RTX1000 SERIES ELECTRO-PNEUMATIC POSITIONER

RTX1000 SERIES ELECTRO-PNEUMATIC POSITIONER Installation Operation and Maintenance Manual RTX-IOM-RTX1000/1000L-R01-0416 Page 1 of 26

Contents 1. Introduction... 4 1.1. General information... 4 1.2. Definitions... 5 1.3. Explosion proof warning... 5 2. Product Description... 6 2.1. General... 6 2.2. Label description... 6 2.3. Product number... 7 2.4. Product specification... 8 2.4.1. RTX1000L & R... 8 2.5. Part and assembly... 9 2.6. RTX1000R... 9 2.7. RTX1000L... 10 2.8. Product dimension... 11 2.9. RTX1000L... 11 2.10. RTX1000R... 11 3. Installation... 12 3.1. Safety... 12 3.2. RTX1000L Installation... 12 3.3. Installation steps... 12 3.4. RTX1000R Installation... 14 3.5. Bracket information... 14 3.6. Installation steps... 14 4. Connections... 16 4.1. Safety... 16 RTX-IOM-RTX1000/1000L-R01-0416 Page 2 of 26

4.2. Supply Pressure Condition... 16 4.3. Piping Condition... 16 4.4. Pipe Connection with actuator... 17 4.4.1. Single acting actuator... 17 4.4.2. Double acting actuator... 17 5. Adjustment... 18 5.1. Adjustment cam... 18 5.2. Adjustment Zero point... 18 5.3. Adjustment Span... 19 5.4. Adjustment - A/M Switch (Auto/Manual)... 19 5.5. Adjustment - Seat Adjuster... 20 5.6. Adjustment Orifice... 20 6. Maintenance... 21 7. Troubleshooting... 22 8. Position transmitter calibration... 24 8.1. Calibration... 25 8.1.1. Potentiometer setting... 25 8.1.2. ZERO (Close 0%) & SPAN (Open 100%) setting... 25 9. Packaging & store... 26 10. Assistance... 26 RTX-IOM-RTX1000/1000L-R01-0416 Page 3 of 26

1. Introduction 1.1. General information Thank you for choosing ROTEX product. Each product is fully inspected after the production to offer you the highest quality. In order to fully utilize the product, we strongly recommend users to read this manual carefully and understood. This manual provides information on installation, operation and maintenance procedures and related instructions for the ROTEX make Positioner (RTX series). The aim of this literature is to support the use of products in correct manner, and all the technical information provided in the catalogue. The manual should be given to the end user. The manual can be changed or revised without any prior notice. Any changes in product's specification, structure, and/or any components may not result immediate revised version of the manual. The manual should not be duplicated or reproduced for any purpose without any consent of Rotex Manufacturers & Engineers Private Limited, INDIA. Manufacturer Warranty For the safety, it is vital to follow instructions in the manual. It is not ROTEX s liability for any damages which caused by users' negligence. It is not ROTEX's liability for any damages or accidents which resulted by any alteration or modification of the product and parts. If alteration or modification is necessary, please contact the ROTEX directly. ROTEX warrants the product from the date of original retail purchase of the product for one (1) year, except as otherwise stated. ROTEX warranty will not cover the products that the product have been subjected to abuse, accident, alteration, modification, tampering, negligence, misuse, faulty installation, lack of reasonable care, repair or service in any way that is not contemplated in the documentation for the product, or if the model or serial number has been altered, tampered with, defaced or removed; damages that occurs in shipment, failure due to power surge, and cosmetic damage. Improper or incorrectly performed maintenance or report voids this Limited Warranty. For detailed warranty information, please contact : ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, Manapada road, Dombivli (e), Maharashtra, India, Pin - 421204 RTX-IOM-RTX1000/1000L-R01-0416 Page 4 of 26

1.2. Definitions WARNING: If not observed, user incurs a high risk of severe damage to product and/or fatal injury to personnel. CAUTION: If not observed, user may incur damage to product and/or injury to personnel. NOTE: Advisory and information comments provided to assist maintenance personnel to carry out maintenance procedures. NOTE: The manual should be given to the end user The manual can be changed or revised without any prior notice. Any changes in product's specification, structure, and/or any components may not result immediate revised version of the manual. The manual should not be duplicated or reproduced for any purpose without any consent of Rotex Manufacturers & Engineers Private Limited., INDIA 1.3. Explosion proof warning Please ensure the unit is being used and installed within the explosion proof certified environment. NOTE: RTX1000 Series explosion proof grades are flameproof Ex d IIC T6 and it can be used ZONE 1 and ZONE 2 Explosion proof type of cables and gaskets should be used, when explosion gases are present at the installation site. WARNING: Power should be turned off completely when opening product s cover. When opening the cover, ensure that there is no power remaining in any electrical parts nearby. RTX-IOM-RTX1000/1000L-R01-0416 Page 5 of 26

2. Product Description 2.1. General RTX-1000 series Electro-Pneumatic Positioner accurately controls valve stroke in response to an input signal of 4-20mA from the controller. 2.2. Label description A. MODEL: Indicates model number of the positioner. B. EXPLOSION PROOF: Indicates certified explosion proof grade. C. INPUT SIGNAL: Indicates input signal range. D. SUPPLY PR: Indicates the supply pressure range. E. SERIAL NO: Indicates the unique serial number. RTX-IOM-RTX1000/1000L-R01-0416 Page 6 of 26

2.3. Product number RTX100 b c d e f g h i j k b TYPE R ROTARY L LINEAR c ACTING S SINGLE ACTING D DOUBLE ACTING d ORIFICE # NILL 1 1.0 mm 2 2.0 mm e FEEDBACK LEVER # NILL 50 18537 100 51-100 150 101-150 200 151-200 f CONNECTION TYPE # BSP 2R NPT g CONDUTE TYPE # 1/2"NPT 3M M20 h AMBIENT TEMPERATURE # -20 TO +80 C AV -20 TO +120 C HN -40 TO +80 C i INDICATOR # FLAT DOME HD HIGH DOME j POSITION TRANSMITTER # NILL IP INTERNAL POSITION TRANSMITTER EP EXTERNAL POSITION TRANSMITTER EEP EXTERNAL POSITION TRANSMITTER EXD k LIMIT SWITCH # NILL WP WEATHER PROOF EX EXPLOSION PROOF RTX-IOM-RTX1000/1000L-R01-0416 Page 7 of 26

2.4. Product specification 2.4.1. RTX1000L & R Category RTX 1000R Input Signal 4 ~ 20mA * Impedance Supply Pressure 250 ± 15 Ω 1.4 ~ 8.0 kgf/cm² (20 ~ 120psi) Stroke 0 ~90 ** Air Connection PT (2G / 2R) Conduit Entry PF 1/2 or G 1/2 Explosion Proof ATEX: Protection IP 65 Cam Ambient Temp. Linearity Hysteresis Linear / Equal / SQ. / SQ. RT Standard: -40 C ~ +150 C ± 1.0 % F.S 1.0% F.S. Sensitivity ±0.2% F.S. ±0.5% F.S. Repeatability Internal Bleeding Flow Capacity Material Weight ± 0.3 % F.S. 3.0LPM(Sup=1.4kgf/cm², 20psi), 80LPM(Sup=1.4kgf/cm², 20psi) Aluminium Die casting 2.8 kg. RTX-IOM-RTX1000/1000L-R01-0416 Page 8 of 26

2.5. Part and assembly 2.6. RTX1000R RTX-IOM-RTX1000/1000L-R01-0416 Page 9 of 26

2.7. RTX1000L RTX-IOM-RTX1000/1000L-R01-0416 Page 10 of 26

2.8. Product dimension 2.9. RTX1000L 2.10. RTX1000R RTX-IOM-RTX1000/1000L-R01-0416 Page 11 of 26

3. Installation 3.1. Safety When installing a positioner, please ensure to read and follow safety instruction NOTE: Use bypass valve or other supportive equipment to avoid entire system shut down. WARNING: Any input or supply pressure to valve, actuator and / or to other related devices must be turned off Ensure there is no remaining pressure in the actuator. 3.2. RTX1000L Installation RTX 1000 L should be installed on linear motion valves such as globe or gate type which uses spring return type diaphragm or piston actuators. Before proceeding with the installation, ensure following components are available a. Positioner unit b. Feedback lever and lever spring c. Mounting bolts and washer 3.3. Installation steps Proper bracket must be made in order to adapt the positioner on the actuator. Please consider following important points when a bracket is being designed. NOTE: a. Positioner feedback lever must be parallel to the ground at 50% of valve stroke b. Feedback lever connection with the pin of the actuator clamp should be installed in such a way that the valve stroke length coincides with the corresponding figure in mm marked on feed back lever. Improper setting may cause poor linearity and may create unnecessary hunting during operation. RTX-IOM-RTX1000/1000L-R01-0416 Page 12 of 26

Assemble the positioner with bracket made in previous step by fastening the bolts. Attach Positioner with bracket to the actuator yoke NOTE: Do not tighten Positioner completely Connect supply pressure to actuator temporarily. Supply enough supply pressure to the actuator in order to position the actuator clamp at 50% of the valve stroke. Insert connection pin into the feedback lever. The pin should be inserted when the actuator clamp is at 50% of the total valve stroke. Check if feedback lever is parallel to the ground at 50% of the valve stroke. If it is not parallel, adjust the bracket or feedback link bar to make parallel. Improper installation may cause poor linearity and may create unnecessary hunting during the operation. or both.. Check the valve stroke. The stroke marks are indicated on the feedback lever of the positioner. Position the connection pin at the number on the feedback lever which corresponds to the desired valve stroke. To adjust, move the bracket, the connection pin After installing the positioner, operate the valve from 0% to 100% stroke by using direct air to the actuator (manual position). On both 0% and 100%, the feedback lever should not touch the lever stopper, which is located on the backside of the positioner. If the feedback lever touches the stopper, the positioner should be installed further away from the yoke. RTX-IOM-RTX1000/1000L-R01-0416 Page 13 of 26

After the installation, tighten all of the bolts on the bracket, the feedback lever, and the connection pin. 3.4. RTX1000R Installation RTX 1000R can be used for rotary actuator as well as linear actuator (Cylinder). Rotary actuator motion valves are used for regulating ball valve, butterfly valve using rack and pinion, scotch yoke of complex type actuator, which its stem rotates 90 degrees. And linear actuators are used to regulate the motion of dampers, In this arrangement we use a profile plate which converts linear movement of cylinder into rotary motion. Be sure to check the following components before installation on rotary actuator. d. RTX - 1000 main assembly e. IOM f. 1 Set of bracket (Not as a part of supply, needs to be order separately) g. 4 Socket set screw h. 4 Spring washer i. 4 Hexagon head bolt 3.5. Bracket information Standard bracket (included with the positioner) contains two components. The bracket can be used for NAMUR lever type. The bracket is designed to fit onto the actuator with 20mm stem height (H). 3.6. Installation steps Please check the actuator s stem height Mount bracket onto the actuator. It is recommended to use spring washer so the bolts will not be loosen from vibration RTX-IOM-RTX1000/1000L-R01-0416 Page 14 of 26

Set rotation position of the actuator stem at zero point, "0%." For a single type of actuator, it is easy to check zero point, because the actuator stem is positioned at zero point when there is no supply pressure. If double acting actuator is used, check actuator stem's rotation direction (clockwise or counter-clockwise) by supplying pressure. Tighten RTX 1000 base and the bracket with hexagon-headed bolts and plate washer. It is recommended to tighten four bolts after checking RTX - 1000's position. RTX-IOM-RTX1000/1000L-R01-0416 Page 15 of 26

4. Connections 4.1. Safety Supply pressure should be clean and dry air avoiding moisture, oil or dust. Always recommended to use air filter regulator (i.e. YT-200 series). ROTEX has not tested positioner operation with any gases other than clean air. Please contact ROTEX for any questions. 4.2. Supply Pressure Condition Dry air with at least 10 0 C lower than ambient temperature. Avoid from dusty air. Positioner inner filter can only filter 5 micron or larger. Avoid oil. Comply with ANSI/ISA-57.3 1975(R1981) or ISA S7.3-1975(R1981). Supply pressure range is 1.4 ~ 7 kgf/cm2 (140-700 kpa) Set air filter regulator s pressure level 10% higher than actuator s spring range pressure. 4.3. Piping Condition Ensure inside of pipe is clean of obstructions. Do not use pipeline that is squeezed or shows any type of damages. Pipeline should have more than 6mm of inner diameter (10mm outer diameter) to maintain flow rate. The length of pipeline system should not be extremely long. Longer pipeline system may affect flow rate due to the friction inside of the pipeline. RTX-IOM-RTX1000/1000L-R01-0416 Page 16 of 26

4.4. Pipe Connection with actuator 4.4.1. Single acting actuator RTX 1000R series single acting type is set to use OUT1 port. OUT1 port should be connected with supply pressure port from actuator when using single acting type of spring return actuator. Fig. 7 & 8. 4.4.2. Double acting actuator For RTX-1000R series double acting type, when inputting current signal, supply pressure is out from OUT1. RTX-IOM-RTX1000/1000L-R01-0416 Page 17 of 26

5. Adjustment 5.1. Adjustment cam Direction of actuator's stem rotation must be checked when supply signal is supplied. When actuator's stem rotates clockwise, the face of cam must be shown "DA." On the other hand, when the stem rotates counter-clockwise, adjust cam so "RA" shows on the face of cam. Check whether actuator's angle is at the initial point. After checking the initial point, release the hexagonal flange nut and adjust the position of the bearing so it is at 0 point. Fig. 11 When produced, the cam is set as RA. 5.2. Adjustment Zero point Set supply signal at 3 psi and rotate adjuster clockwise or counter-clockwise to adjust actuator's rotation angle. Fig.12 When adjusting zero for single actuator, rotation angle is equal to positioner's pressure gauge. RTX-IOM-RTX1000/1000L-R01-0416 Page 18 of 26

5.3. Adjustment Span After setting zero, rotate Span screw so supply signal reaches at the span point on the indicator. Changing span point affects zero point setting. So zero setting must be set again. After setting zero point, confirm the span point. This step must be repeated until both points are properly set. For RTX 1000R with 1/2 split range, the span spring must be changed. After setting is completed, tighten Lock Screw. 5.4. Adjustment - A/M Switch (Auto/Manual) A/M switch adjusts the valve operation to automatic or manual. When produced, RTX-1000 series is set at "A(Automatic)". If user prefers the positioner setting as "M (Manual)," the setting can be changed by turning the switch counterclockwise. Fig. 14 If it is set as "M (Manual)", the air pressure will be supplied to the actuator directly. Always set back to "A (Automatic)" after setting change. If OUT2 in single acting actuator or double acting actuator is used, A/M Switch will not operate. Fig.14 RTX-IOM-RTX1000/1000L-R01-0416 Page 19 of 26

5.5. Adjustment - Seat Adjuster Seat Adjuster is set according to the customer's request before the positioner is delivered. Please do not adjust the Seat Adjuster. Seat Adjuster is used for double acting actuator always. Please do not touch the Seat Adjuster, because it can affect the positioner's performance. 5.6. Adjustment Orifice If the size of actuator is too small relative to the flow rate, positioner can have hunting. In order to avoid hunting, orifice can be used. There are three types of the orifice. Actuator Size Orifice Size Suffix symbol 90cm² less Ø1.0 1 90 ~ 180cm² Ø2.0 2 180cm² and above None 3 Remove the o-ring from OUT1 and OUT2 port and insert appropriate orifice. After inserting orifice, place back the o-ring. Make sure there is no substance entering into port. If hunting persists after inserting the orifice, please contact ROTEX or its appropriate agent. RTX-IOM-RTX1000/1000L-R01-0416 Page 20 of 26

6. Maintenance Maintenance should be performed on pilot Valve Relay at least once a year. When dissembling the pilot valve relay, please do make sure not to lose o-ring or stabilizer spring. Pl. refer to Fig. 16 for the instruction. Remove stopper bolt. Unlock the Auto/manual Switch. Remove if there is any blocking within the port and orifice. RTX-IOM-RTX1000/1000L-R01-0416 Page 21 of 26

7. Troubleshooting Positioner does not respond to the input signal. Check supply pressure level. The level must be at least 1.4 kgf/cm². Check if input signal is properly supplied to the positioner. The signal should be 4~20mA DC. Check if the positioner nozzle has been blocked. Also, check if the pressure is supplied to the positioner and the pressure is being exhausted through the nozzle. If the nozzle has been blocked by any substances, please send the product to ROTEX for repair. Check if feedback lever has been installed properly. Check if zero point or span point is properly set. Check if feedback lever has been installed properly. The pressure of OUT1 reaches exhausting pressure level and does not come back down. Check A/M Switch. If the switch has been damaged, replace the switch or pilot relayvalve. Check for a gap or damages between the nozzle and the flapper. If damaged, please send the product to ROTEX for repair. The pressure is exhausted only by A/M Switch. Check if the positioner nozzle has been blocked. Also, check if the pressure is supplied to the positioner and the pressure is being exhausted through the nozzle. If the nozzle has been blocked by any substances, please send the product to ROTEX for repair. Hunting occurs. Check if safety spring has been displaced. (Next to Pilot relay valve) Check if the size of actuator is too small. If so, insert an orifice in order to reduce the pressure flow rate. Check if there is any friction between the valve and the actuator. If so, increase actuator's size or reduce the friction level. Actuator only operates by On/Off. RTX-IOM-RTX1000/1000L-R01-0416 Page 22 of 26

Check pipe connection. Check cam direction. Linearity is too low. Check if the feedback lever is properly installed. Especially check if the feedback lever is parallel to the ground at 50% point. Check if zero and span have been properly adjusted, that is not too low or not too high. Check if supply air pressure level is stable from the regulator. If the level is unstable, replace the regulator. Hysteresis is too low. In case of double acting actuator, check if seat adjustment has been properly done. Please contact ROTEX for any further inquiries regarding the seat adjustment. Backlash can occur when feedback lever and lever spring is loosen. To avoid backlash, adjust the lever spring. Check if the connection bar to the feedback lever is tightly fastened. RTX-IOM-RTX1000/1000L-R01-0416 Page 23 of 26

8. Position transmitter calibration NOTE: Apply and maintain 24 V supply at the supply terminal. Ensure the polarity. Use proper height bush to maintain to maintain card contactless with the enclosure surface mountings. Handle with care, while fixing card on mounting. Keep hands clean and dry while handling the card. Keep switches at home position after calibration of card i.e. OFF. Enclosure should be enclosed with proper gasket and cables that are going inside the enclosure should be properly covered with cable glands. Use appropriate size of screw driver for card calibration and connectors. CAUTION: Don t touch the card components with bare hands. Don t handle the card with moist or dirty hands. Don t clean the card with hard brushes, if necessary use air blower. Details for PCB mounted Dinkle Connectors 1. +24V Supply 2. - Ve supply (Gnd) 3. Potentiometer Connection :- If rotation of shaft is counter clockwise a. Variable Terminal 1 (1) b. Common 2 (2) c. Variable Terminal 2 (3) If rotation of shaft is clockwise a. Variable Terminal 3 (1) b. Common 2 (2) c. Variable Terminal 1 (3) RTX-IOM-RTX1000/1000L-R01-0416 Page 24 of 26

8.1. Calibration 8.1.1. Potentiometer setting To set the potentiometer (10K) measure voltage between terminal shown J1 and ( ) terminal. For 4-20mA range, voltage range should be in between 0 to 2 Volts. 8.1.2. ZERO (Close 0%) & SPAN (Open 100%) setting 1. Switch on DIP Switch 1(PROG Key) & Switch off DIP Switch 2. 2. Keep the actuator in closed condition; at this point 4mA output is needed. 3. Set rotary switch at 0 (Arrow position at 0). 4. Press the Enter Key (Push Button) to set the value for 0 % or 4 ma. 5. Keep the actuator in open condition; at this point 20mA output is needed. 6. Set rotary switch at 0 (Arrow position at 0). 7. Switch on DIP SW 2 (20 ma). 8. Press the Enter Key (Push Button) to set the value for 100 % or 20 ma. 9. After setting the zero and span position as per above method, exit from the Program Mode by turning the PROG KEY & DIP SW 2 OFF. 10. Now card is set for 4-20 ma. RTX-IOM-RTX1000/1000L-R01-0416 Page 25 of 26

9. Packaging & store 1. When not in use, Positioner should be kept in a sealed plastic bag in a cardboard box to prevent moisture or dust from contacting product. 2. Positioner should be stored in a dry place free from water and dust. 3. Store at temperature between 40 o F and 120 F (4 C and 49 C). 4. Locate in an area to avoid damage by impact. 10. Assistance For technical questions or assistance, contact any authorized distributor of ROTEX or: ROTEX MANUFACTURERS AND ENGINEERS PRIVATE LIMITED Manpada Road, Dombivli (East)-421204 Maharastra, INDIA. Tel: +91 251 2871033/ 2871390/ 2871196/ 2871989 Fax: +91 251 2871191 aftersales@rotexautomation.com To find your local ROTEX representative: For more information about ROTEX and its network, Please visit RTX-IOM-RTX1000/1000L-R01-0416 Page 26 of 26