OMC RE20 User manual

OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
SMART POSITIONER
RE20

2
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

Contents
1. Introduction................................................................................................................................................ 5
1.1 General Information for the users........................................................................................................ 5
1.2 Manufacturer Warranty ........................................................................................................................ 5
2. Product Description .................................................................................................................................. 6
2.1 General ................................................................................................................................................ 6
2.2 Main Features and Functions .............................................................................................................. 6
2.3 Label Description ................................................................................................................................. 7
2.4 Product Code ....................................................................................................................................... 8
2.5 Product Specification ........................................................................................................................... 9
2.6 Certifications ...................................................................................................................................... 10
2.7 Parts and Assembly........................................................................................................................... 11
2.8 Product Dimension ............................................................................................................................ 12
3. Installation................................................................................................................................................ 13
3.1 Safety................................................................................................................................................. 13
3.2 Tools for installation........................................................................................................................... 13
3.3 Linear positioner Installation .............................................................................................................. 14
3.3.1 Linear positioner Installation of Standard lever type ..................................................................... 14
3.3.2 Safety............................................................................................................................................. 14
3.3.3 Standard lever type positioner Installation Steps .......................................................................... 15
3.4 Rotary positioner Installation ............................................................................................................. 19
3.4.1 Components................................................................................................................................... 19
3.4.2 Rotary Bracket Information ............................................................................................................ 20
3.4.3 Rotary positioner Installation Steps ............................................................................................... 21
4. Connection - Air ....................................................................................................................................... 22
4.1 Safety................................................................................................................................................. 22
4.2 Supply Pressure Condition ................................................................................................................ 22
4.3 Piping Condition................................................................................................................................. 22
4.4 Connection – Piping with actuator ..................................................................................................... 22
4.4.1 Single acting actuator .................................................................................................................... 22
4.4.2 Double acting actuator................................................................................................................... 22
5. Connection – Power ................................................................................................................................ 24
5.1 Safety................................................................................................................................................. 24
5.2 Connection......................................................................................................................................... 24
5.3 Ground ............................................................................................................................................... 24
6. Adjustments ............................................................................................................................................. 25
6.1 Orifice Installment .............................................................................................................................. 25
6.1.1 Plate type Orifice Installment ......................................................................................................... 25
7. Optional Sub-PCB Installment ............................................................................................................... 26

3
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
7.1 Installation steps ................................................................................................................................ 26
8. Auto Calibration and PCB Operation..................................................................................................... 27
8.1 Warning.............................................................................................................................................. 27
8.2 LCD display and buttons.................................................................................................................... 27
8.2.1 LCD display and symbols .............................................................................................................. 27
8.2.2 Button and function........................................................................................................................ 28
8.3 Menu levels........................................................................................................................................ 29
8.4 RUN Mode Monitor ............................................................................................................................ 30
8.5 Configuration and Operation.............................................................................................................. 31
8.6 Calibration (CALIb) ............................................................................................................................ 33
8.6.1 Acting Type (SINGLE / dOUBLE).................................................................................................. 33
8.6.2 Auto Calibration 1 (AUTO 1).......................................................................................................... 34
8.6.3 Auto Calibration 2 (AUTO 2).......................................................................................................... 34
8.6.4 Travel Zero (TVL ZERO) and Travel end (TVL ENd) .................................................................... 35
8.7 Manual Operation (MAN OPER)........................................................................................................ 36
8.7.1 Manual Operation by Set position (MAN SP) ................................................................................ 36
8.7.2 Manual Operation by MV (MAN MV) ............................................................................................. 37
8.8 Control Parameters (CTL PARM) ...................................................................................................... 38
8.8.1 Dead Band (dEAdbANd)................................................................................................................ 38
8.8.2 Forward P parameter (KP UP) and reverse P parameter (KP dN)................................................ 39
8.8.3 Forward Integral time parameter (TI UP) and reverse Integral time parameter (TI dN)................ 39
8.8.4 Forward D parameter (Kd UP) and reverse D parameter (Kd dN) ................................................ 40
8.8.5 Auto Dead band Mode (AUTO db) ................................................................................................ 40
8.8.6 Performance Mode (PER) ............................................................................................................. 41
8.9 Input Configuration (IN CFG)............................................................................................................. 42
8.9.1 Signal Direction (SIG NORM / REVS) ........................................................................................... 42
8.9.2 Split Range Mode (SPLIT)............................................................................................................. 43
8.9.3 Custom Split Range Zero (CST ZERO)......................................................................................... 43
8.9.4 Custom Split Range End (CST ENd)............................................................................................. 44
8.9.5 Valve Flow Characterization Curves (CHAR)................................................................................ 44
8.9.6 User Set Characterization 5 Points (U5) ....................................................................................... 45
8.9.7 User Set Characterization 21 Points (U21) ................................................................................... 46
8.9.8 Tight Shut Open (TSHUT OP) ....................................................................................................... 47
8.9.9 Tight Shut Close (TSHUT CL) ....................................................................................................... 48
8.10 Output Configuration (OUT CFG)...................................................................................................... 49
8.10.1 Position Transmitter Direction (PTM NORM / REVS)................................................................ 49
8.10.2 Position Transmitter Zero / End (PTM ZERO / ENd)................................................................. 50
8.10.3 Back Calculation (bACKCAL oFF / on)...................................................................................... 51
8.11 Device Configuration (dEV CFG)....................................................................................................... 52
8.11.1 Action Setting (ACT) .................................................................................................................. 52
8.11.2 Linear Interpolation (ITP oFF / on)............................................................................................. 53

4
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
8.11.3 Lock of Parameters (Write Protect, W UNLOCK / LOCK) ......................................................... 53
8.11.4 Actual Position View Mode (View Mode, VI NORM / REVS) .................................................... 54
8.11.5 Factory Reset (dEFAULT oFF / on)........................................................................................... 54
8.11.6 Positioner Self-Test (SELFTEST).............................................................................................. 55
8.12 Diagnosis Mode (dIAGNd)................................................................................................................. 56
8.12.1 Default Alarm Settings ............................................................................................................... 56
8.12.2 Device Status (dS)..................................................................................................................... 57
8.12.3 Reset Alarm Status (RST ALRM oFF / on)................................................................................ 58
8.12.4 View Event Log (EVT LOG)....................................................................................................... 59
8.13 Position information (INFO) ............................................................................................................... 60
8.14 Status and Alarm Code...................................................................................................................... 62
9. Main Software Map .................................................................................................................................. 64

5
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
1. Introduction
1.1 General Information for the users
Each product has been fully inspected after its production to offer you the highest quality and reliable
performance. Please read the product manual carefully prior to installing and commission the
product.
Installation, commissioning, and maintenance of the product may only be performed by trained
specialist personnel who have been authorized by the plant operator accordingly.
The manual should be provided to the end-user.
The manual can be altered or revised without any prior notice. Any changes in product’s
specification, design, and/or any components may not be printed immediately but until the
following revision of the manual.
When the manual refers to “Valve Zero / Zero” means the final valve position upon pneumatic
pressure has been fully exhausted from positioner’s OUT1 port. For example, the valve zero
position may differ between linear direct and reverse actions. (DA/RA).
In case of any other problems that are not stated in this manual, please make immediate contact
to OMC Spa.
Positioner is an accessory of the control valve, so please make sure to read the applicable
instruction manual of the control valve prior to installation and operation.
1.2 Manufacturer Warranty
For the safety, it is important to follow the instructions in the manual. Manufacturer will not be
responsible for any damages caused by user’s negligence.
Any modifications or repairs to the product may only be performed if expressed in this manual.
Injuries and physical damages caused by customer’s modifying or repairing the product without
a prior consultation with OMC Spa will not be compensated. If any alterations or modifications
are necessary, please contact OMC Spa directly.
The warranty period of the product is (18) months from the date of shipment unless stated
otherwise. Date of shipment can be checked by providing the LOT NO. or SERIAL NO. to us.
Manufacturer warranty will not cover products that have been subjected to abuse, accidents,
alterations, modifications, tampering, negligence, misuse, faulty installation, lack of reasonable
care, repair or service in any way that is not contemplated in the documentation for the product,
or if the model or serial number has been altered, tampered with, defaced or removed; damages
that occurs in shipment, due to act of God, failure due to power surge, or cosmetic damage.
Improper or incorrectly performed maintenance will void this limited warranty.

6
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2. Product Description
2.1 General
RE20 Smart Valve Positioner accurately controls valve stroke in response to an input signal of
4~20mA from the controller. Built-in micro-processor optimizes the positioner’s performance and
provides unique functions such as Auto-Calibration, PID Control.
2.2 Main Features and Functions
LCD display enables users to monitor the positioner status.
User will easily understand the method of using 4 buttons because it work same in all versions of
firmware interfaces.
When unexpected situation like momentary blackout happens, our positioner boot-time only take
0.5 second and this can minimize the travel of valve which consequentially increase the safety of
system.
Positioner operates normally even there are sudden changes in supply pressure and / or high
vibration environment.
The method of Auto Calibration is very simple.
As an advantage of having very low air consumption, It could greatly reduce operating costs in
large-scale plants.
It is compatible with most of controllers.
Orifices can be installed even in the field to minimize the hunting occurrence and optimize
operating conditions.
Valve system becomes more stable by outputting analog feedback signal.
Different valve characteristics can be adjusted – Linear, Quick Open, Equal Percentage, and
User Set which user can make 5 or 21 points characterizations.
Tight Shut – Close and Shut - Open can be set.
PID parameters can be adjusted in the field without any additional communicator.
Split range 4~12mA or 12~20mA can be set.
Operating temperature for positioners is -30 ~ 85℃(Please check certified explosion proof
temperature in case of Ambient temperature)
Hand calibration function can set Zero point or End point manually.
It has IP66 protection grade.
Polyester powder coating resists the corrosion process.
Maintenance of the positioner is easy because of modularized inner structure.

7
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2.3 Label Description
MODEL : Indicates the model number and any options of the positioner.
INGRESS PROTECTION : Indicates enclosure protection grade.
INPUT SIGNAL : Indicates input signal range.
OPERATING TEMP. : Indicates the allowable operating temperature.
SUPPLY PRESSURE : Indicates the supply pressure range.
SERIAL NUMBER : Indicates unique serial number.
YEAR.MONTH : Indicates manufactured year and month.
AMBIENT TEMP. : Indicates the allowable ambient temperature for explosion proof.
Ui, Ii, Pi, Ci, Li : Indicates the allowable electrical data in the certificate.
You can also see the details in the certificate.
※Precautions
Be careful not to apply volatile solvent (hardener of instant adhesive, acetone, WD-40, etc.) to
the sticker nameplate. Printed contents may be erased.

8
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2.4 Product Code
RE20 follows suffix symbols as follows.
RE20 1 2 3 4 5 6 7
1 Motion Type L :
R :
Linear (Positioner is attached the right yoke of actuator.)
Rotary
2 Acting type S :
D :
Single
Double
3 Lever Type
Linear
0 :
1 :
2 :
10 ~ 40 mm (Standard type)
20 ~ 100 mm (Standard type)
90 ~ 150 mm (Standard type)
Rotary 5 : Namur
4 Conduit - Air
Connection Type
1 :
2 :
G 1/2 – Rc 1/4
G 1/2 – 1/4 NPT
5 Gauge block 0 :
1 :
None
+ Gauge block
6 Option 0 :
1 :
None
+ Position Transmitter
7 Operating Temp.
(Non-explosion proof)
1)
S : -30 ~ 85℃
1) This option is just the normal operating temperature of the product and is not related to explosion proof
temperature. See “2.6 Certificates” for explosion proof temperature.

9
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2.5 Product Specification
Model RE20
Housing Material Body : Aluminum
Cover : Polycarbonate
Motion Type Linear Rotary
Acting Type Single / Double
Input Signal 4~20mA DC
Minimum Current Signal 3.2mA
Supply Pressure 0.14 ~ 0.7 MPa (1.4 ~ 7 bar)
Stroke 10 ~ 150 mm 55 ~ 110°
Impedance Max. 500Ω@ 20mA DC
Air Connection Rc 1/4 or 1/4 NPT
Gauge Connection Rc 1/8 or 1/8 NPT
Conduit Entry G 1/2
Ingress Protection IP66
Operating Temperature -30℃~ 85℃(-22℉~ 185℉)
Linearity ±0.5% F.S.
Hysteresis ±0.5% F.S.
Sensitivity ±0.2% F.S
Repeatability ±0.3% F.S.
Flow Capacity 70 LPM (Sup.=0.14 MPa)
Air Consumption Below 2 LPM (Sup.=0.14 MPa @ idle)
Output Characteristic Linear, Quick Open, EQ%, User Set
Vibration No Resonance up to 100Hz @ 6G
Humidity 5-95% RH @ 40℃
Feedback Signal (Option) 4~20mA (DC 9~28V)
Weight 1.7 kg (3.7 lb)
Painting of base body Polyester Powder Coating

10
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]

11
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2.6 Parts and Assembly
Fig. 2-1: exploded view
1. BaseCover 6. Pilot
2. PCB Cover 7. Pilot Block
3. Main PCB 8. Base body
4. Torque Motor 9. Feedback Lever
5. Main Shaft 10. Gauge Block

12
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
2.7 Product Dimension
Fig. 2-2: RE20L Fig. 2-3: RE20R

13
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
3. Installation
3.1 Safety
When installing a positioner, please ensure to read and follow safety instructions.
Any input or supply pressures to valve, actuator, and / or to other related devices must be turned
off.
Use bypass valve or other supportive equipment to avoid entire system “shut down”.
Ensure there is no remaining pressure in the actuator.
The positioner has a vent cover to exhaust internal air and drain internal condensation water.
When installing the positioner, make sure the vent cover must be facing downward. Otherwise,
the condensation water could cause damages to PCB.
Fig. 3-1: The correct positions of a vent cover
3.2 Tools for installation
Hex key set for hex socket cap bolts
(+) & (-) Screw drivers
Spanners for hexagonal-head bolts

14
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
3.3 Linear positioner Installation
Linear positioner should be installed on linear motion valves such as globe or gate type which uses
spring return type diaphragm or piston actuators.
3.3.1 Linear positioner Installation of Standard lever type
Fig. 3-2: installation example
Before proceeding with the installation, ensure following components are available.
Positioner
Feedback lever and lever spring
M6 nut and spring washer (fastening feedback lever to a main shaft)
Bracket, bolts and washers for positioner or sensor – not supplied with the positioner
Connection bar – not supplied with the positioner
3.3.2 Safety
Proper bracket must be made in order to adapt the positioner on the actuator yoke.
Please consider following important points when a bracket is being designed.
Positioner’s feedback lever must be vertical to the valve stem at 50% of the valve stroke.
The connection bar of the actuator clamp for the feedback lever should be installed in such a
way that the valve stroke length coincides with the corresponding figure in “mm” marked on the
feedback lever. Improper setting may cause poor linearity

15
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
3.3.3 Standard lever type positioner Installation Steps
1. Assemble the positioner with the bracket made in previous step by fastening the bolts.
Fig. 3-3: Linear (Standard Lever Type)
2. Attach the positioner with the bracket to the actuator yoke
– DO NOT TIGHTEN THE BRACKET COMPLETELY.
3. Connect connection bar to the actuator clamp. The hole gap on the feedback lever is 6.5mm so
the connection bar’s outer diameter should be less than 6mm.

16
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
4. Connect an air-filter regulator to the actuator temporarily. Supply enough air pressure to the
actuator in order to position the valve stroke at 50% of the total stroke.
Fig. 3-4: Linear (Standard Lever Type)
5. Insert the connection bar between the feedback lever and lever spring. The connection bar must
be located upward from the lever spring as shown below left figure. If it is located downward from
the lever spring as shown below right figure, the connection bar or the lever spring will be worn
out quickly because of excessive strong tension.
Fig. 3-5: Proper way to insert connection bar between feedback lever and lever spring

17
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
6. Check if feedback lever is vertical to the valve stem at 50% of the valve stroke. If it is not
vertical, adjust the bracket or the connection bar to make vertical. Improper installation may
cause poor linearity.
Fig. 3-6: Linear feedback lever and valve stem
7. Check the valve stroke. The stroke numbers are engraved on the feedback lever of the
positioner. Position the connection bar at the number on the feedback lever which corresponds
with the desired valve stroke. To adjust, move the bracket, the connection bar or both.
※The effective linear feedback lever angle is 60 degree
Stroke : 75mm
Stroke : 45mm
Fig. 3-7: Linear feedback lever and location of the connection bar

18
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
8. After installing the positioner, operate the valve from 0% to 100% stroke by using direct air to the
actuator. On both 0% and 100%, the feedback lever should not touch the lever stopper, which
is located on the backside of the positioner. If the feedback lever touches the stopper, the
positioner should be installed further away from the center of the actuator.
Fig. 3-8: Feedback lever should not touch lever stopper on 0% ~ 100% valve stroke.
9. After the installation, tighten all of the bolts on the bracket and the connection bar.

19
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
3.4 Rotary positioner Installation
Rotary positioner should be installed on rotary motion valve such as ball or butterfly type which uses
rack and pinion, scotch yoke or other type of actuators which its stem rotates 90 degrees. Before
proceeding with the installation, ensure following components are available.
3.4.1 Components
Positioner
Rotary bracket set (2 piece)
4 pcs x wrench headed bolts (M6 x 1P x 10L) : For the positioner and the upper bracket
4 pcs x wrench headed bolts (M6 x 1P x 15L) : For the bracket set
4 pcs x M6 nuts : For the bracket set
4 pcs x M6 spring washers : For the bracket set
Bolts and washers to attach bracket to actuator – not supplied with the positioner
Fig. 3-9: Rotary Namur type

20
Installation
,
O
p
eration and Maintenance Manual ManRE20en Rev.06/2022
OMC S.p.A: Via G. Galilei, 18 - 20060 - Cassina de Pecchi (MI) - ITALY - www.omcvalves.com - Tel.: [phone]
3.4.2 Rotary Bracket Information
The rotary bracket set (included with the positioner) contains two components. (but the upper
brackets of Fork lever type and Namur type are different). The bracket is designed to fit onto the
actuator with 20mm, 30mm and 50mm stem height (H) according to VDI/VDE 3845 standard. Please
refer to below table how to adjust the height of the bracket.
Actuator stem
height (H)
Markings of bolt holes
A-L B-L A-R B-R
20mm H : 20 H : 20, 30 H : 20 H : 20, 30
30mm H : 30 H : 20, 30 H : 30 H : 20, 30
50mm H : 50 H : 50 H : 50 H : 50
Fig. 3-10: Rotary brackets and positioner