rotork 3450 Series User manual

SMART POSITIONER PRODUCT MANUAL
YT-3400 / 3450 SERIES
VERSION 1.46
YT-3400
YT-3450
Rotork YTC Limited

Smart Positioner
YT-3400 / 3450 series Product manual
Ver. 1.46 2
Contents
1Introduction.................................................................................................................................................5
1.1 General Information for the users.........................................................................................................5
1.2 Manufacturer Warranty.........................................................................................................................5
1.3 Explosion Proof Warning & Specific Conditions of Use .......................................................................6
2Product Description ...................................................................................................................................7
2.1 General.................................................................................................................................................7
2.2 Main Features and Functions ...............................................................................................................7
2.3 Label Description..................................................................................................................................8
2.4 Product Code..................................................................................................................................... 14
2.5 Product Specification......................................................................................................................... 15
2.6 Certifications...................................................................................................................................... 16
2.7 Parts and Assembly........................................................................................................................... 18
2.8 Product Dimension ............................................................................................................................ 19
2.8.1 YT-3400......................................................................................................................................... 19
2.8.2 YT-3450......................................................................................................................................... 20
3Installation................................................................................................................................................ 21
3.1 Safety................................................................................................................................................. 21
3.2 Tools for installation........................................................................................................................... 22
3.3 Linear positioner Installation.............................................................................................................. 22
3.3.1 Safety............................................................................................................................................. 22
3.3.2 Positioner Installation Steps .......................................................................................................... 23
3.4 Rotary positioner Installation ............................................................................................................. 26
3.4.1 Components................................................................................................................................... 26
3.4.2 Rotary Bracket Information............................................................................................................ 27
3.4.3 Rotary positioner Installation Steps............................................................................................... 28
4Connection - Air....................................................................................................................................... 30
4.1 Safety................................................................................................................................................. 30
4.2 Supply Pressure Condition................................................................................................................ 30
4.3 Piping Condition................................................................................................................................. 30
4.4 Connection –Piping with actuator..................................................................................................... 31
4.4.1 Single acting actuator .................................................................................................................... 31
4.4.2 Double acting actuator................................................................................................................... 31
5Connection – Power ................................................................................................................................ 32
5.1 Safety................................................................................................................................................. 32
5.2 Terminal overview.............................................................................................................................. 33
5.2.1 Input Signal Terminal..................................................................................................................... 33
5.2.2 Feedback Signal Terminal............................................................................................................. 34
5.2.3 Limit Switch Terminal..................................................................................................................... 34
5.2.4 Ground........................................................................................................................................... 35

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6Adjustments ............................................................................................................................................. 36
6.1 Limit Switch Adjustment..................................................................................................................... 36
6.2 A/M switch adjustment....................................................................................................................... 37
6.3 Variable Orifice Adjustment............................................................................................................... 37
7Maintenance ............................................................................................................................................. 38
7.1 Supply air........................................................................................................................................... 38
7.2 Seals.................................................................................................................................................. 38
8Auto Calibration and PCB Operation..................................................................................................... 39
8.1 Warning.............................................................................................................................................. 39
8.2 Button Description ............................................................................................................................. 39
8.3 Run Mode (RUN)............................................................................................................................... 39
8.4 Auto Calibration mode (AUTO CAL).................................................................................................. 40
8.4.1 AUTO1 Calibration (AUTO1)......................................................................................................... 40
8.4.2 AUTO2 Calibration (AUTO2)......................................................................................................... 41
8.4.3 AUTO 3 Calibration (AUTO 3)....................................................................................................... 41
8.4.4 AUTO HF Calibration (AUTO HF).................................................................................................. 41
8.5 Manual Mode (MANUAL)................................................................................................................... 42
8.6 Parameter Mode (PARAM)................................................................................................................ 42
8.6.1 Dead-Zone (dEAdZONE, %) ......................................................................................................... 43
8.6.2 P Value (KP).................................................................................................................................. 43
8.6.3 I Value (KI)..................................................................................................................................... 44
8.6.4 D Value (Kd) .................................................................................................................................. 44
8.6.5 P_ (KP_), I_(KI_), D_ (Kd_) Values............................................................................................... 44
8.6.6 KF Up Value (KFUP) ..................................................................................................................... 45
8.6.7 KF Down Value (KFdN) ................................................................................................................. 45
8.6.8 Control mode (CTRL) .................................................................................................................... 46
8.7 Hand Calibration Mode (HAND CAL) ................................................................................................ 47
8.7.1 Zero-Point (PV ZERO) and End-Point (PV END) for Valves......................................................... 47
8.7.2 Zero-Point (TR ZERO) and End-Point (TR END) for Transmitter ................................................. 48
8.7.3 Normal / Reverse Feedback Signal (TR NORM / REVS).............................................................. 49
8.7.4 Normal / Reverse HART Signal (HT NORM / REVS).................................................................... 49
8.8 Valve Mode (VALVE)......................................................................................................................... 50
8.8.1 Acting Adjustment (ACT RA / dA).................................................................................................. 50
8.8.2 Valve flow Characteristic Adjustment (CHAR)............................................................................... 51
8.8.3 User defining flow Characteristics (USER SET)............................................................................ 52
8.8.4 Tight Shut Open (TSHUT OP)....................................................................................................... 54
8.8.5 Tight Shut Close (TSHUT CL) ....................................................................................................... 54
8.8.6 Split Range Mode (SPLIT)............................................................................................................. 55
8.8.7 Custom Zero Setting Mode of Split Range (CST ZERO) .............................................................. 55
8.8.8 Custom End Setting Mode of Split Range (CST ENd) .................................................................. 56

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8.8.9 Interpolation Mode (ITP ON/OFF, ITP USER SET)....................................................................... 56
8.8.10 Acting Type (SINGLE / dOUBLE).............................................................................................. 57
8.8.11 Lever Type (STd / AdT) ............................................................................................................. 57
8.9 Diagnostic (dIAGNO)......................................................................................................................... 58
8.9.1 PST Introduction............................................................................................................................ 59
8.9.2 PST Mode (PST)............................................................................................................................ 60
8.9.3 PST Configuration (PST CFG) ...................................................................................................... 60
8.9.4 PST Result (PST RSLT)................................................................................................................ 63
8.10 View Mode (VIEW) ............................................................................................................................ 64
9Error and Warning Code ......................................................................................................................... 66
9.1 Error code which is displayed during Auto calibration....................................................................... 66
9.2 Error code which is displayed while using the product...................................................................... 67
9.3 Error code which can be checked from View mode .......................................................................... 67
9.4 Warning code which can be checked from View mode..................................................................... 68
10 Main Software Map .................................................................................................................................. 69

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YT-3400 / 3450 series Product manual
Ver. 1.46 5
1 Introduction
1.1 General Information for the users
Thank you for purchasing Rotork YTC Limited products. 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 commissioning 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)
➢The manual should not be duplicated or reproduced for any purpose without prior approval from
Rotork YTC Limited, Gimpo-si, South Korea.
➢In case of any other problems that are not stated in this manual, please make immediate contact
to Rotork YTC Limited.
➢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 Rotork YTC Limited will not be compensated. If any alterations or
modifications are necessary, please contact Rotork YTC Limited 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.
➢For detailed warranty information, please contact the corresponding local Rotork YTC Limited
office or main office in South Korea.

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Ver. 1.46 6
1.3 Explosion Proof Warning & Specific Conditions of Use
Please ensure the unit is being used and installed in explosion proof certified environment.
➢The positioners are Explosion proof construction for internal pressure.
For detail information, refer to “2.6 Certifications”
➢Explosion proof type of cables and gaskets should be used, when explosion gases are present at
the installation site.
➢Keep cover tight while circuits are alive.
➢Power should be turned off completely when opening product’s cover. When opening the cover,
ensure that there is no power remaining in any electrical parts nearby.
➢The positioners have 2 ports for power connection. Explosion proof type wires and packing should
be used. Blind plug is required when any port is not being used.
➢Ring terminal with surface area of more than 1.25 mm2 with M4 spring washer should be used to
connect the power.
➢For external ground terminal, ring terminal with surface area of more than 5.5 mm2 should be used.
➢There is risk of explosion due to electro-static charge. Static electricity charge may develop
when cleaning the product with a dry cloth. It is imperative to avoid static electricity charge in the
hazardous environment. If cleaning the surface of the product is needed, must use wet clothes.
➢Seal required within 50 mm of enclosure.
➢Consult the manufacturer for dimensional information on the flameproof joint for repair.
➢To maintain IP66 rating, when installing threaded conduit, use type PTFE tape according to
instructions.
➢Special conditions for safe use :
The ambient temperature range is from -20 °C to +70 °C for temperature class T6(T85°C ) or -
20 °C to +80 °C for temperature class T5(T100°C).
With silicone gasket material the minimum ambient temperature can be extended to -40 °C.
Hazardous area with carbon disulfide shall be excluded.

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YT-3400 / 3450 series Product manual
Ver. 1.46 7
2 Product Description
2.1 General
The smart positioner accurately controls valve stroke in response to an input signal of 4 ~ 20 mA from
the controller. Built-in micro-processor optimizes the positioner’s performance and provides unique
functions such as Auto-Calibration, PID Control, and HART Protocol Communications.
2.2 Main Features and Functions
➢The LCD can be checked and the buttons can be operated without opening the cover which allows
use of various functions of the positioner such as parameter adjustment in explosive gas
atmosphere.
➢User will easily understand the method of using 4 buttons because it work same in all mode 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.
➢Variable orifice can be used even to minimize the hunting occurrence and optimize operating
conditions.
➢Various information about positioner can be processed by HART communication(Option)
➢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 18 points characterizations.
➢Tight Shut – Close and Shut - Open can be set.
➢PID parameters can be adjusted in the field without any additional communicator.
➢A/M switch can be used to direct supply air to the actuator or to manually operate the positioner
or valve without any signal.
➢Split range 4 ~ 12 mA or 12 ~ 20 mA can be set.
➢Operating temperature for positioners is -30 ~ 85 °C or -40 ~ 85 °C (Please check certified
explosion proof ambient temperature)
➢Hand calibration function can set Zero point or End point manually.
➢It has Type 4, 4X(CSA), IP66 protection grade.
➢Polyester powder coating resists the corrosion process. (except YT-3450).
➢Maintenance of the positioner is easy because of modularized inner structure.
➢SIL2 certified.(For more information, see SIL Safety Instruction on homepage)

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YT-3400 / 3450 series Product manual
Ver. 1.46 8
2.3 Label Description
•MODEL : Indicates the model number of the positioner.
•SUFFIX : Indicates any options.
•SERIAL NO. : Indicates unique serial number.
•MONTH.YEAR : Indicates manufactured month and year
•EXPLOSION PROOF RATING : Indicates certified explosion proof grade
•INGRESS PROTECTION : Indicates enclosure protection grade.
•INPUT : Indicates input signal range.
•AMBIENT TEMP. : Indicates the allowable ambient temperature.
•SUPPLY : Indicates the supply pressure range.
Fig. L-1: YT-3400, 3450 sticker label
※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.

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YT-3400 / 3450 series Product manual
Ver. 1.46 9
Fig. L-2: YT-3400 metal label Fig. L-3: YT-3400 metal label (KCs)
(ATEX, IECEx, NEPSI)

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Fig. L-4: YT-3400 labels (FM, CSA) Fig. L-5: YT-3450 metal label
(FM, CSA)