User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Logix ® 420
Digital Positioner
FCD LGENIM0106-0612/13
Installation
Operation
Maintenance
Safety Manual
USER INSTRUCTIONS
flowserve.com 1
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Quick Start Instructions 15
CONTENTS
1 GENERAL INFORMATION ................................. 3
1.1 USING THIS DOCUMENT ............................................................3
1.2 TERMS CONCERNING SAFETY ......................................................3
1.3 PROTECTIVE CLOTHING .............................................................3
1.4 QUALIFIED PERSONNEL .............................................................3
1.5 VALVE AND ACTUATOR VARIATIONS .............................................3
1.6 SPARE PARTS .........................................................................3
1.7 SERVICE / REPAIR ....................................................................3
1.8 BASIC OPERATION ...................................................................4
1.9 HART ..................................................................................4
1.10 POSITION DEFINITION ...............................................................4
1.11 COMMAND INPUT AND FINAL COMMAND ......................................4
1.12 OUTER LOOP ..........................................................................5
1.13 INNER LOOP ...........................................................................5
1.14 DETAILED SEQUENCE OF POSITIONER OPERATIONS ...........................5
1.15 INNER LOOP OFFSET.................................................................5
2 SPECIFICATIONS ............................................... 6
2.1 INPUT SIGNAL ........................................................................6
2.2 AIR SUPPLY ...........................................................................6
2.3 PHYSICAL SPECIFICATIONS ..........................................................6
2.4 PNEUMATIC OUTPUT................................................................6
2.5 STROKE OUTPUT .....................................................................6
2.6 TEMPERATURE ........................................................................6
2.7 POSITIONER PERFORMANCE CHARACTERISTICS ................................6
2.8 VALVESIGHT DTM SOFTWARE SPECIFICATIONS ...............................6
3 HAZARDOUS AREA CERTIFICATIONS............ 7
4 STORAGE AND UNPACKING ............................ 8
4.1 STORAGE ..............................................................................8
4.2 UNPACKING ...........................................................................8
4.3 PRE-INSTALLATION INSPECTION ...................................................8
5 MOUNTING AND INSTALLATION ..................... 9
5.1 DIRECT MOUNTING TO VALTEK GS AND FLOWTOP ..........................9
5.2 MOUNTING TO NAMUR VALVES ............................................. 10
6 TUBING ............................................................. 11
6.1 DETERMINE AIR ACTION ......................................................... 11
6.2 CONNECT SUPPLY PORT .......................................................... 11
6.3 VENTED DESIGN .................................................................... 11
6.4 PURGING ............................................................................ 11
7 ELECTRICAL CONNECTIONS ......................... 12
7.1 ELECTRICAL TERMINALS ........................................................... 12
7.2 COMMAND INPUT (4-20 MA) CONNECTION ................................ 12
7.3 CONNECTIONS FOR INTRINSICALLY SAFE OPERATION ....................... 14
9 POSITIONER FUNCTIONS (NO DISPLAY
REQUIRED) ....................................................... 18
9.1 LIVE MANUAL TUNING (ADJUSTING THE GAIN) ............................. 18
9.2 LOCAL CONTROL OF VALVE POSITION ......................................... 18
9.3 COMMAND SOURCE RESET ...................................................... 18
9.4 FACTORY RESET .................................................................... 18
9.5 VIEWING VERSION NUMBERS ................................................... 19
10 POSITIONER FUNCTIONS (LCD DISPLAY) .... 19
10.1 MAIN DISPLAY VIEW .............................................................. 19
10.2 MENU OVERVIEW ................................................................. 21
10.3 MENU FEATURES .................................................................. 22
11 HART COMMUNICATION ................................. 27
11.1 VALVESIGHT DTM ................................................................ 27
11.2 HART 475 HANDHELD COMMUNICATOR .................................... 27
11.3 BURST MODE ....................................................................... 27
11.4 CHANGING HART VERSIONS .................................................... 27
12 REQUIREMENTS FOR SAFETY INTEGRITY .. 28
12.1 FAIL SAFE STATE ................................................................... 28
12.2 SAFETY FUNCTION ................................................................. 28
12.3 FAIL SAFE STATE RESPONSE TIME .............................................. 28
12.4 INSTALLATION ...................................................................... 28
12.5 REQUIRED CONFIGURATION SETTINGS......................................... 28
12.6 MAXIMUM ACHIEVABLE SIL..................................................... 28
12.7 RELIABILITY DATA .................................................................. 28
12.8 LIFETIME LIMITS .................................................................... 28
12.9 PROOF TESTING .................................................................... 29
12.10 MAINTENANCE ..................................................................... 29
12.11 REPAIR AND REPLACEMENT ...................................................... 29
12.12 TRAINING REQUIREMENTS ....................................................... 29
13 MAINTENANCE AND REPAIR ......................... 30
13.1 SCHEDULED MAINTAINANCE .................................................... 30
13.2 REQUIRED TOOLS AND EQUIPMENT ............................................ 30
13.3 REPLACING A MAIN BOARD ..................................................... 30
14 TROUBLESHOOTING ....................................... 31
14.1 TROUBLESHOOTING GUIDE ...................................................... 31
14.2 STATUS CODE INDEX .............................................................. 32
14.3 STATUS CODE DESCRIPTIONS .................................................... 33
14.4 HELP FROM FLOWSERVE ......................................................... 39
15 POSITIONER DIMENSIONS.............................. 40
15.1 POSITIONER DIMENSIONS ........................................................ 40
16 HOW TO ORDER ............................................... 41
16.1 POSITIONERS ........................................................................ 41
16.2 SPARE PARTS KITS ................................................................. 41
16.3 MOUNTING KITS ................................................................... 41
INDEX ........................................................................... 42
8 STARTUP .......................................................... 15
8.1 QUICK START INSTRUCTIONS .................................................... 15
8.2 LOCAL USER INTERFACE OVERVIEW ............................................ 15
8.3 CONFIGURATION SWITCH SETTINGS ............................................ 15
8.4 STROKE CALIBRATION ............................................................. 16
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User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
1 GENERAL INFORMATION
1.1 Using This Document
Product users and maintenance personnel should thoroughly
review this manual prior to installing, operating, or performing
any maintenance on the positioner.
The following instructions are designed to assist in unpacking,
installing and performing maintenance as required on Logix®
420 positioners. .
Separate Flow Control Products User Instructions cover the
valve, actuator, or portions of the system and other accessories.
Refer to the appropriate instructions when this information is
needed. In most cases FLOWSERVE valves, actuators and
accessories are designed for specific applications with regard to
medium, pressure and temperature. For this reason they
should not be used in other applications without first
contacting the manufacturer.
To avoid possible injury to personnel or damage to positioner
parts, DANGER 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.
1.2 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.
NOTE: Indicates and provides additional technical information,
which may not be very obvious even to qualified personnel.
CAUTION: Indicates that minor personal injury and/or
property damage can occur if proper precautions are not taken.
DANGER: Indicates that death, severe personal injury
and/or substantial property damage can occur if proper
precautions are not taken.
Compliance with other, not particularly emphasized notes, with
regard to assembly, operation and maintenance and technical
documentation (e.g., in the operating instruction, product
documentation or on the product itself) is essential in order to
avoid faults, which in themselves might directly or indirectly
cause severe personal injury or property damage.
1.3 Protective Clothing
FLOWSERVE positioners use high pressure gas to operate. Use
eye protection when working around pressurized equipment.
Follow proper procedures for working with natural gas if it is
used.
DANGER: Standard industry safety practices must be
adhered to when working on this or any process control product.
Specifically, personal protective equipment must be used as
warranted.
1.4 Qualified Personnel
Qualified personnel are people who, on account of their
training, experience, instruction and their knowledge of
relevant standards, specifications, accident prevention
regulations and operating conditions, have been authorized by
those responsible for the safety of the plant to perform the
necessary work and who can recognize and avoid possible
dangers.
In unpacking, installing and performing maintenance as
required on FLOWSERVE products, product users and
maintenance personnel should thoroughly review this manual
prior to installing, operating or performing any maintenance.
1.5 Valve and Actuator Variations
These instructions cannot claim to cover all details of all
possible product variations, nor can they provide information
for every possible example of installation, operation or
maintenance. This means that the instructions normally include
only the directions to be followed by qualified personal where
the product is being used for its defined purpose. If there are
any uncertainties in this respect particularly in the event of
missing product-related information, clarification must be
obtained via the appropriate Flowserve sales office.
1.6 Spare Parts
Use only FLOWSERVE original spare parts. FLOWSERVE
cannot accept responsibility for any damages that occur from
using spare parts or fastening materials from other
manufactures. If FLOWSERVE products (especially sealing
materials) have been in storage for longer periods check
these for corrosion or deterioration before using these
products. See section 4 STORAGE AND UNPACKING more
information.
1.7 Service / Repair
To avoid possible injury to personnel or damage to products,
safety terms must be strictly adhered to. Modifying this
product, substituting non-factory parts, or using maintenance
procedures other than outlined in this instruction could
drastically affect performance and be hazardous to personnel
and equipment, and may void existing warranties.
Between actuator and valve there are moving parts. To avoid
injury FLOWSERVE provides pinch-point-protection in the
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User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Figure 1: Principles of Operation of Logix 420
Piezo
Hall
Air Supply
Poppet
Single Acting
Piezo
Piezo Kill
Inner
Spool
Position
Control
Actuator
Final
Command
Input
Characterization,
Soft Limits,
Digital
Command
Analog
(4-20 mA)
Output
+
+
I
D
+
_
Inner-Loop
+
_
Inner-Loop
form of cover plates, especially where side-mounted
positioners are fitted. If these plates are removed for
inspection, service or repair special attention is required.
After completing work the cover plates must be refitted.
Logix 420 positioner repair is limited to the replacement of
sub-assemblies and circuit boards with FLOWSERVEmanufactured replacements as outlined in this manual.
DANGER: Substitution of with non-factory positioner
components may impair intrinsic safety.
CAUTION: Before products are returned to
FLOWSERVE for repair or service, FLOWSERVE must be
provided with a certificate which confirms that the product
has been decontaminated and is clean. FLOWSERVE will
not accept deliveries if a certificate has not been provided (a
form can be obtained from FLOWSERVE).
Apart from the operating instructions and the obligatory
accident prevention directives valid in the country of use, all
recognized regulations for safety and good engineering
practices must be followed.
PRINCIPLES OF OPERATION
1.8 Basic Operation
The Logix 420 digital positioner is a two-wire 4-20 mA input
digital valve positioner which uses the HART protocol to
allow two-way remote communications. The positioner is
completely powered by the 4-20 mA input signal. Start-up
current must be at least 3.8 mA. The positioner is
configurable through the local user interface, hand-held or
DTM. The Logix 420 positioner can control single-acting
pneumatic actuators with linear or rotary mountings.
The Logix 420 digital positioner is an electronic and
pneumatic closed-loop feedback instrument. Figure 1 shows
a schematic of a Logix 420 positioner installed on a singleacting linear actuator for air-to-open action.
1.9 HART
The Logix 420 receives power from the two-wire, 4-20 mA
input signal. However, since this positioner utilizes HART
communications, two sources can be used for the command
signal: Analog and Digital. In Analog source, the 4-20 mA
signal is used for the command source. In Digital source, the
level of the input 4-20 mA signal is ignored (used only for
power) and a digital signal, sent via the HART
communication protocol, is used as the command source.
The command source can be accessed with ValveSight
software, the HART 375 communicator, or other host
software. See section 11 HART COMMUNICATION
HART COMMUNICATION for more information.
1.10 Position Definition
Whether in Analog or Digital Source, The position at 0% is
always defined as the valve in a closed position and 100% is
always defined as the valve in an open position. In Analog
Source, the 4-20 mA signal is converted to a position (in
percent). During loop calibration, the signals corresponding
to 0% and 100% are defined.
1.11 Command Input and Final Command
The Command Input signal (in percent) passes through a
characterization/limits modifier block. This function is done in
software, which allows for in-the-field customer adjustment.
The characterization block can apply no adjustment (Linear),
Command
Input
Σ
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Circuit
Loop
Σ
Σ
one of several pre-defined characterization curve
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Vent
adjustments (including several Equal Percent), or a 21-point
Custom Characterization curve adjustment. 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 rangeability equal
percent curve. If Custom Characterization is enabled, the
input signal is mapped to a custom, user-defined 21-point
output curve. The custom user-defined 21-point output curve
is defined using a handheld or ValveSight software. In
addition, two user-defined features, Soft Limits and Tight
Shutoff may affect the position. The actual command being
used to position the stem after the evaluation of
characterization curves and user limits, is called the Final
Command.
1.12 Outer Loop
The Logix 420 uses a two-stage, stem-positioning algorithm.
The two stages consist of an inner-loop (pilot relay 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 Final 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
relay in a direction, depending upon the deviation. The innerloop then quickly adjusts the spool position. The actuator
pressures change and the stem begins to move. The stem
movement reduces the deviation between Final Command
and Stem Position. This process continues until the deviation
goes to zero.
1.13 Inner Loop
The inner-loop controls the position of the relay valve by
means of a driver module. The driver module consists of a
temperature-compensated 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 poppet
valve moves up or down respectively. The Hall effect sensor
transmits the position of the poppet back to the inner-loop
electronics for control purposes.
1.14 Detailed Sequence of Positioner Operations
A more detailed example explains the control function.
Assume the unit is configured as follows:
Unit is in Analog command source.
Custom characterization is disabled (therefore
characterization is Linear).
No soft limits enabled. No tight shutoff (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 Command
source of 50 percent. Custom characterization is disabled so
the command source is passed 1:1 to the Final Command.
Since zero deviation exists, the stem position is also at 50
percent. With the stem at the desired position, the poppet
valve will be at a middle position that balances the pressures
and spring force in the actuator. This is commonly called the
null or balanced poppet position.
Assume the input signal changes from 12 mA to 16 mA. The
positioner sees this as a command source of 75 percent.
With Linear characterization, the Final Command becomes
75 percent. Deviation is the difference between Final
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 the poppet up from its present position. As the poppet
moves, the supply air is applied to the bottom 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 poppet opening. This process
continues until the Deviation goes to zero. At this point, the
poppet will be back in its null or balanced position. Stem
movement will stop and the desired stem position is now
achieved.
1.15 Inner Loop Offset
The position of the poppet at which the pressure and springs
are balanced, holding the valve position in a steady state, is
called the Inner Loop Offset. The controlling algorithm uses
this value as a reference in determining the Piezo voltage.
This parameter is important for proper control and is
optimized and set automatically during stroke calibration.
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User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Table 1: Input Signal
Power Supply
Two-wire, 4-20 mA
10.0 VDC terminal voltage
Input Signal Range
4 - 20 mA (HART)
Compliance Voltage
10.0 VDC @ 20 mA
Effective Resistance
500 Ω @ 20 mA Typical
Minimum Required Operating
Current
3.8 mA
Signal Interrupt Without Restart
Time (after powering positioner
for at least one minute)
80 ms
Maximum Shut-down Current
3.6 mA
Communications
HART protocol
Table 2: Air Supply
Minimum Input Pressure
1.5 Bar (22 PSI)
Maximum Input Pressure
Single Acting Relay – 6 Bar (87 PSI)
Air Supply Quality
The air supply must be free from
moisture, oil and dust by conforming to
the ISA 7.0.01 standard. (A dew point
at least 18 degrees Fahrenheit below
ambient temperature, particle size
below five microns—one micron
recommended—and oil content not to
exceed one part per million).
Operating Humidity
0 - 100% non-condensing
Acceptable Supply
Gasses
Air, sweet natural gas, nitrogen and
CO2 are acceptable supply gasses.
Sour natural gas is not acceptable.
Air Consumption
0.069 Nm³/h @ 1.5 bar
(0.041 SCFM @ 22 PSI)
0.082 Nm³/h @ 4.1 bar
(0.050 SCFM @ 60 PSI)
Table 3: Physical Specifications
For dimensions, see section 15 POSITIONER .
Housing Material
Cast, powder-painted aluminum
EN AC-AlSi12(Fe)
Soft Goods
Fluorosilicone
Weight of Base Positioner
Without Accessories
With LCD and Glass Cover
2.70 kg (5.95 lb)
With Solid Cover
3.11 kg (6.85 lb)
Table 4: Pneumatic Output
Output Pressure
Range
0 to 100% of air supply pressure.
Output Air Capacity
Single Acting Relay –
9.06 Nm³/h @ 1.5 bar
(5.33 SCFM @ 22 PSI)
20.8 Nm³/h @ 4.1 bar
(12.2 SCFM @ 60 PSI)
Table 5: Stroke Output
Feedback shaft
Rotation
Min 15°, Max 90°
45° recommended for linear applications.
Table 6: Temperature
Operating
Temperature Range*
-52 to 85°C (-61.6 to 185°F)
Transport and Storage
Range
-52 to 85°C (-61.6 to 185°F)
Table 7: Performance Characteristics
Better than or equal to the following values on a 25 square inch
Mark I actuator per standard ISA 75.13.
Resolution
0.25%
Linearity
+/-1.25%
Repeatability
0.25%
Hysteresis
1.0%
Deadband
0.3%
Sensitivity
0.25%
Stability
0.4%
Long term drift
0.5%
Supply Pressure Effect
0.2%
Table 8: ValveSight DTM 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 serial,
PCMCIA and USB connections)
HART Modem
RS-232, PCMCIA card, or USB
HART Filter
May be required in conjunction with some
DCS hardware.
HART MUX
MTL 4840/ELCON 2700
2 SPECIFICATIONS
2.1 Input Signal
2.2 Air Supply
2.4 Pneumatic Output
2.5 Stroke Output
2.6 Temperature
*Reduced performance at low temperatures.
2.7 Positioner Performance Characteristics
2.3 Physical Specifications
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2.8 ValveSight DTM Software Specifications
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Table 9: Logix 420 Hazardous Locations Information
ATEX
Explosion Proof/Flame Proof
FM13ATEX0097X
II 2 G
Ex d IIB+H2 Gb T4/T6
T4 Tamb = -52˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
IP 66
Intrinsically Safe
FM12ATEX0009X
II 1 G
Ex ia IIC Ga T4/T6
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
IP 66
Entity
Parameters
4-20
Input
Ui (Vdc)=
30
Ii (mA)=
100
Pi (mW)=
800
Ci (nF)=
0
Li (µH)=
47
Note: Reference installation drawing # 291780
North America (cFMus)
Explosion Proof
Class I, Div 1, Groups B,C,D
Class I, Zone 1, AEx d IIB+H2 T4/T6 (US)
Class 1, Zone 1, Ex d IIB +H2 T4/T6 (Canada)
T4 Tamb = -52˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
Intrinsically Safe
Class I, Div 1, Groups A,B,C,D
Class I, Zone 0, AExia IIC (US)
Class I, Zone 0, Ex ia IIC (Canada)
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
Type 4X
Entity
Parameters
4-20
Input
Ui (Vdc)=
30
Ii (mA)=
100
Pi (mW)=
800
Ci (nF)=
0
Li (µH)=
47
Note: Reference installation drawing # 291780
IECEx
Explosion Proof/Flame Proof
FMG 13.0038X
II 2 G
Ex d IIB+H2 Gb T4/T6
T4 Tamb = -52˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
IP 66
Intrinsically Safe
FMG 12.0001X
Ex ia IIC Ga T4/T6
T4 Tamb = -20˚C ≤ Ta ≤ +85˚C
T6 Tamb = -52˚C ≤ Ta ≤ +45˚C
IP 66
Entity
Parameters
4-20
Input
Ui (Vdc)=
30
Ii (mA)=
100
Pi (mW)=
800
Ci (nF)=
0
Li (µH)=
47
Note: Reference installation drawing # 291780
Warning!
Covers must be properly installed in order to maintain
environmental ratings.
Special Conditions for Safe Use:
The equipment must be installed in such a manner as to
minimize the risk of impact or friction with other metal surfaces.
To avoid possibility of static discharge clean only with a damp
cloth.
For Intrinsically Safe installations the positioner must be
connected to suitably rated intrinsically safe equipment, and
must be installed in accordance with applicable intrinsically safe
installation standards.
Substitution of components may impair Intrinsic Safety.
Use appropriately rated cable insulation at higher temperatures.
Contact Flowserve for flame path information.
Conditions spéciales pour une utilisation en toute sécurité:
Le matériel doit être installé de sorte à réduire au minimum le
risque de choc ou de frottement avec d'autres surfaces
métalliques.
Pour éviter les risques de décharge d'électricité statique
Nettoyez uniquement avec un chiffon humide.
Pour les installations en sécurité intrinsèque, le positionneur
doit être connecté à un équipement sécurité intrinsèque
convenablement qualifié, et doit être installé conformément aux
normes d'installation sécurité intrinsèque applicables.
La substitution de composants peut compromettre la sécurité
intrinsèque.
Utiliser une isolation appropriée du câble à des températures
plus élevées.
Contactez Flowserve pour les informations de trajet de flamme.
3 HAZARDOUS AREA CERTIFICATIONS
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User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
4 STORAGE AND UNPACKING
4.1 Storage
FLOWSERVE Control valve packages (a control valve and
its instrumentation) are typically well protected from
corrosion. Nevertheless FLOWSERVE products must be
stored in a clean, dry environment such as 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. Plastic caps are fitted to
protect the flange faces and positioner ports to prevent the
ingress of foreign materials. These caps should not be
removed until the valve or positioner is actually mounted into
the system.
If FLOWSERVE products (especially sealing materials) have
been in storage for longer periods check these for corrosion
or deterioration before using these products. Fire protection
for FLOWSERVE products must be provided by the end
user.
4.2 Unpacking
While unpacking the valve and/or Logix 500MD+ positioner,
check the packing list against the materials received. Lists
describing the system and accessories are included in each
shipping container.
In the event of shipping damage, contact the shipper
immediately. Should any problems arise, contact a Flowserve
Flow Control Division representative.
4.3 Pre-installation Inspection
When installing a positioner, verify the shaft has not been
damaged and that the plugs and cover are in place. The
plugs keep debris and moisture from damaging the internal
components of the positioner. If the positioner has been
contaminated, clean the positioner components gently with a
soft damp cloth. Some components may be removed for
better access. See section 13 MAINTENANCE AND
REPAIR. Check connectors to ensure that no debris is
present. Port screens can be removed with a flat screwdriver
for access to internal passages.
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User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Actuator
Take-Off Plate
Take-Off
Take-Off Plate
Actuator O-
Figure 2: Valtek GS and FlowTop Mounting
5 MOUNTING AND INSTALLATION
5.1 Direct Mounting to Valtek GS and FlowTop
Refer to Figure 2: Valtek GS and FlowTop Mounting.
1 Assemble the take-off pin to the take-off plate and
mount the take-off plate to the valve stem using the two
screws. See Table 10: FlowTop and GS Take-Off
Plate and Pin Configuration for proper plate and pin
orientation.
2 Place the actuator O-ring.
3 Ensure the 1/16 NPT plug for the control port (if
present) has been removed.
4 Place the positioner on the actuator, ensuring the take-
off pin is inside the follower arm slot. Adjust the
follower arm as needed.
NOTE: The feedback shaft has a clutch mechanism that
allows for over-rotation of the shaft for easy adjustments.
Just move the follower arm to the desired location.
5 Use the actuator screws to secure the positioner in
place.
6 Connect regulated air supply to appropriate port in
manifold. See section 6 TUBING.
7 Connect the power to the 4-20 mA terminals. See
section 7 ELECTRICAL CONNECTIONS.
8 Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
9 Refer to sticker on main board cover and set DIP
switches accordingly. See section 8 STARTUP.
10 Press the QUICK-CAL/ACCEPT button for three to four
seconds or until the positioner begins to move. The
positioner will now perform a stroke calibration.
CAUTION: Performing a Stroke Calibration will cause full
movement of the valve in both directions.
11 If the calibration was successful the green LED will blink
GGGG or GGGY and the valve will be in control mode.
12 If calibration fails, as indicated by a RGGY blink code,
retry the calibration. If it still fails, the feedback values
were exceeded and the arm must be adjusted away
from the positioner’s limits. Rotate the feedback shaft
so that the full free travel of the feedback shaft is in the
range of the actuator movement. Optionally, continue
to attempt the calibration. Each calibration attempt
adjusts the acceptable limits and it should pass
eventually.
CAUTION: Remember to remove the air supply before
re-adjusting follower arm.
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.
NOTE: To virtually eliminate any non-linearity due to linkage
geometry, use the Linearization feature on the Custom
Characterization page of the DTM.
flowserve.com 9
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Table 10: FlowTop and GS Take-Off Plate and Pin
Configurations
Actuator
Stroke
(mm)
Plate and Pin Orientation
127 / 252
10
127 / 252
20
502
20 or 40
Figure 3: NAMUR Bracket
5.2 Mounting to NAMUR Valves
1 Attach the mounting plate to the positioner using 4
screws.
2 Rotate the feedback shaft to match the orientation of
the receiver on the actuator.
NOTE: The feedback shaft has a clutch mechanism that
allows for over-rotation of the shaft for easy adjustments.
3 Mount the positioner onto the actuator using the
washers and nuts.
4 Connect regulated air supply to appropriate port in
manifold. See section 6 TUBING.
5 Connect the power to the 4-20 mA terminals. See
section 7 ELECTRICAL CONNECTIONS.
6 Remove main cover and locate DIP switches and
QUICK-CAL/ACCEPT button.
7 Refer to sticker on main board cover and set DIP
switches accordingly. See section 8 STARTUP.
8 Press the QUICK-CAL/ACCEPT button for three to four
seconds or until the positioner begins to move. The
positioner will now perform a stroke calibration.
9 If the calibration was successful the green LED will blink
GGGG or GGGY and the valve will be in control mode.
10 If calibration fails, as indicated by a RGGY blink code,
retry the calibration. If it still fails, remove power from
the positioner, disconnect the air, and remove the
positioner from the actuator. Rotate the feedback shaft
so that the full free travel of the feedback shaft is in the
range of the actuator movement. Optionally, continue
to attempt the calibration. Each calibration attempt
adjusts the acceptable limits and it should pass
eventually.
CAUTION: Remember to remove the air supply before
re-adjusting take-off arm.
flowserve.com 10
Figure 4: AutoMax Assembly
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Exhaust (Piezo and
Out
(Control)
6 TUBING
After mounting has been completed, tube the positioner to
the actuator using the appropriate compression fitting
connectors. For best performance, use 10 mm (3/8 inch)
tubing for 645 square cm (100 square inch) actuators or
larger.
6.1 Determine Air Action
The port labeled “Out” delivers air when an air supply is
present and the relay is energized. This port should be tubed
to the pneumatic side of the actuator (the side that would
result in the air compressing the actuator spring). When
tubed this way, the spring is designed to return the valve to
the fail safe state should supply air or power to the unit fail.
If air from the output should open the valve, set the Air Action
configuration switch on the positioner to Air-to-Open,
otherwise set it to Air-to-Close.
The Air-to-Open and Air-to-Close selection is determined by
the actuator assembly, not the software.
6.2 Connect Supply Port
The positioner ports are threaded with 1/4 NPTF. The direct
mount output is 1/16 NPTF.
In order to maintain the recommended air quality, a
coalescing filter should always be installed in the supply gas
line. An air filter is highly recommended for all applications
where dirty air is a possibility. The positioner passage ways
are equipped with small filters, which remove medium and
coarse size dirt from the pressurized air. If necessary, they
are easily accessible for cleaning.
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.
6.3 Vented Design
A standard Logix 420 positioner is vented directly 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.
The exhaust port is located on the bottom of the positioner.
The port is tapped with either ¼ NPTF threads and covered
with a protective cap. To control vented gas, remove the cap
and connect the necessary tubing/piping to this port.
This piping system may cause some positioner back
pressure.
The maximum allowable back pressure from the exhaust port
is 0.14 barg (2.0 PSIG). For output flow rates, see section 2.4
Pneumatic Output.
CAUTION: The back pressure in the main housing must
never rise above 0.14 barg (2.0 PSIG). This could cause the
positioner to become unresponsive under some
circumstances.
6.4 Purging
Purging is intended to supply the non-pressurized side of a
single acting actuator with instrument air. This helps prevent
air from the environment (which may be salty, dirty or humid)
from corroding the springs and other actuator components.
Purging uses exhaust air from the positioner to flush the
spring side of the actuator.
Tubing Configuration - Tube the Exhaust port with a “T”
where one line goes to the non-pressurized side of the
positioner and the second line goes to the atmosphere.
Install an exhaust plug on the second line to prevent debris
from entering the tubing.
(Direct
Mount
Control)
Out
In
(Supply)
Actuator)
(0.14 barg (2 psi) Max)
flowserve.com 11
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
HART 4-20
mA
Housing EARTH
Terminal
Internal
External
7 ELECTRICAL CONNECTIONS
7.1 Electrical Terminals
7.2 Command Input (4-20 mA) Connection
The Logix 420 is reverse polarity protected, however, verify
polarity when making field termination connection. Wire 4-20
mA current source to the input terminal labeled “HART 420mA INPUT”. See Figure 6: Terminal Diagram.
Depending on the current source, a HART filter may be
required. See 14.1 Troubleshooting Guide.
7.2.1 Compliance Voltage
Output compliance voltage refers to the voltage limit the
current source can provide. A current loop system consists of
the current source, wiring resistance, barrier resistance (if
present), and the Logix 420 impedance.
The Logix 420 requires that the current loop system allow for
a 10 VDC drop across the positioner at maximum loop
current. The operating current range is from 3.8 to 24 mA.
In order to determine if the loop will support the Logix 420,
perform the calculation in Equation 1. The Available Voltage
must be greater than 10VDC in order to support the Logix
420. Also, see Table 1: Input Signal.
Equation 1
Inp
Figure 6: Terminal Diagram
Example:
The available voltage (12.5 V) is greater than the required
voltage (10.0 V) therefore; this system will support the Logix
420. The Logix 420 has an input resistance equivalent to 500
Ω at a 20 mA input current.
CAUTION: The current must always be limited for 4-20
mA operation. Never connect a voltage source directly
across the Logix 420 terminals. This could cause permanent
circuit board damage.
flowserve.com 12
Barrier
(If Present)
Wire
R
R
Compliance 10
Voltage VDC
Controller
+
-
Current
Grounding
Terminal
Conduit
Connection
7.2.2 Cable Requirements
The Logix 420 digital positioner utilizes the HART
Communication protocol. This communication signal is
superimposed on the 4-20 mA current signal. The two
frequencies used by the HART protocol are 1200 Hz and
2200 Hz. In order to prevent distortion of the HART
communication signal, cable capacitance and cable length
restrictions must be calculated. The cable length must be
limited if the capacitance is too high. Selecting a cable with
lower capacitance/foot rating will allow longer cable runs. In
addition to the cable capacitance, the network resistance
also affects the allowable cable length.
In order to calculate the maximum network capacitance, use
the following formula:
Equation 2
Example:
4-20 mA
Current
Source
(if present)
flowserve.com 13
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Logix
420
Voltage
= 0.08
Figure 7: Compliance Voltage
In order to calculate the maximum cable length, use the
following formula:
Equation 3
Example:
To control cable resistance, 24 AWG cable should be used
for runs less than 5000 feet. For cable runs longer than 5000
feet, 20 AWG cable should be used.
The input loop current signal to the Logix 420 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, not at the positioner.
Figure 8: Conduit and Grounding
User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13
Display
LED
QUICK-CAL/
Button
UP Button
DOWN Button
Selectable
Configuration
BACK
Left)
HART
Input
7.2.3 Intrinsically Safe Barriers
When selecting an intrinsically safe barrier, make sure the
barrier is HART compatible. Although the barrier will pass the
loop current and allow normal positioner control, if not
compatible, it may prevent HART communication.
7.2.4 Grounding and Conduit
The grounding terminal, located by the electrical conduit port
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.
This product has electrical conduit connections in a thread
size of 1/2" NPTF. Conduit fittings must match equipment
housing threads for installation.
NOTE: The grounded screw must not be used to terminate
signal shield wires. Shield wires should be terminated only at
the signal source.
4-20
mA
Button
(Move
Figure 9: Local User Interface
7.2.5 Electromagnetic Compatibility
The Logix 420 digital positioner has been designed to
operate correctly in electromagnetic (EM) fields found in
typical industrial environments. Care should be taken to
prevent the positioner from being used in environments with
excessively high EM field strengths (greater than 10 V/m).
Portable EM devices such as hand-held two-way radios
should not be used within 30 cm of the device.
Ensure proper wiring and shielding techniques of the control
lines, and route control lines away from electromagnetic
sources that may cause unwanted electrical noise. An
electromagnetic line filter can be used to further eliminate
noise (FLOWSERVE Part Number 10156843).
In the event of a severe electrostatic discharge near the
positioner, the device should be inspected to ensure correct
operability. It may be necessary to recalibrate the Logix 420
positioner to restore operation.
7.3 Connections for Intrinsically Safe Operation
For intrinsically safe connections, see entity parameters in
section 3 HAZARDOUS AREA CERTIFICATIONS. If a
control drawing is required, ask your Flowserve
representative for drawing 314746 - CONTROL DRAWING,
LOGIX 420 DIGITAL POSITIONER.
GAIN
Switch
Status
ACCEPT
flowserve.com 14
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