USER`S MANUAL - Rajdeep Industries Limited, Pune India
Contents
1. Repeatability 0 5 F S Internal Bleeding 3 0LPM Sup 1 4kgf cm 20psi Flow Capacity 80LPM Sup 1 4kgf cm 20psi Material Aluminum Die casting Weight 2 8 kg For Split Control it can be applied by adjusting zero and span For inquiry regarding strokes under 20mm PI contact ROTEX e Test under ambient temperature of 20 C absolute pressure of 760mmHg And humidity of 8096 Please contact us for more detailed specification 7 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Parts and Assembly 8 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Dimensions 90 15 47 5 31 _ faye ome ey i AN pe O JD e re Ses H 120 00 TL u f I Ke 35 40 57 Ed Installation Safety Warning When installing positioner please ensure to read and follow safety instruction e All input and supply pressure to valve actuator and other related devices must be turned off e Use bypass valve or other equipment to avoid entire system shut down e Make sure to exhaust air from actuator Tools for Installation 1 Adjustable wrench 2 Screw drivers amp 3 Allen Key bmm Amm 2 5mm 2mm RTX 1000R 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 butterfly2. 17 RTX1000 RO 2010 Pneumatic Positioner RTX 1000 series TROUBLE SHOOTING Positioner does not respond to the input signal 1 Check supply pressure level The level must be at least 1 4 kgf cm 2 Check if input signal is properly supplied to the positioner The signal should be 4 20mA DC 3 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 through the nozzle If the nozzle has been blocked by any substances please send the product to ROTEX for repair 4 Check if feedback lever has been installed properly 5 Check if zero point or span point is properly set 6 Check if feedback lever has been installed properly The pressure of OUT1 reaches exhausting pressure level and does not come back down 1 Check A M Switch If the switch has been damaged replace the switch or pilot relay valve 2 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 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 through the nozzle If the nozzle has been blocked by any substances please send the product to ROTEX for repair Hunting occurs 1 Check if safety spring has been displaced Next to Pilot relay valve 2 Check if the size of actuator i
3. 2010 Pneumatic Positioner RTX 1000 series Adjustment Seat Adjuster 1 Seat Adjuster is set according to the customer s request before the positioner is delivered Please do not adjust the Seat Adjuster 2 Seat Adjuster is used for double acting actuator always Please do not touch the Seat Adjuster because it can affect the positioner s performance Adjustment Orifice 1 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 90cm less 91 0 1 90 180cm 2 0 2 180cm and above None 3 2 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 3 If hunting persists after inserting the orifice please contact ROTEX or its appropriate agent ORIFI 16 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Fig 15 Maintenance Pilot valve 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 loose o ring or stabilizer spring Pl refer to Fig 16 for the instruction 1 Remove stopper bolt 2 Unlock the Auto manual Switch 3 Remove if there is any blocking within the port and orifice Fig 16
4. angle is equal to positioner s pressure gauge ERUIT INA Fig 12 14 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Adjustment Span Lock Screw iil 0 ULL SPAN m 9 Fig 13 1 After setting zero rotate Span screw so supply signal reaches at the span point on the indicator 2 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 3 For RTX 1000R with 1 2 split range the span spring must be changed 4 After setting is completed tighten Lock Screw Fig 13 Adjustment A M Switch Auto Manual 1 A M switch adjusts the valve operation to automatic or manual 2 When produced RTX 1000 series is set at A Automatic If user prefers the positioner s setting as M Manual the setting can be changed by turning the switch counter clockwise Fig 14 3 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 4 If OUT2 in single acting actuator or double acting actuator is used A M Switch will not operate Fig 14 neat Adjuster Auto Manual Switch Lock Screw 15 RTX1000 RO
5. 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 2 Check whether actuator s angle is at the initial point 3 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 4 When produced the cam is set as RA Counter clackwise Clockwise Bearing Reverse Acting Direct Acting Fig 11 13 RTX1000 RO 2010 Pneumatic Positioner RTX 1000 series Connection Cable Gland 1 Use certified explosion proof products 2 End of cable must be crimp style terminal PI refer to below table 3 Insert the terminal connection into the housing completely 4 Insert washer and rubber packing and fasten the cable gland completely Connection Power 1 Open positioner body cover 2 Locate the poles and connect them properly Make sure to fasten the connection 3 Close the cover completely Safety warning 1 Apply proper protection deice to reduce frictions 2 Protect the wires from damage 3 Grounding must be done properly according to the field s procedures Connection Ground 1 Open the positioner body cover 2 Locate the poles and connect them Adjustment Zero Point 1 Set supply signal at 3 psi and rotate adjuster clockwise or counter clockwise to adjust actuator s rotation angle Fig 12 2 When adjusting zero for single actuator rotation
6. current input signal range Supply Pressure Indicates the range of supply pressure Serial Number Indicates unique serial number Suffix Symbol RTX 1000 series follows suffix symbol as follows RTX 1000 1 2 3 a 5 le z a Rotary 1 Motion Type linear Single 2 Acting Type Double Nil 1 0mm 2 0mm Nil 50 100 150 200 BSP NPT 20 C 70 C 20 C 120 C 40 C 150 C Flat dome indicator High dime indicator Nil PTR Internal PTR External Explosion proof L S Internal L S External Explosion proof PTM L S Internal PTM L S External Explosion proof 3 Orifice 4 Feedback Lever AO 5 Connection Type 6 Ambient Temp TIIN O J N N OI N PO N O UW ra O 4 7 Indicator 8 Accessories O Q Q N O e For Special specification please contact our sales department 6 RTX1000 R0 2010 Pneumatic Positioner Specification RTX 1000 series Category RTX 1000R Input Signal 4 20mA Impedance 250 15 O Supply Pressure 1 4 8 0 kgf cm 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 Linear Equal SQ SQ RT Ambient Temp Standard 40 C 150 C Linearity 1 0 F S Hysteresis 1 0 F S Sensitivity 0 2 F S 0 5 F S
7. 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 1 RTX 1000 main assembly IOM 1 Set of bracket Not as a part of supply needs to be order separately 4 Socket set screw 4 Spring washer 4 Hexagon head bolt DRON 9 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series RTX 1000R Install Layout on Rotary Actuator POSITIONER LSP RING WASHER SCREW SOCKET SET ACTUATOR Fig 2 RTX 1000R on Rotary Actuator Bracket Information ol V INLET s a Ll SIGNAI v MON IH NPUT Ir tb Fig 3 RTX 1000R on NAMUR Shaft 10 RTX1000 RO 2010 Pneumatic Positioner RTX 1000 series RTX 1000 is supplied with standard bracket Please see above Figure for more detailed information Refer Fig 2 1 Standard actuator stem height H is 20 30 or 50mm After checking H assemble with the bracket as shown in Fig 3 amp 4 For bracket selection refer bracket selection chart in ROTEX positioner catalogue Fig 4 2 Attach bracketed RTX 1000 to the actuator by using slotted screw and hexagon nuts When tightening bolts use spring washer or sim
8. NAPADA ROAD DOMBIVLI E MAHARASTRA INDIA PIN 421204 3 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series General Service Information 8 9 Service procedure is offered as a guide to enable general maintenance to be performed on ROTEX Pneumatic Positioner Normal recommended service interval under normal working condition for Pneumatic Positioner is five years It may vary on usage performance ratio Note Storage time is counted sad part of the service interval Storage temperature 20 C to 70 C This procedure is applicable with the understanding that all pneumatic pressure has been removed from the positioner Remove all piping amp mounting accessories that will interface with the module s that are to be worked on This procedure should only be implemented by a technically competent technician who should take care to observe good workmanship practices Number in parentheses indicates the bubble number reference number used on the ROTEX assembly drawing When removing seals from seal grooves use a commercial seal removing tool or a small screw driver with sharp corner rounded off Use a non hardening thread sealant on all pipe thread CAUTION Apply the thread sealant per the ROTEX s instruction 10 ROTEX recommends that servicing of the positioner should be done in a clean area on a workbench 4 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Product Description Main Features a
9. Pneumatic Positioner RTX 1000 series Electro Pneumatic Positioner RTX Series USER S MANUAL ROTEX E P Ver 0 1 Dated dd mm yy Page 1 of 18 1 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Table of Contents Introduction 3 Manufacturer Warranty 3 General Service Information 4 Product Description 5 Label Description 6 Suffix Symbol 6 Specification 7 Parts and Assembly 8 Dimension 9 Safety Warning 9 Tools for Installation 9 RTX 1000 Installation 9 Bracket Information 10 11 Piping Connection 12 Supply Pressure Condition 12 Pipe Condition 12 Piping Connection with Actuator 12 Single Acting Actuator 12 Double Acting Actuator 13 Adjustment 13 Adjustment Cam 13 Connection Cable gland 14 Adjustment Zero 14 Adjustment Span 15 Adjustment A M Switch Automatic Manual 15 Adjustment Seat Adjuster 16 Adjustment Orifice 16 Maintenance pilot Valve 17 Trouble Shooting 18 2 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Introduction 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 1 The manual should be given to the end user 2 The manual can be changed or revised without an
10. d the range of 1 4 8 kgf cm2 140 700 kPA e Set air filter regulator s supplied pressure 10 higher than actuator s spring range pressure Pipe Condition Before piping conduct air blow to clean the inside of the pipe to get rid of extraneous materials powers etc Do not use apparatus or joint which could cause leakage and resistance in the pipe Do not use pipeline that is squeezed or has hole To maintain flow rate use the pipeline that has more than 6mm inner diameter 10mm outer diameter e Do not use extremely long pipeline system It may affect flow rate due to the friction inside of the pipeline e When connecting pipes be sure that sealing tape on adhesive does not mix with the pipes Pipe Connection with actuator 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 amp 8 SIGNAL OY INPUT ih Fig 7 Fig 8 12 RTX1000 RO 2010 Pneumatic Positioner RTX 1000 series Double acting actuator For RTX 1000R series double acting type when inputting current signal supply pressure is out from OUT1 Please refer to Fig 9 amp 10 SIGNAL NPUT Fig 9 Fig 10 Adjustments Adjustment Cam 1 Direction of actuator s stem rotation must be checked when supply signal is supplied When actuator s stem rotates clockwise the face of
11. ilar for firm attachment to the actuator so RTX 1000 have no effect by vibration or any other impact The positioner is installed as shown in Fig 5 Fig 5 3 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 4 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 RTX1000 RO 2010 Pneumatic Positioner RTX 1000 series Piping Connection RTX 1000 has a nozzle with a very small orifice thus use clean and less humid air in order to prevent extraneous material from mixing into the air As per the filter pay attention to filtration rating flow rate mounting position etc Note e To avoid entering moisture oil or dust into the product please carefully make selection of supply pressure compressor e It is recommended to attach air filter regulator before supply port of RTX 1000 Supply Pressure Condition Dry air with at least 10 C lower than ambient temperature Avoid from dusty air 5 micron filter provided Avoid any oil Comply with ANSI ISA 57 3 1975 R1981 ISA S7 3 1975 R1981 e Not to be used beyon
12. nd Functions e The product can operate normally in very extreme environment such as vibration e The durability has proven after testing of 1 million times at least e Response time is very short and accurate e Simple part change can set 1 2 Split Range e t is economical due to less air consumption e Direct Reverse action can be set easily e Zero amp Span adjustment process is simple Feedback Connection is easy Operation Logic OUT 1 X OUT 2 SUPPLY N N Oy N Moy f MJ Input Signal 4 20 mAmp RTX 1000R Fig 1 If supply pressure increased flapper 2 gets pushed by the force from torque motor 1 As the gap between flapper 2 and the nozzle 3 increases air pressure exhausts from pilot valve 40 and upper spool 5 As a result spool 5 rises Then the air pressure will be supplied to the actuator 10 As actuator 10 moves the cam 16 receives the movement This movement pulls the span spring 13 Fig 1 5 RTX1000 R0 2010 Pneumatic Positioner RTX 1000 series Label Description f ELECTROPNEUMATIC POSITIONER C c H C T E gt Ex 1 2 GD T6 www rotexindia com y MODEL RTX 1000 AMBIENT TEMP 20 C 70 C WEATHER PROOF IP 65 SUPPLY PR 1 4 8 0 bar INPUT SIGNAL 4 20 mAmp SERIAL NO y Model No Indicates model name and any options if any Input Signal Indicates
13. s too small If so insert an orifice in order to reduce the pressure flow rate 3 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 1 Check pipe connection 2 Check cam direction Linearity is too low 1 Check if the feedback lever is properly installed Especially check if the feedback lever is parallel to the ground at 50 point 2 Check if zero and span have been properly adjusted that is not too low or nottoo high 3 Check if supply air pressure level is stable from the regulator If the level is unstable replace the regulator Hysteresis is too low 1 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 2 Backlash can occur when feedback lever and lever spring is loosen To avoid backlash adjust the lever spring 3 Check if the connection bar to the feedback lever is tightly fastened 18 RTX1000 RO 2010
14. y prior notice Any changes in product s specification structure and or any components may not result immediate revised version of the manual 3 The manual should not be duplicated or reproduced for any purpose without any consent of Rotex Manufacturers amp Engineers Private Limited INDIA Manufacturer Warranty e 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 e It is not ROTEXS 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 e ROTEX warrants the product from the date of original retail purchase of the product for one 1 year except as otherwise stated e 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 e For detailed warranty information please contact ROTEX MANUFACTERURS amp ENGINEERS PRIVATE LIMITED MA
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