Flowserve 420 User Manual

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

flowserve.com 2

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

flowserve.com 3

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

flowserve.com 4

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.

flowserve.com 5

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

flowserve.com 6

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

flowserve.com 7

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.

flowserve.com 8

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

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

8 STARTUP

8.1 Quick Start Instructions

Once installed, the DIP switch settings and Quick-Cal
function listed below are typically all that are needed to
calibrate and tune the positioner for use. This simple
procedure takes only seconds for most valves.

1 Using the Configuration Switches, select the desired

configuration. See section 8.3 Configuration Switch
Settings for details.

2 Hold the Quick-Cal button for 3 seconds. This will

initiate a stroke calibration. (LCD Screen must show
the main menu before pressing Quick-Cal button. See
Figure 9.)

After the stroke calibration is complete, the positioner is
ready for control.

CAUTION: During the QUICK-CAL operation the valve

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

8.2 Local User Interface Overview

The Logix 420 local user interface allows the user to
calibrate, configure the basic operation, and tune the
response of the positioner without additional tools or
configurators. The Local interface consists of:
 Configuration Switches (7) – Used to set basic

configuration. See explanations in section 8.3
Configuration Switch Settings.

 Interface Buttons – Used to calibrate the positioner,

perform special functions and navigate the display
menu.

o ►QUICK-CAL / ACCEPT(Move Right)
o ▲Up
o ▼Down
o ◄Back (Move Left)

 Selectable GAIN Switch (Rotary) – Used to manually

fine-tune the performance.

 LED Indicators (Red, Yellow, and Green) – Indicate

status, alarms and warnings.

 Display (Optional) – Provides a full menu of detailed

information and configuration.

8.3 Configuration Switch Settings

Before placing the unit in service, set the Configuration
Switches to the desired control options.

NOTE: The Configuration Switch settings are activated only

by performing a Stroke calibration (pressing the “QUICK­CAL” button for 3 seconds). However, the Configuration

Switch settings may be edited from the DTM or Handheld at
any time.

8.3.1 Air Action Switch

This must be set to match the configuration of the
valve/actuator mechanical tubing connection since the tubing
determines the air action of the system.

ATO - Increasing pressure from the output port causes the
valve to open.

ATC - Increasing pressure the output port causes the valve
to close.

8.3.2 Signal at Closed Switch

Normally this will be set to 4 mA for an Air-To-Open actuator
configuration, and 20 mA for Air-To-Close.

4 mA - Selecting 4 mA will make the valve close when the
signal is low (4 mA) and open when the signal is high (20
mA).
20 mA - Selecting 20 mA will make the valve close when the
signal is high (20 mA) and open when the signal is low (4
mA).

NOTE: When using an Analog Output (AO) function of the
Multi-Function Card, the AO signal corresponds with the
Signal At Closed selection. If the valve closes with a 4 mA
signal, the AO will show a 4 mA signal at closed. If the valve
closes with a 20 mA signal, the AO will show a 20 mA signal
at closed.

8.3.3 Characterization Switch

The Characterization Switch allows a better match between
the input command and the actual fluid flow through the
valve. This feature is typically used with valves that have
non-linear flow characteristics. The positioner makes a
correction by applying an adjustment to the input command
according to a characterization curve.

Linear - Select Linear if the actuator position should be
directly proportional to the command input signal. (For most
rotary valves, this setting gives an =% Cv characteristic due
to their inherent =% characteristics.)

Other - Select Other if one of the pre-set characterization
curves or a custom curve is desired. The default will be the
Custom curve which is populated with a standard 30:1 equal
percent rangeability curve which generally opens less than
the input command. To select one of the other curve options,
use the LCD menu, a Handheld or the ValveSight DTM. To

flowserve.com 15

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

More

Stable

More

Responsive

modify the Custom curve, use the DTM. See section 10.3.6
Configuration (Characterization) for more information.

8.3.4 Auto Tune Switch

This switch controls whether the positioner will automatically
tune itself during the stroke calibration (Quick-Cal), or use
preset tuning parameters.

On - Selecting On enables an auto tune feature that will
automatically determine the positioner gain settings. The
automatic tuning will be based on response parameters
measured during the latest Quick-Cal. The valve response is
a combination of these response parameters and the current
position of the Selectable GAIN Switch.

Off - Selecting Off forces the positioner to use one of the
factory preset tuning sets determined by the Selectable GAIN
Switch. Settings “B” through “J” are progressively higher
predefined tuning sets. Selecting “A” on the Selectable Gain
Switch during a Quick-Cal allows the user to use and
preserve manually adjusted gains.

See section 8.4 Stroke Calibration for more details.

NOTE: The gain switch is live meaning that regardless of the
Auto Tune selection, the gain settings can be adjusted at any
time during operation by changing the selectable GAIN
switch position.

Figure 10: Selectable GAIN Switch

8.3.5 Quick Calibration Switch

This switch selects between Auto and Jog calibration modes.
Auto - Use the Auto setting if the fully opened position of the

valve has a mechanical stop. This is typical for most valves.
In Auto mode during a stroke calibration (Quick-Cal), the
positioner will fully close the valve and register the 0%
position, then fully open the valve to register the 100%
position.

Jog - Use the Jog setting if the fully opened position of the
valve has no hard stop, but needs to be set manually. In Jog
mode during a stroke calibration (Quick-Cal), the positioner
will fully close the valve and register the 0% position, then
wait for the user to move the valve to the 100% open position
using the ▲Up and ▼Down buttons. Press the
►ACCEPT/QUICK-CAL button to accept the 100% location.

See section 8.4 Stroke Calibration for more details.

8.3.6 Valve Stability Switch

This switch adjusts the position control algorithm of the
positioner for use with low-friction control valves or high­friction automated valves.

Lo Friction - Placing the switch to Lo Friction 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.

Hi Friction - 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. See
section 10.3.7 Configuration (Pressure Control) for more
details.

8.3.7 Spare Switch

If special features have been purchased they may be
controlled by this switch. See associated documentation for
more details.

8.4 Stroke Calibration

The ►ACCEPT/QUICK-CAL button is used to initiate an
automatic stroke calibration. The stroke calibration
determines the closed (0%) and open (100%) positions of the
valve and gathers information about the response of the
valve (such as valve stroke time) in order to determine the
gains. The gains are then set automatically. After a stroke
calibration, the positioner is ready to control.

To perform a Quick-Cal, first ensure the Quick Calibration
Switch is set to Auto or Jog (to manually adjust the stroke
limits) as appropriate. Press and hold the
►ACCEPT/QUICK-CAL button for approximately 3 seconds.
This will initiate the automatic stroke calibration. While the
calibration is in progress, the LED lights will flash status
codes indicating the calibration progress. See section 14.3
Status Code Descriptions for an explanation of the status
code sequences.

The initial calibration of extremely large or very small
actuators may require several calibration attempts and will
perform these automatically. 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.

flowserve.com 16

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

8.4.1 Quick Calibration Switch – Jog

Set the Quick Calibration Switch to Jog if the valve/actuator
assembly has no internal mechanical stop at the fully open
position. In this case, follow these instructions:

1 Press and hold the ►ACCEPT/QUICK-CAL button for

approximately 3 seconds.

This will initiate the jog stroke calibration. The positioner will
then close the valve and set the zero position. The zero
position is automatically always set at the valve seat. At this
point the LED‘s will flash in a sequence of G-R-R-R (green­red-red-red) which indicates that the user must use the jog
keys to manually position the valve to approximately 100%.

2 Use the up and down keys to position the valve at

approximately 100% open.
3 Press the ►ACCEPT/QUICK-CAL button to proceed.
No more user actions are required while the calibration

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

8.4.2 Tuning Options

Quick-Cal Custom Gains – This is typically the fastest way to
achieve ideal gains. Set the Auto Tune Configuration Switch

to On and the Selectable GAIN Switch to “E”. Then perform

a Quick-Cal. During the Quick-Cal, custom tuning
parameters will be determined based on measured response
parameters. The gains can then be fine-tuned by adjusting

the Selectable GAIN Switch. Selecting “D” “C” or “B” will

progressively provide a more stable response. Selecting “F”
through “J” will progressively provide a more active response.

In most cases selecting “E” will give the best results. This is
the default setting for all actuator sizes. Raising or lowering
the Selectable GAIN Switch setting is a function of the
positioner/valve response to the control signal, and is not
actuator size dependent.

Standard Preset Gains - If standard, preset gains are
desired, set the Auto Tune Configuration Switch to Off. After
performing a Quick-Cal, use the Selectable GAIN switch to
the desired level (“B” – “J”). The standard, preset gain
settings are not affected by Quick-Cal. It may be necessary
to set the gain switch before the Quick Cal. Very fast
stroking valves may need to be at lower gains and very slow
stroking valves may need to be at higher gains.

It may be necessary to set the gain switch BEFORE the
Quick Cal. Very fast stroking valves may need to be at lower
gains and very slow stroking valves may need to be at higher
gains.

Custom Manual Gains - To set gains manually, set the
selectable GAIN switch to “A”. Changing the switch from “B”

to “A” will write the standard “B” settings into the “A”

parameters, allowing a starting point for modification.

Similarly, changing the switch from “J” to “A” will write the

standard “J” settings into the “A” parameters. Custom tuning

values can then be entered using the Display Menu, a
Handheld or ValveSight DTM. With the Selectable GAIN
Switch set to “A”, the tuning will not be modified during a
Quick-Cal.

8.4.3 Aborting a Quick-Cal

The Quick-Cal can be aborted at any time by briefly pressing
the ►ACCEPT/QUICK-CAL button again. In this case, the
previous settings will be retained.

8.4.4 On Line Stroke Calibration Adjustments

At times an adjustment to the calibration is desired, but the
process cannot be interrupted. The stroke calibration can be
adjusted with minimal valve movement. Contact your local
Field Service Technician for more information.

flowserve.com 17

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

9 POSITIONER FUNCTIONS (No

Display Required)

The following features can be performed using the local
interface. No display is required for these features.
Additional features are offered with the use of a display,
Handheld or DTM.

NOTE: In order to prevent unintentional adjustments of the
configuration, tuning, or control of the valve, the Tamper Lock
feature may be used. This is set in the DTM and disables the
buttons and menus except for the ability to view the status of
the positioner. When locked, the positioner may be
temporarily unlocked by entering a PIN. (An LCD is required
to enter the PIN.) Or, the positioner can be unlocked from
the DTM.

9.1 Live Manual Tuning (Adjusting the

Gain)

Use the Selectable GAIN Switch to adjust the gain at any
time during operation. This adjustment takes effect
immediately. For faster response select settings above “E”
(F-J). For more stable response, select settings below “E”
(B-D). See Figure 10: Selectable GAIN Switch on page 16.

9.2 Local Control Of Valve Position

To manually adjust the position of the valve regardless of the
input command (analog or digital), press and hold the ▲Up,

▼Down and ◄ BACK buttons for about 3 seconds. The

▲Up, ▼down buttons can then be used to position the valve.

While in this mode the LED‘s will flash a GRRY (green-red-

red-yellow) sequence. To exit the local control mode and
return to normal operation, briefly press the ►
ACCEPT/QUICK-CAL button.

CAUTION: When operating using local control of the

valve, the valve will not respond to external commands.
Notify proper personnel that the valve will not respond to
remote command changes, and make sure the valve is
properly isolated.

9.3 Command Source Reset

Performing a command source reset will reset the command
source to analog if it has been inadvertently left in digital
mode. This is done by holding down both the ▲Up and

▼Down buttons, then briefly pressing the
►ACCCEPT/QUICK-CAL button.

9.4 Factory Reset

To perform a factory reset, hold ► ACCEPT/QUICK-CAL
button while applying power. All of the internal variables
including calibration will be reset to factory defaults. The
positioner must be re-calibrated after a factory reset. Tag
names and other user configured limits, alarm settings, and
valve information will also be lost and need to be restored. A
factory reset will always reset the command source to analog
4-20 mA.

CAUTION: Performing a factory reset may result in the

inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and make
sure the valve is properly isolated.

flowserve.com 18

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 11: Viewing Version Numbers

First

Blink Color

Second

Blink Color

Third

Blink Color

Version

Number

G G G 0 G G Y 1 G G R 2 G Y G 3 G Y Y 4 G Y R 5 G R G

6

G R Y

7

G R R 8 Y G G 9 Y G Y

10 Y G R 11 Y Y G 12 Y Y Y 13

Y Y R

14

Y R G

15 Y R Y 16 Y R R 17 R G G 18

R G Y

19

R G R

20 R Y G 21 R Y Y 22 R Y R 23 R R G 24 R R Y 25 R R R 26

Figure 11: Main Display View

Final Command

Status Icon

Position

Scrolling Status
Message

Current Alarm Status

9.5 Viewing Version Numbers

The version number of the positioner software may be
checked at any time except during a calibration. To see the
major version number, hold the ▲Up button. This will not
alter the operation of the unit other than to change the blink
sequence to 3 blinks indicating the major version number.
Holding the ▼Down button will give the minor version
number without affecting operation. The version codes are
interpreted according to the following table:

For example, if holding the ▲Up button gave a G-G-R code,
and holding the ▼Down gave a Y-Y-G code then the
resulting version number would be 2.12.

10 POSITIONER FUNCTIONS (LCD

Display)

The optional LCD display provides a variety of useful
information and functions. The Main View shows important
information using icons and scrolling status lines. Using the
directional buttons (▼▲►◄) to navigate the menu, the user
can view detailed information perform commonly used
functions.

NOTE: The LCD backlight may change brightness during
use. This is normal. The backlight uses any residual power
not used by other functions of the circuitry. When current
supply is low (4mA) the light will appear darker. When
current supply is high (20mA) the light will appear brighter.

10.1 Main Display View

The main view provides an instant display of important status
parameters: Position, Final Command, Scrolling Status
Message, Current Alarm Status and Status Icons.

10.1.1 Position and Command

The current Position and Command are always shown. This
shows the Final Command which has been adjusted
according to a Characterization Curve, MPC, or Soft Limits
that have been applied and should match the Position.

flowserve.com 19

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 12: Status Icons

Icon Location

Icon

Icon Meaning

Command

Source

Analog command mode

Digital command mode

Out of service

Pressure

Control

Pressure control locked

(blank)

Pressure control not locked

HART

Communicatio

ns

HART communication currently in
progress

Burst mode in progress

(blank)

No HART communication currently
in progress

10.1.2 Scrolling Status Messages

The Scrolling Status Message provides the following
information as applicable:
Ambient Temperature – This is the temperature inside the
positioner.
DIP Switch Override – This indicates that the Configuration
(DIP) Switches do not reflect the actual configuration of the
positioner. This can happen if a Configuration Switch is
changed after a Quick-Cal, or if the configuration is was
changed from the DTM. Performing a Quick-Cal will reset
the configuration to what the Configuration Switches show,
which may not be desirable. Ensure the Configuration
Switches are set properly before performing a Quick-Cal.

10.1.3 Current Alarm Status

The Current Alarm Status area shows the highest priority
alarm, warning, alert or status indication. This matches the
code indicated by the flashing LEDs.

10.1.4 Status Icons

Status icons continuously show the state of the features and
modes.

Pressure Control – When the position of the valve gets very
close to the commanded position, the positioning algorithm
will change to pressure control. This means the pressures
will be held constant (locked), improving the stability of the
valve position. The point at which the pressure control is
locked depends on the Valve Stability switch on the

positioner. When the switch is set to “Lo Friction”, the locking

point is self-adjusting to optimize accuracy. When the switch
is set to “Hi Friction” and the deviation is smaller than +/-

1.0%, the pressure “locks”. This value can be adjusted using
the Display Menu or DTM. See section 10.3.7 Configuration
(Pressure Control).

HART Communications Icons – When the positioner is
sending or receiving data via the HART communication
protocol, the icon will be displayed. During burst mode, a
pulsating heart icon will be displayed.

10.1.5 Adjusting the Display Contrast

To adjust the display contrast, hold the ◄ Back button for 3
seconds. Use the ▲Up and ▼ Down buttons to adjust the
contrast. Use the ►ACCEPT/QUICK-CAL to accept the
settings.

Command Source Icons – The positioner is in Analog
Command mode if it is using the 4-20 mA signal to control
the location of the valve. In Digital Command mode, the
positioner ignores the 4-20 command and responds to the
position command given through HART. In Out Of Service
mode, the positioner is performing a calibration, signature,
partial stroke test or is in a factory reset state.

flowserve.com 20

10.2 Menu Overview

Status

Command (mA)
Command (%)
Position (%)
Temperature
Valve Cycles
Valve Travel (%)

Alerts and Alarms

Current Alarms (Prioritized)
Event History

Last Event
2nd Event
3rd Event

*
*
*

32nd Event

Partial Stroke Test

Start
Last Result

Calibration

Stroke/Quick Calibration
Command Input Calibration
Calibration Dates

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Configuration

Positioner Tuning
Characterization
Pressure Control
Soft Limits & Cutoff

High Soft Limit
Low Soft Limit
Upper Position Cutoff
Lower Position Cutoff

User Preferences

All Units
Temperature Units
Actuator Area Units
Date Format
Number Format
LCD Orientation

Burst Mode

ON/OFF

Positioner Revs

EC Major Rev
EC Minor Rev
EC Build Date and Time
Universal Rev
Hardware Rev

Factory Reset

Language

English
German
French
Spanish
Portuguese
Russian
Turkish
Italian

flowserve.com 21

►Status

►Command (mA)
►Command (%)
►Position (%)
►Temperature
►Valve Cycles
►Valve Travel (%)

►Alerts and Alarms

►Current Alarms (Prioritized)
►Event History

►Last Event
►2nd Event
►3rd Event

*
*
*

►32nd Event

►Partial Stroke Test

►Start
►Last Result

►Calibration

►Stroke/Quick Calibration
►Command Input Calibration
►Calibration Dates

10.3 Menu Features

10.3.1 Status

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

10.3.3 Partial Stroke Test

The Status menu is used to view information about the
configuration and operation of the system.

Command displays the final command in mA.
Command displays the final command in %.
Position displays the valve position in %.
Temperature displays the temperature inside the positioner.
Valve Cycles are counted each time the positioner changes
direction. The movement must be beyond a dead-band
window. This window is set to 0.5% as a default, but can be
changed using the DTM.
Valve Travel is counted in small increments every time the
valve moves beyond the dead-band window. The travel is
displayed in % of full stroke.

10.3.2 Alerts and Alarms

The Alerts and Alarms menu shows current and past alarms,
warnings, alerts, and calibrations.

Current Alarms displays all events that are actively sounding.
Event History displays past 32 events including alarms,
warnings, alerts, and calibrations. The event that occurred
most recently is displayed first (event 32) with later events
recorded below.

The Partial Stroke Test (PST) menu provides the user the
ability to start a PST and see the results of the latest PST.

CAUTION: Performing a Partial Stroke Test will result in

valve movement and the inability to operate the valve until
the test is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated if
required by plant procedures.

Start allows the user to initialize the (PST).
Last Result shows “Pass” or “Fail” from the last PST attempt.

10.3.4 Calibration

The Calibration menu allows the user to calibrate the

positioner’s sensors. The positioner can accurately control

with only a Quick-Cal. Typically this is all that is needed. A
friction calibration is recommended if the positioner has been
upgraded to Pro diagnostics. See section 8 STARTUP for
more details.

CAUTION: Performing a calibration may result in valve

movement and the inability to operate the valve until the
calibration is complete. Notify proper personnel that the valve
may stroke, and make sure the valve is properly isolated
before proceeding.

Stroke/Quick Calibration starts an automatic calibration of the
position feedback sensor. The stroke calibration determines
the closed (0%) and open (100%) positions of the valve and
gathers information about the response of the valve (such as
valve stroke time) in order to determine the gains. The gains
are then set automatically. After a stroke calibration, the
positioner is ready to control. See section 8.4 Stroke
Calibration for more information.
Command Input Calibration is used to adjust the input range.
Set the lowest current (Set 0%) and the highest current (Set
100%) that will be used. The default input range is 4 to 20
mA. The “Set 0%” value must be lower than the “Set 100%
value.

flowserve.com 22

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

►Configuration

►Positioner Tuning

►P-Gain Open
►I-Gain Open
►D-Gain Open
►P-Gain Close
►I-Gain Close
►D-Gain Close
►Open Stroke Time
►Close Stroke Time
►Minimum Open Time
►Minimum Close Time

►Configuration

►Characterization

►MaxFlo Linear
►MaxFlo Equal %
►Valdisk Linear
►Valdisk Equal %
►ShearStream Linear
►ShearStream Equal %
►Custom

Split Range Example:

A split range is easily configured. For example, a 4 to 12 mA
signal can be set to correspond to a 0 to 100% stroke. When
the display shows “Set 0%”, set the command input current
to 4 mA. (The display will show a low Analog to Digital Count
(ADC) that corresponds to 4 mA.) Then press the

►ACCEPT/QUICK-CAL button to set the value. Press the
▼Down button to move to “Set 100%”. Set the command

input current to 12 mA. (The display will show a high ADC to
correspond to 12 mA.) Again press the ►ACCEPT/QUICK­CAL button to set the value. Select the ◄Back Button to
exit.

Signal At Closed = 20mA Example:

If the desired signal at closed is 20 mA, first set the Signal at
Closed DIP switch to 20 mA. Then perform a stroke
calibration by pressing the ►ACCEPT/QUICK-CAL button for
more than 3 seconds. This registers the DIP switch settings.
Then, in the Command Input Calibration menu, when the
display shows “Set 0%” it is expecting the lowest current
value. Set the input current to 4 mA. For “Set 100%”, it is
looking for the highest current value. Set the input current to
20 mA. After accepting theses values, the positioner will
interpret the 20 mA input as 0% valve position and the 4 mA
input as 100%.

Calibration Dates lists the most recent date of each
calibration. The date is available only if the calibration was
performed using the DTM.

10.3.5 Configuration (Positioner Tuning)

NOTE: Only those with specific training in PID tuning

algorithms should attempt to adjust the tuning by manually
changing the PID values.

Open Stroke Time is the fastest time it took the valve to
stroke from 0% to 100% during Quick-Cal. Increasing this
parameter will affect the responsiveness of the valve in the
opening direction.
Close Stroke Time is the fastest time it took the valve to
stroke from 100% to 0% during Quick-Cal. Increasing this
parameter will affect the responsiveness of the valve in the
closing direction.
Minimum Open Time and Minimum Close Time (Speed
Limits) are used to prevent the valve from moving too quickly.
This can be used when the process is sensitive to rapid flow
or pressure changes. This shows the time (in seconds) that
the positioner will allow the valve to travel a full stroke. This
speed limit applies to smaller movements of the valve too.

For example, if the Minimum Open Time were set to 20
seconds, and the command was changed from 40% to 50%,
the positioner would move the valve at a constant rate, taking
2 seconds to complete the move. If the Minimum Close Time
was set to 0, and the command was changed from 50% back
to 40%, the positioner would make the move as quickly as
possible.

The default values are 0 seconds, meaning the positioner will
move the valve as quickly as possible.

10.3.6 Configuration (Characterization)

The Configuration – Positioner Tuning menu allows the user
to manually adjust individual tuning parameters. All tuning
parameters are automatically set to optimal values during
Quick-Cal. Typically a Quick-Cal is all that is needed for
positioner tuning. See section 8 STARTUP for more details.

CAUTION: Adjusting the tuning parameters will affect

the responsiveness of the valve and could cause rapid
changes to the valve position. Notify proper personnel that
the valve may stroke, and make sure the valve is properly
isolated before proceeding.

P-Gain, I-Gain and D-Gain are the proportional, integral, and
differential elements of the feedback algorithm. These gains
are different for the opening and closing directions because
typically responsiveness is different in each direction.

The Configuration – Characterization menu allows the user to
change the characterization of the command. This allows a
better match between the input command and the actual fluid
flow through the valve. This feature is typically used with
valves that have non-linear flow characteristics. The
positioner makes a correction by applying an adjustment to
the input command according to a characterization curve.
The table below shows the available characterization curve
options. Each point of the Custom curve can be adjusted
using the ValveSight DTM.

To view the characterization curve options, set the
Characterization switch “Other” before performing a Quick­Cal. Otherwise, the only option available is “Linear”. If a
Quick-Cal is not possible, use the ValveSight DTM to select
the curve.

flowserve.com 23

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80 90100

Final Command

Command Input

Linear
MaxFlo

Linear
MaxFlo

=%
Valdisk

Linear
Valdisk

=%
ShearStre

am Linear
ShearStre

am =%

Table 13: Characteristic Curve Data

Command

Input

Final Command

Characterizatio

n DIP set to

“Linear”

Characterization

DIP set to

“Other”

Linear

MaxFlo

Linear

MaxFlo

=%

Valdisk

Linear

Valdisk

=%

Shear-

Stream

Linear

Shear-

Stream

=%

Custom

(Default)

(Linear =%)

0.0

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

5.0

5.00

6.50

1.00

13.00

4.00

25.00

8.00

0.62

10.0

10.00

11.60

2.00

20.00

6.00

35.00

14.00

1.35

15.0

15.00

16.20

3.00

26.25

7.80

44.00

17.00

2.22

20.0

20.00

20.50

4.40

32.10

9.30

50.20

21.00

3.25

25.0

25.00

24.60

5.80

37.50

11.50

55.50

24.00

4.47

30.0

30.00

28.50

7.40

42.60

14.00

60.20

27.50

5.91

35.0

35.00

32.40

9.30

47.40

16.50

64.30

31.50

7.63

40.0

40.00

36.20

11.20

51.80

19.30

68.00

35.50

9.66

45.0

45.00

40.00

13.50

56.00

22.50

71.50

39.50

12.07

50.0

50.00

43.80

16.10

60.00

26.00

74.70

43.90

14.92

55.0

55.00

47.60

19.10

63.60

30.00

77.70

48.10

18.31

60.0

60.00

51.50

22.40

67.20

34.70

80.50

52.80

22.32

65.0

65.00

55.50

26.20

70.60

39.60

83.20

57.40

27.08

70.0

70.00

59.50

30.60

73.90

45.10

85.90

62.40

32.71

75.0

75.00

63.80

35.70

77.20

51.30

88.40

67.50

39.40

80.0

80.00

68.20

41.70

81.30

57.80

90.80

72.90

47.32

85.0

85.00

73.00

48.90

84.00

64.80

93.20

78.60

56.71

90.0

90.00

78.40

57.70

87.80

72.50

95.50

84.70

67.84

95.0

95.00

85.00

69.20

92.10

81.30

97.80

91.20

81.03

100.0

100.00

100.00

100.00

100.00

100.00

100.00

100.00

100.00

►Configuration

►Pressure Control

►Window

Figure 12: Characterization Curves

Select the appropriate curve as required by the process
design.

Custom - Select Custom for a standard 30:1 linear equal
percent rangability curve. The curve may be customized
point-by point. To modify the Custom curve, use the
ValveSight DTM.

flowserve.com 24

CAUTION: Changing the characterization curve may

cause the valve to move suddenly. Notify proper personnel
that the valve may stroke and if required, make sure the
valve is properly isolated before proceeding.

10.3.7 Configuration (Pressure Control)

The Configuration (Pressure Control) menu allows the user
to change the size of the pressure control window. This
window becomes active when the Valve Stability Switch is
set to “Hi”. The Valve Stability Switch optimizes the
response for valves and actuators with high friction levels.
When set to “Hi”, it slightly slows the response and will
normally stop limit cycling that can occur on high friction
valves.

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 14: User Preference Options

Units/Format

International

System (SI)

(Default)

North

American

(English)

Other

Options

All Units

SI

North American

-

Temperature

degrees C

degrees F

-

Actuator Area

cm2

in2

-

Date Format

Day.Mon.Year

Mon/Day/Year

-

Number

Comma

Decimal Point

-

►Configuration

►Soft Limits & Shutoff

►High Soft Limit
►Low Soft Limit
►Upper Position Shutoff
►Lower Position Shutoff

►Configuration

►User Preferences

►All Units
►Temperature Units
►Actuator Area Units
►Date Format
►Number Format
►LCD Orientation

Window - When the position of the valve gets within the
pressure control window, the positioning algorithm will
change to pressure control. This means the pressures will
be held constant (locked), improving the stability of the
valve position.

NOTE: The pressure control feature of the Logix 420
functions without the use of pressure sensors. In the DTM,
this feature is configured on the Valve Stability page.

10.3.8 Configuration (Soft Limits and Shutoff)

Soft Limits allows the user to limit the movement of the
valve. Shutoff allows the user to tightly shut the valve with
all available force.

High Soft Limit and Low Soft Limit - This feature is used to
simulate physical blocks on the valve that restrict
movement past a set point. Once the Soft Limit is set, the
positioner will not attempt to move the valve position (final
command) beyond the set point, regardless of the analog
or digital command input signal.

CAUTION: Changing the Soft Limits may limit the

movement of the valve. The valve may not shut or open
fully.

NOTE: Removing power to below 3.6 mA will still cause the
valve to move to the de-energized state regardless of the
Soft Limits.

Upper Position Shutoff and Lower Position Shutoff - This
feature, (also called Minimum Position Cutoff or MPC) is
used to tightly close or open the valve. It is used when a
tight seal is needed or when debris or friction may
otherwise interfere with complete closure. When the valve
is commanded past the Shutoff points, the pilot relay will
direct full supply pressure to the appropriate port, applying
all available force to close (or open) the valve. The Shutoff
points apply to the Final Command.

CAUTION: Changing the Shutoff limits may cause the

valve to fully open or fully close after the command passes
a set limit.

Though Shutoff and Soft Limit features should not be used
together, if both are set, the greater of the two settings will
take precedence at the closed end; and the lesser of the
two settings will take precedence at the open end.

flowserve.com 25

10.3.9 Configuration (User Preferences)

The User Preferences menu allows the user to format how
information is displayed.

The following table shows the available options. By default
the positioner is set to show information in International
System (SI) units. To change all units to North American
(English), make the selection under All Units. Each
selection can also be changed individually.

LCD Orientation – Use this selection to turn the turn the
display upside down (rotate 180 degrees). Use this feature
when the positioner is mounted upside down.

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

►Configuration

►Burst Mode

►On/Off

►Configuration

► Positioner Revs

► SW Rev
► Bld Date
► Bld Time
► HW Rev
► CPU Rev
► HART Ver

►Configuration

► Factory Reset

► Language

►English
►German
►French
►Spanish
►Portuguese
►Russian
►Turkish
►Italian

10.3.10 Configuration (Burst Mode)

Burst Mode continuously transmits HART information.
On/Off – Use this feature to turn burst mode on and off.

10.3.11 Configuration (Positioner Revs)

Positioner revisions are shown in this menu.
SW Rev –The revision of the embedded software.

Bld Date –The date of the embedded software build.
Bld Time –The time of day of the embedded software build.
HW Rev –The revision of the main board.
CPU Rev – The revision of the CPU.
HART Ver –The revision of the HART protocol (5, 6, or 7).

10.3.12 Configuration (Factory Reset)

10.3.13 Language

The display menu is available in several languages.

NOTE: To navigate directly to the language menu,
select the following sequence of buttons: ▲Up ,
▲Up, ►QUICK-CAL/ACCEPT.

At times, it may be convenient to reset all of the variables
to a default state. In this case, perform a Factory Reset.

Factory Reset – Use this feature to reset all variables to
their factory default state. All of the internal variables
including calibration will be reset to factory defaults. The
positioner must be re-calibrated after a factory reset. Tag
names and other user configured limits, alarm settings, and
valve information will also be lost and will need to be
restored. A factory reset will always reset the command
source to analog 4-20 mA.

CAUTION: Performing a factory reset may result in the

inability to operate the valve until reconfigured properly.
Notify proper personnel that the valve may stroke, and
make sure the valve is properly isolated.

flowserve.com 26

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

HART DIP
Switch

HART 6
HART 7

1 2 3 4 5 6 7 8

11 HART COMMUNICATION

The Logix 420 series positioners use the HART
communication protocol specified by the HART
Communication Foundation.

11.1 ValveSight DTM

Flowserve Corporation has produced a custom Device
Type Manager (DTM) for the Logix 420 digital positioner to
support the ValveSight diagnostics platform.

The DTM contains a high level “Dashboard” view of the

system health and status information. It also contains
comprehensive user-friendly interfaces for control and
reporting of alarms, of-line and on-line diagnostic tests,
calibrations and system configurations.

The ValveSight DTM is available from a Flowserve
representative or from www.valvesight.com.

11.4 Changing HART Versions

The Logix 420 positioner comes standard with the HART 6
communication protocol. Follow this procedure to change
to HART 7.

1 Remove the outer cover.
2 Remove the inner cover by removing the 3 inner

cover retaining screws.

CAUTION: Observe precautions for handling

electrostatically sensitive devices.

3 With a clean, non-conductive instrument, change the

position of DIP switch according to Figure 14: HART
DIP Switch. After changing the DIP switch, the
positioner will immediately recognize the new HART
communication protocol.

4 Replace the covers.

Figure 13: ValveSight DTM Dashboard

11.2 HART 475 Handheld Communicator

The Logix 420 digital positioner supports and is supported
by the HART 475 Handheld Communicator. The Device
Description (DD) files can be obtained from the HART
Communication Foundation or from your Flowserve
representative.

11.3 Burst Mode

Burst Mode is available with a handheld device. In the
menu of the handheld, select the Burst Mode feature under
the Configuration Menu.

NOTE: The DTM will not function while the positioner is in
Burst Mode.

Figure 14: HART DIP Switch

flowserve.com 27

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

12 REQUIREMENTS FOR SAFETY

INTEGRITY

This section provides information and additional user
responsibilities in order to meet Safety Integrity Level 2
(SIL 2) per IEC 61508.
The safety function of the positioner is to go to the fail-safe
state (vent air from the actuator) given a low power
condition to the 4 to 20 mA input terminal.

12.1 Fail Safe State

The fail safe state is when the relay valve is at less than
5% of full stroke such that output port is venting.

NOTE: The fail safe state above represent the fail safe
state of the positioner. The valve fail safe state may be
different depending on spring configuration and tubing.
Ensure the valve fail-safe state is appropriate for your
application.

12.2 Safety Function

The Logix 420 positioner moves to fail-safe state upon the
removal of analog input power (less than 3.6 mA)

12.3 Fail Safe State Response Time

Test to find the final valve assembly response time to
ensure it meets application-specific requirements.
Response times will vary widely with actuator size, the use
of boosters, stroke length, starting position, fail-safe
direction, tubing size, supply pressure, and temperature.
The air flow capacity also affects the response time. See
section 2.4 Pneumatic Output for air flow capacity.

Typically, the Logix 420 can de-energize a 122 cm^2 (19
in^2) diaphragm actuator from fully open to fully closed in
under 2 seconds. This test was performed at 22 °C, using

4.1 bar supply, quarter inch tubing.
The typical response times for a relay to travel from fully

energized to fully de-energized (exhausted) state are:

 4180 ms at -52 °C
 650 ms at -40 °C;
 172 ms at 22 °C;
 214 ms at 85 °C;

NOTE: During the stroke calibration (Quick-Cal), stroke
times are measured and recorded in the positioner. To find
these times, see tuning parameters on the positioner menu
or in the DTM.

12.4 Installation

Ensure installation of the positioner is properly performed
according to this manual. Ensure tubing is configured to
the actuator so that the fail-safe state of the positioner
matches the desired fail-safe state of the valve.

12.5 Required Configuration Settings

The following user settable options must be properly
configured for the individual application in order to provide
the designed safety integrity for that application.
 Calibrate the analog input (command). The fail safe

state of the valve must correspond to the analog input
command at less than 3.6 mA.

 Set the desired PST settings using the DTM.
 It is recommended to lock the local interface to prevent

unintended adjustments of the settings by an
unauthorized user.

12.6 Maximum Achievable SIL

The Flowserve 420 Valve Positioner covered by this safety
manual is suitable for use in low demand mode of
operation Safety Integrity Functions (SIF) up to SIL 2 in
simplex (1oo1) configurations and up to SIL 3 in redundant
configurations with a HFT of at least 1. The achieved SIL
for a particular SIF needs to be verified by PFDavg
calculation for the entire SIF including the failure rates of
the associated sensors and valves that are also part of the
SIF.
Use of the Flowserve 420 Valve Positioner in a redundant
(1ooN) configurations is also limited to SIL 2.

For details, contact your Flowserve representative for
Failure Mode, Effects, and Diagnostics Analysis (FMEDA)
report for Logix 420.

12.7 Reliability data

For reliability data, a detailed Failure Mode, Effects, and
Diagnostics Analysis (FMEDA) report has been prepared
and is available from Flowserve with all failure rates and
failure modes for use in SIL verification. See FMEDA
report for Logix 420.

Note that the failure rates of the associated actuator need
to be accounted for in the Safety Instrumented Function
(SIF) level Probability of Failure High over Average
Probability of Failure on Demand (PFH / PFDAVG)
calculation.

12.8 Lifetime limits

The expected lifetime of the Flowserve 420 positioner is
approximately 10 years. The reliability data listed the
FMEDA report is only valid for this period. The failure rates
of the Flowserve 420 Valve Positioner may increase
sometime after this period. Reliability calculations based on
the data listed in the FMEDA report for lifetimes beyond 10
years may yield results that are too optimistic, i.e. the
calculated Safety Integrity Level may not be achieved.

flowserve.com 28

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Steps for Proof Test

1. Bypass the safety PLC or take other appropriate
action to avoid a false trip.

2. Set the trip output to the trip state (below 3.6mA) and
ensure that the attached valve is fully in the safe state
(defined by application) and has moved to that
position within the allowed time. This tests for failures
that could prevent the closure of the valve, including
electronic and mechanical faults, as well as valve
faults.

3. Inspect the Logix 420 Digital Positioner for any visible
damage or contamination.

4. Remove the bypass from the safety PLC or otherwise
restore normal operation.

Steps for Partial Valve Stroke Test

Step Action

1. Verify the control loop is ready for valve movement in

the amount set for the Partial Stroke Test (PST).

2. Excecute the PST via the LCD menu, DD, or DTM.

3. View the results of the PST via the LCD menu, DD, or

DTM.

4. Check the errors generated by accessing the Alerts and

Alarms menu on the LCD menu, DD, or the Alarm
Annunciator in the DTM or other HART system using
command 48.

12.9 Proof Testing

The objective of proof testing when used in low demand
mode of operation is to detect failures within the Flowserve
420 Valve Positioner and its associated sensors and
actuators that may not be detected by the normal self­diagnostics. Of main concern are undetected failures that
prevent the safety instrumented function from performing
its intended function.

The frequency of the proof tests (or the proof test interval)
is to be determined in the reliability calculations for the
safety instrumented functions for which the Flowserve 420
valve positioner is applied. The actual proof tests must be
performed at least as frequently as specified in the
calculation in order to maintain required safety integrity of
the safety instrumented function.

The following tests need to be specifically executed when a
proof test is performed. The results of the proof test need to
be documented and this documentation should be part of a
plant safety management system. Positioner failures that
are detected should be reported to Flowserve.

To perform the proof testing, an LCD display or HART
communicator such as a 375 Handheld or software such as
ValveSight DTM for Logix 420 are required.

When the tests listed above are executed, a proof test
coverage of 95 % can be claimed. Failure modes not
covered include possible leaking of the valve seat for fail
closed valves.

flowserve.com 29

When the tests listed above are executed, a partial valve
stroke coverage of 95% can be claimed. Failure modes
not covered include possible valve sticking in the travel
range not tested and leaking of the valve seat for fail closed
valves.

12.10 Maintenance

Follow routine maintenance. See section 13.1 Scheduled
Maintainance.

12.11 Repair and replacement

In the unlikely event that the Flowserve 420 valve
positioner fails, the failure should be reported to Flowserve.
Replace faulty components according to section 13
MAINTENANCE AND REPAIR or return the positioner to
Flowserve for service. With experience and the right parts,
repair times for any component can be less than an hour,
however a 24 hour mean time to repair should be assumed
for safety availability calculations.

12.12 Training Requirements

Activities specified in this manual shall be performed by a
service technician trained in the installation and
maintenance of process instrumentation. See section 1.4
Qualified Personnel.

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Feedback
Pot
Connector

Piezo
Connector

Hall
Sensor
Connector

13 MAINTENANCE AND REPAIR

The kits listed in section 16.2 Spare Parts Kits can be
replaced by a technician trained in positioner function and
handling of static sensitive devices.

CAUTION: Depressurize the positioner before

servicing.

CAUTION: Use eye protection.
CAUTION: When touching the circuit boards, observe

precautions for handling electrostatically sensitive devices.

13.1 Scheduled Maintainance

The supply gas filter(s) should be scheduled for regular
maintenance as required to maintain supply gas quality. If
contamination is found in the filter, the inside of the
positioner should be visually inspected for contamination.
If contamination is found in the positioner, the positioner
should be replaced.

Philips Screwdriver #2 _______

Philips Screwdriver #1 _______

Flat Screwdriver _______

2.5 mm Hex Driver _______

13.2 Required Tools and Equipment

The Logix 420 digital positioner has modular components
that can be replaced using these tools:

Figure 15: Tools for Positioner Maintenance

13.3 Replacing a Main Board

Removal
1 Make sure the valve is bypassed or in a safe

condition.
2 Remove the outer cover.
3 Disconnect the power to the positioner.
4 Remove the inner cover by removing the 3 retaining

screws.
5 Gently lift the main board rotating the bottom up while

keeping the top in place.

6 Disconnect the hall sensor cable, the piezo cable and

the feedback cable. Use a small flat screwdriver to
press in the locking features and carefully separate
the connector from the main board. Be careful not to
pull the cable, as this may cause damage to the
cable.

Installation
1 Place the main board on the positioner base with the

4-20 mA input on the same side as the electronic
access ports.

2 Lift the main board rotating the bottom (configuration

switches) upwards while keeping the top in place.

3 Connect the pressure sensor board cable, the hall

sensor cable, and the feedback cable. Ensure the
connector’s locking features engage.

4 Place the main board on the positioner base, ensuring

the cables are clear of the feedback gears.

5 Replace the inner cover by inserting the 6 retaining

screws.

6 Calibrate.

Figure 16: Main Board Connectors

flowserve.com 30

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 15: Troubleshooting Guide

Failure

Probable Cause

Corrective action

No LED is blinking.

1. Current source too low.

2. Voltage of current source is too low.

3. Incorrect wiring polarity.

1. Verify current source supplies at least 3,8 mA.

2. Verify voltage source supplies at least 10VDC.

3. Check wiring for correct polarity.

Erratic communications.

1. Current source bandwidth not
limited to 25Hz.

2. Maximum cable length or cable
impedance exceeded.

3. HART modem connected to PC RS-232
port not receiving enough power

4. Interference with I.S. barrier.

5. Current source stripping (filtering)
HART signal.

1. Maximum allowable current source rate of
change is 924 mA per second.

2. Check cable size, length and capacitance. See
Section 7 ELECTRICAL CONNECTIONS.

3. Verify laptop battery is not low.

4. Must use HART compatible I.S. barrier.

5. Use a 250Ω resistor and a 22 µF capacitor to
create a HART filter according to the following
schematic.

Unit does not respond
to analog commands.

1. The positioner is in digital
command mode.

2. An error occurred during
calibration.

1. Switch to analog command mode using
the procedure outlined in Section 9.3
Command Source Reset, use the
ValveSight DTM, or use a handheld
communicator.

2. Check Status Codes. Correct calibration

Valve position reading
is not what is
expected.

1. Stem position sensor mounting is
off 180 degrees.

2. Stroke not calibrated

3. Tight shutoff (MPC-Minimum
position cutoff) is active.

4. Custom characterization or soft
stops are active.

1. Reposition the sensor.

2. Perform a Stroke calibration (Quick-Cal).

3. Verify Tight Shutoff settings.

4. Verify custom characterization or soft-stop limits.

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

1. Stroke is not calibrated.

2. Inner-loop hall sensor is not connected.

3. Wrong air action was entered in
software.

4. Actuator tubing is backward.

5. Electro-pneumatic converter
is malfunctioning.

6. Control parameter inner-loop offset
is too high/low.

1. Perform stroke calibration (Quick-Cal)

2. Verify hardware connections.

3. Check ATO (Air-to-open) and ATC (Air-to­Close) settings. Recalibrate using Quick-Cal to
apply settings.

4. Verify ATO/ATC actuator tubing.

5. Replace electro-pneumatic converter.

6. Adjust inner-loop and see if proper control
resumes.

Sticking or hunting
operation of the positioner

1. Contamination of the electro-pneumatic
converter.

2. Control tuning parameters not correct.

3. Packing friction is high.

1. Check air supply for proper filtering and meeting
ISA specifications ISA-7.0.01.

2. Lower proportional gain settings.

3. Enable the stability DIP switch on the local
interface and recalibrate. If problem persists,
adjust pressure control window with handheld
communicator or ValveSight and recalibrate.

LCD backlight flickering or
dim.

1. The backlight uses any residual power
not used by other functions of the
circuitry.

1. Fluctuations in the LCD backlight are normal.
No action required.

22 µF 250Ω

Control

HART

Device

→

To Logix

14 TROUBLESHOOTING

14.1 Troubleshooting Guide

Comm

flowserve.com 31

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 16: Status Code Index

Status Code Name

Blink Code

Command Input Below ADC Range

RGGG

Command Input Above ADC Range

RGGG

Command Input Calibration in Progress

GRGY

Command Input Range Too Small

RGGG

Digital Command Mode

GGYY

Driver Module Alarm

RRYR

Factory Reset State

RGRR

Feedback Linkage Alarm

RRYG

Initializing

GGYR

Inner Loop Offset Time Out

RGGR

Jog Calibration Set 100% Position

GRRR

Jog Command Mode

GRRY

Local Interface Off

GGYG

Main Board Electronic Failure Warning

RYRR

Memory Error Warning

YYYR

No Motion Time Out

RGYY

Partial Stroke Test Failed Warning

YGRR

Piezo Voltage High Alarm

RRRY

Piezo Voltage High Warning

YRRY

Piezo Voltage Low Alarm

RRRY

Piezo Voltage Low Warning

YRRY

Pilot Relay Cycles Warning

YGGY

Pilot Relay Response Alarm

RRGG

Pilot Relay Response Warning

YRGG

Pilot Relay Travel Warning

YGGY

Position Deviation Alarm

RRRR

Position High Limit Alert

YGGG

Position Low Limit Alert

YGGG

Position Range Too Small

RGGY

Position Sensor Above ADC Range

RGGY

Position Sensor Below ADC Range

RGGY

Position Sensor Failure Alarm

RYRG

Power ON

GGGG

Setting Inner Loop Offset

GRGY

Settle Time Out

RGYG

Signature or Partial Stroke Test in Progress

GRGG

Soft Stop High Limit Alert

GYGY

Soft Stop Low Limit Alert

GYGY

Software Error Warning

YYRG

Squawk Mode

GGRR

Stroke Calibration in Progress

GRGY

Stroke Calibration Required

RGRG

Stroke Shift

RGRY

Stroke Span Decrease

RGRY

Stroke Span Increase

RGRY

Supply Pressure Low Alarm

RYYG

Temperature High Warning

YYGG

Temperature Low Warning

YYGG

Tight Shut Off Mode

GGGY

Valve Can't Open Alarm

RYGG

Valve Can't Shut Alarm

RYGG

Valve Closed Too Far Warning

YYGY

Valve Cycles Warning

YGGY

Valve Opened Too Far Warning

YYGY

Valve Travel Warning

YGGY

14.2 Status Code Index

flowserve.com 32

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

14.3 Status Code Descriptions

GGGG ●●●●

POWER ON

Description: No issues.
Possible Solutions: Not applicable.

GGGY ●●●●

TIGHT SHUT OFF MODE

Description: (Also called MPC.) The Final Command is
beyond the user set limit for the tight shutoff feature and the
positioner is applying full actuator pressure to close (or open)
the valve. This is a normal condition for all valves when
closed. The factory default setting triggers this at command
signals below 1%. This indication may also occur on 3 way
valves at both ends of travel if the upper Tight Shut Off value
has been set.

Possible Solutions: If tight shutoff is not desired reset the
tight shutoff limits or adjust the command signal inside of the
specified Tight Shut Off values.

GGYG ●●●●

LOCAL INTERFACE OFF

Description: Control and configuration features are locked at
the positioner's local interface. This is to prevent
unauthorized or accidental adjustments. The buttons can still
be used to view information on the LCD. The status code is
only present for a short time when the user attempts to make
a change through the display menu.

Possible Solutions: The DTM's Local Interface page is used
to unlock the local interface, turn this feature on and off, and
to set the PIN. For temporary access, a Personal
Identification Number (PIN) can be entered from the
positioner if an LCD is installed.

GGYY ●●●●

DIGITAL COMMAND MODE

Description: The input command is set by a digital HART
command instead of the 4-20 mA signal.

Possible Solutions: The input command source can be
changed back to the 4-20 mA signal by using a handheld, the
Dashboard page of the DTM, or performing a manual
Command Reset. Perform the Command Reset by holding
both the UP and DOWN buttons and briefly pressing the
QUICK-CAL/ACCEPT button.

Description: The positioner has powered up and is displaying
a blink sequence 3 times.

Possible Solutions: Wait for 3 blink sequences to complete.

GGRR ●●●●

SQUAWK MODE

Description: A user has set the positioner to flash a special
sequence so that it can be visually located.

Possible Solutions: This mode is cancelled if one of the
following occurs: 1) The QUICK-CAL/ACCEPT button is
briefly pressed. 2) The Squawk mode is turned off remotely.

3) More than one hour has passed since the command was
issued.

GYGY ●●●●

SOFT STOP HIGH LIMIT ALERT
SOFT STOP LOW LIMIT ALERT

Description: The Final Command would move the valve
beyond the user-set Soft Limit, but the internal software is
holding the position at the limit. The function is similar to a
mechanical limit stop except it is not active if the unit is un­powered.

Possible Solutions: If more travel is needed, reset the Soft
Limits. If not, adjust the Final Command signal back into the
specified range.

GRGG ●●●●

SIGNATURE OR PARTIAL STROKE TEST IN PROGRESS

Description: The positioner is in Out Of Service (OOS) mode
because a test or signature has been initiated. These
include Step Test, Ramp Test, or Partial Stroke Test.

Possible Solutions: Signatures and tests can be defined,
initiated, and cancelled through the Off-Line Diagnostics
pages of the DTM.

GGYR ●●●●

INITIALIZING

flowserve.com 33

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

GRGY ●●●●

STROKE CALIBRATION IN PROGRESS
SETTING INNER LOOP OFFSET
COMMAND INPUT CALIBRATION IN PROGRESS

Description: A calibration sequence is in progress. The inner
loop offset is an important step of the stroke calibration.

Possible Solutions: The calibration can be canceled from the
corresponding calibration page of the DTM, from the
handheld, or by briefly pressing the BACK button.

GRRY ●●●●

JOG COMMAND MODE

Description: The positioner has been placed in a local
override mode where the valve can only be stroked using the
UP and DOWN buttons. The positioner will not respond to
analog or digital input commands from HART.

Possible Solutions: Control the valve using the UP and
DOWN buttons. This mode may be cancelled by briefly
pushing the QUICK-CAL/ACCEPT button.

GRRR ●●●●

JOG CALIBRATION SET 100% POSITION

Description: During a jog calibration, the unit is waiting for the
user to manually adjust the valve position to the desired
100% open position.

Possible Solutions: Use the Up and Down buttons on the
positioner to adjust the valve to the desired fully open
position. The QUICK-CAL/ACCEPT button to accept.

YGGG ●●●●

POSITION HIGH LIMIT ALERT
POSITION LOW LIMIT ALERT

Description: The position has reached or is exceeding a user
defined position limit. This is similar to a limit switch
indicator.

Possible Solutions: Set the limit to a higher (or lower) value if
more travel is needed, or adjust the command signal back in
the specified range.

YGGY ●●●●

PILOT RELAY CYCLES WARNING
PILOT RELAY TRAVEL WARNING
VALVE CYCLES WARNING
VALVE TRAVEL WARNING

Description: The cycle or travel limit of the valve, actuator,
bellows or pilot relay has been exceeded. Each cycle
represents two reversals of the direction of valve movement.
The cycle counting criterion and count limit (for the valve,
actuator and bellows) are set by the user to track the usage
of the valve assembly.

Possible Solutions: Follow routine procedures for
maintenance when the limit is reached. For example valve
inspection may include checking the packing tightness, and
checking linkages for wear, misalignment, and tightness.
Bellows inspection may include checking bellows for cracking
or leaking. Actuator inspection may include checking the
actuator seals and lubrication. Relay inspection may include
checking for high air consumption and signs of wear on the
spool. After maintenance, reset the travel accumulator.

YGRR ●●●●

PARTIAL STROKE TEST FAILED WARNING

Description: Measured times or forces during the last partial
stroke test did not pass the criteria set by the user. This may
be an indication of corrosion build-up on the valve stem or in
the actuator, low or restricted supply pressure, or a sticking
positioner relay.

Possible Solutions: This warning will clear upon completion
of a successful partial stroke test.

YYGG ●●●●

TEMPERATURE HIGH WARNING
TEMPERATURE LOW WARNING

Description: The temperature of the internal electronics has
exceeded the manufacturer set limits of -40°C (-40°F) to
85°C (176°F). Low temperature may inhibit responsiveness
and accuracy. High temperature may affect performance or
limit the life of the positioner.

Possible Solutions: Regulate the temperature of the
positioner by shading or cooling supply gas. Heat the
positioner if needed. If the temperature reading is in error,
replace the main board.

flowserve.com 34

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

YYGY ●●●●

VALVE CLOSED TOO FAR WARNING
VALVE OPENED TOO FAR WARNING

Description: While the valve was in use, it closed or opened
farther than it did at the last calibration by 0.5%.

Possible Solutions: Check the feedback arm linkage and
ensure the valve stem connection is tight. Recalibrate the
stroke. If the process cannot be interrupted a service
technician may be able to adjust the calibration.

YYYR ●●●●

MEMORY ERROR WARNING

Description: The microprocessor's memory has a problem.
Possible Solutions: Error may clear with time. If error

persists, cycle power and complete a QUICK-CAL. If the
error still persists, perform a factory reset, reprogram or
replace the main circuit board.

YYRG ●●●●

SOFTWARE ERROR WARNING

Description: There has been a watch dog time out, stack
overflow warning, or CPU usage warning.

Possible Solutions: If the problem persists, perform a factory
reset. If it still persists, reprogram or replace the main board.

YRGG ●●●●

PILOT RELAY RESPONSE WARNING

Description: The pilot relay is sticking or slow to respond.
This affects the responsiveness, increases the chance of limit
cycling and excessive air consumption. The pilot relay is part
of the inner loop and consists of the driver module assembly
with piezo (I-P relay) which is coupled to the spool valve or
poppet. The value of this indicator corresponds with inner
loop lag. Delayed response can be caused by a partially
clogged piezo or debris, oil, corrosion, or ice on the spool, or
low supply pressure.

Possible Solutions: Check response of the valve. If OK,
adjust Pilot Relay Response limits. Check supply pressure.
Check the spool or poppet for debris, oil, corrosion, ice on
the spool. Clean or replace the spool or poppet assembly.
Replace the piezo or driver module assembly. Maintain a
clean, water-free air/gas supply.

YRRY ●●●●

PIEZO VOLTAGE HIGH WARNING
PIEZO VOLTAGE LOW WARNING

Description: If the voltage to the piezo is to high, this could
indicate an error with the relay or the main board. This may
result from an extended period of inactivity, but in this case
should not persist for more than 30 minutes when the valve is
controlling. The positioner may still be functioning, but have
reduced performance under some circumstances. If the
voltage to the piezo is too low, the piezo may be damaged.
This may prevent the proper failure position upon loss of
signal/power. This condition may occur briefly on an air-to­close valve that is held for long periods of time in the closed
position, or an air-to-open valve held in the open position.

Possible Solutions: Ensure the supply pressure is not low. If
alarm persists for more than 30 minutes, the Piezo assembly
is damaged. Replace the pilot relay.

RGGG ●●●●

COMMAND INPUT BELOW ADC RANGE
COMMAND INPUT ABOVE ADC RANGE
COMMAND INPUT RANGE TOO SMALL

Description: During Command Loop Calibration, the signal
was out of the Analog to Digital Converter (ADC) range, or
difference between the signal at 0% and the signal at 100%
was too small. The system is designed to accept a
difference greater than 5 mA and between 10 and 4085 ADC.

Possible Solutions: Recalibrate making sure to use valid
command signal values.

RGGY ●●●●

POSITION RANGE TOO SMALL
POSITION SENSOR ABOVE ADC RANGE
POSITION SENSOR BELOW ADC RANGE

Description: During calibration, the range of motion of the
position feedback arm was too small for optimum
performance or the feedback sensor moved beyond its range
of operation.

Possible Solutions: Check for loose linkages. Adjust the
positioner mounting. Adjust the feedback pin back into range.
Adjust the feedback pin to a position closer to the follower
arm pivot to create a larger angle of rotation and recalibrate.
The minimum angle of rotation should be greater than 15
degrees. Briefly pressing the QUICK-CAL/ACCEPT button
acknowledges a small range and the positioner will operate
using the short stroke calibration if otherwise a good
calibration.

flowserve.com 35

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

RGGR ●●●●

INNER LOOP OFFSET TIME OUT

Description: During calibration the Inner Loop Offset (ILO)
value did not settle. This could result in less accurate
positioning.

Possible Solutions: Repeat the stroke calibration to get a
more accurate ILO value. To proceed using the less accurate
ILO value, this error may be cleared by briefly pushing the
QUICK-CAL/ACCEPT button. Lowering the setting on the
gain selection switch may help if the actuator is unstable
during the calibration.

RGYG ●●●●

SETTLE TIME OUT

Description: During calibration, the position feedback sensor
showed movement, but did not settle.

Possible Solutions: Check for loose linkages or a loose
positioner sensor. This error may appear on some very small
actuators during the initial calibration. Recalibrating may
clear the problem, or this error may be cleared by briefly
pushing the QUICK-CAL/ACCEPT button.

RGYY ●●●●

NO MOTION TIME OUT

Description: During a stroke calibration, there was no valve
motion detected. Because some valves are quite large, this
indicator can take up to 9 minutes to detect an error.

Possible Solutions: Check linkages and air supply to make
sure the system is properly connected. If the time out
occurred because the actuator is very large then simply retry
the QUICK-CAL and the positioner will automatically adjust
for a larger actuator by doubling the time allowed for
movement. This error may be cleared by briefly pushing the
QUICK-CAL/ACCEPT.

RGRY ●●●●

STROKE SHIFT

Description: The 0% and 100% valve positions have both
shifted in the same direction since the last stroke calibration.
This may be related to a bent or adjusted feedback linkage,
loose positioner mounting, or an over rotated feedback
potentiometer.

STROKE SPAN DECREASE

Description: The 0% and 100% valve positions are closer
together compared to the last stroke calibration. This could
indicate debris or build up at valve seat.

STROKE SPAN INCREASE

Description: The 0% and 100% valve positions are farther
apart compared to the last stroke calibration. This could
indicate seat wear.

Possible Solutions: Ensure the feedback linkage is not bent
and the positioner is mounted securely. If the feedback
potentiometer is over-rotated, repeat the stroke calibration
until the Stroke Shift error is no longer present. Inspect valve
or schedule valve for inspection. This notification can be
cleared by briefly pressing the QUICK-CAL/ACCEPT button.

RGRG ●●●●

STROKE CALIBRATION REQUIRED

Description: A factory reset was performed and the positioner
has not yet been calibrated. The unit will not respond to
commands and will remain in the failsafe position until a
calibration is successfully completed.

Possible Solutions: Perform a Stroke Calibration (QUICK­CAL) by holding the QUICK-CAL/ACCEPT button down for 3
seconds, or perform a Pressure or Friction calibration if
desired. See the Calibration section of the IOM for warnings.

flowserve.com 36

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

RGRR ●●●●

FACTORY RESET STATE

Description: The positioner is in factory reset state.
Calibration is required to enable control.

Possible Solutions: Perform a Stroke Calibration (QUICK­CAL).

RYGG ●●●●

VALVE CAN'T OPEN ALARM
VALVE CAN'T SHUT ALARM

Description: Pressure has been applied (or removed) to open
or shut the valve, but the valve is not moving. This may be
caused by excessive friction.

Possible Solutions: Verify adequate supply pressure is
applied. Verify the feedback linkage is connected. View the
friction trends if available. Consider the following: Clear any
external or internal mechanical obstruction, loosen the
packing, clean the stem, repair or replace the actuator, repair
the valve if galling is suspected.

RYYG ●●●●

SUPPLY PRESSURE LOW ALARM

Description: The supply pressure is below the user set
warning limit. Low supply pressure can cause poor valve
response or positioner failure. The minimum recommended
supply pressure for proper operation is 1.3 bar (19 PSI).

Possible Solutions: Regulate the supply pressure at the
positioner above 1.3 bar (19 PSI). Ensure system air/gas
supply is adequate. Repair kinked or restricted supply
tubing. Check for pneumatic leaks in the actuator and
actuator tubing. Recalibrate pressure sensors. Check the
pressure sensor board connections and replace pressure
sensor board if necessary.

RYRG ●●●●

POSITION SENSOR FAILURE ALARM

Description: The feedback arm may be disconnected from
the valve assembly or the sensor has failed.

Possible Solutions: Check the feedback arm linkage.
Recalibrate. If the problem persists return the unit for repair.

RYRR ●●●●

MAIN BOARD ELECTRONIC FAILURE WARNING

Description: There has been an oscillator fault, position
sensor ADC failure, supply voltage error, reference voltage
error, shunt voltage error, or piezo voltage error.

Possible Solutions: This may be caused by transient
conditions. If the error persists, replace the main board.

RRGG ●●●●

PILOT RELAY RESPONSE ALARM

Description: The pilot relay is sticking or extremely slow to
respond. This affects the responsiveness, increases the
chance of limit cycling and excessive air consumption. The
pilot relay consists of the driver module assembly with piezo
(I-P relay) which is coupled to the spool valve or poppet.
Delayed response can be caused by a partially clogged piezo
or debris, oil, corrosion, or ice on the spool, or low supply
pressure.

Possible Solutions: Check response of the valve. If OK,
adjust Pilot Relay Response limits. Check the supply
pressure. Check the spool or poppet for debris, oil,
corrosion, ice on the spool. Clean or replace the spool
assembly. Replace the piezo or driver module assembly.
Maintain a clean, water-free air/gas supply.

RRYG ●●●●

FEEDBACK LINKAGE ALARM

Description: The feedback linkage is broken or the position
feedback POT is out of range.

Possible Solutions: Fix broken linkage or adjust feedback
arm until full motion is within the range of the POT.

RRYR ●●●●

DRIVER MODULE ALARM

Description: The pilot relay can't open, the pilot relay can't
shut, or the Hall sensor circuit has failed.

Possible Solutions: Check the internal wiring connections.
Replace the pilot relay.

flowserve.com 37

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

RRRY ●●●●

PIEZO VOLTAGE HIGH ALARM

Description: The voltage driving the piezo is above the alarm
limit. This could indicate an error with the relay or the main
board. The positioner may still be functioning, but have
reduced performance under some circumstances.

PIEZO VOLTAGE LOW ALARM

Description: The voltage to the piezo is too low. The piezo
may be damaged. This may prevent the proper failure
position upon loss of signal/power. This condition may occur
briefly on an air-to-close valve that is held for long periods of
time in the closed position, or an air-to-open valve held in the
open position.

Possible Solutions: Ensure the supply pressure is not low. If
alarm persists for more than 30 minutes, the Piezo assembly
is damaged. Replace the pilot relay.

RRRR ●●●●

POSITION DEVIATION ALARM

Description: The difference between the command and the
actual position has been greater than the user-set limit for
longer than a user-set time.

Possible Solutions: Review active alarms and warnings to
find root causes of this alarm. The deviation settings can be
changed in the Valve Health page of the DTM.

flowserve.com 38

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

14.4 Help From Flowserve

14.4.1 Phone Support

Over-the-phone troubleshooting is often available for
positioner issues. Should your positioner be experiencing
problems, or if you have questions that are not answered by
this manual, feel free to call your local sales representative or
a Quick Response Center (QRC). See the back cover of this
manual for contact details.

14.4.2 Returning the 420 Positioner for Service

If troubleshooting is unable to solve the problem, the unit
may be returned. Please follow the steps below.

1. Request a Return Goods Authorization (RGA) form.
An RGA form will be e-mailed to you to accompany
the unit being returned.

2. Remove all fittings, brackets, filters, feedback arms,
etc. from the unit before packaging.

3. If the unit was operated with a gas other than clean
air, please include the related MSDS with the return.

4. Complete the RGA form. Write any specific issues
with the positioner you would like us to evaluate.
Please include the customer name and contact
information

5. When packaging, please secure the unit in a
method that will insure it will reach our facility
undamaged (the weight of positioners will often
settle through packing peanuts and pop large air
packets).

6. Please insert a copy of the completed RGA form
inside the package and write the RGA number on
the outside of the package. Send the unit to the
address at the bottom of the form.

If the cause of the unit failure is found to be a manufacturing
defect and the unit is within the warranty period (18 months
from manufacture) it will be repaired free of charge. If no
problem is found with the unit and the unit is still under
warranty, a fee for the evaluation will be required. If the
cause of the unit failure is not covered under the warranty a
fee will be charged for the evaluation and a quote will be
provided showing the cost of the repair. If the customer
decides to purchase a new positioner, the evaluation fee will
be waved.

flowserve.com 39

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

15 POSITIONER DIMENSIONS

15.1 Positioner Dimensions

Figure 17: Overall Dimensions

flowserve.com 40

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Table 17: 420 Positioner Configurations

Selection

Description

Code

Example

Base Model

Logix 420

4

4

Communications

HART 6 (HART 7 Configurable)

2

2

Diagnostics

Standard (Basic Functionality)

0

0

Certifications

-

Certifications

General Purpose

14

14

Intrinsically Safe, IP66, Explosion Proof Cl I Div 1 Gr. B,C,D, Ex d IIB+H2

40

Positioner Configuration

-

General Options

Housing: Aluminum; Paint: White; Static Seals: Buna-N; Dynamic Seals: Fluorosilicone (Standard)

W

W

Housing: Aluminum; Paint: White; Static Seals: Buna-N; Dynamic Seals: Buna-N (Sweet Natural
Gas)*

N

Threaded

Connections

Mounting: 5/16" 18 UNC and M6; Pneumatics: 1/4" NPTF; Conduit: 1/2" NPTF; Vent 1/4" NPTF

1

1

Mounting: 5/16" 18 UNC and M6; Pneumatics: 1/4" NPTF; Conduit: M20 x 1.5; Vent 1/4" NPTF

2

Feedback Shaft

“D” - 316 Stainless Steel Shaft (Valtek Standard)**

D

D

NAMUR VDI/VDE 3845 Stainless Steel Shaft**

R

Optional Mechanical Add-Ins

-

Gauges

No Gages

0

1

Nickel Plated with Brass Internals, psi (bar/kPa)

1

Nickel Plated with Brass Internals. psi (kg/cm2 )

2

SS with SS Internals. psi (bar/kPa)

3

SS with SS Internals. psi (kg/cm2 )

4

UCC Press Test Plug, 1/8" NPT

A

Valve, Tank, Schrader 645A

B

Display

No LCD; Solid Cover

0

1

LCD; Window Cover

1

No LCD; Widow Cover

2

Table 18: Spare Parts Kits

Description

Part-no.

Main Board without LCD

307428.999.000

Main Board with LCD

307429.999.000

Table 19: Mounting Kits

Description

Part-no.

FlowTop Mounting Kit

314871.999.000

Shaft Converter - D to NAMUR

314586.999.000

16 HOW TO ORDER

16.1 Positioners

* Not for use below -30°C.
** When viewing the front of the positioner, the feedback shaft spring bias is as follows:

16.2 Spare Parts Kits

D - counterclockwise
R - clockwise

16.3 Mounting Kits

flowserve.com 41

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

INDEX

A

Air Action Switch · 15
Air Supply · 6
Auto Tune Switch · 16

C

Calibration · 16, 17, 21, 22, 23, 35, 36, 37
Characterization · 15, 16, 23
Command Source Reset · 18
Compliance Voltage · 12
Configuration Switch Settings · 15

Local User Interface · 15

M

Main Board · 30
Maintenance · 8, 29, 30
MaxFlo Rotary Valves · 10
Minimum Close Time · 23
Minimum Open Time · 23
Mounting · 9

O

Outer Loop · 5

D

DIP Switch Override · 20
Display Contrast · 20

E

Electrical Connections · 12
Event History · 21, 22

F

Factory Reset · 18, 26
FlowTop · 9
Friction · 16, 20, 36

H

Handheld Communicator · 27
HART · 4, 6, 20, 26, 27, 29
Hazardous Area Certifications · 7

I

Inner Loop · 5
Installation · 9

L

P

Partial Stroke Test · 21, 22, 33
Performance · 6
Positioner Dimensions · 40
Pressure Control · 16, 20, 24

Q

Quick Calibration Switch · 16
Quick-Cal · 15

R

Repair · 30

S

Safety · 3
Shutoff · 25
Signal at Closed Switch · 15
Soft Limits · 25
Spare Parts · 3, 41
Specifications · 6
Status Code · 16, 32, 33
Status Icons · 20
Status Messages · 20
Stroke Calibration · 15, 16
Stroke Time · 23

Language · 26
LCD Menu · 19
Limit Switch · 14
Local Control Of Valve Position · 18

flowserve.com 42

T

Temperature · 6, 20, 21, 22, 25
Troubleshooting · 12, 31

Tubing · 11
Tuning · 18, 23

V

Valtek GS · 9

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Valve Cycles · 22
Valve Stability Switch · 16
Valve Travel · 22
ValveSight DTM · 6, 27
Vented Design · 11
Version Numbers · 19, 26

flowserve.com 43

User Instructions - Logix® 420 Series Digital Positioners FCD LGENIM0106-06 12/13

Flowserve Headquarters

5215 N. O'Connor Blvd. Suite 2300
Irving, Tx. 75039
Phone: [phone]

Flowserve Corporation

Flow Control
1350 N. Mt. Springs Parkway
Springville, UT 84663 USA
Phone: [phone]
Fax: [phone]

Flowserve S.A.S.

12, avenue du Quebec
B.P. 645
91965 Courtaboeuf Cedex France
Phone: [phone]
Fax: [phone]

Flowserve Pte Ltd.

12 Tuas Avenue 20
Singapore 638824
Singapore
Phone:+ 65 6868 4600
Fax: [phone]

Flowserve Australia Pty Ltd.

14 Dalmore Drive
Scoresby, Victoria 3179 Australia
Phone: [phone]
Fax: [phone]

Flowserve Ltda .

Rua Tocantins, 128
São Caetano do Sul, SP 09580-130
Brazil
Phone: [phone]
Fax: [phone]

Flowserve Control Valves gmbH

Control Valves - Villach Operation
Kasernengasse 6
9500 Villach Austria
Phone: [phone]
Fax: [phone]

Flowserve (China)

585, Hanwei Plaza
7 Guanghau Road
Beijing, China 100004
Phone: [phone]

Flowserve India Controls

Pvt. Ltd Plot # 4, 1A, E.P.I.P,
Whitefield Bangalore Kamataka
India 560 066
Phone: [phone]
Fax: [phone]

Flowserve Essen GmbH

Schederhofstr. 71
45145 Essen Germany
Phone: [phone]
Fax: [phone]

Kämmer Valves inc.

1300 Parkway View Drive
Pittsburgh, Pa 15205 USA
Tel.: [phone]
Fax: [phone]

NAF Ab

Gelbgjutaregatan 2
SE-581 87 Linköping Sweden
Phone: [phone]

Fax: [phone]

Bulletin FCD LGENIM0106-06 12/13
Control per SPP-250

To find your local Flowserve representative please use

[e-mail]

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is

Download Logix 420 Manual

(Certification information in manual
may not be applicable. Certifications
on positioner label are valid.)

the Sales Support Locator System found at
www.flowserve.com

Or call
Europe [phone]
North America [phone]
Asia + (65) 6879 8900

designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve
products might be used in numerous applications under a wide variety of industrial service conditions. Although Flowserve can (and often does) provide general
guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore assume the ultimate responsibility for
the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection
with the specific application.

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

© 2012 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation.
For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.

flowserve.com 44