Flowserve 3400MD User Manual

USER INSTRUCTIONS

Installation

3400MD Digital Positioner

FCD LGENIM3404-08 5/15

Operation

Maintenance

Experience In Motion

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

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Contents

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

1 Terms Concerning Safety 4
2 General Information 4
3 Unpacking and Storage 4

3.1 Unpacking 4

3.2 Storage 4

3.3 Pre-installation Inspection 5

4 Logix 3400MD Positioner Overview 6

4.1 Specifications 7

4.2 Positioner Operation 9

4.3 Detailed Sequence of Positioner Operations 10

5 Mounting and Installation 11

5.1 Mounting to Valtek Linear Mark One Valves 11

5.2 Mounting to Standard Valtek Rotary Valves
(See Figure 4) 11

5.3 Optional Valtek Rotary Mounting Procedure
(See Figure 5) 13

6 Wiring and Grounding Guidelines (See Figure 6) 14

6.1 FF Command Input Wiring 14

6.2 Grounding Screw 14

6.3 Segment Compliance Voltage
(See Figure 7) 15

6.4 Cable Requirements 15

6.5 Intrinsically Safe Barriers 15

6.6 DD Support 15

7 Startup 15

7.1 Logix 3400MD Local Interface Operation 15

7.2 Initial DIP Switch Settings 16

7.3 Description of Configuration DIP Switch Settings 16

7.4 Description of Cal DIP Switch Settings 17

7.5 RE-CAL Operation 17

7.6 Manual Jog Calibration Operation 18

7.7 Local Control of Valve Position 18

7.8 Factory Reset 18

7.10 Version Number Checking 20

7.11 475 Handheld Communicator 20

7.12 Device Description (DD) Files 20

7.13 Calibration 20

7.13.1 CALIBRATE_FLAGS 20

7.13.2 Control and Tuning 21

7.14 Alerts 21

7.14.1 FINAL_VALUE_CUTOFF 21

7.14.2 Effects of FINAL_VALUE_CUTOFF on Operation 22

7.14.3 Soft Limits 22

7.14.4 Travel Accumulator 22

7.14.5 Cycle Counter 22

7.14.6 Position Deviation 22

7.14.7 Advanced and Features 22

7.14.8 Standard vs. Advanced Diagnostics 22

7.14.9 Temperature and Pressure Units 22

7.14.10 Stroke Length 22

7.15 Characterization Retention 23

7.15.1 Initiating a Valve Signature 23

7.15.2 System Preparation 23

7.15.3 Signature Procedure 24

7.16 Step Signature 24

7.16.1 Collection of Stored Signature 24

7.17 Glossary 24

8 Maintenance and Repair 31

8.1 Driver Module Assembly 31

8.2 Regulator 33

8.3 Checking or Setting Internal 34

8.4 Spool Valve 34

8.5 Spool Valve Cover 35

8.6 Stem Position Sensor 36

8.7 Main PCB Assembly 36

8.8 Pressure Sensor Board 37

8.9 User Interface Board 38
9 Optional Vented Design 38
10 Parts List 40
11 Logix 3400MD Spare Parts Kits
(See Figure 22 for item numbers.) 40
12 Logix 3400MD Mounting Kits 41

12.1 Valtek Mounting Kits 41

12.2 Logix O.E.M. Mounting Kits 42

12.3 NAMUR Accessory Mounting Kit Part Numbers 42
13 Frequently Asked Questions 43
14 How to Order 44
15 Troubleshooting 45

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

1 Terms Concerning Safety

The safety terms DANGER, CAUTION and NOTE are used in these
instructions to highlight particular dangers and/or to provide
additional information on aspects that may not be readily apparent.

DANGER: Indicates that death, severe personal injury and/or

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substantial property damage will occur if proper precautions are
not taken.

CAUTION: Indicates that minor personal injury and/or property

a

damage can occur if proper precautions are not taken.

NOTE: Indicates and provides additional technical information, which
may not be obvious even to qualified personnel. Compliance with all
other notes, even those not particularly emphasized, with regard to
transport, assembly, operation and maintenance and with regard to
technical documentation (e.g., in the operating instruction, product
documentation or on the product itself) is essential, in order to avoid
problems, which in themselves might directly or indirectly cause
severe personal injury or property damage.

2 General Information

The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Flowserve
Valtek Logix
used for all the positioners herein; however, specific numbers
indicate features specific to model (i.e., Logix 3400 indicates that the
positioner has Foundation Fieldbus protocol). See Logix 3400MD
Model Number table in this manual for a breakdown of specific model
numbers. Product users and maintenance personnel should thoroughly
review this bulletin prior to installing, operating, or performing any
maintenance on the valve.

Separate Valtek Flow Control Products Installation, Operation,
Maintenance instructions cover the valve (such as IOM 1 or IOM 27)
and actuator (such as IOM 2 or IOM 31) portions of the system and
other accessories. Refer to the appropriate instructions when this
information is needed.

To avoid possible injury to personnel or damage to valve parts,
WARNING and CAUTION notes must be strictly followed. Modifying
this product, substituting non-factory parts or using maintenance
procedures other than outlined could drastically affect performance
and be hazardous to personnel and equipment, and may void existing
warranties.

®

3400MD digital positioners. Series 3000 is the term

DANGER: Standard industry safety practices must be adhered to

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when working on this or any process control product. Specifically,
personal protective and lifting devices must be used as warranted.

3 Unpacking and Storage

3.1 Unpacking

1. While unpacking the Logix 3400MD positioner, check the packing
list against the materials received. Lists describing the system
and accessories are included in each shipping container.

2. When lifting the system from the shipping container, position
lifting straps to avoid damage to mounted accessories. Systems
with valves up to six inches may be lifted by actuator lifting ring.
On larger systems, lift unit using lifting straps or hooks through
the yoke legs and outer end of body.

WARNING: When lifting a valve/actuator assembly with lifting

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straps, be aware the center of gravity may be above the lifting
point. Therefore, support must be given to prevent the valve/
actuator from rotating. Failure to do so can cause serious injury
to personnel or damage to nearby equipment.

3. In the event of shipping damage, contact the shipper immediately.

4. Should any problems arise, contact a Flowserve Flow Control
representative.

3.2 Storage

Control valve packages (a control valve and its instrumentation) can
be safely stored in an enclosed building that affords environmental
protection; heating is not required. Control valve packages must be
stored on suitable skids, not directly on the floor. The storage location
must also be free from flooding, dust, dirt, etc.

Long-Term Storage of Logix 3000 Series Positioners in
Humid Locations

The Logix 3000 series positioners are designed to operate in humid
environments when connected to a proper instrument air supply.
There are some occasions when valves and positioners are stored
at job sites or installed and commissioned and then left without
instrument air for months. To make startup easier for units that are
left without instrument air and insure that the positioners will be
ready to operate, it is recommended that the vent assembly of the
positioner be sealed preferably with a desiccant pouch sealed with the
vent assembly.

4

The vent assembly is located in the upper left side of the positioner.
The gaps around the assembly as noted by the arrows should be
sealed for long term storage

A small desiccant package as shown can be included under the
sealing tape to ensure proper protection.

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

3.3 Pre-installation Inspection

If a valve control package has been stored for more than one year,
inspect one actuator by disassembling it per the appropriate Instal­lation, Operation, and Maintenance Instructions (IOM) prior to valve
installation. If O-rings are out-of-round, deteriorated, or both, they
must be replaced and the actuator rebuilt. All actuators must then
be disassembled and inspected. If the actuator O-rings are replaced,
complete the following steps:

1. Replace the pressure-balance plug O-rings.

2. Inspect the solenoid and positioner soft goods and replace
as necessary.

All of the edges around the vend assembly should be sealed similar to
the picture below.

The sealing tape and desiccant should be removed when instrument
air is permanently applied to the positioner.

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

4 Logix 3400MD Positioner Overview

The Logix 3400MD digital positioner is a two-wire Foundation
Fieldbus compliant digital valve positioner. The positioner is
configurable through the local user interface. The Logix 3400MD
utilizes the FF protocol to allow two-way remote communications

Figure 1: Logix 3400MD Digital Postioner Schematic (air-to-air open configuration)

with the positioner. The Logix 3400MD positioner can control both
double- and single- acting actuators with linear or rotary mountings.
The positioner is completely powered by the FF signal. Startup voltage
must be from a FF power supply source.

Figure 2: System Postioning Algorithm

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4.1 Specifications

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

Table 1: Electrical Specifications

Item Description

Power Supply Two-wire, 9 to 32 V DC FF compatible

IS Fisco compliant

Communications FF Protocol ITK 5.1

Operating Current 18 mA

36.0 VDC
9 to 32 V DC for general use and flameproof

Voltage Limits

Wire

applications
9 to 24 V DC for Intrinsically safe applications
9 to 17.5 VDC for Intrinsically safe applications

per FISCO requirements
FF-844 FS1.2 H1 Cable Test Specifications
Terminal Lug 12-22 AWG. 0.27 in. max OD, 0.13

min ID.
Maximum Torque Rating: 7 in-lbs.

Table 2: Environmental Conditions

Item Description

Operating Temperature Range Standard

Transport and Storage

Temperature Range
Operating Humidity 0 – 100% non-condensing

*Note: The Logix 3400MD is designed to operate with clean, dry, oil-free instrument grade air per ISA

7.0.01-1996 or with dry nitrogen, sweet natural gas.

-40° to 185°F (-40° to 85°C)

-40° to 185° F
(-40° to 85°C)

Table 5: Air Supply Requirements

Item Description

Dew Point

Particulate Matter Filtered to 5 microns

Oil Content Less than 1 ppm w/w

Contaminants Free of all corrosive contaminants

At least 180°F (100°C) below minimum anticipated
ambient temperature

Table 6: Function Blocks

Item Description

AO One Analog Output

DI Two Discrete Inputs

DO One Discrete Output

PID One PID Control Function

OS One Output Splitter

IS One Input Selector

Table 3: Physical Specifications

Item Description

Housing Material Cast, powder-painted aluminum, stainless steel

Soft Goods Buna-N / Florosilicone

Weight

8.3 pounds (3.9 kg) aluminum

20.5 pounds (9.3 kg) stainless steel

Table 4: Positioner Specifications

Item Description

Deadband <0.1% Full Span

Repeatability <0.05% Full Span

Linearity

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

Air Supply 30-150 psig (ISA 7.0.0.1 compliant)

<0.5% (Rotary), <0.8%, (Linear Valve) Full Span
Per ISA 75.25.01-2000

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Table 7: Hazardous Locations Information

ATEX

Flame Proof

FM07ATEX0005X
II 2 G
Ex d IIB+H2 T4/T6 Gb IP65
T4 Ta = -52˚C to +80˚C
T6 Ta = -52˚C to +60˚C

II 2 D
Ex tD A21 IP65 T95˚C Db
Ta = -52˚C to +55C

Intrinsically Safe

FM07ATEX0029X
II 1 G
Ex ia IIC T4/T6
T4 Ta = -40˚C to +80˚C
T6 Ta = -40˚C to +40˚C

Explosion Proof

IECEx FMG 11.0002X
Ex d IIB+H2 T4/T6 Gb IP65
T4 Ta = -52˚C to +80˚C
T6 Ta = -52˚C to +60˚C
Ex tb IIIC T95C Db
Ta = -52C to +55C

Intrinsically Safe

IECEx FME 07.0001X
Ex ia IIC T4/T6 Ga IP65
T4 Ta = -40˚C to +80˚C
T6 Ta = -40˚C to +40˚C

Entity Parameters

Fisco Field Device
Vmax = 24V
Imax = 380mA
Pi = 5.32W
Ci = 3.3nF
Li = 1uH

TR CU
Ex d IIB+H2 T4/T6 Gb IP65
Ex ia IIC T4/T6 Ga IP65
Ex nL nA IIC T6

T4 (Ta = -52˚C to +80˚C)
T6 (Ta = -52˚C to +60˚C)

Ex tb IIIC T95C Db IP65

Entity Parameters

Fisco Field Device
Vmax = 24V
Imax = 380mA
Pi = 5.32W
Ci = 3.3nF
Li = 1uH

IECEx

Gost

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

North America (FM/CSA)

Explosion Proof

Class I, Div 1, Groups B,C,D T6
DIP Class II, III, Div 1 Groups E,F,G T6
T6 Ta = -40˚C to +60˚C (FM US)
T4 Ta = -55˚C to +80˚C (CSA)
T5 Ta = -55˚C to +60˚C (CSA)
Type 4/4X IP65

Class 1, Zone 1, AEx d IIB+H2 T6 (FM US)
T6 Ta = -40˚C to +60˚C (FM US)
Type 4/4X IP65

Class 1, Zone 1, Ex d IIB+H2 T4/T6 (CSA)
T4 Ta = -55˚C to +80˚C
T6 Ta = -55˚C to +60˚C
Type 4/4X IP65

Intrinsically Safe

Class I,II, III, Div 1, Groups A,B,C,D,E,F,G T4/T6
Class I, Zone 0, AExia IIC T4/T6 (FM US)
Class I, Zone 0, Ex ia IIC T4/T6 (CSA)
T4 (Ta = -40˚C to +80˚C)
T6 (Ta = -40˚C to +40˚C)
Type 4/4X IP65

Entity Parameters

Fisco Field Device
Vmax = 24V
Imax = 380mA
Pi = 5.32W
Ci = 3.3nF
Li = 1uH

InMetro

Explosion Proof

TÜV 12.0646
Ex d IIB+H2 T5 Gb IP65
Ta = -55˚C to +80˚C
Ex tb IIIC T95C Db IP65
Ta = -55C to +55C

Intrinsically Safe

TÜV 12.0605
Ex ia IIC T4 Ga IP65
T4 Ta = -40˚C to +60˚C

Entity Parameters

Fisco Field Device
Vmax = 24V
Imax = 380mA
Pi = 5.32W
Ci = 3.3nF
Li = 1uH

Special Conditions for Safe Use:

1. When used within a Zone 0 location, cast-aluminum (when Enclosure Option b = 0, 2, 3, 4,or 5) enclosures shall be installed in such manner as to prevent the possibility of sparks resulting from
friction or impact against the enclosure.

2. To prevent the risk of electrostatic sparking, the equipment’s mechanical pressure gauges shall be cleaned only with a damp cloth.

3. Using the box provided on the nameplate, the user shall permanently mark the protection type chosen for the specific installation. Once the type of protection has been marked it shall not be
changed.

4. Consult the manufacturer if dimensional information on the flameproof joints is necessary.

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

4.2 Positioner Operation

The Logix 3400MD positioner is an electric feedback instrument.
Figure 1 shows a Logix 3400MD positioner installed on a double­acting linear actuator for air-to-open action.

The Logix 3400MD receives power from the two-wire, FF input signal.
This positioner utilizes FF communications for the command signal.
The command source can be accessed with the Rosemount 375
communicator or other host software.

0% is always defined as the valve closed position and 100% is always
defined as the valve open position. During stroke calibration, the
signals corresponding to 0% and 100% are defined.

The input signal in percent passes through a characterization/

limits modifier block. The positioner no longer uses CAMs or other
mechanical means to characterize the output of the positioner. This
function is done in software, which allows for in-the-field customer
adjustment. The positioner has four basic modes: Linear, Equal
Percent (=%), Quick Open (QO) and Custom characterization. In
Linear mode, the input signal is passed straight through to the control
algorithm in a

1:1 transfer. In Equal Percent (=%) mode, the input signal is mapped
to a standard 30:1 rangeability =% curve. In Quick Open the input
signal is mapped to an industry standard quick-open curve. If Custom
characterization is enabled, the input signal is mapped to either a
default =% output curve or a custom, user-defined 21-point output
curve. The custom user-defined 21-point output curve is defined

using a handheld or the Host configuration tool software. In addi­tion, two user-defined features, Soft Limits and Final Value Cutoff,
may affect the final input signal. The actual command being used to
position the stem, after any characterization or user limits have been
evaluated, is called the Control Command.

The Logix 3400MD uses a two-stage, stem-positioning algorithm. 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
sensor provides a measurement of the stem movement. The Control
Command is compared against the Stem Position. If any deviation
exists, the control algorithm sends a signal to the inner-loop control
to move the spool up or down, depending upon the deviation. The
inner- loop then quickly adjusts the spool position. The actuator
pressures change and the stem begins to move. The stem movement
reduces the deviation between Control Command and Stem Position.
This process continues until the deviation goes to zero.

The inner-loop controls the position of the spool valve by means
of a driver module. The driver module consists of a temperature­compensated Hall Effect sensor and a piezo valve pressure modulator.
The piezo valve pressure modulator controls the air pressure under
a diaphragm by means of a piezo beam bender. The piezo beam
deflects in response to an applied voltage from the inner-loop
electronics. As the voltage to the piezo valve increases, the piezo
beam bends, closing off against a nozzle causing the pressure under
the diaphragm to increase. As the pressure under the diaphragm
increases or decreases, the spool valve moves up or down respec­tively. The hall effect sensor transmits the position of the spool back
to the inner-loop electronics for control purposes.

Figure 3: Linear Mark OneTM Control Valve Mounting

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

4.3 Detailed Sequence of
Positioner Operations

A more detailed example explains the control function. Assume the
unit is configured as follows:

• Unit is in OOS.

• Custom characterization is disabled (therefore
characterization is Linear).

• No soft limits enabled. No Final Value Cutoff set.

• Valve has zero deviation with a present input command of 50.

• Write to Final_Value to change command.

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

Given these conditions, 50 represents a Command source of 50
percent. Custom characterization is disabled so the Command source
is passed 1:1 to the Control Command. Since zero deviation exists,

the Stem Position is also at 50 percent. With the stem at the desired
position, the spool valve will be at a middle position that balances
the pressures above and below the piston in the actuator. This is
commonly called the null or balanced spool position.Assume the
input signal changes from 50 to 75. The positioner sees this as a
Command source of 75 percent. With Linear characterization, the

Control Command becomes 75 percent. Deviation is the difference
between Control Command and Stem Position : Deviation = 75% ­50% = +25%, where 50 percent is the present stem position. With
this positive deviation, the control algorithm sends a signal to move to
spool up from its present position. As the spool moves up, the supply
air is applied to the bottom of the actuator and air is exhausted from
the top of the actuator. This new pressure differential causes the stem

to start moving towards the desired position of 75 percent. As the
stem moves, the Deviation begins to decrease. The control algorithm
begins to reduce the spool opening. This process continues until the
Deviation goes to zero. At this point, the spool will be back in its null
or balanced position. Stem movement will stop and the desired stem
position is now achieved.

One important parameter has not been discussed to this point: Inner
loop offset. Referring to Figure 2, a number called Inner loop offset

is added to the output of the control algorithm. In order for the spool
to remain in its null or balanced position, the control algorithm must
output a non-zero spool command. This is the purpose of the Inner
loop offset. The value of this number is equivalent to the signal that
must be sent to the spool position control to bring it to a null position
with zero deviation. This parameter is important for proper control
and is optimized and set automatically during stroke calibration.

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Figure 4: Standard Rotary Mounting

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

5 Mounting and Installation

5.1 Mounting to Valtek Linear
Mark One Valves

To mount a Logix 3400MD positioner to a Valtek linear Mark One
valve, refer to Figure 3 and proceed as outlined below. The following
tools are required:

9

•

⁄16” open-end wrench (or ½” for spud sizes 2.88 and smaller)

7

⁄16” box wrench

•

3

⁄8” open-end wrench

•

1. Remove washer and nut from follower pin assembly. Insert pin
into the appropriate hole in follower arm, based on stroke length.
The stroke lengths are stamped next to their corresponding holes
in the follower arms. Make sure the unthreaded end of the pin is
on the stamped side of the arm. Reinstall lock washer and tighten
nut to complete follower arm assembly.

2. Slide the double-D slot in the follower arm assembly over the
flats on the position feedback shaft in the back of the positioner.
Make sure the arm is pointing toward the customer interface side
of the positioner. Slide lock washer over the threads on the shaft
and tighten down the nut.

3. Align the bracket with the three outer mounting holes on the
positioner. Fasten with ¼” bolts.

4. Screw one mounting bolt into the hole on the yoke mounting pad
nearest the cylinder. Stop when the bolt is approximately 3⁄16”
from being flush with mounting pad.

5. Slip the large end of the teardrop shaped mounting hole in the
back of the positioner/bracket assembly over the mounting bolt.
Slide the small end of the teardrop under the mounting bolt and
align the lower mounting hole.

6. Insert the lower mounting bolt and tighten the bolting.

7. Position the take-off arm mounting slot against the stem clamp
mounting pad. Apply Loctite 222 to the take-off arm bolting and
insert through washers into stem clamp. Leave bolts loose.

8. Slide the appropriate pin slot of the take-off arm, based on stroke
length, over the follower arm pin. The appropriate stroke lengths
are stamped by each pin slot.

9. Center the take-off arm on the rolling sleeve of the follower pin.

10. Align the take-off arm with the top plane of the stem clamp and
tighten bolting. Torque to 120 in-lb.

NOTE: If mounted properly, the follower arm should be horizontal

when the valve is at 50% stroke and should move approximately
±30° from horizontal over the full stroke of the valve. If mounted
incorrectly, a stroke calibration error will occur and the indicator
lights will blink a YRYR or YRRY code indicating the position
sensor has gone out of range on one end of travel. Reposition the
feedback linkage or rotate the position sensor to correct the error.

5.2 Mounting to Standard Valtek
Rotary Valves (See Figure 4)

The standard rotary mounting applies to Valtek valve/actuator
assemblies that do not have mounted volume tanks or handwheels.
The standard mounting uses a linkage directly coupled to the valve
shaft. This linkage has been designed to allow for minimal misalign­ment between the positioner and the actuator. The tools required for
the following procedure are:

5

•

⁄32” Allen wrench

• ½” open-end wrench

7

⁄16” open-end wrench

•

3

⁄8” socket with extension

•

3

⁄16” nut driver

•

1. Fasten the spline lever adapter to the splined lever using two 6 x
½” self-tapping screws.

2. Slide the take-off arm assembly onto the spline lever adapter
shaft.Insert the screw with star washer through the take-off arm
and add the second star washer and nut. Tighten nut with socket
so arm is lightly snug on the shaft but still able to rotate. This will
be tightened after linkage is correctly oriented.

3. Attach follower arm to positioner feedback shaft using the star
washer and 10-32 nut.

NOTE: The arm will point up when feedback shaft is in the free
position.

4. Using four ¼-20 x ½” bolts, fasten positioner to universal bracket
using appropriate hole pattern (stamped on bracket).

5. Using a ½” end wrench and two
to actuator transfer case pad. Leave these bolts slightly loose
until final adjustments are made.

6. Rotate take-off arm so the follower pin will slide into the slot on
the take-off arm. Adjust the bracket position as needed noting
the engagement of the follower pin and the take-off arm slot. The
pin should extend approximately
properly adjusted, securely tighten the bracketing bolts.

5

⁄16-18 x ½” bolts, attach bracket

1

⁄16” past the take-off arm. When

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Figure 5: Optional Rotary Mounting

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

Orienting the Take-off Arm for Final Lock Down

1. Tube the Logix 3400MD positioner to the actuator according
to the instructions given in Section 5.5, “Tubing Positioner to
Actuator.”

2. With supply pressure off, rotate the follower arm in the same
direction the shaft would rotate upon a loss of supply pressure.
When the mechanical stop of the follower arm (positioner) is
reached, rotate back approximately 15 degrees.

3. Hold the take-off arm in place; tighten the screw of the take-off arm.

NOTE: The take-off arm should be snug enough to hold the
follower arm in place but allow movement when pushed.

4. Connect regulated air supply to appropriate port in manifold.

5. Remove main cover and locate DIP switches and RE-CAL button.

6. Refer to sticker on main board cover and set DIP switches accord-

12

ingly. (A more detailed explanation of the DIP switch settings is
given in Section 7, “Startup.”)

7. Press the RE-CAL button for three to four seconds or until the
positioner begins to move. The positioner will now perform a
stroke calibration.

8. If the calibration was successful the green LED will blink GGGG
or GGGY and the valve will be in control mode. Continue with
step 9. If calibration failed, as indicated by a YRYR or YRRY
blink code, the A/D feedback values were exceeded and the arm
must be adjusted away from the positioners limits. Return to
step 2 and rotate the arm back approximately 10 degrees.

NOTE: Remember to remove the air supply before re-adjusting
take-off arm.

9. Tighten the nut on the take-off arm. The socket head screw of
the take-off arm must be tight, about 40 in-lb.

NOTE: If the take-off arm slips, the positioner must be
recalibrated.

WARNING: Failure to follow this procedure will result in

c

positioner and/or linkage damage. Check air-action and stroke
carefully before lockdown of take-off arm to spline lever adapter.

5.3 Optional Valtek Rotary Mounting
Procedure (See Figure 5)

The optional rotary mounting applies to Valtek valve/actuator
assemblies that are equipped with mounted volume tanks or
handwheels. The optional mounting uses a four-bar linkage coupled
to the valve shaft. The following tools are required:

3

•

⁄8” open-end wrench

7

⁄16” open-end wrench

•

• ½” open-end wrench

1. Using a ½” open-end wrench and two 5⁄16-18 x ½” bolts, attach
bracket to actuator transfer case pads. Leave bracket loose to
allow for adjustment.

2. Using four ¼-20 x ½” bolts and a
positioner to universal bracket, using the four-hole pattern
that locates the positioner the farthest from the valve. Rotate
positioner 90 degrees from normal so gauges are facing upward.

3. Attach follower arm to positioner feedback shaft, using the star
washer and 10-32 nut.

4. Attach tripper and tripper clamp to valve shaft using two ¼-20
bolts and two ¼-20 locknuts. Leave tripper loose on shaft until
final adjustment.

5. Thread ball joint linkage end to tripper and tighten (thread
locking compound such as Loctite is recommended to prevent
back threading). Adjust the length of tie rod so follower arm and
tripper rotate parallel to each other (the rod must be cut to the
desired length). Connect the other ball joint end to follower arm
using a star washer and a 10-32 nut.

6. Tighten bracket and tripper bolting.

7. Check for proper operation, note direction of rotation.

DANGER: If rotating in wrong direction, serious damage will

c

occur to the positioner and/or linkage. Check air action and stroke
direction carefully before initiating operation.

7

⁄16” open-end wrench, fasten

5.4 NAMUR Mounting Option

Logix 3200MD is available with a NAMUR output shaft and mounts
on an actuator using the ISO F05 holes. Proper alignment of the
positioner shaft to the actuator shaft is very important since improper
alignment can cause excess wear and friction to the positioner.

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

5.5 Tubing Positioner to Actuator

The Logix 3400MD digital positioner is insensitive to supply pressure
changes and can handle supply pressures from 30 to 150 psig.

NOTE: A supply regulator is recommended if the customer will
be using the diagnostic features of the Logix 3400MD but is not
required. In applications where the supply pressure is higher than
the maximum actuator pressure rating a supply regulator is required
to lower the pressure to the actuator’s maximum rating (not to be
confused with operating range). An air filter is highly recommended
for all applications where dirty air is a possibility.

NOTE: The air supply must conform to ISA Standard ISA 7.0.01 (a
dew point at least 18°F below ambient temperature, particle size
below five microns—one micron recommended—and oil content not
to exceed one part per million).

Air-to-open and air-to-close are determined by the actuator
tubing, not the software. When air action selection is made during
configuration, that selection tells the control which way the actuator
has been tubed. The top output port is called Output 1. It should be
tubed to the side of the actuator that must receive air to begin the
correct action on increasing signal. Verify that tubing is correct prior
to a stroke calibration.

NOTE: Proper tubing orientation is critical for the positioner to
function correctly and have the proper failure mode. Refer to Figure 1
and follow the instructions below:

Linear Double-acting Actuators

For a linear air-to-open actuator, the Output 1 port of the positioner
manifold is tubed to the bottom side of the actuator. The Output 2
port of the positioner manifold is tubed to the top side of the actuator.
For a linear air-to-close actuator the above configuration is reversed.

Rotary Double-acting Actuators

For a rotary actuator, the Output 1 port of the positioner manifold
is tubed to the bottom side of the actuator. The Output 2 port of
the positioner manifold is tubed to the top side of the actuator. This
tubing convention is followed regardless of air action. On rotary
actuators, the transfer case orientation determines the air action.

Single-acting Actuators

For single-acting actuators, the Output 1 port is always tubed to the
pneumatic side of the actuator regardless of air action. The Output 2
port must be plugged.

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

6 Wiring and Grounding
Guidelines

DANGER: This product has electrical conduit connections in either

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thread sizes ½” NPT or M20 which appear identical but are not
interchangeable. Housings with M20 threads are stamped with
the letters M20 above the conduit opening. Forcing dissimilar
threads together will damage equipment, cause personal injury
and void hazardous location certifications. Conduit fittings must
match equipment housing threads before installation. If threads
do not match, obtain suitable adapters or contact a Flowserve
representative.

DANGER Any unused cable entries are to be closed off with

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appropriately certified blanking devices.

DANGER: When using cable glands, ensure that they are

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appropriately certified.

Figure 6: Field Termination

(See Figure 6)

6.1 FF Command Input Wiring

The Logix 3400MD is non-polarity sensitive. Wire FF source to the
input terminals (see Figure 6). Minimum operating voltage is 9 VDC.

The FF signal to the Logix 3400MD digital positioner should be in
shielded cable. Shields must be tied to a ground at only one end of
the cable to provide a place for environmental electrical noise to be
removed from the cable. In general, shield wire should be connected
at the source. Refer to guidelines in FF AG-140 and FF AG-181 for
proper wiring methods.

6.2 Grounding Screw

The green grounding screw, located inside the termination cap,
should be used to provide the unit with an adequate and reliable earth
ground reference. This ground should be tied to the same ground as
the electrical conduit. Additionally, the electrical conduit should be
earth grounded at both ends of its run.

DANGER: The green grounding screw must not be used to

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terminate signal shield wires.

14

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

6.3 Segment Compliance Voltage

(See Figure 7)

Output compliance voltage refers to the voltage limit that can be
provided by the FF source. A FF system consists of the FF source,
wiring resistance, barrier resistance (if present), and the Logix
3400MD positioner voltage. The Logix 3400MD digital positioner
requires that the system allows for a 9.0 VDC drop across the
positioner at minimum segment voltage. The actual voltage at the
terminals varies from 9.0 to 32.0 VDC depending on the FF signal and
ambient temperature.

Determine if the segment will support the Logix 3400MD digital
positioner by performing the following calculation.

Equation 1

Voltage = Compliance Voltage (@ 18 mA) - 18 mA x (R

The calculated voltage must be greater than 9 VDC in order to safely
support the Logix 3400MD digital positioner.

Example:

DCS Compliance Voltage = 19 VDC

= 25 Ω

R

barrier

= 25 Ω

R

wire

Current
Voltage = 19 VDC – 0.018 A • (300 Ω + 25 Ω) = 13.15VDC
The voltage 13.15 VDC is greater than the required 9.0 VDC; there-

fore, this system will support the Logix 3400MD digital positioner.

= 18 mA

max

barrie

r + R

wire

)

6.6 DD Support

The DD for the Logix 3400MD can be downloaded from either the
Flowserve website: www.valvesight.com or the Foundation Fieldbus
website: www.Fieldbus.org.

7 Startup

7.1 Logix 3400MD Local Interface Operation

The Logix 3400MD local user interface (Figure 8) allows the user to
configure the basic operation of the positioner, tune the response,
and calibrate the positioner without additional tools or configurators.
The local interface consists of a RE-CAL button for automatic
zero and span setting, along with two jog buttons (
spanning valve/actuators with no fixed internal stop in the open
position. There is also a DIP switch block containing eight switches.
Six of the switches are for basic configuration settings and two are
for FF options. There is also a rotary selector switch for adjusting the
positioner gain settings. For indication of the operational status or
alarm conditions there are three LEDs on the local user interface.

Figure 8: Local User Interface

▲

and ▼) for

6.4 Cable Requirements

The Logix 3400MD digital positioner utilizes the FF protocol. This
communication signal is superimposed on the supply voltage.

FF rated cable should be used. Refer to H1 wiring specification (FF-844).

6.5 Intrinsically Safe Barriers

When selecting an intrinsically safe barrier, make sure the barrier is
FF compatible. Although the barrier will pass the segment voltage
and allow normal positioner operation, if not compatible, it may
prevent FF communication.

Figure 7: Compliance Voltage

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Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ –5/15

7.2 Initial DIP Switch Settings

Before placing the unit in service, set the DIP switches in the Configu­ration boxes to the desired control options. A detailed description of
each DIP switch setting follows.

NOTE: The Logix 3400MD positioner reads the DIP switch settings
each time the RE-CAL button is pressed. If a FF handheld or Host
software is used to configure and then calibrate the positioner, the
DIP switches are not read. The auto-tune adjustment switch labeled
“GAIN” is always live and can be adjusted at any time.

Transducer block settings will always override the DIP switch settings
until the RE-CAL button is pressed.

7.3 Description of Configuration DIP
Switch Settings

The first six DIP switches are for basic configuration. The function
of each switch is described below.

Air Action

This must be set to match the configuration of the valve/actuator
mechanical tubing connection and spring location since these deter­mine the air action of the system.

Pos. Characterization

Linear Select Linear if the actuator position should be directly
proportional to the input signal.

Other Select Other if another characteristic is desired, which is set in
conjunction with the Control_Flags parameter in the transducer block.

Optional Pos. Characterization

If the Pos. Characterization switch is set to Other then the CURVE_
SELECT parameter is active with the following options:

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

QO Quick open is based on a standard industry quick-open curve.

Custom If Custom is selected, the positioner will be characterized

to a custom table that must be set-up using a properly configured
475 handheld or other host software. Custom characterization can
be thought of as a “soft CAM.” The user can define a characterization
curve using 21 points. The control will linearly interpolate between
points. Points do not have to be equally spaced in order to allow more
definition at critical curve areas. The default values will linearize the
output of a valve with an inherent =% characteristic (e.g. ball valves.)

ATO (air-to-open)

Selecting ATC if increasing output pressure from the positioner is
tubed so it will cause the valve to close.

ATC (air-to-close)

Selecting ATC if increasing output pressure from the positioner is
tubed so it will cause the valve to close.

Figure 9: Default Custom Characterization

16

Table 8: Characteristic Curve Data

% Command

0 0 0 0 0

5 0.62 5 8.66 18.8
10 1.35 10 16.24 37.6
15 2.22 15 23.17 56.4
20 3.25 20 30.11 74.0
25 4.47 25 35.31 84.3
30 5.91 30 40.51 90.0
35 7.63 35 45.42 92.0
40 9.66 40 50.34 93.4
45 12.07 45 54.40 94.2
50 14.92 50 58.47 94.8
55 18.31 55 62.39 95.5
60 22.32 60 66.31 96.0
65 27.08 65 70.27 96.5
70 32.71 70 74.23 97.0
75 39.40 75 78.17 97.5
80 47.32 80 82.11 98.0
85 56.71 85 85.50 98.5
90 67.84 90 88.89 99.0
95 81.03 95 94.45 99.5

100 100.00 100 100.00 100.0

=% Linear Custom QO

% Control Command

Logix 3400MD Digital Positioner FCD LGENIM3404-08-AQ – 5/15

Auto Tune

This switch controls whether the positioner will auto tune itself every
time the RE-CAL button is pressed or use preset tuning parameters.

On On enables an auto tune feature that will automatically determine
the positioner gain settings based on the current position of the
adjust- able GAIN switch setting and response parameters measured
during the last RE-CAL. The GAIN switch is live, meaning the settings
can be adjusted at any time by changing the rotary switch position.
(Note that there is a small black arrow indicating the selection. The
slot in the switch is NOT the indicator.)

Figure 10: Adjustable GAIN Switch

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

High-friction Valves Placing the switch to the right optimizes the
response for valves and actuators with high friction levels. This
setting slightly slows the response and will normally stop limit cycling
that can occur on high-friction valves.

7.4 Description of Cal DIP Switch Settings

The sixth DIP switch selects between two calibration options. The
function of the Cal DIP switch is described below.

NOTE: The unit must be in OOS mode before a calibration sequence
can begin.

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

Jog Select Jog if the valve/actuator assembly has no physical
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 open position using the Jog buttons labeled with the up and
down arrows. See the detailed instructions in Section 7.6 on how to
perform a manual calibration using the Jog buttons.

DANGER: During the RE-CAL operation the valve may stroke

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unexpectedly. Notify proper personnel that the valve will stroke,
and make sure the valve is properly isolated.

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

Off Off forces the positioner to use one of the factory preset tuning
sets determined by the adjustable GAIN selector switch. Settings “A”
through “H” are progressively higher gain predefined tuning sets. The
GAIN selector switch is live and can be adjusted at any time to modify
the tuning parameters.

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

Stability Switch

This 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.

7.5 RE-CAL Operation

NOTE: The unit must be in OOS mode before a calibration sequence
can begin.

The RE-CAL button is used to locally initiate a calibration of the
positioner. Pressing and holding the RE-CAL button for approximately
three seconds will initiate the calibration. If the Config-Switches
option is enabled, the settings of all the configuration switches are
read and the operation of the positioner adjusted accordingly. A
RE-CAL can be aborted at any time by briefly pressing the RE-CAL
button and the previous settings will be retained.

If the Quick Calibration switch (be careful not to confuse this with the
RE-CAL button) is set to Auto and the valve/actuator assembly has
the necessary internal stops the calibration will complete automati­cally. While the calibration is in progress you will notice a series of
different lights flashing indicating the calibration progress. When
the lights return to a sequence that starts with a green light the
calibration is complete. An explanation of the various light sequences
follows. The initial calibration of extremely large or small actuators
may require several calibration attempts. The positioner adapts to
the actuator performance and begins each calibration where the last
attempt ended. On an initial installation it is recommended that after
the first successful calibration that one more calibration be completed
for optimum performance.

17

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