logix 3200iq digital positioner - flowserve 3200iq digital positioner ... logix 3200 indicates that...

Flowserve Corporation 1350 N. Mountain Springs Parkway 1978 Foreman Dr.Flow Control Division Springville, Utah 84663-3004 Cookville, TN 38501www.flowserve.com Phone: 801 489 2233 Phone: 931 432 4021

FCD AXAIM3200-00 9/04 Page: 1 of 32© 2004, Flowserve Corporation, Printed in USA

Logix 3200IQ Digital Positioner

Automax Logix 3200IQ Digital Positioner

Installation, Operation and Maintenance Instructions

Terms Concerning SafetyThe safety terms DANGER, WARNING, CAUTION and NOTEare used in these instructions to highlight particular dangersand/or to provide additional information on aspects that maynot be readily apparent.

DANGER: indicates that death, severe personal injuryand/or substantial property damage will occur if properprecautions are not taken.

WARNING: indicates that death, severe personal injuryand/or substantial property damage can occur if properprecautions are not taken.

CAUTION: indicates that minor personal injury and/orproperty damage can occur if proper precautions are not taken.

NOTE: indicates and provides additional technicalinformation, which may not be very obvious even to qualified personnel. Compliance with other, notparticularly emphasized notes, with regard to transport,assembly, operation and maintenance and with regard to technical documentation (e.g., in the operatinginstruction, product documentation or on the productitself) is essential, in order to avoid faults, which inthemselves might directly or indirectly cause severepersonal injury or property damage.

General InformationThe following instructions are designed to assist inunpacking, installing and performing maintenance asrequired on Automax Logix® 3200IQ digital positioners.Series 3000 is the term used for all the positioners herein;however, specific numbers indicate features specific tomodel (i.e., Logix 3200 indicates that the positioner hasHART® protocol). See Logix 3200IQ Product SpecificationSheet (AXAPS3200-00) for a breakdown of specific modelnumbers. Product users and maintenance personnel shouldthoroughly review this bulletin prior to installing, operating,or performing any maintenance on the valve.

To avoid possible injury to personnel or damage tovalve parts, WARNING and CAUTION notes must bestrictly followed. Modifying this product, substitutingnon-factory parts or using maintenance proceduresother than outlined could drastically affect performance and be hazardous to personnel andequipment, and may void existing warranties.

WARNING: Standard industry safety practices must beadhered to when working on this or any process controlproduct. Specifically, personal protective and liftingdevices must be used as warranted.

Table of ContentsTerms Concerning Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 1General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Logix 3200IQ Positioner Overview . . . . . . . . . . . . . . . . . . . 2Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Positioner Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Detailed Sequence of Positioner Operations . . . . . . . . . . . . 4Mounting the Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Tubing Positioner to Actuator . . . . . . . . . . . . . . . . . . . 6Wiring and Grounding Guidelines. . . . . . . . . . . . . . . . . . . . 6

4-20 mA Command Input Wiring . . . . . . . . . . . . . . . . 6Grounding Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Compliance Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 8Intrinsically Safe Barriers . . . . . . . . . . . . . . . . . . . . . . 8

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Logix 3200IQ Local Interface Operation. . . . . . . . . . . . 8Initial DIP Switch Settings. . . . . . . . . . . . . . . . . . . . . . 8Description of Configuration DIP Switch Settings . . . . 9Description of Cal DIP Switch Settings . . . . . . . . . . . 10QUICK-CAL Operation . . . . . . . . . . . . . . . . . . . . . . . . 11Manual Jog Calibration Operation . . . . . . . . . . . . . . . 11Local Control of Valve Position . . . . . . . . . . . . . . . . . 11Factory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Command Source Reset . . . . . . . . . . . . . . . . . . . . . . 11Logix 3200IQ Status Condition . . . . . . . . . . . . . . . . . 11Version Number Checking. . . . . . . . . . . . . . . . . . . . . 13SoftTools™ Configuration and Diagnostic Software andHART 275/375 Handheld Communicator . . . . . . . . . . 13

Maintenance and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 14Driver Module Assembly . . . . . . . . . . . . . . . . . . . . . . 14Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Checking or Setting Internal Regulator Pressure . . . . 17Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Spool Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 18Stem Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . 18Main PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20Customer Interface Board . . . . . . . . . . . . . . . . . . . . . 21

Optional Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Vented Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22HART VHF Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22HART Modem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234-20 mA Analog Output Board . . . . . . . . . . . . . . . . . 23

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Logix 3200IQ Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . 27Logix 3200IQ Mounting Kits . . . . . . . . . . . . . . . . . . . . . . 28

Logix O.E.M. Mounting Kits . . . . . . . . . . . . . . . . . . . 28NAMUR Accessory Mounting Kit Part Numbers . . . . . 28

Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . 29Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30





Figure 1: Logix 3200IQ Digital Positioner

Positioner OverviewThe Logix 3200IQ digital positioner is a two-wire 4-20 mA input digital valve positioner. The positioner isconfigurable through the local user interface. The Logix3200IQ utilizes the HART protocol to allow two-wayremote communications with the positioner. The Logix3200IQ positioner can control both double- and single-acting actuators with linear or rotary mountings. Thepositioner is completely powered by the 4-20 mA inputsignal. Start up current must be at least 3.6 mA withoutAO card or 3.85 mA with AO card.

Specifications

Table I: Electrical Specifications

Power Supply Two-wire, 4-20 mA10.0 to 30.0 VDCCompliance Voltage 10.0 VDC @ 20 mA

495 Ω @ 20 mA TypicalEffective Resistance Add 20 Ω when HART

communication activeCommunications HART ProtocolMinimum Operating 3.6 mA without AO boardCurrent 3.85 mA with AO boardMaximum Voltage 30.0 VDC

Table II: SoftTools Suite Software Specifications

Computer Minimum Pentium processor running Windows 95, 98, NT, 2000, XP, 32 MB total memory (64 MB recommended), 30 MB available hard disk space, CD-ROM drive

Ports 1 minimum available with 8 maximum possible. (Can also communicate via

PCMCIA and USB connections)HART Modem RS-232/PCMCIA card/USBHART Filter May be required in conjunction with

some DCS hardwareHART MUX MTL 4840/ELCON 2700

Table III: Environmental Conditions

Standard -4° to 176°FOperating Temperature (-20° to 80°C)Range Low -40° to 176°F

(-40° to 80°C)Transport and Storage Temperature Range -40° to 176°F (-40° to 80°C)

Operating Humidity 0 to 100% non-condensing

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

Table IV: Physical Specifications

Housing Material Cast, powder-painted aluminum, stainless steel

Soft Goods Buna-N / Fluorosilicone

Weight 8.3 pounds (3.9 kg) aluminum20.5 pounds (9.3 kg) stainless steel

Table V: Positioner Specifications

Deadband <0.1% full scaleRepeatability <0.05% full scale

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

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

Piezo Valve

Output 2

Output 1

Hall EffectSensor

FlameArrestor

Exhaust

Spool Valve

FlameArrestor

PressureSensor Board

Air Supply

Analog Output Signal Main PCB

Regulator

Filter

FlameArrestor

Digital Position Algorithm

LEDDisplay

HART Terminals

CommandInput Signal

Air-to-OpenConfiguration

Steam PositionSensor





Positioner OperationThe Logix 3200IQ positioner is an electric feedbackinstrument. Figure 2 shows a Logix 3200IQ positionerinstalled on a double-acting actuator.

The Logix 3200IQ receives power from the two-wire, 4-20 mA input signal. However, since this positionerutilizes HART communications, two sources can be usedfor the command signal: Analog and Digital. In Analogsource, the 4-20 mA signal is used for the commandsource. In Digital source, the level of the input 4-20 mAsignal is ignored and a digital signal, sent via HART, is used as the command source. The command sourceselection can be accessed with SoftTools software, theHART 275/375 communicator, or other host software.

The input signal in percent passes through acharacterization/limits modifier block. The positioner no longer uses CAMs or other mechanical means tocharacterize the output of the positioner. This function is done in software, which allows for in-the-field customer adjustment. The positioner has three basicmodes: Linear, Equal Percent (=%) and Customcharacterization. In Linear mode, the input signal ispassed straight through to the control algorithm in a 1:1 transfer. In Equal Percent (=%) mode, the input signalis mapped to a standard 30:1 rangeability =% curve. If Custom characterization is enabled, the input signal is mapped to either a default =% output curve or acustom, user-defined 21-point output curve. The custom

Figure 2: Logix 3200IQ Digital Positioner Schematic (air-to-open configuration)

Table VI: 4 to 20 mA Analog Output SpecificationsPotential Range 40° to 95°of RotationPower Supply Range 12.5 to 40 VDC, (24 VDC typical)Maximum Load (Supply voltage - 12.5) / 0.02Resistance (ohms)Current Signal Output 4-20 mALinearity 1.0% F.S.Repeatability 0.25% F.S.Hysteresis 1.0% F.S.Operating Temperature -40° to 176°F, -40° to 80°C

Table VII: Hazardous Area Certifications

FM/CSAIntrinsically Safe Explosion Proof

Class I, Div 1, Groups A, B, C, D Class I, Div 1,Groups A, B, C, D

Class II, Div 1, Groups E, F, G Class II, Div 1,Groups E, F, G

(See Figure 2 for installation requirements.)CENELEC

II 1G EEx ia IIC T4, T5Intrinsically Safe T4 Ta = -40°C to 80°C

T5 Ta = -40°C to 35°C

Flameproof II 2 GD EEx d IIB + H2T5, Ta = -40°C to 80°C

Compliant





user-defined 21-point output curve is defined using ahandheld or PC software. In addition, two user-definedfeatures, Soft Limits and MPC (Minimum Position Cutoff),may affect the final input signal. The actual commandbeing used to position the stem, after any characterizationor user limits have been evaluated, is called the ControlCommand.

The Logix 3200IQ uses a two-stage, stem-positioningalgorithm. The two stages consist of an inner-loop, spool control and an outer-loop, stem position control.Referring again to Figure 1, a stem position sensorprovides a measurement of the stem movement. TheControl Command is compared against the Stem Position.If any deviation exists, the control algorithm sends asignal to the inner-loop control to move the spool up or down, depending upon the deviation. The inner-loopthen quickly adjusts the spool position. The actuatorpressures change and the stem begins to move. The stem movement reduces the deviation between ControlCommand and Stem Position. This process continuesuntil the deviation goes to zero.

The inner-loop controls the position of the spool valve by means of a driver module. The driver module consistsof a temperature-compensated hall effect sensor and apiezo valve pressure modulator. The piezo valve pressuremodulator controls the air pressure under a diaphragm bymeans of a piezo beam bender. The piezo beam deflects in response to an applied voltage from the inner-loopelectronics. As the voltage to the piezo valve increases,the piezo beam bends, closing off against a nozzlecausing the pressure under the diaphragm to increase. Asthe pressure under the diaphragm increases or decreases,the spool valve moves up or down respectively. The halleffect sensor transmits the position of the spool back tothe inner-loop electronics for control purposes.

Detailed Sequence of Positioner OperationsA more detailed example explains the control function.Assume the unit is configured as follows:

• Unit is in Analog command source.

• Custom characterization is disabled (thereforecharacterization is Linear).

• No soft limits enabled. No MPC set.

• Valve has zero deviation with a present input signal of 12 mA.

• Loop calibration: 4 mA = 0% command, 20 mA = 100% command.

• Actuator is tubed and positioner is configured air-to-open.

Given these conditions, 12 mA represents a Commandsource of 50 percent. Custom characterization is disabledso the Command source is passed 1:1 to the ControlCommand. Since zero deviation exists, the Stem Positionis also at 50 percent. With the stem at the desiredposition, the spool valve will be at a middle position thatbalances the pressures above and below the piston in theactuator. This is commonly called the null or balancedspool position.

Assume the input signal changes from 12 mA to 16 mA.The positioner sees this as a Command source of 75percent. With Linear characterization, the ControlCommand becomes 75 percent. Deviation is the differencebetween Control Command and Stem Position: Deviation= 75% - 50% = +25%, where 50 percent is the presentstem position. With this positive deviation, the controlalgorithm sends a signal to move the spool up from itspresent position. As the spool moves up, the supply air isapplied to the bottom of the actuator and air is exhaustedfrom the top of the actuator. This new pressure differentialcauses the stem to start moving towards the desiredposition of 75 percent. As the stem moves, the Deviationbegins to decrease. The control algorithm begins toreduce the spool opening. This process continues untilthe Deviation goes to zero. At this point, the spool will beback in its null or balanced position. Stem movement willstop and the desired stem position is now achieved.

One important parameter has not been discussed to thispoint: Inner loop offset. Referring to Figure 3, a numbercalled Inner loop offset is added to the output of thecontrol algorithm. In order for the spool to remain in itsnull or balanced position, the control algorithm mustoutput a non-zero spool command. This is the purpose of the Inner loop offset. The value of this number isequivalent to the signal that must be sent to the spoolposition control to bring it to a null position with zerodeviation. This parameter is important for proper controland is optimized and set automatically during strokecalibration.





Mounting the PositionerCAUTION: Positioner shaft is spring-loaded andfeatures mechanical stops at each end of stroke.Failure to follow these procedures carefully mayresult in severe damage to positioner. Read throughentire procedure before starting.

1. Attach positioner mounting bracket to actuator usingfasteners supplied with bracket (Figure 4). Tightenbolts finger-tight only at this time.

2. Install coupler (if required – coupler is not required for NAMUR mounting) on actuator shaft, making sureit is centered.

Figure 4: Linear Mark One Control Valve Mounting

3. Stroke the actuator to determine direction of rotation as shown in Figure 5. Pay specific attention to the slotthat will engage positioner shaft.

Figure 5: Actuator Shaft

4. Carefully grasp positioner shaft with pliers as shown inFigure 6. Turn shaft to determine direction of rotation.

Figure 6: Turn Positioner Shaft

Sensor

–

++

+

+

SummerIntegration

I

OffsetLoopInner

+

–

GmultPminPmax

Deviation

4-20 mA(Analog Mode)

Command In (DigitalMode)

SignalInput

DigitalAnalog CONTROL

COMMAND

OutputD/A

Percentage

AlgorithmControl

SupplyAir

ControlSpool LoopInner

ATOTubed

SensorPosition

Stem

VoltageValvePiezo

MPCSoft Limits

CharacterizationLinear Mode

Output Inner-Loop

Figure 3: System Positioning Algorithm





5. Making sure positioner shaft rotation matches actuatorshaft rotation, place positioner on mounting bracket(Figure 7). Make sure shafts engage. Do not insertfasteners into positioner at this time.

Figure 7: Positioner on Mounting Bracket

6. Double-check actuator and positioner rotation. Holdpositioner against bracket with fingertips as shown inFigure 8.

Figure 8: Check Positioner Shaft Alignment

WARNING: Keep away from positioner sides, aspositioner will suddenly rotate on bracket if notproperly aligned and cause injury.

Slowly rotate the actuator. If the positioner shaft isproperly aligned, the shaft will rotate freely. If not, themechanical stops will grab, causing the positioner body to rotate on bracket.

7. If the shaft is not properly aligned, repeat steps 3-6.Otherwise, attach positioner to bracket with fastenersincluded with bracket. Tighten bolts finger-tight only atthis time.

8. Stroke actuator/positioner several times to align shafts.Tighten all fasteners.

Tubing Positioner to ActuatorProper tubing orientation is critical for the positioner tofunction correctly and have the proper failure mode. Referringto Figure 2, note that for air-to-open valves, the Output 1 portof the positioner manifold is tubed to the ‘open’ side of theactuator. The Output 2 port of the positioner manifold is tubedto the ‘closed’ side of the actuator. For air-to-close valves theabove configuration is reversed.

Wiring and Grounding Guidelines (See Figure 9)

WARNING: This product has electrical conduitconnections in either thread sizes 1/2" NPT or M20which appear identical but are not interchangeable.Housings with M20 threads are stamped with theletters M20 above the conduit opening. Forcingdissimilar threads together will damage equipment,cause personal injury and void hazardous locationcertifications. Conduit fittings must matchequipment housing threads before installation. If threads do not match, obtain suitable adapters or contact a Flowserve representative.

4-20 mA Command Input WiringVerify polarity when making field termination connection.The Logix 3200 is reverse polarity protected. Wire 4-20mA current source to the input terminal labeled 4-20 mAInput on the user interface board (see Figure 9). Neverconnect a voltage source directly across the Logix 3200IQterminals. The current must always be limited for 4-20mA operation. Minimum operating current is 3.6 mA.

The input loop current signal to the Logix 3200IQ digitalpositioner should be in shielded cable. Shields must betied to a ground at only one end of the cable to provide a place for environmental electrical noise to be removedfrom the cable. In general, shield wire should beconnected at the source.





NOTE: The Logix 3200IQ positioner carries anintrinsically safe barrier rating of 100 mA. Inputcurrents should not exceed 100 mA.

Figure 9: Field Termination

Grounding ScrewThe green grounding screw, located inside the terminationcap, should be used to provide the unit with an adequateand reliable earth ground reference. This ground shouldbe tied to the same ground as the electrical conduit.Additionally, the electrical conduit should be earthgrounded at both ends of its run.

WARNING: The green grounding screw must not beused to terminate signal shield wires.

Compliance Voltage (See Figure 10)Output compliance voltage refers to the voltage limit thatcan be provided by the current source. A current loopsystem consists of the current source, wiring resistance,barrier resistance (if present), and the Logix 3200IQpositioner impedance. The Logix 3200IQ digital positionerrequires that the current loop system allows for a 10.0VDC drop across the positioner at maximum loop current.The 10.0 VDC drop across the Logix 3200IQ positionerterminals is generated by the positioner from the 4-20 mAloop current input. The actual voltage at the terminalsvaries from 9.8 to 10.0 VDC depending on the current mAsignal, HART communications and ambient temperature.

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

Determine if the loop will support the Logix 3200IQ digitalpositioner by performing the following calculation.

Equation 1

Voltage = Compliance Voltage (@Currentmax) – Currentmax • (Rbarrier+Rwire)

The calculated voltage must be greater than 10 VDC inorder to safely support the Logix 3200IQ digitalpositioner.

Example:

DCS Compliance Voltage = 19 VDC

Rbarrier = 300 Ω

Rwire = 25 Ω

Currentmax = 20 mA

Voltage = 19 VDC – 0.020 A • (300 Ω + 25 Ω) = 12.5 VDC

The voltage 12.5 VDC is greater than the required 10.0 VDC; therefore, this system will support the Logix3200IQ digital positioner. The Logix 3200IQ positioner has a worst case input resistance equivalent to 500 Ωat a 20 mA input current.

ANALOGOUTPUT

HART4-20 mA INPUT

Shielded Cable

4-20 mA Current Source

Connect Shield at SourceGround 4-20 mA Current Source

Housing EARTH Terminal

4-20 mA FeedbackTerminals (Optional)

HART Terminals

FieldTerminators

CurrentSource

Logix3200IQ

If Present

R

Barrier

Current

ComplianceVoltage

R

Wire10 VDC

+

–

Figure 10: Compliance Voltage





Cable RequirementsThe Logix 3200IQ digital positioner utilizes the HARTCommunication protocol. This communication signal issuperimposed on the 4-20 mA current signal. The twofrequencies used by the HART protocol are 1200 Hz and2200 Hz. In order to prevent distortion of the HARTcommunication signal, cable capacitance and cable lengthrestrictions must be calculated. The cable length must belimited if the capacitance is too high. Selecting a cablewith lower capacitance/foot rating will allow longer cableruns. In addition to the cable capacitance, the networkresistance also affects the allowable cable length.

In order to calculate the maximum network capacitance,use the following formula:

Equation 2

To control cable resistance, 24 AWG cable should be usedfor runs less than 5000 feet. For cable runs longer than5000 feet, 20 AWG cable should be used.

Intrinsically Safe BarriersWhen selecting an intrinsically safe barrier, make sure thebarrier is HART compatible. Although the barrier will passthe loop current and allow normal positioner control, ifnot compatible, it may prevent HART communication.

StartupLogix 3200IQ Local Interface OperationThe Logix 3200IQ local user interface (Figure 11) allowsthe user to configure the basic operation of the positioner,tune the response and calibrate the positioner withoutadditional tools or configurators. The Local interfaceconsists of a QUICK-CAL button for automatic zero andspan setting, along with two jog buttons (↑ and ↓ ) forspanning valve/actuators with no fixed internal stop in theopen position. There is also a DIP switch block containingeight switches. Seven of the switches are for basicconfiguration settings and one is for calibration options.There is also a rotary selector switch for adjusting thepositioner gain settings. For indication of the operationalstatus or alarm conditions there are also three LEDs onthe local user interface.

Figure 11: Local User Interface

Initial DIP Switch SettingsBefore placing the unit in service, set the DIP switches inthe Configuration and Cal boxes to the desired controloptions. A detailed description of each DIP switch settingfollows.

NOTE: The Logix 3200IQ positioner reads the DIPswitch settings each time the QUICK-CAL button ispressed. If a HART handheld or Flowserve PC softwareis used to configure and then calibrate the positioner,the DIP switches are not read. The auto-tuneadjustment switch labeled “GAIN” is always live andcan be adjusted at any time.

Cnetwork (µF) ≤ - 0.003265

(Rbarrier + Rwire + 390) LEDs

DIP Switch Block

Jog Buttons

Rotary SelectorSwitch

QUICK-CAL Button

Example: Rbarrier = 300 Ω

Rwire = 50 Ω

Ccable = =

- 0.0032 = 0.08 µF = Cmax network (µf)

=

Maximum Cable Length

Maximum Cable Length

= = 3636 ft

65(300 + 50 + 390)

22 pFfoot

0.000022 µFfoot

Cmax network (µF)Ccable

0.08 µF0.000022 µF/foot





Description of Configuration DIP Switch SettingsThe first seven DIP switches are for basic configuration.The function of each switch is described below.

Air ActionThis must be set to match the configuration of thevalve/actuator mechanical tubing connection and springlocation since these determine the air action of thesystem.

ATO (air-to-open) – Selecting ATO if increasing outputpressure from the positioner is tubed so it will cause thevalve to open.

ATC (air-to-close) – Selecting ATC if increasing outputpressure from the positioner is tubed so it will cause thevalve to close.

Signal at ClosedNormally this will be set to 4 mA for an Air-to-openactuator and 20 mA for an Air-to-close actuatorconfiguration.

4 mA – Selecting 4 mA will make the valve fully closedwhen the signal is 4 mA and fully open when the signalis 20 mA.

20 mA – Selecting 20 mA will make the valve fullyclosed when the signal is 20 mA and fully open whenthe signal is 4 mA.

Figure 12: Default Custom Characterization

Pos. CharacterizationLinear – Select Linear if the actuator position should bedirectly proportional to the input signal.

Optional – Select Optional if another characteristic isdesired, which is set in conjunction with the next switch,labeled Optional Pos. Char.

Optional Pos. CharacterizationIf the Pos. Characterization switch is set to optional thenthis switch is active with the following options:

=% – The =% option will characterize the actuatorresponse to the input signal based on a standard 30:1equal percent rangeability curve.

Custom – If Custom is selected, the positioner will becharacterized to a custom table that must be set-upusing a properly configured HART 275/375 handheld orother host software. Custom characterization can bethought of as a “soft CAM.” The user can define acharacterization curve using 21 points. The control willlinearly interpolate between points. Points do not haveto be equally spaced in order to allow more definition atcritical curve areas. The default values will linearize theoutput of a valve with an inherent =% characteristic (e.g., ball valves).

Table VIII: Characteristic Curve Data

% Command % Control Command=% Linear Custom

0 0 0 05 0.62 5 8.66

10 1.35 10 16.2415 2.22 15 23.1720 3.25 20 30.1125 4.47 25 35.3130 5.91 30 40.5135 7.63 35 45.4240 9.66 40 50.3445 12.07 45 54.4050 14.92 50 58.4755 18.31 55 62.3960 22.32 60 66.3165 27.08 65 70.2770 32.71 70 74.2375 39.40 75 78.1780 47.32 80 82.1185 56.71 85 85.5090 67.84 90 88.8995 81.03 95 94.45

100 100.00 100 100.00

0 10 20 30 40 50 60 70 80 90 100

=%

Custom

Linear

0

10

20

30

40

50

60

70

80

90

100

% C

ontro

l Com

man

d

% Command





Auto TuneThis switch controls whether the positioner will auto tuneitself every time the QUICK-CAL button is pressed or usepreset tuning parameters.

On – On enables an auto tune feature that willautomatically determine the positioner gain settingsbased on the current position of the adjustable GAINswitch setting and response parameters measuredduring the last QUICK-CAL. The GAIN switch is live,meaning the settings can be adjusted at any time bychanging the rotary switch position. (Note that there is asmall black arrow indicating the selection. The slot inthe switch is NOT the indicator.)

Figure 13: Adjustable GAIN Switch

If the adjustable GAIN selector switch is set to “E” with the auto tune switch on, a Flowserve standardresponse tuning set will be calculated and used basedon response parameters measured during the lastQUICK-CAL.

If the adjustable GAIN selector switch is set to “D”, “C”,“B”, or “A” with the auto tune switch on, progressivelylower gain settings will be used based on responseparameters measured during the last QUICK-CAL.

If the adjustable GAIN selector switch is set to “F”, “G”, or “H” with the auto tune switch on, progressivelyhigher gain settings will be calculated and used basedon response parameters measured during the last QUICK-CAL.

Off – Off forces the positioner to use one of the factorypreset tuning sets determined by the adjustable GAINselector switch. Settings “A” through “H” are progress-ively higher gain predefined tuning sets. The GAINselector switch is live and can be adjusted at any time to modify the tuning parameters.

NOTE: “E” is the default adjustable GAIN selectorswitch setting for all actuator sizes. Raising orlowering the gain setting is a function of thepositioner/valve response to the control signal, and is not actuator size dependent.

Configuration SwitchesEnabled – By selecting Enabled, the Logix 3200IQ will read all of the configuration switches each time aQUICK-CAL is performed to determine the configuration.

Disabled – Selecting Disabled retains the lastconfiguration in memory (from the last successfulcalibration) before the switch was set to Disabled. With this setting a QUICK-CAL only zeros and spans the positioner.

Stability SwitchThis switch adjusts the position control algorithm of the positioner for use with low-friction control valves or high-friction automated valves.

Low-Friction Valves – Placing the switch to the left optimizes the response for low-friction, high-performance control valves. This setting provides for optimum response times when used with most low-friction control valves.

High-Friction Valves – Placing the switch to the rightoptimizes the response for valves and actuators withhigh friction levels. This setting slightly slows theresponse and will normally stop limit cycling that canoccur on high-friction valves.

Description of Cal DIP Switch SettingsThe eighth DIP switch selects between two calibrationoptions. The function of the Cal DIP switch is describedbelow.

Auto – Select Auto if the valve/actuator assembly has an internal stop in the open position. In Auto mode thepositioner will fully close the valve and register the 0%position and then open the valve to the stop to registerthe 100% position when performing a self-calibration. See detailed instructions in the next section on how toperform an auto positioner calibration.

Jog – Select Jog if the valve/actuator assembly has nophysical calibration stop in the open position. In the Jog mode the positioner will fully close the valve for the 0% position and then wait for the user to set the openposition using the Jog buttons labeled with the up anddown arrows. See the detailed instructions in the nextsection on how to perform a manual calibration usingthe Jog buttons.

WARNING: During the QUICK-CAL operation thevalve may stroke unexpectedly. Notify properpersonnel that the valve will stroke and make sure the valve is properly isolated.

A

GAIN

B

C

DE

F

G

H





QUICK-CAL OperationThe QUICK-CAL button is used to locally initiate acalibration of the positioner. Pressing and holding theQUICK-CAL button for approximately three seconds willinitiate the calibration. If the Config-Switches option isenabled, the settings of all the configuration switches are read and the operation of the positioner adjustedaccordingly. A QUICK-CAL can be aborted at any time bybriefly pressing the QUICK-CAL button and the previoussettings will be retained.

If the Quick Calibration switch (be careful not to confusethis with the QUICK-CAL button) is set to Auto and thevalve/actuator assembly has the necessary internal stopsthe calibration will complete automatically. While thecalibration is in progress you will notice a series ofdifferent lights flashing indicating the calibration progress.When the lights return to a sequence that starts with agreen light the calibration is complete. An explanation ofthe various light sequences follows. The initial calibrationof extremely large or small actuators may require severalcalibration attempts. The positioner adapts to the actuatorperformance and begins each calibration where the lastattempt ended. On an initial installation it is recommendedthat after the first successful calibration that one morecalibration be completed for optimum performance.

WARNING: When operating using QUICK-CAL orlocal control, the valve will not respond to externalcommands. Notify proper personnel that the valvewill not respond to remote command changes and make sure the valve is properly isolated.

Manual Jog Calibration OperationIf the Quick Calibration switch is set to Jog, the calibrationwill initially close the valve then cause a small jump in thevalve position. The jog calibration process will only allowthe user to manually set the span; zero position isautomatically always set at the seat. If an elevated zero is needed a handheld or other PC based configurationsoftware is required. When performing a jog calibration,the LEDs will flash in a sequence of Y-R-R-G (yellow-red-red-green) which indicates that the user must use the Jog buttons (↑ and ↓ ) to manually position the valve toapproximately 100%. When the valve is approximately100% open press both the Jog buttons (↑ and ↓ )simultaneously to proceed to the next step. The valve willstroke and then wait while flashing the Y-R-R-G sequenceagain, allowing the user to adjust the valve position asecond time to exactly 100% using the Jog buttons (↑ and ↓ ). When the stem is properly positioned press

both the Jog buttons (↑ and ↓ ) simultaneously again toregister the 100% position and proceed. No more useractions are required while the calibration process iscompleted. When the lights return to a sequence thatstarts with a green light the calibration is complete. An explanation of the various light sequences follows.

Local Control of Valve PositionLocal control of valve position can be achieved from theuser interface by holding down both Jog buttons and theQUICK-CAL button simultaneously for three seconds.While in this mode the LEDs will flash a YGRR (yellow-green-red-red) sequence. Use the two Jog buttons (↑ and ↓ ) to manually control the position of the valve. To exit the local control mode and return to normaloperation, briefly press the QUICK-CAL button.

Factory ResetTo perform a factory reset, disconnect power, hold theQUICK-CAL button down and reconnect power.Performing a factory reset will cause all of the internalvariables, including calibration, to be reset to factorydefaults. The positioner must be recalibrated after afactory reset. Tag names and other user configured limits,alarm settings and valve information will also need to be restored.

WARNING: Performing a factory reset may result inthe inability to operate the valve until reconfiguredproperly. Notify proper personnel that the valve maystroke and make sure the valve is properly isolated.

Command Source ResetPerforming a command source reset will reset thecommand source to analog source if it has beeninadvertently left in digital mode. This is done while aQUICK-CAL is in process by holding down both the Jogbuttons (↑ and ↓ ) while briefly pressing the QUICK-CALbutton. A new QUICK-CAL must be done after resetting.

Logix 3200IQ Status ConditionThe blink codes used to convey the status of the Logix3200IQ digital positioner are described in the table below.In general, any sequence starting with a green lightflashing first is a normal operating mode and indicatesthat there are no internal problems. Any sequence startingwith a yellow light flashing indicates that the unit is in aspecial calibration or test mode, or that there was acalibration problem. Any sequence starting with a red lightflashing indicates that there is an operational problemwith the unit.

Colors ID Indication and Resolution





Logix 3200IQ Status Condition CodesColors ID Indication and ResolutionG - - - Any sequence starting with a green light flashing first is a

normal operating mode and indicates that there are nointernal problems.

GGGG 1 Normal operation - Analog Command mode. No errors,alerts, or warnings.

GGGY 2 Tight shutoff (MPC) active - The command is below theuser-set limit for tight shutoff feature. This is a normalcondition for a closed valve. The factory default setting is1% command. To clear the condition use handheld orFlowserve-supplied software to reset the tight shutoff if therange is incorrect or adjust the command signal above thespecified MPC value.

GGYG 3 Digital command mode - The analog 4-20 mA input signalis ignored in this mode and a handheld or Flowserve-supplied software is needed to change the positioncommand. (Note a command reset is provided to changethe command back to analog control mode from the localinterface if a PC or handheld configurator is not available.)

GGYR 4 Initializing - This sequence should only be visible for threesequences when powering up the unit.

GGRG 5 Cycle limit exceeded (user-set) - The cycle limit set by theuser has been exceeded. To clear use handheld orFlowserve-supplied software to reset.

GGRY 6 Travel limit exceeded (user-set) - The total accumulatedtravel limit set by the user has been exceeded. To clear usehandheld or Flowserve-supplied software to reset.

GYYR 7 Lower soft stop reached (user-set) - The unit is beingcommanded to exceed a user-defined lower position limitand the internal software is holding the position at the limit.The function is similar to a mechanical limit stop except it isnot active if the unit is un-powered. To clear the conditionuse handheld or Flowserve-supplied software to reset thelimit if more travel is needed or adjust the command signalback in the specified range.

GYRY 8 Upper soft stop reached (user-set) - The unit is beingcommanded to exceed a user-defined upper position limitand the internal software is holding the position at the limit.The function is similar to a mechanical limit stop except it isnot active if the unit is un-powered. To clear the conditionuse handheld or Flowserve-supplied software to reset thelimit if more travel is needed or adjust the command signalback in the specified range.

GRYR 9 Lower position alert (user-set) - The position has reachedor is exceeding a user-defined lower position indicatorsimilar to a limit switch indicator. To clear the condition usehandheld or Flowserve-supplied software to reset theindicator if more travel is needed or adjust the commandsignal back in the specified range.

GRRY 10 Upper position alert (user-set) - The position has reachedor is exceeding a user-defined upper position indicatorsimilar to a limit switch indicator. To clear the condition usehandheld or Flowserve-supplied software to reset theindicator if more travel is needed or adjust the commandsignal back in the specified range.

Y - - - Any sequence starting with a yellow light indicates that theunit is in a special calibration or test mode, or that therewas a calibration problem.

YGYG 11 Signature test in progress - This is a test initiated byFlowserve-supplied software that can only be cancelled bythat software.

YYYG 12 Loop calibration in progress - Calibration sequencecontrolled by a handheld or Flowserve-supplied softwarethat can only be cancelled by that software.

YRGG 13 Stroke calibration in progress - Calibration sequencestarted either using the local QUICK-CAL button or by ahandheld or Flowserve-supplied software. It may becancelled by briefly pushing the QUICK-CAL button.

YGRR 14 Local jog control model - The unit has been placed in alocal override mode where the valve can only be strokedusing the two local jog buttons. It may be cancelled bybriefly pushing the QUICK-CAL button.

YYGR 15 Pressure calibration in progress - Calibration sequencecontrolled by a handheld or Flowserve-supplied softwarethat can only be cancelled by that software.

YYYY 16 Local user interface disabled - PC software has been usedto disable the local interface. If local control is desired thenthe local interface must be re-enabled from the remotesoftware. This code is only present for a short time whenthe QUICK-CAL button is pressed.

YRRG 17 Waiting - Adjust to full open position setting from User — only used during Jog calibration see explanation on page 11, “QUICK-CAL,” for operation.

YRYG 18 Setting IL offset while calibrating - An automatic step inthe calibration process that is done with the valve at 50%position. This must be completed for proper calibration.

YRYY 19 No feedback motion while calibrating - Indicates that therewas no motion of the actuator based on the current stroketime configuration. Check linkages and air supply to makesure the system is properly connected. If the time outoccurred because the actuator is very large then simplyretry the QUICK-CAL and the positioner will automaticallyadjust for a larger actuator by doubling the time allowed formovement. This error may be cleared by briefly pushing theQUICK-CAL button, which will force the positioner to usethe parameters from the last good calibration.

YRYR 20 Feedback 0% out of range - Calibration error indicating thatthe position sensor was out of range during the calibrationof the closed position. To correct the condition, adjust thepositioner mounting, linkage or feedback potentiometer tomove the position sensor back into range then restart thecalibration. This error may be cleared by briefly pushing theQUICK-CAL button, which will force the positioner to usethe parameters from the last good calibration.

YRRY 21 Feedback 100% out of range - Calibration error indicatingthat the position sensor was out of range during thecalibration of the open position. To correct the condition,adjust the positioner mounting, linkage or feedbackpotentiometer to move the position sensor back into rangethen restart the calibration. This error may be cleared bybriefly pushing the QUICK-CAL button, which will force thepositioner to use the parameters from the last goodcalibration.

YRRR 22 Feedback span too small - The range of motion of theposition feedback arm was too small for optimumperformance. Check for loose linkages and/or adjust thefeedback pin to a position closer to the follower arm pivotto create a larger angle of rotation and recalibrate. Brieflypushing the QUICK-CAL button acknowledges this conditionand the positioner will operate using the current shortstroke calibration if otherwise a good calibration.

YRGR 23 Feedback unstable while calibrating - Check for looselinkages or loose positioner sensor. This error may becleared by briefly pushing the QUICK-CAL button, which willforce the positioner to use the parameters from the lastgood calibration. This error may appear on some very smallactuators during the initial calibration. Redoing thecalibration may clear the problem.

Colors ID Indication and Resolution





R - - - Any sequence starting with a red light indicates that there isan operational problem with the unit.

RGRR 24 Position deviation (user-set) - The position has exceededuser-defined error band between command and position.

RGYY 25 Pressure reading out of range - The internal pressuresensors are either saturated with a pressure over 150 psi orthe sensor has failed. Check supply pressure and if OKcheck the pressure sensor board connections and replacepressure sensor board if necessary.

RGYR 26 Loss of supply pressure - The positioner has determinedthat the supply pressure is below 15 psi. Check the supplypressure and if OK check the pressure sensor boardconnections and replace pressure sensor board ifnecessary. Minimum recommended supply pressure is 30 psi for proper operation.

RYYY 27 Pilot relay non-motion alert - Check to make sure the airsupply is connected. Also check the internal wiringharnesses for good connections. This error may be clearedby briefly pushing the QUICK-CAL button, which will forcethe positioner to use the parameters from the last goodcalibration. If the positioner still does not operate replacethe pneumatic relay assembly.

RYYR 28 Pilot relay lower position alert - Check to make sure theair supply is connected. Also check the internal wiringharnesses for good connections. This error may be clearedby briefly pushing the QUICK-CAL button, which will forcethe positioner to use the parameters from the last goodcalibration. If the positioner still does not operate replacethe pneumatic relay assembly.

RYRY 29 Pilot relay upper position alert - Check to make sure theair supply is connected. Also check the internal wiringharnesses for good connections. This error may be clearedby briefly pushing the QUICK-CAL button, which will forcethe positioner to use the parameters from the last goodcalibration. If the positioner still does not operate replacethe pneumatic relay assembly.

RRGG 30 Watchdog timer timeout (also listed as internal voltagereference) - This is often caused when intermittentoperation occurs when connecting power. Remove powerand then reconnect to clear. If problem persists it is a badelectronic assembly, replace.

RRYG 31 Internal temperature alert - The internal positionertemperature is currently exceeding operational limits of -40°F (-40°C) or 185°F (85°C).

RRYY 32 Piezo voltage error - Bad electronic assembly, replace.RRYR 33 Internal voltage reference error - Indicates that the circuit

board is drawing too much power. Check internal wiring andconnectors for electrical shorts – if no shorts are present,replace the electronic assembly.

RRRY 34 NV RAM checksum error - The checksum of the internaldata was not updated correctly. Cycle power and complete a QUICK-CAL if error persists. Check internal data to verifycorrect settings. If the error still occurs, replace the electronic assembly.

Version Number CheckingThe version number of the embedded code may bechecked at any time except during a calibration by holdingdown the up arrow Jog button (↑ ). This will not alter theoperation of the unit other than to change the blinksequence to three blinks indicating the major versionnumber. Holding the down arrow Jog button (↓ ) will givethe minor version number without affecting operation. The version codes are interpreted by adding up thenumbers assigned according to the following table:

ColorFirst Second Third

blink value blink value blink value

Green 0 0 0

Yellow 9 3 1

Red 18 6 2

For example if holding the up arrow Jog button (↑ ) gave aG-G-R code, and holding the down arrow Jog button (↓ )gave a Y-Y-G code then the resulting version numberwould be (0+0+2).(9+3+0) or version 2.12.

SoftTools™ Configuration and Diagnostic Software and HART 275/375 Handheld CommunicatorFlowserve Corporation has written custom configurationand diagnostic software for the Logix 3200IQ digitalpositioner called SoftTools. This software and theSoftTools Quick Start Guide are available from a Flowserve representative.

The Logix 3200IQ digital positioner supports and issupported by the HART 275/375 Handheld Communicator.The Device Description (DD) files and the manuals listedbelow can be obtained from the HART CommunicationFoundation or from your Flowserve representative. Formore information please see the following guides:

• Product Manual for the HART Communicator.

• Logix 3200IQ Digital Positioner with HART 275/375Communicator User Guide.

Diagnostic features such as the datalog, signature tests,and ramp tests are performed using the SoftToolssoftware. Certain calibration features such as loopcalibration, analog output calibration and actuatorpressure sensor calibrations are performed using theHART 275/375 Handheld Communicator or usingdiagnostic software such as SoftTools.





Maintenance and RepairDriver Module AssemblyThe driver module assembly moves the spool valve bymeans of a differential pressure across its diaphragm. Airis routed to the driver module from the regulator througha flexible hose. A barbed fitting connects the flexible hoseto the driver module assembly. Wires from the drivermodule assembly connect the hall effect sensor and thepiezo valve modulator to the main PCB assembly.

Driver Module Assembly ReplacementTo replace the driver module assembly, refer to Figures14-18 and 28 and proceed as outlined below. Thefollowing tools are required:

• Flat plate or bar about 1 ⁄8" thick• Phillips screwdriver• 1/4" nutdriver

WARNING: Observe precautions for handlingelectrostatically sensitive devices.

Figure 14: Driver Module Assembly

1. Make sure the valve is bypassed or in a safe condition.2. Disconnect the power and air supply to the unit.3. Remove the driver module cover (Figure 17), using a

flat bar or plate in the slot to turn the cover.4. Remove the spool valve cover by removing the screw

and sliding the cover assembly backwards until the tabis clear of the slot (Figure 15). The sheet metal cap,hydrophobic filter and O-ring should be removed withthe spool valve cover. It is not necessary to take theseparts out of the spool valve cover.

Figure 15: Spool Valve Cover Assembly

Figure 16: Spool and Block

5. Being careful not to lose the nylon washer, remove thePhillips-head screw that attaches the driver module tothe main housing (Figure 16).

WARNING: Spool (extending from the driver moduleassembly) is easily damaged. Use extreme cautionwhen handling spool and spool valve block. Do nothandle the spool by the machined portions of spool.The tolerances between the block and spool areextremely tight. Contamination in the block or on thespool may cause the spool to hang.

6. Remove the spool valve block by removing the twoPhillips-head screws and carefully sliding the block offthe spool (Figure 16).

7. Carefully remove the spool by sliding the end of thespool out of the connection clip. Excessive force maybend spool.

8. Remove the main cover.9. Remove the plastic board cover by removing the three

retaining screws (see Figure 17).

Pressure Sensor Board

Hall SensorConnection

PressureModulatorConnection

O-ringDriver ModuleAssembly

AnalogOutputBoard

Connection

AnalogOutput Board

Install Barbed Fitting afterDriver Module is in housing

Hall Sensor Connector

Pressure Modulator Connector

Position wiresto the rearof Modulator

Regulator

Pressure SensorBoard Connection

User InterfaceBoard Connection

Stem Position SensorConnection

Main PCBRetainingScrew

Screw

Spool Valve Cover

Spool ValveScrew Nylon

Gasket

Driver toHousing Screw

Spool

Spool Valve Block

Housing





Figure 17: Driver Module Barbed Fitting

10. Disconnect the flexible tubing from the barbed fitting atthe driver module assembly (see Figure 17).

11. Use the 1/4" nutdriver to remove the barbed fittingfrom the driver module assembly.

12. Unplug the two wiring connections that link the drivermodule assembly to the main PCB assembly.

13. Feed the two wires on the driver module back into thedriver module compartment so that they stick out thedriver module opening (see Figure 14). This will allowthe driver module to thread out without tangling orcutting the wires.

14. Grasp the base of the driver module and turn itcounterclockwise to remove. After it is threaded out,carefully retract the driver module from the housing.

Barbed FittingFlat onHousing

Flat onDriverModule

Driver Module Cover

Main PCB

Analog Output Board

Pressure Sensor Board

Regulator

PlasticBoardCover

Main PCBRetaining Screws

Plastic CoverRetaining Screws

Figure 18: Main PCB Assembly





15. Remove the barbed fitting from the side of the newdriver module using the 1/4" nutdriver.

16. Verify that the O-ring is in place on the top of the newdriver module. Lay the wires back along the side of thedriver module as shown in Figure 14 and hold thewires in position by hand.

17. Gently insert the driver module into the driver modulecompartment in the housing. Turn the driver moduleclockwise to thread it into the housing. Continuerotating the driver module until it bottoms out.

18. Once the driver module has bottomed out so that thethreads are fully engaged, rotate the driver modulecounter clockwise until the flat on the driver moduleand the flat on the housing are aligned. This will alignthe screw hole for the next step.

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

20. Insert a driver-to-housing screw into the driver housingthrough the counterbored hole in positioner mainhousing. Tighten with a Phillips screwdriver.

21. Reach through the main compartment into the drivermodule compartment of the positioner and install thebarbed fitting on the side of the driver module usingthe 1/4" nutdriver.

NOTE: Do not mix the barbed fitting with those fromolder Logix positioners. Older models contain orificesthat will not work in the Logix 3200IQ model. Orificesare brass-colored, barbed fittings are silver-colored.

22. Reconnect the flexible tube coming from the regulatorto the barbed fitting.

23. Feed the driver module wires into the main chamber of the housing, and connect them to the main PCBAssembly.

24. Verify that the three O-rings are in the counterbores onthe machined platform where the spool valve block isto be placed (Figure 28).

25. Carefully slide the spool into the connecting clip on thetop of the driver module assembly.

26. Carefully slide the block over the spool, using themachined surface of the housing base as a register(Figure 16). Slide the block toward the driver moduleuntil the two retaining holes line up with the threadedholes in the base.

27. Install two spool-valve screws and tighten securelywith a Phillips screwdriver (see Figure 16).

28. Slide the spool valve cover assembly over the spoolvalve until the tang engages into the housing slot.

Install spool valve cover screw and tighten securely(see Figure 15).

29. Install the plastic board cover. Insert the three retainingscrew through the plastic cover into the threaded bossand tighten evenly, using a Phillips screwdriver. Do notovertighten (see Figure 18).

30. Reconnect power and air supply to the positioner andperform a stroke calibration.

31. Reinstall all covers.

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

Replacing RegulatorTo replace the regulator, refer to Figures 14 and 18 andproceed as outlined below. The following tools arerequired:

• Phillips screwdriver

• 1/4" nutdriver


1. Make sure valve is bypassed or in a safe condition.2. Disconnect the power and air supply to the unit.3. Remove the main cover.4. Remove the plastic board cover by removing the three

retaining screws (see Figure 18).5. Remove the five wire connections from the main PCB

assembly (six wire connections if the unit is equippedwith the 4-20 mA analog output option).

6. Remove the retaining screw from the main PCBassembly and lift the main PCB out of the housing.

7. Remove the four screws from the regulator base. Verify that as regulator is removed, the O-ring and filterremain in the counter-bore (please see Figure 14).

8. Remove tubing and barbed fitting from the regulatorbase.

9. Install barbed fitting and tubing to the new regulator.10. Verify O-ring and filter are in the counterbore. Install

new regulator using 8-32 x 1/2" screws.

NOTE: Do not mix the regulator with those from olderLogix positioners. Older models contain regulatorswith different settings that will not work in the Logix3200IQ model. The regulator pressure setting isprinted on the top of the regulator. The Logix 3200IQregulator is set to 17.4 psig.





11. Install the main PCB into the housing. Insert theretaining screw through the board into the threadedboss and tighten evenly, using a Phillips screwdriver.Do not overtighten.

12. Reinstall the five wire connections (six wireconnections if the unit is equipped with the 4-20 mAanalog output option).

13. Install the plastic board cover. Insert the three retainingscrews through the plastic cover into the threadedboss and tighten evenly, using a Phillips screwdriver.Do not overtighten (see Figure 18).


Checking or Setting Internal Regulator PressureTo check or set the internal regulator pressure, refer toFigure 19 and proceed as outlined below. The tools andequipment used in the next procedure are from indicatedvendors. The following tools are required:

• Calibrated pressure gauge (0 to 30 psi)

• 1 ⁄16" flexible tubing

• Barbed Tee (Clippard Minimatic part number T22-2 or equivalent)

• 3 ⁄32" Allen wrench

• 3 ⁄8" open-end wrench


Figure 19: Driver Module Regulator Pressure Check

1. Make sure the valve is bypassed or in a safe condition.2. Remove the main cover.3. Remove the plastic board cover by removing the three

retaining screws.4. Remove the 1 ⁄16" flexible tubing from the barbed

fitting on the side of the driver module.5. Obtain a barbed tee and two pieces of 1 ⁄16" flexible

tubing, a few inches in length each.6. Position the barbed tee between the internal regulator

and the driver module by connecting the 1 ⁄16" flexibletubing, found in the positioner, to one side of thebarbed tee. Using one of the new flexible tubing pieces,connect the barbed tee to the barbed fitting on the sideof the driver module. Connect the remaining port onthe barbed tee to a 0 to 30 psi pressure gauge.

7. Reconnect the air supply to the positioner and read theinternal regulator pressure on the 0 to 30 psig gauge.The internal pressure should be set to 17.4 ±0.2 psig.If adjustment is needed, loosen the set screw retainingnut on the top of the regulator using the 3 ⁄ 8" open-endwrench. Then adjust the regulator pressure by turningthe set screw on the top of the regulator with the 3 ⁄ 32"Allen wrench.

8. Once the regulator pressure is set, tighten the setscrew retaining nut on the top of the regulator, removethe air supply to the positioner, remove the barbed tee,and reconnect the flexible tubing from the regulator tothe barbed fitting on the side of the driver module.



Spool ValveThe spool valve routes the supply air to one side of theactuator while venting the opposite side (see Figure 2).The position of the spool valve is controlled by the driver module.

Replacing the Spool ValveTo replace the spool valve, refer to Figures 15, 17 and 28and proceed as outlined below. The following tools arerequired:


1. Make sure the valve is bypassed or in a safe condition.2. Disconnect the power and air supply to the unit.3. Remove the spool valve cover by removing the screw

and sliding the cover assembly backwards until the tab

Regulator PressureTest Port

Barbed Tee(Clippard MinimaticPart No. T22-2)

Flexible Tubefrom Regulator

Driver ModuleBarbed Fitting10-32 x 1/16"





is clear of the slot. It is not necessary to remove thesheet metal cap, hydrophobic filter, or O-ring from thisassembly (Figure 17).

WARNING: The spool (extending from the drivermodule assembly) is easily damaged. Use extremecaution when handling spool and spool valve block. Do not handle the spool by the machined portions ofspool. The tolerances between the block and spoolare extremely tight. Contamination in the block or onthe spool may cause the spool to hang.

4. Remove the spool valve block by removing the twoPhillips-head screws and carefully sliding the block offthe spool (Figure 15).

5. Carefully remove spool by sliding end of spool out ofconnecting clip. Excessive force may bend the spool.

6. Verify that the three O-rings are in the counterbores onthe machined platform where the new spool valveblock is to be placed (Figure 28).

7. Carefully slide the spool into the connecting clip of thedriver module assembly.

8. Carefully slide the block over the spool, using themachined surface of the housing base as a register(Figure 15). Slide the block toward the driver moduleuntil the two retaining holes line up with the threadedholes in the base.

9. Install two spool valve screws and tighten securelywith a Phillips screwdriver (see Figure 16).

10. Slide the spool valve cover assembly over the spoolvalve until the tang engages into the housing slot.Install the spool valve cover screw and tighten securely(see Figure 15).

11. Reconnect power and air supply to the positioner andperform a stroke calibration.

Spool Valve CoverThe spool valve cover incorporates a coalescing filterelement in a two-piece cover. This protects the spoolvalve chamber from dirt and moisture and provides a lowback pressure vent for exhaust air from the spool valve.

Replacing Filter in Spool Valve CoverTo replace the filter in the spool valve cover, refer toFigures 15 and 20 and proceed as outlined below. The following tools are required:


1. Remove the spool cover by removing the screw andsliding the cover assembly backwards until the tab is clear of the slot. The sheet metal cover may beremoved and cleaned with a brush or by blowing out with compressed air (Figure 15).

2. Remove the O-ring from around the hydrophobic filterelement and set aside (Figure 20).

3. Remove the molded filter element by pulling it straightout of the chamber cover vent piece.

4. Install O-ring into base of chamber cover vent piece asshown in Figure 20.

5. Place new molded filter element into the chambercover vent piece. This filter element provides part ofthe track to secure the O-ring installed in the last step.

6. Place spool valve shroud onto spool valve cover.7. Place the spool valve cover assembly in place by

setting it on the ramp and sliding it until the tab seatsin the slot (Figures 15 and 20) and secure with a 8-32 screw.

Figure 20: Spool Valve Cover Assembly

Stem Position SensorThe position feedback assembly transmits valve positionsinformation to the processor. This is accomplished bymeans of a rotary position sensor that connects to thevalve stem through a feedback linkage. To provide foraccurate tracking of the pin in the slot, the follower arm isbiased against one side of the slot with a rotary spring.This spring also automatically moves the positionfeedback assembly to its limit in the unlikely event offailure of any component in the linkage.

Stem Position Sensor ReplacementTo replace the stem position sensor, refer to Figure 18, 21and 28 and proceed as outlined below. The following toolsare required:



1. Make sure the valve is bypassed or in a safe condition.2. Disconnect the power and air supply to the unit.

O-ring

HydrophobicFilter

SpoolValveCover

SpoolValve Shroud





3. Remove the main cover.4. Remove the plastic board cover by removing the three

retaining screws (see Figure 18).5. Disconnect the position sensor wires from the main

PCB assembly.6. Remove the two rotary position sensor-retaining

screws and lift the sensor out of the housing.7. Turn the new position sensor shaft until the dot on the

side of the shaft is aligned with the wires on the side ofthe position sensor (Figure 21).

8. Insert the position sensor into the shaft with the wirespointing toward the main PCB assembly. Turn theposition sensor clockwise until bolting slots align withthe housing screw holes and the wires on the sensorprotrude over the main PCB assembly.

Note: Do not mix the position sensor with those fromolder Logix positioners. Older models contain sensorswith different ranges that will not work in the Logix3200IQ model. The wires on the Logix 3200IQposition sensor are red, white and black.

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

10. Route the wires along the side of the position sensorand reconnect to the main PCB assembly.


12. Reinstall all covers.13. Reconnect power and air supply to the positioner and

perform a stroke calibration.

Stem PositionSensor DotBearing

FeedbackShaft Sensor

Cable

StemPositionSensorHousing

Figure 21: Stem Position Sensor Orientation





Main PCB AssemblyThe main printed circuit board (PCB) assembly containsthe circuit board and processor that perform controlfunctions of the positioner. The main PCB is to bereplaced as a unit. None of the components on the mainPCB are serviceable.

Replacing Main PCB AssemblyTo replace the main PCB assembly, refer to Figure 14 and18 and proceed as outlined below. The following tools are required:



1. Make sure the valve is bypassed or in a safe condition.2. Disconnect the power and air supply to the unit.3. Remove the main cover.4. Remove the plastic board cover by removing the three

retaining screws (see Figure 18).5. Remove the five wire connections from the main

PCB assembly (six wire connections if the unit isequipped with the 4-20 mA analog output option) (see Figure 14).

6. Remove the retaining screw from the main PCBassembly and lift the main PCB out of the housing (see Figure 18).

7. Install the new main PCB into the housing. Insert theretaining screw through the board into the threadedboss and tighten, using a Phillips screwdriver. Do not overtighten.

8. If the old main PCB is equipped with a 4-20 mA analogoutput board, gently lift the board off the main PCB.Align the two connectors of the 4-20 mA output boardwith the mating sockets on the main PCB and gentlypress the connectors together.

9. Reinstall the five wire connections (six wireconnections if the unit is equipped with the 4-20 mAanalog output option) (see Figure 14).


11. Reinstall all covers.12. Reconnect power and air supply to the positioner and

reconfigure the positioner being sure to perform astroke calibration.

Pressure Sensor BoardOn advanced model Logix 3200IQ positioners, a pressuresensor board is installed in the positioner. The pressuresensor board contains two pressure sensors that measurethe pressure on output ports 1 and 2. The main PCBelectronics automatically senses the presence of thepressure sensor board. If present, the actuator pressuresensors are used in the positioner control algorithm toenhance valve stability. For optimal performance, theactuator pressure sensors need to be calibrated. Theactuator pressure sensor calibration is performed using aHART 275/375 Handheld Communicator or configurationsoftware such as SoftTools.

In the standard model, the pressure sensor board isreplaced by a plate that plugs the actuator pressuresensor ports. This plate can be replaced by a pressuresensor board to field-upgrade a standard model to anadvanced model.

Removing the Pressure Sensor Board (Advanced Model)To replace the pressure sensor board, refer to Figures 14,18 and 28 and proceed as outlined below. The followingtools are required:




retaining screws (see Figure 18).5. Disconnect the ribbon cable on the pressure sensor

board from the PCB assembly (see Figure 14).6. Remove the two screws holding the pressure sensor

board to the housing. Lift the metal stiffener plate offthe pressure sensor board and set aside for future use.

7. Remove the pressure sensor board.

Removing the Pressure Sensor Plug Plate (Standard Model)To upgrade a standard model to an advanced model, thepressure sensor plug plate must be removed and replacedby a pressure sensor board. The main PCB electronicsautomatically senses the presence of the pressure sensorboard. If present, the actuator pressure sensors are usedin the positioner control algorithm to enhance valvestability. For optimal performance, the actuator pressuresensors need to be calibrated. The actuator pressure





sensor calibration is performed using a HART 275/375Handheld Communicator or configuration software such as SoftTools. To upgrade a standard model to anadvanced model, refer to Figures 14, 18 and 28 andproceed as outlined below. The following tools arerequired:



retaining screws (see Figure 18).5. Remove the two screws holding the pressure sensor

plug plate to the housing. Lift the metal stiffener plateoff the pressure sensor plug plate and set aside forfuture use.

6. Remove the pressure sensor plug plate and discard.

Installing the Pressure Sensor Board (Advanced Model)The pressure sensor board is installed on the advancedmodel only. To install the pressure sensor board, refer toFigures 14, 18 and 28 and proceed as outlined below. The following tools are required:


• Torque wrench

WARNING: Observe precautions for handlingelectrostatic sensitive devices.

1. Verify that the two pressure sensor O-rings (item 15)are in place in the housing.

2. Set the pressure sensor board assembly in place sothat the O-rings make contact with the faces of thepressure sensors.

3. Place the metal stiffener plate (item 12) on top of thepressure sensor board over the pressure sensors andalign the two holes in the pressure sensor plate withthe threaded bosses in the housing.

4. Insert two screws through the stiffener plate andpressure sensor board into the threaded holes in thehousing and tighten evenly, to 8 in-lb.

5. Connect the ribbon cable on the pressure sensor boardto the main PCB assembly.

6. Install the plastic board cover. Insert the three retainingscrews through the plastic cover into the threadedboss and tighten evenly, using a Phillips screwdriver.Do not overtighten.


8. Reconnect power and air supply to the positioner. Use SoftTools or a handheld communicator to performa pressure sensor calibration.

Customer Interface BoardThe customer interface board provides a connection point inside the explosion-proof housing for all hookupsto the positioner. Calibration of the loop current and theanalog output current (optional) are performed using aHART 275/375 Handheld Communicator or configurationsoftware such as SoftTools.

Replacing the Customer Interface BoardTo replace the customer interface board, refer to Figures 9, 14, 18 and 28 and proceed as outlined below.The following tools are required:


WARNING: Observe precautions for handlingelectrostatic sensitive devices.


retaining screws (see Figure 18).5. Remove the five wire connections from the main

PCB assembly (six wire connections if the unit isequipped with the 4-20 mA analog output option) (see Figure 14).

6. Remove the retaining screw from the main PCBassembly and lift the main PCB out of the housing (see Figure 18).

7. Remove the user interface cover.8. Disconnect the field wiring from the customer interface

board terminals and remove the three screws that hold the customer interface board in the housing (see Figure 9).

9. Remove the customer interface board, carefully pullingthe wiring through the bore.

10. Verify that the O-ring is in place in the counterbore inthe positioner housing.

11. Feed the wires on the back of the new customer userinterface board through the passageway into the mainchamber of the housing.

12. Set the customer interface board in place and securewith three screws (see Figure 9).

13. Reconnect the field wiring to the customer interfaceboard terminals.





14. Install the main PCB into the housing. Insert theretaining screw through the board into the threadedboss and tighten evenly, using a Phillips screwdriver.Do not overtighten.

15. Reinstall the five wire connections (six wireconnections if the unit is equipped with the 4-20 mAanalog output option) on the main PCB assembly (seeFigure 14).

16. Install the plastic board cover. Insert the three retainingscrews through the plastic cover into the threaded bossand tighten evenly, using a Phillips screwdriver. Do notovertighten (see Figure 18).


Optional HardwareVented Design (See Figures 21 and 23)A standard Logix 3200IQ positioner is vented directly tothe atmosphere. When supply air is substituted with sweetnatural gas, piping must be used to route the exhaustednatural gas to a safe environment. This piping system maycause some positioner back pressure in the main chamber(from the modulator and regulator) and spool chamber(from the actuator). Back pressure limitations aredescribed below.

Two chambers must be vented on the Logix 3200IQpositioners: the main housing chamber and the spoolvalve chamber (Figures 21 and 23). The main chambervent is located on the backside of the positioner (seeFigure 19). Vented-design Logix 3200IQ positioners aresupplied from the factory with a fitting installed in themain chamber vent. Connect the necessary tubing/pipingto this fitting to route the exhausted natural gas to a safeenvironment.

The maximum allowable back pressure from the collectiondevice on the main housing vent is 2.0 psig (0.14 barg).Vent flow rate is 0.5 std ft3/min (1.4 std liter/min).

WARNING: The back pressure in the main housingmust never rise above 2.0 psig (0.14 barg).

The spool valve chamber (see Figure 23) must also bevented through the spool valve cover. Vented-design Logix 3200IQ positioners are supplied from the factorywith a fitting installed in the spool valve cover (item SKU 179477). Connect the necessary tubing/piping to this fitting to route the exhausted natural gas to a safeenvironment. The maximum allowable back pressure inthe spool valve chamber is 8 psig (0.55 barg). Pressuresgreater than 8 psig will cause vented gas to leak past thespool cover O-ring to the atmosphere and will result inovershoot of the positioner.

Figure 22: Main Housing Vent

Figure 23: Spool Cover Vent

HART VHF FilterHART communication superimposes two frequencies,1200 Hz and 2200 Hz, on the DC 4-20 mA current signal.Some current sources (DCS or 4-20 mA calibrator) caninterfere with the HART signal. This may preventcommunication with SoftTools or the HART 275/375handheld. Intermittent communication may also be theresult of a HART incompatible current source. In thiscase, a filter is necessary between the current source andLogix 3200 to allow HART communication.

Flowserve makes a filter (Part No. 139774) that must beused on each 4-20 mA line if the current source interfereswith communication (see Figure 24). The filter does notaffect the DC current but prevents the source fromaffecting the HART frequencies. The filter comes in a DIN rail-mount package.

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

Maximum AllowableHousingBack Pressure2.0 psig (0.14 barg)

1/4" NPT x 1/4" Swagelok Tube Fitting

1/4" FNPT x 1/8" NPT Reducer

Maximum AllowableSpool Back Pressure8 psig (0.55 barg)

Customer Connection Tubing3⁄8"

NPT x Swagelok Tube Fitting3⁄8" 3⁄8"





Figure 24: HART VHF Filter

HART ModemThe HART modem is a device that connects to the serial communications port of a computer. This modemconverts the RS-232 COM port signals to the HARTsignal. A HART modem is optional in SoftTools since aMUX can be used in its place. The HART modem takespower from the RS-232 COM port lines. If using a laptop computer running on an internal battery, HARTcommunication may become erratic as the batteries begin to lose charge. This is due to a reduction in HARTmodem power. Allow batteries to recharge or apply ACadapter power to the laptop to correct the problem. A HART modem is available through your Flowserverepresentative. (Please refer to Logix 3200IQ Spare Parts Kit Section for part numbers.)

When using a HART modem with SoftTools or when usingthe HART 275/375 handheld, the leads can be connectedanywhere across the 4-20 mA current signal. The leadsare not polarity sensitive. When using a filter, theconnection must be made between the filter output andthe Logix 3200IQ (see Figure 25).

4-20 mA Analog Output BoardThe Logix 3200IQ digital positioner can be supplied toprovide an analog feedback signal of the stem position.This option can also be retrofitted in the field. The 4-20mA analog output board is wired in series with a 12.5 to40 VDC power supply (see Figure 26). This positionfeedback option has the following features andspecifications:

• Does not interfere with positioner operation.

• Calibration of the analog output signal is performedusing a HART 275/375 Handheld Communicator orconfiguration software such as SoftTools.

• Output follows actual position of valve, including allfailure modes of positioner except loss of power. Anoutput of ≤3.15 mA is transmitted with loss of power to the positioner.

• Immune to RFI/EMI disturbances.

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

Replacing the 4-20 mA Analog Output BoardTo replace the 4-20 mA analog output board, refer toFigures 14, 18 and 28 and proceed as outlined below. The following tools are required:



Figure 25: HART VHF Filter Schematic

+

–

+

–

+

–

C

D

F

E

G, H A, B

DCS

LOGI

X

HART Connection

FILTER

Drain Wire

4-20 mACurrent Source

Logix3200IQ





Figure 26: Analog Output Board Power

CAUTION: Isolated power sources required.


retaining screws (see Figure 18).5. Disconnect the two wire connection from the side of

the 4-20 mA analog output board.6. Gently lift the 4-20 mA analog output board off the

main PCB assembly.7. Align the two connectors on the new 4-20 mA analog

output board with the mating sockets on the main PCBboard and gently press the connectors together.

8. Connect the two wire connection coming from the UserInterface board to the side of the 4-20 mA analogoutput board.

9. Install the plastic board cover. Insert the three retainingscrews through the plastic cover into the threadedboss and tighten evenly, using a Phillips screwdriver.Do not overtighten.

10. Connect the Analog Output filed termination wiring tothe Analog Output terminals on the User Interfaceboard (see Figure 26.)


Figure 27: 4-20 mA Analog Output Board

HART4-20 mA

ANALOG

INPUT OUTPUT

Position FeedbackCurrent Loop(Logix Output)

Position CommandCurrent Loop(Logix Input)

12 VDC to 40 VDCPowerSupply

4 to 20 mACurrent Source

+

+

–

–





Figure 28: Exploded View

2

43

5

6

9

8

16

17

18

19

20

21

2322

242526

2728

29

30

34

3531

32

33

56

55

54

53

5251

49

50

47

48

37

3638

39

40

41

46

45

44

43

42 11

12

13

14

15

7

1

10





Item No. Part

1 Housing Logix 3000IQ Positioner2 Main Housing Cover3 O-ring, Main Housing Cover4 Screw, Anti-rotation5 Plastic Main PCB Cover6 Screw, Main PCB Cover Short (2)7 Screw, Main PCB Cover Long8 Main PCB Assembly9 Screw, Main PCB Assembly Retaining10 4-20 mA Analog Output Board (Optional)11 Screw, Pressure Sensor Board (2)12 Pressure Sensor Board Stiffener13 Pressure Sensor Board (Advanced Only)14 Pressure Sensor Plug Plate (Standard Only)15 O-ring, Pressure Sensor to Housing (2)16 Pressure Regulator, 5 to 30 psig

(Includes 2 O-rings)17 Screw, Regulator Plate to Housing (4)18 Hex Barbed Fitting with Captive O-ring19 Internal Filter20 O-ring, Interface Plate to Housing Seal21 Customer Interface Cover22 O-ring, Customer Interface Cover23 Screw, Anti-rotation24 Screw, Customer Interface Board (3)25 Customer Interface Board26 O-ring, Customer Interface Board27 Grounding Screw (2)28 Threaded Plug

Item No. Part

29 Main Vent Cover30 Screw, Main Vent Cover31 Driver Module Cover32 O-ring, Driver Module Cover33 Driver Module Assembly34 Hex Barbed Fitting with Captive O-ring35 Flexible Tubing36 Screw, Driver to Housing37 Nylon Washer38 Spool Valve39 Spool Valve Block40 Screw, Spool Valve to Housing (2)41 O-ring, Spool Valve (3)42 Screw, Spool Valve Cover43 Spool Valve Shroud44 Spool Valve Cover45 Hydrophobic Filter, Spool Valve Chamber46 O-ring, Spool Valve Cover47 Pressure Gauge, 0-160 psig (2)48 Air Screen (3)49 Screw, Position Feedback Potentiometer to

Housing (2)50 Metal Washer (2)51 Position Feedback Potentiometer52 Feedback Shaft53 Screw, Spring to Feedback Shaft54 O-ring, Feedback Shaft55 Torsion Spring56 E-ring

Parts List





Item No. Description Quantity

Kit 7: Soft Goods Kit, P/N 199789.999.0003 O-ring, Main Housing Cover 115 O-ring, Pressure Sensor to Housing 220 O-ring, Regulator to Housing 122 O-ring, Customer Interface Cover 126 O-ring, Customer Interface Board 135 Flexible Tube 137 Nylon Washer 141 O-ring, Spool Valve to Housing 345 Hydrophobic Filter, Spool Valve Chamber 146 O-ring, Spool Valve Cover 154 O-ring, Feedback Shaft 1Kit 8: Standard Model Pressure Sensor Plug Plate Kit,

P/N 199790.999.00011 Screw, Pressure Sensor Board 214 Pressure Sensor Plug Plate 115 O-ring, Pressure Sensor to Housing 2Kit 9: Advanced Model Pressure Sensor Board Kit,

P/N 199791.999.00011 Screw, Pressure Sensor Board 213 Pressure Sensor Board 115 O-ring, Pressure Sensor to Housing 2Kit 10: Main PCB Assembly Kit, P/N 199792.999.0006 Screw, Main PCB Cover Short 27 Screw, Main PCB Cover Long 18 Main PCB 19 Screw, Main PCB Retaining Screw 1Kit 11: User Interface Board Kit, P/N 199793.999.00024 Screw, Customer Interface to Housing 325 Customer Interface Board 126 O-ring, Customer Interface Board 1Kit 12: Analog Output Board Kit,

P/N 218795.999.00010 Analog Output Board 1Kit 13: Position Feedback Potentiometer Kit,

P/N 199794.999.00049 Screw, Feedback Potentiometer to

Housing 250 Metal Washer 251 Position Feedback Potentiometer 1HART Filter, P/N 139774.999.000HART ModemRS 232 P/N 10078999PCMICIA P/N 10079000USB P/N 216421.999.000

Item No. Description Quantity

Kit 1: Driver Module Assembly -20° to 80°C Kit, P/N 218811.999.000

16 Pressure Regulator 117 Screw, Regulator to Housing 433 Driver Module Assembly 134 Hex Barbed Fitting w/ Captive O-ring 136 Screw, Driver to Housing 137 Nylon Washer 1Kit 2: Driver Module Assembly -40° to 80°C Kit,

P/N 199786.999.00016 Pressure Regulator 117 Screw, Regulator to Housing 433 Driver Module Assembly 134 Hex Barbed Fitting w/ Captive O-ring 136 Screw, Driver to Housing 137 Nylon Washer 1Kit 3: Spool Assembly Valve Kit, P/N 199787.999.00038 Spool 139 Spool Valve Block 140 Screw, Spool Valve to Housing 241 O-ring, Spool Valve 3Kit 4: Pressure Regulator, P/N 215814.999.00016 Pressure Regulator with Captive O-rings 117 Screw, Regulator to Housing 4Kit 5: Feedback Shaft Kit, P/N 199788.999.00052 Feedback Shaft 153 Screw, Spring to Feedback Shaft 154 O-ring, Feedback Shaft 155 Torsion Spring 156 E-ring 1Kit 6: Feedback Shaft Kit (NAMUR),

P/N 218814.999.00052 Feedback Shaft 153 Screw, Spring to Feedback Shaft 154 O-ring, Feedback Shaft 155 Torsion Spring 156 E-ring 1

Spare Parts Kits (See Figure 28 for item numbers.)





Logix 3200IQ Mounting KitsFlowserve Mounting Kits

Table IX: Logix O.E.M. Mounting KitsBrand Model Size Mounting Kit

33 B 173298Masoneilan 4(Rotary 35 6 173298Actuators) 7

70 10 173298

Brand Model Size Mounting Kit30 213905

0.5" - 1.5"34 141410 stroke40

171516 0.5" - 1.5" 50 stroke

657 & 667 171517 2" stroke

171516 0.5" - 1.5" Fisher 60 stroke

171517 2" stroke70 171518 4" stroke80 171519

1250225

173371450675

1052 33 171549 Rotary657-8 40 173798

Neles RC 171512RD 178258

Foxboro Slid-Std 173567Linear 178258

Honeywell VST-VA3R 17-in. dia. 173798VSL-VA1D 12-in. dia. 173798

9 17172111

37 13 17172018 17338224 17389611 17323513 173234

38 15 186070Masoneilan 18 173382*(Linear 24 173896Actuators) 25 173325

71 Domotor 50 173335100 173336

88 6 17172216 173827

47 B 17336148 B 173361“D” 200 175141

Domotor71-2057AB-D 17617971-40413BD 176251

* Adjustable mounting kit 173798 may be needed if handwheels are used.

Table IX: Logix O.E.M. Mounting Kits (continued)

NAMUR Accessory Mounting Kit Part NumbersUse prefix “NK” and choose bracket and bolt options fromthe following table.

Table XII: NAMUR Accessory Mounting Kit Part NumbersBracket Option Description

28 20 mm pinion x 80 mm bolt spacing28 38 mm pinion x 80 mm bolt spacing313 30 mm pinion x 80 mm bolt spacing513 50 mm pinion x 130 mm bolt spacing

Bolt Option DescriptionA 10-24 UNC boltingB 10-32 UNF boltingL M5-0.8 metric bolting

Example: NK313A, NAMUR Accessory Mounting Kit with 30 mm pinion x 80 mm bolt spacing and 10-24 UNC bolting.





Frequently Asked QuestionsQ: My DCS uses 24 VDC, can I run a Logix 3200IQ? A: A DCS output current card does run from 24 VDC butthe card regulates the actual current output. However, if the 24 VDC were applied directly across the terminals,nothing would limit the current and the Logix 3200IQField Termination Board could be damaged. The currentsource voltage supply can be anywhere between 10 VDCto 30 VDC as long as the current is limited in the 4-20 mA range.

Q: I accidentally placed a voltage supply across theLogix 3200IQ. How do I know if I damaged something?A: The typical failure in an over-current situation is a shortcircuit. Your loop current will be maintained but the Logix3200IQ control board will receive no power. With powerremoved from the Logix 3200IQ, use an ohmmeter tomeasure across the terminals. If the reading is a short(close to zero ohms), the Customer Interface Board mustbe replaced. Make sure the positive lead is on the ‘+’terminal and negative lead is on the ‘-’ terminal whenmeasuring the resistance.

Q: What is the input resistance of the Logix 3200IQ?A: The Logix 3200IQ does not have a simple resistiveinput. When measuring the voltage across the Logix3200IQ, it only varies slightly when the current is changedfrom 4 mA to 20 mA (9.8 to 10.0 VDC nominal withoutHART communications. Add 0.3 V with HART active). This is because the Logix 3200IQ is an active device. The resistance at a given current is commonly referred to as the effective resistance.

Equation 3:Effective Resistance = (Terminal Voltage)/Current

For example:at 20 mA: Effective resistance = 9.9 VDC/0.02 A = 495 ΩThe Logix 3200IQ has a specification of 495 Ω @ 20 mA.

NOTE: You cannot measure across the terminals of anunpowered Logix 3200 and get the effectiveresistance.

Q: How do I know if I need a VHF HART filter?A: If the current source is interfering with communication,it will affect both SoftTools and the HART 275/375handheld. If the positioner communicates to SoftTools orthe HART 275/375 handheld when using a current source(a 4-20 mA current calibrator, for example) and not theDCS, it indicates a filter is necessary with that currentsource. Some 4-20 mA calibrators that work without afilter are listed below. If one of these is available, try toconnect with SoftTools or the HART 275/375 handheldagain. If communications are established while using

one of these sources but fails on the original source, a filter is needed.

Handheld 4-20 mA calibrators which do not require a filter:

• Altek Model 334

• Rochester Instrument Systems (RIS) CL-4002

• Unomat UPS-II

Q: I set the MPC at 5 percent. How will the positioneroperate?A: Assume that the present command signal is at 50 percent. If the command signal is decreased, thepositioner will follow the command until it reaches 5 percent. At 5 percent, the spool will be driven fully openor fully closed, depending on the air action of the valve, in order to provide full actuator saturation and tightshutoff. The positioner will maintain full saturation below5 percent command signal. As the command increases,the positioner will remain saturated until the commandreaches 6 percent (there is a 1 percent hysteresis valueadded by the positioner). At this point, the stem positionwill follow the command signal. While in MPC, the Logix3200IQ LEDs will blink GGGY.

Q: I have MPC set to 3 percent but the valve will not gobelow 10 percent.A: Is a lower soft stop enabled? The lower soft stop mustbe less than or equal to zero percent in order for the MPCto become active. If a positive lower soft stop is written,this stop will take priority over the MPC feature. When thelower soft stop is reached, the positioner will blink aGYYR code.

Q: Will soft stops prevent the valve from going to itsfail position?A: No.

Q: What is the difference between a model withStandard diagnostics and a model with Advanceddiagnostics?A: The model with Advanced diagnostics adds top andbottom actuator pressure sensors. This allows for morediagnostic calculations such as loss of pressure, friction,advanced signatures, and troubleshooting. The pressuresensors, if present, are also used in the positioner controlalgorithm to enhance valve stability.

Q: Can I upgrade from a Standard to an Advanced?A: Yes. Referencing the IOM, an advanced pressuresensor board assembly can be purchased. Simply replacethe pressure sensor plug plate with the advanced pressuresensor board. Using SoftTools or the HART 275/375handheld, configure the positioner for AdvancedDiagnostics and perform an actuator pressure calibration.





Probable CauseCurrent source below 3.6 mA without AO card or 3.85 mA with AO cardIncorrect wiring polarityVoltage of current source is not high enoughCurrent source bandwidth not limited to 25 HzMaximum cable length or cable impedanceexceededHART modem connected to PC RS-232 portnot receiving enough powerInterference with I.S. barrierCurrent Source stripping (filtering) HART signal

Unit is in digital command mode

Error occurred during calibration

Positioner tubing backwardsStem position sensor mounting is off 180°Stroke not calibratedTight shutoff (M.P.C)* is activeCustomer characterization or soft stopsactiveStroke not calibratedInner-loop hall sensor not connected

Wrong air action entered in software

Actuator tubing backwardElectro-pneumatic converter malfunctioningControl parameter inner-loop offset is too high/low

Contamination of the driver module

Control tuning parameters not correct

Packing friction high

Corroded or dirty spool valve

Corrective ActionVerify current source is outputting at least 3.6 mA withAO card or 3.85 mA with AO cardCheck wiring for correct polarityVerify that current source can supply at least 10 VMaximum allowable current source rate of change is924 mA per secondCheck cable conduction size, length and capacitance.Refer “Cable Requirements”

Verify laptop battery is not low

Must use HART-compatible I.S. barrier

Use the HART filter (VHF) available from Flowserve

Switch to analog command mode by doing aCommand Source Reset from the local interface orwith a handheld communicator or SoftTools, pleaserefer to “Command Source Reset”Check blink codes on positioner and correct calibrationerror. RecalibrateRe-tube the actuatorRemount position sensorPerform QUICK-CALVerify settings using PC or handheld software

Verify customer characterization and soft stops

Check DIP switch settings and calibrate valve strokeVerify hardware connectionsCheck ATO (Air-to-open) and ATC (Air-to-close)settings. RecalibrateVerify ATO/ATC actuator tubingReplace electro-pneumatic converterAdjust inner-loop offset and see if proper controlresumesCheck air supply for proper filtering and meeting ISAspecifications ISA-7.0.01. Check the spool valve forcontaminationAdjust gain settings using local gain switchEnable the stability DIP switch on the local interfaceand recalibrate. If problem persists, enable pressurecontrol with handheld communicator or SoftTools and recalibrateDisassemble and clean spool valve

Failure

No LED is blinking

Erratic communications

Unit does not respond to analog commands

Valve position reading is not what is expected

Position is driven fully open or closed and will not respond to command

Sticking or hunting operation of thepositioner

*M.P.C.: Minimum position cutoff

Troubleshooting





Notes:

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Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected this Flowserve productis designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware thatFlowserve products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and oftendoes) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assumethe ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user shouldread and understand the Installation Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in thesafe use of Flowserve products in connection with the specific application.

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

For more information about Flowserve Corporation, visit www.flowserve.com or call USA 1-800-225-6989.

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