rotork YT-3100 User manual

SMART POSITIONER PRODUCT MANUAL
YT-3100
VERSION 1.19
Rotork YTC Limited

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YT-3100 Product Manual
Ver. 1.19 2
Contents
1Introduction.................................................................................................................................................5
1.1 General Information for the users.........................................................................................................5
1.2 Manufacturer Warranty.........................................................................................................................5
1.3 Explosion Proof Warning (Only for Intrinsic safety type positioners)....................................................6
2Product Description ...................................................................................................................................7
2.1 General.................................................................................................................................................7
2.2 Main Features and Functions...............................................................................................................7
2.3 Label Description..................................................................................................................................8
2.4 Product Code..................................................................................................................................... 10
2.5 Product Specification......................................................................................................................... 11
2.6 Certifications...................................................................................................................................... 12
2.7 Parts and Assembly........................................................................................................................... 13
2.8 Product Dimension ............................................................................................................................ 14
3Installation................................................................................................................................................ 15
3.1 Safety................................................................................................................................................. 15
3.2 Tools for installation........................................................................................................................... 15
3.3 Linear positioner Installation.............................................................................................................. 16
3.3.1 Safety............................................................................................................................................. 16
3.3.2 Standard lever type positioner Installation Steps .......................................................................... 17
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....................................................................................................................................... 24
4.1 Safety................................................................................................................................................. 24
4.2 Supply Pressure Condition................................................................................................................ 24
4.3 Piping Condition................................................................................................................................. 24
4.4 Connection –Piping with actuator..................................................................................................... 24
4.4.1 Single acting actuator .................................................................................................................... 24
4.4.2 Double acting actuator................................................................................................................... 25
5Connection – Power ................................................................................................................................ 26
5.1 Safety................................................................................................................................................. 26
5.2 Connection......................................................................................................................................... 26
5.3 Ground............................................................................................................................................... 27
6Adjustments ............................................................................................................................................. 27
6.1 Orifice Installment.............................................................................................................................. 27
6.1.1 Plate type Orifice Installment......................................................................................................... 27
7Optional Sub-PCB Installment ............................................................................................................... 28

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7.1 Installation steps................................................................................................................................ 28
8Maintenance ............................................................................................................................................. 29
8.1 Supply air........................................................................................................................................... 29
8.2 Seals.................................................................................................................................................. 29
9Auto Calibration and PCB Operation..................................................................................................... 30
9.1 Warning.............................................................................................................................................. 30
9.2 LCD display and buttons.................................................................................................................... 30
9.2.1 LCD display and symbols .............................................................................................................. 30
9.2.2 Button and function........................................................................................................................ 31
9.3 Menu levels........................................................................................................................................ 32
9.4 RUN Mode Monitor............................................................................................................................ 33
9.5 Configuration and Operation.............................................................................................................. 34
9.6 Calibration (CALIb) ............................................................................................................................ 36
9.6.1 Acting Type (SINGLE / dOUBLE).................................................................................................. 36
9.6.2 Auto Calibration 1 (AUTO 1).......................................................................................................... 37
9.6.3 Auto Calibration 2 (AUTO 2).......................................................................................................... 37
9.6.4 Travel Zero (TVL ZERO) and Travel end (TVL ENd) .................................................................... 38
9.7 Manual Operation (MAN OPER)........................................................................................................ 39
9.7.1 Manual Operation by Set position (MAN SP) ................................................................................ 39
9.7.2 Manual Operation by MV (MAN MV)............................................................................................. 40
9.8 Control Parameters (CTL PARM)...................................................................................................... 41
9.8.1 Dead Band (dEAdbANd)................................................................................................................ 41
9.8.2 Forward P parameter (KP UP) and reverse P parameter (KP dN)................................................ 41
9.8.3 Forward Integral time parameter (TI UP) and reverse Integral time parameter (TI dN)................ 42
9.8.4 Forward D parameter (Kd UP) and reverse D parameter (Kd dN)................................................ 42
9.8.5 Auto Dead band Mode (AUTO db) ................................................................................................ 43
9.8.6 Performance Mode (PER) ............................................................................................................. 43
9.9 Input Configuration (IN CFG)............................................................................................................. 44
9.9.1 Signal Direction (SIG NORM / REVS)........................................................................................... 44
9.9.2 Split Range Mode (SPLIT)............................................................................................................. 45
9.9.3 Custom Split Range Zero (CST ZERO)......................................................................................... 45
9.9.4 Custom Split Range End (CST ENd)............................................................................................. 46
9.9.5 Valve Flow Characterization Curves (CHAR)................................................................................ 46
9.9.6 User Set Characterization 5 Points (U5) ....................................................................................... 47
9.9.7 User Set Characterization 21 Points (U21) ................................................................................... 48
9.9.8 Tight Shut Open (TSHUT OP)....................................................................................................... 49
9.9.9 Tight Shut Close (TSHUT CL) ....................................................................................................... 50
9.10 Output Configuration (OUT CFG)...................................................................................................... 51
9.10.1 Position Transmitter Direction (PTM NORM / REVS)................................................................ 51
9.10.2 Position Transmitter Zero / End (PTM ZERO / ENd)................................................................. 52

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9.10.3 Back Calculation (bACKCAL oFF / on)...................................................................................... 53
9.11 Device Configuration (dEV CFG)....................................................................................................... 54
9.11.1 Action Setting (ACT).................................................................................................................. 54
9.11.2 Linear Interpolation (ITP oFF / on)............................................................................................. 55
9.11.3 Lock of Parameters (Write Protect, W UNLOCK / LOCK)......................................................... 55
9.11.4 Actual Position View Mode (View Mode, VI NORM / REVS) .................................................... 56
9.11.5 Factory Reset (dEFAULT oFF / on)........................................................................................... 56
9.11.6 Positioner Self-Test (SELFTEST).............................................................................................. 57
9.12 Diagnosis Mode (dIAGNd)................................................................................................................. 58
9.12.1 Default Alarm Settings............................................................................................................... 58
9.12.2 Device Status (dS)..................................................................................................................... 59
9.12.3 Reset Alarm Status (RST ALRM oFF / on)................................................................................ 60
9.12.4 View Event Log (EVT LOG)....................................................................................................... 61
9.13 Position information (INFO) ............................................................................................................... 62
9.14 Error codes during automatic calibration........................................................................................... 64
9.15 Status and Alarm Code...................................................................................................................... 65
10 Main Software Map .................................................................................................................................. 67

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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 commission the product.
➢Installation, commissioning, and maintenance of the product may only be performed by trained
specialist personnel who have been authorized by the plant operator accordingly.
➢The manual should be provided to the end-user.
➢The manual can be altered or revised without any prior notice. Any changes in product’s
specification, design, and/or any components may not be printed immediately but until the
following revision of the manual.
➢When the manual refers to “Valve Zero / Zero” means the final valve position upon pneumatic
pressure has been fully exhausted from positioner’s OUT1 port. For example, the valve zero
position may differ between linear direct and reverse actions. (DA/RA)
➢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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1.3 Explosion Proof Warning (Only for Intrinsic safety type positioners)
Please ensure the unit is being used and installed in conformity with local, regional, and national
explosion proof within the proper safety barrier environment.
➢Refer to “2.6 Certifications”
➢Explosion proof type of cables and gaskets should be used, when explosion gases are present at
the installation site.
➢Positioner has 1 port for power connection. Explosion proof type wires and packing should be
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.
➢The enclosure of the product contains aluminum, which is considered to constitute a potential
risk of ignition when subjected to impact or friction. Care must be used during installation in
locating this equipment to prevent impact or friction
➢Some of the enclosure parts are made of non-metallic materials. To prevent the risk of
Electrostatic sparking, clean the enclosure only with a damp cloth.
➢The product must be installed in such a manner as to minimize the risk of impact or friction with
other metal surfaces.
➢For Intrinsically Safe installations, the product must be connected to suitably rated intrinsically
safe equipment, and must be installed in accordance with applicable intrinsically safe installation
standards.
➢Special conditions for safe use of sign “X” of ATEX/IECEx :
The ambient temperature range deviates from the standard temperature range and amounts to:
Temperature class T5: -30 °C to +60 °C
Temperature class T6: -30 °C to +40 °C.
Equipment must be protected from high electrostatic charge hazards and placed with a warning
marking to be cleaned only with damp cloth.

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2 Product Description
2.1 General
YT-3100 Smart Valve 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.
2.2 Main Features and Functions
➢LCD display enables users to monitor the positioner status.
➢User will easily understand the method of using 4 buttons because it work same in all versions of
firmware interfaces.
➢When unexpected situation like momentary blackout happens, our positioner boot-time only take
0.5 second and this can minimize the travel of valve which consequentially increase the safety of
system.
➢Positioner operates normally even there are sudden changes in supply pressure and / or high
vibration environment.
➢The method of Auto Calibration is very simple.
➢As an advantage of having very low air consumption, It could greatly reduce operating costs in
large-scale plants.
➢It is compatible with most of controllers.
➢Orifices can be installed even in the field to minimize the hunting occurrence and optimize
operating conditions.
➢Valve system becomes more stable by outputting analog feedback signal.
➢Different valve characteristics can be adjusted – Linear, Quick Open, Equal Percentage, and User
Set which user can make 5 or 21 points characterizations.
➢Tight Shut – Close and Shut - Open can be set.
➢PID parameters can be adjusted in the field without any additional communicator.
➢Split range 4 ~ 12 mA or 12 ~ 20 mA can be set.
➢Operating temperature for positioners is -30 ~ 85 °C (Please check certified explosion proof
temperature in case of Ambient temperature)
➢Hand calibration function can set Zero point or End point manually.
➢It has IP66 protection grade.
➢Polyester powder coating resists the corrosion process.
➢Maintenance of the positioner is easy because of modularized inner structure.

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2.3 Label Description
•MODEL : Indicates the model number and any options of the positioner.
•EXPLOSION PROOF : Indicates certified explosion proof grade.
•INGRESS PROTECTION : Indicates enclosure protection grade.
•INPUT SIGNAL : Indicates input signal range.
•OPERATING TEMP. : Indicates the allowable operating temperature.
•SUPPLY PRESSURE : Indicates the supply pressure range.
•SERIAL NUMBER : Indicates unique serial number.
•MONTH.YEAR : Indicates manufactured month and year.
•INTRINSIC SAFETY / NONINCENDIVE : Indicates intrinsic safety explosion proof grade.
•AMBIENT TEMP. : Indicates the allowable ambient temperature for explosion proof.
•Ui, Ii, Pi, Ci, Li : Indicates the allowable electrical data in the certificate.
You can also see the details in the certificate.
※Precautions
Be careful not to apply volatile solvent (hardener of instant adhesive, acetone, WD-40, etc.) to the
sticker nameplate. Printed contents may be erased.
Fig. L-1: Non-explosion proof
Fig. L-2: Intrinsic safety type (ATEX, IECEx, NEPSI, KCs)

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Fig. L-3: Intrinsic safety type (CCC)

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2.4 Product Code
YT-3100 follows suffix symbols as follows.
YT-3100 1 2 3 4 5 6 7 8
1 Motion Type
L :
R :
Linear (Positioner is attached the right yoke of actuator.)
Rotary
2 Acting type
S :
D :
Single
Double
3 Explosion Proof
N :
i :
Z :
Non-Explosion
Ex ia IIC T5/T6 Gb : ATEX, IECEx, KCs, NEPSI
Ex ia IIC T5/T6 Gb : CCC
4 Lever Type
Linear
0 :
1 :
2 :
10 ~ 40 mm (Standard type)
20 ~ 100 mm (Standard type)
90 ~ 150 mm (Standard type)
Rotary
5 :
Namur
5 Conduit - Air
Connection Type
1 :
2 :
G 1/2 – Rc 1/4
G 1/2 – 1/4 NPT
6 Gauge block
0 :
1 :
None
+ Gauge block
7 Option
0 :
1 :
None
+ Position Transmitter
8 Operating Temp.
(Non-explosion proof) 1)
S :
-30 ~ 85 °C
1) This option is just the normal operating temperature of the product and is not related to explosion
proof temperature. See “2.6 Certificates” for explosion proof temperature.

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2.5 Product Specification
Model
YT-3100
Housing Material
Body : Aluminum
Cover : Polycarbonate
Motion Type
Linear
Rotary
Acting Type
Single / Double
Input Signal
4~20mA DC
Minimum Current Signal
3.2mA
Supply Pressure
0.14 ~ 0.7 MPa (1.4 ~ 7 bar)
Stroke
10 ~ 150 mm
55 ~ 110°
Impedance
Max. 500 Ω @ 20 mA DC
Air Connection
Rc 1/4 or 1/4 NPT
Gauge Connection
Rc 1/8 or 1/8 NPT
Conduit Entry
G 1/2
Ingress Protection
IP66
Explosion Proof
1. Non-explosion proof
2. Ex ia IIC T5/T6 Gb : ATEX, IECEx, KCs, NEPSI, CCC
Ambient Temperature
Of Explosion proof
T5
-30 ~ 60 °C (-22 ~ 140 °F)
T6
-30 ~ 40 °C (-22 ~ 104 °F)
Operating Temperature
-30 ~ 85 °C (-22 ~ 185 °F)
Linearity
± 0.5 % F.S.
Hysteresis
± 0.5 % F.S.
Sensitivity
± 0.2 % F.S
Repeatability
± 0.3 % F.S.
Flow Capacity
70 LPM (Sup. = 0.14 MPa)
Air Consumption
Below 2 LPM (Sup. = 0.14 MPa @ idle)
Output Characteristic
Linear, Quick Open, EQ%, User Set
Vibration
No Resonance up to 100 Hz @ 6 G
Humidity
5 ~ 95 % RH @ 40 °C
Feedback Signal (Option)
4 ~ 20 mA (DC 9 ~ 28 V)
Weight
1.7 kg (3.7 lb)
Painting of base body
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 YTC homepage(www.ytc.co.kr).
➢KCs (Korea)
Type : Intrinsic safety
Rating : Ex ia IIC T5/T6
Certification No. : 19-KA2BO-0502X
Ambient temperature : -30 ~ +60°C (T5), -30 ~ +40°C (T6)
➢ATEX
Type : Intrinsic safety
Rating : II 2G Ex ia IIC T5/T6 Gb
Certification No. : EPS 19 ATEX 1 039 X
Ambient temperature : -30 ~ +60°C (T5), -30 ~ +40°C (T6)
➢IECEx
Type : Intrinsic safety
Rating : Ex ia IIC T5/T6 Gb
Certification No. : IECEx EPS 19.0016X
Ambient temperature : -30 ~ +60°C (T5), -30 ~ +40°C (T6)
➢NEPSI
Type : Intrinsic safety
Rating : Ex ia IIC T5/T6
Certification No. : GYJ19.1262X
Ambient temperature : -30 ~ +60°C (T5), -30 ~ +40°C (T6)
➢CCC (China)
Type : Intrinsic safety
Rating : Ex ia IIC T5/T6 Gb
Certification No. : 20200322307002522
Ambient temperature : -30 ~ +60°C (T5), -30 ~ +40°C (T6)
➢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. Base Cover 6. Pilot
2. PCB Cover 7. Pilot Block
3. Main PCB 8. Base body
4. Torque Motor 9. Feedback Lever
5. Main Shaft 10. Gauge Block

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2.8 Product Dimension
Fig. 2-2: YT-3100L Fig. 2-3: YT-3100R

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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.
➢The positioner has a vent cover to exhaust internal air and drain internal condensation water.
When installing the positioner, make sure the vent cover must be facing downward. Otherwise,
the condensation water could cause damages to PCB.
Fig. 3-1: The correct positions of a vent cover
3.2 Tools for installation
➢Hex key set for hex socket cap bolts
➢(+) & (-) Screw drivers
➢Spanners for hexagonal-head bolts

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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. 3-2: installation example
Before proceeding with the installation, ensure following components are available.
➢Positioner
➢Feedback lever and lever spring
➢M6 nut and spring washer (fastening feedback lever to a main shaft)
➢Bracket, bolts and washers for positioner or sensor – not supplied with the positioner
➢Connection bar – not supplied with the positioner
3.3.1 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 Standard lever type positioner Installation Steps
1) Assemble the positioner with the bracket made in previous step by fastening the bolts.
Fig. 3-3: Linear (Standard Lever Type)
2) Attach the positioner with the bracket to the actuator yoke
– DO NOT TIGHTEN THE BRACKET COMPLETELY.
3) Connect connection bar to the actuator clamp. The hole gap on the feedback lever is 6.5 mm so
the connection bar’s outer diameter should be less than 6 mm.

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4) Connect an air-filter regulator to the actuator temporarily. Supply enough air pressure to the
actuator in order to position the valve stroke at 50 % of the total stroke.
Fig. 3-4: Linear (Standard Lever Type)
5) Insert the connection bar between the feedback lever and lever spring. The connection bar must
be located upward from the lever spring as shown below left figure. If it is located downward from
the lever spring as shown below right figure, the connection bar or the lever spring will be worn out
quickly because of excessive strong tension.
Fig. 3-5: Proper way to insert connection bar between feedback lever and lever spring

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6) Check if feedback lever is vertical to the valve stem at 50 % of the valve stroke. If it is not vertical,
adjust the bracket or the connection bar to make vertical. Improper installation may cause poor
linearity.
Fig. 3-6: Linear feedback lever and valve stem
7) Check the valve stroke. The stroke numbers are engraved on the feedback lever of the positioner.
Position the connection bar at the number on the feedback lever which corresponds with the
desired valve stroke. To adjust, move the bracket, the connection bar or both.
※ The effective linear feedback lever angle is 60 degree
Stroke : 75 mm
Stroke : 45 mm
Fig. 3-7: Linear feedback lever and location of the connection bar

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8) After installing the positioner, operate the valve from 0 % to 100 % stroke by using direct air to the
actuator. On both 0 % and 100 %, the feedback lever should not touch the lever stopper, which
is located on the backside of the positioner. If the feedback lever touches the stopper, the
positioner should be installed further away from the center of the actuator.
Fig. 3-8: Feedback lever should not touch lever stopper on 0 % ~ 100 % valve stroke.
9) After the installation, tighten all of the bolts on the bracket and the connection bar.