rotork YT-2600 Series User manual

SMART POSITIONER PRODUCT MANUAL
YT-2600 SERIES
VERSION 1.30
Rotork YTC Limited

Smart Positioner
YT-2600 series Product manual
Ver. 1.30 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..................................................................................................................................... 11
2.5 Product Specification......................................................................................................................... 12
2.6 Certifications...................................................................................................................................... 13
2.7 Parts and Assembly........................................................................................................................... 14
2.8 Product Dimension ............................................................................................................................ 15
3Installation................................................................................................................................................ 16
3.1 Safety................................................................................................................................................. 16
3.2 Tools for installation........................................................................................................................... 16
3.3 Linear positioner Installation.............................................................................................................. 17
3.3.1 Safety............................................................................................................................................. 17
3.3.2 Linear positioner Installation Steps................................................................................................ 18
3.4 Rotary positioner Installation ............................................................................................................. 21
3.4.1 Components................................................................................................................................... 21
3.4.2 Rotary Bracket Information............................................................................................................ 22
3.4.3 Rotary positioner Installation Steps............................................................................................... 23
4Connection - Air....................................................................................................................................... 25
4.1 Safety................................................................................................................................................. 25
4.2 Supply Pressure Condition................................................................................................................ 25
4.3 Piping Condition................................................................................................................................. 25
4.4 Connection –Piping with actuator..................................................................................................... 26
4.4.1 Single acting actuator .................................................................................................................... 26
4.4.2 Double acting actuator................................................................................................................... 26
5Connection – Power ................................................................................................................................ 27
5.1 Safety................................................................................................................................................. 27
5.2 Terminal overview.............................................................................................................................. 28
5.2.1 Input Signal Terminal..................................................................................................................... 28
5.2.2 Feedback Signal Terminal............................................................................................................. 29
5.2.3 Limit Switch Terminal..................................................................................................................... 29
5.2.4 Ground........................................................................................................................................... 30
6Adjustments ............................................................................................................................................. 31
6.1 Limit Switch Adjustment..................................................................................................................... 31

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6.2 Variable Orifice Adjustment............................................................................................................... 32
7Maintenance ............................................................................................................................................. 33
7.1 Supply air........................................................................................................................................... 33
7.2 Seals.................................................................................................................................................. 33
8Auto Calibration and PCB Operation..................................................................................................... 34
8.1 Warning.............................................................................................................................................. 34
8.2 Button Description ............................................................................................................................. 34
8.3 Run Mode (RUN)............................................................................................................................... 35
8.4 Auto Calibration mode (AUTO CAL).................................................................................................. 35
8.4.1 AUTO1 Calibration (AUTO1)......................................................................................................... 36
8.4.2 AUTO2 Calibration (AUTO2)......................................................................................................... 36
8.4.3 AUTO3 Calibration (AUTO3)......................................................................................................... 36
8.5Manual Mode (MANUAL)................................................................................................................... 37
8.6 Parameter Mode (PARAM)................................................................................................................ 38
8.6.1 Dead-Zone (dEAdZONE, %) ......................................................................................................... 38
8.6.2 P1 Value (KP1).............................................................................................................................. 39
8.6.3 D1 Value (Kd1) .............................................................................................................................. 39
8.6.4 P2 (KP2) and D2 (Kd2) values ...................................................................................................... 39
8.6.5 P_ (KP_) and D_ (Kd_) Values...................................................................................................... 39
8.6.6 PT1 (PT1) and PT2 (PT2) Values.................................................................................................. 40
8.6.7 Period T (PERIOd T) ..................................................................................................................... 40
8.6.8 Auto DZ (AUTO dZ)....................................................................................................................... 40
8.7 Hand Calibration Mode (HAND CAL) ................................................................................................ 41
8.7.1 Zero-Point (PV_ZERO) and End-Point (PV_END) for Valves....................................................... 41
8.7.2 Zero-Point (TR_ZERO) and End-Point (TR_END) for Transmitter ............................................... 42
8.7.3 Normal / Reverse Feedback Signal (TR NORM / REVS).............................................................. 43
8.7.4 Normal / Reverse HART Signal (HT NORM / REVS).................................................................... 43
8.8 Valve Mode (VALVE)......................................................................................................................... 44
8.8.1 Acting Adjustment (ACT RA / dA).................................................................................................. 44
8.8.2 Valve flow Characteristic Adjustment (CHAR)............................................................................... 45
8.8.3 User defining flow Characteristics (USER SET)............................................................................ 46
8.8.4 Tight Shut Open (TSHUT OP)....................................................................................................... 48
8.8.5 Tight Shut Close (TSHUT CL) ....................................................................................................... 48
8.8.6 Split Range Mode (SPLIT)............................................................................................................. 49
8.9 View Mode (VIEW) ............................................................................................................................ 50
9Error and Warning Code ......................................................................................................................... 52
9.1 Error code which is displayed during Auto calibration....................................................................... 52
9.2 Error code which is displayed while using the product...................................................................... 53
9.3 Error code which can be checked from View mode .......................................................................... 54
9.4 Warning code which can be checked from View mode..................................................................... 55

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10 Main Software Map .................................................................................................................................. 56

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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.

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➢In case of Fail Freeze product, it keeps the position of current valve in case of input current signal
and pneumatic failure. However, please do not leave it in that state for a long time and take
immediate action to restore the system. There is no fault in the positioner, but it is often reported
that the valve is out of position due to an unexpected leak in the pipe or actuator.
➢For detailed warranty information, please contact the corresponding local Rotork YTC Limited
office or main office in South Korea.
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 -30 °C to +70 °C for temperature class T6(T85 °C ) or
-30 °C to +80 °C for temperature class T5(T100 °C).
Hazardous area with carbon disulfide shall be excluded.

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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, PD Control, and HART Protocol Communications.
2.2 Main Features and Functions
➢When Input signal fails, Positioner keeps the current position of the valve stroke without any
additional device. (Fail Freeze option)
➢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.
➢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.
➢PD parameters can be adjusted in the field without any additional communicator.
➢Split range 4 ~ 12 mA or 12 ~ 20 mA can be set.
➢Operating temperature for positioners is -30 ~ 80 °C (Please check certified explosion proof
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.

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2.3 Label Description
Fig. L-1: Sticker Label
•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
※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.
Fig. L-2: Stainless steel plate Label (ATEX, IECEx, KCs)
•MODEL: Indicates the model number of the positioner.
•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.

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Fig. L-3: EAC label

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Fig. L-4: CCC label

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2.4 Product Code
YT-2600 series follows suffix symbols as follows.
YT-2600 1 2 3 4 5 6 7 8
1 Motion Type
L :
R :
Linear
Rotary
2 Acting type
S :
D :
Single
Double
3 Explosion Proof
C :
E :
Z :
ATEX, IECEx, KCs
EAC
CCC
4 Lever Type
Linear
1 :
2 :
3 :
4 :
10 ~ 40 mm
20 ~ 70 mm
50 ~ 100 mm
100 ~ 150 mm
Rotary
1 :
2 :
3 :
4 :
5 :
M6 x 34L
M6 x 63L
M8 x 34L
M8 x 63L
Namur
5 Conduit - Air
Connection Type
1 :
2 :
3 :
4 :
5 :
G 1/2 – Rc 1/4 (N/A for CCC)
G 1/2 – 1/4 NPT (N/A for CCC)
G 1/2 – G 1/4 (N/A for CCC)
M20x1.5P – 1/4 NPT
1/2 NPT – 1/4 NPT
6 Communication
0 :
2 :
None
+ HART Communication
7 Option
0 :
1 :
2 :
3 :
None
+ Position Transmitter
+ Limit Switch 1)
+ Position Transmitter and Limit Switch 2)
8 Fail Option
F :
S :
Fail Freeze
Fail Safe
1) 2) Limit switch: DC 24 V (50 mA) and transistor type

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2.5 Product Specification
Model
YT-2600
Housing Material
Aluminum
Motion Type
Linear
Rotary
Acting Type
Single / Double
Input Signal
4 ~ 20 mA DC
Minimum Current Signal
3.5 mA(Standard) or 3.8 mA(HART Included)
Supply Pressure
0.14 ~ 0.7 MPa (1.4 ~ 7 bar)
Stroke
10 ~ 150 mm
55 ~ 110°
Impedance
Max. 450 Ω @ 20 mA DC
Air Connection
Rc 1/4 or G 1/4 or 1/4 NPT
Gauge Connection
Rc 1/8 or 1/8 NPT
Conduit Entry
G 1/2 (N/A for CCC) or 1/2 NPT or M20x1.5P
Ingress Protection
IP66
Explosion Proof
Flameproof enclosure. Refer to “2.6 Certifications”
Operating Temperature
-30 ~ 80 °C (-22 ~ 176 °F)
Ambient Temperature
Of Explosion proof
T5
-30 ~ 80 °C (-22 ~ 176 °F)
T6
-30 ~ 70 °C (-22 ~ 158 °F)
Linearity
± 0.5 % F.S.
Hysteresis
± 0.5 % F.S.
Sensitivity
± 0.2 % F.S.
Repeatability
± 0.3 % F.S.
Flow Capacity
Fail Freeze
60 LPM (Sup. = 0.14 MPa)
Fail Safe
40 LPM (Sup. = 0.14 MPa)
Air Consumption
Fail Freeze
0.01 LPM (Sup. = 0.14 MPa)
Fail Safe
0.06 LPM (Sup. = 0.14 MPa)
Output Characteristic
Linear, Quick Open, EQ%, User Set
Vibration
No Resonance up to 100 Hz @ 6 G
Humidity
5 ~ 95 % RH @ 40 °C
Communication (Option)
HART Communication (HART 5)
Feedback Signal (Option)
4 ~ 20 mA (DC 9 ~ 28 V)
Weight
3.0 kg (6.61 lb)
Painting
Polyester Powder Coating
Tested under ambient temperature of 20 °C, absolute pressure of 760 mmHg, and humidity of 65 %.
Please contact Rotork YTC Limited for detailed testing specification.

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2.6 Certifications
※ All certifications below are posted on Rotork YTC Limited homepage(www.ytc.co.kr).
➢KCs (Korea)
Type : Explosion proof construction for internal pressure
1. Rating : Ex d IIC T6/T5
Certification No. : 19-KA2BO-0868X
2. Rating : Ex tb IIIC T85°C/T100°C
Certification No. : 19-KA2BO-0869X
Ambient temperature : -30 ~ +70°C(T6), -30 ~ +85°C(T5)
➢ATEX
Type : Explosion proof construction for internal pressure
Rating : II 2G Ex db IIC T5/T6, II 2D Ex tb IIIC T85°C/T100°C
Certification No. : EPS 12 ATEX 1 404 X
Ambient temperature : -30 ~ +70°C T6(T85°C), -30 ~ +80°C T5(T100°C)
➢IECEx
Type : Explosion proof construction for internal pressure
Rating : Ex db IIC T5/T6, Ex tb IIIC T85°C/T100°C
Certification No. : IECEx EPS 12.0001X
Ambient temperature : -30 ~ +70°C T6(T85°C), -30 ~ +80°C T5(T100°C)
➢EAC (TRCU)
Type : Explosion proof construction for internal pressure
Rating : 1Ex d IIC T6/T5 Gb X, Ex tb IIIC T85°C/T100°C Db X, IP66
Certification No. : RU C-KR.AM02.B.00104/19
Ambient temperature : -30 ~ +70°C T6(T85°C), -30 ~ +80°C T5(T100°C)
➢CCC (China)
Type : Explosion proof construction for internal pressure
Rating : Ex d IIC T5/T6 Gb, Ex tD A21 IP66 T100°C/T85°C
Certification No. : 2020322307000619
Ambient temperature : -30 ~ +70°C T6(T85°C), -30 ~ +80°C T5(T100°C)
➢Electromagnetic Compatibility (EMC)
- EMC directive 2014/30/EC from April 2016
- EC Directive for CE conformity marking

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2.7 Parts and Assembly
Fig. 2-1: Exploded view
1. Pilot cover 6. Terminal Cover
2. Pilot unit 7. Main Cover
3. Pilot block 8. Main PCB
4. Main body 9. Potentiometer
5. Terminal PCB 10. Feedback Lever

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2.8 Product Dimension
Fig. 2-2: YT-2600L (Linear type) Fig. 2-3: YT-2600R (Rotary, Fork lever type)
Fig. 2-4: YT-2600R (Rotary, Namur type)

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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.
➢YT-2600 series have two drain ports to be used for internal condensation. Please use larger drain
plug for the condensation and block other remaining port with blind plug.
Fig. 3-1: Location of drain plug according to orientation of positioner’s mounting
➢After assembling the drain plug at the correct hole, make sure the positioner must be installed as
shown below. Otherwise, the condensation water could cause damages to PCB.
Fig. 3-2: 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
Drain Plug

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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.
Fig. 3-3: 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 – not supplied with the positioner
➢Connection bar – not supplied with the positioner
3.3.1 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

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3.3.2 Linear positioner Installation Steps
1) Assemble the positioner with the bracket made in previous step by fastening the bolts. The bolt
size is M8 x 1.25P.
Fig. 3-4: Attaching to positioner to bracket Fig. 3-5: Attaching the bracket to actuator yoke
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 6.5 mm so
the connection bar’s outer diameter should be less than or equal to 6 mm.
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. 3-6: Supplying proper regulated air to the actuator to position the valve at 50 %

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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 the below left figure. If it is located downward
from the lever spring as shown the below right figure, the connection bar or the lever spring will be
worn out quickly because of excessive strong tension.
Fig. 3-7: Proper way to insert connection bar between feedback lever and lever spring
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. 3-8: 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 lever angle is 30 degree.

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Stroke : 30 mm
Stroke : 70 mm
Fig. 3-9: Feedback lever and location of the connection bar
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 center of the actuator.
Fig. 3-10: 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.