Flowserve Logix 3800zb User Instructions
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Flowserve Logix 3800zb User Instructions

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Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23
USER INSTRUCTIONS
Installation
Operation
Logix™ 3800zb
Maintenance
Digital Positioner
Safety
FCD AIIOM001030_EN 02/23
1
flowserve.com

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Summary of Contents for Flowserve Logix 3800zb

  • Page 1 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 USER INSTRUCTIONS Installation Operation Logix™ 3800zb Maintenance Digital Positioner Safety FCD AIIOM001030_EN 02/23 flowserve.com...

  • Page 2: Table Of Contents

    OPERATION – USER INTERFACE ............25 OPERATION – DIAGNOSTIC LEVELS ............ 29 MAINTENANCE – TROUBLESHOOTING ..........30 MAINTENCANCE - REPAIR ..............32 MAINTENANCE - HELP FROM FLOWSERVE ........35 POSITIONER SPECIFICATIONS .............. 36 CUSTOM INSTALLATION HARDWARE REQUIREMENTS ....39 HAZARDOUS LOCATION SPECIFICATIONS ......... 40 APPENDIX A –...

  • Page 3: Quick Start Guide

    Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 1 QUICK START GUIDE Logix 3800zb Positioner Features Control Buttons Grounding Lug Conduit (3x) Main Cover Bolts Viewing (6x) Window Mounting Bolt Patterns Contactless Feedback Shaft Figure 1: Logix 3800zb External Positioner Features flowserve.com...
  • Page 4 DIP Switches (8x) Display LED Indicators (5x) HART Connector Discrete Discrete Output (2) Output (1) 4 – 20 mA Internal Analog Input Analog Output Discrete Input Remote Mount Command Grounding Lug Figure 2: Logix 3800zb (HART) Internal Positioner Features flowserve.com...
  • Page 5 XP approved conduit connections. Installation - Remote mount MOUNTING The Flowserve Zero Bleed Automation Package provides a solution for remote mount installations that includes the positioner and solenoid-controlled valve block as one panelized package. This package can be mounted to existing installation panels or can be used stand alone.
  • Page 6 4mA. For a 20mA signal to move the valve to closed, select 20mA. HART SWITCH (HART) (HART 6◄►HART 7) For HART 6 protocol, select HART6. For HART 7 protocol, select HART7. --- END OF QUICK START GUIDE --- flowserve.com...

  • Page 7: Safety Information

    Refer to the appropriate instructions when this Qualified personnel are people who, on account of their information is needed. The design of FLOWSERVE valves, training, experience, instruction and their knowledge of actuators, and accessories are for specific applications...
  • Page 8 Special attention is required when removing these plates for inspection, service or repair. Refit the cover plates after completing work. Logix 3800zb positioner repair is limited to the replacement of sub-assemblies and circuit boards with FLOWSERVE- manufactured replacements as outlined in this manual.

  • Page 9: Pre-Installation

    Unpacking While unpacking the valve and Logix 3800zb positioner, check the packing list against the materials received. Each shipping container includes a list describing the system and accessories included.
  • Page 10 Verify that the labels match the intended application. See section 17 , Hazardous Location Specifications for more details.  NOTE: The installer should mark the checkbox on the label that is appropriate for the intended use of the Logix 3800zb. Figure 3: Certification Labels (Explosion Proof Housing) Figure 4: Model Code Label...

  • Page 11: Installation - Mounting

    Slip the large end of the slotted mounting hole in the back of the positioner/bracket assembly over the mounting To attach a Logix 3800zb positioner to a Valtek linear Mark I bolt. Slide the small end of the teardrop under the valve, refer to Figure 5: Mounting to Mark I Linear Valve and mounting bolt and align the lower mounting hole.

  • Page 12: Installation - Tubing

    Air-to-Close. The Air-to-Open and Air-to- Figure 8: Rotary, Double Acting, Air to Open Close selection is only a reflection of the tubing. When selecting air action during configuration, the selection tells the control which way the actuator was tubed. Example: Tubing Single-Acting Actuators flowserve.com...
  • Page 13 Figure 10: Purging Venting Figure 9: Linear, Single Acting, Air to Open Venting for the Logix 3800zb controlled 4-Way valve block Connect Supply Port happens at ports “3” and “5” to the atmosphere. When supply air is substituted with sweet natural gas, piping must be used to route the exhausted natural gas to a safe environment.
  • Page 14 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 Remote Mount The Logix 3800zb can be remote mounted away from the actuator using the Flowserve Zero Bleed Automation Package The tubing requirements are the same for the remount mount and the Flowserve Logix Remote mount P/N LGENIM0001- options as defined in sections 5.1 through 5.5.

  • Page 15: Installation - Electrical Connections

    32 VDC. The current operating range is from 4 to 20 mA. for HART protocol. See Figure 15: Compliance Voltage. To determine if the loop will support the Logix 3800zb, perform the calculation in the following equation. The Available Voltage must be greater than 10VDC to support the Logix 3800zb.
  • Page 16 EN61000-4-3 Radiated Immunity and EN55011 Radiated Emissions, to operate correctly in electromagnetic The input loop current signal to the Logix 3800zb digital (EM) fields found in typical industrial environments. The positioner should be in shielded cable. By tying shields to...
  • Page 17 The AI circuit requires that the current loop system allows for connection a 10 VDC drop across the positioner at maximum loop current. The current operating range is from 4 to 20 mA. See Figure 8 for more details. flowserve.com...
  • Page 18 The remote mount is an integrated part of the Logix 3800zb circuitry. Wire the remote mount with Black to terminal C, White to terminal B, and Red to terminal A.
  • Page 19 Output (mA) No Loop Less than 10 V on AO terminals. Power Monitoring AI Terminals (typical 4- Input 20mA ) (mA) No Loop Less than 7 V on AI terminals. Power (input < 2.5 VDC) High (input > 8.0 VDC) flowserve.com...

  • Page 20: Peration - How It Works

    0% and 100% are defined. Basic Operation (HART) Command Input and Final Command The Logix 3800ZB digital positioner is a two-wire 4-20 mA The Command Input signal (in percent) passes through a input digital valve positioner which uses the HART protocol to characterization/limits modifier block.
  • Page 21 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 Control Loop The Logix 3800zb uses a proportional control loop, stem- positioning algorithm. A stem position sensor provides a measurement of the stem movement. The final command is compared against the stem position. If any deviation exists,...

  • Page 22: Operation - Dip Switch Configuration

    Single. CONFIGURATION Characterization Switch (LINEAR◄►OTHER) The Logix 3800zb local user interface allows the user to calibrate, configure the basic operation, and tune the response The Characterization Switch allows a better match between of the positioner without additional tools or configurators.
  • Page 23 AO signal corresponds with the Signal At Closed selection. If the valve closes with a 4 mA signal, the AO will show a 4 mA signal at closed. If the valve closes with a 20 mA signal, the AO will show a 20 mA signal at closed. flowserve.com...

  • Page 24: Operation - Calibration And Control

    The calibration is complete when the lights return to a sequence that starts with a green light. The jog calibration process will only allow the user to set the span. If an elevated zero is needed, a handheld or ValveSight DTM are required. flowserve.com...

  • Page 25: Operation - User Interface

    Factory reset causes a reset of all the internal variables to factory defaults, including calibration. The 10.1.2 Scrolling Status Messages positioner must be re-calibrated after a factory reset. Restore tag names and other user configured limits, alarm settings, and valve information. flowserve.com...
  • Page 26 Communications Icons – When the positioner is sending or receiving data via the HART communication protocol, the heart icon will be displayed. During burst mode, a pulsating heart icon will be displayed. flowserve.com...
  • Page 27 When locked, the positioner may be temporarily unlocked by entering a PIN. The PIN may be entered using LCD. The tamper lock feature can also be disabled in the DTM. flowserve.com...
  • Page 28 Enable and Disable Write Protect (HART) Clear PST fail error message (Hold III for 3 Sec, then briefly press II) *A full calibration (Quick-Cal with other diagnostic evaluations) will run the first time, if a full calibration has not been completed. flowserve.com...

  • Page 29: Operation - Diagnostic Levels

    “Standard” diagnostics provide complete safety and position-related diagnostics and data. 5-LED Indicator 8-DIP Configuration For more detail, see Table 6: Logix 3800zb Features. 10-Position Gain Adjustment Switch Remote Mount Option Teminal Voltage < 10.0 V Alarms Stamped with Time and Date...

  • Page 30: Maintenance - Troubleshooting

    Check ATO (Air-to-open) and ATC (Air-to-Close) connected. will not respond to the settings. Recalibrate using Quick-Cal to apply Selected the wrong air action in the command. settings. software. Verify ATO/ATC actuator tubing. Actuator tubing is backward. flowserve.com...
  • Page 31 Improper sizing of Valve/Actuator for process conditions. The backlight uses any residual Fluctuations in the LCD backlight are normal. No LCD backlight is flickering power not used by other functions of action required. or dim. the circuitry. flowserve.com...

  • Page 32: Maintencance - Repair

    Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 13 MAINTENCANCE - REPAIR 13.5 Torque Specification for Screws Table 8: Torque Specification shows the Logix 3800zb 13.1 Training and Precautions torque specifications. Torque all screws to the proper specification to avoid damaging components or loosening of The replacement of the kits listed in section 15, Positioner the screws during use.
  • Page 33 Connect the shaft assembly to the follower arm assembly Figure 26: Piezo Installation within the working range of the shaft assembly. Finish mounting the positioner. Reconnect power as directed by this manual. Perform a Stroke Calibration as directed by this manual. flowserve.com...
  • Page 34 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 Feedback Screws (3) Figure 28: Replacing the Shaft Assembly flowserve.com...

  • Page 35: Maintenance - Help From Flowserve

    Over-the-phone troubleshooting is available for positioner issues. Should your positioner be experiencing problems, or if Although the Logix 3800zb is not within the scope of the Waste you have questions that are not answered by this manual, feel Electronics and Electrical Equipment (WEEE) Directive...

  • Page 36: Positioner Specifications

    30.5 m (100 ft) for ½” dia. tubing Max Cable and Tube Distance 9.1 m (30 ft) for ¼” dia. tubing Operating Temperature -55 to 124°C (-67 to 255°F)  NOTE: When using tubing near maximum lengths the positioner performance may be degraded. flowserve.com...
  • Page 37 -55 to 85°C (-67 to 185°F) connections) Range HART Filter Often required in conjunction with some  NOTE: Reduced performance possible at low and high DCS hardware. temperatures. LCD may not be readable at temperatures below -20°C (-4°F) and temperatures above 70°C (158°F). flowserve.com...
  • Page 38 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 15.10 Positioner Dimensions - Explosion Proof Housing Figure 29: Positioner Physical Dimensions flowserve.com...

  • Page 39: Custom Installation Hardware Requirements

    Holding current less than 400mA Remote mount feedback 16.1.1 The remote mount feedback must be potentiometer based and Explosion Proof certified for Class I Div. I installations. The potentiometer resistance must be between 5K to 50K ohms. (5000 to 50,000 ohms) flowserve.com...

  • Page 40: Hazardous Location Specifications

    Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 17 Hazardous Location Specifications 17.1 Hazardous Location Information Table 18: Logix 3800zb Ex Hazardous Location Information Certification Temperature Enclosure Area Protection Method Markings Code Code Ratings US Explosion Proof XP - Class I, Div 1, Groups A,B,C,D, T6…T4...
  • Page 41 • Use appropriately rated cable insulation at higher temperatures. • Contact Flowserve for Flame Path information. • The Model 38X0 and 38X1 Positioner enclosures contain aluminum and are considered to present a potential risk of ignition by impact or friction. Care must be taken into account during installation and use to prevent impact or friction.
  • Page 42 Follow routine maintenance. See section 12, Maintenance – Troubleshooting. 17.4 Repair and Replacement Report any failure of the FLOWSERVE Logix 3800zb Valve Positioner immediately to FLOWSERVE. Replace faulty components according to section 0 of this manual or return the positioner to FLOWSERVE for service. With experience and the right parts, repair times for any component can be less than an hour.

  • Page 43: Appendix A - Lcd Menu Tree Overview

    Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 APPENDIX A – LCD MENU TREE OVERVIEW LOGIX 3800zb MAIN MENU 1. Status 6. Configuration 7. Auxiliary I/O Command (mA) Command (%) Position (%) 6.1 Positioner Tuning 6.4 Positioner Feedback 7.1 AO Temperature...

  • Page 44: Appendix B - Lcd Menu Tree Descriptions

    The Calibration menu allows the user to calibrate the positioner’s sensors. The positioner can accurately control with only a Quick-Cal. Calibration Typically this is all that is needed. Calibrate the friction calibration of the positioner when upgrading to Pro diagnostics. flowserve.com...
  • Page 45 (Set 0%) and the highest current used (Set 100%). Calibration The default input range is 4 to 20 mA. The “Set 0%” value must be lower than the “Set 100% value. Calibration Dates Calibration Dates lists the most recent date of each calibration. Back Configuration Positioner Tuning flowserve.com...
  • Page 46 Once the Soft Limit is set, the Soft Limit High positioner will not attempt to move the valve position (final command) 6.3.1 beyond the set point, regardless of the analog or digital command input signal. flowserve.com...
  • Page 47 A factory reset will always reset the command source to analog 4-20 mA. The terminal block gives options for analog output (AO), Analog input Auxiliary I/O (AI), Discrete Input (DI) and Discrete Output (DO) 1 and 2. flowserve.com...
  • Page 48 Trigger to start a Cmd Overide 7.3.4 Set Cmd Point Change Set Cmd Point variable. 7.3.5 Back Language English German French Spanish Portuguese Russian Italian Back Display Contrast LCD Contrast. Customer's Choice Backlight LCD Backlight. Customer's Choice LCD Orientation (Standard, Rotate 180˚) Back flowserve.com...

  • Page 49: Appendix C - Programmed Flow Characterization Options

    90.80 72.90 47.32 85.0 85.00 73.00 48.90 84.00 64.80 93.20 78.60 56.71 90.0 90.00 78.40 57.70 87.80 72.50 95.50 84.70 67.84 95.0 95.00 85.00 69.20 92.10 81.30 97.80 91.20 81.03 100.0 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 flowserve.com...
  • Page 50 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 Command Input Figure 29: Characterization Curve Options flowserve.com...

  • Page 51: Appendix D - 4-Blink Status Codes

    The calibration can be canceled from the Analog Output Calibration Analog Output The analog output calibration page of the DTM, from the Calibration in Progress sequence is in progress. handheld, or by briefly pressing all three buttons at once. flowserve.com...
  • Page 52 The user has selected a combination of key presses (Hot Key) that initiates a Refer Appendix F – Hot Keys to see Calibration Type Set calibration. The positioner is waiting for the calibration options. the user to select the type of calibration to run. flowserve.com...
  • Page 53 Configure the DI function and set DI Command Override preconfigured set point. The DI signal point using the menu, a handheld or is active and the positioner is the Configuration page of the DTM. attempting to control the valve at the set point. flowserve.com...
  • Page 54 LCD. a Personal Identification Number The status code is only present for a (PIN) can be entered from the short time when the user attempts to positioner if an LCD is installed. make a change through the display menu. flowserve.com...
  • Page 55 30 minutes, the Piezo assembly is valve that is held for long periods of damaged. Replace the pilot relay. time in the closed position, or an air-to- open valve held in the open position. flowserve.com...
  • Page 56 Set the limit to a lower value if more exceeding a user defined lower travel is needed, or adjust the Position Low Limit Alert position indicator. This is similar to a command signal back in the limit switch indicator. specified range. flowserve.com...
  • Page 57 New software is ready to be The software download is complete. Complete activated. No action is required. Wait for the Software Download in The system is downloading new system to indicate that the software Progress software. download is complete. flowserve.com...
  • Page 58 System Exception System has logged an internal error. Update the firmware. Warning Temperature Contact your Flowserve Temperature Calibration Required Calibration Required representative. The temperature of the internal Regulate the temperature of the electronics has exceeded the...
  • Page 59 The Valve Travel Warning packing tightness, and checking travel counting criterion and limit are linkages for wear, misalignment, set by the user to track the usage of and tightness. After maintenance, the valve. reset the travel accumulator. flowserve.com...

  • Page 60: Appendix F - Hot Keys

    Set input value and press II briefly. Brief Calibration (HART) Set input value and press II briefly to Set 100% and complete calibration. Brief complete calibration. Abort calibration at any time. Press I, II and III together briefly. Brief Brief Brief flowserve.com...
  • Page 61 Exit contrast adjusting mode. Press II briefly. Brief Remote Change from RM to Positioner or Mount Hold I and III together for 6 seconds. back. Toggle *A full calibration will run if no previous full calibration has been performed since factory reset. flowserve.com...

  • Page 62: Appendix G - How To Order

    NAMUR Shaft KIT LOGIX 38X 381226.999.000 DD Shaft KIT LOGIX 38X 381227.999.000 Reverse Spring DD Shaft KIT, LOGIX 38X 603676.999.000 NAF Shaft KIT LOGIX 38X 381228.999.000 4 Direct Mounting Kit: Alum. Ex d Housing 373043.999.000 Figure 30: Spare Parts flowserve.com...
  • Page 63 380424.150.000 Mounting kits consist of all bracketing, bolting, stem clamps and stem clamp bolting, etc. required to mount the Logix 3800zb positioner. It does not include any actuator parts nor yoke clamps and bolting. Contact Flowserve for assistance in selected the correct mounting kit.
  • Page 64 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/23 Table 21: Logix 3800zb Positioner Model Code Selection Description Code Base Model Logix 3800zb Series Communication HART Aluminum – Ex d Housing Stainless Steel – Ex d Certifications US Explosion Proof, Class I, Div 1, Gp A,B,C,D, Class II, Gp E,F,G, Class III...
  • Page 65 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/9 This page intentionally left blank. flowserve.com...
  • Page 66 Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product Flowserve Abahsain (Saudi Arabia) Flow Control is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Company Ltd.
  • Page 67 Logix™ 3800zb Digital Positioner FCD AIIOM001030_EN 02/9 Description Date Initial release February 9, 2023 flowserve.com...

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