Logix 500si Series Digital Positioners Operation Maintenance

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Logix 500si seriesDigital PositionersInstallationOperationMaintenance

2Contents1. General information . 31.1 Using . 31.2 Terms concerning safety . 31.3 Protective clothing . 31.4 Qualified personnel . 31.5 Installation . 31.6 Spare parts . 41.7 Service / repair . 41.8 Storage . 41.9 Valve and actuator variations . 42.3.4.5.6.Unpacking .LOGIX 500si overview .Specifications .Principle of operation .Mounting and installation .455666.1 General . 66.2 Mounting of the Logix 500si Positioner on a Linear Pneumatic Actuator(NAMUR / IEC 534 part 6) . 76.3 Rotary actuators . 87. Tubing positioner to actuator.118. Wiring and grounding guidelines . 128.1 Grounding screw . 128.2 Electromagnetic compatibility . 128.3 Compliance voltage . 138.4 Cable requirements . 139. Startup . 149.1 Local interface operation . 149.2 Initial DIP switch setting . 149.3 Configuration dipswitch setup . 149.4 Calibration switches . 169.5 Quick-Cal operation . 179.6 HART 275 Handheld Communictor . 189.7 Use of sorttools communication software . 189.8 Integration of third-party software . 1910. Status codes . 1911. Version number checking . 2112. Limit switch unit (Optional) . 2212.1 General . 2212.2 Model selection . 2212.3 Principle of operation . 2212.4 Installation . 2212.5 Start-up . 2212.6 Technical data . 2313. Trouble shooting . 2414. Certificates . 2515. Spare pars . 30

31. General information1.1 UsingThe following instructions are designed to assist inunpacking, installing and performing maintenance asrequired on FLOWSERVE products. Product users andmaintenance personnel should thoroughly review this bulletin prior to installing, operating or performing anymaintenance.In most cases FLOWSERVE valves, actuators andaccessories are designed for specific applications (e.g.with regard to medium, pressure, temperature). For thisreason they should not be used in other applicationswithout first contacting the manufacturer.1.2 Terms concerning safetyThe safety terms DANGER, WARNING, CAUTIONand NOTE are used in these instructions to highlight particular dangers and/or to provide additionalinformation on aspects that may not be readilyapparent.DANGER: indicates that death, severe personalinjury and/or substantial property damage will occurif proper precautions are not taken.WARNING: indicates that death, severe personalinjury and/or substantial property damage can occurif proper precautions are not taken.CAUTION: indicates that minor personal injury and/or property damage can occur if proper precautionsare not taken.NOTE: indicates and provides additional technicalinformation, which may not be very obvious evento qualified personnel.1.3 Protective clothingFLOWSERVE products are often used in problematicapplications (e.g. extremely high pressures, dangerous,toxic or corrosive mediums). In particular valves withbellows seals point to such applications. When performingservice, inspection or repair operations always ensure,that the valve and actuator are depressurised and thatthe valve has been cleaned and is free from harmfulsubstances. In such cases pay particular attention to personal protection (protective clothing, gloves, glasses etc.).1.4 Qualified personnelQualified personnel are people who, on account of theirtraining, experience and instruction and their knowledgeof relevant standards, specifications, accident preventionregulations and operating conditions, have beenauthorised by those responsible for the safety of the plantto perform the necessary work and who can recogniseand avoid possible dangers.1.5 InstallationDANGER: Before installation check the order-no,serial-no. and/or the tag-no. to ensure that thevalve/actuator is correct for the intendedapplication.Do not insulate extensions that are provided forhot or cold services.Pipelines must be correctly aligned to ensure thatthe valve is not fitted under tension.Fire protection must be provided by the user.Compliance with other, not particularly emphasisednotes, with regard to transport, assembly, operationand maintenance and with regard to technical documentation (e.g. in the operating instruction, productdocumentation or on the product itself) is essential,in order to avoid faults, which in themselves mightdirectly or indirectly cause severe personal injuryor property damage.Disposal of product when taken out of service.According to EU legislation, this product must be recovered for separation of materialsand may not be disposed of as unsorted municipal waste.If you wish you can return this Sensistor product to the manufacturer for recovery.The manufacturer has the right to refuse taking back products that are inadequatelypackaged and thereby presents safety and/or health risks to the staff.The manufacturer will not reimburse you for the shipping cost.

41.6 Spare parts1.8 StorageUse only FLOWSERVE original spare parts.FLOWSERVE cannot accept responsibility for any damages that occur from using spare parts or fasteningmaterials from other manufactures. If FLOWSERVEproducts (especially sealing materials) have been on storefor longer periods check these for corrosion or deterioration before using these products. Fire protection forFLOWSERVE products must be provided by the end user.In most cases FLOWSERVE products are manufacturedfrom stainless steel. Products not manufactured fromstainless steel are provided with an epoxy resin coating.This means that FLOWSERVE products are well protectedfrom corrosion. Nevertheless FLOWSERVE products mustbe stored adequately in a clean, dry environment. Plasticcaps are fitted to protect the flange faces to prevent theingress of foreign materials. These caps should not beremoved until the valve is actually mounted into the system.1.7 Service / repairTo avoid possible injury to personnel or damage toproducts, safety terms must be strictly adhered to.Modifying this product, substituting nonfactory parts, orusing maintenance procedures other than outlined in thisinstruction could drastically affect performance and behazardous to personnel and equipment, and may voidexisting warranties. Between actuator and valve there aremoving parts. To avoid injury FLOWSERVE providespinch-point-protection in the form of cover plates,especially where side-mounted positioners are fitted. Ifthese plates are removed for inspection, service or repairspecial attention is required. After completing work thecover plates must be refitted.Apart from the operating instructions and the obligatoryaccident prevention directives valid in the country of use,all recognised regulations for safety and good engineering practices must be followed.WARNING:Before products are returned to FLOWSERVE forrepair or service FLOWSERVE must be providedwith a certificate which confirms that the producthas been decontaminated and is clean.FLOWSERVE will not accept deliveries if acertificate has not been provided (a form can beobtained from FLOWSERVE).1.9 Valve and actuator variationsThese instructions cannot claim to cover all details of allpossible product variations, nor in particular can they provide information for every possible example of installation,operation or maintenance. This means that the instructionsnormally include only the directions to be followed byqualified personal where the product is being used for isdefined purpose. If there are any uncertainties in thisrespect particularly in the event of missing product-relatedinformation, clarification must be obtained via theappropriate FLOWSERVE sales office.2. UnpackingEach delivery includes a packing slip. When unpacking,check all delivered valves and accessories using thispacking slip.Report transport damage to the carrier immediately.In case of discrepancies, contact your nearestFLOWSERVE location.

53. LOGIX 500si overviewThe Logix 500si is a two-wire loop powered, 4-20 mAinput digital valve positioner.The Logix 500si positioner controls actuators with linearand rotary mountings.Logix 520si also utilizes the HART protocol to allowe twoway remote communication with the positioner.The Logix 500si is completely powered by the 4-20 mAinput signal. The minimum input signal required to functionis 3,6 mA.Since the positioner is insensitive to supply pressurechanges and can handle supply pressures from 1,5 to 6barg (22 to 105 psig), a supply regulator is usually notrequired; however, in applications where the supplypressure is higher than the maximum actuator pressurerating a supply regulator is required to lower the pressureto the actuator’s maximum rating (not to be confused withoperating range). A coalescing air filter is recommendedfor all applications due to the close tolerances in the positioner.Logix 500si positioner accessories: Optional analog feedback system as well as limit switch unit and a directlyattachable double acting module.NOTE: The air supply must conform to ISA 7.0.01 orIEC770 (a dew point at least 10 C/18 F below ambienttemperature, particle size below five microns – one micronrecommended – and oil content not to exceed one partper million).4. SpecificationsTable 1: Input Signal510si520si4 - 20 mA6,0 VDC12,0 VDC(analog)with HART signal30 VDCInput Signal RangeCompliance VoltageVoltage Supply (max.)Minimum RequiredOperating Current3,6 mATable 2: Stroke OutputFeedback ShaftRotation510si520si0 to 90 normalmin15 max 90 0 to 40 min.40 recommendedfor linear appl.Table 3: Supply AirSupply Air QualityInput Pressure RangeAir Consumption(steady state)Free from moisture, oil anddust per IEC 770 and ISA-7.0.011,5 to 6,0 bar (22 – 102 psi)0,08 Nm3/h @ 1,5 bar0,047 SCFM @ 22 psi0,120 Nm3 /h @ 6,0 bar0,071 SCFM @ 102 psiTable 4: Output SignalOutput Pressure0 - 100 % of supply airRangepressureOutput Flow Capacity2,4 Nm3/h @ 1,5 bar(input @ pressure)1,41 SCFM @ 22 psi7,0 Nm3/h @ 6,0 bar4,12 SCFM @ 90 psiTable 5: Performance Characteristics (typical)510si520siLinearity 1,0%Resolution 0,3% 0,1%Repeatability 0,5% 0,2%Deadband 0,5% 0,2%Table 6: Environmental ConditionsOperating Temperature Standard–20 to 80 C–4 to 178 FLow–40 to 80 C–40 to 178 FTransport and Storage–40 to 80 CTemperature–40 to 178 FOperating Humidity0 – 100% non-condensingTable 7: Hazardous Area SpecificationsATEXEx II 1G EEx ia II C T6Certificate No.Sira03ATEX2243Non-incendiveFMClass 1, Division 2Groups A, B, C, DTemp. Class. T4Ta 85 CIntrinsic SafetyFMClass 1, Division 1Groups A, B, C, DTemp. Class. T4 Ta 85 CTable 8: Physical SpecificationsHousing MaterialCast aluminum,powder-paintedSoft GoodsNitrileWeight1,2 kg (2,7 lbs)Table 9: Shipping weightsShipping weightswith pressure gauges: 1,6 kg(incl. mounting kit) without pressure gauges: 1,2 kg

6Filter/Regulatorfor supply air1.5 - 7.0 bar (22 - 102 psi)2 Electro-pneumaticConverter ModuleAir SupplyPressure regulator1 Digital Control CircuitInner LoopPiezo ControlInner LoopPosition feedback510si4–20 mA Input4–20 mA outputmA Input520si 4–20 HARTHARTMicroProcessorPiezo ValveGainPneumaticAmplifier3 Valve PositionSensorLocalUserInterfaceStrokeConrol ValveFigure 1. Principle of Operation5. Principle of operationThe Logix 500si positioner is a digital positioner withvarious options. The positioner consists of three mainmodules:1. The microprocessor-based electronic control moduleincludes direct local user interface switches2. The piezo valve-based electro-pneumatic convertermodule3. The infinite resolution valve position sensor.The basic positioner operation is best understood byreferring to figure 1. The complete control circuit ispowered by the two-wire, 4-20 mA command signal. Theanalog 4-20 mA command is passed to themicroprocessor, where it is compared to the measuredvalve stem position. The control algorithm in the processor performs control calculations and produces an outputcommand to the piezo valve, which drives the pneumaticamplifier. The position of the pilot valve in the pneumaticamplifier is measured and relayed to the inner loop controlcircuit. This two-stage control provides for more responsiveand tighter control than is possible with a single stagecontrol algorithm. The pneumatic amplifier controls theairflow to the actuator. The change of pressure and volumeof the air in the actuator causes the valve to stroke. Asthe valve approaches the desired position, the differencebetween the commanded position and the measured position becomes smaller and the output to the piezo is decreased. This, in turn, causes the pilot valve to close andthe resulting flow to decrease, which slows the actuatormovement as it approaches, the new commanded position. When the valve actuator is at the desired position.the pneumatic amplifier output is held at zero, which holdsthe valve in a constant position.6. Mounting and installation6.1 GeneralBefore starting installation, inspect the digital positioner for any transit damages. The Logix 500si positioneris installed with a mounting kit (according to NAMURspecification) to the left-hand actuator support rod.Generally, the unit can be installed in any mountingposition. The stroke feed-back is realized by a followerarm and stem clamps.The mounting of rod actuators (according to NAMUR)is described in Figure 3.For the two mounting possibilities of cast yoke actuators(according to NAMUR, lEC 534 part 6) refer to Figure5.After installation, ensure all screw connections aretightened correctly and all moving parts are free fromexcessive friction.

7Figure 2. Dimensional drawing6.2 Mounting of the Logix 500si positioneron a linear pneumatic actuator(NAMUR / IEC 534 part 6)(See Figure 3)The mounting of a rod actuator kit (according to IEC 534part 6) is described in an example by using the followingequipment:Valve: Standard globe valve or equivalentActuator: Single-acting pneumatic actuatorPositioner: Logix 500si Series with NAMUR mounting kitPre-assembly: Valve with actuator (valve stroke is matchedwith the actuator stroke).For mounting, proceed as follows:Mounting the Follower Arm (Figures 3 and 6)1. Unscrew the lock nut for the follower arm attachment.2. Place the follower arm on the shaft at the back of thepositioner and fasten it with the lock nut. The follower pinshould point back from the positioner.CAUTION: Maximum torque 0,25 Nm (0,18 ft-lbs).Mounting the stem clamp bracket and take-off arm(Figure 3)1. Attach the stem clamp bracket to the stem clamp andfasten it with two hexagon socket screws and lockwashers.2. Attach the take off arm to the stem clamp bracket andfasten it with a hexagon socket capscrew and a washer.Ensure the take-off arm slot is centered.Mounting the positioner (Figure 3)1. Adjust the actuator to mid-stroke.2. Pre-assemble the mounting bracket on the left actuatorleg hand-tight with two U-bolts, nuts andlockwashers.3. Attach the positioner to the pre-assembled mountingbracket and fasten it with two hexagon head screws andtwo lock washers. Check that the follower pin is insertedin the slot of the take-off arm and the follower arm ispositioned at a right angle to the outer edge of the positioner.4. Tighten all screws and nuts.NOTE: A slight unsymmetrical mounting increasesthe linearity deviation but does not affect theperformance of the device. Depending on theactuator size and stroke it may be necessary to flipthe take-off arm (Figure 3) by 180 and attach it tothe opposite side of the stem clamp bracket.

8Figure 3. Mounting on a Rod Actuator (IEC 534 part 6)Follower pin adjustment (Figure 4)The positioner follower pin must be adjusted to match thevalve stroke in the following manner:1. Adjust the follower pin (STROKE 10 mm) as indicatedon the follower arm’s embossed scale (Figure 6).NOTE: Stroke the actuator carefully and ensure thefollower arm does not interfere with valve parts, actuatoror positioner. Do not adjust the follower pin too near tothe slot end of the take-off arm.2. Exhaust the actuator.The minimum lateral distance should be approximately 5mm (0,2 inches) to prevent bending of the feed-backmechanisim.3. Loosen the follower pin and shift it along the followerarm until the control marking on the feedback gear (Figure4) is horizontal (points to the center of the feedbackpotentiometer). Fasten the follower pin in this position.6.3 Rotary actuators4. Adjust the actuator to full stroke and check the followerpin adjustment the same way as described in step 3. Asthe actuator strokes, the rotation of the feedback gearshould be between the inner control markings. If the lengthof rotation is outside the control markings, adjust thefollower pin farther out on the feedback lever to reducethe angle of rotation.Mounting the Logix 500si positioner on a quarterturn actuator (closed or open by spring)The mounting of a pneumatic double-piston part-turn valveactuator (in accordance with VDI/VDE 3845) is describedas an example by using the following equipment:Quarter-turn valve actuator: Rack & pinion or scotchyoke, closed or open by spring.

9Rotary actutaors VDI/VDE 3485 (Namur)Mount bracket 1 to positioner. Secure with 4 x M6 screws2.4Fit positioner on actuator and secure with 4 x screws 3.Install tubing 4 between actuator and positioner.See section 7.132Linear actuator “Flow act” (Direct mounting,integrated tubing.1Check O-rings, Install bracket 1 to positioner and securewith screws.Fit pin on valve stem.2Fit lever arm to positioner shaft.Fit and check O-rings and positioner to actuator andsecure with 2 x screws 2.No tubing needed, it’s integrated with actuator, fit plug inpositioner out port.Linear actuator VDI/VDE 3847 (Direct mounting,integrated tubing.Check O-rings, Install bracket1 to positioner and secure with 2 x screws 2.32Fit pin on valve stem.Fit lever arm to positioner shaft.Fit and check O-rings and positioner to actuator andsecure with 2 x screws 3.No tubing needed, it’s integrated with actuator.1

10Figure 4. Basic Adjustment for a Linear Pneumatic ActuatorMounting AMounting BHexagon head screwLockwasherFigure 5. Yoke Actuator Mounting(according to IEC 534 part 6)Figure 6. Follower Arm (standard)

11Mounting the positioner (Figure 7)2. Place the positioner (1) onto the mounting block (2) ofthe actuator using four screws (3) Ensure the coupler fitson to the shaft of the quarter-turn connection on the partturn valve actuator.321Figure 7. Mounting a Part-turn Valve Actuator in acc. with VDI/VDE38457. Tubing positioner to actuatorAfter mounting has been completed, tube the positionerto the actuator using the appropriate compression fittingconnectors:Air connections: 1/4” NPT (standard air connection).Auxiliary power: Pressurized air or permissible gases, freeof moisture and dust in according with IEC 770 or ISA7.0.01.Pressure range: 1,5 – 6,0 bar (22 – 102 psi).For connecting the air piping, the following notesshould be observed:1. The positioner passageways are equipped with filters,which remove medium and coarse size dirt from thepressurized air. If necessary, they are easily accessiblefor cleaning.2. Supply air should meet IEC 770 or ISA 7.0.01requirements. A coalescing filter should be installed in frontof the supply air connection(Figure 8). Now connectthe air supply to the filter, which is connected to the Logix500 Series positioner.3. With a maximum supply pressure of 6 bar (102 psi) aregulator is not required.4. With an operating pressure of more than 6 bar (102psi), a reducing regulator is required.The flow capacity of the regulator must be larger than theair consumption of the positioner (7 Nm3 /h @ 6 bar / 4,12scfm @ 102 psi).5. Connect the outlet connector (Figure 8) of the positioner with tubing, independent of the action (direct orreverse).

12510siConnection TablesConnection 11–12 31*–32*DescriptionInput 4-20 mAInput –4-20 mAOutput 4-20 mAOutput –4-20 mAPneumatic outputsignal (outlet)Air supplyConnection 11–128. Wiring and grounding guidelines520siFigure 8. ConnectionsPneumatic outputsignal (outlet)Electrical connections: signal cable with cable passage( ”NPT, or M20 x 1,5) to terminals 2 x 2,5 mmInput signal: 4 – 20 mADescriptionInput 4-20 mAInput –4-20 mAAir supply* 0ptionalNOTE: Observe the minimum requirements of voltage andequivalent electrical load:6,0 VDC / 300Ω / at 20 mA (510si)12,0 VDC / 600Ω / at 20 mA (520si)8.2 Electromagnetic compatibilityThe performance is ensured only for a minimum input current of 3,6 mA.For wiring, the following notes should be observed:NOTE: The input loop current signal to the Logix 500sishould be in shielded cable. Shields must be tied to aground at only one end of the cable to provide a place forenvironmental electrical noise to be removed from thecable. In general, shield wire should be connected at thesource. (Figure 8)The Logix 500si digital positioner has been designed tooperate correctly in electromagnetic (EM) fields found intypical industrial environments. Care should be taken toprevent the positioner from being used in environmentswith excessively high EM field strengths (greater than 10V/m). Portable EM devices such as hand-held two-wayradios should not be used within 30 cm of the device.Ensure proper wiring and shielding techniques of thecontrol lines, and route control lines away from electromagnetic sources that may cause unwanted noise.Connect the 4-20 mA current source to terminals 11 and-12, see connection table.An electromagnetic line filter can be used to furthereliminate noise.8.1 Grounding screwIn the event of a severe electrostatic discharge near thepositioner, the device should be inspected to ensurecorrect operability. It may be necessary to recalibrate theLogix 500si positioner to restore operation.The grounding screw, located inside the positioner cover,should be used to provide the unit with an adequate andreliable earth ground reference. This ground should betied to the same ground as the electrical conduit.Additionally, the electrical conduit should be earthgrounded at both ends of its run. The grounded scrrewmust not be used to termingate signal shield wires.

13If 6,0 VDC (510si)12,0 VDC (520si)Logix500siCurrentFigure 9. Compliance voltage8.3 Compliance voltage8.4 Cable requirementsThe Logix 520 si digital positioner utilizes the HARTcommunication protocol. This communication signal is superimposed on the DC 4-20 mA currentsignal. The two frequencies used by the HARTprotocol are 1200 Hz and 2200 Hz. To preventdistortion of the HART communication, cablecapacitance and cable length restrictions must becalculated. The cable length must be limited if thecapacitance is too high. Selecting a cable with lowercapacitance/mm rating will allow longer cable runs.In addition to cable capacitance, the networkresistance also affects the allowable cable length.520si510siOutput compliance voltage refers to the voltage limit thecurrent source can provide. A current loop system consistsof the current source, wiring resistance, barrier resistance(if present), and the Logix 510/520 impedance.The Logix 510siThe Logix 520sirequires that therequires that thecurrent loop systemcurrent loop systemallow for a 6,0 VDCallow for a 12,0 VDCdrop across the podrop across the posisitioner at maximumtioner at maximumloop current.loop current.CAUTION: Never connect a voltage source directlyacross the positioner terminals. This could causepermanent circuit board damage.Cnetwork(µF) In order to determine if the loop will support the Logix500si, perform the following calculation:To support theLogix 520 thecalculated voltagemust be greaterthan 12.0 VDC.Example:Rbarrier 300 Ω (if present)520siTo support theLogix 510 thecalculated voltagemust be greaterthan 6.0 VDC.520si510siVoltage Compliance Voltage (@CurrentMAX)– CurrentMAX(Rbarrier Rwire)65Ω– 0,0032(Rbarrier Rwire 390Ω)Rwire 50 ΩCcable 72 ρF0.000072 µF mm65– 0,0032 0,08 µF (300 50 390) Cnetwork(µF)(Max)Example: DCS Compliance Voltage 19 VRbarrier 300ΩMax. Cable Length Cnetwork (µF)CcableMax. Cable Length 0,08µF 1111 m0.000072 µF/mRwire 25ΩCURRENTMAX 20 mAThis system will support the Logix 510si,as the voltage 12,5 Vis greater than therequired 6,0 V. TheLogix 510si has aninputresistanceequivalent to 300Ω ata 20 mA input current.520si510siVoltage 19 V – 0,020 A(300Ω 25Ω) 12,5 VThis system will support the Logix 520si,as the voltage 12,5 Vis greater than therequired 12,0 V. TheLogix 520si has aninputresistanceequivalent to 600Ω ata 20 mA input current.To control cable resistance, No. 24 AWG cableshould be used for runs less than 1500 m. For cableruns longer than this, No. 20 AWG cable should beused.Note! When installing Logix 500siintrinsically safe, always consider the information on page 24-27.

149. StartupThe Logix 500si local user interface allows the user tofully configure the operation of the positioner, tune theresponse, and calibrate the positioner. The Local interfaceconsists of:- a quick calibration button for automatic zero and spansetting- two jog buttons for manually spanning the positioner, orfor local Jogging of the valve- a switch block containing eight switches for basic configuration settings and calibration options- a rotary selector switch for adjusting the positioner gainsettings- a 4-20 current loop calibration button accessed througha hole in the cover next to the bottom dipswitch Characteristic 510siLinearThe actuator position directly proportional to theinput signal.510si9.1 Local interface operation Pos. Characterization 520siLinearThe actuator position directly proportional to theinput signal.OptionalIf another characteristic is desired, which is set inconjunction with the next switch, labeled OptionalPos. Char.Before placing the un

Figure 1. Principle of Operation 5. Principle of operation The Logix 500si positioner is a digital positioner with various options. The positioner consists of three main modules: 1. The microprocessor-based electronic control module includes direct local user interface switches 2. The piezo valve-based electro-pneumatic converter module 3.

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