rotork TMP-3000 User manual

SMART POSITIONER PRODUCT MANUAL
TMP-3000 (Old PCA and software)
VERSION 1.23
Rotork YTC Limited

Smart Positioner
TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 2
Contents
1Introduction..................................................................................................................................................4
General Information for the users .........................................................................................................4
Safety precautions and Manufacturer Warranty ...................................................................................4
2Product Description ....................................................................................................................................5
General .................................................................................................................................................5
Main Features and Functions ...............................................................................................................5
Label types and contents......................................................................................................................6
Product Code ........................................................................................................................................7
Product Specification ............................................................................................................................8
Certificate and Approvals......................................................................................................................8
Parts and Assembly (Exploded View)...................................................................................................9
Exterior Parts and Description ........................................................................................................... 10
Filter Cleaning.................................................................................................................................... 10
Dimensions .........................................................................................................................................11
3Installation................................................................................................................................................. 12
Safety................................................................................................................................................. 12
Tools required for Installation............................................................................................................. 12
TMP-3000 Installation........................................................................................................................ 12
TMP-3000 Installation Example..................................................................................................... 12
Installing......................................................................................................................................... 13
Warning.......................................................................................................................................... 15
4Pneumatic Connections .......................................................................................................................... 16
Safety................................................................................................................................................. 16
Supply Pressure Condition ................................................................................................................ 16
Piping Condition................................................................................................................................. 16
Piping Connection of the Positioner and Actuator ............................................................................. 16
Single Acting Actuator .................................................................................................................... 16
Double Acting Actuator .................................................................................................................. 17
5Power Connection .................................................................................................................................... 18
Warning.............................................................................................................................................. 18
Terminal Connections ........................................................................................................................ 19
Ground ............................................................................................................................................... 19
6Maintenance.............................................................................................................................................. 20
Supply air ........................................................................................................................................... 20
Seals .................................................................................................................................................. 20
7Auto Calibration and How to Operate .................................................................................................... 21
Warning.............................................................................................................................................. 21
Button Description ............................................................................................................................. 21
Run Mode (RUN) ............................................................................................................................... 21

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 3
Auto Calibration Mode (AUTO CAL).................................................................................................. 22
Auto 1 Calibration Mode (AUTO1)................................................................................................. 22
Auto 2 Calibration Mode (AUTO2)................................................................................................. 23
Manual Mode (MANUAL)................................................................................................................... 23
Parameter Mode (PARAM) ................................................................................................................ 24
Dead-Zone (dEAdZONE, %) ......................................................................................................... 24
Auto Dead Zone (AUTO Dz).......................................................................................................... 25
PT1, PT2 Values ............................................................................................................................ 25
ESR1, ESR2 Values ...................................................................................................................... 26
PR1, PR2 Values ........................................................................................................................... 26
PERIOD Time ( PERIOD ) ............................................................................................................. 27
Hand Calibration Mode (CALIb) ........................................................................................................ 27
Input Signal Selection (SEL IN) ..................................................................................................... 27
Zero-Point (PV_ZERO) and End-Point (PV_END) ........................................................................ 28
Zero-Point (TR_ZERO) and End-Point (TR_END) ........................................................................ 29
Normal/Reverse Feedback Signal (TR NORM / REVS)................................................................ 29
Valve Mode (VALVE).......................................................................................................................... 30
Acting Adjustment (ACT RA / dA) .................................................................................................. 30
Characteristic Adjustment (CHAR) ................................................................................................ 31
User defining flow Characteristics (USER SET)............................................................................ 32
Tight Shut Open (TSHUT OP) ....................................................................................................... 33
Tight Shut Close (TSHUT CL) ....................................................................................................... 33
Custom Zero Setting Mode (CST ZERO) ...................................................................................... 34
Custom End Setting Mode (CST ENd) .......................................................................................... 34
Single and Double Acting Adjustment (SINGLE / dOUBLE).......................................................... 35
INFO Mode (INFO) ............................................................................................................................ 36
8Error Code................................................................................................................................................. 37
Error Code during Auto calibration .................................................................................................... 37
Error Code during operating .............................................................................................................. 37
9LCD Operating Order ............................................................................................................................... 38

Smart Positioner
TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 4
1 Introduction
General Information for the users
Thank you very much for purchasing our products. Our products are manufactured, inspected and
delivered in uniform quality with strict regulations at the factory. To use this product correctly and
efficiently, please read this manual carefully before 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 contents of this manual are subject to change without prior notice. Product specifications,
designs and parts are not immediately reflected in the manual when they are changed, but are
reflected in the next revision.
➢The meaning of the valve original point (Zero) in this manual is the position of the valve when the
air pressure is completely out of positioner OUT1. That is, in the case of the linear direct acting
type actuator, the stem of the actuator is raised when the air pressure is completely released from
the OUT1 of the positioner. In the case of the linear reverse type actuator, when the air pressure
is completely released from the OUT1 of the positioner, the stem of the actuator comes down and
this is called original point (Zero).
➢This manual cannot be reproduced or reused for any purpose without our approval.
➢If any problem arises that is not described in this manual, please contact us immediately.
➢This product is an accessory device of control valve. Be sure to read the instruction manual of the
corresponding control valve before starting operation.
Safety precautions and Manufacturer Warranty
➢When handling this product, for the protection and safety of the operator, the product and the
system in which the product is installed, should follow the safety instructions mentioned in this
manual. If you do not follow the safety instructions in this manual correctly, we cannot guarantee
the safety of the operator.
➢Any changes or repairs to the product are allowed only when described in this manual. If any
changes or modifications are made by the customer without a prior consultation with Rotork YTC
Limited, we will not compensate for any personal or material damage that may occur. If you need
to change or modify the product, please contact us.
➢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.
➢Any misuse, accident, alteration, modification, manipulation, negligence, improper installation,
improper maintenance, repair, maintenance or service, or model or serial number change,
manipulation, damage, disasters, power surges, or serious damage are not covered by the
warranty.
➢Please contact us for further information on product warranty.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 5
2 Product Description
General
The TMP-3000 Smart Positioner not only precisely controls the valve opening according to the electric
input signal from the controller or the central control room, but also performs the auto calibration by the
computation action of the built-in high performance microprocessor and PD control. It is a highly reliable
positioner that performs various powerful functions such as optimum control.
Main Features and Functions
➢In case of Fail Freeze or Fail Safe optional product, it maintains the current valve position without
any additional equipment such as lockup valve or solenoid valve in case of power supply (24V)
failure.
➢Back light function LCD is attached so you can check the status of the positioner directly in the
field.
➢Four adjustment buttons and unique functions of the buttons are applied in the same way
throughout the firmware, so it is very easy to use.
➢The initialization time is very short, which minimizes the change of valve stroke in case of
temporary power failure and improves system stability.
➢Very strong against vibration and can be used in extremely high vibration areas.
➢The change in supply pressure during use has almost no effect on the adjustability of the positioner.
➢Auto calibration is very simple, so first time users can handle the product easily.
➢Compact size makes it easy to attach to small actuators.
➢Very low air consumption which allows large plants to reduce their operating costs.
➢The valve system can be stabilized by outputting an analog feedback signal.
➢Different valve characteristics can be adjusted – Linear, Quick Open, Equal Percentage, and User
Set which user can make 5 points or 21 points characterizations.
➢You can minimize valve leakage by setting the sealing function of Tight Shut-Off / On.
➢Half-interval control (Split Range) is available such as 4 ~ 12mA and 12 ~ 20mA etc..
➢You can change Zero and Span freely through Hand Calibration function.
➢By manual operation, valve can be operated arbitrarily irrespective of input signal, so it is easy to
judge whether or not there is an abnormality of valve.
➢Ingress protection of IP67.
➢The product's enclosure is made of a material with excellent chemical resistance and moisture
resistance, so it can be used stably for a long time even in a corrosive atmosphere.
➢The internal structure is very simple and modular, so there is little possibility of failure and
maintenance is simple.
➢It is equipped with a foreign material prevention filter which is easy to maintain.
➢Flow rate can be selected according to actuator size.
➢Solenoid valve with superior durability of over 200 million cycles.
➢Non-contact potentiometer has permanent wear resistance.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 6
Label types and contents
Fig. L-1 : TMP-3000 Label
• MODEL : Indicates the model number and additional symbols.
• EXPLOSION PROOF : Indicates certified explosion proof grade.
• INGRESS PROTECTION : Indicates IP protection level.
• POWER SUPPLY : Indicates the supply power applied to the product. 24VDC ± 10%
• INPUT SIGNAL : The range of the input current or voltage signal is indicated.
• OPERATING TEMP. : The ambient temperature range in which the positioner can operate is indicated.
• SUPPLY PRESSURE : Indicates the range of pneumatic pressure supplied to the positioner.
• SERIAL NUMBER : The unique serial number of the product.
• MONTH.YEAR : Indicates the month and year of manufacture of the product.
※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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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 7
Product Code
TMP-3000 1 2 3 4 5 6
1 Pneumatic Output
S :
D :
Single Acting
Double Acting
2 Explosion Protection
N :
Non-Explosion
3 Conduit –
Pneumatic Connection
G :
M16x1.5P – G 1/8
4 Flow Capacity
1 :
2 :
20LPM
50LPM
5 Options
0 :
1 :
None
Internal Position Transmitter
6 Fail Option
F :
S :
Fail Freeze
Fail Safe

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 8
Product Specification
Model
TMP-3000
Acting Type
Single / double
Power supply
24V DC ±10%, DC 260mA(@21.6VDC)
Input Signal
0~20mA / 4~20mA / 0~5V / 0~10V
Impedance
0~20mA / 4~20mA : 164Ω
0~5V / 0~10V : 561kΩ
Power Consumption
< 5.8W
Output Signal
4~20mA (DC 9~28V)
Fail Option (Power supply off)
Fail freeze(stay in current position),
Fail safe (move to safe position)
Supply Pressure
0~0.7MPa (0~7bar)
Flow Capacity : 0.6MPa Supplied
20LPM / 50LPM
Air consumption
0 LPM
Filtering Size, particle size
5 Micron
Air Connection
G 1/8 (Ø 6mm Tube)
Operating Temp.
-10 ~ 60°C (14 ~ 140°F)
Conduit
2-M16×1.5P
Stroke
5~40mm
Ingress Protection
IP67
Output Characteristic
Linear, Quick Open, EQ%, User Set
Vibration
100Hz @ No resonance up to 6G
Body Material
PPS
Cover Material
PC (Transparent)
Weight
750 g (1.7 lb)
Tested under ambient temperature of 20°C, absolute pressure of 760mmHg, and humidity of 65%.
Please contact Rotork YTC Limited for detailed testing specification.
Certificate and Approvals
➢Electromagnetic Compatibility (EMC)
- EMC directive 2014/30/EC from April 2016
- EC Directive for CE conformity marking

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 9
Parts and Assembly (Exploded View)
Fig. 2-1: TMP-3000 Exploded View
1. Base Cover 6. Solenoid Valve
2. PCB Cover 7. Manifold
3. Main PCB 8. Filter
4. Potentiometer 9. Base Body
5. Feedback Shaft
1
8
4
3
7
4
3
2
5
4
3
4
3
3
6
4
3
9
4
3

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 10
Exterior Parts and Description
Fig. 2-2: TMP-3000 Exterior Parts and Description (Base Cover Removed)
Filter Cleaning
TMP-3000 has a built-in filter that filters foreign substances from the outside. During maintenance,
please observe the followings to clean the filter.
➢All input signals to valves, actuators, and other peripherals, pneumatics, etc. must be completely
stopped.
➢Disconnect the control valve from the system with a bypass valve or other similar device to prevent
shutdown of the entire system.
➢Make sure there is no air pressure in the actuator.
➢Filter size is 5 micron.
➢Please assemble carefully after disassembly and be careful of the direction of filter.
➢Tool required for disassembly is 6mm wrench.
Fig. 2-3: TMP-3000 Filter Cleaning
Filter

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Ver. 1.23 11
Dimensions
Fig. 2-4: TMP-3000 Dimensions

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 12
3 Installation
Safety
When installing the positioner, be sure to read and follow the safety instructions below.
➢Ensure that all input signals to the valves, actuators and other peripherals, pneumatics, etc. are
completely shut off and there is no pneumatic pressure left in the actuator.
➢Disconnect the control valve from the system with a bypass valve or other similar device to prevent
shutdown of the entire system.
Tools required for Installation
➢Hexagonal wrench set
➢(+) (-) Screw driver
➢Spanner
TMP-3000 Installation
The TMP-3000 is used for linear motion valves. It is used for the angle valve in which the actuator stem
is moved up and down linearly by using the spring return type diaphragm actuator or by using the
piston actuator.
TMP-3000 Installation Example
Fig. 3-1: TMP-3000 Installation Example

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 13
Make sure you have the following parts before proceeding with the installation.
➢Positioner
➢Feedback Shaft
Installing
1) Check actuator stroke (max. 40mm) and screw size (M26X1.5P) on actuator.
Please check if it is possible to assemble with the feedback shaft provided.
The screw at the bottom of the feedback shaft is M6 with 8mm depth.
Fig. 3-2: TMP-3000 Feedback Shaft

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Ver. 1.23 14
2) Assemble the Actuator adapter on top of the actuator.
Fig. 3-3: TMP-3000 Feedback Shaft Assembly
3) Using a flat head screwdriver, tighten the M6x1.0P male thread of the actuator to the female thread
of the coupling at the top end of the feedback shaft.
Fig. 3-4: TMP-3000 Fixing the Stem

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 15
4) Insert the TMP-3000 main body into the assembled actuator adapter, rotate it in the desired
direction and tighten both wrench bolts. (The head of the wrench bolt is 3mm.)
Fig. 3-5: TMP-3000 Fixing the Body
Warning
After installation, temporarily connect the pneumatic regulator directly to the actuator and operate the
valve from 0 to 100% stroke. At 0% and 100%, check if feedback shaft works smoothly.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 16
4 Pneumatic Connections
Safety
➢Be careful to select pneumatic compressors and pneumatic systems so that moisture, oil, foreign
substances, etc. are not mixed in the pneumatic pressure used in the positioner.
➢Prevent the entry of moisture, oil and foreign substances by attaching a separate filter to the
positioner's supply port or applying a pneumatic regulator (such as YT-200) with a built-in filter.
➢We have not tested the operation of the positioner using gases other than clean normal air. If you
have additional questions, please contact us.
Supply Pressure Condition
➢Use dry air with a dew point of at least 10 °C below the ambient temperature dew point.
➢Filter out foreign substances with 5 micron filter.
➢Do not include oil or lubricant in the air.
➢Must comply with ISO 8573-1 or ISA 7.0.01.
➢This positioner is intended for use in the pneumatic range of 0.05 to 0.7 MPa (0.5 to 7 bar). Do
not use it outside this range.
➢Set the pressure output from the regulator to 10% higher than the operating pressure of the
actuator or the spring range pressure of the actuator.
Piping Condition
➢Remove any foreign substances inside the piping before installing for piping.
➢The piping must be free of any pressed or damaged parts.
➢The piping of the positioner and actuator connection at the time of piping should be free from
leakage.
Hunting occurs when there is a leakage, which also shortens product life.
➢Use the one-touch fitting provided by our company to prevent leakage of piping.
Piping Connection of the Positioner and Actuator
Single Acting Actuator
Our positioner is set to use only OUT1 port for single acting type. Therefore, when using a single acting
spring return type actuator, connect the OUT1 port to the actuator's pneumatic port.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 17
Fig. 4-1: Single Acting Actuator Pneumatic Piping Example
Double Acting Actuator
For double acting actuators, both OUT1 and OUT2 ports are used. If the electric input signal is
increased, the air pressure is output from the OUT1 port. Refer to below and install the piping.
Fig. 4-2: Double Acting Actuator Pneumatic Piping Example

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 18
5 Power Connection
Warning
➢Make sure power is off before connecting to the terminal.
➢There are two conduit entries on the product. Conduit entry threads are M16x1.5P.
➢The operating power supply uses DC 24V and the input signal uses one of 4 ~ 20mA, 0 ~ 20mA,
0 ~ 5V and 0 ~ 10V.
➢When input signal is current source, compliance voltage of current source must be Min. 10V and
Max. 28V. If the length of the supply cable between the current source and the positioner is long,
or if there is a filter or safety barrier, then consider using a current source which could supply
higher Compliance voltage.
➢If PTM option is available, supply 9 ~ 28V DC power separately.
The maximum voltage must not exceed 30V.
➢DO NOT connect Voltage source (9~28V DC) to Input terminal (+IN, -IN) as it will cause
PCB failure.
➢Plug an unused conduit entry with a plug to prevent foreign materials from entering.
➢Do not install cables near noise-generating equipment such as high-capacity transformers or
motors.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 19
Terminal Connections
Fig. 5-1: TMP-3000’s Terminal
Ground
1) Ground must be done before operating the positioner.
2) There is an internal ground “F.G” in the positioner.
Please make sure that the resistance is less than 100 ohm.

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TMP-3000 (Old PCA and software) Product Manual
Ver. 1.23 20
6 Maintenance
Supply air
If Supply air pressure is not stable or Supply air is not clean, the positioner may not function properly.
Air quality and pressure should be checked regularly to see if the air is clean and pressure set is normal.
Seals
Once a year, it is recommend to check if there are any damaged parts of the positioner. If there are
damaged rubber parts such as diaphragms, o-rings and packings, replace with new ones.