Rexa Manual X2 Iom 10-2014 1s165o

Installation and Operation Manual for the REXA Series 2 Xpac IOM 10/2014 Original Instructions ISO 9001: 2008 REXA Electraulic™Actuation

Serial #____________________________ Model #___________________________ Application________________________ Tag # _____________________________

REXA

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4 Manley Street

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W. Bridgewater, MA 02379

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(P) 508.584.1199

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(F) 508.584.2525

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Contents FUNDAMENTAL SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . XI WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii When to Lock-Out/Tag-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Procedures: Lock-Out/Tag-Out. . . . . . . . . . . . . . . . . . . . . . . . . xvi Education and Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii PRODUCT COMPLIANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIX INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . xx ATEX Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . xxi Declaration of Noise Emission. . . . . . . . . . . . . . . . . . . . . . . . . . xxii Waiver of Translations Agreement. . . . . . . . . . . . . . . . . . . . . . xxiii Waiver of Mains Supply Disconnect / Emergency Stop Agreement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv 1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 About Rexa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Actuator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2

Figure 1.3 ID Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.1 Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 1.3.1 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.3.2 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.3.3 Build Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.4 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.4.1 Recommended Fluids and Lubricants . . . . . . . . . . . . . . 5 1.4.2 Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 1.4.2-1 Linear Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 1.4.2-2 Rotary Actuators & Drives . . . . . . . . . . . . . . . . . . . . . . 6 Table 1.4.2-3 CSA Temperature Ratings . . . . . . . . . . . . . . . . . . . . . . 7 1.4.3 Relative Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4.5 Transportation and Storage. . . . . . . . . . . . . . . . . . . . . . . 8 1.5 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Monthly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.6 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.6.1 Oil Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.6.2 Standard Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Figure 1.6.2-4 External Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 1.6.2-1 Add oil indication . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 1.6.2-2 Full oil indication . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 1.6.2-3 Oil Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.6.3 Accumulator Fail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 1.6.3 Reservoir Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12



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1.6.4 Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Figure 1.6.4-1 Castrol EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Figure 1.6.4-2 Fill Valve with cover. . . . . . . . . . . . . . . . . . . . . . . . . 14 Figure 1.6.4-3 Fill the oil gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Figure 1.6.4-4 Purge the air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Figure 1.6.4-5 Oil Pump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 1.6.4-6 Fill Valve with Schrader fitting. . . . . . . . . . . . . . . . . 15 1.6.5 Overfilling, Oil Weeping & Thermal Expansion . . . . . . . 16 1.6.6 Air Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.6.7 Reservoir Purging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Figure 1.6.7-1 Reservoir Purging Ports . . . . . . . . . . . . . . . . . . . . . . 17 Figure 1.6.7-2 Full Indicator “OK”– flush with front face . . . . . . . . . 18 1.6.8 Hydraulic System Purging. . . . . . . . . . . . . . . . . . . . . . . 18 Figure 1.6.8-1 Extend/CW and Retract/CCW Ports . . . . . . . . . . . . . 19 Figure 1.6.8-2 Bleed Kit (PN: K09275) . . . . . . . . . . . . . . . . . . . . . . 20 1.7 Tool Requirements (Power Module Only) . . . . . . . . . . . . . . . . 20 1.8 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.8.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.8.2 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Figure 1.8.2-1 B Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Figure 1.8.2-2 C Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Figure 1.8.2-3 ½D, & D Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 1.8.2-4 C &D Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.8.3 Control Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 26 Figure 1.8.3 Typical Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . 27 Table 1.8.3-1 Control Enclosure Terminal Blocks . . . . . . . . . . . . . . 28 Table 1.8.3-2 Actuator Terminal Blocks . . . . . . . . . . . . . . . . . . . . . 28 1.8.4 Operational Summary. . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 1.8.4-1 Hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 1.8.4-2 By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2 DELIVERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Unpacking System, Lifting. . . . . . . . . . . . . . . . . . . . . . . 2.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 Operational and Maintenance Clearances. . . . . . . . . . . 2.4.2 Hazards Due to Height. . . . . . . . . . . . . . . . . . . . . . . . . .

31 31 31 32 32 32 32 33

3 ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Control Enclosure Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.1 Control Enclosure Installation. . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 3 Electrical Installation Block Diagram . . . . . . . . . . . . . . . . . 36 3.2 Main Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 3.2 Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Table 3.2 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.2.1 Supply Disconnect Device . . . . . . . . . . . . . . . . . . . . . . 38 3.2.2 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.2.3 Grounding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 3.2.4 Main Power Supply Wiring. . . . . . . . . . . . . . . . . . . . . . . 40 3.2.5 Cordage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 3.2.6 Fuse Identification / Replacement . . . . . . . . . . . . . . . . . 42 3.3 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Cable (Stepper & Servo Motor Units) . . . . . . . . . . 44 Power Module Cable (Stepper Motor Units). . . . . . . . . . . . . . 44 Heater/Solenoid Cable (Servo Motor Units Only). . . . . . . . . . 45 Motor Resolver Cable (Servo Motor Units Only). . . . . . . . . . . 45 Motor Power Cable (Servo Motor Units Only) . . . . . . . . . . . . 46 Booster Cable (D,P9 and D,P40 Units Only). . . . . . . . . . . . . . 46 D,P9 (REXA P/N #P97117). . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 D,P40 (REXA P/N #P97882) . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.3.1 Cable Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Table 3.3.1 Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 3.3.2 Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.4 Conduit and Conduit Fittings. . . . . . . . . . . . . . . . . . . . . . . . . 48 4 MECHANICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.1 Pre-Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.2 R Series (Rotary). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 4.2.1 Rotary Mounting (Fail in Place). . . . . . . . . . . . . . . . . . . 51 4.2.2 Rotary Mounting (Universal Spring Fail). . . . . . . . . . . . 52 Figure 4.2.2 Solenoid Override Position . . . . . . . . . . . . . . . . . . . . . . 52 4.2.3 Rotary Mounting Accumulator. . . . . . . . . . . . . . . . . . . 53 4.3 L Series (Linear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 4.3.1 Linear Mounting (Fail in Place) . . . . . . . . . . . . . . . . . . . 55 4.3.2 Linear Mounting (Spring Fail) . . . . . . . . . . . . . . . . . . . . 56 Figure 4.3.2 Solenoid Override Position . . . . . . . . . . . . . . . . . . . . . . 57 4.3.3 Linear Mounting Accumulator. . . . . . . . . . . . . . . . . . . . 57 4.4 D Series (Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4.4.1 Drive Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Table 4.4.1 Drive Base Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 4.4.2 Drive Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 4.4.2-1 Drive Arm Assembly Reference Drawing . . . . . . . . . 59 Figure 4.4.2-2 Drive Arm Alignment . . . . . . . . . . . . . . . . . . . . . . . 60 5 START-UP CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Inspection of Electronic Sub-Assembly Installation. . . 5.1.2 Inspection of Mechanical Actuator Installation. . . . . . . 5.2 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Lateral Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



61 61 61 62 62 63

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5.2.2 Longitudinal Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 63 5.3 Initial Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.4 Rotary and Drive Spring Stops . . . . . . . . . . . . . . . . . . . . . . . 66 Figure 5.4 Universal Spring Alignment . . . . . . . . . . . . . . . . . . . . . . 66 5.5 Cylinder End Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Figure 5.5 Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.5.1 End Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Figure 5.5.1-1 Cylinder End Stops . . . . . . . . . . . . . . . . . . . . . . . . . 68 Figure 5.5.1-2 End Stop Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Table 5.5.1 Stroke Adjustor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 5.5.2 R200 000/R400 000 End Stroke Adjustments. . . . . . . . 70 Figure 5.5.2 R200 000/R400 000 Stroke Adjuster . . . . . . . . . . . . . . 71 6 MODES OF OPERATION & CONTROL PARAMETERS . . . . . . . . . 72 Figure 6 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6.1 Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6.1.1 Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 6.1.1 Control Parameter Menus . . . . . . . . . . . . . . . . . . . . . . 74 6.1.2 Changing a Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . 75 6.1.3 CALIBRATE Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 6.1.4 CONTROL Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 6.1.5 SPEED/ACCEL Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 6.1.5 Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Hi Accel {High Acceleration}: Drive Type = Step . . . . . . . . . . 82 Hi Accel {High Acceleration}: Drive Type = Servo . . . . . . . . . 82 6.1.6 INPUTS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 6.1.7 DRIVES Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 6.1.8 OUTPUTS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 6.1.9 CURRENT STATS Menu and HISTORIC STATS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6.2 Auto Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 6.2.1 Display Fields in Auto Mode. . . . . . . . . . . . . . . . . . . . . 99 6.2.2 Display Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 100 6.2.3 Parameter Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 6.3 Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Figure 6.3 s Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . 103 A. MECHANICAL LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1 Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1.2 Linear Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.1.3 Linear Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Figure A.1 Linear Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.2 Rotary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.2.1 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . A-4 Figure A.2 Rotary Limit Switch Schematic . . . . . . . . . . . . . . . . . . A-5

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A.2.2 Rotary Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A.2.3 Rotary Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Figure A.2.3 Rotary Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . A-6 B. STEM CONNECTION & SEAT LOADING METHODS . . . . . . . . . B-1 B.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 B.2 Elastic Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 Figure B.2-1 Preloaded Coupling . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Figure B.2-2 Rated Load Coupling . . . . . . . . . . . . . . . . . . . . . . . B-2 B.3 Seat Loading Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Figure B.3 Seat Loading Cylinder . . . . . . . . . . . . . . . . . . . . . . . . B-3 B.3.1 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . B-4 B.3.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Table B.3.2 SLC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Figure B.3.2 SLC Board . . . . . . . . . . . . . . . . . . . . . . . . B-5 B.4 Solenoid Auto-Seating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 B.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Figure B.5-1 SLC Indicator–Seated . . . . . . . . . . . . . . . . . . . . . . . B-7 Figure B.5-2 Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 C. ACCUMULATOR FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 C.1.1 Trip Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Figure C.1.1-A Trip Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 C.1.2 Recharge Function. . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Figure C.1.2-B Recharge Condition . . . . . . . . . . . . . . . . . . . . . . . C-3 C.2 Accumulator Control Parameters. . . . . . . . . . . . . . . . . . . . C-4 DRIVES Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C.3 Recharging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 C.4 Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Figure C.4-1 Solenoid Manual Override Levers (Position A) . . . . . C-5 Figure C.4-2 Solenoid Manual Override Levers (Position B) . . . . . C-6 C.5 Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7 Figure C.5 By Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7 D. BOOSTER PUMP CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . D.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2.1 Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . D.3 Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.4 Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D-1 D-1 D-1 D-2 D-2 D-2

E. PULSE OPERATING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 E.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 E.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Figure E.2-1 Input Board Wiring Options . . . . . . . . . . . . E-2 Figure E.2-2 Input Board Wiring Options . . . . . . . . . . . . E-2 E.3 Signal Input Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3



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ON state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFF state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.4 Pulse Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . E.5 Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-3 E-3 E-3 E-4

F. ERRORS AND ERROR DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . FB bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CS bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dir error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drv fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +15 fail or - 15 fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pres bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pres low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Op Pres bad or Cl Pres bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slc Fb bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slc stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mem fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No inp bd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/D fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-1 F-1 F-2 F-2 F-2 F-3 F-3 F-3 F-4 F-4 F-4 F-5 F-5 F-5 F-6 F-6 F-6 F-7

G. SURGE CONTROL OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 G.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 Figure G.1-1 Overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Figure G.1-2 Target position . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Figure G.1-3 Undershoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 G.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 G.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 Figure G.3-1 Surge Solenoid Connection . . . . . . . . . . . . . . . . . . .G-5 Figure G.3-2 Solenoid & “Wet” Trip Connection . . . . . . . . . . . . . G-6 Figure G.3-3 Solenoid & “Dry” Trip Connection . . . . . . . . . . . . . . G-7 H. BUILD NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1 Linear Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2 Rotary Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3 Electronic Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . H-4 Mounting Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Linear Series Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Rotary Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5 Drive Series Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6 Linear Fisher Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7 K. FIELDBUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1 Resource block: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-2

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Analog Output block (AO). . . . . . . . . . . . . . . . . . . . . . . . . . . K-2 Anaput blocks (AI). . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3 Discrete Output block (DO). . . . . . . . . . . . . . . . . . . . . . . . . . K-4 Discrete Input block (DI). . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 Transducer block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-5 X2 Actuator Configuration Parameters. . . . . . . . . . . . . . . . . K-5 Other X2 actuator parameters:. . . . . . . . . . . . . . . . . . . . . . . K-8 ERROR_BYTE1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-10 ERROR_BYTE2:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11 ERROR_BYTE3:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11 X2 Actuator Data Collection Parameters. . . . . . . . . . . . . . K-11 M. MANUAL OPERATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 M.1 Declutchable Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . M-1 Figure M.1-1 Handwheel Assembly . . . . . . . . . . . . . . . . . . . . . . . M-2 Figure M.1-2 Drill Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 Figure M.1-3 Drill Drive with Drill . . . . . . . . . . . . . . . . . . . . . . . . . M-2 M.1.2 Declutchable Drill Drive . . . . . . . . . . . . . . . . . . . . . . M-2 M.2 Manual Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . M-3 Figure M.2 Manual Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . M-4 M.3 Fail Safe Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 Figure M.3 Solenoid Manual Override Levers (Position B) . . . . . . . M-5 N. DIGITAL COMMUNICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1 N.1 HART® Field Device Specification. . . . . . . . . . . . . . . . . . . N-3 1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6 1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6 1.2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6 1.3 Who should use this document?. . . . . . . . . . . . . . . . . . N-6 1.4 Abbreviations and definitions. . . . . . . . . . . . . . . . . . . . . N-6 1.5 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7 2. Device Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7 3. Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7 4. Product Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8 4.1 Process Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8 4.2 Host interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8 4.3 Local Interfaces, Jumpers And Switches . . . . . . . . . . . N-8 5. Device Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9 6. Dynamic Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9 7. Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9 7.1 Device Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9 7.2 Additional Device Status (Command #48). . . . . . . . . . N-10 8. Universal Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-12 8.1 ed Commands. . . . . . . . . . . . . . . . . . . . . . . . . N-12 9. Common-Practice Commands . . . . . . . . . . . . . . . . . . . . . . N-21



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9.1 ed Commands. . . . . . . . . . . . . . . . . . . . . . . . . N-21 9.2 Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-27 10. Device-Specific Commands . . . . . . . . . . . . . . . . . . . . . . . N-27 10.1 ed Device Specific Commands. . . . . . . . . . . N-27 11. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-28 12. Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29 12.1 Sampling Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29 12.2 Power-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29 12.3 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29 12.4 Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29 12.5 Command Response Times. . . . . . . . . . . . . . . . . . . . N-30 12.6 Delayed-Response. . . . . . . . . . . . . . . . . . . . . . . . . . . N-30 12.7 Non-Volatile Memory. . . . . . . . . . . . . . . . . . . . . . . . . N-30 12.8 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30 12.9 Write Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30 12.10 Damping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30 ANNEX A. Capability Checklist. . . . . . . . . . . . . . . . . . . . . . . . N-31 ANNEX B. Hart® Interface Board Connection. . . . . . . . . . . . N-32 O. OUTPUT LOAD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 O.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 O.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 Table O.2 Adjustment Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1 Figure O.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . O-2 O.3 Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-3 O.4 Spring Change: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-3 P. INTERCONNECT DIAGRAMS & CONTROL ENCLOSURE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . P-1 D97904 — Stepper Wiring Diagram . . . . . . . . . . . . . . . . . . . . . P-2 B Quick Connect Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3 C Quick Connect Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4 D97904-.5d — ½D Servo Wiring Diagram. . . . . . . . . . . . . . . . . P-5 ½D Quick Connect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6 D97904-D — D Servo Wiring Diagram. . . . . . . . . . . . . . . . . . . . P-7 D Quick Connect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8 D97904-2D — 2D Servo Wiring Diagram. . . . . . . . . . . . . . . . . . P-9 D97904-P9 — D,P9 Servo Wiring Diagram . . . . . . . . . . . . . . . P-10 D97904-P40 — D,P40 Servo Wiring Diagram . . . . . . . . . . . . . P-11 D97904-STEPACCUM — Stepper with Accumulator Fail Opt. . P-12 D97904-.5DACCUM — ½D Servo with Accumulator Fail Opt. . P-13 D97904-DACCUM — D Servo with Accumulator Fail Opt . . . . . P-14 D97904-2DACC — 2D Servo with Accumulator Fail Opt . . . . . . P-15 D97904-P9ACC — D,P9 Servo with Accumulator Fail Opt. . . . P-16 D97904-P40ACC — D,P40 Servo with Accumulator Fail Opt. . . P-17

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B and C-Pump Control Enclosure Drawing . . . . . . . . . . . . . . P98492 — Control Enclosure for Quick Connect Cables . . . ½D and D-Control Enclosure Drawing (QCC) . . . . . . . . . . . . . ½D and D-Pump Control Enclosure Drawing . . . . . . . . . . . . . 2D & DP9 Control Enclosure Drawing . . . . . . . . . . . . . . . . . . . DP40 Control Enclosure Drawing. . . . . . . . . . . . . . . . . . . . . . .

P-18 P-19 P-20 P-21 P-22 P-23

Q. INPUT OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1 Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1 Q.1 Signal Input Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1 ON state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2 OFF state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2 Q.2 1 Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2 Figure Q.2-1 1 Cont “Dry” Input Board . . . . . . . . . . . . . . . . . . Q-3 Figure Q.2-2 1 Cont “Wet” Input Board . . . . . . . . . . . . . . . . . . Q-4 Q.3 2 Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-4 Figure Q.3-1 2 Cont “Dry” Input Board . . . . . . . . . . . . . . . . . . Q-5 Figure Q.3-2 2 Cont “Wet” Input Board . . . . . . . . . . . . . . . . . . Q-6 R. REMOTE MANUAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . R-1 R.1 Remote Manual (RemoteMan). . . . . . . . . . . . . . . . . . . . . . . R-1 Figure R.1-1 “Dry” s Input Board . . . . . . . . . . . . . . . . . . . R-2 Figure R.1-2 “Wet” s Input Board . . . . . . . . . . . . . . . . . . R-3 S. SAFETY MANUAL FOR ESD SIL COMPLIANCE. . . . . . . . . . . . . S-1 S.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 Figure S.1 Example Safety Instrumented Function . . . . . . . . . . . . . s-2 S.2 System Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 S.3 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2 S.4 Safety Critical Components . . . . . . . . . . . . . . . . . . . . . . . . S-3 S.5 System Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3 S.6 Site Acceptance Test Procedures. . . . . . . . . . . . . . . . . . . . S-4 S.7 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . S-5 T. POSITION TRANSMITTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 T.1 Position Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2 Figure T.1-1 Figure T.1-2

ive Position Transmitter Connections . . . . T-3 Active Position Transmitter Connections . . . . . T-4

U. ELECTRONIC RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1 U.1 Limit Switch Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1 U.2 Alarm and Warning Relay. . . . . . . . . . . . . . . . . . . . . . . U-1 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-2 Figure U-1 U Board’s Electronic Relays . . . . . . . . . . . . . . . . . . U-3 V. LOCAL MODE INDICATION BOARD. . . . . . . . . . . . . . . . . . . . . . . V-1 Local Mode Indication Board. . . . . . . . . . . . . . . . . . . . . . . . . . . V-1 Figure V-1 Local Mode Indication Board . . . . . . . . . . . . . . . . . . . V-2



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x Contents

W. ELECTRONIC UNIT RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . W-1 Table W-1 Electronic Unit Ratings . . . . . . . . . . . . . . . . . . . . . . . . W-3 X. REDUNDANT CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . X-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1 X.1 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2 X.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2 X.2.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2 X.2.2 Redundant Interconnections. . . . . . . . . . . . . . . . . . . . X-3 X.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-3 X.4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-4 X.5 U Set Up for MAIN and Backup. . . . . . . . . . . . . . . . . . . . X-4 X.6 Simultaneous CALIBRATE . . . . . . . . . . . . . . . . . . . . . . . . . . X-4 X.7 AUTO Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-6 X.8 Redundant High Speed Solenoids for Spring Fail Operation. . X-6 Figure X. Redundant Unit Interconnection Diagram . . . . . . . . . . . X-7

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xi

Fundamental Safety Information

REXA actuators all produce extremely high forces, have hydraulic lines under pressure and have dangerous electrical power input levels. In addition to these standard characteristics, optional actuator constructions possess other hazards such as coil and disk springs under compression and high pressure accumulator bottles.

WARNINGS Based on these hazards, the following could occur if this safety information is not observed: •

Serious physical injury

•

Death

•

Damage to actuator or other equipment

Always observe the safety information listed in this documentation.

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xii

Safety Considerations

WARNING LABELS Hazardous Voltage Turn Off and Lock Out system power before servicing. Do Not Operate this equipment from any power source that does not match the voltage rating stamped on the equipment. Refer to the manufacturer’s identification nameplate for operational requirements. General Warning Refer to Installation Manual before servicing. Attention Important information provided. Do No Use this equipment for any purpose not described in this manual. Crush or Pinch Point Hazard Turn Off and Lock Out system power before servicing. Warn of Actuator movement if Spring Fail Unit. Guard Warning All Guards MUST be in place before operation. Failure to do so may result in injury or damage to equipment. Tripping, Slipping and Falling Hazards These hazards can be avoided by cleaning spilled hydraulic oil in a timely manner. •

Airborne noise greater than 80 dB, ear protection suggested.

•

Using the actuator for uses other than what it is intended may result in injury or death. Use the Actuator for its intended purpose ONLY.

•

Do not use the Actuator should it be damaged in shipping or installation. REXA, Inc.

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11 xiii

RESIDUAL RISKS This section is to help identify the risks associated with the Actuator System. These items are identified as: ACTUATOR & DRIVEN DEVICE CONNECTION: The point at which the actuator couples to the driven device poses the risk of injury due to pinch or crush point. Use appropriate Lock-Out/Tag-Out procedures when connecting Actuator to the driven device. MANUAL OVERRIDE HANDWHEEL ASSEMBLY: The Manual Override Handwheel Assembly is to remain declutched until it is required. The Motor Shaft Cover MUST be in place during normal operation. Failure to do so poses a risk of injury. MANUAL OVERRIDE HANDWHEEL ASSEMBLY: When the Manual Override, Handwheel Assembly is used, adhere to proper Lock-Out/Tag-Out procedures. COVER: Cover MUST be in place during operation. Failure to do so may result in injury. Use proper Lock-Out/Tag-Out procedures before accessing housing. SHOCK HAZARD: Wire Cover must be in place during operation. Use proper LockOut/Tag-Out procedures before removing cover. SHOCK HAZARD: Control Enclosure Cover must be closed during normal operation. Failure to do so may result in injury. Use proper Lock-Out/Tag-Out

Safety Considerations

xiv

Safety Considerations

procedures before accessing Control Enclosure. SHOCK HAZARD: Hazardous voltage levels are present in the actuator. Only qualified service and installation personnel should install or adjust this device. ALIGNMENT: Ensure that the actuator shaft is in line with the valve plug stem. Misalignment could damage the actuator and driven device or cause injury to installation personnel. AVOID ACCIDENTAL STARTING: When installing the actuator, insure that line power to the unit is shut off. When power is applied, the actuator may immediately respond to the control signal. Inadvertent motion could damage the actuator and driven device or cause injury to installation personnel. IMPORTANT: When machining the control enclosure, thoroughly clean any metal chips or residue from the enclosure before applying power. HYDRAULIC OIL: The standard oil used in REXA actuators or drives is Castrol EDGE® SAE 5W-50 motor oil. The introduction of other fluids may cause damage to the unit. SPRING UNDER TENSION: REXA actuators, denoted by an E, R or U as the last character in the model number, contain a spring under tension. Failure to properly remove this force before disassembly can cause serious injury to maintenance personnel. REXA for disassembly

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11 xv

instructions. RELIEVING INTERNAL PRESSURE: When the electric power is off or the motor is not turning, hydraulic pressure remains locked within the cylinder and/or accumulator. This internal pressure must be relieved before disconnecting any hydraulic fitting. Open the by cylinder (3/16” hex) located on the power module for fail in place units and manually override all solenoid valves that are closed. Note: Reservoir lines may contain up to 60 psi (4 bar) that cannot be relieved. Note: Accumulators will still contain up to 2 000 psi (138 bar) of nitrogen gas that cannot be relieved.

ACCUMULATOR FAIL OPTION: REXA actuators denoted by an A as the last character in the model number contain an accumulator charged with high-pressure nitrogen. These actuators also have an automatic recharging cycle for the accumulator. Failure to properly follow installation instructions may cause serious injury to maintenance personnel and/or damage to equipment.

NPT PLUG and CONDUIT CONNECTIONS: During assembly, Loctite® 767 compound—or its equivalent—must be used on threads of all NPT plug and conduit connections to ensure a watertight seal. WHEN TO LOCK-OUT/TAG-OUT Lock-out/Tag-out before servicing.

Most equipment is installed along with safe switches allowing the equipment to be disabled for minor repair. In general, these switches provide adequate

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xvi

Safety Considerations

protection for minor repair, which is routine, repetitive, and necessary to the normal use of the equipment. Lock-Out/Tag-Out procedures shall be used for the following situations. •

Major repairs or overhaul.

•

When working alone, out of visual of the controlling switch.

•

Anytime there is danger of injury from an unexpected release of energy.

•

Any situation that threatens an employees safety.

Note: Always follow local & plant procedures.

PROCEDURES: LOCK-OUT/TAG-OUT The following are minimum recommended procedures to be followed for Lock-Out/Tag-Out: 1. Notify all affected areas and employees of the impending Lock-Out situation, the reason for it, and estimated start and duration times. 2. Equipment shutdown and isolation: Place all switches in the “off” or “safe” position. Disconnect sources of power, ensuring all sources of both primary and secondary power to the equipment are interrupted. 3. Dissipate residual energy. Shutting down equipment does not mean there is no energy left in it. Check for trapped pressure, compressed spring or residual electricity in the system. 4. Lock-Out or Tag-Out all in-line points of control. In most cases, there may be more than one place, or more than one lock, if several people are working on the equipment. 5. Lock-Out verification: Take nothing for granted. that the lockedout switch or control cannot be overridden. Test the equipment to be certain that the locked-out switch is de-energized, and not simply

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11 xvii

malfunctioning. Test all control points and modes to be sure that the equipment does not start. 6. Perform the work scheduled. Try to foresee all possible hazards. Ensure the new/repair work does not by the Lock-Out and reactivate the system. 7. Lock and/or tag removal. All locks and tags are to be left in place until all work is completely finished. This is especially true when more than one employee is working on the equipment. A lock is never to be removed except by the person who placed it there. 8. Equipment start-up. Make a final safety check before restarting equipment, to be certain it is safe to operate. Make sure of the following: a) All tools and other items have been removed. b) All machine guards are returned to their proper position. All electric, hydraulic, pneumatic or other systems are properly reconnected. c) All employees are clear of equipment. Many of the Lock-Out/Tag-Out procedures appear to be common sense, and they are. Following them will ensure safe operation calibration, maintenance and repair of equipment and/or processes, without dangerous surprises or injury.

EDUCATION AND DISCIPLINE The key to worker safety is education. The purpose of this document is for everyone to understand the importance of Lock-Out/Tag-Out and how to recognize when it is in use. By educating all employees to the importance of following proper safety procedures, we ensure a safer working environment. As with all safety procedures, a fair uniform enforcement of discipline must be in place. Employees are responsible for their own safety, the safety of their fellow employees and the safety of the facility.

Safety Considerations

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xix

Product Compliance

INFORMATION Inclusion of the following symbols indicates that the supplied REXA actuator complies with applicable standards:

For the U.S. and Canada: A CSA mark with the indicators “C” and “US” means that the product is certified for both the U.S. and Canadian markets, to the applicable U.S. and Canadian standards. The REXA Actuator/Drive with Control Enclosure is certified by CSA for use in General Locations per EN 61010-1 and for Hazardous Locations Class 1, Division 2, Groups A, B, C and D or Class 1, Division 1, Groups C and D.

A

mark indicates that the product is certified for European markets, and complies to the standards listed in the Declaration of Conformity.

Product Compliance

xx

Product Compliance

EC DECLARATION OF CONFORMITY ACCORDING TO: MACHINERY DIRECTIVE 2006/42/EC EMC DIRECTIVE 2004/108/EC PED DIRECTIVE 97/23/EC (APPLIES WHERE APPLICABLE) We, REXA, Inc., Hereby declare under our sole responsibility, the following products to be in compliance by design according to the relevant essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU representative below. In case of alteration of the product, not agreed upon by us, this declaration will lose its validity. Manufactured:

4 Manley Street West Bridgewater, MA 02379 USA

EU Authorized Representative: Koso Kent Introl Limited Armytage Road Brighouse, West Yorkshire HD6 1QF : Brian Richmond (QHSE Director) or Jonathan Lodge (Technical Director) Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407 Brand Name:

(REXA)

Product Description: X-Pac and X2 Series Electraulic (Self-Contained Electro-Hydraulic) Actuator and Drive Systems Models:

Linear, Rotary and Drive Units Servo or Stepper Units

Applicable Directives: Machinery Directive 2006/42/EC including Low Voltage Directive EMC Directive 2004/108/EC PED Directive 97/23/EC; applies where applicable, to accumulator systems Applicable Harmonized Standards: Health/Safety: Machinery Directive 2006/42/EC Annex I, EN60204-1:2006, EN ISO 12100:2010, EN61310-1:1995, EN61310-2:1995, EN ISO 13850:2006, IEC61010-1:2001 EMC:

EN61326-1:2006, EN61000-6 Part -2:2005 and -4:2007; EN55011:2007: IEC61000-4-2:2008, IEC 61000-4-3:2010, IEC61000-4-4:2010, IEC61000-4-5:2005, IEC61000-4-6:2008, IEC61000-4-8:2009, IEC61000-4-11:2004

PED:

Directive 97/23/EC; designed as ‘Sound Engineering Practice’ Equipment

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xxi

ATEX DECLARATION OF CONFORMITY ACCORDING TO: DIRECTIVE 94/9/EC We, REXA, Inc., Hereby declare under our sole responsibility, the following products to be in compliance by design according to the relevant essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU representative below. In case of alteration of the product, not agreed upon by us, this declaration will lose its validity. Manufactured:

4 Manley Street West Bridgewater, MA 02379 USA

EU Authorized Representative: Koso Kent Introl Limited Armytage Road Brighouse, West Yorkshire HD6 1QF : Brian Richmond (QHSE Director) or Jonathan Lodge (Technical Director) Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407 Brand Name:

(REXA)

Product Description: X-Pac and X2 Series Electraulic (Self-Contained Electro-Hydraulic) Actuator and Drive Systems Models: Designation:

Linear, Rotary and Drive Units Servo or Stepper Units II 3G EEx nA II T3

-40 °C ≤ Ta ≤ 65 °C

Applicable Directives: ATEX Directive 94/9/EC Machinery Directive 2006/42/EC including Low Voltage Directive EMC Directive 2004/108/EC PED Directive 97/23/EC; applies where applicable, to accumulator systems Applicable Harmonized Standards: Health/Safety: ATEX Directive 94/9/EC including Annex I and II; Machinery Directive 2006/42/EC Annex I, EN60204-1:2006, EN ISO 12100:2010, EN613101:1995, EN61310-2:1995, EN ISO 13850:2006, IEC61010-1:2001 EMC:

EN61326-1:2006, EN61000-6 Part -2:2005 and -4:2007; EN55011:2007: IEC61000-4-2:2008, IEC 61000-4-3:2010, IEC61000-4-4:2010, IEC61000-4-5:2005, IEC61000-4-6:2008, IEC61000-4-8:2009, IEC61000-4-11:2004

ATEX:

EN50021:1999

PED:

Directive 97/23/EC; designed as ‘Sound Engineering Practice’ Equipment Product Compliance

xxii

Product Compliance

DECLARATION OF NOISE EMISSION The REXA, Incorporated Model REXA Electraulic™ Actuator System Sound Pressure Levels per EN ISO 11202 is as follows: Model No: As above Serial No: On Nameplate Year of Construction: 2011 Operating

Idle

LpAm (Operator Position)

81 dB (A)

66 dB (A)

LpAm (Bystander Position)

84 dB (A)

67 dB (A)

Peak C-weighted instantaneous SPL in the Operator’s position LpC peak

88 dB (c)

—

Sound power emitted where the equivalent continuous A-weighted SPL exceeds 80 dB (A).

8.8 Bel

—

The average difference between the extraneous noise level and the sound intensity level at each measuring point is:

LpAm ∆ = 16 dB (A)

Ambient Correction Factor K3A calculated according to EN ISO 11204 Appendix A.

4 dB (A)

Measurements were made at a height of 1.5 m and 1 m from the Operator Position and all four sides of the equipment. The figures quoted are emission levels and are not necessarily safe working levels. While there is a correlation between the emission and exposure levels this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of noise, etc. such as the number of machines and other adjacent processes. Also, the permissible level of exposure can vary from country to country. This information, however, will enable the of the machine to make a better evaluation of the hazard and risk. KOSO America 4 Manley Street West Bridgewater, MA 02379 USA

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xxiii

WAIVER OF TRANSLATIONS AGREEMENT We, REXA, Inc., Hereby declare exclusion of the responsibility at the time of sale to provide translated documentation of REXA products. This includes and is not limited to the following documents: •

Installation and Operation Manual (IOM)

•

Interconnect, layout and wiring schematics and drawings

•

Technical Service and Repair Manual

This document also waives the responsibility of translations of the following system components and markings: •

Human Machine Interface (HMI Keypad Display) textual read-out of system parameters and status display

•

Modification of keypad display symbols to ISO characters

•

Internal labeling and identification symbols and statements

•

Individual wire and component marking identification is not required. The fully assembled factory wired is only serviced by REXA personnel and not the end . However, end – terminations are readily identified.

Translations of the above mentioned may be made by the end and/or the authorized representative listed on this document. Any of which may be translated must bear the statement ‘Translation of Original Instructions’ within the document(s)’ header or footer. EU Authorized Representative: Koso Kent Introl Limited Armytage Road Brighouse, West Yorkshire HD6 1QF : Brian Richmond (QHSE Director) or Jonathan Lodge (Technical Director) Telephone: +44(0)1484 710311 Fax: +44(0)1484 407407

Product Compliance

xxiv

Product Compliance

WAIVER OF MAINS SUPPLY DISCONNECT / EMERGENCY STOP AGREEMENT We, REXA, Inc., Hereby declare it the responsibility of the installer of this equipment to provide a suitable disconnect for the Control supplying power to the system. The disconnect must: •

Be suitable for the Voltage and Full Load Ampere Rating of all downstream equipment supplied by the ;

•

The supply disconnecting device shall be one of the following types: o Switch-disconnector with fuses, in accordance with IEC 60947-3, utilization category AC-23B or DC-23B o As above, except one that has an auxiliary that in all cases causes switching devices to break the load circuit before the opening of the main s of the disconnector. o A circuit breaker suitable as an isolation device per IEC 60947-2 o Any other switching device in accordance with an IEC product standard that also meets the isolation requirements of IEC 60947-1 and is appropriate for on-load switching of the largest motor or other inductive loads;

•

Be approved for use as a disconnect for the country in which the system is installed.

•

Be provided with a Lock-Out / Tag-Out capability in the Off (Down) position.

• The Handle must be RED in color to indicate it is suitable as an E-Stop device. If assistance is required in specifying an appropriate device, please our engineering department for recommendations.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 08/14 1

1 General Information

1.1 ABOUT REXA REXA is located in West Bridgewater, Massachusetts, USA. We manufacture, sell and service the highest quality actuators and drives. The driving force of these units is a self-contained electrically driven hydraulic pumping system, thus the term Electraulic™ is coined. This Installation and Operation Manual is part of REXA’s continuing commitment to supply only the highest quality products and services to our customers. Customer is our top priority at REXA. Please the factory if this manual or your Sales Representative fails to provide required information.

1.2 FACTORY REXA is a full service company. We have a fully staffed service department with factory trained and certified service personnel for both factory and on site repair. For repair, service, sales, warranty or parts order, you may the factory at the following:

General Information

2

General Information

REXA 4 Manley Street West Bridgewater, MA 02379

Phone: (508) 584-1199 Fax: (508) 584-2525 Web: www.rexa.com

Note: It is important to have the model code and build number for both the electronics and the actuator in addition to the serial number for the actuator so we can provide better service.

This information can be found on the metal tags on the actuator and on the front of the electronics. Reference the sections below on Actuator Identification for more detailed explanation.

1.3 ACTUATOR IDENTIFICATION The model number, mechanical build number, electronics build number and serial numbers are all used to identify an individual actuator and electronics. The model number will provide a general description of the actuator and electronics as a set. These numbers also provide the information required to correctly define what sections of this manual applies to a particular actuator. The build number provides more detailed information of the components used in the construction of the actuator. Finally the serial number will allow the factory to determine any special considerations or features your actuator may have that make it unique. Since most applications are custom, this is the only identification that fully allows us to identify the unit. The factory requires these numbers whenever service or information is requested. Supplying the model, both mechanical and electrical build numbers, and the serial number will ensure the quickest and most accurate response to your request. These numbers can be found on the ID tags located on the actuator and on the serial tag on the electronics. Figure 1.3 shows a typical ID tag.

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REXA Series 2 Xpac – Installation and Operation Manual – 08/14

3

Figure 1.3 ID Tag

General Information

4

General Information

1.3.1 Model Number The basic model number is a generic description of the actuator. Figure 1.3.1 shows a break down of the model number tree and how it works.

MODEL NUMBER X2__

__ __ __ __ – __ __ – __ – __-__ Thrust Torque

– Stroke – Rotation

Spring Fail Option (Upon Power Loss)

Series 2 L Series – Xpac Linear R Series – Xpac Rotary D Series – XPac Drive R or D SERIES

L SERIES

 Torque Rotation (lbf·in) (degrees)

Thrust (lb)

Strokes (in inches)

2 000 4 000 5 000 10 000 15 000 20 000 30 000 40 000 50 000 60 000 80 000 120 000

–.75, –2, –4 –6, –8, –11 –.75, –2, –4 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22 –.75, –2, –4, –6, –8, –11, –16, –22

2 500 5 000 10 000 20 000 50 000 100 000 200 000 400 000

–90, –120 –90, –120  –90, –120 –90, –120  –90, –120 –90, –120 –90, –120 –90, –120

C1: CSA-Class 1, Div 1 Actuator Only P: None – Lock in Place C2: CSA-Class 1, Div 2 U: Universal (Rotary) Actuator and Electronics E: Extend (Linear) C5: CSA-Class 1, Div 1 R: Retract (Linear) Actuator Only, Class 1, Div 2 A: Accumulator Failure Electronics Only C6: CSA- Class 1, Div 1 Actuator and Electronics Power Modules CA: CSA-Class 1, Div 2 B: Single B Actuator Only C: Single C ½D: Single ½D D: Single D 2C: Dual C Manifold 2D: Dual D Manifold D,P9: Booster Pump D,P40: Booster Pump

Model Numbers — Examples: X2L4000-4-C-P Is a Linear L Series 2 Xpac with 4 000 lb of thrust, stroke adjustable up to 4 inches, and C size power module. Lock in position upon loss of power. X2R2500-90-B-U A Rotary R Series 2 Xpac with 2 500 lbf·in of torque, rotation adjustable to 90 degrees, and B size Power module. Spring failure upon loss of power. Figure 1.3.1 Model Number

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

Hazardous Area Code

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

5

1.3.2 Serial Number Serial numbers are assigned to every job at REXA. Job specific information as well as sales and engineering information are stored under a specific serial number. A typical serial number will look like: C060000. The C06 indicates the year of manufacture and the next four digits correspond to the unique order number.

1.3.3 Build Number The build number is a catalog number we use to designate in complete detail the construction of the actuator. From this number all configurations can be defined. There are two different categories of build numbers; one is for the mechanical sub-assembly, and the second is for it’s corresponding electronics sub-assembly. Within the mechanical sub-assembly there is a build number for Rotary and Drive actuators, and a separate build number for Linear actuators. The build numbers are shown in Appendix H.

1.4 GENERAL SPECIFICATIONS 1.4.1 Recommended Fluids and Lubricants Intended Use

Specifications

Operating fluid, all REXA Actuators Castrol EDGE® SAE 5W-50 Motor Oil* Anti-Seize Compound

Bostik Never-Seez® or equivalent

O-ring Lubricant

Parker Super-O-Lube or equivalent

Thermal Grease

Thermalcote™ or equivalent

Molybdenum Disulfide Grease

Mobilgrease® XHP 222 or equivalent

Parts Cleaner

ZEP® BRAKE WASH or equivalent

Note: In special applications the type of oil used is system dependant and the should refer to the system documentation.

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1.4.2 Operating Temperatures The following is a general guideline; refer to Technical Memo TM19-2 for further information.

Temperature Range¹

Table 1.4.2-1 Linear Actuators Actuator Construction Type L Linear Cylinder Type C Linear Cylinder Installation Requirements

Electronics Temp. Range Motor Type

Standard

High Temp.

-5 °F to +200 °F

-30 °F ‡ to +200 °F

-76 °F to +200 °F

-5 °F to +250 °F

(-20 °C to +93 °C)

(-34 °C to +93 °C)

(-60 °C to +93 °C)

(-20 °C to 121 °C)

+10 °F to +200 °F

-10 °F to +200 °F

-76 °F to +200 °F

-5 °F to +250 °F

(-12 °C to +93 °C)

(-23 °C to +93 °C) (-60 °C to +93 °C) (-20 °C to 121 °C) 1 inch thermal Heat tracing & 1 inch None None insulation 2 thermal insulation 2 Separate Control Enclosure with U, motor driver, power supply, transient protection and termination. -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C) Stepper

Servo

1. High ambient temperatures affect oil viscosity which may affect actuator rated output. 2. These items are not supplied by REXA.

Temperature Range1

Table 1.4.2-2 Rotary Actuators & Drives Actuator Construction Type R Rotary or D Drive Cylinder Installation Requirements

Electronics Temp. Range Motor Type

Standard +10 °F to +200 °F

-10 °F to +200 °F

High Temp. -76 °F to +200 °F

-5 °F to +250 °F

(-20 °C to +121 °C) Optional Standard oil & 1” of thermal Heat tracing & 1” High Temp. cartridge heater insulation 2 therm 2 Construction Separate Control Enclosure with U, motor driver, power supply, transient protection and termination. -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C) Stepper Servo (-12 °C to +93 °C)

(-23 °C to +93 °C)

(-60 °C to +93 °C)

1. High ambient temperatures affect oil viscosity which may affect actuator rated output. 2. These items are not supplied by REXA.

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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Table 1.4.2-3 CSA Temperature Ratings Power Module

Operating Temperatures Actuator

T-Code

Electronics

Duty* Notes Actuator/Elec Cycle

B 115V

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F

(-40 °C to +60 °C)

T3/T3C

S1

B 230V

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +104 °F

(-40 °C to +40 °C)

T3/T3C

S8

24V B

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3/T3C

S1

48V B

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3C/T3C

S1

5

24V C

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3C/TC3

S1

6

C 115V

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F

(-40 °C to +60 °C)

T3/T3C

S1

C 230V

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +104 °F

(-40 °C to +40 °C)

T3/T3C

S8

2C 115V

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +140 °F

(-40 °C to +60 °C)

T3/T3C

S1

.5D 115V -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3C/T3C

S1

.5D 230V -40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

4

4

(-40 °C to +65 °C)

T3C/T3C

S1

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +131 °F

(-40 °C to +55 °C)

T3C/T3C

S1

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3C/T3C

S1

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +150 °F

(-40 °C to +65 °C)

T3C/T3C

S1

2D

-40 °F to +150 °F (-40 °C to +65 °C) -40 °F to +131 °F

(-40 °C to +55 °C)

T3C/T3C

S1

D,P9**

-40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +122 °F

(-40 °C to +50 °C)

T3C/T3C

S8

1, 3

D,P40**

-40  °F to +140°F (-40 °C to +60 °C) -40 °F to +122 °F

(-40 °C to +50 °C)

T3C/T3C

S8

2, 3

D 230V Dual .5D 115V Dual .5D 230V

Notes 1. Duty cycle for D,P9 PM motor is S1, booster motor will remain S8. 2. Duty cycle for D,P40 PM motor is S1, booster motor will remain at S8. 3. CSA duty cycle tested at 31.8% for continuous operation at maximum load and speed. 4. Uses internal 240 to 120 Vac step-down transformer P98246. 5. Uses 48 Vdc to 72 Vdc converter. 6. Uses 24 Vdc to 165 Vdc converter.

**

Exclude from CSA Class 1, Div. 1, Groups C & D.

S1 Duty: Duty cycle S1 is defined as continuous operation at load.

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S8 Duty: Duty cycle S8 is defined as periodic duty with rest period between operation, variable load/speeds. *Duty Cycle definitions taken from IEC 60034-1 applies to all rotating electrical machines.

1.4.3 Relative Humidity The equipment will operate correctly within an environment at 50% RH, +40 °C (+104 °F). Higher RH may be allowed at lower temperatures. Measures shall be taken by the Purchaser to avoid the harmful effects of occasional condensation.

1.4.5 Transportation and Storage This equipment will withstand, or has been protected against, transportation and storage temperatures of −25 °C (−13 °F) to +55 °C (+131 °F) and for short periods up to +70 °C (+158 °F). It has been packaged to prevent damage from the effects of normal humidity, vibration and shock.

1.5 MAINTENANCE SCHEDULE The REXA actuator requires minimal routine maintenance consisting primarily of visual inspections. However, as with any mechanical device, components will wear out. The frequency of use and the operating conditions are both factors that will dictate the maintenance schedule. For additional information refer to TM9-2. The following is a recommended list of visual inspections and their frequency. Note: With time and experience, a predictable schedule of maintenance and replacement of seals may be developed.

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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Monthly Check the oil indicator for proper oil level. Add oil if necessary following the instructions in section 1.6.4. When oil is added, a visual inspection of the actuator is needed to determine where the loss of oil occurred and the necessary repair required. Note: Ambient temperature swings will affect the oil indicator position.

Quarterly Perform a visual inspection of the actuators for damage, oil leakage, obstruction and hazards. Repair items found damaged during this inspection in accordance with company procedures. During this inspection, check the following items at a minimum: • Mounting hardware and fasteners are tight • Oil level is correct • Tubing and fittings are tight • Tubing is not touching or rubbing • Power module fasteners are tight • Actuator can hold position without re correcting • Oil leaks • Spring washer stack for damage (not all models) • Check for moisture ingression or contaminants under the housing, wire cover and in the electronics enclosure • Ground wire connectivity • Ensure the signal on the actuator is stable • Inspect wiring for cuts, abrasions or tears

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1.6 OIL The REXA Xpac Actuator is a sealed, self-contained, hydraulic positioning system in which oil is pumped from one side of a double acting cylinder to the other. An internal oil reservoir provides a source of make up oil for thermal expansion and is an integral component within the module. As the size of the actuator cylinders increase so does the need for additional make up oil, therefore larger systems will have external reservoir bottles in addition to the standard internal reservoir. A closed-loop hydraulic system means that the oil in the actuator is isolated from the environment and immune to degradation with time as a result of exposure to moisture and other atmospheric elements. Since the hydraulic system is sealed and spring-loaded, it is also unaffected by the orientation in which the actuator is applied. A periodic, visual inspection of the REXA Xpac Actuator is required in order to that the hydraulic system has not been compromised for any reason. Any external signs of a major oil leak or repeated refilling of the unit will indicate damage to the actuator that will require servicing of the unit and investigation for a cause.

1.6.1 Oil Level Inspection 1.6.2 Standard Units There is a reservoir indicator on the actuator body located on the same face as the motor shown in Figures 1.6.2-1—1.6.2-3. It is used to display the oil level within the actuator. The indicator is a silver rod with a scale beside it reading “HOT”, “OK” and “ADD”. As the unit cools down and heats up the indicator will move in and out. At 70 °F the indicators ideal position will be in the middle of the “OK” region. The unit may be indicating near the “ADD” limit if the ambient temperature is lower and will indicate in the “HOT” region if the ambient temperature is elevated. The reservoir volume has been sized for 110 °F temperature swings. Reference Figures 1.6.2-1 through 1.6.2-3 showing the different indication levels.

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

Figure 1.6.2-1 Add oil indication

Figure 1.6.2-2 Full oil indication

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Figure 1.6.2-3 Oil Expansion

Larger units will require additional make up oil and an external reservoir will be plumbed in series with the internal reservoir. The internal reservoir will still show the oil level however there is also an indicator rod in the external reservoir. At an ambient condition of 70 °F it should be protruding out approximately 3-½ inches as measured from the base of the bushing shown in Figure 1.6.2-4.

Figure 1.6.2-4 External Reservoir

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1.6.3 Accumulator Fail In an accumulator fail unit the reservoir contains oil for thermal expansion and also provides oil to charge the accumulator system. There are two different style accumulator reservoir bottles used depending on the size of the system. The first type uses a visual indicator rod as shown in Figure 1.6.2-4 and is typically used on smaller units. As the reservoir volume needs increase, a gas pressurized reservoir bottle is used and a pressure gauge is provided (Figure 1.6.3) to show the oil level.

Figure 1.6.3 Reservoir Gauge In order to check the level of the oil in an accumulator system you must locate the “Auxiliary Reservoir Settings” label shown below. This can be found on the reservoir bottle. Auxiliary Reservoir Settings With the accumulator fully discharged, the accumulator pressure gauge must read 0 PSI. Fill until Indicator Extension is XXX ± ½"

Auxiliary Reservoir Settings With the accumulator fully discharged, the accumulator pressure must read 0 PSI. Fill until Reservoir pressure is XXX ± 5 PSI

WARNING: Adding oil to the unit without ing the Accumulator is at 0 PSI before filling will cause damage And potential injury or Death.

When accumulator is full @ XXX PSI. The indicator Extension should be @ XXX ± ½"

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

WARNING: Adding oil to the unit without ing the Accumulator is at 0 PSI before filling will cause damage And potential injury or Death.

When accumulator is full @ XXX PSI. The reservoir Pressure should be @ XXX ± 5 PSI

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1.6.4 Filling If the addition of oil is required, it should be filled with Castrol EDGE® SAE 5W-50 motor oil (Figure 1.6.4-1). In special applications the type of oil used is system dependant and the should refer to the system documentation. The actuator does not need to be taken out of service when adding oil. Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.

Figure 1.6.4-1 Castrol EDGE REXA Xpac Actuators are filled through a standard Schrader-style Fill Valve located on a face of the Reservoir Assembly. Use any oil gun equipped with a Schrader-style fitting. The mating half of a Schrader-style fitting can be obtained at any auto parts store, purchased through a REXA Sales Rep, or purchased directly from REXA’s Inside Sales Office. The following steps will guide a to successfully fill a REXA Xpac Actuator with oil: NOTE: DO NOT OVERFILL THE RESERVOIR. While overfilling will not harm the actuator on non-accumulator units, overfilling will force oil from the Thermal Expansion Valve. Overfilling will also promote oil weeping from the relief valve due to thermal expansion. If an accumulator unit is over filled, the reservoir can be over pressurized and catastrophic seal damage can occur.

PROCEDURE (9 steps):

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1. Locate and Remove the fill valve cover (Figure 1.6.4-2).

Figure 1.6.4-2 Fill Valve with cover. 2. Fill the oil gun with oil (Figure 1.6.4-3).

Figure 1.6.4-3 Fill the oil gun. 3. To purge any air out of the oil gun, line and fitting; first, pump the handle a few times until the lever gets firm (Figure 1.6.4-4).

Figure 1.6.4-4 Purge the air. 4. Depress the small valve in the center of the Female Schrader fitting (on REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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the oil Pump) with a suitable device like a small screwdriver or punch until you get clean, air-free oil (Figure 1.6.4-5).

Figure 1.6.4-5 Oil Pump Valve. 5. Attach the oil fill gun to the actuator’s Schrader fitting (Figure 1.6.4-6).

Figure 1.6.4-6 Fill Valve with Schrader fitting. 6. Add oil until the indicator is in the “OK” section of the scale (Figure 1.6.2-2). Reference the reservoir labels for correct filling of Accumulator units. 7. Remove the oil gun from the Fill Valve. 8. Re-install the fill valve cover. 9. Drain and store the Fill Gun in a clean place for future use.

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1.6.5 Overfilling, Oil Weeping & Thermal Expansion All REXA Xpac Actuators contain a Thermal Expansion Valve located next to the Schrader-style Fill Valve. If an actuator is overfilled with oil, it should be expected that oil will purge out of the Thermal Expansion Valve. Simply wipe-off whatever oil may be purged. The Thermal Expansion Valve is built into every REXA Xpac Actuator in order to allow the actuator to relieve the Thermal Reservoir of excess oil pressure due to thermal expansion. Thermal expansion refers to the volumetric changes a fluid, such as oil, experiences given changes in environmental temperature. It is not uncommon to discover trace amounts of residual oil collected around the Thermal Expansion Valve of an actuator if the unit has been overfilled. This residual oil is typically the result of oil weeping from the relief valve as the ambient temperature increases causing the oil to expand. As previously mentioned, the actuator is a closed-loop hydraulic system, and any increase in oil volume will be purged. On large oil volume actuators REXA adds an external auxiliary reservoir in order to compensate for the greater volume of oil that may expand due to increases in ambient temperature. If the temperature is lowered, the reservoir indicator will retract as the oil volume decreases. Oftentimes, s will mistake the indicator retraction as a sign that the actuator has lost oil due to a service issue. If a adds oil to the actuator at this time, oil will likely purge out of the Thermal Expansion Valve upon an eventual rise in ambient temperature. It is when oil is evidently leaking, or collected in large amounts somewhere on, or dripping off, a REXA Xpac Actuator that a service-related issue is likely, and oil filling is needed. For this reason, we ask s to perform periodic inspections with ambient temperature changes in mind.

1.6.6 Air Purging As previously noted, all REXA Xpac Actuators are characterized by a closedloop, hydraulic system that is responsible for their distinguished reputation as being unmatched in rigidity, precision and control. This is, in part, due to

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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the advantages of using hydraulics in place of pneumatic actuation. Air is a compressible medium that results in many inherent disadvantages, such as poor control and rigidity, when used in actuation. In light of these facts, it is obvious that the presence of any air in the closedloop hydraulic system of a REXA Xpac Actuator is extremely disadvantageous and detracts from performance of the actuator. Certain repair and replacement procedures will involve exposing the internal hydraulic system to the outside environment and may introduce unwanted air to the system. The presence of air in the hydraulic system is likely to cause problems such as unstable positioning. For this reason, whenever the closed-loop hydraulic system of a REXA Xpac Actuator is opened to the atmosphere, it is imperative that necessary steps are taken to remove any air from the system. When purging a REXA Xpac Actuator of air, there are two main areas of concern: the reservoir, and the hydraulic system.

1.6.7 Reservoir Purging

Figure 1.6.7-1 Reservoir Purging Ports 1. It is important to first identify if the reservoir has entrapped air. This can be done by pressing in on the reservoir indicator. If it does not feel “stiff,” there is air in the reservoir system. Note: Be aware of external reservoirs or additional modules; press evenly on all reservoirs to check for entrapped air.

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2. Depending on the orientation of the actuator the highest purge point on the module must be identified, as any entrapped air will migrate to the highest point. Purge Port 1 and Purge Port 2 (Figure 1.6.7-1) are both at corners of the reservoir volume and most likely will be the highest points. Note: Some modules will have auxiliary reservoirs attached and plugged ports on those reservoir may be the highest points.

3. Slowly unthread the highest purge point fastener and have an oil catch pan ready. It may not be necessary to fully remove these plugs as air will purge out with a few threads still installed. 4. Retighten the plug before proceeding. 5. Refill to the correct oil level. Note: Some actuator orientation will not allow for proper purging and the actuator may need to be removed and re-orientated for purging, then re-installed. The best position for purging is with purge port 1 facing up.

Figure 1.6.7-2 Full Indicator “OK”– flush with front face

1.6.8 Hydraulic System Purging NOTE: It is important to purge the reservoir before continuing.

To purge the actuator of air, it is recommended that you use the REXA bleed kit (P/N: K09275) See Figure 1.6.8-2 for details.

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REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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1. Change the Max Man Spd to 30% or less. (Refer to section 6.1.5.) 2. Open the manual by to relieve internal pressure. (Refer to C.5.) NOTE: Some units can have a solenoid instead of a manual by; ensure that the solenoid is open before proceeding. (Refer to section 1.8.4.)

3. Locate the best available pressure ports to bleed air from the system. The best position is the highest point that is accessible and will allow air to escape the system. Keep in mind that the porting may be located on the module, cylinder, manual hydraulic pump or SCL, etc. 4. Attach the REXA bleed kit (Figure 1.6.8-2) to the open ports Extend/CW and Retract/CCW. Follow the hydraulic lines to differentiate between pressure direction (Figure 1.6.8-1).

Figure 1.6.8-1 Extend/CW and Retract/CCW Ports 5. Run the actuator through its full stroke constantly pumping oil into the reservoir. Do not let the reservoir run dry, or you will need to purge the reservoir and start over.

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Figure 1.6.8-2 Bleed Kit (PN: K09275)

1.7 TOOL REQUIREMENTS (Power Module Only) All these common tools may be required during installation and maintenance. • Flashlight • Set of Flat Tip Screwdriver • Standard Set of Allen Wrenches • Set of Combination Wrenches • Set of Picks • 12 ˝ Channel Lock Pliers 3 • ⁄ 16 ˝ Nut Driver • 3⁄ 8 ˝ Nut Driver • Snap Ring Pliers • Needle Nose Pliers • Wire Strippers • Wire Cutter • Crimper • Digital Volt Meter • Oil Gun with Schrader Fill Assembly • Soft Blow Hammer

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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1.8 THEORY OF OPERATION 1.8.1 Overview The REXA Xpac is a microprocessor controlled, self-contained, Electraulic™ (electro-hydraulic) actuator or drive designed specifically for modulating service. Hydraulic, electronic and mechanical technologies are combined to achieve REXA’s state-of-the-art line of actuators. The patented Flow Match System is simply described as a highly efficient method of pumping hydraulic fluid (motor oil Castrol EDGE® SAE 5W-50) from one side of a double acting cylinder to the other. Once the correct position is reached, the motor shuts off. Power is not required to maintain actuator position. The hydraulics are controlled by a dedicated microprocessor contained within the control enclosure. Software designed for the Xpac allows the to set actuator operation parameters. Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.

The Xpac consists of two major components, the actuator (cylinder, and Electraulic power module) and the control enclosure. The actuator is installed on the driven device, while the enclosure is remotely mounted. Connecting the actuator and enclosure are the module cable and the cable.

1.8.2 Actuator The heart of the actuator is the Electraulic Power Module. Consisting of a motor, gear pump, flow match valve (FMV), make-up oil reservoir, heater, thermostat and by solenoid (spring fail units only), the Power Module delivers oil at a nominal 2000 psi to a hydraulic cylinder. Four different size modules, B, C, ½D and D, are available meeting hazardous area but non-explosion proof requirements. For applications requiring hazardous area and explosion proof approvals, two different power modules, C and D are available. The major functional difference between the sizes is pumping volume and thus, the maximum stroking speed of an actuator. The B and C modules are driven with a stepper motor and therefore have a slower frequency response then the D series modules which are driven with

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servo motors. More detailed information on the frequency response and flow rates can be found in product/technical memos. The only visible difference among all 4 sizes of modules is the motor. There are three types of hydraulic cylinders. On smaller size linear actuators (thrust of 10 000 lb or less and strokes of 6 inches or less), the L series cylinder is manufactured from a solid block of aluminum. Larger size C series cylinders are made of a fabricated tie-rod construction. The third type, used on rotary (series R) and drive (series D) units, is a rack and pinion rotary design. A position sensor, provides position to the control electronics. The assembly is sealed in a NEMA 4X cover and mounted within or adjacent to the cylinders. The connection of the position sensor is by direct mechanical means. The B and C modules shown in Figure 1.8.2-1&2 are the two sizes of stepping motor modules. They both have cylindrical motor cases. The motor case lengths are depicted in Figure 1.8.2-1&2 for module identification purposes. With the exception of pump and motor size, these two modules share many of the same components so both modules will be depicted on one rebuild diagram for each of the applicable service sections.

Figure 1.8.2-1 B Module

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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Figure 1.8.2-2 C Module

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The 1/2D and D modules shown in Figure 1.8.2-3 are the two sizes of servo motor modules. They both have square case motors. The motor case lengths are depicted in Figure 1.8.2-3 for module identification purposes. Again, with the exception of pump and motor size, these two modules share many of the same components so both modules will be depicted on one rebuild diagram for each of the applicable service sections.

1/2D-Module

D-Module

Figure 1.8.2-3 ½D, & D Module

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

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The C and D explosion proof modules shown in Figure 1.8.2-4 are two sizes of power modules offered for applications requiring hazardous area and explosion proof approvals. The motor case lengths are depicted in Figure 1.8.2-4 for module identification purposes. With the exception of pump, motor size, and cover, these modules share many of the same componenets as the non-explosion proof modules so both modules will be depicted on one rebuild diagram for each of the applicable service sections. C- Module

D-Module

Figure 1.8.2-4 C & D Module

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1.8.3 Control Sub-Assembly The control sub-assembly consists of the enclosure, Central Processing Unit (U), Power Supply, Motor Drivers, Main Power Transient Suppression, and a termination area. The control sub-assembly also provides the interface. The enclosure mounted 2-line x 20 character/line Vacuum Fluorescent Display (VFD) and 5 button keypad will be the point for setup and calibration of the actuator as well as visual of actuator status. The Keypad and Display can be optionally mounted inside the Control Enclosure should the installation warrant it. The U consists of a microprocessor, an Analog-to-digital (A/D) converter, an isolated 4-20 mA Position Transmitter, Electronic (PhotoMOS) limit switches, as well as warning and alarm relays. The U will also accept optional I/O interface boards. The power supply develops DC voltages from the incoming AC Power. The DC voltages, +5, +15, -15 and +24 Vdc, provide power to the U, actuator circuit, the optional interface boards as well as optional loop supply (+24 Vdc) for the Position Transmitter. The motor driver is the component that supplies power to the motor. It can either be a DC Stepper Motor Driver or an AC Servo Motor Driver, depending on the model actuator. The motor driver accepts command signals from the U and provides DC Step Pulses (Stepper Motor) or Pulse Width Modulated (PWM) DC Voltage (Servo Motor) to the module mounted motor to drive it in one direction or the other. There is one motor driver for each power module. Field wiring is terminated inside the control enclosure. Refer to Tables 1.8.3-1 and 1.8.3-2 for Terminal Block ratings.

REXA Series 2 Xpac – Installation and Operation Manual – 8/14

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Figure 1.8.3 Typical Control Enclosure Standard Painted-Steel Enclosure Specifications For Single Module Actuators: UL 508 Types 12, 4 CSA Type 12, 4 Complies with NEMA Type 12 and 4

IEC 529, IP66 Construction Refer to Appendix P for dimensions and alternative construction.

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Table 1.8.3-1 Control Enclosure Terminal Blocks MECHANICAL Termination Torque

10 lbf·in Max.

Operating Temperature

-40 °F to +221 °F (-40 °C to +105 °C) MATERIAL



Brass, Tin Plated

Screw

#6-32, Combo Head, with SEMS Washer

Insulator Body

Polycarbonate, UL 94V-0, Black ELECTRICAL

Voltage Rating

300 Vac

Current Rating

20 Amp

Wire Range

12-24 AWG

Table 1.8.3-2 Actuator Terminal Blocks MECHANICAL Termination Torque

12 lbf·in Max.

Operating Temperature

-40 °F to +250 °F (-40 °C to +125 °C) MATERIAL



Copper Alloy

Screw

Screw M3, Slotted

Insulator Body

Polyamide PA, UL 94V-2, Gray ELECTRICAL

Voltage Rating

300 Vac

Current Rating

20 Amp

Wire Range

10-28 AWG

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REXA Series 2 Xpac – Installation and Operation Manual – 08/14

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1.8.4 Operational Summary The U converts an incoming control signal into a target position. The current position is determined through the assembly mounted on the actuator. The difference between the target and current position is the error. If the error exceeds the set deadband then the U will initiate corrective action by starting the motor. A reversible hydraulic pump is driven by the motor. The pump can pressurize either side of a double acting cylinder through one of two sides of the Flow Matching Valves, FMV-1 and FMV-2. Each FMV side is comprised of a ported spool with an integral pilot operated check valve. In the example in Figure 1.8.4-1; to move the cylinder piston to the left, the pump turns in the direction to pressurize FMV-2 through port A2. The spool in FMV-2 becomes unbalanced by the pressure differential and moves to the left, lifting its check valve, opening port D2 to port B2 and port A2 to port E2. High pressure fluid flows through Port E2 to the right side chamber of the cylinder. Since the hydraulic circuit is closed, the same amount of oil that flows into the right side of the piston must be extracted from the left side. This allows oil movement without an active reservoir. This oil flows through the open check valve of FMV-2 and into pump suction. By rotating the pump in the opposite direction, the FMVs operate in reverse to move the cylinder piston to the right. When the pump stops, both check valves close, and the hydraulic oil is locked within the cylinder. Motor operation is not required to maintain position.

Figure 1.8.4-1 Hydraulic schematic General Information

30

General Information

Each actuator has an internal hydraulic by circuit. This circuit creates a direct connection from one side of the hydraulic cylinder to the other. It is useful for relieving internal pressure in the actuator and allowing an external load to move the actuator. The nut labeled by on the actuator face as shown in Figure 1.8.4-2 controls this circuit. Turning this by in all the way puts the unit in its normal operation. Turning the by out 1 to 2 turns will open this by circuit. Note: This by nut is only on units without internal solenoids.

Each pressure gauge on the actuator has its own on/off isolation valve (Figure 1.8.4-2). This valve should remain off unless pressure is being read from the gauge. This will protect the gauge from constant cycling, thus extending its life. When closing this valve you will create an internal pressure trap in the gauge; therefore, you should not expect to see 0 psi when off.

Gauge

Gauge

CW Off CCW On

CW Off CCW On

By CW Off CCW On

Figure 1.8.4-2 By

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2 Delivery

2.1 RECEIPT REXA makes every effort to package products to avoid damage in shipping. Upon receipt inspect the crate and make note of any physical damage. If severe damage is present, then consideration should be given to rejecting the shipment and ing the shipping company concerning in-transit damage claims.

2.2 STORAGE If the actuator and control enclosure sub-assemblies are not immediately installed, provisions for storage must be made. The equipment should not be removed from the original containers and should be protected from the elements. The ambient environment must be: Clean—no airborne particles or contaminants. Non Corrosive—minute quantities of gases can concentrate in a confined area. Dry—relative humidity must be sufficiently low to prevent moisture condensation on chilled metal components. Temperature—recommended storage temperature is between

10 °F – 120 °F (–12 °C – 50 °C).

Delivery

32 Delivery

2.3 UNPACKING The REXA Xpac actuator is shipped filled with oil and ready to be installed. It has been operated, tested and thoroughly inspected. After removing the actuator from the packaging, inspect it for any signs of mechanical damage that may have occurred during shipping. Immediately report any damage to the factory. Compare the contents to the packing list included with every shipment. Immediately report any discrepancies to the factory.

2.3.1 Unpacking System, Lifting If a piece of the system weighs between 40 – 79 lb (18 –36 kg), the manual must tell the installer that a two-man lift is required. If a piece of the system weighs between 80 lb and 129 lb (36 kg – 59 kg), a three-man lift must be used. Above 129 lb (59 kg), a machine assist must be used (forklift or crane)

2.4 INSTALLATION REQUIREMENTS 2.4.1 Operational and Maintenance Clearances

Volts to Ground 0–600

Condition 1 900 mm (3 ft)

Exposed live parts are on one side and no live or grounded parts are on the other side of the working space. Or, exposed live parts on both sides are effectively guarded by wood or other suitable insulating materials. Insulated wire or insulated busbars operating at not over 300 V to ground shall not be considered as live parts.

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11

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2.4.2 Hazards Due to Height Use Safety Harness when working aloft above 1.8 m and consult Plant Safety Policy for safety consciousness and harness requirements.

Delivery

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35

3 Electrical Installation CONTROL ENCLOSURE OVERVIEW The Block Diagram (Figure 3) on the following page gives a general overview of the Control Enclosure and Actuator installation. Note: Not all actuators will have all the options shown in Figure 3.

3.1 CONTROL ENCLOSURE INSTALLATION The Control Enclosure must be mounted in a location conducive to its operation. Ideally, it should be mounted in a Control Room environment. The Control Enclosure rating is as follows:

General Locations (Standard): Environmental: NEMA 4 and 12, IP 66 Ambient Temperature: – 40 to +130 °F (-40 to +55 °C)

Optional Construction: Hazardous Locations: CSA Class 1, Div. 2, Groups A, B, C & D, T3 Available Units: All units in Table 1.4.2-3 are available Protection Method: Non-Incendive (non-sparking), limitation of surface temperatures Ambient Temperature: – 40 to +104 °F (-40 to +40 °C) Hazardous Locations: CSA Class 1, Div.1, Groups C & D, T3 Available Units: All units in Table 1.4.2-3 are available except D-P9 AND D-P40 Protection Method: Explosion Proof and Intrinsically Safe Ambient Temperature: Refer to Table 1.4.2-3

Electrical Installation

Figure 3 Electrical Installation Block Diagram

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37

It is necessary to the enclosure door is closed tightly and any openings added are sealed to comply with the ratings given above. Note: Reaffirm with unit’s tagging the Control Enclosure’s intended location.

3.2 MAIN POWER The Main Power requirements for the Control Enclosure/Actuator vary according to model. The Main Power requirements are given as part of the Nameplate Information attached to the lower left corner of the control enclosure as shown in Figure 3.2. If no control enclosure is used, the nameplate will be attached to the backplane on which the Electronics is mounted.

Figure 3.2 Control Enclosure In general, the Main Power requirements are given in Table 3.2; however, the Nameplate rating takes precedence.

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38

Electrical Installation

Table 3.2 Power Requirements Module Size

Incoming Voltage*

Maximum Current Required

VA Rating

B Module

115 Vac ±10%, 50/60 Hz

4.0 amp

500

C Module

115 Vac ±10%, 50/60 Hz

8.5 amp

1 100

½ D Module

115 Vac ±10%, 50/60 Hz

20.0 amp

2 400

D Module

230 Vac ±10%, 1Ø, 50/60 Hz

10.0 amp

2 400

2D Module

230 Vac ±10%, 1Ø, 50/60 Hz

20.0 amp

4 800

D,P9

230 Vac ±10%, 3Ø, 50/60 Hz

25.0 amp

9 000

D,P40

230 Vac ±10%, 3Ø, 50/60 Hz

50.0 amp

21 000

* If another voltage is to be used, an External Step Up/Down Transformer of the proper size must be used.

3.2.1 Supply Disconnect Device To comply with IEC 61010-1, Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, a supply disconnect device with the proper rating MUST be installed. The supply disconnecting device: a) Shall disconnect (isolate) the Control Enclosure/Actuator from the supply when required. b) Shall be included in the building installation. c) Shall be in close proximity and within easy reach of the Control Enclosure. d) Shall be marked as the disconnecting device for the equipment. Refer to the Nameplate Rating of the Control Enclosure sub-assembly for proper sizing of the required disconnect device. It is the responsibility of the installer of this equipment to provide a suitable disconnect for the Control supplying power to this equipment. This disconnect must:

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— Be suitable for the Voltage and Full Load Ampere Rating of all downstream equipment supplied by the ; — The supply disconnecting device shall be one of the following types: (a) Switch-disconnector with fuses, in accordance with IEC 60947-3, utilization category AC-23B or DC-23B. (b) As above, except one that has an auxiliary that in all cases causes switching devices to break the load circuit before the opening of the main s of the disconnector. (c) A circuit breaker suitable as an isolation device per IEC 60947-2. (d) Any other switching device in accordance with an IEC product standard that also meets the isolation requirements of IEC 60947-1 and is appropriate for on-load switching of the largest motor or other inductive loads. — Be approved for use as a disconnect for the country in which this equipment is installed. — Be provided with a Lock Out Tag Out capability in the Off (Down) position. — The Handle must be RED in color to indicate it is suitable as an E-Stop device.

3.2.2 Grounding Protective Earth Ground A dedicated Protective Bonding Conductor (Protective Earth, PE) must be provided. The conductor must be connected to the terminal labeled PE or Protective bonding provides protection against electrical shock and should be provided at both Control and Actuator.

.

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40

Electrical Installation

3.2.3 Grounding Symbols —Protective Earthing —Safety Earth Ground —Noise Free (EMI) Ground —Frame/Chassis Ground

3.2.4 Main Power Supply Wiring It is the responsibility of the Installer of this equipment to supply suitable main power supply wiring. Consult the Manufacturer’s Identification Nameplate on the Machine to determine Voltage and amperage requirements when determining the wiring size (mm2). — The supply wiring must be approved for use in the country in which this equipment is installed or bear the Mark. — A separate bi-color ground wire that is green in color with a yellow stripe must be run in the hard-pipe conduit along with the supply wiring. — The conduit must be grounded in accordance with the National wiring rules of the country where installed. — The fittings installed where the service wiring enters the body of the must not reduce the Ingress Protection rating.

3.2.5 Cordage It is the responsibility of the Installer of this equipment to supply a suitable length of heavy duty supply cordage. It should meet the following requirements: — It must be approved for use in the country in which this equipment is installed or bear the Mark. — The maximum length of the cordage should not exceed the values established by the National Electric Code of the country in which it is installed.

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REXA Series 2 Xpac – Installation and Operation Manual – 07/12

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— The outer jacketing of the cordage should be rated for exposure to water, oil and other similar substances. — The Voltage and Ampere rating of this equipment, as noted on the Manufacturer’s Identification Label, should be consulted when selecting the proper size (mm2) of the cordage. — A suitable industrial style attachment plug should be selected for connecting to the branch circuit. As an alternative, the end that terminates at the building supply source may be permanently connected in accordance with local wiring rules. — The supply cordage should be routed to the Control Cabinet in a manner that does not allow it to be stepped on, pinched, subject to abrasion, excessive bending, become a trip hazard or subject to other abuse. — Refer to REXA interconnect drawings for details of interconnect cable requirements.

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Electrical Installation

3.2.6 Fuse Identification / Replacement Unit Description

Main Fuse (V, A, IR, Class)

Branch Fuse(s)

B, 115 Vac

600V, 5A, SCR 200k, Class CC

none

B, 230 Vac

600V, 5A, SCR 200k, Class CC

none

B, 24 Vdc

600V, 20A, SCR 200k, Class CC

DC/DC; 250V, 2A, SCR 100,1/4x1/4 TD Glass Tube Heater; 250V, 8A, SCR 200, 1/4x1/4 TD Glass Tube Solenoid; 250V, 5A, SCR 200, 1/4x1/4 TD Glass Tube

B, 48 Vdc

600V, 5A, SCR 200k, Class CC

DC/DC; 250V, 2A, SCR 100,1/4x1/4 TD Glass Tube Heater; 250V, 8A, SCR 200, 1/4x1/4 TD Glass Tube Solenoid; 250V, 5A, SCR 200, 1/4x1/4 TD Glass Tube

C, 115 Vac

600V, 10A, SCR 200k, Class CC

none

Dual C, 115 Vac

600V, 15A, SCR 200k, Class CC

none

C, 24 Vdc

600V, 50A, SCR 300k, Class J

DC/DC; 250V, 2A, SCR 100,1/4x1/4 TD Glass Tube Heater; 250V, 8A, SCR 200, 1/4x1/4 TD Glass Tube Solenoid; 250V, 5A, SCR 200, 1/4x1/4 TD Glass Tube

½ D, 115 Vac

600V, 20A, SCR 200k, Class CC

none

½ D, 230 Vac

600V, 10A, SCR 200k, Class CC

none

Full D, 230 Vac

600V, 10A, SCR 200k, Class CC

none

Dual D, 230 Vac 600V, 20A, SCR 200k, Class CC

none

D,P9, 230 Vac

600V, 25A, SCR 200k, Class J

none

D,P40, 230 Vac

600V, 50A, SCR 200k, Class J

D; 600VAC, 10A, SCR 200k, Class CC P40; 600VAC, 35A, SCR 200k, Class J

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 10/13

24/48 Vdc Power Supply

115 V Power Supply

230 V Power Supply

Power Supply

Fuse Location

Description

Voltage (V)

Amperage (A)

SC I/R (A)

43

Type

Size

F1

Triple Power suuply

250

1

35

GMC

5 × 20mm

F2

24 Vdc Supply

250

1

35

GMC

5 × 20mm

GMA

5 × 20mm

A15QS

Form 101

GMA

5 × 20mm 5 × 20mm

⁄4 ⁄8

F3

Input Board

250

1

35

F4

Trip Solenoid

150

5

100  000

F5

Fail Solenoid

250

1

35

F6

Fail Solenoid

250

1

35

GMA

F7

Heater

250

1

35

GMA

5 × 20mm

F8

Heater

250

1

35

GMA

5 × 20mm

F1

Triple Power suuply

250

1

⁄2

35

GMC

5 × 20mm

F2

24 Vdc Supply

250

¼

35

GMC

5 × 20mm

F3

Input Board

250

1

35

GMA

5 × 20mm

F4

Trip Solenoid

150

5

100 000

A15QS

Form 101

F5

Fail Solenoid

250

2

100

GMA

5 × 20mm

F7

Heater

250

2

100

GMA

5 × 20mm

Branch Fuse Protection

DC/DC; 250V, 2A, SCR 100, ¼×¼ Time Delay Glass Tube

3.3 CABLES Each Actuator and Control Sub-Assembly are interconnected by a set of cables. These cables are supplied by REXA. The following will help you identify the cables.

Electrical Installation

44

Electrical Installation

Cable (Stepper & Servo Motor Units) The Actuator Cable carries the Actuator signal to the Control Sub-Assembly. The Cable (REXA P/N #P96192) specifications are: Cable Type:

3 Conductors #18 AWG 16/30 STRANDED TINNED COPPER

Insulation: COLOR CODE 1. RED 2. WHITE 3. BLACK Jacket: GRAY Cable O.D.:

0.230-0.250 ˝

Cable must be shielded.

Power Module Cable (Stepper Motor Units) The Stepper Motor Actuators use a Power Module Cable to interconnect between the Control Sub-Assembly and Actuator. The Power modules function is to transfer motor power, Heater Power and Solenoid Power. The Power Module Cable (REXA P/N #P96191–X2) specifications are: Cable Type:

4 TWISTED PAIR, 1 TWISTED TRIAD, #16 AWG 19/29 STRANDED TINNED COPPER Insulation: COLOR CODE PAIR 1 – RED WITH RED/BLACK PAIR 2 – GREEN WITH GREEN/BLACK PAIR 3 – BLUE WITH BLUE PAIR 4 – YELLOW WITH YELLOW TRIAD – BROWN & BROWN & GREEN/YELLOW Jacket: GRAY Cable O.D.: 0.50-0.55 ˝ If not using Power Module Cable Supplied by REXA, it is important that the motor power conductors be twisted pairs to avoid adverse effects of radiated noise from the cable.

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Heater/Solenoid Cable (Servo Motor Units Only) The Servo Motor Actuator uses a Heater/Solenoid Cable to interconnect between the Control Sub-Assembly and Actuator. The cable supplies power to the Power Module heater and Fail Safe Solenoid (for Spring Fail units). There is also a Ground Conductor. The Heater/Solenoid Cable (REXA P/N #P97335-X2) specifications are: Cable Type:

1 TWISTED PAIR, 1 TWISTED TRIAD

Insulation:

COLOR CODE PAIR 1 – BLUE WITH BLUE TRIAD – BROWN & BROWN & GREEN/YELLOW

Jacket: GRAY Cable O.D.:

0.4-0.45 ˝

Motor Resolver Cable (Servo Motor Units Only) The Servo Motor Actuator uses a dedicated Motor Resolver Cable to interconnect between the Control Enclosure and Actuator. The cable supplies motor speed and position to the Servo Amplifier. The Resolver Cable (REXA P/N #P96399) specifications are: Cable Type:

Power Limited Tray Cable (PLTC), 20 AWG (7/28) stranded, tinned copper conductors, twisted pairs, individually shielded plus an overall foil shield (100% coverage), PVC jacket. Pairs: 1. RED paired with BLACK 2. GREEN paired with BLUE 3. BROWN paired with WHITE 4. ORANGE paired with YELLOW Characteristics: Voltage Rating: 300 Volts Temp. Rating: -30 °C to +105 °C Flammability: es UL VW-1 Flame Test UL Type TC Sunlight Resistant Direct Burial Indoor/Outdoor Use Cable O.D.: 0.41˝ Max. Resolver Cable must be shielded.

Electrical Installation

46

Electrical Installation

Motor Power Cable (Servo Motor Units Only) The Servo Motor Actuator uses a dedicated Motor Power Cable to interconnect between the Control Enclosure and Actuator. The cable supplies power to the Servo Motor. The Servo Motor Power Cable (REXA P/N #P96402) specifications are: Cable Type:

UL Type TC, (Tray Cable), 4 conductor, overall foil shield, #14 AWG 41×30 stranded tinned copper with #14 AWG drain wire pulled under foil tape. Conductors: 1. ORANGE 2. GRAY 3. BLUE 4. GREEN Characteristics: Voltage Rating: 600 Volts Temp. Rating: -30 °C to +90 °C Flammability: es UL VW-1 Flame Test UL Type TC Sunlight Resistant Direct Burial Indoor/Outdoor Use Cable O.D.: 0.61˝ Motor Power Cable must be shielded.

Booster Cable (D,P9 and D,P40 Units Only) The Booster Pump actuator uses a dedicated cable to interconnect between the Control Enclosure and Booster Pump motor.

D,P9 (REXA P/N #P97117) Cable Type:

4 CONDUCTOR, OVERALL FOIL SHIELD, 10 AWG

Insulation:

COLOR CODE 1. ORANGE 2. BLUE 3. GRAY 4. GREEN

Jacket: GRAY Cable O.D.:

0.60-0.65˝

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REXA Series 2 Xpac – Installation and Operation Manual – 07/12

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D,P40 (REXA P/N #P97882) Cable Type:

4 CONDUCTOR, OVERALL FOIL SHIELD, 8 AWG

Insulation:

COLOR CODE: Black, labeled 1. ONE 2. TWO 3. THREE 4. FOUR

Jacket: BLACK Cable O.D.:

0.70˝

3.3.1 Cable Lengths The length of cabling between the Control Enclosure and Actuator is limited. The following table gives the appropriate lengths for each type of cable and whether the actuator is using a Stepper or Servo type motor. It is important to adhere to the length limits and conductor size for proper operation of the system.

Table 3.3.1 Cable Lengths Cable

Used on Unit Type

Max. Length

Cable

Step or Servo

700 ft

Module Cable

Stepper

300 ft*

Motor Power Cable

Servo

700 ft

Resolver Cable

Servo

700 ft

Heater/Solenoid Cable

Servo

700 ft

* 300 ft limit is for 16 AWG Cable. Consult factory for longer lengths.

Electrical Installation

48

Electrical Installation

3.3.2 Cable Routing Important for proper operation. Cables between Control Enclosure and Actuator should be run in flex conduit, rigid conduit or dedicated cable tray. It is important to separate Low level signals from High Power cables. Please adhere to the following: •

Actuator and Resolver cables can be in the same tray or conduit.

•

If and Resolver cables are run with other equipment cables, be sure those cables are signal level only. No high power Cables.

•

Power Module Cable(s) for Stepper Motor units can be in the same conduit with each other, but must be separate from the Cable.

•

The Power Module cable is considered a High Power cable.

•

Motor Power Cable(s) (Servo Motors) must be in their own conduit or tray. Failure to do so may cause the high frequency of the PWM (Pulse Width Modulated) signal to affect surrounding equipment or actuator operation.

•

Heater/Solenoid Cable can be in the same conduit or tray with other AC signals.

3.4 CONDUIT AND CONDUIT FITTINGS •

Conduit and Conduit fittings suitable for the environment must be used. Failure to do so may cause ingress of contaminants or water into the enclosure.

•

A removable gland plate is provided on the bottom of the Control Enclosure. The gland plate can be removed to machine the appropriate conduit openings. Be sure to reattach the gland plate securely with its gasket in place.

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REXA Series 2 Xpac – Installation and Operation Manual – 07/12

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•

Seal all conduit threads with Locktite 567™ or equivalent to prevent ingress of moisture.

•

Be sure fittings are tightened securely.

•

Must maintain IP66 for steel, IP67 for stainless and fiberglass electronics enclosures, as well as actuator assembly.

For applications requiring hazardous and explosion proof systems, conduit and conduit fittings must be properly installed to NEC (National Electrical Code) wire standards to meet the area classifications: •

CSA Class I Division 1, Groups C and D; -40C to 65C; T3

•

ATEX II 2G EEX ‘d’ IIB, T3, -40C≤Tamb≤65C.

•

Follow the National Electrical Code (NEC) and appropriate Local Codes for installation of Industrial equipment.

Refer to Appendix P for Interconnect Diagram. WARNING: The position transmitter used in the REXA U is extremely accurate and sensitive. Because of its high sensitivity, directly shorting this circuit with an ammeter can cause damage to the circuit. The load resistance of the DCS needs to be present to protect this circuit from a direct short. Without the load resistance (i.e., using an ammeter), premature failure of the Position Transmitter may occur. Refer to the Troubleshooting and Repair Manual for proper testing procedure.

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50

Mechanical Installation

4 Mechanical Installation

The Xpac can operate any device requiring force and stroke or torque and rotation. These include louvers, dampers, variable speed drives and valves. While the instructions below are primarily focused on valves, they also apply to any device that may be controlled by the Xpac.

4.1 PRE-INSTALLATION CHECKLIST Before installation of the actuator, check for the following: • Ensure that the equipment was not damaged during shipping. • Confirm that the electronic sub-assembly number and actuator serial number match. • that there is sufficient clearance for installation. • Ensure that interconnect cables are present and are the proper length. • Make certain that all the necessary equipment, tools and personnel are present for installation. • Ensure all hydraulic tube fittings are tight.

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11

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4.2 R SERIES (ROTARY) Generally, R Series actuators are shipped with a four bolt mounting pattern and stem connection. REXA can also provide custom mounting components to adapt to the device being controlled. your sales representative for more details.

4.2.1 Rotary Mounting (Fail in Place) The following operation requires the unit to be in the CLOSED position; If it is not, use the handwheel or manual hydraulic pump. Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump. If the unit is not supplied wtih a Handwheel or Manual Hydraulic Pump, the unit must be connected to the electronics and manual operation use to drive it to the CLOSED position. Refer to Manual Mode in section 6. a)

With the actuator separated from its mounting, rotate the driven device to the closed position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b)

Place the mounting bracket on the driven device.

c)

Hand tighten fasteners.

d)

Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

e)

Carefully install actuator to the assembly; hand tighten fasteners.

Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f)

Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g)

Tighten fasteners in a star pattern.

Mechanical Installation

52

Mechanical Installation

4.2.2 Rotary Mounting (Universal Spring Fail) The universal rotary spring package is a bolt on addition to the REXA R series actuator. The unit may rotate in either a clockwise or counterclockwise direction upon power loss. To complete this feature, a normally open solenoid valve is installed in the power module and usually wired to the input power. Please refer to Product Memo 4, Spring Fail, for additional information. If the unit has a REXA solenoid valve it will have the toggle lever shown below. Toggling this lever will override the function of the solenoid. If the unit has no power and you need to use the Handwheel, Drill Drive or Manual Hydraulic Pump the lever must be in the solenoid override position as shown in Figure 4.2.2. CAUTION: Make sure the toggle lever is returned to its normal position when solenoid power is returned, or the spring fail function will not operate properly.

Figure 4.2.2 Solenoid Override Position The spring package will be pre loaded (compressed) to a specified torque as indicated on the order. The pre loaded torque is set at an angle of 45° to

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

53

the spring axis. Installation of the driven device within 5° of this position is acceptable. Actuators are usually shipped in the fail position. Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump.

CAUTION!

REXA actuators, denoted by an E, R or U in the model number, contain a spring under tension.

a)

With the actuator separated from its mounting, rotate the driven device to the fail position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b)

Place the mounting bracket on the driven device.

c)

Hand tighten fasteners.

d)

Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

e) Carefully install actuator to the assembly; hand tighten fasteners. Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f)

Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g) Tighten fasteners in a star pattern.

4.2.3 Rotary Mounting Accumulator Fail mode operation uses a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The accumulator is sized to provide full rated output at end of stroke during fail mode.

Mechanical Installation

54

Mechanical Installation

The following operation requires the unit to be in the closed position; if it is not, use the handwheel or manual hydraulic pump. Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump. If the unit is not supplied with a Handwheel or Manual Hydraulic Pump, the unit must be connected to the electronics and manual operation used to drive it to the closed position. Refer to Manual Mode in section 6. a)

With the actuator separated from its mounting, rotate the driven device to the closed position.

Note: Be aware that not all bolt patterns are square; refer to layout drawing for reference.

b)

Place the mounting bracket on the driven device.

c)

Hand tighten fasteners.

d)

Install the shaft coupling if applicable. Confirm the correct position of the shaft key position on both actuator and driven device.

Note: Be sure to use anti-seize compound on mating surfaces.

e)

Carefully install actuator to the assembly; hand tighten fasteners.

Note: If a discrepancy exists between mating connections, check orientation of assembly components.

f)

Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.

g)

Tighten fasteners in a star pattern.

4.3 L SERIES (LINEAR) REXA L series actuators utilize a sliding stem, piston-style cylinder. Mounting to the driven device is typically done with a bolted yoke assembly. Stem connections will vary by application. Refer to Appendix B for information on Stem Connection & Seat Loading Methods.

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4.3.1 Linear Mounting (Fail in Place) Actuators are usually shipped in the retracted position. Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump. Refer to Appendix B, Stem Connections and Seat Loading Methods.

CAUTION!

When mounting linear actuators, take care to avoid mechanical misalignment that would cause side-load to the actuator output shaft. Be sure that the driven device is straight and true. Severe side-load will cause excessive wear to both the actuator and driven device.

a)

With the actuator separated from its mounting, rotate the driven device to the retracted position.

b)

Retract the actuator stem to a position that will allow mounting the actuator without ing the valve stem. If the optional handwheel is not available, the unit must be connected to the electronics and manual operation used to drive it to the closed position. Refer to Manual Mode in section 6.

c)

Place the actuator onto the driven device’s mating surface and loosely install the mounting hardware.

Note: Loose set up allows for float and self-alignment.

d)

Extend the actuator stem until the coupling s the valve stem.

e)

Thread the driven device stem into the coupling for a distance of at least one and one half times the stem diameter and use a lock nut against the coupling to prevent the stem from rotating out.

Note: There are wrench flats machined on the actuator stem for this purpose. No damage will occur if the actuator stem is rotated.

f)

If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align.

Mechanical Installation

56

Mechanical Installation

g)

Securely tighten the mounting connection. Visually inspect the stem for any noticeable indication of bending.

For all other orientations, the actuator in a manner that prevents any noticeable indication of stem bending. Securely tighten the mating connection. Manually stroke the actuator and carefully observe the stem for any evidence of lateral (side to side) misalignment. h) For verification, once the mounting hardware is tight and the actuator is installed, de couple the actuator shaft. If any movement of the actuator shaft can be seen during the process, loosen the mounting hardware, realign the actuator and repeat steps f, g and h.

4.3.2 Linear Mounting (Spring Fail) The spring fail option for linear actuators consists of a spring mounted underneath the hydraulic cylinder and a normally open solenoid valve installed on top of the power module. The spring can be specified to extend or retract the stem upon power loss. It is not field reversible. The solenoid valve is usually wired to the input power. If the unit has a REXA solenoid valve it will have the toggle lever shown in Figure 4.3.2. Toggling this lever will override the function of the solenoid. If the unit has no power and you need to use the hand wheel, drill drive or manual hydraulic pump the lever must be in the solenoid override position as shown in Figure 4.3.2. Note that the REXA solenoid valve option is only available for systems with B, C, 1/2D, and D power modules rated for hazardous but nonexplosion proof environments. CAUTION: Make sure the toggle lever is returned to its normal position when solenoid power is returned, or the spring fail function will not operate properly.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

57

Figure 4.3.2 Solenoid Override Position

CAUTION!

REXA actuators, denoted by an E, R or U in the model number, contain a spring under tension.

4.3.3 Linear Mounting Accumulator Fail mode operation uses a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The accumulator is sized to provide full rated output at end of stroke during fail mode. Actuators are usually shipped in the retracted position. Refer to Appendix M, Manual Operators, for information concerning the Handwheel or Manual Hydraulic Pump. Refer to Appendix B, Stem Connection and Seat Loading Methods.

CAUTION!

When mounting linear actuators, take care to avoid mechanical misalignment that would cause side-load to the actuator output shaft. Be sure that the driven device is straight and true. Severe side-load will cause excessive wear to both the actuator and driven device.

Mechanical Installation

58

Mechanical Installation

a)

With the actuator separated from its mounting, rotate the driven device to the retracted position.

b)

Retract the actuator stem to a position that will allow mounting the actuator without ing the valve stem. If the optional handwheel is not available, the unit must be connected to the electronics and manual operation used to drive it to the closed position. Refer to Manual Mode in section 6.

c)

Place the actuator onto the driven device’s mating surface and loosely install the mounting hardware.

Note: Loose set up allows for float and self-alignment.

d)

Extend the actuator stem until the coupling s the valve stem.

e)

Thread the driven device stem into the coupling for a distance of at least one and one half times the stem diameter and use a lock nut against the coupling to prevent the stem from rotating out.

Note: There are wrench flats machined on the actuator stem for this purpose. No damage will occur if the actuator stem is rotated.

f)

If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align.

g)

Securely tighten the mounting connection. Visually inspect the stem for any noticeable indication of bending.

For all other orientations, the actuator in a manner that prevents any noticeable indication of stem bending. Securely tighten the mating connection. Manually stroke the actuator and carefully observe the stem for any evidence of lateral (side to side) misalignment. h) For verification, once the mounting hardware is tight and the actuator is installed, de couple the actuator shaft. If any movement of the actuator shaft can be seen during the process, loosen the mounting hardware, realign the actuator and repeat steps f, g and h.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

59

4.4 D SERIES (DRIVE) By the addition of a rugged L-shaped mounting base, a lateral load bushing and a lever arm, the R series actuator becomes an excellent drive. Applications requiring long strokes or non-axial loaded rotary motion are effectively solved by this unit. Traditionally, a drive-type actuator is used for “DAMPER” control.

4.4.1 Drive Mounting The base of a REXA drive contains a four-hole mounting pattern. These holes have been sized to accept the appropriate diameter bolt for the imposed load. Table 4.4.1 lists the base hole, minimum bolt diameter and recommended bolt torques. Standard bolting or threaded studs are acceptable, but material strength must be an SAE Grade 8. Hardened load washers and lock washers must be used. The Handwheel or Manual Hydraulic Pump is used to position the Drive Arm.

Table 4.4.1 Drive Base Bolting RECOMMENDED Model Hole Min. Bolt Bolt Torque Diameter Diameter Minimum Maximum D2 500/5 000 D10 000/20 000 D50 000/100 000

.56 ˝ .81˝ 1.00 ˝

½˝ ¾˝ 1˝

20 lb·ft 200 lb·ft 650 lb·ft

30 lb·ft 250 lb·ft 700 lb·ft

Note: Bolting to be SAE Grade 8.

4.4.2 Drive Arm Connection to the driven device (linkage) is by means of the drive arm. Standard arms are based upon actuator size. Each arm includes multiple connection points. See Figure 4.4.2-1. Custom arms are available upon request.

Figure 4.4.2-1 Drive Arm Assembly Reference Drawing

Mechanical Installation

60

Mechanical Installation

The connecting link and other linkage should be selected to withstand the maximum load imposed by the drive. This will vary depending upon the effective length of the arm. The following equation should be used to determine the minimum safe working load of the connecting linkage: Load=

Rated Drive Torque ×5 Effective Lever

For most installations, the optimum alignment of the drive arm and the driven (damper) arm is when they are parallel to each other and perpendicular to the connecting linkage at mid-rotation. Refer to Figure 4.4.2-2. This is accomplished by a combination of linkage length and drive arm adjustments. A slotted spline connection between the drive arm and shaft provides multiple mating angles (5°-10° intervals).

Figure 4.4.2-2 Drive Arm Alignment

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11

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5 Start-Up Considerations

5.1 START-UP CHECKLIST At this time the actuator, electronics sub-assembly and driven device should be installed. Before applying power to the unit and calibrating the actuator the following items should be considered:

5.1.1 Inspection of Electronic Sub-Assembly Installation Check the following: Inspect incoming voltage connection. Test for correct incoming voltage Control signal connections are secure. Outgoing signals are connected properly. Interconnection cable wiring is correct at electronic sub-assembly, actuator junction boxes and terminal blocks. cables are connected and shielded properly at actuator/ electronics.

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62

Start-Up Considerations

All ground wires are secured. All electrical connections are tightened properly. Conduit connections are secure and watertight with thread sealant. Electronics are free of tools and debris. Proper personnel has been notified for lock out/ tag out procedures.

5.1.2 Inspection of Mechanical Actuator Installation Check the following: Oil level is correct. Motor and wires are connected properly and securely. Actuator mounting fasteners are tight. Coupling/split clamp installed properly. All conduit connections are secure and watertight with thread sealant. All tools and equipment are clear of operating area. Safety related covers and labels are installed and clearly marked. Proper personnel has been notified for lock-out/tag-out procedures.

5.2 ALIGNMENT Any noticeable bending of the actuator stem or driven device should be immediately corrected. Not only will operation be impaired, but damage to the actuator seals and bushings or driven device may occur. When mounting the actuator to the driven device the actuator shafts and couplings MUST align properly.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11 63

5.2.1 Lateral Alignment Any misalignment needs to be corrected or it will reduce the life of the actuator and cause damage to the driven device. In most cases, lateral alignment is corrected by stroking the actuator with the mounting or mating connection in a loosened condition. This will allow the connection to self-align. If there is insufficient clearance, then the appropriate bore diameters must be increased.

5.2.2 Longitudinal Alignment LINEAR Failure to reach full stroke is caused by a mechanical limitation within the actuator or driven device. Incorrect yoke leg lengths or thread engagement in the stem coupling may reduce the travel. In most cases, the required adjustment is small and can simply be made by changing the length of thread engagement of the stem coupling. Further adjustment can only be made by changing the length of the yoke legs. If the actuator is installed in a vertical position, manually stroke it to allow the stem connection to self-align. Securely tighten the mounting connection. Visually inspect the stem for any noticeable indication of bending. For all other orientations, the actuator in a manner so that there is no noticeable indication of stem bending. Securely tighten the mating connection. Manually stroke the actuator and carefully observe the stem for any evidence of lateral (side to side) misalignment. ROTARY (<90° Rotation) Failure to reach the full 90° rotation is usually not binding, but rather an installation problem. With the actuator separated from the driven device, rotate the driven device to the closed position. Move the actuator in the same direction until the end of rotary piston travel is reached. The connections between the driven device and the actuator should be within 2-4 degrees. If a large discrepancy exists between the mating connections, the adapter may be incorrect.

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64

Start-Up Considerations

DRIVE Drive units can create an extraordinary amount of force. Any misalignment of the drive/driven arms, or incorrect linkage arrangements, can cause damage to the actuator or the driven device. All mechanical connections and stroke limits should be set carefully and inspected.

5.3 INITIAL CALIBRATION Refer to Section 5.4, Rotary and Drive Spring Stops, and Section 5.5, Cylinder End Stops, prior to calibrating rotary or drive units with spring or accumulator fail option. • Apply AC Power. Line 2 will display the CALIBRATE menu header. • If not already in CALIBRATE, simultaneously press AUTO/MANUAL for 5 seconds. • Scroll down to Position Lo with the arrow. • Press the ENTER (   ) key. = will begin to flash. Value will change to current actuator position. • Move the actuator with the or to the Position that corresponds to 4.0 mA. Refer to Appendix B, Stem Connection & Seat Loading Methods. • Press the ENTER (   ) key to lock in that value. CAUTION! The end point should not be set against a mechanical stop without a spring coupling or damage will occur.

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11 65

Note: If the actuator is stroked beyond the factory set cylinder limit, the display will show CylEnd while the down key is held. If the enter key is pressed, the display will show TooLow. Position Lo will need to be calibrated higher until this warning goes away.

• Scroll down to Position Hi with the

arrow.

• Press the ENTER (   ) key to lock in that value. • Press the ENTER (   ) key. = will begin to flash. Value will change to current actuator position. • Move the actuator with the 20.0 mA.

or

to the Position that corresponds to

• Press the ENTER (   ) key to lock in that value. CAUTION! The end point should not be set against a mechanical stop without a spring coupling or damage will occur. Note: If the actuator is stroked beyond the factory set cylinder limit, the display will show CylEnd while the up key is held. If the enter key is pressed, the display will show TooHi. Position Hi will need to be calibrated lower until this warning goes away.

• Scroll down to Signal Lo with the

arrow.

• Press the ENTER (   ) key. = will begin to flash. • Apply the actual 4.0 mA Control Signal from the DCS. The value in the display will change; showing what is being read from the DCS. • Press the ENTER (   ) key to lock in that value. • Scroll down to Signal Hi with the

arrow.

• Press the ENTER (   ) key. = will begin to flash. • Apply the actual 20.0 mA Control Signal from the DCS. The value in the display will change; showing what is being read from the DCS.

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66

Start-Up Considerations

The Actuator has now been calibrated. It is recommended at this point that all Current Status be reset to 0. Refer to Current Status menu section for procedure. To enter the Auto mode: • Simultaneously press Auto (  ) and ENTER (   ). Line 1 of the display will change to Auto followed by the Current Status. Line 2 will be blank. • When the keys are released Line 2 will display the current Position.

5.4 ROTARY AND DRIVE SPRING STOPS Spring stops provide the actuator the means to prevent over-travel during a fail safe condition. If the driven device does not limit over-rotation or overtravel, spring stops can be utilized for this purpose by turning the spring stop adjustment screw in or out to modify the actuator’s final fail position. To install a Spring Fail unit, position the spring lever to the 45° location by extending the spring stop as shown in Figure 5.4. Rotate the driven device to the required failure position. Adjust the spring stop to allow mating of the shafts and alignment of the mounting bolts.

Figure 5.4 Universal Spring Alignment

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11 67

Once mounted, the spring stops should be adjusted to a position that transfers torque onto the driven device at the fail position.

5.5 CYLINDER END STOPS Cylinder end stops provide the actuator the means to prevent over-travel during a fail safe condition. If the driven device does not limit over-rotation or over-travel, cylinder end stops can be utilized for this purpose. These stroke adjusters can reduce cylinder rotation 0–5 degrees.

1

2 3

Figure 5.5 Stroke Adjustment

CAUTION!

Ensure that there is no hydraulic pressure in the system prior to cracking any hydraulic lines. All pressure gauges should read 0 psi.

Note: Each actuator is tested and shipped from the factory with the thread seal and jam nut lightly torqued—enough to seal during factory acceptance testing. This procedure assures that the sealing rubber is undamaged and will properly seal once the stroke adjustor is fully adjusted in the field by the end , and the threaded elements are firmly tightened to full torque.

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68

Start-Up Considerations

5.5.1 End Stop Adjustment Counter Clockwise Adjuster

Clockwise Adjuster

Figure 5.5.1-1 Cylinder End Stops WARNING: The Calibrated end points PL and PH must not be set with the actuator against the cylinder end stop. 1. Position the actuator in the desired final fail position slightly beyond the calibrated end stop. This can be done when calibrating PL and PH. Note: Failure to follow this step will lead to a potential situation where the electronics may try to drive the actuator beyond its physical limit, and a stall condition will result.

2. Turn off the power breaker in the electronics. 3. Locate the correct stroke adjuster (refer to Figure 5.5.1-1). 4. Locate the hydraulic fitting (1) connected directly to the stroke adjuster cylinder cap as shown in Figure 5.5. Loosen this fitting to allow oil to escape during this adjustment process. 5. Loosen the jam nut (Figure 5.5.1-2) by turning counterclockwise. Back off this jam nut 4 to 5 turns and move the countersunk washer away from the thread seal and against the repositioned jam nut.

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11 69

6. Using light oil and a small brush or squirt can, generously lubricate the thread seal rubber and the threads of the adjustment screw. 7. Carefully pry the thread seal washer away from the end cap and then pull and twist it back and forth to carefully slide it along the adjustment screw threads to gain adjustment clearance. 8. The actuator stroke adjustment can now be made using the threaded adjustment rod. This rod has a hollow hex in the end to allow easy adjustment. WARNING: As the stroke adjusters are turned in, fluid will be displaced and need to leak out of the system. Failure to exhaust fluid will damage internal components of the actuator. 9. The actuator is shipped from the factory with this adjustment rod threaded fully out to the end of travel to give the full rotation of the actuator. The adjustment screw can only be rotated clockwise (inward) from this shipped position. Caution: A mechanical lock at the end of the threads restricts inadvertent disassembly outward. Rotating the adjustment screw counterclockwise (outward) from this end position may cause damage to the hardware.

Figure 5.5.1-2 End Stop Detail 10. Use an allen wrench drive inserted into the hollow hex adjustment screw end to adjust the stroke adjustor. Rotate clockwise to decrease the stroke of the actuator. Each stroke adjustor provides a minimum of 5 degrees of actuator rotation adjustment.

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70

Start-Up Considerations

11. The number of adjustment screw rotations needed to achieve the 5 degree rotational adjustment of the actuator depends on the size (model) of the actuator and the pitch of the adjustment thread on the adjustment screw. The Table 5.5.1 shows this relationship. 12. After final positioning of the adjustment screw to achieve the desired actuator rotation, readjust the position of the thread seal along the adjustment screw threads to the end cap. Caution: use generous lubrication during this step to assure no damage to the rubber seal by the threads. 13. Reposition the countersunk washer and the jam nut and torque the jam nut to the requirements of the Table 5.5.1. 14. Tighten the hydraulic fitting that was loosened in step 4.

Table 5.5.1 Stroke Adjustor Model

One Turn Adjustment Jam Nut Final Torque (degrees) (lb·ft)

R2 500/R5 000

3.3

50

R10 000/R20 000

2.0

150

R50 000/R100 000

2.0

300

R200 000/R400 000

1.2

375

5.5.2 R200 000/R400 000 End Stroke Adjustments R200 000/R400 000 actuators do not use an external thread seal arrangement. The seal is contained internally while the jam nut and adjustment screw drive is located externally. Refer to Figure 5.5.2. An external drive square is provided on the adjustment screw end and can be driven by using a standard wrench. No special lubrication of the threads is needed during adjustment. The unit is shipped from the factory with the stroke adjustor positioned at the full outward position as described above. Adjustment is made by disconnecting the hydraulic line to vent out any displaced fluid, loosening the jam nut several turns counter clockwise and then using the square drive to position the adjustor

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REXA Series 2 Xpac – Installation and Operation Manual – 09/11 71

to provide the desired actuator stop position. The total adjustment range is 5 degrees minimum. Table 5.5.1 shows the adjustment achieved from one turn of the adjustor. The jam nut is repositioned after adjustment is complete and torqued to the final tightness value specified.

Jam nut

Drive square

Adjustment screw Figure 5.5.2 R200 000/R400 000 Stroke Adjuster

Start-Up Considerations

72

Modes of Operation & Control Parameters

6 Modes of Operation & Control Parameters

The interface is a 2-line, 20 character/line vacuum fluorescent emissive display with a membrane keypad. The display may suffer phosphor burnout if a static display is left on for a long period of time. To avoid this, the display is dimmed after one hour of no keypad usage. The display may be turned back on by pressing any key. If, while in Auto or Local Manual mode, an alarm condition is detected, the entire display will blink on and off until acknowledged by an operator pressing any key. The electronics can be put into 3 different modes of operation. They are:

o Setup o Automatic (Auto) o Manual (Local Man, RemoteMan)

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 73

Each mode can be entered as shown in Figure 6:

Figure 6 Modes of Operation

6.1 SETUP MODE The Setup mode is the means of setting the control parameters of the actuator such as actuator span, speed, etc. Most parameters are factory set and provide excellent actuator performance. However, some applications may require fine tuning of the actuator. The eight menus and accompanying control parameters are covered in the following sections. To access and change the Control Parameters (See Figure 6.1.1), the electronics must be in the Setup mode. protection of the Setup mode is optional. The default value of 0000 indicates no is required. If any other value is set as the , the will be prompted to enter it prior to entering the Setup mode.

6.1.1 Menu Navigation To get the electronics in Setup mode, simultaneously press AUTO (  MANUAL (  ) for 5 seconds.

) and

Note: The actuator will no longer follow a control signal when in setup mode.

To scroll from column to column, you must have the column header in the display and press ENTER (   ). This will scroll from left to right and then repeat. To scroll up and down a column, use the



and

arrows.

Modes of Operation & Control Parameters

X2 Control Parameters Menu

Only if Flow Char = On

Only if Sol. Seat = On

Requires Special Construction

Only if Signal Type = Analog

Signal Hi

Only if Signal Type = Analog

Signal Lo

Position Hi

Position Lo

CALIBRATE

CS 90% Pt

CS 10% Pt

Only if Signal Type = Analog or Commun

Flow Char

Cal. Stroke

Sol. Seat

Seat Load

Seat Ld Cyl

Only if Signal Type = Analog or Commun

Bumpless

NA if Signal Type = 1 Cont

Min Mod

Max Hi Spd

Deadband

Accum Pres

Accum Dir

Rechrg Time

Warn Pres

Rechrg Pres

Accumulator

Surge Offpt

Only if Surge Bkpt = Off

Version

Close Pres

Open Pres

00000

Xmitter Hi

Xmitter Low

Pos Xmitter

SB - only if Sig. Type = Analog Accum. = No & Booster Pump = Off

BP - only if Drive Type = Servo & Surge Bkpt = Off

Only if Surge Bkpt ≠ Off

See SB below

Surge Bkpt

See BP below

Boost Pump

Relay #2

Relay #1

Drive Type Stall Time

OUTPUTS

DRIVES

Figure 6.1.1 Control Parameter Menus

Max Man Spd

Power On

Trip

Only if Signal Type = Commun

Shed Time

Only if Signal Type = Analog or Commun

Failsafe

Only if Signal Type = Pulse

Pulse Inc

Only if Signal Type = Pulse

Pulse Dur

Signal Type

INPUTS

If 2-Speed = Bkpt >> Lo Up/Dn >> Dn

Only if 2-Speed = Bkpt

Speed Bkpt

Max Dn Spd

Max Lo Spd

2-Speed

Lo Accel

Accel Bkpt

Hi Accel

Gain

If 2-Speed = Up/Dn

Max UP Spd

SPEED/ ACCEL

CONTROL

Only if Accumulator = Yes

REXA Series 2 Xpac – Installation and Operation Manual – 10/14 Last Error

Strokes x1k

Starts x1k

Over Temp

Low Oil

Strokes x1k

Starts x1k

Over Temp

Low Oil

Cl Pres bad

Op Pres bad

Op Pres bad Cl Pres bad

Stall

SLC Stop

Direction

CS bad

Fb bad

SLC Fb bad

Shed Time

Pressure bd

Drive fault

A/D Fail

Mem Fail

HISTORIC STATS

Stall

SLC Stop

Direction

CS bad

Fb bad

SLC Fb bad

Shed Time

Pressure bd

Drive fault

A/D Fail

Mem Fail

CURRENT STATS

Errors will only be shown if they have occurred Require special construction

Requires special construction

REXA Series 2 Xpac – Installation and Operation Manual – 10/14 75

6.1.2 Changing a Parameter To access and change a parameter, the Parameter ID must be visible on the display, i.e. Position Lo. Pressing the button will cause the “=” sign to blink. The parameter is now accessible to change. Use the and arrows to change the value of the parameter. To accept the new value, press the button. The “=” sign will stop flashing. When a value is entered for any parameter, updating is briefly displayed. Pressing the or arrow in parameters Position Lo and Position Hi will cause the Actuator to move. Parameters Signal Lo and Signal Hi cannot be changed by pressing the arrows. An active 4-20 mA signal must be applied. The actual signal in milliamperes will be displayed.



Modes of Operation & Control Parameters

76

Modes of Operation & Control Parameters

6.1.3 CALIBRATE Menu The CALIBRATE menu consists of the following parameters: Note: When changing Position Lo and Position Hi, the actuator will move.

Position Lo defines the actuator position corresponding to Signal Lo setting. When Signal type is set to Inputs, Position Lo defines the actuator position corresponding to the Close Input. Note: The span between Position Lo and Position Hi must be greater than 10%.

Position Hi defines the actuator position corresponding to the Signal Hi setting. If the Signal type is set to Inputs, Position Hi defines the actuator position corresponding to Open Input. Note: If a value for Position Lo is entered that is within 10.0% of the current value of Position Hi, the value is accepted, and parameter Position Hi is displayed. If the display shows the = blinking, it is ready to be set to a value more than 10.0% different than Position Lo. The menu will alternate between Position Lo and Position Hi until a span greater than 10% is achieved. Similar action occurs when setting Position Hi. While uncommon, if Driver Type (see Drives Menu) does not match the actuator, a continuous loop between Position Hi and Position Lo will occur.

Signal Lo is the Input Signal, typically 4 mA, that corresponds to Position Lo.

Signal Hi is the Input Signal, typically 20 mA, that corresponds to Position Hi. Signal Lo and Signal Hi are only visible in the menu if Signal Type = Analog. Range: 0.0 to 25.0 mA Note: Unknwn appears if control signal failure occurs while calibrating. Error appears, briefly, if an unacceptable value is entered. The unacceptable value is rejected and the previous value is retained. Note: If Failsafe does not = Off, input signal value must be greater than 2.5 mA and the span must be greater than 3.8 mA. Refer to INPUTS menu. Note: If Failsafe = Off, the span for Signal Hi must be greater than 3.8 mA or vice versa.

Refer to INPUTS menu for Failsafe information.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 77

Refer to section Initial Calibration (Start-Up Considerations) for additional information on Position Lo, Position Hi, Signal Lo and Signal Hi settings.



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78

Modes of Operation & Control Parameters

6.1.4 CONTROL Menu The CONTROL menu provides the following:

Deadband sets the maximum deviation allowed between Input Signal and current position before actuator movement in Auto mode. Units: % of calibrated stroke Range: 0.05 to 5.00 % of calibrated stroke` The deadband should not be set any smaller than the process requires. Check to ensure the actuator is not reacting to noise in the control signal, but to actual signal changes.

Min Mod {Minimum Modulating} defines a set-point in the actuator stroke below which the actuator will not modulate. Min Mod sets the upper limit of a no-modulating band with respect to Position Lo. This may be used to minimize seat wear. Not in menu if parameter Signal Type = 1 Cont. Operational in both Auto and Local Man/RemoteMan Units: % of calibrated stroke (Refer to INPUTS Menu.) Range: Off or 0.1 to 99.9 % of calibrated stroke

Bumpless {Bumpless Transfer} sets the total time the actuator takes to travel from its current position to a new target control position when the actuator is switched from either Manual or Setup into Auto. This feature is designed as a safeguard in the event the control signal was changed while the actuator was not in Auto mode. When the unit is switched into Auto and the Bumpless parameter is On, the actuator seeks the new target position at less than normal

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 79

speed. The actuator will take 100 small steps to reach the new target position in the time set as the bumpless parameter. A delay will be defined between each step until the actuator reaches the new target position. This feature only appears in the menu if the incoming control signal parameter Signal Type is set to Analog or Commun. •

If Bumpless is set to any value other than Off when the actuator is switched to Auto and the deviation between the incoming control signal and the actuator’s current position is LESS than ten times the dead band parameter, the operation of the actuator is the same as Bumpless = Off.

•

If Bumpless is set to any value other than Off when the actuator is switched to Auto and the current deviation between the incoming control signal and the actuator’s current position is GREATER than ten times the dead band parameter, the operation of the actuator is to:



Divide the Bumpless time parameter by 100 to define the time interval between actuator steps. These steps are how the actuator will track to its new control position.



Divide the deviation between the current actuators position and the new control signal position by 100. This defines the size of each step.

Once the actuator reaches the control signal set point the actuator will resume normal operation. Only in menu if Signal Type=Analog and Accumulator=No, and Booster Pump= No. See INPUTS and DRIVES menus. Units: Seconds Range: Off or, from 10 to 990 seconds



Modes of Operation & Control Parameters

80

Modes of Operation & Control Parameters

Seat Ld Cyl {Seat Load Cylinder}: Specifies whether or not the actuator employs a seat load cylinder. This yes or no option is set at the factory. Refer to Appendix B, Stem Connection & Seat Loading Methods, for additional information.

Seat Load {Seat Load Switching}: Specifies that the actuator does not employ a seat load cylinder (Off) or that a seat load cylinder is employed and the value entered is the transition point at which the seat load cylinder is engaged/ disengaged via solenoid action.

Sol. Seat {Solenoid Seating}: Uses software to allow the stored energy of a failsafe actuator to provide the seating force. Can only be used on linear failsafe actuators where the fail direction is the same as the seating direction. Replaces the elastic coupling and seat load cylinder for these applications.

Cal. Stroke {Calibrated Stroke}: When Sol. Seat = On, Cal. Stroke can be set from .3" to 99.9" in one inch increments. Flow Char {Flow Characterization}: The actuator is designed to have a linear relationship between Control Signal and stroke (10% CS, 10% stroke, etc.) The ability to modify this characteristic can assist in loop tuning or linearization of a control scheme. Changing this actuator characteristic can have a profound effect on the behavior of the control loop and should only be undertaken wtih a thorough understanding of the effect. The stroke position can be modified at 10% control signal intervals. The only restriction is that each stroke position must be at least 2.5% from its neighbors.

CS 10% Pt thru CS 90% Pt {Control Signal 10% Point thru Control Signal 90% Point): When Flow Char= On, parameters CS 10% Pt thru CS 90% Pt are added to the CONTROL menu. Each of these 9 parameters specifies the desired actuator position when the Analog control signal is equal to the corresponding point. Operation between Setpoints is linear. Units: % of calibrated stroke Range: CS 10% Pt: 2.5 to CS 90% Pt 97.5 Each calibrated stroke must be at elast 2.5% distant from the adjacent position.

Ex.; If CS 10% Pt= 2.5 when a 10% Control Signal is applied, the actuator will travel 2.5% of calibrated stroke.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 81

6.1.5 SPEED/ACCEL Menu The SPEED/ACCEL menu displays the following:

Max Hi Spd {Maximum High Speed} specifies the maximum motor speed when operating in the Auto mode when 2-Speed is set to Off or to Bkpt. This speed parameter will go above 100%, but the output of a stepper module will be reduced if setting it beyond this value. The motor may run into stall conditions. Conversely, turning the speed down below 100% will allow the motor to make more torque if a stalling condition exists. When running a stepper module near the low temperature specification the speed may need to be lowered to avoid occasional stalls

Max Up Spd {Maximum Up Speed} is in the menu when operating in Auto mode when 2-Speed is set to Up/Dn. Max Up Spd specifies the maximum motor speed when moving from Position Lo toward Position Hi. Range: 5 to 125 % of actual motor speed, but no greater than Max Hi Spd.

Gain: In the Auto mode Gain is used to determine how motor speed is adjusted as the actuator approaches the target position. The higher the Gain setting, the closer the actuator will get to the target position before decelerating. The lower the Gain setting, the further away the actuator will be from the target position when it begins to decelerate. This value is typically factory set; however, it may be changed should the application warrant it. Range: 1 to 250

Figure 6.1.5 Gain



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Modes of Operation & Control Parameters

Hi Accel {High Acceleration}: Drive Type = Step Hi Accel defines the rate at which the motor speed will be increased or decreased until maximum speed is achieved for all modes of operation. It may be replaced by Lo Accel if dual acceleration is used in combination with Gain to define the rate of motor speed decrease until it reaches the target position. Hi Accel allows the actuator to use two separate acceleration rates. If the actuator is to make a large move, increase the acceleration rate to get to the new Setpoint as quickly as possible. If the actuator is modulating and requires small step changes, a slower acceleration eliminates overshoot. The acceleration breakpoint allows the value for Hi Accel for changes in Setpoint that are greater than Accel Bkpt and Lo Accel for changes in Setpoint that are less than Accel Bkpt value. Acceleration Breakpoint defines the maximum deviation for which Lo Accel is used in place of Hi Accel. Set Hi Accel for large changes and Lo Accel for small changes.

Hi Accel {High Acceleration}: Drive Type = Servo Hi Accel defines the rate at which motor speed will be increased until maximum motor speed is reached for all modes of manual stroking. (Manual stroking = Local Man, RemoteMan, and when setting Position Lo/Hi in Setup mode.) Range: Lo Accel to 99 (Can not be set below value set in Lo Accel)

Accel Bkpt {Acceleration Breakpoint} defines maximum deviation for which Lo Accel is used in place of Hi Accel. Note: If deviation between signal and position is < or = to Accel Bkpt, Lo Accel is used in place of Hi Accel. Note: If deviation between signal and position is > than Accel Bkpt, only Hi Accel is used.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 83

Range: 0.1 to 5.0 Note: If Lo Accel = Hi Accel or if Accel Bkpt = 0.1, dual acceleration is nullified.

Lo Accel {Low Acceleration} defines an optional low rate of acceleration for small deviations (< Accel Bkpt) in Auto mode. Range: 1 to Hi Accel (Can not be set above value set in Hi Accel)

2-Speed defines status of optional two speed operation. Select: Off, Up/Dn or Bkpt Default: Off When 2-Speed = Off, Max Hi Spd specifies maximum motor speed when operating in Auto. When 2-Speed = Up/Dn, Max Dn Spd defines motor speed as unit moves toward parameter Position Lo. Max Hi Spd is changed to Max Up Spd and defines motor speed as unit moves toward parameter Position Hi. Note: When operating in Auto, Local Man, or RemoteMan and traveling toward the position specified by parameter Position Hi, Max Up Spd sets the speed limit. Note: When operating in Auto, Local Man, or RemoteMan and traveling toward the position specified by parameter Position Lo, Max Dn Spd sets the speed limit. Note: When operating in Setup, Max Man Spd sets the speed limit. When 2-Speed = Bkpt, Max Lo Spd and Speed Bkpt are added to the menu. Note: Max Hi Spd defines motor speed between Spd Bkpt and Position Hi Note: Max Lo Spd {Maximum Low Speed} defines maximum low speed between Spd Bkpt and Position Lo. Note: Speed Bkpt {Speed Breakpoint}: Provides a speed transition point.



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Modes of Operation & Control Parameters

Range: 0.1 to 99.9

Max Man Spd {Maximum Manual Speed} defines the maximum motor speed when operating in Setup. Sets the maximum motor speed when operating in Local Man or RemoteMan only if 2-speed = Off. Range: 5 to 125 (but no greater than Max Hi Spd) Default: 80

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 85

6.1.6 INPUTS Menu The INPUTS menu consists of the following parameters:

Signal Type: Selects the main control signal(s) for the Auto mode. Allows the to define the type of control signal being sent to the actuator. Select Analog, 1 Cont, 2 Cont, Pulse, or Commun. Note: 1 Cont, 2 Cont and Pulse are only included in the Inputs menu if / Pulse Inputs Board is installed. Refer to Appendix E, Pulse Operating System, and Appendix Q, Input Options, for additional information.

When Signal Type = Analog, the main control signal is the 4-20 mA anaput. This selection provides the full modulating capability of the actuator. When Signal Type = 1 Cont (one ), “two position” operation— open/closed position—is selected. The applied signal defines actuator position. If the Open input is active (powered), the actuator goes to Position Hi. If the Open input is not active (un-powered), the actuator goes to Position Lo. When Signal Type = 2 Cont (two s), “manual modulation” operation is selected. The main input signals are the Main s Open and Close inputs of the Input Board. If both inputs are active or inactive, the actuator remains in its current position. If only the Open input is active, the actuator travels towards Position Hi. If only input Close is active, the actuator travels towards Position Lo. Note: Actuator will continue to move in desired direction as long as a signal is present or until target is reached.

When Signal Type = Pulse, ”pulse” operation is selected.

Pulse Dur {Pulse Duration} sets the minimum time that the Pulse Input must remain active in order to be recognized as a valid signal. A continuous signal may be measured as multiple pulses.



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Modes of Operation & Control Parameters

Ex.; With pulse Duration set at 50 milliseconds, a 100 millisecond pulse equals two pulses. Units: ms (milliseconds) Range: 10 to 999 milliseconds

Pulse Inc {Pulse Increment} sets the amount of actuator travel for each valid pulse received. It only appears in menu if Signal Type= Pulse Range: 0.1 to 5.0 % of calibrated stroke The input signals are the Main s Open and Close inputs of the Input Board. If only input Open is active and meets the requirements of Pulse Dur, the value set in Pulse Inc is added to (direct acting) or subtracted from (reverse acting) the current position to become the new target position. The actuator then seeks this new position. If only input Close is active and meets the requirements of Pulse Dur, the value set in Pulse Inc is subtracted from (direct acting) or added to (reverse acting) the current position to become the new target position. The actuator then seeks this new position. If both inputs are active or inactive, the actuator holds its current position. Pulse input has the ability to control the actuator by an Open or Close pulse signal. Each Input signal must meet the minimum pulse duration. For a period of time it will be recorded as a number of pulses based on defined pulse duration. Target position can be adjusted based on the number of pulses and defined pulse increments. The motor will then move in desired direction until new target position has been reached. When Signal Type = Commun, the full modulating capability of the actuator is also provided. However, the controlling signal is the Setpoint Parameter which may be written via one of the communication interfaces( HART or Foundation Field Bus™ ). Note: When set to Commun, parameters Failsafe and Shed Time are added to this menu.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 87

Failsafe defines the position the actuator moves to via the motor if the Analog control signal falls below 2.5 mA. Only in menu if Signal Type = Analog. Select:

Inplac: Actuator remains in current position. 0% to 100%: Actuator goes from 0% to % set. Off: Used for zero based control signal, i.e., 0-20 mA. “Off” will appear above a setting of 100%. Default: Inplac. Note: Local and Remote Manual will override the Failsafe position.

Shed Time specifies the maximum amount of time allowed between writes to parameter Setpoint before the action specified in parameter Failsafe is taken. When set to OFF, no action is taken. Only in menu if Signal Type = Commun

Trip parameter defines the active state of the AUX CLOSE input on the s Inputs Board. This secondary input is used to override the main input to cause actuator movement with the aid of a solenoid/spring package or with an accumulator. This Failsafe position is factory configured to either calibrated end, but not to both, and is not field reversible. When Trip = Off, trip function is not used When Trip = Unpwrd, and AUX CLOSE input is not powered, go to end point (Trip = Logic ø) When Trip = Pwrd, and AUX CLOSE input is powered, go to end point (Trip = Logic I) Note: Trip = Unpwrd/Trip = Pwrd is only selectable if Inputs Board is installed.



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Modes of Operation & Control Parameters

Power On parameter defines the mode the Control Enclosure will be in when Main Power is applied. When Power On = Last, (the default), on power up or reset, the actuator will return to its previous operating mode (Auto, Local or Setup). When Power On = Local, on power up or reset, if the previous mode was Auto, the actuator will enter Local mode instead.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 89

6.1.7 DRIVES Menu The DRIVES menu consists the following parameters:

Drive Type defines the type of motor, stepper or servo, provided with the power module(s) and is factory set to Step or Servo.

Stall Time defines the maximum time, 1 to 50 Sec (seconds), allowed for the actuator to travel 1% of calibrated stroke before a stall is assumed. If 1% travel is not detected in the time set, the motor drive is stopped, the drive is reset and a restart attempted. A maximum of five retries are allowed before a stall error (alarmed) is declared. Note: Stall Time also sets the point at which the Booster Pump will turn off. Note: If Stall Time = 1-5 seconds, the Booster Pump will turn off 2.5% away from the target position. Note: If Stall Time = 6 -10 seconds, the Booster Pump will turn off 1.0% away from the target position. Note: If Stall Time > 10 seconds, the Booster Pump will turn off 0.5% away from the target position.

Boost Pump: {Booster Pump Breakpoint} defines the minimum deviation,5.0 to 99.9% of calibrated stroke or Off, between current position and Control Signal for the booster pump to turn on. Note: Only in menu if Drive Type = Servo, and Surge Bkpt = Off. Note: If no Boost Pump, Boost Pump = Off

Main Valves sets the maximum deviation allowed before the main valves are opened. This is a special parameter; used only with actuators which use an accumulator for all motive force (no power module).



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Modes of Operation & Control Parameters

Note: The main valve off point is set by parameter Stall Time. Note: Main Valves is only visible in the Drives menu if Foundation field bus is installed. Requires special construction.

Surge Bkpt {Surge Breakpoint} defines in % calibrated stroke the minimum deviation between the current position and the new target set by the incoming Control signal, required to operate the surge solenoid. When the deviation exceeds the setting, the Surge Relay output is activated and kept active until the current position matches the current control signal. The Surge Relay controls a solenoid valve allowing the actuator to travel quickly in the surge direction when activated. Only in menu if Signal Type = Analog, Accumulator = No and Booster Pump = No. Note: Surge Bkpt is only included in the SPEED/ACCEL menu if / Pulse Inputs Board is installed. Refer to Appendix G, Surge Control Option, for additional information.

Surge Offpt{Surge Offpoint} will only appear in the DRIVES manu when the Surge Bkpt has a value other than off. Surge Offpt is defined in percentage of calibrated stroke. This percentage will define a distance the actuator will be away from its new target position when it changes the state of the surge solenoid during a surge event. On system with high speed trips this will allow the controller to change states of the solenoid to anticipate hitting the new target position and eliminate overshoot during a surge event. With Surge Offpt set to off the actuator will command the surge solenoid to change state when it reaches its new target position during a surge event. This will result in some overshoot of the new position as the actuator will continue to travel while the solenoid changes states. Surge Offpt has a settable range of 0.1% up to 5% less than the current Surge Break point value.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 91

Accumulator defines whether or not an accumulator system is present, Accumulator action is controlled by parameter Trip; refer to INPUTS menu. Factory set to Yes or No. If Accumulator = Yes, he following 5 parameters are in the menu.

Rechrg Pres {Recharge Pressure} adjusts the pressure level at which an accumulator recharge cycle ends. Factory set in # (psi), from Warn Pres + 100 up to Warn Pres + 3000 psi. Warn Pres {Warning Pressure} adjusts the pressure at which an accumulator low pressure warning is issued. Factory set from 1000 psi up to Rechrg Pres - 100 psi. Note: The Warning relay deactivates and the status display will indicate Pres Low when the accumulator pressure drops below the value set in

Warn Pres. Rechrg Time {Recharge Time} adjusts the maximum time allowed for a recharge cycle to complete. A recharge cycle ends when either the Rechrg Pres setting is reached or the Rechrg Time expires. In either case, the actuator resumes tracking the control signal. Recharge Time is factory set.

Accum Dir {Accumulator Direction} defines the direction the accumulator will cause the actuator to travel during a Trip. This parameter is factory set based on information provided. This parameter is necessary to inform the U as to which direction, Pos Lo (Position lo) or Pos Hi (Position Hi), to operate the motor during a recharge cycle after a Trip.

Accum Pres {Accumulator Pressure}: This parameter cannot be set. It is the “live” pressure reading from the accumulator pressure transducer. Units: # (psi) Range: 0 to 3000 Unknwn if “pressure bad” error



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Modes of Operation & Control Parameters

6.1.8 OUTPUTS Menu The OUTPUTS menu consists of the following parameters:

Relay #1 Relay #2 Pos Xmitter Xmitter Low Xmitter Hi Version Relay #1 defines the point in % of calibrated stroke at which relay output 1 is active. The relay will be active when the actuator position is = or < the value set in Relay #1

Relay #2 defines the point in % of calibrated stroke at which relay output 2 is active. The relay will be active when the actuator position is = or > the value set in Relay #2

Pos Xmitter {Position Transmitter} defines the action of the position transmitter output as being direct acting, Dir or reverse acting, Rev. When set to direct acting, a 4 mA output corresponds to Position Lo. When set to reverse acting, a 4 mA output corresponds to Position Hi.

Xmitter Low {Transmitter Low} is the parameter to calibrate the Output zero of the 4-20 mA Position Transmitter. To calibrate the 4mA Zero, Set a digital multi-meter, DMM, to read milliamps (mA) DC. Connect the DMM to the Position Transmitter Output on the U. Connect the Red lead of the DMM to the LOOP OUT terminal. Connect the black lead of the DMM to LOOP INT RTN terminal. Press Enter to access this setting.

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REXA Series 2 Xpac – Installation and Operation Manual – 10/14 93

The Value displayed on the REXA display corresponds to Digital bits. Each increment or decrement of 4 bits and will increment or decrement the current output by one micro-amp (1 µA). The acceptable range for Xmitter Lo is 3.9 to 4.1 mA.

Note: The Position Transmitter will output the mA signal that corresponds to the actuators current position until the Enter button is pressed and the “=” sign is flashing. When the “=” sign is flashing, the output will change to the “Zero” or Lo Calibration value.

Xmitter Hi {Transmitter Hi} is the parameter to calibrate the Output span of the 4-20 mA Position Transmitter. To calibrate the 20 mA Span, Set a digital multi-meter, DMM, to read milliamps (mA) DC. Connect the DMM to the Position Transmitter Output on the U. Connect the Red lead of the DMM to the LOOP OUT terminal. Connect the black lead of the DMM to LOOP INT RTN terminal. Press Enter to access this setting. The Value displayed on the REXA display corresponds to Digital bits. Each increment or decrement is steps of 4 bits and will increment or decrement the current output by one micro-amp (1 mA). Note: The Position Transmitter will output the mA signal that corresponds to the actuators current position until the Enter button is pressed and the “=” sign is flashing. When the “=” sign is flashing, the output will change to the “Span” or Hi Calibration value. Note: Xmitter Hi and Xmitter Lo values are not transmitted over the bus in Foundation Fieldbus units.



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Once the position transmitter calibration is complete, there is no need to recalibrate the transmitter for changes in actuator span. Changing the actuator span will cause the transmitter span to automatically re-calibrate its output.

{} defines the required to enter the

Setup mode in order to change any control parameters. The default value of 0000 indicates no is required. If a value is entered into other than the default value, future entry into Setup mode will require that the enter the value prior to gaining access to the Setup menus. Version {Software version} displays the version of software. Example:

Version X01_0_AA_xxxx

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6.1.9 CURRENT STATS Menu and HISTORIC STATS Menu The CURRENT STATS and HISTORIC STATS menus both provide error counters and usage indicators. The two menus provide identical information, the difference being that the CURRENT STATS parameters can be reset to 0 in the Setup mode where as the HISTORIC STATS cannot. Also, the CURRENT STATS can be viewed (but not altered) in Auto mode. HISTORIC STATS can only be viewed in Setup mode. The error counters are provided as an aid to diagnosing a problem. They are particularly useful in identifying intermittent problems since they record ALL instances of detected errors, rather than just those which result in an “alarmed” condition. They are also useful in identifying problems associated with actuator “tuning”. Note: Refer to the TS&R Manual for trouble shooting .

The error counters generally operate in the Auto mode (inclusive of Local Man / RemoteMan) only. Errors detected in Setup are not recorded. If the Auto mode is entered from Setup with an existing error, the error is not counted. The only exception to the “Auto mode only” rule is the Mem Fail counter which operates only in Setup mode. Usage indicators only record in Auto mode. The CURRENT STATS error counters and usage indicators may be reset to zero by the following; While in Setup and the counter/indicator to be reset is on display: Press (E)nter – the equals sign begins blinking Press (D)own – the value field resets to zero Press (E)nter – the new count is now zero Note: If the (U)p key is pressed prior to step 3, the old count is returned to the display and will be retained if the (E)nter key is then pressed.



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Modes of Operation & Control Parameters

Mem fail indicates the number of times that the Setup parameter memory failed to erase/write a parameter value properly.

A/D fail indicates the number of times the A/D converter failed to respond to a command.

Drive fault indicates the number of times a drive fault was detected. Pressure bd {Accumulator pressure bad} indicates the number of times that the Accumulator pressure transducer was detected out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA or greater than 21 mA. Shed Time indicates the number of times that a Setpoint update did not occur within the time set in parameter Shed Time.

SLC Fb bad {Seat Load Cylinder bad} indicates the number of times that the from the seat load cylinder (4-20mA) was below 2 mA.

Fb bad {Actuator } indicates the number of times that the actuator’s was below 2 mA.

Cs Bad {Analog control signal bad} indicates the number of times the analog control signal was below 2.5 mA

Direction {Direction error} indicates the number of times the motor was stopped because the actuator was detected moving in the wrong direction.

SLC stop {Seat Load Cylinder stop} indicates the number of times the actuator stopped at the “Seated” position of the seat load cylinder but the control signal did not require the valve to be seated (control signal was > 0.2%)

Stall indicates the number of times the motor was stopped because the Stall Time was reached prior to achieving 1% of travel. Note: For units with a Seat Load Cylinder, Stall will indicate the number of times the “Seated” position was reached while position of the main cylinder was greater than 1% above Position Lo.

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The following four counters non-standard hardware configurations:

Op Pres bad indicates the number of times that the open side pressure transducer was detected out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA.

Cl Pres bad indicates the number of times that the close side pressure transducer was detected out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA.

Low Oil indicates the number of times the reservoir level switch detected a low oil condition. Over Temp indicates the number of times the oil temperature switch detected an over temperature condition. The following two parameters are usage counters; each indicates the number of times an event counter reached a count of 1 000. Event counters are located in volatile memory. Each power-on/reset causes the loss of any partial 1 000 counts. Entry into Setup followed by a return to Auto mode preserves partial 1 000 counts.

Starts x1K indicates the number of times the motor was started while in Auto. e.g., Starts x1K=2 is 2 000 starts.

Strokes x1K indicates the number of times the actuator traveled a distance equal to its calibrated stroke divided, by 1 000. e.g., Strokes x1K=2 is 2 000 strokes.



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Modes of Operation & Control Parameters

Last Error is not a counter; it indicates the last error detected. May be manually reset to None in Setup {press (E)nter while Last Error is on display}. It is automatically reset to None from reset/power on. The following may appear in the value field (field 6) if a Last Error occurs:

Fb bad Cs bad Dir er Stall DrvFlt Pwr 15 PresBd Shed Op bad Cl bad Lo Oil HiTemp SLC Fb SLCstp ADfail MemBad

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6.2 AUTO MODE Auto is the mode in which the actuator will automatically follow the control signal. When the deviation between current position and control signal is greater than the dead band setting, the actuator will move to decrease that error.

6.2.1 Display Fields in Auto Mode Field 2 (Blank)

Field 1

Au t o Po s i t i o n =

St a t u s : OK

Field 3

0.0%

Field 4

Field 5

Field 6

Field 1 displays the Operating mode. Field 2 is left blank to separate Fields 1 and 3. Field 3 displays the unit status. Field 4 displays the parameter position or alternate. Field 5 separates fields 4 and 6 with “space = space”. Field 6 shows the value for the parameter.



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6.2.2 Display Information Auto (Field 1) indicates the unit is in Auto mode, standard operation. Auto – Bt (Field 1) indicates Auto mode with Bumpless transfer in progress. Refer to the CONTROL menu.

Auto – mm (Field 1) refers to Auto mode with minimum modulating active. Refer to the CONTROL menu.

Auto – Rchg (Field 1) indicates the unit is in Auto mode with accumulator Recharge cycle in progress. Refer to the DRIVES menu.

Auto – Trip (Field 1) indicates the unit is in Auto mode with the Trip input active. Refer to the INPUTS menu.

Status:OK (Field 3) or an error/warning message indicates the status of the unit. Refer to the CURRENT STATS menu.

Position (Field 4) identifies the value displayed in Field 6. Value (Field 6): Low if current position is more than 0.5% below Position Lo

0.0 to 100.0 if current position is between Position Lo and Position Hi



High if current position is more than 0.5% above Position Hi Note: Lo or Hi value indicates overtravel past Position Hi or Position Lo settings; typically due to spring/accumulator driven operation.

If set up for Reverse Acting: Value (Field 6): Low if current position is more than 0.5% above Position Lo

0.0 to 100.0 if current position is between Position Lo and Position Hi



High if current position is more than 0.5% below Position Hi

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Position value may display the following in the situations stated:

Unknwn (Field 6) if the signal from the actuator to the Control enclosure is not present.

Seated (Field 6) if the seat load cylinder is at the “seated” position 6.2.3 Parameter Viewing In Auto mode the Control Parameters may be viewed (but not altered) by using the or keys. The first press of the key displays the “Live Control Signal”; successive presses of the key steps the display down through the CALIBRATE menu. The first press of the key displays the current Deviation. Successive presses of the key steps the display up through the CURRENT STATS menu. A 5-second timer reverts the display back to current position if no  /  key presses are detected. Holding the key down holds the current parameter on display indefinitely.

Control Sig {Live Control Signal} (Field 4) identifies the value of the analog control signal. The display is 0 -100 % for easy comparison with the position display. Value (Field 6): None when parameter Signal does not equal Analog.

Low when current signal is more than 0.5% below Signal Lo.



0-100% Active 4-20 mA signal is applied and is in between Signal Lo and Signal Hi.



High when current signal is more than 0.5% above Signal Hi.



Unknwn when control signal is not applied.

Deviation (Field 4): Identifies the value in Field 6 as the difference, in % of calibrated stroke, between the actuator’s current position and the actuator’s



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Modes of Operation & Control Parameters

target position. The value is prefixed with “-” if the current position is less than the target and with “+” if above the target position. Value (Field 6): 0.0 to 99.9% of calibrated stroke

Unknwn when the signal from the actuator to the Control enclosure is not present.

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6.3 MANUAL MODE Local Man indicates the manual operation of the actuator locally through the Control Enclosure keypad. Once the Local Manual mode is entered, the current status will be displayed along with position. To enable local control, the status must be active. The actuator may be stroked throughout its calibrated range. To do so, press . The = sign in Field 5 will begin blinking. Use the and keys to stroke the actuator. Pressing again prevents operation of the unit with the  /  keys. When stroking the actuator in Local Manual mode, parameter Max Man Spd sets the maximum speed of travel. While in the Local Manual mode (= sign not blinking), the used to examine (but not change) any Setup parameter.

and

keys may be

RemoteMan allows manual operation from a remote-station control unit. The actuator can be stroked throughout its calibrated range. Once the Remote Manual mode is entered, the current status will be displayed along with Position. The RemoteMan mode is only accessible if the s Input board is installed. Refer to Appendix R, Remote Manual Control and Appendix Q, Input Options.

Figure 6.3 s Input Board



Modes of Operation & Control Parameters

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

A-1

A. MECHANICAL LIMIT SWITCHES

The mechanical limit switches are independent devices installed on the yoke of the linear units and in the housing area of rotary or drive units. Electrical connections are made directly to the switches independent of REXA electronics. Position will be indicated regardless of actuator power status.

A.1 LINEAR A.1.1 General Specifications Quantity: 2 or 4 Type: Single Pole, Double Throw (SPDT), Form C. Rating: 5 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): 5/16” Environmental: NEMA 4, FM/CSA CL.I, DIV.1 & 2,

GRP. A, B, C & D.

Connection: ½”-14 NPT, screw terminals

Appendix A

Mechanical Limit Switches

A-2

Mechanical Limit Switches

Optional DPDT Limit Switches Quantity: 2 or 4 Type: Double Pole Double Throw (DPDT), Form CC Rating: 3 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): ¼˝ Environmental: NEMA 4, FM/CSA CL.I, DIV.1 & 2,

GRP. A, B, C & D.

Connection: ½˝-14 NPT, screw terminals

A.1.2 Linear Wiring Remove the access plate by unscrewing the four slotted screws on the bottom of the unit. Thread the cable through the ½˝ NPT fitting and connect to the appropriate Normally Open (NO), Normally Closed (NC) and Common (C) screw terminals. The cable should be grounded in accordance with Local and National Electrical Code. Make sure that the gasket is in place and tightly seal the cavity.

A.1.3 Linear Adjustment Loosen the two mounting screws approximately 1½ to 2 turns and slide the entire switch to the required position. Securely retighten the screws.

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Appendix A

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

A-3

Figure A.1 Linear Limit Switches

Appendix A

Mechanical Limit Switches

A-4

Mechanical Limit Switches

A.2 ROTARY A.2.1 General Specifications Quantity: 2 or 4 Type: Single Pole, Double Throw (SPDT) Rating: 10 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive

Differential Travel (Hysteresis): 5½” Environmental: NEMA 4, FM/CSA CL.I, DIV.1 & 2,

GRP. A, B, C & D (optional).

Connection: Within the housing (½˝-NPT) screw terminals

Optional DPDT Rotary Limit Switches Quantity: 2 Type: Double Pole, Double Throw (DPDT), Hermetically Sealed Rating: 0.3 amp @ 125 Vdc, 0.15 amp @ 250 Vdc,

10 amp @ 125 or 250 Vac

Differential Travel (Hysteresis): 5½” Environmental: NEMA 4, FM/CSA CL.I, DIV.1 & 2, Connection: Directly to screw terminal on the switch.

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

Appendix A

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

A-5

Figure A.2 Rotary Limit Switch Schematic

A.2.2 Rotary Wiring Remove the cylinder cover (over the cylinder pinion) by unscrewing. Refer to Figure A.2.3. Take care to keep threads clean and free from damage. Thread the cable through the ½” NPT fitting and make connections directly to the microswitches. Refer to Figure A.2. The cable should be grounded in accordance with Local and National Electrical Code.

A.2.3 Rotary Adjustment For adjustment, the switch cam can be relocated by loosening the set screw and repositioning. Make sure that the O-ring gasket is in place and tightly seal the cavity. (See Figure A.2.3)

Appendix A

Mechanical Limit Switches

A-6

Mechanical Limit Switches

Appendix A

Switch Cam



Set Screw

Figure A.2.3 Rotary Limit Switch

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

B-1

B. Stem Connection & Seat Loading Methods B.1 THEORY OF OPERATION Actuators which must come up against a hard stop require a spring loaded element between the actuator and driven device. This spring loaded element provides a controlled loading without over stressing mating parts. Its purpose is the same as torque limit switches found on gear motor actuators but without the inherent adjustment difficulties and potential for faulty calibration.

B.2 ELASTIC COUPLING For applications that extend or retract against a hard stop, linear Xpac actuators are provided with an “elastic coupling” for connecting the driven device to the actuator. The elastic coupling contains a set of disc springs which are precompressed to approximately 80% of the rated thrust for fail-in-place units and 50% of the rated thrust for spring fail actuators. The coupling provides a visual indication of compression (seat load) and should be compressed to its rated mark when the driven device is at the end of travel. At that point, the load on the driven device is approximately the net rated output

Appendix B

Stem Connection & Seat Loading Methods

B-2

Stem Connection & Seat Loading Methods

Appendix B

of the actuator. Lower rated couplings are available for applications that require reduced seat load. The force indicator on the elastic coupling is a pin captured in a slot on the side of the coupling. As the coupling compresses, the pin slides in the slot. A scribed line marks the rated output position.

Figure B.2-1 Preloaded Coupling

Figure B.2-2 Rated Load Coupling

Enclosed spring couplings (not shown) have a small telltale pin protruding from the top or bottom. As the coupling compresses, the pin is drawn into the coupling. When the pin is flush with the coupling, it is at its rated output. Note: The output of each coupling may be verified through the pressure gauges. Note: To translate pressure gauge readings into actuator output, use the following formula:

(

)

[

]

Pressure gauge reading × actuator rated output = actual output 2 000 psi

For additional output calculation data, refer to Appendix O.

B.3 SEAT LOADING CYLINDER On larger size units the forces are too great to use a mechanical elastic coupling. Instead, a smaller Seat Loading Cylinder (SLC) with a spring load is hydraulically connected to the actuator cylinder as shown Figure B.3. The Seat Loading Cylinder utilizes a pre-compressed load equivalent to 80% (1 600 psi) of the nominal working pressure (2 000 psi). As the power module

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

B-3

pumps hydraulic fluid into the actuator cylinder, the output shaft will begin to extend. Once the force on the extension shaft reached the preset 80% of the actuator’s rated output, the pressure in the top of the actuator cylinder will reach the limit that begins to compress the spring on the seat load cylinder. This will occur when the driven device reaches its end of stroke. As the pressure builds within the actuator cylinder, oil flows into the SLC, designated by the high pressure flow arrow and retracts the SLC shaft. When the spring is compressed to the full nominal working pressure, the position of the SLC will trigger the power module to shut off. The rated actuator output is now applied to the driven device and retained within the cylinders by the Flow Matching Valves.

Seat Load Cylinder

Figure B.3 Seat Loading Cylinder

Appendix B

Stem Connection & Seat Loading Methods

B-4

Stem Connection & Seat Loading Methods

Appendix B

B.3.1 Mechanical Installation The Seat Loading Cylinder is mounted to the side of the main cylinder at the factory. All hydraulic piping and spring preload will be complete. Mechanical installation is not required.

B.3.2 Electrical Installation Operation of the Seat Loading Cylinder requires the connection of a cable between the SLC and the control enclosure. The standard cable consists of a red, white and black wire and a tinned copper ground wire. Each individual wire is 18 AWG. The cable is not restricted by distance. The SLC Connections are terminated inside the Control Enclosure at the U Board Assembly, TB1, +15, SLC+ and SLC-. Refer to Figure B.3.4-1. The connection is made directly to the screw terminals on the printed circuit board. Remove the four cap screws cover using care not to damage the internal components. Feed the cable through the ½ inch NPT opening. Wiring connection is made directly to the printed circuit board per Figure B.3.2. Replace the cover on the cylinder and securely fasten. Refer to the Electrical Installation section.

Table B.3.2 SLC Connections SLC—½ inch NPT on cylinder (Screw Termination) Signal name

Wire colors

Terminal

+15 Vdc

Red

15V

(+)

White

4-20

(-)

Black

GND

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

Figure B.3.2 SLC Board

B-6

Stem Connection & Seat Loading Methods

B.4 SOLENOID AUTO-SEATING For linear valve applications that require fail-safe in the same direction as the seated position, the elastic coupling and seat load cylinder are considered to be redundant and unnecessary. Using an elastic coupling on a spring fail or accumulator fail REXA is like using a spring in series with another spring. For these applications REXA handles the seat loading with software that automatically controls the solenoid operation as the actuator positions close to the seat. This control menu parameter is called Solenoid Seat (Sol. Seat). The software concept is similar in operation to the Min Mod functionality. Rather than use the motor to drive to the seat, once the actuator reaches a position close to the seat the solenoid valve(s) open and the remaining travel is accomplished by using the stored energy (spring or accumulator) to drive the valve into the seat.

B.5 CALIBRATION Operation of the actuator is the same as a unit with an elastic coupling. The only difference is at the seated position. Instead of compressing a coupling, the spring on the SLC is compressed until the indicator on the SLC leg is at the seated point. See Figure B.5-1.

Position Lo is set by moving the stem to the corresponding low signal position. If the signal low position is the “SEAT” position, the seat load cylinder flag must line up with the “SEAT” indicator mark on the spring housing cover. The “SEAT” indicator mark is factory set for each application. The preset tension of the spring should not be changed without consulting the REXA factory.

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

Appendix B

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

B-7

Figure B.5-1 SLC Indicator–Seated With Position Lo on the display, press the (E)NTER key. = will begin to blink. Using the Scroll Up and Scroll Down keys, position the actuator to the desired point and press (E)NTER again. The displayed value will be recorded as the Position Low endpoint.

Position Hi is set by moving the stem to the corresponding high signal position. If the signal high position is the “SEAT” position, the seat load cylinder flag must line up with the “SEAT” indicator mark on the spring housing cover. The “SEAT” indicator mark is factory set for each application. The preset tension of the spring should not be changed without consulting the REXA factory. With Position Hi on the display, press the (E)NTER key. = will begin to blink. Using the Scroll Up and Scroll Down keys, position the actuator to the desired point and press (E)NTER again. The displayed value will be recorded as the Position Hi endpoint. When calibration is complete, and before returning to “AUTO” mode, depress the RESET button located on the right side of the REXA U board. This will set the new seated value as the SLC target. See Figure B.5-2.

Appendix B

Stem Connection & Seat Loading Methods

B-8

Stem Connection & Seat Loading Methods

Appendix B

Reset Switch

Figure B.5-2 Reset Switch

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

C-1

C. Accumulator Fail

C.1 THEORY OF OPERATION System operation is based on a piston type accumulator with nitrogen gas on one side of the piston and oil on the other.

Appendix C

Accumulator

C-2

Accumulator

Appendix C

C.1.1 Trip Function Refer to Figure C.1.1-A, Trip Condition, to follow the fluid flow path during a trip. The arrows indicate the flow direction Under a trip condition or loss of electric power, two solenoid valves open simultaneously. One solenoid allows oil under pressure from the accumulator to be released and enter the failure side of the actuator driving it in the fail direction. The other solenoid allows the oil displaced from the opposite side of the cylinder into an auxiliary reservoir. To control the fail speed a needle valve is installed on the outlet of the second solenoid valve. Auxiliary Reservoir

Actuator Cylinder Isolation Valve Trip Solenoid Power Module Trip Speed Control Valve

Port A (Unit will trip on power loss) A Optional Plumbing B Port B (Unit will not trip on power loss)

C

Trip Solenoid Accumulator Pressure Gauge Accumulator Bottle

Auxiliary Reservoir

Pre-charged Nitrogen Gas Figure C.1.1-A Trip Condition

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

C-3

C.1.2 Recharge Function Reference Figure C.1.2-B to follow fluid path during recharge. When the trip condition ends or power is restored, a pressure transducer signals the U of low pressure in the accumulator. This signal tells the U to run the power module in the direction required to drive the actuator in the fail direction. Since the actuator cylinder is already at the end of its travel, the oil being pumped from the reservoir by the power module will be allowed to flow into the accumulator. When the proper recharge pressure is reached, the U stops the power module and closes the solenoid valves. Normal operation is now resumed and the actuator will follow the control signal. Auxiliary Reservoir

Actuator Cylinder Isolation Valve Trip Solenoid Port A (Unit will trip on power loss)

Power Module Trip Speed Control Valve

Optional Plumbing

A

C

B Port B (Unit will not trip on power loss)

Trip Solenoid Accumulator Pressure Gauge Accumulator Bottle

Pressure Transducer

Pre-charged Nitrogen Gas

Figure C.1.2-B Recharge Condition

Appendix C

Accumulator

C-4

Accumulator

C.2 ACCUMULATOR CONTROL PARAMETERS Five parameters in the electronics are used to control accumulator functions. These may be found under the Drives menu and are: Rechrg Pres, Warn Pres, Rechrg Time, Accum Dr and Accum Pres.

DRIVES Menu The DRIVES menu provides the following:

Drive Type Stall Time Boost Pump Accumulator Rechrg Pres Warn Pres Rechrg Time Accum Dir Accum Pres Reference the DRIVES Menu in Modes of Operation & Control Parameters.

C.3 RECHARGING The recharge cycle will only occur if: 1. The U is in the Auto mode when power is restored after a loss of power or removal of trip signal, And 2. The pressure transducer output is less than Rechrg Pres If U is NOT in Auto mode when power is restored or trip signal removed, the unit MUST be placed in Auto and the reset button pushed.

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

Appendix C

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

C-5

IMPORTANT!

All actuators are shipped in the failed or tripped condition. The actuator may initially power up in Setup mode. With the trip signal inactive (or not connected), put the actuator in Auto then either press the reset button or cycle power off and back on. The actuator will go through a fail cycle, a recharge cycle and then return to following the control signal. If this operation is not performed, the actuator will follow the control signal, but the accumulator will remain uncharged, rendering the actuator incapable of performing a trip or fail operation. However, a low pressure warning will indicate insufficient pressure to perform a fail operation.

C.4 MANUAL OVERRIDE Accumulator actuators with solenoid valves are supplied with manual override levers. This feature enables a way to manually change states of the solenoid valves with electrical power off or in trip mode. Units are shipped from the factory with the solenoid override levers in position A (Figure C.4-1).

Figure C.4-1 Solenoid Manual Override Levers (Position A) They must be in this position for normal operation of the actuator. To use the handwheel during a power off or trip situation both solenoid override levers must be moved to position B.

Appendix C

Accumulator

C-6

Accumulator

Figure C.4-2 Solenoid Manual Override Levers (Position B) Once both overrides are moved to position B, the handwheel may be operated in a normal manner (Refer to Appendix M, Manual Operators). After handwheel use and prior to returning the actuator to normal service, (power restored or trip signal removed) both solenoid override levers must be returned to position A. NOTE: When returning the levers to the normal open position the actuator will stroke in the trip direction.

It is recommended that both override levers be safety wired in position A when the handwheel is not in use. For operation of Manual Override, refer to Appendix M, Manual Operators.

WARNING!

After using the handwheel, the overrides must be returned to the A position or the unit will not operate correctly when power is restored or trip signal removed. If only one override is returned to the A position after a trip, damage to the power module may occur.

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

Appendix C

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

C-7

C.5 DISCHARGING There will be times that it is necessary to fully discharge the oil-side of the accumulator system; such as when maintenance is being performed. To perform this task, do the following: 1. Remove power to the actuator. 2. If the unit is fail in place during power loss, place both solenoid valves in position B as shown in Figure C.4-2. 3. Open the manual by located on the front face of the module. Refer to Figure C.5. 4. Check to ensure that all the pressure gauges read 0 psi.

Gauge

Gauge

CW Off CCW On

CW Off CCW On

By CW Off CCW On

Figure C.5 By Drawing

Appendix C

Accumulator

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

D-1

D. Booster Pump Configuration

D.1 THEORY OF OPERATION Booster Pump Configurations utilize an Xpac power module and a large capacity “Booster Pump”. The power module provides fine positioning, while a volume booster pump provides the speed for large or coarse position changes. This dual pump operation allows REXA to extend its unique capabilities to very high thrust or torque units and high-speed operation without sacrificing position accuracy. Two sizes of BOOSTER PUMPS are available: the P9 and the P40. The P9 is used in combination with the D size power module to provide 5 times the capacity of a D size power module or 2.5 GPM. A P40 with D size power module has the pumping capacity for 11 GPM.

D.2 MECHANICAL INSTALLATION An Xpac with the Booster Pump Configuration has no special installation procedure. Therefore, the standard installation should be followed.

Appendix D

Booster Pump

D-2 Booster Pump

Appendix D

D.2.1 Control Enclosure The major electrical components are located in a NEMA 4 enclosure. They have a wide temperature range¹ (-40 °F to 120 °F1 [-40 °C to +49 °C]) and can be field installed at a convenient location. Avoid areas subject to excessive vibration or heat. To reduce the possibility of water incursion, we recommend that any fitting be pointed downward. 1

Ambient temperature only. Direct solar heat load must be avoided.

D.3 ELECTRICAL INSTALLATION The Xpac consists of two major components, the Electraulic actuator (cylinder and power module) and the control enclosure. The actuator is installed on the driven device, while the enclosure is remotely mounted. Connecting them are the motor power, resolver, and module cables. Some cables may not be run within the same conduit or seal-tite flex hose. Preferred wiring procedures recommend that power voltages (motor power and module cables) be kept separate from low level signal lines (resolver and cables). connections of electric power and control signals are made at the enclosure. Refer to Appendix P, Interconnect Diagrams.

! Important ! • Motor power and motor resolver cables for the power module and booster pump motors must be shielded! The shield of each is connected to the green ground screw on the back of the control enclosure only.

• The motor resolver signals are low level voltages.

The motor resolver cables must be kept separate from the motor power cables or any other high power wiring. However, the resolver cables may be run with the cable or other low power conductors.

• Failure to follow the above may inhibit the proper operation of the actuator.

D.4 CONTROL PARAMETERS Refer to DRIVES menu, Modes of Operation & Control Parameters.

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

E-1

E. Pulse Operating System

E.1 THEORY OF OPERATION The pulse operating system allows the use of a voltage input signal instead of the standard 4-20 mA signal. Pulses are not merely motor power commands, but change the target position. The actuator will continue moving until the actual position satisfies the target position. The motion (speed, acceleration, resolution) of the unit will be in accordance with the values set during calibration. To receive the pulses, a input board is mounted on the U. This board accepts 3 or 4 wire signals in the range of 24 to 120 volts, AC or DC. The pulses are interpreted by the U based on the values set for the two pulse control parameter, Pulse Duration and Pulse Increment. Refer to the CALIBRATE menu and the INPUTS menu for additional information.

E.2 INSTALLATION Wiring for pulse input is performed at the inputs board located on top of the U. Terminal block TB3 provides six terminals to connect the HIGH signal and the LOW signal. Refer to Figure E.2-1, -2, for wiring options.

Appendix E

Pulse Operating System

E-2

Pulse Operating System

Figure E.2-1 Input Board Wiring Options

Figure E.2-2 Input Board Wiring Options

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

Appendix E

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

E-3

E.3 SIGNAL INPUT RANGE Voltage: OFF: 0 to 8 volts, AC or DC ON: 22 to 120 volts, AC or DC Undefined: 8 to 22 volts, AC or DC Current: OFF: less than 1 mA ON: 1.8 mA to 10 mA; proportional to voltage Impedance: 12K ohms Electromechanical or solid state switching devices may be used to activate the control signal. The following points should be observed:

ON state: Most AC and many DC solid state switching devices require a minimum current flow in order to remain in the closed state. If this minimum current exceeds the input signal current at the activation voltage, the current flow may be increased by adding a shunt resistor across the input signal terminals of the pulse auxiliary board.

OFF state: The OFF state leakage current must be less than 1 mA. Diode clamps or RC snubber networks placed across mechanical relays and the semiconductor junctions of solid state switches will some current in the OFF state. If this leakage exceeds 1 mA, a resistor added across the input signal terminals will by the current.

E.4 PULSE CONTROL PARAMETERS Refer to the CALIBRATE menu and INPUTS menu for additional information.

Appendix E

Pulse Operating System

E-4

Pulse Operating System

E.5 TUNING On systems that utilize position to control the pulse train, it is usually necessary to tune the Pulse Increment to replicate the actuator speed. The ideal Pulse Increment is determined by dividing the Pulse Duration (in seconds) by the total stroking time and multiplying by 100%. Duration Pulse Increment = Pulse Stroke Time × 100% To allow for motor acceleration, round this value up to the next highest tenth of a percent.

REXA Series 2 Xpac – Installation and Operation Manual – 10/07

Appendix E

REXA Series 2 Xpac – Installation and Operation Manual – 01/14

F-1

F. Errors and Error Displays

The following are the error messages which appear on line 1 in place of Status:OK when one or more errors are detected. If more than one error is active, each is displayed at 1 second intervals in a repeating fashion. All errors are cleared by: 1. Cycling the main power; 2. Pushing the reset switch; 3. Entering the Setup mode; or 4. By means identified in the “Cleared by” sections which follow. To fix some of these alarm code errors it may be necessary to refer to the Trouble Shooting and Repair manual.

FB bad Cause: The actuator’s main is below 2 mA; either (+) or (-) 15 fail is set, or A/D fail is set. Indicators: Alarm and Warning opens. FB bad is displayed. Actuator will not move. Cleared by: Self clearing when > 2 mA, or when 15 fail or A/D fail clears.

Appendix F

Errors and Error Displays

F-2

Errors and Error Displays

CS bad Cause: The analog Control Signal is below 2.5 mA; either the (+) or (-) 15 fail is set, or A/D fail is set. Indicators: Alarm and Warning relays open. CS bad is displayed. Actuator will move to Failsafe position. Cleared by: Self clearing when Control Signal > 2.5 mA, or when 15 fail or A/D fail clears.

Stall Cause: After five attempts the actuator was unable to move 1% of stroke within the defined Stall Time. The “Seated” position was reached on the Seat Load Cylinder while the position of the main cylinder was greater than 1% above Position Lo. Indicators: Alarm and Warning relays open. Stall is displayed. Actuator will not move. Cleared by: Any control signal change which effects movement in the opposite direction of the stall will clear the stall error.

Dir error Cause: The actuator was detected moving in the wrong direction. Indicators: Alarm and Warning relays open. Dir error is displayed. Actuator will not move. Cleared by: Cleared by cycling main power on, by pushing the reset switch, or entering the Setup mode.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix F

REXA Series 2 Xpac – Installation and Operation Manual – 01/14

F-3

Drv fault Cause: At least one motor drive has detected a problem. Indicators: Warning relay opens. Drv fault is displayed. The actuator may or may not continue normal operation depending on actuator construction. Cleared by: U will attempt to clear Drv fault error until fault condition is corrected.

+15 fail or - 15 fail Cause: The (+) or (-) 15 volt power supply is out of range if it exceeds a (+) or (-) 10% error band. Indicators: Alarm and Warning relays open. (+/-)15 fail is displayed. Actuator will not move. Cleared by: U will attempt to clear fail error until fault condition is corrected.

Pres bad Cause: The accumulator’s pressure transducer {Accum Pres} is out of range if the 4 - 20 mA signal is less than 3 mA or greater than 21

mA. Indicators: Warning relay opens. Pres bad is displayed. Actuator continues to operate normally. Cleared by: Cleared when transducer signal is greater than 3 mA or less than 21 mA.

Appendix F

Errors and Error Displays

F-4

Errors and Error Displays

Pres low Cause: The accumulator pressure {Accum Pres} is below the value set in parameter Warn Pres. Indicators: Warning relay opens. Pres low is displayed. Actuator continues to operate normally. Cleared by: Successful Accumulator recharge cycle.

Op Pres bad or Cl Pres bad Cause: The open or close pressure transducer is out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA.. Indicators: Warning relay opens. Op or Cl Pres bad is displayed. Actuator continues to operate normally in Auto mode.. Cleared by: Transducer signal being greater than 3 mA.

Low Oil * Cause: The reservoir oil level switch indicates that the oil level is low. Indicators: Alarm and Warning relays open. Low Oil is displayed. Actuator continues to operate normally but will not attempt a recharge cycle.

Cleared by: Oil level returning to normal. * Available on REXA MEGApac only. factory for additional details.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix F

REXA Series 2 Xpac – Installation and Operation Manual – 01/14

F-5

Over Temp * Cause: The oil temperature switch indicates an over temperature condition exists. Indicators: Warning relay opens. Over Temp is displayed. Actuator attempts to continue to operate normally. Cleared by: Temperature returning to normal range.

* Available on REXA MEGApac only. factory for additional details.

Slc Fb bad Cause: The signal from the Seat Load Cylinder is less than 2 mA. Indicators: Alarm and Warning relays open. Slc Fb bad is displayed. Actuator will not move. Cleared by: Self clearing when > 2 mA.

Slc stop Cause: The actuator has detected a “Seated” position from the seat load cylinder , but the main cylinder is more than 0.2% from its “Seated” position. Indicators: Warning relay opens. Slc stop is displayed. The actuator continues with normal operation; however, the main cylinder may not seat properly. Cleared by: Any control signal change which effects movement in the opposite direction in which the stop occurred will clear the error.

Appendix F

Errors and Error Displays

F-6

Errors and Error Displays

Key bad Cause: A bad reading of the key pad has occurred. Indicators: Warning relay opens. Key bad is displayed. Actuator continues to operate normally. Cleared by: Self clearing with a valid keypad reading.

Mem fail Cause: A memory location containing a Setup parameter value has failed to erase/write. Indicators: Alarm and Warning relays open. Mem fail is displayed. Actuator will not move. Cleared by: Only cleared by cycling main power or pushing the reset switch.

No inp bd Cause: 1. Signal Type is set to 1 Cont, 2 Cont, or Pulse when a input board is not installed or is faulty. 2. Trip is not Off. Indicators:

Alarm and Warning relays open. No inp bd is displayed. Actuator will not move. Unit will go to Setup mode.

Cleared by: Changing the Signals menu parameter(s), or (with power off) installing the required board.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix F

REXA Series 2 Xpac – Installation and Operation Manual – 01/14

F-7

A/D fail Cause: The A/D converter on the U Board has failed to respond. Indicators: Alarm and Warning relays open. A/D fail is displayed. Actuator will not move. Cleared by: Self clears if/when A/D responds.

Appendix F

Errors and Error Displays

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

G-1

G. Surge Control Option

G.1 THEORY OF OPERATION High speed operation in one direction during upset conditions can best be handled with REXA’s Surge Control Option. This option gives the actuator the ability for fast operation in one direction. During normal movements actuator stroking speed is determined by Power Module speed capabilities. To obtain this second surge speed a coil spring drives the actuator when a solenoid valve opens. Four additional components are added to the standard actuator: Mechanical Spring - provides the force to move the actuator in the surge direction. Solenoid By Valve - byes the actuator’s normal hydraulic circuit. Solid State Relay - interfaces the U with the solenoid. Needle Valve - allows adjustment in Surge Control speed The U will pulse the solenoid through the electronic relay to allow controlled high speed motion in the spring direction. Control of this feature is accomplished with the Surge Breakpoint (SG) parameter in the Setup menu.

Appendix G

Surge Control Option

G-2

Surge Control Option

If the change in control signal is less than the Surge Breakpoint, the actuator operates normally. If the change in control signal is greater than the Surge Breakpoint (and in the surge motion direction), then the solenoid opens and the actuator is driven by the spring to the new position. If the actuator is overshooting during a surge event, the Surge Offpt parameter can be used to eliminate this overshoot. Reference the Drive Menu section in Modes of Operation & Control Parameters in the IOM for additional information regarding setting the Surge Offpt parameter. Increasing this Surge Offpt parameter will reduce the overshoot until the unit begins to slow down too much prior to hitting its target position. Figure G.1-1 illustrates the overshoot from a surge event. Increasing the Surge Offpt would be required to eliminate this issue. Figure G.1-2 shows the expected results when the Surge Offpt parameter is tuned properly. Figure G.1-3 shows an undershoot condition. Decreasing the Surge Offpt percentage will reduce the undershoot. Various configurations of the spring package may have been provided. The spring may be installed to open or close the driven device. Fail-safe position can either be lock in place or in the surge direction.

Figure G.1-1 Overshoot

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

Appendix G

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

G-3

Figure G.1-2 Target position

Figure G.1-3 Undershoot

Appendix G

Surge Control Option

G-4

Surge Control Option

G.2 INSTALLATION The fast response solenoid is a 3-way configuration and piped external to the hydraulic cylinder. An adjustable needle valve is in line with the solenoid to allow custom adjustment of the surge speed to meet a particular installation. The wires used for the surge solenoid are a pair of blue wires in the module cable. Connection for the solenoid within the control enclosure is made to TB4 of the power supply assembly as shown in G.2-1. Refer to Figures G.2-1,-2,-3.

G.3 CALIBRATION Refer to the CONTROL menu for additional information.

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

Appendix G

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

G-5

Figure G.3-1 Surge Solenoid Connection

Appendix G

Surge Control Option

G-6

Surge Control Option

Figure G.3-2 Solenoid & “Wet” Trip Connection

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

Appendix G

REXA Series 2 Xpac – Installation and Operation Manual – 02/10

G-7

Figure G.3-3 Solenoid & “Dry” Trip Connection

Appendix G

Surge Control Option

REXA Series 2 Xpac – Installation and Operation Manual – 04/13 H-1

H. Build Numbers

The build number is a catalog number REXA uses to designate in complete detail the construction of the actuator. From this number all configurations can be defined. There are two different categories of build numbers; one is for the mechanical sub-assembly, and the second is for it’s corresponding electronics sub-assembly. Within the mechanical sub-assembly there is a build number for Rotary and Drive actuators, and a separate build number for Linear actuators.

Appendix H

Build Numbers

H-2

Build Numbers

Appendix H

LINEAR SERIES ACTUATOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A Actuator Type L=REXA Block Cylinder C=Commercial Cylinder Output C=2 000 lbf (8 896 N) D=4 000 lbf (17 793 N) E=5 000 lbf (22 241 N) F=10 000 lbf (44 482 N) G=15 000 lbf (66 723 N) H=20 000 lbf (88 964 N) I=30 000 lbf (133 447 N) J=40 000 lbf (177 929 N) M=60 000 lbf (266 893 N) K=80 000 lbf (355 858 N) L=120 000 lbf (533 787 N) Z=Special Actuator Stroke A=.75" (.02 m) B=2" (.05 m) C=4" (.10 m) D=6" (.15 m) E=8" (.20 m) F=11" (.28 m) G=16" (.40 m) H=22" (.56 m) I=28" (.71 m) J=36" (.91 m) K=42" (1.07 m) L=48" (1.22 m) Z=Special

15

1 14

2

3

Power Module Size B=B Module C=C Module D=D Module F=½D Module G=2D Module H=D,P9 Module I=D,P40 Module M=2C Xpac Module Z=Special

Output Limit / Protection C=37%-73% Total Output D=74%-99% Total Output E=100%-140% Total Output (Std) Z=Special

13

12

11

10

4

Fail Safe Mode P=Fail In Place (Std) E=Fail Extend Low Spring Load R=Fail Retract Low Spring Load H=Fail Extend High Spring Load B=Fail Retract High Spring Load A=Accumulator Extend M=Accumulator Retract Z=Special

9

5

Fail Mode Speed N=N/A (Std) S=Standard Solenoid H=High Speed Solenoid E=Surge Control Extend R=Surge Control Retract Z=Special

8

6

7

Heater/Solenoid Voltage A=120 Vac B=240 Vac C=125 Vdc F= 48 Vdc E=24 Vdc G=12 Vdc N=No Heater Z=Special

Design X2-A X2-B Z=Special

Construction S=NEMA 4X, (Std) T=NEMA 4X, TNEMEC Paint C=NEMA 4X Class1/Div2 D=NEMA 4X, Class1/Div2, TNEMEC Paint N=CE, IP66, ATEX Zone 2 Z=Special

Mechanical Switches N=No Switches (Std) A=2 Switches–SPDT 4X Hi Temp C=2 Switches–SPDT Class1/Div2 E=4 Switches–SPDT Class1/Div2 G=2 Switches–DPDT Class1/Div2 J=4 Switches–DPDT Class1/Div2 O=Oil Level D=Oil Level & 2 Switches–SPDT Cl1/Div2 F=Oil Level & 4 Switches–SPDT Cl1/Div2 H=Oil Level & 2 Switches–DPDT Cl1/Div2 K=Oil Level & 4 Switches–DPDT Cl1/Div2 Z=Special

Seat Loading Method N=None (Std) S=Seat Load Cylinder C=Elastic Coupling Extend U=Elastic Coupling Retract Z=Special

Cable Connections S=Terminal Strip (Std) Q=Quick Disconnect Z=Special

Manual Override H=Handwheel / Drill Drive P=Manual Hydraulic Pump N=None (Std) Z=Special

Temperature Rating and Stem Boot S=Standard 200 °F (93 °C) Temp Rating (Std) H=High 250 °F (121 °C) Temp Rating B=Standard 200 °F (93 °C) with Linear Stem Boot T=High 250 °F (121 °C) with Linear Stem Boot R=Standard 200 °F (93 °C) Remote L=Standard 200 °F (93 °C) Remote with Stem Boot Z=Special

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

H-3

ROTARY SERIES ACTUATOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A Actuator Type R=Rotary Cylinder D=Drive Unit

1

Output C=2 500 lbf·in (282 N·m) D=5 000 lbf·in (565 N·m) E=10 000 lbf·in (1 130 N·m) F=20 000 lbf·in (2 260 N·m) G=50 000 lbf·in (5 650 N·m) H=100 000 lbf·in (11 300 N·m) I=200 000 lbf·in (22 597 N·m) J=400 000 lbf·in (45 194 N·m) Z=Special

14

13 2

12 Actuator Rotation A=90 degree (Std) B=180 degree C=270 degree D=280 degree E=120 degree Z=Special

3 11

Power Module Size B=B Module C=C Module D=D Module F=½D Module G=2D Module H=D,P9 Module I=D,P40 Module M=2C Xpac Module Z=Special

4

Fail Safe Mode P=Fail In Place (Std) C=Clockwise Spring R=Counter Clockwise Spring A=Accumulator Clockwise M=Accumulator Counter Clockwise Z=Special

10

9

5

Fail Mode Speed N=N/A (Std) S=Standard Solenoid H=High Speed Solenoid E=Surge Control CW R=Surge Control CCW Z=Special

8

6 7

15

Design X2-A Z=Special

Output Limit / Protection C=37%-73% Total Output D=74%-99% Total Output E=100%-140% Total Output (Std) Z=Special

Construction S=MEMA 4X, (Std) T=NEMA 4X, TNEMEC Paint C=NEMA 4X, Class1/Div2 D=NEMA 4X, Class1/Div2, TNEMEC Paint N=CE, IP66, ATEX Zone 2 Z=Special

Mechanical Switches N=No Switches (Std) C=2 Switches–SPDT E=4 Switches–SPDT G=2 Switches–DPDT O=Oil Level D=Oil Level & 2 Switches–SPDT F=Oil Level & 4 Switches–SPDT H=Oil Level & 2 Switches–DPDT Z=Special

Seat Loading Method N=None (Std) S=Seat Load Cylinder Z=Special

Cable Connections S=Terminal Strip (Std) Q=Quick Disconnect Z=Special

Manual Override H=Handwheel / Drill Drive P=Manual Hydraulic Pump N=None (Std) Z=Special

Temperature Rating S=Standard 200 °F (93 °C) Temp Rating H=High 250 °F (121 °C) Temp Rating R=Remote Std. Temp Z=Special

Heater/Solenoid Voltage A=120 Vac B=240 Vac C=125 Vdc F=48 Vdc E=24 Vdc G=12 Vdc N=No Heater Z=Special

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

Appendix H

Build Numbers

H-4

Build Numbers

Appendix H

ELECTRONIC NUMBERING SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A Power Module Size B=B Module C=C Module D=D Module F=½D Module G=2D Module H=D-P9 Module I=D-P40 Module M=2C Xpac Module Z=Special

15

Design A=X2 B=X2, Design 2 C=X2, Design 3 D=X2, Design 4 Z=Special

1

Power Supply A=120 Vac B=240 / 208 Vac C=480 Vac D=12 Vdc E=24 Vdc Std 14 to 185 °F (-10 to +85 °C) F=48 Vdc G=125 Vdc I=240 Vac 3–Phase J=480 Vac 3–Phase K=380 Vac 3–Phase L=600 Vac 3–Phase Z=Special

14

13 2

Control Signal G=Analog 4-20 mA w/ Surge Sup. (Std) P=Pulse Operating System T=Two Position - 1 Signal M=Manual - 2 Signal J=Hart 4–20 mA w/ Surge Sup. F=Foundation fieldbus Z=Special

11, 12

10 3

Area Approvals S=General Locations (Std) C=CSA C1/D2 (B,C,D) N=CE, IP66, ATEX Zone 2

9 4

Enclosure Material P=Painted Steel, NEMA 4 (Std) S=304 Stainless Steel, NEMA 4X F=Fiberglass, NEMA 4X Z=Special

5

Controls E=External (Std) I=Internal C=Int Controls with Ext Buttons/Window D=Int Controls with Ext Buttons/No Window Z=Special

8

6

7

Variations N=None (Std) T=Quick Release Connectors U=Quick Release/Conform Coat

Electronics Supplied Y=Yes Z=Special

Software AA=Standard Software (Std) FA=Foundation Fieldbus LA-Standard w/Auto Mode Ind.

Options N=No Options (Std) A=Accumulator System S=Hydraulic Surge Option L=Seat Load Cylinder D=Accum. & Seat Load Cylinder H=Surge & Seat Load Cylinder Z=Special

Position Transmitter A=Active 4–20 mA P=ive 4–20 mA (Std) L=Active 4-20 mA, Local Mode Ind. M=ive 4-20 mA, Local Mode Ind. Z=Special

Actuator Temperature Rating S=Standard 200 °F (93 °C) Temp Rating H=High 250 °F (121 °C) Temp Rating R=Remote Std 200 °F (93 °C) Z=Special

Remote Manual Station A=Basic Station B=Basic Station with Display C=Remote Station Compatibility N=None (Std) Z=Special

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

H-5

MOUNTING SYSTEMS Linear Series Actuator 1 2 3 4 5 6 7 8 9 Actuator Type N=No Mounting Hardware L=REXA Block Cylinder C=Commercial Linear Cylinder Output C=2 000 lbf (8 896 N) D=4 000 lbf (17 793 N) E=5 000 lbf (22 241 N) F=10 000 lbf (44 482 N) G=15 000 lbf (66 723 N) H=20 000 lbf (88 964 N) I=30 000 lbf (133 447 N) J=40 000 lbf (177 929 N) M=60 000 lbf (266 893 N) K=80 000 lbf (355 858 N) L=120 000 lbf (533 787 N) Z=Special

1 9

8

2 Actuator Stroke A=.75" (.02 m) B=2" (.05 m) C=4" (.10 m) D=6" (.15 m) E=8" (.20 m) F=11" (.28 m) G=16" (.40 m) H=22" (.56 m) I=28" (.71 m) J=36" (.91 m) K=42" (1.07 m) L=48" (1.22 m) Z=Special

Valve Attachment S=Down Seat Split Clamp B=Up Seat Split Clamp N=No Clamp

4 7

3 Certified Drawings A= Actuator Outline C=Control Enclosure Outline E=Electrical Interconnect Schematic O=Actuator & Interconnect D=Actuator & Enclosure & Interconnect N=No Certified Drawings

5 6

Packaging D=Domestic (Std) E=Export

Inspection Level S=Standard Inspection A=Advanced Inspection (Level II) P= Inspection (Level I)

Variations N=No Factory Mount & Calibrate A=L2 000 Mount & Calibrate B=L4K-L10K Mount & Calibrate C=L15K & Up, Mount & Calibrate

Other Documentation B=Bill of Materials C=Certificate of Conformance F=Final Inspection Report A=All (BOM, COC & FIR) N=No Other Documentation

Rotary Series Actuator 1 2 3 4 5 6 7 8 9 Actuator Type N=No Mounting Hardware R=Rotary Cylinder Output C=2 500 lb·in (282 N·m) D=5 000 lb·in (565 N·m) E=10 000 lb·in (1 130 N·m) F=20 000 lb·in (2 260 N·m) G=50 000 lb·in (5 650 N·m) H=100 000 lb·in (11 300 N·m) I=200 000 lb·in (22 597 N·m) J=400 000 lb·in (45 194 N·m) Z=Special Actuator Rotation A=90 Degrees (Std) B=180 Degrees C=270 Degrees D=280 Degrees E=120 Degrees Z=Special

9

1

8 2 7

6

3 Valve Attachment N=No Mounting Hardware A=4" or less B=6" to 10" C=12" to 14" D=16" to 20" E=20" and up

4 5

Packaging D=Domestic (Std) E=Export

Inspection Level S=Standard Inspection A=Advanced Inspection (Level II) P= Inspection (Level I)

Variations N=No Factory Mount & Calibrate A=Factory Mount & Cal 4" or Less B=Factory Mount & Cal 6" to 10" C=Factory Mount & Cal 12" to 14" D=Factory Mount & Cal Over 16"

Other Documentation B=Bill of Materials C=Certificate of Conformance F=Final Inspection Report A=All (BOM, COC & FIR) N=No Other Documentation

Certified Drawings A= Actuator Outline C=Control Enclosure Outline E=Electrical Interconnect Schematic O=Actuator & Interconnect D=Actuator & Enclosure & Interconnect N=No Certified Drawings

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

Appendix H

Build Numbers

H-6

Build Numbers

Appendix H

Drive Series Mounting 1 2 3 4 5 6 7 8 9

Actuator Type D=Drive Unit

1

Output C=2 500 lb·in (282 N·m) D=5 000 lb·in (565 N·m) E=10 000 lb·in (1 130 N·m) F=20 000 lb·in (2 260 N·m) G=50 000 lb·in (5 650 N·m) H=100 000 lb·in (11 300 N·m) I=200 000 lb·in (22 597 N·m) J=400 000 lb·in (45 194 N·m) Z=Special

9 2

Actuator Rotation A=90 Degrees (Std) B=180 Degrees C=270 Degrees D=280 Degrees E=120 Degrees Z=Special

8

7

6

3

Valve Attachment S=Standard Base & Arm A=Standard Base & Custom Arm B=Custom Base & Standard Arm C=Custom Base & Custom Arm

4 5

Packaging D=Domestic (Std) E=Export

Inspection Level S=Standard Inspection A=Advanced Inspection (Level II) P= Inspection (Level I)

Variations N=No Linkage Kit C=Custom Linkage Kit

Other Documentation B=Bill of Materials C=Certificate of Conformance F=Final Inspection Report A=All (BOM, COC & FIR) N=No Other Documentation

Certified Drawings A= Actuator Outline C=Control Enclosure Outline E=Electrical Interconnect Schematic O=Actuator & Interconnect D=Actuator & Enclosure & Interconnect N=No Certified Drawings

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

REXA Series 2 Xpac – Installation and Operation Manual – 04/13

H-7

LINEAR FISHER MOUNTING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

– Actuator Type N=No Mounting Hardware L=REXA Block Cylinder C=Commercial Linear Cylinder Output C=2 000 lbf (8 896 N) D=4 000 lbf (17 793 N) E=5 000 lbf (22 241 N) F=10 000 lbf (44 482 N) G=15 000 lbf (66 723 N) H=20 000 lbf (88 964 N) Z=Special Actuator Stroke A=.75" (.02 m) B=2" (.05 m) C=4" (.10 m) D=6" (.15 m) E=8" (.20 m) F=11" (.28 m) G=16" (.40 m) Z=Special

1 17

Revision A=Current Rev

16

Variations N=None

2 15

14 3

Valve Attachment S=Down Seat Split Clamp B=Up Seat Split Clamp N=No Clamp

13 4

Certified Drawings A= Actuator Outline C=Control Enclosure Outline E=Electrical Interconnect Schematic O=Actuator & Interconnect D=Actuator & Enclosure & Interconnect N=No Certified Drawings

12 5

Other Documentation B=Bill of Materials C=Certificate of Conformance F=Final Inspection Report A=All (BOM, COC & FIR) N=No Other Documentation

11 10 6

Fail Safe Mode P=Fail In Place (Std) E=Fail Extend Low Spring Load R=Fail Retract Low Spring Load H=Fail Extend High Spring Load B=Fail Retract High Spring Load A=Accumulator Extend M=Accumulator Retract Z=Special

9 7 8

Valve Stroke A= ¼" to 1" B= 1-1⁄8" to 1-7⁄8" H= 2" and up Z= Special

Stem Height A= 4-¾" B= 6-3⁄16" C= 6-5⁄8" D= 8-7⁄8" E= 9-5⁄8"

Stem Thread B= 3⁄8" –24 D= ½" –20 F= ¾" –16 H= 1" –14 I= 1-¼" –12

Yoke Boss A=2-1⁄8" C=2-3⁄16" E=3-9⁄16" G=5"

Packaging D=Domestic (Std) E=Export

Inspection Level S=Standard Inspection A=Advanced Inspection (Level II) P= Inspection (Level I)

Mount & Cal N=No Factory Mount & Calibrate A=L2 000 Mount & Calibrate B=L4K-L10K Mount & Calibrate C=L15K & Up, Mount & Calibrate

Seat Loading Method N=None (Std) S=Seat Load Cylinder C=Elastic Coupling Extend U=Elastic Coupling Retract Z=Special

The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As such, additional codes may be available or may be added without notice. Please the factory for information on any code not shown above.

Appendix H

Build Numbers

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

K-1

K. Fieldbus

An Xpac Series 2 actuator is represented on a Fieldbus network as a group of blocks through which the X2 actuator may be configured and operated. The blocks include:

- One Resource block - One Analog Output block - One Discrete Output block - Two Anaput blocks - One Discrete Input block - One Transducer block

The Resource block and the Input/Output blocks are standard Fieldbus blocks which implement the networking and control capability of a Fieldbus system. The Transducer block is a custom block which is designed specifically to connect an Xpac 2 actuator to a Fieldbus network. In a control application, the Transducer block reads and writes process variables from the actuator and es these values to the network via the I/O blocks. The Transducer block also provides access to all X2 actuator configuration (Setup) parameters (excluding stroke calibration parameters). Any configuration parameter which may be viewed or changed at the local Operator’s may also be viewed or changed over the Fieldbus network.

Appendix K

Fieldbus

K-2

Fieldbus

The Transducer block is also capable of gathering simultaneous data samples of X2 actuator Position, Setpoint, and (if implemented) Differential Pressure, and storing them for later retrieval. Two hundred samples of each variable are gathered in 20 groups of 10 samples of each variable. Data gathering may be initiated manually at any time, or automatically by a specified change in Setpoint. The rate at which the samples are gathered may also be specified. All blocks have many named parameters. The standard Fieldbus blocks (Resource and I/O) contain only Fieldbus defined parameters which, in this document, are written as FIELDBUS NAME (upper case lettering) and when observed on a Fieldbus host are viewed in a similar manner. The Transducer block also contains Fieldbus defined parameters which are written and viewed as above. The Transducer block also contains X2 actuator specific custom parameters which may be viewed on a host in one of two ways; either as a default, software derived name or as a Device Description supplied name (noted in brackets). In this document the custom parameters are written as DEFAULT NAME {Device Description Name} wherever the names differ. Parameter values where shown are in bold text

Resource block: The Resource block provides device identification and some basic network communications parameters. There are no X2 actuator specific parameters in this block.

Analog Output block (AO) The AO block accepts analog values from the network and writes the value to the Transducer’s block parameter Setpoint to control positioning of the X2 actuator. The AO block also reads the Position of the X2 actuator from the Transducer block and es the value to the network. To use this block:

- Set the AO block parameter CHANNEL to AO Setpoint.

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

Appendix K

REXA Series 2 Xpac – Installation and Operation Manual – 07/12 K-3



- Initialize the AO block parameter SHED_OPT (NormalShed_NormalReturn is sufficient).



- Set the Transducer block parameter CONTROL_CHANNEL {Positioner Control Method} to CH1- Analog Output

Anaput blocks (AI) The AI blocks read a process variable from the Transducer block and the value to the network as an analog value. To use AI1 blocks and propagate Actuator Position:

- Set the AI1 block parameter CHANNEL to Al1 Position.



- Set the AI1 block parameter L_TYPE to Indirect.



- Set the AI1 block parameter XD_SCALE:EU_100 to 100 :EU_0 to 0 :UNITS_INDEX to %.



- Set the AI1 block parameter OUT_SCALE:EU_100 to 100 :EU_0 to 0 :UNITS_INDEX to %. To use AI2 blocks and propagate Actuator Differential Pressure (if the feature is available):

Appendix K



- Set the AI2 block parameter CHANNEL to AI2 Differential Pressure.



- Set the AI2 block parameter L_TYPE to Direct.



- Set the AI2 block parameter XD_SCALE:EU_100 to 3000 :EU_0 to 0 :UNITS_INDEX to psi.



- Set the AI2 block parameter OUT_SCALE:EU_100 to 3000 :EU_0 to 0 :UNITS_INDEX to psi.

Fieldbus

K-4

Fieldbus

Discrete Output block (DO) The DO block accepts discrete values from the network and forwards a value of 0% or 100% to the Transducer block parameter Setpoint to control positioning of the X2 actuator. 0x00 for a Setpoint of 0.0% 0x01 for a Setpoint of 100% The DO block also reads the Position of the X2 actuator from the Transducer block and es the value to the FF network as a discrete value. 0x00 if Position is less than 50.0% 0x01 if Position is equal to or greater than 50.0% To use this block:

- Set the DO block parameter CHANNEL to DO Setpoint.



- Initialize the DO block parameter SHED_OPT (NormalShed_NormalReturn is sufficient).



- Set the Transducer block parameter CONTROL_CHANNEL {Positioner Control Method} to CH4- Discrete Output

Discrete Input block (DI) The DI block reads the X2 actuator Position from the Transducer block and es the value to the FF network as a discrete value. 0x00 if Position is less than or equal to 5% 0x01 if Position is greater than 5% and less than 95% 0x03 if Position is greater than 95% To use this block:

- Set the DI block parameter CHANNEL to DI Position.

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

Appendix K

REXA Series 2 Xpac – Installation and Operation Manual – 07/12 K-5

Transducer block The Transducer block links the XPac X2 actuator to the Input/Output function blocks. It also provides access to all of the X2 actuator’s configuration parameters. Other parameters which provide for control and observation of the X2 actuator are also included. All parameters may be viewed at any time. To change any parameter, the block should be put in OOS (Out Of Service). To change any X2 actuator configuration parameter, the X2 actuator must also be in Comm Setup mode. The X2 actuator’s current mode may be viewed using parameter MODE_STATUS {Mode\Status Byte}. The X2 actuator’s current mode may be changed using parameter OPERATING_MODE {Operating Mode}.

X2 Actuator Configuration Parameters The following lists all of the X2 actuator’s configuration parameters. Details for each parameter may be found in the Setup section of this document. All of the listed parameters will always be visible over a fieldbus network. However, some parameters are not implemented in all X2 actuator Software versions, and some parameters may not be usable due to the current setting of other parameters. In either case, when a parameter is not usable it will have a value of “1.#QNAN”. Any attempt to modify such a parameter will result in an error message.

CONTROL Menu DEADBAND {Deadband}

Deadband

MIN_MODULATING {Minimum Modulating}

Min Mod

BUMPLESS {Bumpless Transfer}

Bumpless

SEAT_LOAD_CYLINDER {Seat Load Cylinder control} Seat Ld Cyl

Appendix K

SEAT_LOAD {Seat Load Switching}

Seat Load

SOLENOID_SEAT {Solenoid Seating}

Sol. Seat

CALIBRATED_STROKE {Calibrated Stroke}

Cal. Stroke

FLOW_CHAR {Flow Characterization}

Flow Char

FLOW_CHAR_CS_10 {CS 10% Pt} thru

CS 10% Pt thru

FLOW_CHAR_CS_90 {CS 90% Pt}

CS 90% Pt

Fieldbus

K-6

Fieldbus

Appendix K

SPEED/ACCEL Menu MAX_HI_SPEED {Max Hi Speed}

Max Hi Spd

MAX_UP_SPEED {Max Up Speed}

Max Up Spd

GAIN {Gain}

Gain

HI_ACCEL {Hi Accel}

Hi Accel

ACCEL_BKPT {Accel Breakpoint}

Accel Bkpt

LO_ACCEL {Lo Accel}

Lo Accel

TWO_SPEED {2 Speed}

2-Speed

MAX_LO_SPEED {Max Lo Speed}

Max Lo Spd

MAX_DN_SPEED {Max Dn Speed}

Max Dn Spd

SPEED_BKPT {Speed Breakpoint}

Speed Bkpt

MAX_MAN_SPEED {Max Man Speed}

Max Man Spd

INPUTS Menu SIGNAL_TYPE {Signal Type}

Signal Type

PULSE_DURATION {Pulse Dur}

Pulse Dur

PULSE_INCREMENT {Pulse Inc}

Pulse Inc

FAILSAFE {Failsafe}

Failsafe

SHED_TIME {Shed Time}

Shed Time

TRIP {trip}

Trip

POWER_ON {Power On}

Power On DRIVES Menu

DRIVE_TYPE {Drive Type}

Drive Type

STALL_TIME {Stall Time}

Stall Time

BOOST_PUMP_BKPT {Boost Pump}

Boost Pump

MAIN_VALVE_BKPT {Main Valves}

Main Valves

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 07/12 K-7

SURGE_BREAKPOINT {Surge Breakpoint}

Surge Bkpt

ACCUMULATOR {Accumulator}

Accumulator

ACCUM_HI_PRES {Recharge Pres}

Rechrg Pres

ACCUM_LO_PRES {Warn Pres}

Warn Pres

RECHARGE_TIME {Rechrg Time}

Rechrg Time

ACCUM_FAIL_DIR {Fail Dir}

Accum Dir

ACCUM_PRES {Accum Pres}

Accum Pres

OUTPUTS Menu RELAY_1 {Relay #1}

Relay #1

RELAY_2 {Relay #2}

Relay #2

POS_XMTR {Position Transmitter}

Pos Xmitter

{}



OPEN_PRES {Open Pres}

Open Pres

CLOSE_PRES {Close Pres}

Close Pres

SOFTWARE_VERSION {Controller Software Version}

Version

CURRENT STATS and HISTORIC STATS Menus:

Appendix K

MEM_FAIL {Memory fail Error Count}

Mem fail

A/D_FAIL {A/D fail Error Count}

A/D fail

DRIVE_FAULT {Drive fault Error Count}

Drive fault

PRESSURE_BAD {Accumulator pressure bad}

Pressure bd

SHED_TIME_ERROR {Shed Time error}

Shed Time

SLC_FB_BAD {SLC bad}

SLC Fb bad

FB_BAD { bad}

Fb bad

CS_BAD {Control signal bad}

Cs bad

DIRECTION {Direction error}

Direction

SLC_STOP {SLC stop}

SLC stop

Fieldbus

K-8

Fieldbus

Appendix K

STALL {Stall}

Stall

CL_PRESS_BAD {Close Pres bad}

Cl Pres bad

OP_PRESS_BAD {Open Pres bad}

Op Pres bad

LOW_OIL {Low Oil}

Low Oil

OVERTEMP {Over Temp}

Over Temp

STARTS_X1K {Starts x1K}

Starts x1K

STROKES_X1K {Strokes x1K}

Strokes x1K

Other X2 actuator parameters: CONTROL_CHANNEL {Positioner Control Method}: This parameter specifies which output block is to provide the Setpoint to the Transducer block.

CH1-Analog Output: Selects the AO block as the Setpoint source.



CH4-Discrete Output: Selects the DO block as the Setpoint source.

OPERATING_MODE {Operating Mode}: This parameter is used to change the mode of operation of the X2 actuator.

Auto mode: Switches the X2 actuator to Auto mode for Setpoint tracking.



Comm Setup mode: Switches the X2 actuator to a Setup mode for configuration over the Fieldbus network.



Setup mode and Local mode: These modes are only selectable at the X2 actuator’s local Operator’s and cannot be invoked over the Fieldbus network.

MODE_STATUS {Mode\Status Byte}: This parameter reports the current mode of operation of the X2 actuator.

Auto mode: The X2 actuator is following the Setpoint input. No X2 actuator configuration parameter may be modified while in Auto mode.

In Comm Setup Mode: The X2 actuator is holding position. Any X2 actuator configuration parameter may be modified over the Fieldbus network.

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 07/12 K-9



Setup Mode: The X2 actuator is holding position. Any X2 actuator configuration parameter may be modified at the local Operators .



Manual Mode (either Local or Remote): The X2 actuator is holding position but may be manually stroked at the local Operator’s or via a remote hand/auto station.

The Mode\Status Byte also reports the presence of the Input Board if it is installed in the X2 actuator, and reports active status of the Trip input (override signal). RESPONSE_CODE {Response Code}: When an X2 actuator configuration parameter is written, a response code is issued as part of the return message indicating the relative success or failure of the write operation.

Success: the data was accepted unconditionally.



Conditional success: the data sent was too large, too small or imprecise. The X2 actuator has corrected the data by rounding down, rounding up, or rounding off the value sent prior to writing.



Failure Not Available: The write attempt was rejected because the parameter is not used in this version of the X2 actuator or the parameter is currently not usable due to settings of other parameters. When a parameter is not available it is displayed with a value of “1.#QNAN”.



Failure Wrong Mode: The write attempt was rejected because the X2 actuator was not in Comm Setup Mode.



Failure No : The write attempt was rejected because the parameter requires use of the Input Board which is not present in the X2 actuator.

POSITION: This parameter reports the X2 actuator’s current position. CONTROL_SIGNAL {Control Signal}: This parameter is not used with a Fieldbus network and should be ignored.

Appendix K

Fieldbus

K-10 Fieldbus

Appendix K

TARGET_POS {Target}: This parameter reports the current target position of the X2 actuator. Target position normally equals the Setpoint value but may be modified by use of other parameters such as Flow Characterization, Minimum Modulating, Bumpless Transfer, etc. SETPOINT: This parameter reports the current value of the X2 actuator’s Setpoint input. DIFF_PRESSURE: This parameter reports the current differential pressure measured across the X2 actuator’s hydraulic cylinder(s). It may be used to calculate thrust or torque by multiplying the value times the net working area of the hydraulic cylinder(s). When the differential pressure measuring feature is not implemented, this parameter’s value will be “1.#QNAN”. ERROR_BYTE1 (error_byte1}, ERROR_BYTE2 (error_byte2}, ERROR_BYTE3 (error_byte3}: These parameters report any error conditions detected within the X2 actuator.

ERROR_BYTE1: main failure

FB bad

seat load cylinder failure

SlcFb bad

control signal failure

CS bad

actuator direction error

Dir error

-15 volt power supply failure

-15 fail

+15 volt power supply failure

+15 fail

seat load cylinder stall

Slc stop

actuator stall

Stall

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

REXA Series 2 Xpac – Installation and Operation Manual – 07/12 K-11

ERROR_BYTE2: motor drive fault

Drv fault

accumulator pressure transducer bad

Pres bad

accumulator requires recharge flag

Pres low

bad keypad

Key bad

eprom erase/program failure

Mem fail

pulse/ board missing

No inp bd

A/D failure

A/D fail

U failure

U fail ERROR_BYTE3:

open direction pressure transducer bad

Op Pres bad

close direction pressure transducer bad

Cl Pres bad

oil over temperature

Over Temp

low oil

Low Oil

shed time exceeded

Shed Time

X2 Actuator Data Collection Parameters COLLECTION_MODE {collection _mode}: specifies the method of initiating data gathering. Select:

MANUAL for operator initiated gathering



AUTO for initiating on a change in Setpoint

COLLECTION_CONTROL {collection_control}: used to START a manually initiated collection. STOP may be used to halt a collection prior to 200 samples of each parameter having been collected. COLLECTION_DELTA_SP {collection_delta_sp}: when collection_mode is AUTO, specifies the change in Setpoint required to initiate collection.

Appendix K

Fieldbus

K-12 Fieldbus

Once automatically initiated, collecting will continue until 200 samples of each variable have been gathered. COLLECTION_SAMPLE_RATE {collection_sample _rate}: specifies the rate at which samples of each variable will be collected in samples per second. Select 1, 2, 4, 5, 10, 20. COLLECTION_INDEX {collection_index}: when reading the collected variables, this specifies which group of 10 values to return. Select Group 1 for the 1st 10 values, Group 2 for values 11 through 20, etc., up to Group 20 for values 191 through 200. Unused samples or samples read prior to gathering will read zero. COLLECTION_SETPOINT {collection_setpoint}, COLLECTION_POSITION {collection_position}, COLLECTION_DIFF_PRESSURE {collection_diff_pressure}: when read, these return 10 successive values of the named variable as specified by the collection_index. When the Differential Pressure measuring feature is not implemented, collection_diff_pressure will read “1.#QNAN”. Notes: Data collection parameters. 1. For each collection variable, the first sample of Group 1 is the value of the variable immediately prior to the initiation of collection. The second sample is the value of the variable one sample interval later. The third sample is the value of the variable a second sample interval later, etc. 2. When collection mode is set to AUTO, the first two samples of the setpoint variable show the change in setpoint which initiated the collection. 3. The variable differential pressure is collected using peak detection methods. During a sampling interval, differential pressure is continuously monitored and the largest value found during the sampling interval is reported as the value for that interval. 4. The differential pressure peak detector runs continuously. Therefore, the first sample of Group 1 for the collection variable differential pressure is the maximum value detected since the end of the last collection period. This value is generally not meaningful and can be discarded.

REXA Series 2 Xpac – Installation and Operation Manual – 07/12

Appendix K

REXA Series 2 Xpac – Installation and Operation Manual – 10/09

M-1

M. Manual Operators

The Xpac has two types of manual operators available: Declutchable Handwheel / Drill Drive and Manual Hydraulic Pump. Since both options utilize our hydraulic circuit for override operation, they will only function if the system is in working order. CAUTION: Before attempting to operate any manual override feature, make sure that the electric power is OFF.

M.1 DECLUTCHABLE HANDWHEEL The handwheel is mounted to the motor output end of the actuator. To operate, depress and turn the handwheel. One half-revolution may be required before proper engagement, as the inside of the handwheel must engage with the motor shaft. The handwheel will declutch by moving outwards when released. Clockwise rotation of the manual operator will retract the stem on a linear unit and clockwise rotate the shaft (looking at the housing) on a rotary unit.

Appendix M

Manual Operators

M-2 Manual Operators

Appendix M

HANDWHEEL REVOLUTIONS Linear

Rotary

(To move one inch per 1 000 lb of rated thrust)

(90° of rotation/1 000 lb·in of rated torque)

B

~75

~200

C, ½D

~25

~65

D

~13

~33

Power Module

Figure M.1-1 Handwheel Assembly

Figure M.1-2 Drill Drive

Figure M.1-3 Drill Drive with Drill

M.1.2 Declutchable Drill Drive The drill drive is part of the handwheel assembly that can be used on standard B, C, 1/2D, and D power modules rated for hazardous but non-explosion proof environments to drive the unit. The handwheel can be removed by simply pulling on it to expose a 5/16” hex drive. To operate, connect an appropriate drill to the 5/16” hex. Push the drive in and turn. One half-revolution may be required before proper engagement, since the drive must a slot on the end of the motor shaft. Clockwise rotation of the manual operator will retract the stem on a linear unit and rotate the shaft clockwise (looking at the housing) on a rotary unit. The drive will declutch by moving outwards when released. Note: The actuator’s drive train and cylinder must be in proper working order to operate handwheel/drill drive.

REXA Series 2 Xpac – Installation and Operation Manual – 10/09

REXA Series 2 Xpac – Installation and Operation Manual –10/09

M-3

CAUTION: Care must be taken to ensure the drill gun is limited to 2 000 rpm. Running into a mechanical stop using a drill may damage the actuator and potentially the equipment it is attached to. As the actuator nears the end point, decrease drill speed so damage doesn’t occur.

M.2 MANUAL HYDRAULIC PUMP The manual hydraulic pump can be installed on all units and needs only the cylinder side of the hydraulic circuit and the FMV check valves to be in working order. If the gear pump or suction check valves fail, the manual hydraulic pump will still provide a means for manual operation. To operate the manual hydraulic pump, insert lever into the piston assembly and pump the handle up and down. To reverse the actuator direction, either push in or pull out the black, direction control knob located on the bottom of the assembly. Note: It is not advisable to leave the lever in the piston assembly when the hydraulic pump is not in use.

MANUAL HYDRAULIC PUMP SPEEDS (# of pumps)

Appendix M

Linear

Rotary

(To move one inch/1 000 lb of rated thrust)

(90º of rotation/1000 lb·in of rated torque)

~1

~2.5

Manual Operators

M-4 Manual Operators

Appendix M

Directional control knob

Figure M.2 Manual Hydraulic Pump

M.3 FAIL SAFE UNIT OPERATION Fail Safe units, Spring Return and Accumulator, utilize solenoid valves in the fail safe operation. Upon loss of power these solenoids will change state. In order for manual operation, solenoids must be in position B for normally open solenoids. Manually override them so they appear as shown in Figure M.3. Refer to Rotary Spring Fail and Linear Spring Fail sections under Mechanical Installation for additional information.

WARNING!

After using the handwheel, the overrides must be returned to their open position or the unit will not operate correctly when power is restored or trip signal removed. If only one override is returned to the open position after a trip, damage to the power module may occur. Changing the override(s) back may also cause the actuator to run to the fail safe position.

REXA Series 2 Xpac – Installation and Operation Manual – 10/09

REXA Series 2 Xpac – Installation and Operation Manual –10/09

M-5

Figure M.3 Solenoid Manual Override Levers (Position B)

Appendix M

Manual Operators

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-1

N. Digital Communications

N.1 HART® FIELD DEVICE SPECIFICATION

Appendix N

Digital Communications

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-3

N.1 HART® FIELD DEVICE SPECIFICATION

HART® Field Device Specification: REXA Xpac Series X2 Rexa Electrohydraulic Actuator

Author: Larry Schoonover REXA Version 1.0

Appendix N

Digital Communications

N-4 Digital Communications

Appendix N

TABLE OF CONTENTS 1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Who should use this document?. . . . . . . . . . . . . . . . . . . . . . . 1.4 Abbreviations and definitions . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 6 6 6 6 7

2. DEVICE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3. PRODUCT OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4. PRODUCT INTERFACES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Process Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Sensor Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Host interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Anaput 1: Actuator Setpoint. . . . . . . . . . . . . . . . . . 4.3 Local Interfaces, Jumpers And Switches. . . . . . . . . . . . . . . . 4.3.1 Local Controls And Displays. . . . . . . . . . . . . . . . . . . . . . 4.3.2 Internal Jumpers And Switches. . . . . . . . . . . . . . . . . . .

8 8 8 8 8 8 8 8

5. DEVICE VARIABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6. DYNAMIC VARIABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7. STATUS INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.1 Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7.2 Additional Device Status (Command #48). . . . . . . . . . . . . . . 10 8. UNIVERSAL COMMANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 8.1 ed Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9. COMMON-PRACTICE COMMANDS . . . . . . . . . . . . . . . . . . . . . . . 21 9.1 ed Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 9.2 Burst Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 10. DEVICE-SPECIFIC COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . 27 10.1 ed Device Specific Commands . . . . . . . . . . . . . . . 27 11. TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 12. PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 12.1 Sampling Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-5

12.2 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Command Response Times. . . . . . . . . . . . . . . . . . . . . . . . . 12.6 Delayed-Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 Non-Volatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9 Write Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 29 29 30 30 30 30 30 30

ANNEX A. CAPABILITY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 31 ANNEX B. HART® INTERFACE BOARD CONNECTION. . . . . . . . . . 32

Appendix N

Digital Communications

N-6 Digital Communications

1. INTRODUCTION 1.1 Scope The Xpac Series X2 Rexa Electrohydraulic Actuator complies with HART Protocol Revision 5.0. This document specifies all the device specific features and documents HART Protocol implementation details. The HART functionality of this Field Device is described sufficiently to allow its proper application in a process and its complete in HART capable Host Applications.

1.2 Purpose This specification is designed to compliment other documentation (e.g., the Xpac Series X2 Rexa Electrohydraulic Actuator Installation Manual) by providing a complete, unambiguous description of this Field Device from a HART Communication perspective

1.3 Who should use this document? The specification is designed to be a technical reference for HART capable Host Application Developers, System Integrators and knowledgeable End s. It also provides functional specifications (e.g., commands, enumerations and performance requirements) used during Field Device development, maintenance and testing. This document assumes the reader is familiar with HART Protocol requirements and terminology.

1.4 Abbreviations and definitions Abbreviations ADC

Analog to Digital Converter

U

Central Processing Unit (of microprocessor)

EEPROM Electrically-Erasable Read-Only Memory

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-7

Definitions Actuator

A field device whose primary purpose is to vary its output thus affecting the connected process. An actuator typically uses the 4-20 mA Loop Current as a setpoint.

1.5 References Hart Revision 5 specifications: HCF_SPEC-11, HCF_SPEC-54, HCF_SPEC-81, HCF_SPEC-99, HCF_SPEC-127, HCF_SPEC-151, HCF_SPEC-183, HCF_SPEC307. Available from the HCF. Xpac Series X2 Rexa Electrohydraulic Actuator Installation Manual, Available from REXA.

2. DEVICE IDENTIFICATION Manufacturer Name:

REXA

Model Name(s):

Manufacture ID Code:

222 (DE Hex)

Device Type Code: 128 (80 Hex)

HART Protocol Revision

5.0

Device Revision:

Number of Device Variables

None

Physical Layers ed

FSK

Physical Device Category

Actuator

X2

1

3. PRODUCT OVERVIEW The X2 is an electrohydraulic actuator that is powered separately from the primary anaput signal. The actuator and its electronics do not draw current from the circuit which is used only for HART signaling. The X2 is configured using the pushbuttons on the front of the device. The analogue input of this device is interpreted by the device as a setpoint. The setpoint can be treated linearly or characterized according to input. The

Appendix N

Digital Communications

N-8 Digital Communications

HART communication over the anaput is used primarily for monitoring of position, signal, and cylinder differential pressure (may not be available on all models).

4. PRODUCT INTERFACES 4.1 Process Interface 4.1.1 SENSOR INPUT CHANNELS The X2 has sensors that measure actuator position, actuator differential pressure, and anaput signal. The measurements from these sensors are scaled by the device into engineering units and are available as variables using HART communication. Other sensors are available as options but are not available using HART communication. These are described in the X2 manual.

4.2 Host interface 4.2.1 ANAPUT 1: ACTUATOR SETPOINT The two-wire 4-to-20mA current loop is connected to the X2 . Refer to the Installation Manual for connection details.

4.3 Local Interfaces, Jumpers And Switches 4.3.1 LOCAL CONTROLS AND DISPLAYS The local controls and displays are described in the X2 manual. 4.3.2 INTERNAL JUMPERS AND SWITCHES This internal jumpers and switches are described in the X2 manual.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-9

5. DEVICE VARIABLES This Field Device does not expose any Device Variables.

6. DYNAMIC VARIABLES Two Dynamic Variables are implemented. Meaning

Units

PV

Position of the actuator

%

SV

Pressure differential

psi

7. STATUS INFORMATION 7.1 Device Status Bit 4 (“More Status Available”) is set whenever any status bit is detected. Command #48 gives further detail.

Appendix N

Digital Communications

N-10 Digital Communications

Appendix N

7.2 Additional Device Status (Command #48) Command #48 returns 6 bytes of status data, with the following status information: Byte

Bit

0*

1

Meaning

Class

0

Invalid EEPROM state

Error

1

Invalid EEPROM write

Error

2

EEPROM write error

Error

3

Not used

4

Not used

5

Not used

6

Not used

7

Not used

0

Main failure

Error

Seat load cylinder failure

Error

2

Control signal failure

Error

3

Actuator direction error

Error

4

-15v supply failure

Error

5

15v supply failure

Error

Seat load cylinder stall

Warning

7

Actuator stall

Error

0

Motor drive fault

Warning

1**

Bad pressure reading

Warning

2**

Accumulator requires recharge

Warning

3

Bad keypad

Warning

4

EEPROM erase failure

Error

5

Pulse board missing

Error

6

A/D failure

Error

7

U failure

Error

1**

6** 2

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

3

4

5

N-11

0**

Open direction pressure bad

Error

1**

Close direction pressure bad

Error

2**

Temperature too high

Warning

3**

Low oil

Warning

4

Not used

5

Not used

6

Not used

7

Not used

0

Local manual control

Information

1

Remote manual control

Information

2

Not used

3

Not used

4

Not used

5

Not used

6

Not used

7

Not used Not used

*Byte 0 refers to the HART interface board. The remaining bytes refer to the controller board. **Not available on all models. “Not used” bits are always set to 0. These bits are set or cleared by the self-test executed at power up, or following a reset command. They are also set (but not cleared) by any failure detected during continuous background self-testing.

Appendix N

Digital Communications

N-12 Digital Communications

8. UNIVERSAL COMMANDS 8.1 ed Commands Command Number: 0 Command Name: Read Unique Identifier Command Type: Read Sets Configuration Changed: no Description: Returns the manufacturer and device information needed for other communication with the device. This command can be sent using short addressing (polling address) and thus can be used before knowing the full device address. Request: no data Response: Byte 0: u8 - Device code for expansion – 254 Byte 1: u8 – Manufacturers code – 222 for Rexa Byte 2: u8 – Manufacturers device code – 128 for this device Byte 3: u8 – Number of preambles required for this device – default is 5 Byte 4: u8 – Universal command revision – 5 for this device Byte 5: u8 – Transmitter revision – 1 for this device Byte 6: u8 – Software revision – 1 for this device Byte 7: u8 – Hardware revision multiplied by 8 – 8 for this device (revision of 1) Byte 8: u8 – Flags – 0 for this device Bytes 9 – 11: u24 – Device ID Command Errors: none

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-13

Command Number: 1 Command Name: Read Primary Variable Command Type: Read Sets Configuration Changed: no Description: Returns the primary variable (position) and its units (%) Request: no data Response: Byte 0: u8 – Position units code – 57 for this device which is the code for percent Bytes 1-4: float – Primary variable – position for this device Command Errors: none

Command Number: 2 Command Name: Read Current and Percent of Range Command Type: Read Sets Configuration Changed: no Description: Returns the input signal in mA and the signal as a percent of the signal scale. Request: no data Response: Bytes 0-3: float – Input signal in mA Bytes 4-7: float – Input signal as a percent of range in percent Command Errors: none

Appendix N

Digital Communications

N-14 Digital Communications

Command Number: 3 Command Name: Read Dynamic Variables Command Type: Read Sets Configuration Changed: no Description: Returns the primary variable (position), the secondary variable (pressure differential) and the input signal. The units of the PV and SV are also returned. Request: no data Response: Bytes 0-3: float – input signal in mA Byte 4: u8 – Units code of the primary variable – 57 (percent) for this device Bytes 5-8: float – The primary variable - position for this device Byte 9: u8 – Units code of the secondary variable – 6 (psi) for this device Bytes 10-13: The secondary variable – pressure differential for this device Command Errors: none

Command Number: 6 Command Name: Write Polling Address Command Type: Write Sets Configuration Changed: yes Description: Sets the polling address for the device. Request: Byte 0: u8 – Polling address. Can be 0 to 15. Since this device is controlled by the 4-20 signal, only polling address 0 should be used.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-15

Response: Byte 0: u8 – Polling address Command Errors: 2 – Invalid parameter if the polling address is greater than 15

Command Number: 11 Command Name: Read Unique Identifier Associated with Tag Command Type: Read Sets Configuration Changed: no Description: Returns device identification information if the device tag matches the tag sent in this command. Request: Bytes 0-5: ascii – The device tag which can be up to 8 text characters long. Response: Note: the device only responds if the tag matches the tag saved in the device. If the tag does not match, the device does not respond at all. Byte 0: u8 - Device code for expansion – 254 Byte 1: u8 – Manufacturers code – 222 for Byte 2: u8 – Manufacturers device code – 128 for this device Byte 3: u8 – Number of preambles required for this device – default is 5 Byte 4: u8 – Universal command revision – 5 for this device Byte 5: u8 – Transmitter revision – 1 for this device Byte 6: u8 – Software revision – 1 for this device Byte 7: u8 – Hardware revision multiplied by 8 – 8 for this device (revision of 1)

Appendix N

Digital Communications

N-16 Digital Communications

Byte 8: u8 – Flags – 0 for this device Bytes 9 – 11: u24 – Device ID Command Errors: none

Command Number: 12 Command Name: Read Message Command Type: Read Sets Configuration Changed: no Description: Returns the “message” field saved in the device. The message field can be up to 32 text characters long. Request: no data Response: Bytes 0-23: ascii – The message saved in the device up to 32 text characters long. Command Errors: none

Command Number: 13 Command Name: Read Tag and Descriptor Command Type: Read Sets Configuration Changed: no Description: Returns the tag field, the descriptor field, and the date field. All of these fields are settable. These fields can be used in whatever manner the wants. Request: no data

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-17

Response: Bytes 0-5: ascii – The tag, up to 8 text characters long Bytes 6-17: ascii – The descriptor, up to 16 text characters long Bytes 18-20: u8 – The date as 3 unsigned bytes. The first byte represents the day of the month (1 to 31), the second byte the month (1 to 12), and the third byte the year minus 1900 (e.g. 2006 would be 106). Command Errors: none

Command Number: 14 Command Name: Read Primary Variable Sensor Information Command Type: Read Sets Configuration Changed: no Description: This command is included only for compatibility with certain DCS systems. The data returned in this command is always constant. Request: no data Response: Bytes 0-2: u24 – Sensor serial number – always 0 for this device Byte 3: u8 – units code – 250 (not used) for this device Bytes 4-7: float – upper limit – special code for not-a-number for this device Bytes 8-11: float – lower limit – special code for not-a-number for this device Bytes 12-15: float – minimum span – special code for not-a-number for this device Command Errors: none

Appendix N

Digital Communications

N-18 Digital Communications

Command Number: 15 Command Name: Read Primary Variable Output Information Command Type: Read Sets Configuration Changed: no Description: This command is included only for compatibility with certain DCS systems. The data returned in this command is always constant. Request: no data Response: Byte 0: u8 - Alarm code – 250 (not used) for this device Byte 1: u8 - Transfer function – 250 (not used) for this device Byte 2: u8 - Primary variable units code – 57 (percent) for this device Bytes 3-6: float - Upper range – always 100.0 for this device Bytes 7-10: float - Lower range – always 0.0 for this device Bytes 11-14: float – Damping value – always 0.0 for this device Byte 15: u8 – Write protect code – 250 (not used) for this device Byte 16: u8 – Private label code – 250 (not used) for this device Command Errors: none

Command Number: 16 Command Name: Read Final Assembly Number Command Type: Read Sets Configuration Changed: no

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-19

Description: Returns the final assembly number stored in the device. This number is settable and can be used for whatever the wants. Request: no data Response: Bytes 0-2: u24 – The final assembly number. The value can range from 0 to 16777215. Command Errors: none

Command Number: 17 Command Name: Write Message Command Type: Write Sets Configuration Changed: yes Description: Sets the message field in the device Request: Bytes 0-23: ascii – The message field, up to 32 text characters. Response: Bytes 0-23: ascii – The message field, up to 32 text characters. Command Errors: none

Command Number: 18 Command Name: Write Tag and Descriptor Command Type: Write Sets Configuration Changed: yes

Appendix N

Digital Communications

N-20 Digital Communications

Description: Sets the tag field, the descriptor field and the date field in the device Request: Bytes 0-5: ascii – The tag, up to 8 text characters long Bytes 6-17: ascii – The descriptor, up to 16 text characters long Bytes 18-20: u8 – The date as 3 unsigned bytes. The first byte represents the day of the month (1 to 31), the second byte the month (1 to 12), and the third byte the year minus 1900 (e.g. 2006 would be 106). Response: Bytes 0-5: ascii – The tag, up to 8 text characters long Bytes 6-17: ascii – The descriptor, up to 16 text characters long Bytes 18-20: u8 – The date as 3 unsigned bytes. The first byte represents the day of the month (1 to 31), the second byte the month (1 to 12), and the third byte the year minus 1900 (e.g. 2006 would be 106). Command Errors: none

Command Number: 19 Command Name: Write Final Assembly Number Command Type: Write Sets Configuration Changed: yes Description: Sets the final assembly number in the device Request: Bytes 0-2: u24 – The final assembly number. The value can range from 0 to 16777215.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-21

Response: Bytes 0-2: u24 – The final assembly number. The value can range from 0 to 16777215. Command Errors: none

9. COMMON-PRACTICE COMMANDS 9.1 ed Commands

Command Number: 33 Command Name: Read Transmitter Variables Command Type: Read Sets Configuration Changed: no Description: Returns up to 4 variables specified from the list of variables. For this device, possible variable codes are 0. Input Signal 1. Position 2. Pressure differential Request: Note: fewer than 4 parameters can be sent and the response will be correspondingly shortened Byte 0: u8 – the transmitter variable code for slot 0 Byte 1: u8 – the transmitter variable code for slot 1 Byte 2: u8 – the transmitter variable code for slot 2 Byte 3: u8 – the transmitter variable code for slot 3

Appendix N

Digital Communications

N-22 Digital Communications

Response: Byte 0: u8 – the variable code for slot 0 Byte 1: u8 – the units code for the variable in slot 0 Bytes 2-5: float – the value of the selected variable in slot 0 Byte 6: u8 – the variable code for slot 1 Byte 7: u8 – the units code for the variable in slot 1 Bytes 8-11: float – the value of the selected variable in slot 1 Byte 12: u8 – the variable code for slot 2 Byte 13: u8 – the units code for the variable in slot 2 Bytes 14-17: float – the value of the selected variable in slot 2 Byte 18: u8 – the variable code for slot 3 Byte 91: u8 – the units code for the variable in slot 3 Bytes 20-23: float – the value of the selected variable in slot 3 Command Errors: 2 – Invalid parameter if the variable code is not 0, 1, or 2

Command Number: 38 Command Name: Reset Configuration Changed Flag Command Type: Process Sets Configuration Changed: yes (cleared) Description: Clears the configuration changed flag for the HART master that sent the command.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-23

Request: no data Response: no data Command Errors: none

Command Number: 48 Command Name: Read Additional Status Command Type: Read Sets Configuration Changed: no Description: Returns the device specific status bytes. These bytes indicate: Byte 0 Bit 0: Invalid EEPROM state Bit 1: Invalid EEPROM write Bit 2: EEPROM write error Byte 1 Bit 0: Main failure Bit 1: Seat load cylinder failure Bit 2: Control signal failure Bit 3: Actuator direction error Bit 4: -15v supply failure Bit 5: 15v supply failure Bit 6: Seat load cylinder stall Bit 7: Actuator stall

Appendix N

Digital Communications

N-24 Digital Communications

Byte 2 Bit 0: Motor drive fault Bit 1: Bad pressure reading Bit 2: Accumulator requires recharge Bit 3: Bad keypad Bit 4: EEPROM erase failure Bit 5: Pulse board missing Bit 6: A/D failure Bit 7: U failure Byte 3 Bit 0: Open direction pressure bad ** Bit 1: Close direction pressure bad ** Bit 2: Temperature too high ** Bit 3: Low oil ** Byte 4 Bit 0: Local manual control Bit 1: Remote manual control Byte 0 of the status codes refer to the HART interface board. The remaining bytes refer to the controller board. Bits that apply to options that are not in the delivered model will be set to 0. ** Not available on all models. Request: no data

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-25

Response: Bytes 0-4: u8 – status data, each bit identifying the condition defined above. Byte 5: u8 – reserved Byte 6: u8 – operating mode 1 – 0 for this device Byte 7: u8 – operating mode 2 – 0 for in this device Bytes 8-10: u24 – analog output saturated – 0 for this device Bytes 11-13: u24 – analog output fixed – 0 for this device Command Errors: none

Command Number: 107 Command Name: Write Burst Mode Variables Command Type: Write Sets Configuration Changed: yes Description: Sets the variable codes that will be used in burst mode by command 33. Request: Note: Fewer than 4 variable codes may be specified by sending only those needed. Byte 0: u8 – Variable code for slot 0 Byte 1: u8 – Variable code for slot 1 Byte 0: u8 – Variable code for slot 2 Byte 3: u8 – Variable code for slot 3 Response:

Appendix N

Digital Communications

N-26 Digital Communications

Byte 0: u8 – Variable code for slot 0 Byte 1: u8 – Variable code for slot 1 Byte 0: u8 – Variable code for slot 2 Byte 3: u8 – Variable code for slot 3 Command Errors: 2 – Invalid parameter if any variable code is not 0, 1, or 2

Command Number: 108 Command Name: Write Burst Mode Command Command Type: Write Sets Configuration Changed: yes Description: Sets which command will be used during burst mode Request: Byte 0: u8 – Burst mode command number. Must be 1, 2, 3, or 33 Response: Byte 0: u8 – Burst mode command number. Must be 1, 2, 3, or 33 Command Errors: 2 – Invalid parameter if the burst command is not 1, 2, 3, or 33

Command Number: 109 Command Name: Burst Mode Control Command Type: Write

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-27

Sets Configuration Changed: yes Description: Turns burst mode on or off Request: Byte 0: u8 – Burst mode control. 0 turns burst mode off, 1 turns burst mode on. Response: Byte 0: u8 – Burst mode control. Command Errors: 2 – Invalid parameter if burst mode control is not 0 or 1

9.2 Burst Mode This Field Device s Burst Mode.

10. DEVICE-SPECIFIC COMMANDS 10.1 ed Device Specific Commands

Command Number: 140 Command Name: Clear Status Command Type: Process Sets Configuration Changed: no Description: Clears the HART interface board status flags. Note however, that persistent status conditions may immediately be set again after clearing. Request: no data

Appendix N

Digital Communications

N-28 Digital Communications

Response: no data Command Errors: none

11. TABLES Command Types • Read – returns data from the device • Write – sends data to the device • Process – sends a command to the device Data Types • u8 – unsigned byte (8 bit number) • s8 – signed byte • u16 – unsigned short integer (16 bits) • s16 – signed short integer • u24 – unsigned 24 bit integer • u32 – unsigned long integer (32 bits) • s32 – signed long integer • float – IEEE floating point number • ascii – packed ascii (see Hart foundation documentation for details)

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-29

12. PERFORMANCE 12.1 Sampling Rates Typical sampling rates for HART are shown in the following table: Primary position sensor sample

500 ms

Pressure differential

500 ms

Anaput signal (4-20 mA)

500 ms

12.2 Power-Up On power up, the transmitter goes through a self-test procedure (see section 12.4), which takes approximately 2 seconds. During this period, the device will not respond to HART commands other than HART command 0.

12.3 Reset Command 42 (“Device Reset”) is not implemented. A device reset buttons is available inside the housing, which resets the main electronics board and the HART communications board.

12.4 Self-Test The self-test procedure is executed at power up or after a device reset. The self-test includes: • Microprocessor • Configuration storage eeprom • Analog-to-digital converter • Digital-to-analog converter This self-test takes about 2 seconds. During self-test following power-up or reset, the device will not respond to HART commands.

Appendix N

Digital Communications

N-30 Digital Communications

12.5 Command Response Times Minimum

5 ms

Typical

20 ms

Maximum

150 ms

12.6 Delayed-Response Delayed-response is not used.

12.7 Non-Volatile Memory EEPROM is used to hold the device’s configuration parameters. New data is written to this memory immediately on execution of a write command.

12.8 Modes The actuator can be in auto, manual, or setup modes, however these modes are accessible only from the pushbuttons on the main . In setup mode, HART communication is disabled.

12.9 Write Protection Write protect is not available.

12.10 Damping Damping is not used.

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

N-31

ANNEX A. CAPABILITY CHECKLIST Manufacturer, model and revision

REXA, Xpac Series X2

Device type

Actuator

HART revision

5.0

Device Description available

No

Number and type of sensors

2 available from HART

Number and type of actuators

electrohydraulic

Number and type of host side signals

1: 4 - 20mA analog

Number of Device Variables

3

Number of Dynamic Variables

2

Mappable Dynamic Variables?

No

Number of common-practice commands 6

Appendix N

Number of device-specific commands

1

Bits of additional device status

24

Alternative operating modes?

Yes – but not settable from HART

Burst mode?

Yes

Write-protection?

No

Digital Communications

N-32 Digital Communications

ANNEX B. HART® INTERFACE BOARD CONNECTION

REXA Series 2 Xpac – Installation and Operation Manual – 03/12

Appendix N

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

O-1

O. Output Load Protection

O.1 THEORY OF OPERATION Each Xpac power module is equipped with two pressure limiting cartridges that provide output load protection to the device the actuator is attached to. These valves are located under the wire cover on the power module body as shown in Figure O.2. The valve to the left controls the pressure in the extend or clockwise direction.

O.2 IDENTIFICATION Each valve has a pressure label sticker indicating its range of adjustment. The range corresponds to the spring installed under the adjustment cap as noted in Table O.2

Table O.2 Adjustment Range Adjustment Range (psi)

Appendix O

Spring Color

750-1500

Purple

1500-2250

Orange

2250-3000

Brown (Std)

Output Load Protection

O-2

Output Load Protection

Appendix O

Standard springs are 2 250 – 3 000 psi unless specified otherwise. The limiting cartridge is then factory set to 2 300 – 2 400 psi. To translate pressure into actuator output, use the following formula:

(

Pressure Gauge Reading 2 000 psi

)(

) [

]

× Actuator Rated Output = Actual Output

The pressure gauge reading can be obtained from the corresponding pressure gauge shown in Figure O.2. This value should be the delta between the two gauges when calculating actual output.

Figure O.2 Pressure Relief Valve

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

REXA Series 2 Xpac – Installation and Operation Manual – 4/09

O-3

O.3 ADJUSTMENT: • Loosen the lock nut while holding the adjustment cap in place. • While running the actuator in a hard stop, read the corresponding gauge to the valve that is being adjusted. • Turn the adjustment cap CW to increase the relief pressure and CCW to decrease the relief pressure. Note: The adjustment cap does not have a hard stop and will unthread.

• Tighten lock nut against the cap to 100 lb·in (11 N·m) and test set pressure.

O.4 SPRING CHANGE: • Loosen the lock nut. • Unthread the adjustment cap. • Replace the spring. • Replace the adjustment cap. • Follow the adjustment procedure (O.3), above.

Appendix O

Output Load Protection

REXA Series 2 Xpac – Installation and Operation Manual – 04/13 P-1

P. Interconnect Diagrams & Control Enclosure Drawings D97904 — STEPPER WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . P-2 B QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3 C QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4 D97904-.5D — ½D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . P-5 ½D QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . P-6 D97904-D — D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . P-7 D QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8 D97904-2D — 2D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . P-9 D97904-P9 — D,P9 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . P-10 D97904-P40 — D,P40 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . P-11 D97904-STEPACCUM — STEPPER WITH ACCUMULATOR FAIL OPTION . . . . .P-12 D97904-.5DACCUM — ½D SERVO WITH ACCUMLATOR FAIL OPTION . . . . . P-13 D97904-DACCUM — D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . P-14 D97904-2DACC — 2D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . P-15 D97904-P9ACC — D,P9 SERVO WITH ACCUMLATOR FAIL OPTION . . . . . . . P-16 D97904-P40ACC — D,P40 SERVO WITH ACCUMULATOR FAIL OPTION . . . . . P-17 B AND C-PUMP CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . P-18 B AND C CONTROL ENCLOSURE FOR QUICK CONNECT CABLES . . . . . . . . . P-19 ½D AND D CONTROL ENCLOSURE FOR QUICK CONNECT CABLES . . . . . . . P-20 ½D AND D PUMP CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . P-21 2D & D,P9 CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . . . . P-22 D,P40 CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . . . . . . . P-23

Appendix P

Interconnect Drawings

D97904 — STEPPER WIRING DIAGRAM

B QUICK CONNECT CABLES

P-3

C QUICK CONNECT CABLES

P-4

D97904-.5D — ½D SERVO WIRING DIAGRAM

P-5

½D QUICK CONNECT CABLES

P-6

D97904-D — D SERVO WIRING DIAGRAM

P-7

D QUICK CONNECT CABLES

P-8

D97904-2D — 2D SERVO WIRING DIAGRAM

P-9

D97904-P9 — D,P9 SERVO WIRING DIAGRAM

P-10

D97904-P40 — D,P40 SERVO WIRING DIAGRAM

P-11

D97904-STEPACCUM — STEPPER WITH ACCUMULATOR FAIL OPTION

P-12

D97904-.5DACCUM — ½D SERVO WITH ACCUMULATOR FAIL OPTION

P-13

D97904-DACCUM — D SERVO WITH ACCUMULATOR FAIL OPTION

P-14

D97904-2DACC — 2D SERVO WITH ACCUMULATOR FAIL OPTION

P-15

D97904-P9ACC — D,P9 SERVO WITH ACCUMULATOR FAIL OPTION

P-16

D97904-P40ACC — D,P40 SERVO WITH ACCUMULATOR FAIL OPTION

P-17

B AND C-PUMP CONTROL ENCLOSURE DRAWING

P-18

P98492 — CONTROL ENCLOSURE FOR QUICK CONNECT CABLES

P-19

½D AND D CONTROL ENCLOSURE FOR QUICK CONNECT CABLES

P-20

½D AND D PUMP CONTROL ENCLOSURE DRAWING

P-21

2D & DP9 CONTROL ENCLOSURE DRAWING

P-22

DP40 CONTROL ENCLOSURE DRAWING

P-23

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

Q-1

Q. Input Options

INPUTS Note: Refer to the INPUTS menu, Signal Type parameter in the Modes of Operation & Control Parameters section.

Q.1 SIGNAL INPUT RANGE Voltage: OFF: 0 to 8 volts, AC or DC ON: 22 to 120 volts, AC or DC Undefined: 8 to 22 volts, AC or DC Current: OFF: less than 1 mA ON: 1.8 mA to 10 mA; proportional to voltage Impedance: 12K ohms Electromechanical or solid state switching devices may be used to activate the control signal. The following points should be observed:

Appendix Q

Input Options

Q-2

Input Options

ON state: Most AC and many DC solid state switching devices require a minimum current flow in order to remain in the closed state. If this minimum current exceeds the input signal current at the activation voltage, the current flow may be increased by adding a shunt resistor across the input signal terminals of the pulse auxiliary board.

OFF state: The OFF state leakage current must be less than 1 mA. Diode clamps or RC snubber networks placed across mechanical relays and the semiconductor junctions of solid state switches will some current in the OFF state. If this leakage exceeds 1 mA, a resistor added across the input signal terminals will by the current.

Q.2 1 CONT The single ( 1 Cont ) option of controlling the actuator is for ON/OFF applications. A single dry or live voltage is applied to the Inputs Board. The dry is biased by 120 Vac available from the input board. A live voltage, 24 to 120 Vac/Vdc, is supplied by the end . When Signal Type = 1 Cont (one ), “two position” operation— open/closed position—is selected. The applied signal defines actuator position. If the Open input is active (powered), the actuator goes to Position Hi. If the Open input is not active (un-powered), the actuator goes to Position Lo. Note: Actuator will continue to move in desired direction as long as a signal is present or until target is reached.

Typical wiring schemes are shown in Figure Q.2-1, -2.

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

Appendix Q

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

Q-3

Figure Q.2-1 1 Cont “Dry” Input Board

Appendix Q

Input Options

Q-4

Input Options

Figure Q.2-2 1 Cont “Wet” Input Board

Q.3 2 CONT The dual ( 2 Cont ) option of controlling the actuator is for manual modulation control, using two signals. Two dry s or two live voltages are applied to the Inputs Board. The dry s are biased by 120 Vac available from the input board or live voltages, 24 to 120 Vac/Vdc, are supplied by the end .

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

Appendix Q

REXA Series 2 Xpac - Installation and Operation Manual - 03/14 Q-5

When Signal Type = 2 Cont (two s), “manual modulation” operation is selected. The main input signals are the Main s Open and Close inputs of the Input Board. If both inputs are active or inactive, the actuator remains in its current position. If only the Open input is active, the actuator travels towards Position Hi. If only input Close is active, the actuator travels towards Position Lo. Note: Actuator will continue to move in desired direction as long as a signal is present or until target is reached.

Typical wiring schemes are shown in Figures Q.3-1, -2.

Figure Q.3-1 2 Cont “Dry” Input Board

Appendix Q

Input Options

Q-6

Input Options

Figure Q.3-2 2 Cont “Wet” Input Board

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

Appendix Q

REXA Series 2 Xpac - Installation and Operation Manual - 03/08

R-1

R. Remote Manual Control

R.1 REMOTE MANUAL (RemoteMan) The actuator may be equipped to connect to a remotely located manual station. The basic station includes one Remote/Auto: two-position maintained switch, and one Open/Off/Close: momentary spring-return-to-center switch. The two position switch is used to alternate between Auto and RemoteMan (remote manual) modes. In the RemoteMan mode, turning the momentary switch to Open or Close will move the actuator in the open or close direction. The springreturn-to-center (off) will stop the actuator at the position when the switch is released. As an additional option, a seven segment LED digital display may be connected to the standard position transmitter to display actuator position at the remote manual station.

RemoteMan allows the actuator to operate manually from a remote location. Once the Remote Manual mode is entered, the current status will be displayed along with Position. The RemoteMan mode is only accessible if the s Input board is installed on top of the U. Typical wiring schemes are shown in Figure R.1-1, -2.

Appendix R

Remote Manual Control

R-2

Remote Manual Control

The RemoteMan mode will be entered when the MAN Input of the Remote Auto/MAN Inputs is activated. The actuator is then controlled by activating the Open or Close Inputs of the Remote Auto/MAN Input.

Figure R.1-1 “Dry” s Input Board

REXA Series 2 Xpac - Installation and Operation Manual - 03/08

Appendix R

REXA Series 2 Xpac - Installation and Operation Manual - 03/08

R-3

Figure R.1-2 “Wet” s Input Board

Appendix R

Remote Manual Control

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

S-1

S. Safety Manual for ESD SIL Compliance S.1 GENERAL This REXA actuator is a Type A device with a hardware fault tolerance (HFT) of 0. The Rexa actuator has a safety trip function designed to meet or exceed the requirements of IEC 61508 for a SIL 3 capable designed process. The actuator has been designed and verified to withstand the worst case expected environmental conditions listed in the IOM and specification sheet. This section of the manual covers the operating requirements for the end to ensure their system is operated in compliance with the operating requirements needed to achieve safe operation of the equipment in accordance to the rated SIL level. The time in which an actuator will transition into a safe state is defined as the time required to trip on the Rexa data sheet. This transition time must be reviewed against the process safety time to insure this product is appropriate for the application. Any deviation to the installation, operation or maintenance from this appendix will void the IEC61508 SIL certification and may impact the ability of the actuator to accomplish its safety function. All product failures impacting functional safety should be reported back to Rexa. The FMEDA report for failure rates, failure modes, and proof test information can be found in the Rexa report KOS 13-10-03 R0001, titled FMEDA Rexa, Xpac.

Appendix S

Safety Manual for ESD SIL Compliance

S-2

Safety Manual for ESD SIL Compliance

An example of the system and application environment in which the PRODUCT will be embedded once delivered is shown in the following drawing.

Figure 1: Example Safety Instrumented Function S.2 SYSTEM SET UP In order to properly set up the ESD control system the following measures must be taken: 1. The actuator needs to be calibrated to the driven device. Reference the Mechanical and Electrical installation section of this manual. 2. The actuator end points need to be set. Reference the section of this IOM on setting mechanical end stops.

S.3 SYSTEM OPERATION The primary safety function of the actuator is to place the driven device in the process safe position when input to the actuator’s solenoid valves is de-energized. The safety function that carries the SIL certification is an ESD trip function. This trip function is designed to ensure the actuator can be stroked in one direction to

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

Appendix S

REXA Series 2 Xpac - Installation and Operation Manual - 03/14 S-3

either the full open or the full closed position. This function needs to be controlled directly from the ’s SIS and not through the Rexa control box. The ESD is certified for low demand fail safe applications. 3.1 The safety solenoids defined on the hydraulic schematic must be wired directly into the main safety system. It is possible for the Rexa controller to control these solenoids but in order to minimize the number of components in the safety loop they must be wired directly into the safety system for SIL applications. 3.2 Since the safety solenoids are controlled directly by the safety system a trip relay must be installed to disable the Rexa electronics during a safety event. This relay will insure the Rexa electronics cannot react to the safety system taking control of the actuator. 3.3 This system has been designed to full stroke at rate which is shown on the actuator data sheet provided to by REXA for this specific order. 3.4 The useful life of this actuator is 10 years based on the duty cycle provided to REXA for this application. After recommended seal maintenance the actuators useful product life is 20 years. 3.5 The REXA actuator is available in normally open or normally closed ESD configurations. 3.6 A 24 hour mean time to repair should be assumed for safety availability calculations.

S.4 SAFETY CRITICAL COMPONENTS 4.1 Definition - Some of the components on this actuator are identified as safety critical. If the failure of any component would inhibit the safety function of this Rexa actuator it is deemed a Safety critical component. 4.2 Only OEM supplied replacement parts can be used as suitable replacement parts for any component identified as Safety critical. 4.3 This actuator was supplied to meet a strict number of specifications and may not be modified in the field.

S.5 SYSTEM DIAGNOSTICS 5.1 Built into the Rexa U are numerous diagnostics that can be found in the error codes section of this IOM. These error codes must be

Appendix S

Safety Manual for ESD SIL Compliance

S-4

Safety Manual for ESD SIL Compliance

monitored by the safety system through an alarm relay. The only critical alarmed feature that would indicate the system may not perform its intended trip function is the stall alarm. 5.1.1 Stall Alarm – If the actuator fails to move 1%, within the adjustable stall time setting, while positioning the alarm relay will open indicating an alarm event. 5.1.2 Partial stroke testing is performed to the actuator is capable of performing it’s intended safety function. The actuator shall be designed to proof test intervals of 1 year or greater while consuming less than 40% of the allowable PFDavg for SIL 2 SIF applications when PST is implemented. The control and design of this test should be in the scope of the control system. The Rexa actuator will only follow the requested change in position as defined by the control loop. This PST percentage to activate needs to be calibrated within the scope of the plants SIS system. During a partial stroke test the control system must monitor the position transmitter to insure the actuator actually successfully performed this function. The control room supervisor needs to review and sign off on the results of the proof tests. This PST should be sufficient to achieve a greater than 65% SFF (Safe Failure Fraction). Key points to review during this test: 5.1.3 Verification from the REXA position transmitter that the actuator followed the change in the control position and performed its PST function. 5.1.4 Redundant verification from an optional PST limit switch can be provided, this limit switch needs to be wired directly into the SIS system. 5.2 The test results are to be recorded and stored for the life of the product. 5.3 In order to insure this system can maintain its “as designed” functionality the maintenance section of this IOM must be strictly adhered too.

S.6 SITE ACCEPTANCE TEST PROCEDURES A cognizant engineering ing the operation of the system is responsible for asg individuals to conduct and record automated testing and proof testing of the equipment. The cognizant engineer is then responsible for reviewing the results. 6.1 Run the actuator open and stroking times meet the specification sheet.

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

Appendix S

REXA Series 2 Xpac - Installation and Operation Manual - 03/14

S-5

6.2 Run the actuator close and stroking time meet the specification sheet. 6.3 Perform an ESD trip and stroking time meet the specification sheet. 6.4 Run the actuator to it’s PST position to position and the optional PST limit switch is functioning properly.

S.7 ENVIRONMENTAL REQUIREMENTS 7.1 The actuator has been designed and verified to withstand the worse case environmental conditions as listed in this IOM.

Appendix S

Safety Manual for ESD SIL Compliance

REXA Series 2 Xpac - Installation and Operation Manual - 05/12

T-1

T. Position Transmitter

Appendix T

Position Transmitter

T-2

Position Transmitter

Appendix T

T.1 POSITION TRANSMITTER The position transmitter provides a two-wire 4-20 mA signal that is proportional to actuator position. The transmitter's output is optically isolated from the electronics. Both an active and ive transmitter are available. A ive position transmitter is similar to other two-wire transmitters in that an external dc power source is required. An active two-wire transmitter with its own 24 Vdc power supply is available. Note: Position can be changed in the field from active to ive or ive to active by rewiring the as shown in Figures T.1-1 and T.1-2.

Refer to OUTPUTS Menu (6.1.8) in Modes of Operation & Control Parameters for calibration procedures. ive Resolution Maximum External Load

Active <0.1% of full stroke

1000 ohms @ 36 Vdc

700 ohms @24 Vdc

Minimum Supply Voltage

10 + (0.02 x RLOAD) Vdc

Maximum Supply Voltage

36 + (0.004 x RLOAD) Vdc

24 Vdc (internal supply)

Also included with the transmitter is an Alarm Relay. Whenever the actuator is unable to follow the applied control signal, the Alarm Relay will change state (de-energize). See PM14 for additional details. Alarm Relay: Response: ½ second of any "fail to operate condition" Alarm s: SPST Rating: 1 amp @ 30 Vdc, 0.3 amp @ 120 Vac - resistive Connection: Terminal strip on the auxiliary board

REXA Series 2 Xpac - Installation and Operation Manual - 05/12

REXA Series 2 Xpac - Installation and Operation Manual - 05/12

Figure T.1-1

Appendix T

T-3

ive Position Transmitter Connections

Position Transmitter

T-4

Position Transmitter

Figure T.1-2

Active Position Transmitter Connections

REXA Series 2 Xpac - Installation and Operation Manual - 05/12

Appendix T

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

U-1

U. ELECTRONIC RELAYS —Limit Switch, Alarm and Warning ELECTRONIC RELAYS The electronic limit, alarm and warning relays are located on the U board. All wiring connections are made directly to this board at TB1 and TB5. An indicator LED shows the status (energized-ON) of each relay. Two of the relays are configured in the Setup Mode to activate upon defined stroke limits. The third relay is an alarm indicator and the fourth is a warning indicator.

U.1 Limit Switch Relays LED D4 will illuminate when the Relay 1 is active; indicating the actuator position is at, or below, the value set in parameter Relay 1. LED D5 will illuminate when the Relay 2 is active; indicating the actuator position is at, or above, the value set in parameter Relay 2.

U.2 Alarm and Warning Relay LED’s D6 and D7 on the U Board are always active and light when the actuator operates normally without any error and is following the control signal.

Appendix U

Electronic Relays

U-2

Electronic Relays

Appendix U

Once the actuator detects an error, or is put into “LOCAL” or “SETUP” mode, the Alarm and Warning Relays open and LEDs D6 and D7 will turn off. When the U detects an error, which opens the Warning Relay only, LED D7 will turn off. The Warning relay is a signal from the control enclosure that means the REXA U detects a problem but can still operate and follow the Control Signal. The Alarm relay is a signal from the control enclosure that means the REXA U detects a problem, or is in LOCAL or SETUP modes, and cannot follow the Control Signal.

GENERAL SPECIFICATIONS Quantity:

4 (2 Limit, 1 Warning, 1 Alarm)

Type:

High Capacity PhotoMOS Relay

Rating:

1 amp @ 200 Vac/Vdc

Turn On time:

<3 mS

Differential Travel 0.1% (Hysteresis): Connection:

Terminal strip on the U board

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

U-3

U

PHOTOMOS WARNING RELAY RATING: 200 VAC/VDC, 1.0 AMP PHOTOMOS ALARM RELAY RATING: 200 VAC/VDC, 1.0 AMP

PHOTOMOS LIMIT SWITCH RELAYS RATING: 200 VAC/VDC, 1.0 AMP

Figure U-1 U Board’s Electronic Relays

Appendix U

Electronic Relays

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

V-1

V. Local Mode Indication Board

LOCAL MODE INDICATION BOARD The Local Mode Indication Board is an optional circuit board mounted to the U as shown in Figure V-1.

Appendix V

Local Mode Indication Board

V-2

Local Mode Indication Board

Figure V-1 Local Mode Indication Board The Local Mode Indication board gives an independent Solid State relay closure when the U is in the “Auto” mode, and LED D1 will illuminate. When the U is put into one of the Local operation modes—whether it is “Setup” mode, “Local Man” mode or “Remote Man” mode—the will open, and LED D1 will turn off. The relay will not trigger when an Error code occurs. The relay is the Photo-Mos type, SPST with a rating of 200 Vac @ 1 Amp.

REXA Series 2 Xpac - Installation and Operation Manual - 09/10

Appendix V

REXA Series 2 Xpac - Installation and Operation Manual - 07/12 W-1

W. Electronic Unit Ratings

Appendix W

Electronic Unit Ratings

Appendix W

Voltage 24VDC max

Relays Warning Alarm Limit Switches

Voltage 36VDC max 36VDC max 24VDC - 120VAC/VDC 1-5VDC

Voltage Amps 24VDC 4-20mA

Amps 4-20mA

Voltage Amps 200VAC/VDC 1.0A 200VAC/VDC 1.0A 200VAC/VDC 1.0A

Position Transmitter Output

Out

Control Signal Standard 4-20mA control signal Optional 10 - 50mA Pulse control signal ( 1 or 2 s) Low Coltage control

Amps 4-20mA 10-50mA 1A 20mA

Customer Input @ Circuit Breaker Motor Power Voltage Input Phase Input Fuse Volts Amps B, 24VDC 24VDC 20A 95VDC 6.3A B, 48VDC 48VDC 15A 72VDC 6.3A B, 115VAC 115VAC ±10% 1 5A 170VDC 6.3A B, 230VAC 230VAC ±10% 1 5A 170VDC 6.3A C, 24VDC 24VDC 50A 165VDC 6.3A C, 115VAC 115VAC ±10% 1 10A 170VDC 6.3A Dual C, 115VAC 115VAC ±10% 1 15A 170VDC 6.3A 1/2D, 115VAC 115VAC ±10% 1 20A 160VDC 6.0A 1/2D, 230VAC 230VAC ±10% 1 10A 280VDC 6.5A Full D, 230VAC 230VAC ±10% 1 10A 280VDC 7.5A Dual D 230VAC ±10% 1 20A 280VDC 7.5A D, P9 230VAC ±10% 3 25A 280VDC, 340VDC 7.5A, 22.0A D, P40 230VAC ±10% 3 50A 280VDC, 340VDC 7.5A, 55.0A = N/A with CSA

Electronic Unit

Table W-1 Electronic Unit Ratings Fail Solenoid Volts Amps 24VDC 5A 48VDC 2A 125VDC 1A 125VDC 1A 24VDC 5A 125VDC 2A 125VDC 2A 125VDC 2A 246VDC 1A 246VDC 1A 246VDC 1A 246VDC 1A 246VDC 1A

Circle Seal Solenoid Volts Amps 24VDC 5A 48VDC 5A 115VAC 5A 115VAC 5A 24VDC 5A 115VAC 5A 115VAC 5A 115VAC 5A 115VAC 5A 115VAC 5A 115VAC 5A 115VAC 5A 115VAC 5A

Serial number contains date of manufacture information.

Electronics Enclosure Nameplate

Heater Power Volts Amps 24VDC 8A 48VDC 5A 115VAC 2A 230VAC 1A 24VDC 8A 115VAC 2A 115VAC 2A 115VAC 2A 230VAC 1A 230VAC 1A 230VAC 1A 230VAC 1A 230VAC 1A

W-3

Electronic Unit Ratings

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

X-1

X. Redundant Construction

INTRODUCTION The modular construction of the Xpac allows the duplication of the critical components without a major redesign or sacrificing operational characteristics. Two Power Modules, two complete control electronics and two assemblies are used to operate a single hydraulic cylinder. Each module operates from its own controls and . Wiring and setup are the same as for any standard REXA Actuator. One module is designated as main and the other as backup. In this manner, the operation of the main system is indicated to the backup system via the Main system’s Alarm relay Output. The functional difference between the modules is strictly in the response to a change in control signal. •

The Backup is sixteen times less sensitive than the Main, up to a maximum of 5%.

For instance, setting the dead band of each module to 0.1% would mean that the backup module is at 1.6%. A control signal change of less than 1.6% would result in only the main module taking action to change position. A change greater than 1.6% would have both modules operating. Regardless of the

Appendix X 

Redundant Construction

X-2

Redundant Construction 

change, positioning would still be 0.1% resolution. If the main module cannot respond (indicated by the alarm), then the backup module will automatically revert to fine control and position to the 0.1% setting. This configuration has a redundancy of 90%. The only major component not duplicated is the hydraulic cylinder which is unlikely to suffer a catastrophic failure. Any size module can be upgraded. An R is added to the model number to indicate this enhancement (L2000-2-2BR-P).

X.1 MECHANICAL INSTALLATION Mounting and installation procedures for the actuator or drive are the same as for a standard unit. The location of the mounting holes and shaft connections are not affected.

X.2 ELECTRICAL INSTALLATION The two control electronics can be installed in a single enclosure or two separate enclosures. In either case, there are two complete sets which function, for the most part, independently. Wiring is accomplished as two separate units. Each Power Module and circuit is connected to a single electronics. However, the Alarm relay of the Main Control Enclosure is connected to the Aux s Open Input of the Backup Control Enclosure.

X.2.1 Connections Electrical power and control signal are wired in the conventional manner. However, consideration should be given to maintaining the redundancy down to the following connections: Power should be brought from two sources.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

Appendix X

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

X-3

A single 4-20mA control signal is looped through both electronics.

X.2.2 Redundant Interconnections The Alarm relay of the Main electronics is connected to the Auxiliary Open of the Backup electronics. When the Backup detects the Main is in the ‘alarm” state via this input, ( Input = no voltage detected), the Backup switches to its normal deadband setting until the alarm condition is cleared.

X.2.2.1 Alarm Indication The alarm relay is used to indicate the online status of the Main Power Module. Power for the alarm is obtained from the Backup Actuator Main AC power.

X.3 OPERATION The operation is substantially unchanged from a standard unit. However, some mention should be made to the interaction of two independent Power Modules on the same cylinder. Both Us are looking at the actual position and comparing this to the target position set by the control signal. If the target position for one module is satisfied but not for the other, then one module will reposition the actuator. If the repositioning causes the first module to move outside of its target, then it will move the actuator back. This action would occur with the same signal and low dead band settings (< 0.5%). Such operation is alleviated by simultaneous calibration and the backup unit’s deadband having an internal setting sixteen times that of the main unit. Another extraordinary condition will happen if one module is put into LOCAL MAN and moved manually. The other unit will continue to track the control signal and move the actuator back. Placing both Us in LOCAL MAN and moving only one remedies this situation.

Appendix X 

Redundant Construction

X-4

Redundant Construction 

Appendix X

X.4 WIRING

CALIBRATE

Wiring is accomplished as two separate units. A Power Module and circuit is connected to a single electronics.

X.5 U SET UP FOR MAIN AND BACKUP Each U is set as either the MAIN or BACKUP when shipped from the factory as a complete unit. However, in the case where a U needs to be replaced, the U must be set to either be the MAIN or BACKUP. This is accomplished in the CONTROL menu, parameter Function, as shown. The parameter Function = Backup can only be selected if the Inputs Board, P/N S97713, is installed. If the U is put into Auto mode when Backup is selected and no input board is present, the error No inp bd will be displayed and the U will revert back to the Setup mode.

CONTROL

SPEED / ACCEL

Function

Deadband

INPUTS

Min Mod

DRIVES Bumpless

OUTPUTS Surge Bkpt CURRENT STATS

HISTORIC STATS

Seat Ld Cyl

Flow Char

Se t u p

No i n p b d

Fu n c t i o n = Ba c ku p

X.6 SIMULTANEOUS CALIBRATE Both Us should be calibrated at the same time on a step by step basis. Follow the procedure indicated in Section 5.3. With the exception of the

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

X-5

Position Lo, Position High, all values in the SETUP Parameters should be identical.

Position Lo and Position HI should be set at the same time. 1. Access parameter Position Lo on both the Main and Back Up electronics, so that the “=” is flashing. 2. Operate the actuator, using the Main electronics, to the position that corresponds to 4 mA. 3. The % position value should change on both Control electronics. 4. The value on the Main electronics may be slightly different than the Back Up. That is acceptable. 5. Lock the value into Position Lo on the Main and Back Up by pressing “Enter” and stopping the “=” from flashing. 6. Access parameter Position Hi on both the Main and Back Up electronics, so that the “=” is flashing. 7. Operate the actuator, using the Main electronics, to the position that corresponds to 20 mA. 8. The value on the Main electronics may be slightly different than the Back Up. That is acceptable. 9. Lock the value into Position Hi on the Main and Back Up by pressing “Enter” and stopping the “=” from flashing. 10. Again, Position Lo and Position Hi of the Main Control enclosure may have slightly different values than the Back Up values; however, the physical position of the actuator is the same.

Appendix X 

Redundant Construction

X-6

Redundant Construction 

X.7 AUTO MODE DISPLAY When in Auto mode, the U operating as the MAIN will display Auto-Main, and the U operating as the BACKUP will display Auto-Bkup. When there is no voltage present on the Backup’s Auxiliary Open input, (Main is in Alarm state), the display on the Backup will change to Auto-Main until the alarm on the main is cleared.

X.8 REDUNDANT HIGH SPEED SOLENOIDS FOR SPRING FAIL OPERATION Some actuators may be equipped with redundant hi-speed solenoids to offer a mechanical spring fail on loss of Main AC power. Each solenoid is connected to its respective Control electronics. The two solenoids are hydraulically connected in series with one another. Under normal operation, the solenoid valves are closed. This allows the actuator to operate with the motor and pump. When Main AC Power is removed from BOTH Main and Back Up Control electronics, both solenoids will open, causing the spring to move the actuator to the Fail Safe position. Note: Because the solenoids are hydraulically connected is series, if Main power to only one Controller is removed, the actuator will not travel to the fail position. Rather, it will maintain normal operation with the motor and pump. In addition, should solenoid become defective, the remaining solenoid allows for normal operation.

REXA Series 2 Xpac – Installation and Operation Manual – 09/11

Appendix X

X-7

Figure X. Redundant Unit Interconnection Diagram