Ytc YT-1000 series Product Manual Download Page 4

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Smart Positioner

YT-1000 / 1050 series

Product Manual

Ver. 1.04

7.1.2

Rotary positioner ........................................................................................................... 53

7.2

Adjustment - Zero Point ........................................................................................................ 54

7.3

Adjustment - Span ................................................................................................................. 55

7.4

Adjustment

– L/S (Limit Switch, Internal, Option) ................................................................. 55

7.5

Adjustment

– A/M switch (Auto/Manual) ............................................................................... 56

7.6

Orifice Installment ................................................................................................................. 57

7.7

Reset

– Potentiometer .......................................................................................................... 57

Maintenance ................................................................................................................................ 59

8.1

Pilot valve .............................................................................................................................. 59

8.2

Seals ..................................................................................................................................... 59

Troubleshooting .......................................................................................................................... 60

Summary of Contents for YT-1000 series

Page 1: ...SMART POSITIONER PRODUCT MANUAL YT 1000 1050 SERIES VERSION 1 04 ...

Page 2: ...ion Transmitter option 14 2 5 3 Specification of Internal L S Limit Switch option 15 2 5 4 Specification of External L S option 15 2 6 Certifications 16 2 6 1 YT 1000 YT 1050 16 2 6 2 YT 1000 16 2 6 3 YT 1050 17 2 7 Parts and Assembly 18 2 7 1 YT 1000L 18 2 7 2 YT 1050L 18 2 7 3 YT 1000R 19 2 7 4 YT 1000R SPTM Internal 19 2 7 5 YT 1000R Limits Switch Internal 20 2 7 6 YT 1000R SPTM External 21 2 7...

Page 3: ... 3 1 Preparing Bracket for the positioner 33 4 3 2 Installation Steps 33 4 4 Rotary positioner Installation 37 4 4 1 Components 37 4 4 2 Rotary Bracket Information 38 4 4 3 Rotary positioner Installation Steps 39 5 Connection Air 41 5 1 Safety 41 5 2 Supply Pressure Condition 41 5 3 Piping Condition 41 5 4 Connection Piping with actuator 42 5 4 1 Single action 42 5 4 2 Double acting actuator 43 6 ...

Page 4: ...sitioner 53 7 2 Adjustment Zero Point 54 7 3 Adjustment Span 55 7 4 Adjustment L S Limit Switch Internal Option 55 7 5 Adjustment A M switch Auto Manual 56 7 6 Orifice Installment 57 7 7 Reset Potentiometer 57 8 Maintenance 59 8 1 Pilot valve 59 8 2 Seals 59 9 Troubleshooting 60 ...

Page 5: ... instruction manual of the control valve prior to installation and operation 1 2 Manufacturer Warranty For the safety it is important to follow the instructions in the manual Manufacturer will not be responsible for any damages caused by user s negligence Any modifications or repairs to the product may only be performed if expressed in this manual Injuries and physical damages caused by customer s...

Page 6: ...xplosion proof type wires and packing should be used Blind plug is required when any port is not being used Ring terminal with surface area of more than 0 195mm2 with M4 spring washer should be used to connect the power For external ground terminal ring terminal with surface area of more than 5 5mm2 should be used There is risk of explosion due to static electricity charge Static electricity charg...

Page 7: ...n change Simple Zero Span adjustment Internal External options such as position transmitter PTM and or limit switch L S are available Internal options are for non explosion proof and External options are for explosion proof Orifices can be installed even in the field to minimize the hunting occurrence and optimize operating conditions A M switch can be used to direct supply air to the actuator or ...

Page 8: ...L Indicates input signal range SUPPLY PRESSURE Indicates the supply pressure range OPERATING TEMP Indicates the allowable operating temperature AMBIENT TEMP Indicates the allowable ambient temperature for explosion proof SERIAL NUMBER Indicates unique serial number YEAR Indicates manufactured year Fig L 1 YT 1000 Non explosion Fig L 2 YT 1000 Ex db mb IIB T6 Gb ATEX IECEx TS Fig L 3 YT 1000 Ex d I...

Page 9: ...itioner YT 1000 1050 series Product Manual Ver 1 04 9 Fig L 6 YT 1000 Ex dmb IIB T5 KCs TIIS Fig L 7 YT 1000 Ex d mb IIC T5 FM CSA Fig L 8 YT 1050 Non explosion Fig L 9 YT 1050 Ex db mb IIB T5 Gb ATEX IECEx KCs ...

Page 10: ... NEPSI KCs TIIS TRCU 3 Lever Type 1 2 3 4 10 40 mm 30 70 mm 60 100 mm 100 150 mm 4 Orifice Type 1 2 3 Ø 1 Ø 2 None 5 Conduit Air Connection Type 1 2 3 4 5 G1 2 PT 1 4 G1 2 NPT 1 4 G1 2 G 1 4 M20 M20 adapter is attached to conduit entry NPT 1 4 NPT1 2 NPT 1 4 6 Operating Temp S H L 20 C 60 C 4 F 140 F 20 C 120 C 4 F 248 F Non explosion 40 C 70 C 40 F 158 F Non explosion except KCs 7 Option 0 2 3 No...

Page 11: ...nduit Air Connection Type 1 2 3 4 5 G1 2 PT 1 4 G1 2 NPT 1 4 G1 2 G 1 4 M20 M20 adapter is attached to conduit entry NPT 1 4 NPT1 2 NPT 1 4 6 Operating Temp S H L 20 C 60 C 4 F 140 F 20 C 120 C 4 F 248 F Non explosion 40 C 70 C 40 F 158 F Non explosion except KCs 7 Option 1 0 1 Standard Cover Dome Cover 8 Option 2 0 1 2 3 4 5 6 None SPTM Internal Without LCD Non explosion SPTM External With SPTM 6...

Page 12: ... S D Single Double 3 Explosion Proof N M E Non explosion ATEX KCs TRCU 4 Lever Type Linear 1 2 3 4 10 40 mm 20 70 mm 50 100 mm 100 150 mm Rotary 1 2 3 4 5 M6 x 34L M6 x 63L M8 x 34L M8 x 63L NAMUR 5 Orifice Type 1 2 3 Ø 1 Ø 2 None 6 Conduit Air Connection Type 2 G1 2 NPT 1 4 7 Operating Temp S H L 20 C 60 C 4 F 140 F 20 C 120 C 4 F 248 F Non explosion 40 C 70 C 40 F 158 F Non explosion ...

Page 13: ...b NEPSI 6 Ex dmb IIB T5 KCs TIIS 7 Ex d m IIB T5 FM CSA 8 1Ex d mb IIB T5 Gb X TRCU 2 Ex db mb IIB T5 Gb ATEX IECEx KCs 3 1Ex d mb IIB T5 Gb X TRCU Refer to 2 6 certifications for details Ambient Temperature Of Explosion proof Refer to 2 6 certifications for details Operating Temperature Standard 20 C 60 C 4 F 140 F High Temp 20 C 120 C 4 F 248 F Low Temp 40 C 70 C 40 F 158 F Linearity Single 1 F ...

Page 14: ...earity 1 F S Hysteresis 0 2 F S Sensitivity 0 2 F S Conduit Entry PF G 1 2 Ingress Protection IP67 Explosion Proof Ex d IIC T6 KCs Refer to 2 6 certifications of SPTM 6V product manual for details Ambient Temperature Of Explosion proof 40 C 60 C 40 F 140 F Operating Temperature 40 C 85 C 40 F 185 F LCD Operating Temperature 30 C 85 C 22 F 185 F Weight 1 3 Kg 2 9 lb Painting Epoxy Polyester Powder ...

Page 15: ...g Material Aluminum Switch Type Mechanical Type 2 x SPDT Inductive Proximity Sensor Mechanical Type 2 x DPDT Micro Switch Model SS5GL OMRON SS10GL OMRON PS17 5DU Autonics NJ2 V3 N P F DZ 10G 1B OMRON Switch Rating AC 250V 3A 125V 5A 250V 10 1A 125V 10 1A 125 or 250V 10A 480V 2A DC 250V 0 2A 125V 0 4A 30V 4A 14V 5A 5V 5A 12 24V 8 2V 125V 0 5A 250V 0 25A Terminal 8 Points Conduit Entry NPT 3 4 PF 3 ...

Page 16: ...b IIB T5 Gb X IP66 Certification No RU C KR MЮ62 B 04758 Ambient temperature 40 60 40 140 F 2 6 2 YT 1000 KCs 1 Rating Ex dmb IIB T5 Certification No 10 KB2BO 0028 Ambient temperature 20 70 C 4 158 F 2 Rating Ex d IIC T5 IP66 Certification No 11 KB2BO 0014 Ambient temperature 40 70 C 40 158 F 3 Rating Ex ia IIB T6 Gb Certification No 11 KB2BO 0001X Ambient temperature 40 70 C 40 158 F NEPSI Rating...

Page 17: ...dmb IIB T5 Certification No TC21196 Ambient temperature 20 70 C 4 158 F TS Rating Ex db mb IIB T5 Gb X Certification No TS 1050008222 Ambient temperature 20 60 C 4 140 F 2 6 3 YT 1050 KC Korea Rating Ex dmb IIB T5 Certification No 10 KB2BO 0029 Ambient temperature 20 70 C 4 158 F ...

Page 18: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 18 2 7 Parts and Assembly 2 7 1 YT 1000L 2 7 2 YT 1050L ...

Page 19: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 19 2 7 3 YT 1000R 2 7 4 YT 1000R SPTM Internal ...

Page 20: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 20 2 7 5 YT 1000R Limits Switch Internal ...

Page 21: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 21 2 7 6 YT 1000R SPTM External 2 7 7 YT 1000R Limit Switch External ...

Page 22: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 22 2 8 Product Dimension 2 8 1 YT 1000L Flameproof enclosure 2 8 2 YT 1000L Non explosion proof type or Intrinsic safety ...

Page 23: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 23 2 8 3 YT 1000L Internal SPTM without LCD 2 8 4 YT 1000R Fork Lever type Explosion proof construction for internal pressure ...

Page 24: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 24 2 8 5 YT 1000R Namur type 2 8 6 YT 1000R Dome indicator ...

Page 25: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 25 2 8 7 YT 1000R Internal SPTM without LCD 2 8 8 YT 1000R Internal SPTM with LCD ...

Page 26: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 26 2 8 9 YT 1000R Internal Limit Switch or Limit Switch SPTM ...

Page 27: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 27 2 8 10 YT 1000R External SPTM with LCD ...

Page 28: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 28 2 8 11 YT 1000R External Limit Switch ...

Page 29: ...sitioner YT 1000 1050 series Product Manual Ver 1 04 29 2 8 12 YT 1050L Explosion proof construction for internal pressure type 2 8 13 YT 1050R Fork Lever type Explosion proof construction for internal pressure ...

Page 30: ...l increase and when there is enough pressure inside the chamber to push the actuator s spring actuator s stem will start to go down and through the feedback lever stem s linear motion will be converted to span lever s rotary motion This span lever s rotary motion will then once again rotate the span and pulls the spring When the valve s position reaches to given input signal span spring s pulling ...

Page 31: ...f the actuator through OUT1 Then chamber s OUT 1 pressure will increase and the actuator s stem will rotate and through the feedback shaft actuator s rotating motion will be transferred to the cam This motion will then rotate the span lever and pull the span s spring Once it reaches to given input signal span spring s pulling force and torque motor s power will be balanced and move the flapper bac...

Page 32: ...r CEC Part 1 as applicable FM approved product 4 2 Tools for installation Hex key set for hex socket cap bolts Screw drivers Spanners for hexagonal head bolts 4 3 Linear positioner Installation Linear positioner should be installed on linear motion valves such as globe or gate type which uses spring return type diaphragm or piston actuators Fig 4 1 Installation example Before proceeding with the i...

Page 33: ...nstalled in such a way that the valve stroke length coincides with the corresponding figure in mm marked on the feedback lever Improper setting may cause poor linearity 4 3 2 Installation Steps 1 Assemble the positioner with the bracket made in previous step by fastening the bolts M8 1 25P Fig 4 2 Attaching positioner to bracket Fig 4 3 Attaching the bracket to actuator yoke 2 Attach the positione...

Page 34: ...lve at 50 of the total stroke 5 Insert the connection bar between the feedback lever and lever spring The connection bar must be located upward from the spring lever as shown the below left figure If it is located downward from the spring lever as shown the below right figure the connection bar or the spring lever will be worn out quickly because of excessive strong tension Fig 4 5 Proper way to i...

Page 35: ...y cause poor linearity Fig 4 6 Feedback lever and valve stem 7 Check the valve stroke The stroke numbers are engraved on the feedback lever of the positioner Position the connection bar at the number on the feedback lever which corresponds with the desired valve stroke To adjust move the bracket the connection bar or both The effective linear lever angle is 23 degree Stroke 30mm Stroke 70mm Fig 4 ...

Page 36: ...r should not touch the stopping bosses of positioner which is located on the backside of the positioner If the linear lever stopper touches the stopping bosses the positioner should be installed further away from the yoke Fig 4 8 Linear lever stopper should not touch stopping bosses of positioner on 0 100 valve stroke 9 After the installation tighten all of the bolts or nuts on the bracket and the...

Page 37: ...stem rotates 90 degrees Before proceeding with the installation ensure following components are available 4 4 1 Components Positioner Fork lever Only Fork lever type Rotary bracket set 2 piece 4 pcs x hexagonal headed bolts M8 x 1 25P 4 pcs x M8 plate washers 4 pcs x wrench headed bolts M6 x 1P x 15L 4 pcs x M6 nuts 4 pcs x M6 spring washers Bolts and washers to attach bracket to actuator not supp...

Page 38: ...ith the positioner contains two components The bracket is designed to fit onto the actuator with 20mm 30mm and 50mm stem height H according to VDI VDE 3845 standard Please refer to below figures how to adjust the height of the bracket Fig 4 11 Brackets and positioner Fig 4 12 Actuator stem Height Fig 4 13 Rotary Brackets Assembly ...

Page 39: ...ion of the actuator stem at 0 For single acting actuator it is easy to check 0 point by supplying no pressure to the actuator For double acting actuator check actuator stem s rotation direction clockwise or counter clockwise by supplying pressure to the actuator 4 Only Fork lever type Install the fork lever after setting actuator s stem at 0 Check the actuator stem s rotation direction clockwise o...

Page 40: ... pin 2mm Dia of the main shaft of the positioner into the hole of center of the fork lever The clamping pin will be locked to the fork lever spring Setting alignment of center of main shaft of the positioner and center of the actuator s stem is very important Poor alignment of the main shaft and the actuator s stem decreases the positioner s durability due to unnecessary forces on the main shaft F...

Page 41: ...er than ambient temperature Avoid from dusty air Use 5 micron or smaller filter Avoid oil Comply with ISO 8573 1 or ISA 7 0 01 Supply pressure range is 0 14 0 7 MPa 1 4 7 bar Set air filter regulator s pressure level 10 higher than actuator s spring range pressure 5 3 Piping Condition Ensure inside of pipe is clean of obstructions Do not use pipeline that is squeezed or shows any type of damamges ...

Page 42: ...cting type As input signal ampere increases the supply air pressure will be supplied through Out1 port Fig 5 1 Single acting linear actuator Fig 5 2 Single acting rotary actuator Refer to below diagram and check whether if the valve is a Reverse Acting or Direct Acting Then connect positioner s OUT1 port to the proper actuator s port and in case of need switch the assembly position of the Span Lin...

Page 43: ...ble acting actuator Double acting type positioner is set to use both Out1 and Out2 port As input signal increases the supply pressure will be supplied through Out1 of positioner to actuator and the exhausting air from actuator will be exhausted through Out2 of positioner Fig 5 5 Double acting linear actuator Fig 5 6 Double acting rotary actuator ...

Page 44: ...rse Acting or Direct Acting Then connect positioner s OUT1 port to the proper actuator s port and in case of need switch the assembly position of the Span linear and Cam Rotary Fig 5 7 Setting directions of piping and cam for linear double actuator Fig 5 4 Setting directions of piping and cam for rotary double actuator ...

Page 45: ...alling in hazardous and explosive gas area conduit tube or pressure proof packing union must be used The compound charging box should be the flameproof type and must be sealed completely Before connecting terminal ensure that the power is off completely Do not open the cover when the power is still alive Please use ring terminal to protect against vibration or any other external impact Please use ...

Page 46: ... junction box and open the junction box cover 2 Connect external wires to corresponding polarities within the junction box terminal block To avoid poor contacts make sure all bolts on the terminal block are tightened 3 Close and fix the junction box cover by tightening all M3 set screws Fig 6 3 Connecting cables ...

Page 47: ...Intrinsic safety type circuit and separate it from any other electric circuits 6 3 1 Connection 1 Open the cover base of the positioner 2 Connect external wires to corresponding polarities on the terminal block located at top left corner To avoid poor contacts make sure all bolts on the terminal block are tightened Fig 6 4 Connecting cables ...

Page 48: ...pe but old type slide switch was 2 point position type Smart Position Transmitter can be calibrated by 2 or 5 points setting The slide switch has 3 positions as below 1 2 Point position By setting only zero and end points 0 and 100 of valve stroke the outputs can be set accordingly When zero and end points are set 25 50 75 points are automatically calibrated ...

Page 49: ... and hold the button for 2 seconds and the lamp will flash twice quickly Release the button and then the lamp will flash three times quickly again to confirm that the new setting has been saved 2 8mA button The button is used when setting 25 position of full stroke during calibration Position the valve at 25 press and hold the button for 2 seconds and the lamp will flash twice quickly Release the ...

Page 50: ...osition the valve at 100 press and hold the button for 2 seconds and the lamp will flash twice quickly Release the button and then the lamp will flash three times quickly again to confirm that the new setting has been saved 6 5 Internal SPTM With LCD Refer to product manual of SPTM 6V or SPMT 5V to calibrate the position transmitter Fig 6 6 Connecting cables ...

Page 51: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 51 6 6 Internal L S SPTM Without LCD Refer to above 6 4 1 and 6 4 2 to calibrate the position transmitter Fig 6 7 Connecting cables ...

Page 52: ...Ver 1 04 52 7 Adjustments 7 1 Ra or Da Setting 7 1 1 Linear Positioner 1 If the actuator axis moves down when input signal is increased assemble the Span to upper M6 Tap hole like the below figure Fig 7 1 Span Installation Da Fig 7 2 Linear span assembly ...

Page 53: ... in case of need re assemble the CAM so that DA Direct Acting lettered surface is facing upward 2 If the actuator axis rotates counter clockwise when input signal in increased in case of need re assemble the CAM so that RA Reverse Acting lettered surface is facing upward 3 Position the actuator to initial point 4 Adjust the CAM so that the engraved CAM reference line marked with 0 is placed in the...

Page 54: ... 7 7 Parts LS internal 7 2 Adjustment Zero Point Set input signal at 4mA or 20mA as the initial ampere and rotate the adjuster of zero unit handle upward or downward to adjust actuator s initial point Please refer to the below diagram to increase or decrease the zero point Fig 7 8 Zero unit ...

Page 55: ...If the stroke is too high the span should be decrease 2 Changing span will affect zero point setting so zero point should be set again after span has been adjusted 3 Above two steps are required several times until both zero and span are properly set 4 After proper setting tighten lock screw Fig 7 9 Liear span unit Fig 7 10 Rotary span unit 7 4 Adjustment L S Limit Switch Internal Option Fig 7 11 ...

Page 56: ...irectly supplied from out1 port of positioner to the actuator regardless of input signal ampere On the other hand if the switch is turned clockwise toward A Auto and it is fasten tightly then the positioner will operate normally by input signal ampere It is extremely important to check the allowed pressure level of the actuator when the switch is loosened 2 Check whether the supply pressure is too...

Page 57: ...se make sure that the actuator does not move during the re calibration 2 In the junction box Please pull out the potentiometer cable connector form potentiometer PCB Do not pull out with too much force as wires can be damaged 3 On the potentiometer cable connector there are three holes Out of three holes please measure resistance level by plugging two hole one of right or left and one of center us...

Page 58: ...Smart Positioner YT 1000 1050 series Product Manual Ver 1 04 58 Fig 7 15 Resetting resistance of potentiometer without LCD Fig 7 16 Resetting resistance of potentiometer with LCD ...

Page 59: ...h dusts and other substances and lead to malfunction of the positioner First of all remove the pilot valve from the positioner and see if the holes on the screens are not clogged If the screens are clean and the positioner is not functioning remove the Auto Manual switch and check the back of the switch and see if the orifice is clean Clean the orifice with air and reassemble the switch and the pi...

Page 60: ...y valve 2 Check for a gap or damages between the nozzle and the flapper If damaged please send the product to the corresponding local Young Tech Co Ltd office or main office in South Korea for repair The pressure is exhausted only by Auto manual switch 1 Check if the positioner s nozzle has been blocked Also check if the pressure is supplied to the positioner and the pressure is being exhausted th...

Page 61: ...st be re adjusted as well 3 Check if supply air pressure level is stable from the regulator If the level is unstable the regulator must be replaced Hysteresis is too low 1 In case of double acting actuator check if seat adjustment has been properly performed Please contact YTC for any further inquiries regarding the seat adjustment 2 Backlash can occur when the feedback lever and lever spring are ...

Page 62: ...nufacturer Young Tech Co Ltd 81 Hwanggeum ro 89 Beon gil Yangchon eup Gimpo si Gyeonggi do South Korea 10048 Tel 82 31 986 8545 Fax 82 70 4170 4927 Email ytc sales rotork com Homepage http www ytc co kr Issued 2017 04 21 Copyright Young Tech Co Ltd All Rights Reserved ...

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