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SMART POSITIONER

POSITIONER

Installation
Operation

and
Maintenance

Manual

Содержание Posidapt Expert

Страница 1: ...RTX IOM PRODUCT YY Page 1 of 131 www rotexautomation com SMART POSITIONER POSITIONER Installation Operation and Maintenance Manual...

Страница 2: ...nting Positioner on a Rotary Actuator 26 6 4 Mounting Positioner with bearing assembly on a Rotary Actuator 29 6 5 Mounting Positioner with the bearing assembly on a Control Valve 32 6 6 Remote Mounti...

Страница 3: ...n com 8 3 4 Diagnostics and Setup 87 8 3 5 Diagnostics 103 8 4 Parameter Overview DTM 123 8 4 1 Device Information 123 8 4 2 Online Statistics 128 8 4 3 Valve Offline Test 130 9 Alert and Error Messag...

Страница 4: ...e operated only by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who b...

Страница 5: ...e 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 install...

Страница 6: ...ing menu diagnostics and alarms Quick calibration using two push buttons IP66 Pre fitted gauge enclosed in IP66 enclosure ensure lifetime guaranty and reliability Electronics Encapsulated electronic p...

Страница 7: ...RTX IOM PRODUCT YY Page 7 of 131 www rotexautomation com 1 2 Posidapt Series...

Страница 8: ...acting Failsafe o Failsafe or stay put fail freeze Actuator Travel Range Linear o 0 position can start anywhere 3 to 200 mm stroke other strokes on request Rotary o 0 position can start anywhere max 3...

Страница 9: ...lon Polycarbonate cover o 2 Epoxy coated anodised aluminium housing cover with Makrolon see through window o 3 Explosion proof aluminium housing cover with toughened glass see through window o 4 Explo...

Страница 10: ...Alarm module 0 08 kgs 0 2 lbs Pneumatics Supply pressure o 1 4 to 8 bar 0 to 14 psi 10 bar on request Capacity with 4 bar 60 psi o 1 to 41 Nm h 0 5 to 23 scfm servo controlled orifice Consumption wit...

Страница 11: ...em both with or without HART signal Minimum Signal o 3 6 mA Current max o 36 mA with overload protection Load Voltage o 9 7 VDC 20 mA max 30 VDC Impedance o 485 at20 mA Wire Cross Section o Screw term...

Страница 12: ...ly Voltage o 12 to 30 VDC Total Operating Range o 3 6 to 21 mA Transmission Error o 0 3 Influence of temperature o 0 35 10 K Alarm Module Supply Voltage o 12 to 30 VDC Max Supply Voltage o 35 VDC Sign...

Страница 13: ...TX IOM PRODUCT YY Page 13 of 131 www rotexautomation com Communication HART 5 7 Foundation Field bus Profibus PA Certification Atex o II 2GD Ex ia IIC T6 Gb o II 2GD Ex d IIC T6 Gb Safety o Up to SIL...

Страница 14: ...On screen display of diagnostics alarms and error messages Modular design with encapsulated electronics a Fewer modules make it easy to install operate and maintain b Fewer numbers of internal compon...

Страница 15: ...ty during calibration and testing Communication a ROTEX POSIDAPT is compatible with Foundation fieldbus Profibus and HART version 5 7 b It is also compatible with DTM framework version 1 2 1 c DTM and...

Страница 16: ...131 www rotexautomation com Identification of the product Product code breakdown R T X 7 1 1 2 G H P 4 R R M 0 3 SERIES MODEL ENCLOSURE SERVO PORT CONNECTIONS COMMUNICATION MODULE CABLE ENTRY TEMPERAT...

Страница 17: ...RTX IOM PRODUCT YY Page 17 of 131 www rotexautomation com 4 Bock Diagram...

Страница 18: ...RTX IOM PRODUCT YY Page 18 of 131 www rotexautomation com 5 Dimensional Drawing...

Страница 19: ...LD BE TAKEN TO AVOID WATER SEEPAGE CONFIRM THE AREA IS NON HAZARDOUS BEFORE OPENING THE COVER OF THE ENCLOSURE FOR MAKING ELECTRICAL CONNECTIONS THE PLUGS GIVEN ALONG WITH BOX ARE TO BE REMOVED AND ME...

Страница 20: ...d cable glands and plugs to be used The plugs given along with box are to be removed and metallic plug to be used Operating temperature range should not exceed then the mentioned on the tag plate Avoi...

Страница 21: ...RTX IOM PRODUCT YY Page 21 of 131 www rotexautomation com Basic layout Smart positioner with Globe valve Smart positioner with Rotary Actuator...

Страница 22: ...ed for the installation of the smart Positioner on the linear actuator Table 1 Sr No Part description Qty Note 1 M6 Nut 1 For fixing scale 2 Hex bolt M6 x 35 mm 1 For fixing scale 3 Linear Scale 1 4 M...

Страница 23: ...RTX IOM PRODUCT YY Page 23 of 131 www rotexautomation com Figure 1 Linear scale assembly Figure 2 Attaching the linear scale and the mounting bracket...

Страница 24: ...3 Assemble the linear scale assembly as shown in the figure 1 4 Attach the mounting bracket to the Positioner as shown in the figure 2 also attach the linear scale to the shaft of the Positioner 5 Mou...

Страница 25: ...t in the slot in the scale and lock it using the locking spring as shown in fig 3 Make sure that the scale is horizontal when calibrating the positioner Secure the bolts firmly and proceed for calibra...

Страница 26: ...of components required for the installation Table 2 Sr No Part description Quantity Note 1 Std Mounting bracket 1 2 Plain washer M6 4 For attaching Positioner to bracket 3 Hex Bolt M6 x 12 4 For attac...

Страница 27: ...RTX IOM PRODUCT YY Page 27 of 131 www rotexautomation com Figure 4 Attaching the coupling and the bracket to the positioner Figure 5 Inserting coupling in shaft of the rotary actuator...

Страница 28: ...y using grub screws as indicated in the figure above 3 The assembly is then mounted on the actuator refer figure 6 below while taking care that the shaft enters in the slot of the actuator pinion 4 As...

Страница 29: ...list of components required for the installation Table 3 Sr No Part description Quantity Note 1 Shaft and bearing assembly 1 2 Grub screw M6 X 45 4 For attaching Positioner to bracket 3 Nut M6 4 For a...

Страница 30: ...RTX IOM PRODUCT YY Page 30 of 131 www rotexautomation com Figure 7 Attaching coupling and bracket to positioner...

Страница 31: ...y using grub screws as indicated in the figure above 8 The assembly is then mounted on the actuator refer figure 8 below while taking care that the shaft enters in the slot of the actuator pinion 9 As...

Страница 32: ...ge 32 of 131 www rotexautomation com 6 5 Mounting Positioner with the bearing assembly on a Control Valve This section provides information regarding mounting of smart Positioner on a linear actuator...

Страница 33: ...automation com Table 4 Sr No Part description Quantity Note 1 Smart positioner 1 2 Hex bolt M6 x 30 2 Mounting positioner on valve 3 Std Mounting bracket 1 4 Control Valve 1 5 Linear scale assembly 1...

Страница 34: ...exautomation com The figure 9 below gives a detailed and labelled refer table 4 view for mounting the positioner with the bearing and shaft assembly on a control valve Figure 9 Mounting of positioner...

Страница 35: ...e 1 Fix the positioner along with the mounting bracket at the centre of the control valve depending on the stroke of the control valve Insert the shaft in the slot in the scale and lock it using the l...

Страница 36: ...ecial version of the same includes up to 30m of cables available on request ROTEX shielded cable and circular connectors ensure better connectivity Ideal for extreme environments and harsh conditions...

Страница 37: ...d Mounting bracket 1 3 M5 nut 2 For attaching Remote Mount to bracket 4 M5 Plain washer 2 For attaching Remote Mount to bracket 5 Hex Bolt M5 x 20 2 For attaching Remote Mount to bracket 6 Grub screw...

Страница 38: ...igure 10 above 12 Attach the coupling securely using grub screws as indicated in the figure above 13 The assembly is then mounted on the actuator refer figure 11 below while taking care that the shaft...

Страница 39: ...RTX IOM PRODUCT YY Page 39 of 131 www rotexautomation com Figure 11 Mounting the Positioner on a rotary actuator...

Страница 40: ...RTX IOM PRODUCT YY Page 40 of 131 www rotexautomation com 6 8 Mounting remote unit on a Control Valve This section gives the instructions needed for mounting the Remote Unit on a Control valve...

Страница 41: ...RTX IOM PRODUCT YY Page 41 of 131 www rotexautomation com Figure 12 Detailed mounting of the remote unit on a control valve...

Страница 42: ...unting Instructions Assemble the linear scale assembly as shown in the figure 1 Attach the mounting bracket to the Remote unit Fix the Remote Unit along with the mounting bracket at the centre of the...

Страница 43: ...IOM PRODUCT YY Page 43 of 131 www rotexautomation com 6 9 Unfavourable mounting conditions The ROTEX smart Positioner can be mounted in all orientations except the one where the exhaust is facing upwa...

Страница 44: ...RTX IOM PRODUCT YY Page 44 of 131 www rotexautomation com 7 Electrical Connection...

Страница 45: ...RTX IOM PRODUCT YY Page 45 of 131 www rotexautomation com 8 User Interface 8 1 Menu Structure Posidapt Expert...

Страница 46: ...RTX IOM PRODUCT YY Page 46 of 131 www rotexautomation com...

Страница 47: ...47 of 131 www rotexautomation com 8 2 Display Screen Process Display with Position Process Display with Set point and Position Press Up or Down key for 5 second to display both set point and position...

Страница 48: ...d cannot be changed Linear Turn Use this parameter value for a linear actuator with mechanism movement parallel to the movement of the actuator The device compensates the nonlinearity caused due to th...

Страница 49: ...r Function Applicable for Posidapt Modern Expert Super Ultra and IPST Parameter used for a defining actuator function Double acting Factory default Use this parameter value for double acting actuator...

Страница 50: ...ure Applicable for Posidapt Modern Expert Super Ultra and IPST This parameter is used to set the temperature unit The selected temperature unit is then also applicable for all other temperature based...

Страница 51: ...re unit is then also applicable for all other pressure based parameters bar Factory default This sub parameter value sets the pressure unit to bar psi This sub parameter value sets the pressure unit t...

Страница 52: ...hich operating the device should start in after restart or input signal failure Auto Factory default This parameter will start the device in auto mode Manual This parameter will start the device in ma...

Страница 53: ...ry default This parameter will close the valve Open This parameter will open the valve Stay put not applicable for IPST This parameter will lock the valve in current position Set point not applicable...

Страница 54: ...f the device is not calibrated initially only value Auto1 is allowed for calibration Auto1 Recommended It sets all the parameter which needs to be calibrated in order for valve system to operate as de...

Страница 55: ...and IPST This parameter initializes timeout for calibration 60 Seconds Set calibration time value to 60 seconds 120 Seconds Set calibration time value to 120 seconds 180 Seconds Set calibration time v...

Страница 56: ...This parameter is used to reset the custom values of parameters set by user to factory setting default values Counter reset This parameter is used to reset all counter values to factory reset values R...

Страница 57: ...rotexautomation com Write Protect Applicable for Posidapt Modern Expert Super Ultra and IPST This parameter is used for write protect for HART communication Off This parameter disable write protect O...

Страница 58: ...meter is used to set the current range The selection of the current range depends on the type of connection 4 20 mA Factory default Use this parameter when the supply input signal current range is fro...

Страница 59: ...r Ultra and IPST This parameter used to set the start range for input signal It allows limiting the effective start set point Off Factory Default This parameter disable split range minimum feature Cus...

Страница 60: ...per Ultra and IPST This parameter used to set the end range for input signal It allows limiting the effective end set point Off Factory Default This parameter disable split range maximum feature Custo...

Страница 61: ...ed to set the action of set point direction This parameter is used to reverse the set point direction of action from forward to reverse vice versa Counter clockwise This parameter is use to set the ac...

Страница 62: ...irection of action for display The set point direction of action for display is used to reverse the direction of action from forward to reverse vice versa Increment This parameter is use to set the se...

Страница 63: ...IPST This parameter is used to set the Position transmitter output direction depending on position 10 Increment Factory default This parameter is use to set the position transmitter output to increme...

Страница 64: ...t Modern Expert Super Ultra and IPST This parameter selects functionality of Input pin value for function of input Off Factory default Disable state of input function Normally Open NO Detect logic 1 o...

Страница 65: ...ure or temperature switches can be read over the communication interface or fed through a logical OR combination with other messages to trigger the fault message output Block Configuration NO NC This...

Страница 66: ...gulates to the value specified in parameter Zero point soft stopper Move Valve position to user set point NO NC not applicable for IPST If input 1 is activated then the actuator regulates to the value...

Страница 67: ...t Modern Expert Super Ultra and IPST This parameter selects functionality of Input pin value for function of input Off Factory default Disable state of input function Normally Open NO Detect logic 1 o...

Страница 68: ...e switches can be read over the communication interface or fed through a logical OR combination with other messages to trigger the fault message output Block Configuration NO NC This parameter value c...

Страница 69: ...lue specified in parameter Zero point soft stopper Move Valve position to user set point NO NC not applicable for IPST If input 2 is activated then the actuator regulates to the value set by user The...

Страница 70: ...ly to input signal changes overshoots occurs while achieving the target position Quick In order to optimize the control performance the device responds quickly to input signal changes small overshoots...

Страница 71: ...Modern Expert Super Ultra and IPST This parameter is used to adjust the dead band of the controller Auto Factory default This parameter continuously adaptively adjusts the dead band to the requiremen...

Страница 72: ...ximum force of the actuator Off This parameter will deactivate the tight shut off function at close position This parameter controls 0 0 start position of the device the device is in controlled state...

Страница 73: ...rameter will deactivate the tight shut off function at open position This parameter controls 100 0 end position of the device the device is in controlled state Custom This parameter used for setting t...

Страница 74: ...e start position is same as the actual start position of the actuator determined during auto calibration Custom This parameter is used to cut off start position 0 0 unusable range of the control valve...

Страница 75: ...tion is same as the actual end position of the actuator determined during auto calibration Custom This parameter is used to cut off end position 100 0 unusable range of the control valve It is the per...

Страница 76: ...is mode the start zero mechanical position is the same as the actual start position of the actuator determined during auto calibration Custom The start zero position can be configured to desired value...

Страница 77: ...ult In this mode the end mechanical position is the same as the actual end position of the actuator determined during auto calibration Custom The end position can be configured to desired value This a...

Страница 78: ...100 0 between the actual mechanical stops of the actuator irrespective of the Zero point soft stopper End point soft stopper parameters Scale This parameter value shows the mechanical position from 0...

Страница 79: ...RTX IOM PRODUCT YY Page 79 of 131 www rotexautomation com...

Страница 80: ...r control servo valve spool forward sensitivity Auto It is the minimum spool movement to achieve minimum set point change in forward direction Custom It sets the sensitivity aggressiveness of the posi...

Страница 81: ...Auto It is the maximum forward velocity of the positioner to achieve the set point without being overshot Custom It sets the velocity of the positioner Not recommended to change it manually The value...

Страница 82: ...y Auto It is the minimum spool movement to achieve minimum set point change in reverse direction Custom It sets the sensitivity aggressiveness of the positioner not recommended to change manually The...

Страница 83: ...ivity Auto It is the maximum reverse velocity of the positioner to achieve the set point without being overshot Custom It sets the velocity of the positioner Not recommended to change it manually The...

Страница 84: ...seven pre defined four user defined characteristics Sr no Valve characteristics Values 1 Linear Factory default Linear 2 Square 01 25 3 Square 01 33 4 Square 01 50 5 Square root 25 01 00 6 Square roo...

Страница 85: ...l curve with 20 linear segments which models the valve characteristic The difference between digital and mechanical set point is digital set point are set through keypad or DTM whereas mechanical set...

Страница 86: ...point 5 6 User defined set point 6 7 User defined set point 7 8 User defined set point 8 9 User defined set point 9 10 User defined set point 10 11 User defined set point 11 12 User defined set point...

Страница 87: ...lue exceeds one of the three configurable limit thresholds Threshold Limit 1 Use this sub parameter to set the factor for the formation of limit threshold 1 Off Factory default This parameter value do...

Страница 88: ...one of the three configurable limit thresholds Threshold Limit 1 Use this sub parameter to set the factor for the formation of limit threshold 1 Off Factory default This parameter value does not trigg...

Страница 89: ...to Custom The current value is displayed in the End set point shift in Values and Counters under Counter Thresholds and Trends The device triggers a fault message if the current value exceeds one of...

Страница 90: ...Posidapt Super and Ultra This parameter is used to determine the basic control accuracy of the valve The current dead band value is displayed in the Dead band in Values and Counters under Counter Thr...

Страница 91: ...ed The value can be set from 0 1 to 20 0 Threshold Limit 3 Use this sub parameter to set the factor for the formation of limit threshold 3 Off Factory default This parameter value does not trigger any...

Страница 92: ...figurable limit thresholds Auto Factory default This sub parameter is set to Auto if the device is auto calibrated The time constant is determined from the calibration process by actuating times open...

Страница 93: ...rse changes in the valve position the so called slip jumps let the device close at too large static friction If slip jumps are detected the filtered step height is saved as a de jamming value If slip...

Страница 94: ...r and Ultra This parameter is used for steady state load measurement which is especially significant for single acting actuators since you can use it estimate the actuator spring force and spring cond...

Страница 95: ...f This parameter value does not trigger any message or alarm Custom The threshold 3 fault message is displayed when the limit threshold 3 is exceeded The value can be set from 0 0 to 10 0 bars Lower T...

Страница 96: ...old 2 The device triggers a fault message if the current temperature inside the enclosure undershoots threshold 2 Off This parameter value does not trigger any message or alarm Custom This sub paramet...

Страница 97: ...closure exceeds threshold 1 Off This parameter value does not trigger any message or alarm Custom This sub parameter value is used to monitor the upper limit temperature Set the threshold in a range f...

Страница 98: ...the current value undershoots one of the three configurable limit thresholds Threshold Limit 1 This parameter is used to set the pressure threshold 1 The device triggers a fault message if the current...

Страница 99: ...sensor on the main circuit board The maximum recorded value is displayed in the Maximum pressure recorded diagnostics parameter The device triggers a fault message if the current value overshoots one...

Страница 100: ...0 0 bar Load for Opening Applicable for Posidapt Super and Ultra This parameter is used to determine minimum pressure required to open the valve from full close position The actual value auto calibrat...

Страница 101: ...ter is used to set threshold 3 for the deviation in Load for Opening of current value from the reference value Off This parameter value does not trigger any message or alarm Custom This parameter is u...

Страница 102: ...he average of the measure position is recorded in the corresponding working range The following are the actuating range 0 10 20 30 40 50 60 70 80 90 100 60 50 40 30 20 10 0 10 20 30 40 50 60 70 60 50...

Страница 103: ...Threshold Limit 1 Use this sub parameter to set the limit threshold 1 Off This parameter value does not trigger any message or alarm Custom The threshold 1 fault message is displayed when the limit th...

Страница 104: ...gnostics parameter The device triggers a fault message if the current value exceeds one of the three configurable limit thresholds Threshold Limit 1 Use this sub parameter to set the limit threshold 1...

Страница 105: ...exceeds one of the three configurable limit thresholds The current value is displayed in the Position Average diagnostics parameter Monitoring Time This parameter is used to set the time interval to...

Страница 106: ...ld 2 in percent The device triggers a fault message if the difference between the position average and the reference average exceeds threshold 2 The value can be set from 0 1 to 100 0 Threshold Limit...

Страница 107: ...not trigger any message or alarm Custom The device triggers a fault message if average direction change value exceeds set threshold value The value can be set up to 100000000 Average Direction Change...

Страница 108: ...Posidapt Modern Expert Super Ultra and IPST This value displays the set point current input loop current input signal Number of Strokes Applicable for Posidapt Modern Expert Super Ultra and IPST The...

Страница 109: ...incremented every hour as soon as electric auxiliary power is supplied to the device This value displays number of operational hours of device Actuating Time Open Applicable for Posidapt Modern Expert...

Страница 110: ...apt Modern Expert Super Ultra and IPST This value displays the actuating time required for close down direction determined during auto calibration process The unit is seconds Pneumatic Leak Applicable...

Страница 111: ...rmined deviation from the actual model response The actual position course is compared with the expected position course for this purpose This comparison helps in drawing a conclusion about the correc...

Страница 112: ...e from full close position Value is automatically determined during auto calibration process Zero Set point Shift Applicable for Posidapt Super and Ultra This value displays the current displacement o...

Страница 113: ...splays the current displacement of the upper hard end stops open with respect calibration value The sub parameter Open in Tight shut off parameter is set to Custom to determine this value else Off is...

Страница 114: ...e for Posidapt Modern Expert Super Ultra and IPST Display feedback sensor value determined during auto calibration process in deg Fdbk Sensor Limit 2 Applicable for Posidapt Modern Expert Super Ultra...

Страница 115: ...Sensor Applicable for Posidapt Modern Expert Super Ultra and IPST Display feedback sensor current value in deg Servo Limit 1 Applicable for Posidapt Modern Expert Super Ultra and IPST Display spool f...

Страница 116: ...le for Posidapt Modern Expert Super Ultra and IPST Display spool feedback sensor value determine during auto calibration process Servo Feedback Applicable for Posidapt Modern Expert Super Ultra and IP...

Страница 117: ...a and IPST Display spool feedback sensor value determine during auto calibration process Dead band Applicable for Posidapt Modern Expert Super and Ultra This value displays the dead band of the contro...

Страница 118: ...d IPST This value displays the current temperature inside the enclosure Minimum Temperature Applicable for Posidapt Modern Expert Super Ultra and IPST This value displays the minimum temperature insid...

Страница 119: ...isplays the maximum temperature inside the enclosure recorded during continuous monitoring Supply Pressure Applicable for Posidapt Super and Ultra This value displays the current supply inlet pressure...

Страница 120: ...ring continuous monitoring Minimum Pressure Applicable for Posidapt Super and Ultra This value displays the minimum supply inlet pressure to the device recorded during continuous monitoring Number of...

Страница 121: ...Super and Ultra This value displays the total number of time alarm 1 is actuated during the operation The value can reset to zero Number of Times Alarm 2 Triggered Applicable for Posidapt Super and Ul...

Страница 122: ...RTX IOM PRODUCT YY Page 122 of 131 www rotexautomation com...

Страница 123: ...cording to their function application It can have up to 32 random ASCII characters Applicable with HART 7 Installation Date Applicable for Posidapt Expert Super Ultra and IPST Enter a date when the de...

Страница 124: ...ld there is no recommendation for this field Device Type Applicable for Posidapt Expert Super Ultra and IPST Type of connected device Model of the device Expert Super Ultra IPST Hart Revision Applicab...

Страница 125: ...ld can be used freely and helps to identify the manufacturer of the valve It can have up to 32 random ASCII characters Model Applicable for Posidapt Expert Super Ultra and IPST This field can be used...

Страница 126: ...to enter the description of the solenoid valve mounted It can be used to enter model manufacturer rating etc Volume Booster Quick Exhaust valve Applicable for Posidapt Expert Super Ultra and IPST This...

Страница 127: ...and Quick Exhaust Valve Type 1 Volume booster and quick exhaust valve size up to 1 2 Combination of Volume Booster and Quick Exhaust Valve Type 2 Volume booster and quick exhaust valve size above 1 2...

Страница 128: ...ily average dead band in percentage for past 24 hours 30 days 12 month and corresponding years This Average dead band value can be read from DTM or DD Average Dead band Past 24 Hours 0 48 Average Dead...

Страница 129: ...hroughout the valve movement and is switched back to Steady State when both set point and valve position have reached a steady state Record daily average deviation in percentage for past 24 hours 30 d...

Страница 130: ...ysis Dynamic Loop Test Dynamic loop test provides information on dynamic dead band of the valve assembly The valve will be open or close with the change in the input set point Valve Characteristic Tes...

Страница 131: ...URE Air Pressure related error Adjust pneumatic pressure 8 OVER SUPPLY PRESSURE Air Pressure related error Adjust pneumatic pressure 9 POSITION OUT RANGE Device not calibrated Feedback sensor related...

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