the pastic cover into th threaded boss and tighten evenly using a Philips screwdriver. Do not overtighten (see Figure 15). 14, Reinstall all covers. 8.3 Checking or Setting Internal Regulator Pressure To check or st the internal regulator pressure, refer to Figure 16 and proceed as outlined below. The tools and equipment used inthe next procedure are trom indicated vendors. The following toos are required + Calibrated prossure gauge (0 to 30 psi + teil ubing + Barbed Te (Cppard Minimatic pat number 122-2 or equivalent) + ¥ Allen wrench + 3 open-end wrench WARNING: Observe precautions for handling electrostati cally sensitive devices. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 Figure 16: Driver Module Regulator Pressure heck Fegutar Pressure foaenine wate \ Seoinea \ Fate ibe from epee 1, Make sure the valve is bypassed ori a safe condition 2, Remove the main cover 3, Remove te plastic board cover by removing the three retaining sorews, 4. Remove thee flexible tubing from the barbed fiting onthe side of the driver module 5. Obtain a barbed te and two piace of elie tubing, afew inches in length each, 6, Postion th barbed tee between the internal regulator andthe Aver module by connecting the "flexible ting, found in ‘the positioner, to one side ofthe barbe tee, Using one ofthe new flex tubing pieces, connect the barbed te tothe barbed fiting onthe side ofthe driver module. Connect te remaining port onthe barbed tee to a0 to 30 psi pressure gauge. 7. Reconnect the ar supply tothe pastioner and read the internal regulator pressure on the Oto 30 psig gauge. The internal pressure shouldbe sto 174 402 psig. adjustment is needed Toosen the sot screw retaining nut onthe tp ofthe regulator us- Ing the W open-end wrench. Then adjust the regulator pressure by turning the set screw onthe top ofthe regulator with the Ye Alen wrench, 8, Once the regulator pressures se, tighten the set screw retain- ing nut on the top of the rguitor, remove the ar supply to the positioner, remove the barbed tee, and reconnect te fixie ‘tubing trom the regulator tothe barbed fiting on te side of the dhrver modi 9, Install the paste board cover Insert the three retaining screws through the plastic cover into te threaded boss and tighten evenly, using a Philips screwdriver. Do not ovetighten (see Figure 15) 10, Reinstall all overs 3905056 A ANOFTS- FLOWSERVE ——— 8.4 Spool Valve The spool valve routes the supply arto one side ofthe actuator wile venting the opposite side (se Figure 1). The postion ofthe spool valve is controlled by the driver module. Replacing the Spool Valve To replace the spool valve, refer to Figures 12, 14 and 25 and pro- ‘coed as outined below. The folowing tols are require: + Philips screudriver 1, Make sure the vale is bypassed or in a sae condition 2, Disconnect the power and air supply to the unit 3. Remove the spool valve cover by removing the screw and siding the cover assembly backwards unt the tabs clear ofthe slot Itis not necessary to remove the sheet metal cap, hydrophobic filter, or O-ring from this assembly (Figure 14). & WARNING: The spoo! (extending from the driver module assembly is easy damaged. Use extreme caution when handing sp00l and spool valve block. Do not handle spool by te machined prions of spol The toe ances between the back and spool are extremely tight Contamination nthe block or onthe spool may cause the spool to hang 4. Remove the spool valve block by removing the two Pilips-nead sores and careful sliding the block aff the spool (Figure 12). 5. Carefuly remove spool by sliding end of spoo! out of connecting cp, Excessive force may bend the spoo 6, Vey that the thre O-rings are inthe counterbores onthe ma: chine platform vere the new spool valve bickis to be placed (Faure 25), 7. Gatefuly slide the spool int the connecting clip of the driver ‘module assembly 8, Careful side the block over the spool, using the machined surface of te housing base asa rogister (Figure 12). Slide the block toward the driver module until the two retaining hoes line ‘up with the threaded holes in the base. 9, Install two spool vale serews and tighten securely with a Phi lis serewdtiver (see Figure 13), 410, Slide the spool valve caver assembly over the spool valve unt the tang engages into the housing sot. Install the spoo valve cover screw and tighten securely (see Figure 12) 11, Reconnect power and air supply to the positioner and perform a stroke calibration, User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 8.5 Spool Valve Cover The spool vave cover incorporates a coalescing iter element ina ‘wo-pece cover. This protects the spool valve chamber trom dit and moisture and provides alow back pressure vent fr exhaust air from the spool vaive Replacing Filter in Spool Valve Cover To replace the fiter inthe spool valve cover, refer to Figures 12 and 17 and proceed as outined below. The folowing tools ae required + Philips serowdsiver 1. Remove the spool cover by removing the screw and siding cover assembly backwards untl the tab is clear ofthe sot. The sheet metal cover may be temaved and cleaned vith a brush ot by blowing out with compressed air (Figure 12), 2, Remave the Ong from around the hydrophobic iter element and set aside (Figure 17), ‘3. Remove the molded fier element by pulling it straight out ofthe chamber cover vent piece 4. Install Oring into base of chamber cover vent piece as shown in Figure 17. 5, Place new molded ther element into the chamber cover vent piece. Ths fitr element provides pat ofthe rack to secure the (ting instalag inthe lat step. 6, Place spool valve shroud onto spool vahe cover 7. Place the spool valve cover assembly in place by setting it on the ramp and sliding it until he tab seats in the slot (Figures 12, and 17) and secure with a 8-82 serow, Figure 17: Spool Valve Cover Assembly Hydrophobic Fiter Spool Valve Cover Spoo! Valve Shroud EDATNONOTEET z = 39485056 GS 500870=, FLOWSERVE ——— Figure 18: Stem Postion Sensor Orientation Fascoack shat 8.6 Stem Position Sensor The positon feedback assembly transmits valve postions informa: tion tothe processor. This is accomplished by means ofa rotary postion sensor that connects to the valve stem through a feedback linkage. To provide for accurate tracking of the pin nthe sit, the follower amis biased against onesie ofthe slot with a rotary spring. This spring also automatically moves the postion feedback assembly ois mit inthe unlely evento failure of any component inthe linkage Stem Position Sensor Replacement To replace te stem pasion sensor, refer to Figure 15, 18 and 25, and proceed as autlned below. The following tools are required + Philips screwdriver 2 WARNING: Observe precautions for handling electrostati cally sensitive devices. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 sim Patton StomPoltan SencoeDa Make sure the vale is bypassed or ina safe condtion. Disconnect the power and ar supply tothe unit Remove the main cover. Remove th plastic board cover by removing the three retaining screws (see Figure 15} Disconnect the poston sensor wires from the main PCB assembiy Remove the two rotary position sensorretaining screws and it ‘the sensor out ofthe housing Turn the new position sensor shaft unl the dot on the side of the shattis aligned with the wites on the side ofthe position sensor (Figure 18), Insert the postion sensor into the shaft withthe wires pointing toward the main PCB assombly. Turn the position sensor clock: FE CRATONOVBET =r 39445056 a ‘s1of 70 7]- FLOWSERVE ——— wise until boting slats align withthe housing screw holes and the wires on the sensor protrude over the main PCB assembly. Note: Do not mix the position sensor with those trom older Logi positioners. Older madels contain sensors with iterant ranges that wil not workin the Logic 3200MD model. The wires ‘on the Log 3200MD position sensor are rad, white and black. 9, Carefuly center the position sensor on the shat bore, insert and tighten the screws, Do not overtighten 410. Route the wires along the side ofthe position sensor and recon- rect to the main PCB assembly. 41, Install te paste board cover. Insert the tre retaining sews through ‘he plastic cover int he tiveaded boss and tgten evenly, using a Philips screwdriver Do not overtghten (see Figure 15), 12, Reinstall all overs, 18, Reconnect power and air supply to the postioner and perform a stroke calibration, 8.7 Main PCB Assembly ‘The main printed circuit board (PCB) assembly contains the circuit board and processor that perform control functions ofthe postoner The main PCB is tobe replaced as a unt. None ofthe components ‘on the main PCB are serviceable Replacing Main PCB Assembly To replace the main PCB assembly, refer to gue 11 and 1 and proceed as outlined below. The following tools are required: + Philips screwdriver & WARNING: Obsarve precautions for handing eletrosta- calysestivedevies. 1, Make sure the vale is bypassed ori a safe condition 2. Disconnect the power and air supply to the uit 3. Remove the main cover 4, Remove the plastic board cover by removing the three retaining sotews (see Figure 18) '5, Remove the five wire connections from the main PCB assembly (soc wire connections ifthe units equipped with the 4-20 mA analog output option (se Figure 1). 6. Remove the retaining screw from the main PCB assembly ané lit the main POB out ofthe housing (see Figure 15). 39405056 User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 7. Install the new main POB into the housing, Insert the retaining ‘screw through the board int the threaded boss and tighten, using a Philips screwdriver. Do not overighten 8. Ifthe old main PCB is equipped with 24-20 mA analog output board, gently lit the board off the main PCB, Align the two con- nectrs ofthe 4-20 mA output board with the mating sockets on the main PCB and gently press the connectors together. 9, Reinstall the five wire connections (six wire connections if the units equipped withthe 4-20 mA analog output option) (see ure 1). 10, Instal the plastic board cover. Insert the three relaining screws through the plastic cover into the threaded boss and tightan evenly, using a Philips screwdriver. Do not overtighten (see Figure 15). 11, Reinstall al covers, 12, Reconnect power and ar supply tothe postoner and reconfig= ure the positioner being sure to perform a stoke calibration, 8.8 Pressure Sensor Board Tha pressure sonsor board contains two pressure sensors that measure the pressure on output ports 1 and 2. The actuator pres- sure sensors are used in the positioner control algorithm to enhance valve stability. In positioners with Advanced diagnostics, pressure datas gathered for supply pressure alarm, signatures and data lagging. In postioners with Pro diagnostics, pressure data is used for full on-line iagnosti analyses. For optimal performance, the actuator pressure sensors nee tobe calloratod. The actuator pros sure sensor calbration is performed using @ HART 275 Hancheld| ‘Communicator or configuration software such as ValveSight, Removing the Pressure Sensor Board To replace te pressure sensor board, refer to Figures 11, 18 and 25, and proceed as outlined below. The following tools are required + Philips screwdriver & WARNING: Observe precautions for handling electrostat- cally sensitive devices. 1. Make sure the valves bypassed orn a safe condition 2, Disconnect the power and ar supply to the unit 3, Remove the main cove. 4. Remove the plastic board cover by removing the three retaining screws (see Figure 18) Disconnect the ribbon cable on the pressure sensor board trom the POB assembly (see Figure 11), a=, FLOWSERVE ——— 2 6. Remove the two sctews holding the pressure sensor board to the housing. Lit the meta stiffener plate off the pressure sensor board and set aside for future use 7. Remove the pressure sensor board Installing the Pressure Sensor Board ‘The pressure sensor board is installed onthe advanced mode ony. To instal the pressure sensor board, refer to ures 11, 15 and 25, and proceed as outlined below. The following tools are required + Philips screwdriver + Torque wrench © WARNING: Observe precautions for handling electrostatic sensitive devices. 1. Very thatthe two pressure sensor O-rings (item 15) are in place inthe housing. 2. Sette pressure sensor board assembly in place so thatthe (O-rings make contact withthe faces ofthe pressure sensors. 3. Place the metal tiene pat (tem 12) on top af the pressure ‘sensor board over the pressure sensors and align the two holes inthe pressure sensor plate with the threaded bosses inthe housing 4. Insert two screws through the stifener plat and pressure ‘sensor board into the threaded holes in the housing and tighten evenly, 8 int. '5. Connect the ribbon cable on te pressure sensor board tothe main PCB assembly, 6. Install the plastic board cover, Insert the thee retaining screws ‘through the plastic cover into the threaded boss and tighten evenly using a Philips screwdhive. Do not overtighten 7. Reinstall all covers. ‘8. Reconnect power and ar supply tothe positioner. Use ValveS- ight oa handheld communicator to perform a pressure sensor calibration. 8.9 Customer Interface Board ‘The customer interface board provides a connection point inside the explosion-proot housing fr all hookups to the positioner. Calbration ofthe loop current and the analog output current (optional) are performed using a HART 375 Handheld Communi- ator or configuration software such as ValveSight. User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 Replacing the Customer Interface Board To replace the custor interface board, refer to Figures 6,11 416 and 25 and proceed as outlined below. The following tals are required + Philips sereudriver 10, a 13, 14 46 WARNING: Observe precautions for handling electrostatic sensitive devices Make sure the valve is bypassod or ina safe condition, Disconnect the power and at supply tothe unt, Remove the main cover Remove the paste board cover by removing the three retaining sorews (se Figure 15), Remove the five wire connections from the main PCB assembly (soc wire connections ifthe unit is equipped with the 4-20 mA analog output option (see Figure 1). Remove the retaining screw from the main PCB assembly and It the main PCB out ofthe housing (see Figure 16). Remove the user intertace cove Disconnect the fel wring ftom the customer interace board terminals and remove te three screws that hold te customer interface board in the housing (see Figure 6). Remave the customer interface board, caefuly puling the wir- ing through the bore. Very thatthe O-ring is in place inthe counterbore inthe post tioner housing Food the wires onthe back ofthe new custome user interface board through the passageway into the main chamber of the housing, Set the customer interface board in p sorens (se Figure 6) and secure with three Reconnect the fed iting to the customer interface board terminals, Install the main PCB into the housing. Inset the retaining screw ‘through the board int te threaded boss and tighten evenly, Using a Philips screwdriver Do not ovartighten Reinstall the five wire connections (six wire connections if the Unit's equipped with the 4-20 mA analog output option) on the main PCB assembly (see Figure 1). Tee 394A5056 A Saat7O]- FLOWSERVE ——— 16, Install the plastic board cover. Insor the thee retaining screws ‘through the paste cover into the threaded boss an tighten evenly, using a Philips screwdriver. Do not ovetighten (see Figure 15). 17, Reinstall all overs. 9 Optional Hardware 9.1 Vented Design (see Figures 19 and 20) A standard Logix 3200MD positioners vented directly to the atmo- sphere, When supply aris substituted wih sweet natural gas, piping ‘ust be used to route the exhausted natural gas toa sae environ: ‘ment. Ths piping system may cause some positioner back pressure inthe main chamber (rom the modulator and regulator) and spool chamber (from the actuator). Back pressure imitations are described below, Two chambers must be vented onthe Logix 200MD postoners: ‘the main housing chamber and the spool valve chamber (Figures 19 and 20). The main chamber vents located onthe backside ofthe posiioner (soe Figure 19). Vented-design Logix 3200MD positon es are supplied trom the factory with a fiting installed inthe main chamber vent. Connect the necessary tubingpiping to thisfiting to route the exhausted natural gas to a safe environment The maximum allowable back pressure rom te callecton device on ‘the main housing vent is 2.0 psig (0.14 bar). Vent flow rate fs 0.5 std f!min (1.4 std termi). © WARNING: The back pressure in the main housing must never rse above 2.0 psig (0.14 bar. Figure 19: Main Housing Vent Maximum Allowable Housing fy bac Pressure aan SS werercs Swagelok Tube Fting WENT NPT Reducer User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 Figure 20: Spool Cover Vent 28" NPT x W" Swanlok Tube ting Naximum Allowable Spool Back Pressure psa (058 B00) 1 customer conestion Ye Ting ‘The spool va chamber (se Figure 20) must also be vented through the spoo! valve cover. Vented-design Logix 3200MD positioners are supplied from te factory with iting installed in the spool valve cover tem SKU 179477). Connect the necessary tubing/pipng to this iting to route the exhausted natural gas to a safe environment. The maximum allowable back pressure inthe ‘poo valve chamber i 8 psig (0.55 barg). Pressures greater than 8 psig wll cause vented gas to leak past the spl cover O-ring tothe atmosphere and wil sun avershoot ofthe positioner. 9.2 HART Modem The HART modem is a device that connects tothe serial com: munications pot of a computer. This modem converts the RS-232 ‘COM part signals tothe HART signal, AHART modem is optional in ValveSight since a MUX can be used ints place. The HART modem takes power from the RS-282 COM por lines. I using a laptop computer running onan internal battery, HART communication may become erratic asthe batteries begin to lose charge. This is due to reduction in HART modem power Allow batteries to recharge or apply AC adapter power to the aptop to correct the problem, A HART modem s available through your Flowserve representative. (Please refer to Section 11 for part numbers When using a HART modem vith VabeSight or when using the HART 876 handheld, the leads can be connected anywhere across the 4-20 mA current signal. The leads ae not polarity sensitive When using after, the connection must be made between te iter ‘output and the Logix 3200MD (see Figute 22) Tee 7 394A5056 A Ba0t70—~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ Figure 28: Analog Output Board Power 9.3 4-20 mA Analog Output Board ‘The Logix 3200MD digital postioner can be supplied to provide an ‘analog feedback signal ofthe stem position. Tis option can also be retrofit in the field, The 4-20 mA analog output board is wired in sets with a 12.5 to 40 VDC power supply (see Figure 23). This po Sition feaback option has the fllawing features and specications: + Does not interfere with positioner operation + Calibration ofthe analog output signals performed using a HART ies 375 Handheld Communicator or configuration software such as Valvesigt 200 Poston Feeoback — to 40 VDC + Output follows actual position of valve, including al false modes Current Loop, Power of positioner except loss of power. An output of 2.15 mA is trans- {Logos output) Supply mitt with ass of power tothe positioner. WW + Immune to RFVEM| disturbances, + Availabe for explosion-proot and safe applications (CSA, FM oweceamen CS anna Replacing the 4-20 mA Analog Output Board (Loven KAJ Current Source vont [CAUTION lsvated Power Sources Required. + Philips screwdriver WARNING: Observe precautions for handing lectostat- ‘SQ CAUTION: Isolated power sources required, cally sensitive devices. 41. Make sure the valve is bypassed or ina safe condition 2. Disconnect the power and alr supply to the unit 3, Remove the main cover 4. Remove the plastic board cover by removing the three retaining sores (see Figure 15) 39445056 5, Disconnect the two wire connection fram the side ofthe 4-20 mA analog output boar 55.0170 6, Gently fit the 4-20 mA analog output board oft the main PCB assombiy Figure 22: HART VHF Fite Schematic > v oj} Ici} Drain Wire ABO 4-20 mA en HART Connection- FLOWSERVE ar User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 7. Align the two connectors onthe new 4-20 mA analog output ‘Figure 24: 4-20 mA Analog Output Board board wit the mating sockets onthe main PCB board and gently press the connectors together. 8, Connect the two wire connection eaming from the User Inter- ‘ace board tothe side ofthe 4-20 mA analog output board 8. Install the plastic board cover: Insor the three retaining screws ‘through the plastic cover into the threaded boss and tighten evenly, using a Philips screwdriver. Do not ovetighten, 410. Connect the Analog Output fied termination wiring to the ‘Analog Output terminals onthe User Interface board (se Figure 23) 11, Reinstall all overs. Clee 7] 39445056 A Seor70 |- FLOWSERVE — 2 10 Parts List User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 1 og SCO0K0 Postione 25 | Main Vent cover 2 | Main Housing Cover 30 | Seren, Main Vent Cover 3 Oring, Main Housing Cov 31 | Driver Module Cover 4 Sere, notation 52__ | rrng, Diver Mocuie Gover 5 Pht Main PCB Cover 58__| Diver Module Assembly & Sev; Man PCB Gover Shor (2) 2A__| Hex Barbed iting with Capi 7 Seren, Main PCB Cover Long 35__| ResbleTubing © | Main PB Assamby 36 | Seren, Driver to Rowing © | Sew, Man PCB Assembly Reaning | Rion Waser 10 | #201 Analog Outpt Board (Option 38 | Spool vane 11 | Sera, Pressure Sensor Board (2) 38 | Sooat va ia 12 | Pressure Sencor ard Steer 40___| Ser, Sp00 vate to Hsing) 13 Pressure Senco Board (danced Oni) 41 | ong Spoot va (8) Pressure Sensor Pig Pll (Standard On) 42__| Scrow,Sp00 ave Cover (rng, Pressure Sensor io Housing 2) 42 | sooo! vave Stroud Pressure Regulator, 50 30 psig (eludes 20 4 | Sooo! Vaive Cover 17__| Screw, Regulator Pte to Housing) 45__| Hidrophobic iter, Spo0 Va 18 Barbs Fring wih Capive O-rng 45 | Og Spool Vabe Cover 19 | Iteral iter 17__| Pressure Gauge, 0-160 psa) 20___| Onin, Intrtace Plate to Housing Seal 1 | RrSereen 3) 21__| Customer nertace cover 18 | Seren, Poston Fedbaek Potetoneterto Housing 22___| Oring, Customer interface Cover 50 | Metal Washer) 22 | Sea, Attation 51__| Poston Feedback Poteriometer 24__| Screw, Customer Intetace Board @) 52___| Feedback Shah 25 | Gusto iertace Board 55___| Seren, Spring to Feadbark Sha 25 | Oring Customer intatace Board 27 Grounding Serew (2) 55 [Torsion Song 2 36 | Eing| Cle 7] 39445056 A 57 of 70~_~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ Figure 25: Exploded Drawing E DATNONONGET 39445056 A 58 of 70—~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ 11 Logix 3200MD Spare Parts Kits See Figure 25 for item numbers. a [a ‘2: Driver Module Assembly 0° fo 80° Kt, P/N 198786 998,600 ‘7: Soft Goods Ki PIN 195788 999,000 16 | Pressure Regulator 1 [Oring Main Housing Cover 1 17 _ | Seren Regulator to Housing 4 15 _[O-ing Pressure Sensor to Rousing 2 38 _[ Driver Module Assembly 1 20 _ | Oring. Regustor to Housing 1 ‘34 | Hex Barbed Fting w/ Captve Ong 1 22__ | Oring, Customer netace Cover 1 35 | Screw, Driver to Housing 1 26 | Ovring, Customer Inertace Board 1 37_| Won washer 1 35 | PenbleTube 1 ‘KIS: Spool Assembly Vale Kit, PIN T8678 99.000, 37__| Nyon Was 1 38 | Spool 1 41__ | rng, Spoo valve to Housing 3 138 | Spool Va Biock 1 45 | Hydrophobic Fite, peal Vave Chamber 1 40 | Serou, Spon va to Housing z 48 | Oring, Spool Vave Cover 1 41 | Oring, Spool ave 3 54_| Orrin Fonsback Sat 1 ‘it Pressure Regulator, P/N 218814 998,000, TE: Pressure Sensor Board i, PIN 199791 998,000, 16 | Pressure Reguater wit Captive Ooings 1 11_[ Seren, Pressure Sensor Boaré z 17 | Ser, Regulator to Housing 4 13 _[ Pressure Sensor Board 1 KS Fedback Sat Kit PIN 199788_966000 For ATEN salon oni) _15 _| O-ng Pressure Sensor Rausing 2 32_ |Feedback Shah 1 KS: Main FOB Assembly Kit PIN 255014996000 58_| Seren, Spring to Feedback Sha 1 | Seren, Man PCB Cover Short 2 54_| ing, Fedback Sat 1 7__ | Seren, Man PCB Cover Long 1 Torsion Song 1 8 [Main Poa 7 36 Eng 1 | Seren, Man PCB Reaning Srew 7 ‘i: Fedack Sha Kt NAMURY, PrN2¥8814 888.000 Ki 10: Use trace Board Ki, PN 19878%.998,000 {For TEX instalation ny) 24 | Seren, customer Interac to Housing 2 52_| Feedback Sha 1 25 | Customer trace Board 1 '58_| Seren, Spring to Feedback Shah 1 26 | Ovring, Custer Inertce Board 1 5a | Ong Feedback Sha 1 KIL: Analog Output Board Kt, PIN 214785 899.000, 35 _|TasionSorng 1 10 [ Analog Output Board 1 36 | Eng 1 112: Postion Feedback Pteiiomer Kl, PN 199794 998,000, 49 _| Seren, Feedback Poenometer to Housing 2 30 | Metal Washer 2 31 | Poston Feedback Poteriometer 1 HART Modem R282 198208.986 000 POMICIA PN 198204.996 000 use mn 216427.996 000 Clee 7 39445056 aA 59 of 70 4~_~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 — 12 Logix 3200MD Mounting Kits 12.1. Valtek Mounting Kits 200 164432 168433 168438 162835, 282 168835 168836 Te Tos 288 16437 1608 338 T6499 T6440 475 1699 T6440 A 50 square: 2.0 pu wth ve lading requires WE number * Liveleading i not avaiable ona 100, 2.62 spud, Table X Vator Rotary Mounting Kits” a 135429 I 135437 136430 135433, I 138431 135429 I 135438 1 137212, I 135431, 135429 I 135439 187213 I 135431, 135434 135429 I 137214 I 135431, 137215 CO _eoemmnaniween Tey BOOFTO,- FLOWSERVE — User instructions - Digital Positioner 3200MD LGENIMO0S9-02 10/09 12.2 Logix 0.E.M. Mounting Kits Table Xi: Logie OEM. Mounting Kits x = 5 gs a Sue Ce wo 23% = [8 8 11288 H oss i 4 sarang | Hoe a 4 2] s 6 78 1 z 7 ws [SS Bg so sto 7a 0 788 657 4687 sist? | 7 suo a ste | OS-15"—Valok Trooper eeess | -150" : i vse | eae He @ | 2 stoke _ Rane vara | HD fa se 0 SNAniS irony 228 ie 5128 v0 “0 vert Ar seies | _afO-ATe os__| sma eres | Swat Sua 1082 s 17649 | Rot) gumar [wees | nas0300 era a "7a798 Rewer} RES i C) naar RPC Series [RP TPCt1000 fe ices Gza08T | Const 3 sees 173887 Ganzount | Comublaton g oman 2580 é inet 1258 ie —_ B [estan | nae 173788 tor LS masH0 5 — Unitorg [Mees | weo=Mes58 = Bia 175788 Worcester | 39Seies | 2599-4299 2 “Aastabe moun yb ee anaes ae i ne Asal our 178788 may bended bao ae sed 9 1% iz) ua rae 12.3 NAMUR Accessory Mounting Kit 24 173896 a 7a Part Numbers. % 73238 Use profix "NK" and chose bracket and bo options trom the fl 2 15 116070 towing tbe D sted Table XI: NAMUR Accessor Mounting Kit Part Numbers = = i Ti 28 | 20mmpoionxa0 mm bl spacing concer | iT 28 | 8 mmpiionx80 mm bo sacina m soe 318 | 80 mmpinion x80 mm bot spacing a Tied 318 | 0 rmpisionx 180 mm Bo space = = fe asst A [1024uncsoting ss B 7 3 1es2nF ote = Demat Bo ia —__1_[ws-ameticboning ‘aap NTA, NAVUR Accessory Mounting Kt th 30m ion x ESSTABD) Tas 40mm bo specng and 1-24 UNE boing 74041380 176251 RT = 3945056 A Tet7-_~ FLOWSERVE — 13 Frequently Asked Questions (0: My D¢S uses 26 VOC, can run a Logix 3200MD? AC ADCS outout current ad des run rom 24 VD bat the card equates the acta curentoutput However ithe 24 YOC were appid deci across {the terminals, nthing woud I the curen and th Log 2200MD Felt Termination Board cou be damages The eure source vaapesuppy can be anyerebabven 10 VDC o 80 VDC as ong asthe cure ted in supply across th Logit 320000. How aged something? A The ype flue an overcurrent stuaton fa shot dreut. Your lop ¢urert wil be maintained butte Log 320040 contol board wl receive no power Wth power removed am the Logi 3200MD, use an obmmete to measure across the terminal he reading a shr (closet ero ars the Customer Inerfce Board must be repiced. Make sure the poste ead ison te's terminal and pagaive lea ison he terminal when measung the resistance (0: Whats the input resistance of the Log 3200807 A The Log 3200MD does nt havea simple ress input. When measur Ing the votage across the Logic 20080, ony vais shy when he cur rents ange fom 4 mA to 20 mA (38 ta 100 VOC nominal wot HART ammunieatons.AGs 03 V with HART ate. Ti is eeaus he Lagi 5200MD isan ave device. The resistance at gen cutet is conmeniy refered oas he aflectve resistance (ect sistance = (Terminal Voltage) rent uation3 For example 1 20/m fective resistance = 9.¢ VOID G2 A= 485.2 The Logic 3200M0 has a speciation of 485.9:@ 20 mA NOTE: Your canna measure suoss the terminal ofan unpawered Loox 5200 and get How do Kilt cu ‘VatveSight an the HART 375 handel. the postanercammanicals fo \eiveSight othe HART 275 handveid when using current source a 4-20 mACcuren ealrator, or example) and nol the DCS, inact titers aceseary wth that eurnt sure, Sorte 4-20 mA cabrators hat work Without iter ara sta bean fone o! thee alate, try to comet vith ValveSghtor he HART 375 handheld again. If comsmuniations are {stabished whl using one of these sours bu son te orginal sore, {Peri reedea Handheld 420 mA calbrators which donot require iter: + Atak Model 384 + Rochester Instument Systems RIS) CL-4002 + Unomat UPS User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 (iL set the MPC at Specent How wl he positioner operate? 1 Assume that he present command signal at 50 perer. I the cammané Sigrlis decreased he pstoer wl folow the command unl reach 5 patent. percent, te spool wl be diver fly open oly loses depending on he a acto ofthe vane inorder to provide ul atstor ‘saturation and tight shut, The pstionr wl maintain ful sturaton below S percent command signal Aste command increases, the posioner il ravaneturate ut the command reaches 6 percent heres a perce hysteresis value adced ay te postone) At ts oi th sem poston wl follow th cmmane signal Whe a MPG, te Lopi 200M LEDS wl ink ey. (0:1 have MPC sotto 3 percent but he valve wil ot go below 10 percent Isa lower soft stop onablag? The over sf stop must bless than the lower PM setpoint in orér for tha omer MPC to become ate. When the loner sot stp i eahed the pstner wl lnk a GYGY cade. When MPC |s atv the posioner wi lnk SS. ‘©: Wl sf stops prevent he valve fom going ts al postion? KN. ‘2: Whats he dterance between mades with Standard (2200M0}, ‘Abvaned (2710MD) and Pro (322040) diagnostics? [RAL models use the pressure sensors in the posoner ont algorithm to mance valve stabiy, The mode wh Advanced dagnostes performs Caleulatns such as detection of ss of pressure, cagnst signatures and Aatalogging. The model wit Po agnostics ads fl agnostic capbl- tas incuding continuous on Wictan peumai akan actuation rato analysis. Pro lagnostes support comprehensive ean vis inthe Vae- lah DTM. Parl stoke tests and long term trends of many hey parameters st also aval wih Pre dagnasis, (Can upgrade trom a Standard to Advanced or from Advanced to Pro diagnostics? Yes. Upgrading can be aezomplshed using VaveSght OTM sotare ‘Aes upgrading, passure sna clon ealbatos an be perarmed sing ‘he ValeSignt OTM or the KART 75 handheld pressure sensors tomy 320010 and upgrade itt 3220MD [This depends on the crtyng agency. Soma agecls do not alow tt {ngs ule chang the psi conigurton Irie cetyg agency lows physical uporaes, th pressure sensor board assem canbe pu ‘chased ad instaed A Fiowsere techntan can update he poston sot are rom ote dasied MD verson (Advanced ox Pro) Hf the etying agency does nt allow iysica uporades, a Fowserve teenian can update the postonerettware fram the Ia the dese MD vetelan (Advancad or Pro} ifthe cating agency doesnot alow physical uprate, 2 Howser {wctnican can update the postions sofware to tute 82010 nt 2 ‘52001 (th Stancard dlagostes) allowing to work wit he VaeSight DTM, See he Lag 320010 10M for insuetan on remauing he pug pate and instalng the pressure sensors. Clee 7 39445056 A rarTO—]~_~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 — 14 How to Order Protocol TaRT = Standard Diagnostics -Avanaed (wih pressure sensing) - Pro wih sensing an ul Vaio ianosis) uur, Ware Pst (ara ‘Staess Steel, No Pit Vato “Auuminu, ick Pan (Autoran Material ‘Aum, Foad-Grade White Pain (Avorn) ° ‘Aum, ack Pan (ord) ‘Aluminum Fo0d-Grae White Pant Acord) Design Version = TNOETRO BR-EX a TAT REx BV, TS (South neve} plas onpoot Gass | Dw, Groups B,D lnrnscaly Safe Gass Dit, Groups A trough G (FM, SA) FA Nonincendve, CSA Cass |, 1iv2, ise | Zone 1, Group IB H ad El Cis 1, Zane 0 Group ic ($A On) General Purpose 4 TEE Bplsiongrea 16 cerieaions TEE nisl Safe al] s ATE platen Prot, 2G Ex IB, TS; 120 Ex10 A211, 40°C 0 90° Intresialy Save; M6 Evi IC, TT, 40% to 85% TST, AOC to 58k IND Exiad 20 7580-40 t+ 80 Nonincendve: 3G Ex. nC, T 40% o +86, 15, AFC to 55% Ia) 6x10 A22 79550 Co + 800 KOs Db 316 Sass Stal Shah Watex Sandara) oS Sen TNAMUR 16 Stans Stel (VDIVDE S845) ne | * TE NPT E Conduit connections [= i = Foursay (Doubt) Toe seton Three-way SinoeActing) @ | 2 Fourway Vented Double Aang) aw Three way Vertes Singl-Actag) W Temperature Low Temperature 40°F io 76°F 40°C 10 30°0) oe] & SS nh bras torial, pl bara) (Vaek Standard) 08 5S wth SS internals, si (oaPa) 0s aug 'S wth bras internals, pi ager?) a] oo SS wth $5 itera, si xem? ) KS [os No Gauges v No speci opine 0 “20 mA Poston Fedback oe] o Speealptons [emote Mount Feedback On Ava mu) * al Otion Feedback SF For each category, sls the code fr ane ofthe options. Clee 7 “contact tatory before spetying this opton 394A5056 A * C5 0F70~_~ FLOWSERVE User instructions - Digital Positioner 3200MD LGENIMO059-02 10/09 —_ 15 Troubleshooting eC Currant sours below 3 6 mA without AO cad o 37 mA | Very caren sours f outputing atest 3.6 mA wih with A cara ‘Oca oF37 mh with AO card No LED is inking Tnsoneet wring polar Check ig for cores polariy Votageofeurert sue i not igh enough ‘Ves that curentsoure can supply at ast 10 sium aowsblecurent soue rate a changes 824 mAper secona ‘heck cable eondvtion a, length an Refer to Secon 64, Cable Roque ments ‘currant source bandit nt lad 1 25 Ha lance Masur cable ena or cable impedance excescad Erratic communications THART modem connesod to PO RS 222 pot not ee ing enouah power lnterterenee with LS baror ‘ust use HART-compatbe LS. barter Currant Source striping itering) HART sana Use the HART ite (VHF) avalale rm Flowsere ‘Switch to analog eommand mode by doing a Command Source Rest rm the eal trace wth handheld Uniti in dig! eommmand mode communicator or VaeSight pease retest Section 78 Unit doesnot respond to analog “Command Source Reset" of he quickstart quite for commands detalles instructors). Verity atop battery not ow ‘heck ink codes on pasione and eanet Err oecumed during calraton calibration erat Recabrite Pine aos Reba ator Siem poston senor menting oF EO Reno aon stir ate poston aed nat | Sj at cabs Pero QUCKCAL shat M.CY ase syst ing Porbandar Cater hain os ops ce ‘sso razon ado ts Ske ot card Chek Osh eos aaa ae sa Tne ooh seer Foland estar comes Check ATO (Aito-open) and AT Position is dtven fully open or | Weongalr ation entered in sotware aosk ATO (com) dT closed and will ot respond to comand Aeluator tubing backward ‘Very ATOIATE actuator tung eto-preumatc converter matunctorng Replace electro-peunatic converter ‘Aalst inner op ost an Contra parameter oper cota loop ost to hivow (heck air supply or prope firing and maring ISA Contamination of the driver module speciation ISA-7 00. Check the spoa va for tontansnaton| Contra ning par Steking or unin operation et econ et gn egy a a aa the poston Era te sai IP schon te sal ace andrea Hrtem pret el psu Cant anemones Vow snd tees Packing rition igh Corded or ay sp00l vale Disassemble and clean spool vave “MPC: Minimum poston exit? EDATRONONEET =r 390a5056 nNFlowserve Corporation Flow Control 1350 N. Mt Springs Parkway Springvil, UT 84663, usa Phone: 801 489 8611 Fax: 801 4893719 Flowserve S.A.S. 12, avenue du Quebec BP 645 91865 Courtaboeut Cedex France Phone: 33 (0) 1 6092 92 51 Fax: 38 (0) 1 60.92.32 9 Flowserve Pte Lid 12 Tuas Avenue 20 Singapore 638824 Singapore Phone: 65 6868 4600, Fax: 65 6862 4940 FCD LGENIM0059-02 10/09 Flowserve Australia Ply Lid 14 Dalmore Drive ‘Tofind your local Fiowserve representative please use the Sales Scoresby, Vietoria 3179 Suppart Locator System found a: Australia Phone: 61 7 32686866, Fax 61 7 32685466 vawsflowserve.conveontact htm Flowserve Lida. ua Tocantins, 128 Séo Caetano do Sul, SP 09580-130 Brazil reall USA 801 489-8611 Phone: $5 11 2169 6300 Fax: 55 11 2169 6313 Flown Corporat i xis iy isd he ein se sult pratt When prope sac. hs Reuse produ! scsi parlor sana une afl dugfsatl e. Honee, be phase ‘rasta rst sho ye th onsen roster bdr apes dr wrt trast serve covens. Rough Powsev cat ten des} pone grr ucts, cana rie {pected aa warn fra porive pets. The praetor eet he agen or te proper sng sd seen nut, opton an tenance onsets poche praetor. 2d ners ts installer Operon Marae (OM) rsutors ed wih poditan an enployes and fants nh sls loan prodts ncotnacten wih epee pest Wht eruatn an spcicabens conan tis tatu ae ole be ct, hy supe fo informatie epost ony ns hau al cadre ceri ea pata saat vl y rire reo Ning fantaned hres fb canvas snare er gute. xe eli, gun ay rater wih apa et Predict Braise sere contr nproieg ad ning preset iy. th speciatons, diners are ltormatcn aad aren ae ste ean wou ase. Souda qson ase crea ese ros on, portant sau cate nse Corparaon ay on a wars operaan or aes © 2008 Foner Crane, vg, Tens USK Ponape aka of oar ompoatn, DEINE 39445056 YeFilter Regulator AW10 to 40 Integrated filter and regulator units save space and require less piping. Direct operated, relieving type IS symbol 1D > a8 How to Order a ] AW 30 03 BE iN rane | Tops specetns regulator ba Descer sahocarry ay se heer ante fatal + fisse anes oo sm Thwead type. SSH Oran guide 14 “AW30, 40, ni Re R__[Frow direction: Fight lett ‘AVEO 1640. weet er eee wi OU SERS. SEs Sagres ieee eee wontaprerrateween | — |aezssaatesmn ° “o ‘Sibol Deseribtion ‘Roplieabee model ronsze! — Fi = = Srbs| se | 10 | 20 | 30 | 40 C | Float type auto drain (NG) Hone ‘AV10 1940 mere r=) | Ee tatteeenome ms Stat tetets ie eae as 03 fae | — SF wre roura presse gauge (at ent ian “AVZ0 10 40 oe fue) — | Wn set nt for panes mount ‘AVETO 1040, sete SS aie Q Accessory/Optional specification combinations 2: combraton sab O:Vatesseponig on be mode [a consinstn rot autale Zaller NPT tres ee plo pron aaa rer Accessony/Optional specifications —————" BiC/D/E|GiH a[2ielelely N[R |W] Z | AW10 | AW20 |AW30 to 40| baht oth et) Te pals iofo lero] sleioia, oe [a |e [Roatype sats arn) e[5 310 2 stato 43 | Remy ast ran 0) Aa o10] S. {8 { [Seu enteseatpe peso gape ||| ofl 8. o | 8 § [owns press gue e{2/elofete 2. ool 6 rset for ne a feat [ a S epe[-s Sarwar ang =fe]e/o 7 5 stet-6 2 [iat ea aa 2 S sae 5 | non cele 6 5 stots al ew ee sale 8) a é bon gud OSH ata Now le af Linn GA] Ambient and Hud temperature =510 80°C (wih no rerhng) Nominal iran rng Sum Drain eapacity erm) 25 I = I 25 e s Bowl material Pajaro Bow! guard = eaten J] Sarat Construction eleva ype Weight (es) oe [om [ao on oe te} it one's A. ‘Accessory part no. ee co) wo aso awso | Awsoos Bracket assembly >= [ARYOP-270AS | AW20P-2708S | ARGOP-270AS | ARAOP-270AS | ARAOP-270AS Sein "ARIOP-2608 | ARZOP-2608 | ARGOP-260S _|_ ARGOP-2605 | ARAOP-2605 ound ar-10-Ri | Gaesoro1 | e6-10-7o1 | Ga6-10-702 | Gae10-7ae Pressure| MP*| square enneased ype = Gca0as_| GC3-10AS | _GC3-10AS_| _GC3-10AS. sg geil Rema | G27I0-Atwon| Go62T01 | cae2to1 | _Gte2C02 | _G4e2C02 sua enmectespe| aos2as | Gcs2as | aos2as | Gca.2as oat ype No. = — | AB38 [ADSEN="| ADB] ADABNH| AAS [ADAANT auto drain NC. ADI7, ‘AD27, |ADS7 |ADS7N‘*| AD47| AD47N* 8] AD47 [ADA7NM** 2 Now timer oneatng rena NO pec) MPS:NC. ype-a.1HPa|ADY727 and 15MPs (AOSTA. Carat Cregg psn PI re Now Wher Wi tpctea ste eno pees Sah spe be 0 shoud A\ Specific Product Precautions } {Be sure to read before handling. Refer to pages 75 through 78 for safety Instructions and FR. unt precautions, | selection | A\Warning 1 Residual pressure release (outot pressure reloase) Is rot completed by Warning Set the regulator while checking the “Pull the pressure regulator knob to unio, (You ean visually very tis with the ‘orange mark that appears in Feleasing Inet pressure. To release Fesdual pressure, use a fiter regulator With aback low mechanism A\Warning a 1. Roplace the element every 2 years or when the pressure drop Becomes OAMPa, whichever comes frst. to prevent damage fo the element Tee 394A5056 A Brat7 splayed values of the inlet and outlet pressure gauges. Turing the knob fxcossively can cause damage to the Intoral pans Tho pressure gauge indicated. with regulator for 0.02 19 0.2NPa seting is for 0.2MPa use ony. Exceeding 0.2MPa of pressure can damage the gauge Do not use tools on the pressure regulator xnob as this may cause ‘damage. must be operated manually ACaution Be sure 10 unlock the knob betor adjusting the pressure and lock it ater Setng the pressure. Failure to folow this procedure can 2 cause amage to the nod and the ‘ute pressure may ftute, 9p) Push the pressure regulator knob to jack. When the knob is not easily locked, turn It lft and right tle and sh I (when the knob is locked, ange mack wil disappear). Borns a. 2 operation of te kno, Refer foFitter Regulator AW/10 to 40 Flow Characte 3S (Representative valies) Awio Aws0 nese AWA006 nea Soo j PEERS on —— o ~ Aw40. Re 12 2 wrt Un aN Pinna Urn Pressure Characteristics ronson wt fawa0 ‘awa0-06 LY of on f sah span sane “< SSS =] we U4 05 a6 oF 08 09 Peres on 7 * GE os oe 05 0s a7 a8 OF awa0 waa é somm| |e supa i PSs | dod SC i Paras Of OF oF OT GF OF Sitar OH 25 Ue G7 OF a SE CRATING NUNEER Fe, 394A5056 A 9 SMC Cao]AW10 to 40 Construction AW10 AWw20 ‘AW30, 40 Parts list waa Ne __Deserplen |awio,20_ [awa | AW40, 40-06 Nee 1) Body Ze socast | Aluninum east Patan ser 2 | Bonet Peace ‘Back Replacement parts No. Deseriptior Material Parte. "| " Awi0 “AWw20 AW30 AWaO AW40-06 2 [Vane assembiy | Sanbensse! | anvop.oios | awaop-asoas | AWGDR-ORDAS | AWAOP-OR0AS. | AWAOP.OEOAS 4 [ter element _—_Nersventabre | AFI0P-0608_|azop.a50s | AranPoens | AFwoP-o50s | AE4OP. 060s 3 [Diaphragm assembly Weshernty NA ARTO> 150A ARAOP.ASOAS | ARGOP SOAS |ARAOP-1S0AS | ARAO™-1SOAS «| Bow ing NOR | cistP2eas | cosrP-2e0s | casr.2e0s | casrP-2ens | c4SrP-2008 7 [Bow assembiy |p cis ‘Caspr caseten)cagrtonn) ) cane wenn 59 Ne 1 AWTOIs apa nda gutt KSYPD) Np sorb Ne 2} ees ing Cone eqn he Don seb spy Put pies Nw The ANAC ard AW Bow ase cone ha bon gure brea 9s SMC =r 3945056 A 69 of 70Dimensions Filter Regulator AW10 to 40 AW10, 20 {epi semen : Me Par t + see i ee 9 3 ‘AW30, 40 noi PT se w able tl REE | eri | i! (Ni a ara WEES | weaves | “RSRE | wouvon | MERIC | wmaunane | “ESE” Optional i A : — yes ae ale|c{o /e/G/H\/u|K/m[Ni/Plals|tlulvi[wiy[z es map faeiae Ast pet ee a oer eter eee AW20, ve, 14 | 40 | 160] 73 | 52] 40 | 40] 63 | 5 | 30 | a4| 44| 54/154] 55/23/30 |2a5| 14 | 6 | 177 eee ea at eater ert eet ae tt ee ‘Awao —_|1/4, a8, 12| 70 | 239| 92 | 75 | 73 | @0| 76 |985| 15| 50 | 54] 54/85 |105| 70| 23/355|425| 21 | 7 | 278 Mea ae a eat Pet eet eee obec at esheeb ef asteriaatar trian ———— ve ee = oo ae a “Awa, 247 246 251 [are aw40-06 | 250 249 255 275. 394A5056