Rotex Posidapt Series Installation and operating instructions

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SMARTPOSITIONER
POSITIONER
Installation
Operation
and
Maintenance
Manual

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Contents
1. Posidapt Product Summery.................................................................................... 6
1.1. Key Features ..........................................................................................................6
1.2. Posidapt Series.......................................................................................................7
2. Technical Specification .......................................................................................... 8
3. Posidapt Overview............................................................................................... 14
4. Bock Diagram:...................................................................................................... 17
5. Dimensional Drawing: .......................................................................................... 18
6. Installation / Mounting: ......................................................................................... 19
6.1. Safety Instructions:...............................................................................................19
6.2. Mounting Positioner on Control Valve:..................................................................22
6.3. Mounting Positioner on a Rotary Actuator: ...........................................................26
6.4. Mounting Positioner with bearing assembly on a Rotary Actuator........................29
6.5. Mounting Positioner with the bearing assembly on a Control Valve: ....................32
6.6. Remote Mounting. ................................................................................................36
6.7. Mounting remote unit on Rotary Actuator.............................................................36
6.8. Mounting remote unit on a Control Valve..............................................................40
6.9. Unfavourable mounting conditions........................................................................43
7. Electrical Connection ........................................................................................... 44
8. User Interface....................................................................................................... 45
8.1. Menu Structure.....................................................................................................45
8.2. Display Screen......................................................................................................47
8.3. Parameter Overview –DTM & Display.................................................................48
8.3.1. Basic Setup....................................................................................................48
8.3.2. Calibration......................................................................................................54
8.3.3. Advanced Setup.............................................................................................58

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8.3.4. Diagnostics and Setup ...................................................................................87
8.3.5. Diagnostics...................................................................................................103
8.4. Parameter Overview –DTM ...............................................................................123
8.4.1. Device Information.......................................................................................123
8.4.2. Online Statistics ...........................................................................................128
8.4.3. Valve Offline Test.........................................................................................130
9. Alert and Error Message .................................................................................... 131
9.1. Possible Error/Alert/Troubleshooting..................................................................131

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Safety
Warningnotice
This manual contains notices you have to observe in order to ensure your personal safety, as
well as to prevent damage to property. The notices referring to your personal safety are
highlighted in the manual by a safety alert symbol notices referring only to property damage
have no safety alert symbol. These notices shown below are graded according to the degree
of danger.
WARNING:
•If not observed, user incurs a high risk of severe damage to product and/or fatal
injury to personnel.
CAUTION:
•If not observed, user may incur damage to product and/or injury to personnel.
NOTE:
•Advisory and information comments provided to assist maintenance personnel to carry out
maintenance procedures.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel
qualified for the specific task in accordance with the relevant documentation, in particular its
warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Disclaimer of Liability
This manual provides information on installation, operation and maintenance procedures and
related instructions for the ROTEX make POSITIONER (Smart positioner).
The aim of this literature is to support the use of products in correct manner, and all the
technical information provided in the catalogue.
The manual should be given to the end user.
The manual can be changed or revised without any prior notice. Any changes in product's
specification, structure, and/or any components may not result immediate revised version of
the manual.
The manual should not be duplicated or reproduced for any purpose without any consent of
Rotex Manufacturers & Engineers Private Limited, INDIA.

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Manufacturer Warranty
For the safety, it is vital to follow instructions in the manual. It is not ROTEX’s liability for any
damages which caused by users' negligence.
It is not ROTEX's liability for any damages or accidents which resulted by any alteration or
modification of the product and parts. If alteration or modification is necessary, please contact
the ROTEX directly.
ROTEX warrants the product from the date of original retail purchase of the product for one
(1) year, except as otherwise stated.
ROTEX warranty will not cover the products that the product have been subjected to abuse,
accident, alteration, modification, tampering, negligence, misuse, faulty installation, lack of
reasonable care, repair or service in any way that is not contemplated in the documentation
for the product, or if the model or serial number has been altered, tampered with, defaced or
removed; damages that occurs in shipment, failure due to power surge, and cosmetic
damage. Improper or incorrectly performed maintenance or report voids this Limited
Warranty.
For detailed warranty information, please contact:
ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, R852/853 T.T.C. Industrial
Area, Rabale, Navi Mumbai 400701.

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1. Posidapt Product Summery
1.1. Key Features
LCD Display
•Larger LCD display for readability.
•No abbreviation and short form used.
•User friendly interface
•On screen diagnostic, alarm and error messages
•Structure menu for parameter, setup and diagnostics.
Contactless Feedback
•Contactless feedback, with patented algorithm
•Blind mount, eliminated need to oriented mounting angle.
•Remote mounting
PushButton
•Push button on device allows managing menu, diagnostics and alarms.
•Quick calibration using two push buttons.
IP66
•Pre-fitted gauge, enclosed in IP66 enclosure, ensure lifetime guaranty and reliability.
Electronics
•Encapsulated electronic provide protection against moisture and humidity, avoiding latency
failure of electronics.
•Modular electronic, Alarm Module and Position Transmitter.
Servo Valve
•Metal-to-metal contact, low friction and high sensitivity.
•Can accommodate wide variety of volume without need of flow control valve or volume
booster.
•Build in feedback sensor.
Communication
•HART protocol
•DD/DTM for HART communication.
ProductVariant
•Posidapt series has different product variant as, Modern, Expert, Super, Ultra and IPST.

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1.2. Posidapt Series

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2. Technical Specification
•Overview
➢General
oLoop power no external power supply required.
oExternal 24V DC option available.
oBlind mount.
oSuitable for rotary and linear valves.
oActuator connections in accordance with VDI/VDE 3845 and IEC 60534-6 standards.
➢Action
oDouble or single acting.
➢Failsafe
oFailsafe or stay-put(fail freeze)
•Actuator Travel Range
➢Linear
o0° position can start anywhere, 3 to 200 mm stroke, other strokes on request.
➢Rotary
o0° position can start anywhere, max 359°
➢Measurement range
o0 to 359° with freely rotating contactless feedback shaft.
➢Actuator travel time
o0 to 300 seconds (configurable in incremental steps of 60 seconds)
➢Actuator travel limit
oFreely configurable in 0 to 100%
➢Deadband time limit
o0 to 300 seconds (freely configurable, monitoring parameter until deviation reaches
within deadband)

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•Environmental Condition
➢Standard temperature range
o-20° to +85°C / -4° to +185°F
➢Low temperature range
o-40° to +85°C / -40° to +185°F
o-55° to +135°C / -67° to +185°F available on request
➢Influence of temperature on valve position
o0.35% /10°K
➢Influence on valve position
o<1% under 10g 5-85 Hz. 2.5 85-150 Hz
o1.5g, 150-280 Hz, 0.5g 280-1500 Hz
•Construction/Enclosure
➢Material
o1=Epoxy coated anodised aluminium housing & Makrolon ® (Polycarbonate) cover
o2 =Epoxy coated anodised aluminium housing & cover with Makrolon ® see through
window
o3 =Explosion proof aluminium housing & cover with toughened glass see through
window
o4 =Explosion proof stainless steel housing & cover with toughened glass see
through window
o5 =Intrinsically safe, epoxy coated anodised aluminium housing & Makrolon ®
(Polycarbonate) cover
o6 =Intrinsically safe, epoxy coated anodised aluminium housing & cover with
Makrolon ® (Polycarbonate) cover
o7 =Intrinsically safe, stainless steel housing & cover with toughened glass see
See through window
➢Protection class
oIp66
➢Pneumatic pressure ports
oG1/4”
o¼” NPT
➢Exhaust port
oG1/4”
o¼” NPT

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➢Cable gland
o¼” NPT
oM20 x 1.5
➢Weight (with gauges)
oBare Positioner option 1,5 = 2.25 kgs /5 lbs
oBare Positioner option 2,6 = 2.5 kgs / 5.5 lbs
oBare Positioner option 3 = 6.6 kgs / 10.6 lbs
oBare Positioner option 4,7 = 9.9 kgs / 21.9 lbs
oPositioner transmitter /Alarm module = 0.08 kgs / 0.2 lbs
•Pneumatics
➢Supply pressure
o1.4 to 8 bar / 0 to 14 psi (10 bar on request)
➢Capacity with 4 bar / 60 psi
o> 1 to 41 Nm³/h / 0.5 to 23 scfm (servo controlled orifice)
➢Consumption with 4 bar / 60 psi (Steady state)
o< 1 lpm / 0.037 scfm @ 4 bar
•Instrument Air
➢Air Quality
oIn accordance to ISO 8573-1
➢Solid particles
oClass 5 (maximum density 3mg/m³, 5μm filtration is recommended)
➢Humidity
oClass 1 (Dew point 10° C below minimum operating temperature)
➢Oil
oClass 3 (maximum concentration 5 mg/m³ or < 1 ppm)

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•Electronics and Electricals
➢Supply Power
o4 to 20 mA (2 wire system)
o18 to 30 VDC (4 wire system)
➢Signal
o4 to 20 mA, 0 to 20 mA (only with 4 wire system), both with or without HART signal
➢Minimum Signal
o≥3.6 mA
➢Current max
o36 mA (with overload protection)
➢Load Voltage
o9.7 VDC @ 20 mA (max 30 VDC)
➢Impedance
o485 Ωat20 mA
➢Wire Cross Section
oScrew terminals max 2.5 mm²(AWG 14)
•Characteristics and Performance
➢Characteristics
oLinear 1:25, 1:33, 1:50, 25:1, 33:1, 50:1, and freely configurable
➢Deadband
oConfigurable from 0.1% to 10 %
➢Hysteresis
o≤0.5 %
➢Deviation
o≤0.5 %

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•Position Transmitter module
➢Output
o4 to 20 mA (2 wire system)
➢Supply Voltage
o12 to 30 VDC
➢Total Operating Range
o3.6 to 21 mA
➢Transmission Error
o≤0.3 %
➢Influence of temperature
o0.35 % / 10° K
•Alarm Module
➢Supply Voltage
o12 to 30 VDC
➢Max Supply Voltage
o≤35 VDC
➢Signal Current
o≤2.1 mA (Logically HIGH)
o≤1.2 mA (Logically LOW)
➢Total Digital Output
o3
➢Total Digital input
o2 ^
➢Voltage
o30 VDC

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•Communication
➢HART 5 & 7
➢Foundation Field bus
➢Profibus PA
•Certification
➢Atex
oII 2GD Ex ia IIC T6 Gb
oII 2GD Ex d IIC T6 Gb
➢Safety
oUp to SIL 3

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3. Posidapt Overview
Simplicity in mounting, ease of operation and maintenance coupled with unmatched
performance are some of the highlights of the Rotex smart Positioner, listed below are some
of its unique features:
•LCD Display
a. Large LCD display for readability
b. No abbreviation or short form used
c. User friendly interface
d. On screen display of diagnostics, alarms and error messages
•Modular design with encapsulated electronics
a. Fewer modules make it easy to install, operate and maintain.
b. Fewer numbers of internal components and moving parts, increased reliability and life span.
c. Pre-fitted gauges, enclosed in IP66 enclosures ensure lifetime guarantee and reliability.
d. Encapsulated electronics provide protection against moisture and humidity, avoiding failure
of electronics.
•Superior functionality
a. Contactless feedback, with patented algorithm.
b. Blind mount, eliminates the need to orient mounting angle.

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•Feedback sensors
a. It has built in feedback sensor.
b. Preciservo operates with adaptive dual PID loop and ensures high accuracy, lower dead band
and extremely steady performance of positioner, Primary loop is controlling the spool position
of the Preciservo and secondary loop is controlling the actual position.
c. Dual PID loops eliminate overshoot, undershoot, hysteresis and “hunting”. ROTEX
POSIDAPT can maintain a steady state and set point with the highest degree of confidence.
d. Preciservo has metal to metal contact ensuring low friction and high sensitivity.
e. Precise manufacturing assures negligible hysteresis and dead band.
f. ROTEX Preciservo valve can vary the orifice due to primary PID loop. Hence different sizes
of actuators can be calibrated without the need of flow control valves or volume booster.
g. ROTEX Preciservo has built in self health check, ensures best performance and reliability
during calibration and testing.
•Communication
a. ROTEX POSIDAPT is compatible with Foundation fieldbus, Profibus and HART version 5 &
7.
b. It is also compatible with DTM framework version 1.2.1
c. DTM and EDD based on multi-system support configuration.
•Remote mounting
a. Remote mounting is possible with a non-contact feedback.
b. It is ideal for extreme environments and harsh conditions –high temperature, vibration,
frequency or difficult to reach locations.
c. Remote mounting cables with lengths of 3m, 5m, 7m and 10m available as standard. Special
version up to 30m is available on request.
•Diagnostics
a. Self diagnostics available with errors and recommendations.
b. Alarm based on different threshold.
c. On screen notification up to last 3 alarms or errors.
d. It can record data history for 25 years based on averaging method.
e. Monitoring parameters can be configured with three different threshold levels.
f. Each threshold level can be classified based on severity and generates a digital feedback
signal, once triggered.
g. Colour code represents nature of severity (can be communicated on HART to control system)
this enables users to take necessary preventive action.

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Identification of the product
Product code breakdown
R
T
X
7
1
1
2
G
H
P
4
R
*
*
R
M
0
3
SERIES
MODEL
ENCLOSURE
SERVO
PORT
CONNECTIONS
COMMUNICATION
MODULE
CABLE ENTRY
TEMPERATURE
CERTIFICATION
REMOTE MOUNT

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4. Bock Diagram:

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5. Dimensional Drawing:

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6. Installation / Mounting:
6.1. Safety Instructions:
The equipment must be installed in the accordance with the laws, guide lines and rules
applicable within the country.
WARNING:
•ENSURE THAT SUPPLY VOLTAGE SHOULD NOT EXCEED MORE THAN > 20 % OF
RATED VOLTAGE. (FOR CURRENT AND VOLTAGE RATINGS REFER CATALOGUE)
•NO MECHANICAL REWORK ALLOWED BY CUSTOMER. MECHANICAL REWORK CAN
INCREASE CLEARANCE BETWEEN HOUSING AND COVER.
•DO NOT OPEN COVER / CABLE GLAND WHEN POSITIONER IS UNDER OPERATION
OR IN ENERGIZED CONDITION.
CAUTION:
THE CURRENT AND VOLTAGE LIMITATION HAS TO BE OBSERVED AS PER THE TAG PLATE.
THE WIRING AND CONNECTION SHOULD BE CARRIED OUT WITH PROPER GLAND AND CARE SHOULD BE
TAKEN TO AVOID WATER SEEPAGE.
CONFIRM THE AREA IS NON-HAZARDOUS BEFORE OPENING THE COVER OF THE ENCLOSURE FOR
MAKING ELECTRICAL CONNECTIONS.
THE PLUGS GIVEN ALONG WITH BOX ARE TO BE REMOVED AND METALLIC PLUG TO BE USED.
ENSURE CABLE GLAND IS PROPERLY FITTED USING SOUND ENGINEERING PRACTICE ENSURING THAT
RAIN WATER /OTHER FLUIDS DO NOT ENTER IN THE SMART POSITIONER BOX.
THE PERSON WHO OPERATES THE LIMIT SWITCH SHOULD HAVE ENOUGH KNOWLEDGE OF ELECTRICAL
ENGINEERING.
CAUTION IP67 /IP68:
ENSURE CABLE GLAND AND GASKET IS PROPERLY FITTED USING SOUND ENGINEERING PRACTICE
ENSURING THAT RAIN WATER /OTHER FLUIDS DO NOT ENTER IN THE SMART POSITIONER BOX.
TIGHTEN THE COVER BOLTS FULLY TO AVOID WATER SEEPAGE INSIDE THE SMART POSITIONER
BOX.
USE UCIL SYNCHEM MAKE GRIP SEAL CABLE JOINING COMPOUND OR EQUIVALENT TO SEAL CABLE
GLAND.FOR PRECAUTION &APPLICATION OF SEALING COMPOUND USE ORIGINAL MANUFACTURERS
OPERATIONAL MANUAL.

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SPECIFIC CONDITIONS FOR USE OF Ex ia EQUIPMENT
•Only a damp cloth must be used while cleaning the surface of the Smart Positioner.
•Appropriate certified cable glands and plugs to be used.
•The plugs given along with box are to be removed and metallic plug to be used.
•Operating temperature range should not exceed then the mentioned on the tag plate
•Avoid electrostatic charges that can cause electrostatic discharge when installing.
•The information regarding the minimum ambient temperature for the positioner as
provided in the datasheet must also be observed.