rotork 3450 Series Product Manual
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rotork 3450 Series Product Manual

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

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  • Page 1 SMART POSITIONER PRODUCT MANUAL YT-3400 / 3450 SERIES YT-3400 YT-3450 Rotork YTC Limited VERSION 1.46...

  • Page 2: Table Of Contents

    Smart Positioner YT-3400 / 3450 series Product manual Contents Introduction ..............................5 General Information for the users ......................5 Manufacturer Warranty .........................5 Explosion Proof Warning & Specific Conditions of Use ...............6 Product Description ...........................7 General ..............................7 Main Features and Functions .......................7 Label Description ..........................8 Product Code .............................
  • Page 3 Smart Positioner YT-3400 / 3450 series Product manual Adjustments ............................. 36 Limit Switch Adjustment ........................36 A/M switch adjustment ........................37 Variable Orifice Adjustment ....................... 37 Maintenance ............................. 38 Supply air ............................38 Seals ..............................38 Auto Calibration and PCB Operation ..................... 39 Warning ..............................
  • Page 4 Smart Positioner YT-3400 / 3450 series Product manual 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 Diagnostic (dIAGNO) ......................... 58 8.9.1 PST Introduction ..........................59 8.9.2...

  • Page 5: Introduction

    Introduction 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.

  • Page 6: Explosion Proof Warning & Specific Conditions Of Use

    Smart Positioner YT-3400 / 3450 series Product manual 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. ➢...

  • Page 7: Product Description

    Smart Positioner YT-3400 / 3450 series Product manual Product Description 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.

  • Page 8: Label Description

    Smart Positioner YT-3400 / 3450 series Product manual 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 •...
  • Page 9 Smart Positioner YT-3400 / 3450 series Product manual Fig. L-2: YT-3400 metal label Fig. L-3: YT-3400 metal label (KCs) (ATEX, IECEx, NEPSI) Ver. 1.46...
  • Page 10 Smart Positioner YT-3400 / 3450 series Product manual Fig. L-4: YT-3400 labels (FM, CSA) Fig. L-5: YT-3450 metal label (FM, CSA) Ver. 1.46...
  • Page 11 Smart Positioner YT-3400 / 3450 series Product manual Fig. L-6: YT-3400, 3450 labels (EAC) Fig. L-7: YT-3450 metal label (ATEX, IECEx, KCs, NEPSI) Ver. 1.46...
  • Page 12 Smart Positioner YT-3400 / 3450 series Product manual Fig. L-8: YT-3400, 3450 labels (INMETRO) Ver. 1.46...
  • Page 13 Smart Positioner YT-3400 / 3450 series Product manual Fig. L-9: YT-3400 labels (CCC) Fig. L-10: YT-3450 metal label (CCC) Ver. 1.46...

  • Page 14: Product Code

    Smart Positioner YT-3400 / 3450 series Product manual Product Code YT-3400 / 3450 series follows suffix symbols as follows. YT-3400 / 3450 1 Linear Motion Type Rotary Single Acting type Double ATEX, IECEx, INMETRO, KCs, NEPSI FM, CSA Explosion Proof...

  • Page 15: Product Specification

    Weight 3.4kg (7.5 lb) 7.0 kg (15.4 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. Ver. 1.46...

  • Page 16: Certifications

    Smart Positioner YT-3400 / 3450 series Product manual Certifications ※ All certifications below are posted on Rotork YTC Limited homepage(www.ytc.co.kr). KCs (Korea) ➢ Type : Explosion proof construction for internal pressure Rating : Ex d IIC T5/T6 IP66 (YT-3400) Ex d IIC T5/T6, Ex tb IIIC T85°C/T100°C (YT-3450) Certification No.
  • Page 17 Smart Positioner YT-3400 / 3450 series Product manual ➢ Type : Explosion proof construction for internal pressure Rating : Ex db IIC T5/T6, Ex tb IIIC T85°C/T100°C XP/I/1/BCD/T6 Ta = -40°C to +80°C DIP/II, III/1/EFG/T6/Ta = -40°C to +80°C; IP66 I/1/AEx db IIC T5 Ta = -40/-20°C to +80°C...

  • Page 18: Parts And Assembly

    Smart Positioner YT-3400 / 3450 series Product manual Parts and Assembly Fig. 2-1: Exploded view 1. Pilot Cover 7. Potentiometer 2. Pilot Unit 8. Main Shaft 3. Manifold 9. Main Body 4. Torque Motor 10. Terminal PCB 5. Main Cover 11.

  • Page 19: Product Dimension

    Smart Positioner YT-3400 / 3450 series Product manual Product Dimension YT-3400 2.8.1 Fig. 2-2: YT-3400L (Linear type) Fig. 2-3: YT-3400R (Rotary, Fork lever type) Fig. 2-4: YT-3400R (Rotary, Namur type) Ver. 1.46...
  • Page 20 Smart Positioner YT-3400 / 3450 series Product manual YT-3450 2.8.2 Fig. 2-5: YT-3450L (Linear type) Fig. 2-6: YT-3450R (Rotary, Fork lever type) Fig. 2-7: YT-3450R (Rotary, Namur type) Ver. 1.46...

  • Page 21: Installation

    Smart Positioner YT-3400 / 3450 series Product manual Installation 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.

  • Page 22: Tools For Installation

    Smart Positioner YT-3400 / 3450 series Product manual Tools for installation ➢ Hex key set for hex socket cap bolts ➢ (+) & (-) Screw drivers ➢ Spanners for hexagonal-head bolts 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.

  • Page 23: Positioner Installation Steps

    Smart Positioner YT-3400 / 3450 series Product manual Positioner Installation Steps 3.3.2 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 the positioner to bracket Fig.
  • Page 24 Smart Positioner YT-3400 / 3450 series Product manual 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.
  • Page 25 Smart Positioner YT-3400 / 3450 series Product manual ※ The effective linear lever angle is 30 degree. Stroke : 30mm Stroke : 70mm 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.

  • Page 26: Rotary Positioner Installation

    Smart Positioner YT-3400 / 3450 series Product manual Rotary positioner Installation Rotary positioner should be installed on rotary motion valve such as ball or butterfly type which uses rack and pinion, scotch yoke or other type of actuators which its stem rotates 90 degrees. Before proceeding with the installation, ensure following components are available.

  • Page 27: Rotary Bracket Information

    Smart Positioner YT-3400 / 3450 series Product manual Rotary Bracket Information 3.4.2 The rotary bracket set (included with the positioner) contains two components. The bracket is designed to fit onto the actuator with 20 mm, 30 mm and 50 mm stem height (H) according to VDI/VDE 3845 standard.

  • Page 28: Rotary Positioner Installation Steps

    Smart Positioner YT-3400 / 3450 series Product manual Fig. 3-14: Actuator stem Height Fig. 3-15: Exploded Brackets Rotary positioner Installation Steps 3.4.3 1) Please check the actuator’s stem height and adjust the brackets by referring to the above bracket table.
  • Page 29 Smart Positioner YT-3400 / 3450 series Product manual 5) (Only Fork lever type) After setting fork lever position, fasten lock nuts which are located on the bottom of the fork lever. Ensure to set the gap between the top of upper bracket and the top of the fork lever within 6 ~ 11 mm.

  • Page 30: Connection - Air

    Supply pressure should be clean and dry air – avoiding moisture, oil and dust. ➢ Always recommended to use air filter regulator (i.e. YT-200 series). Rotork YTC Limited has not tested positioner’s operation with any other gases other than ➢ clean air. Please contact Rotork YTC Limited for any questions.

  • Page 31: Connection - Piping With Actuator

    Smart Positioner YT-3400 / 3450 series Product manual Connection – Piping with actuator Single acting actuator 4.4.1 Singe acting type positioner is set to use only OUT1 port. OUT1 port of positioner should be connected with supply port of actuator when using spring return actuator of single acting type.

  • Page 32: Connection - Power

    Smart Positioner YT-3400 / 3450 series Product manual Connection – Power Safety ➢ There are two conduit entries on the product. See “2.4 Product Code” for conduit entry threads. ➢ When installing in hazardous and explosive gas area, conduit tube or pressure-proof packing union must be used.

  • Page 33: Terminal Overview

    Smart Positioner YT-3400 / 3450 series Product manual Terminal overview Fig. 5-3: Terminal Overview IN +: Input Signal (+) Upper right 3 terminals: Limit switch 100 % Point IN -: Input Signal (-) Lower right 3 terminals: Limit switch 0 % Point F.G :...

  • Page 34: Feedback Signal Terminal

    Smart Positioner YT-3400 / 3450 series Product manual Feedback Signal Terminal 5.2.2 Locate terminal of feedback signal and connect (+) and (-) according to the polarity. Make sure to tighten bolts with 1.5 N • m (15 kgf • cm).

  • Page 35: Ground

    Smart Positioner YT-3400 / 3450 series Product manual Ground 5.2.4 1) Ground must be done before operating the positioner. 2) There are three ground bolts at the positioner. Open terminal cover and there are two internal ground bolts on the left inside of housing and on the left of terminal plate. When using internal ground, use 2 mm hex wrench to loosen locking socket set screw of the terminal box cover.

  • Page 36: Adjustments

    Smart Positioner YT-3400 / 3450 series Product manual Adjustments Limit Switch Adjustment 1) HIGH variable resistor adjusts the sensing point of valve end-point. In case of Direct Action type, it will sense 4 mA point, and for Reverse Action type, 20 mA of input signal will be its sensing point.

  • Page 37: A/M Switch Adjustment

    Smart Positioner YT-3400 / 3450 series Product manual A/M switch adjustment 1) On the left hand bottom of positioner, there is A/M switch (Auto/Manual). If the switch is turned clockwise (toward “A”) and it is fasten tightly, then the supply pressure will be transferred to actuator through outport by positioner control.

  • Page 38: Maintenance

    Smart Positioner YT-3400 / 3450 series Product manual 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.

  • Page 39: Auto Calibration And Pcb Operation

    Smart Positioner YT-3400 / 3450 series Product manual Auto Calibration and PCB Operation Warning Following process will operate valve and actuator. Before proceeding with any Auto Calibration, please separate valve from the entire system by using bypass valve, so Auto Calibration will not affect entire valve process.

  • Page 40: Auto Calibration Mode (Auto Cal)

    Smart Positioner YT-3400 / 3450 series Product manual ※ Please note that the screen will return to “RUN PV” mode if 100 seconds elapse from the last button pressed. ※ By pressing <ESC> button several times from any MODES, it will return to “RUN PV” mode.

  • Page 41: Auto2 Calibration (Auto2)

    Smart Positioner YT-3400 / 3450 series Product manual AUTO2 Calibration (AUTO2) 8.4.2 AUTO2 changes all of the parameters. It is recommended to perform AUTO2 when the positioner has been installed on the valve for the first time or the positioner has been reinstalled after dissemble from an actuator.

  • Page 42: Manual Mode (Manual)

    Smart Positioner YT-3400 / 3450 series Product manual Manual Mode (MANUAL) Manual mode is used to maneuver valve stem manually. In Manual mode, the positioner does not control the valve by the signal received from outside, but it could be controlled to move up and down by pressing <+>...

  • Page 43: Dead-Zone (Deadzone, %)

    Smart Positioner YT-3400 / 3450 series Product manual Dead-Zone (dEAdZONE, %) 8.6.1 Dead-Zone indicates the percentage of error allowance. In case of high level of packing friction, which may cause hunting, increasing the value of Dead-Zone can stable the valve operation.

  • Page 44: I Value (Ki)

    Smart Positioner YT-3400 / 3450 series Product manual I Value (KI) 8.6.3 I value indicates the additional compensation signal based on the percentage of error allowance. As the value increase, it is more likely to have hunting. As the value decreases, the positioner will move slowly to the target position.

  • Page 45: Kf Up Value (Kfup)

    Smart Positioner YT-3400 / 3450 series Product manual KF Up Value (KFUP) 8.6.6 KF Up control value corrects valve friction when moving from 0 % to 100 %, reducing the dead time. <+>/<-> → → → Press <+> or <-> button if the above is not displayed.

  • Page 46: Control Mode (Ctrl)

    Smart Positioner YT-3400 / 3450 series Product manual Control mode (CTRL) 8.6.8 This function is used to select the menu that stores the PID values corresponding to the valve, not the way the user changes the KP, KI, KD values respectively..

  • Page 47: Hand Calibration Mode (Hand Cal)

    Smart Positioner YT-3400 / 3450 series Product manual Hand Calibration Mode (HAND CAL) Hand Calibration mode is used when zero-point and end-point require re-adjustment to use partial range of total strokes after Auto Calibration has been performed. Below are the list of features which could be set from Hand CAL mode.

  • Page 48: Zero-Point (Tr Zero) And End-Point (Tr End) For Transmitter

    Smart Positioner YT-3400 / 3450 series Product manual Zero-Point (TR ZERO) and End-Point (TR END) for Transmitter 8.7.2 TR ZERO adjusts the zero point of the transmitter (4 mA feedback), and TR END adjusts the end point of the transmitter (20 mA feedback). This is used when output signal becomes unstable and requires re-adjustment or when feedback output signal and actual stroke need to be used differently.

  • Page 49: Normal / Reverse Feedback Signal (Tr Norm / Revs)

    Smart Positioner YT-3400 / 3450 series Product manual Normal / Reverse Feedback Signal (TR NORM / REVS) 8.7.3 The feedback signal from the positioner can be changed to normal or reverse. <-> → → → Press <+> or <-> button if the above is not displayed.

  • Page 50: Valve Mode (Valve)

    Smart Positioner YT-3400 / 3450 series Product manual Valve Mode (VALVE) Valve mode offers useful and various function settings for operating the control valve. Below are the list of functions which could be set from Valve mode. Acting Adjustment (ACT RA / dA)

  • Page 51: Valve Flow Characteristic Adjustment (Char)

    Smart Positioner YT-3400 / 3450 series Product manual Valve flow Characteristic Adjustment (CHAR) 8.8.2 The valve flow characteristic can be set on the field’s requirement. There are 4 types of characteristics – linear (LIN), user setting (USR), quick open (QO), and equal percentage (EQ).

  • Page 52: User Defining Flow Characteristics (User Set)

    Smart Positioner YT-3400 / 3450 series Product manual User defining flow Characteristics (USER SET) 8.8.3 User can make its own flow characteristic curve with this mode. USER SET can be set in two ways, 5 points and 18 points. User can choose whichever is more suitable for their application.
  • Page 53 Smart Positioner YT-3400 / 3450 series Product manual 2) 18 points setting can be set with 1mA intervals. The initial positions are P0(4 mA = 0 %), P1(5 mA = 6.25 %), P2(6 mA = 12.5 %), … P16(20 mA = 100 %) and P17(21 mA = 106.25 %) but user can change the % values to different values.

  • Page 54: Tight Shut Open (Tshut Op)

    Smart Positioner YT-3400 / 3450 series Product manual Tight Shut Open (TSHUT OP) 8.8.4 Tight shut open shows the current value in percentage (%). Input current of 4 mA is 0 %, 20 mA is 100 %. If temporary Tight shut open value (≤ 100 %) is set and input current value is above the set % value, the valve’s position is immediately moved to 100 %.

  • Page 55: Split Range Mode (Split)

    Smart Positioner YT-3400 / 3450 series Product manual Split Range Mode (SPLIT) 8.8.6 The valve can be operated in full stroke by split range control of input signal as 4 ~ 12 mA or 12 ~ 20 mA. <+>/<-> →...

  • Page 56: Custom End Setting Mode Of Split Range (Cst End)

    Smart Positioner YT-3400 / 3450 series Product manual Custom End Setting Mode of Split Range (CST ENd) 8.8.8 From the initial 4 ~ 20 mA control settings of valve stroke from 0 ~ 100 %, this mode allows the user to change the end point to (≤...
  • Page 57 Smart Positioner YT-3400 / 3450 series Product manual Acting Type (SINGLE / dOUBLE) 8.8.10 Displays or changes actuator’s current acting type. <+>/<-> → → → Press <+> or <-> button if the above is not displayed. <ESC> 3 times →...

  • Page 58: Diagnostic (Diagno)

    Smart Positioner YT-3400 / 3450 series Product manual Diagnostic (dIAGNO) Below are the list of functions which could be set from Diagnostic mode. 1) PST Introduction 2) PST Mode 3) PST Configuation (PST CFG) A. Start Position (START PO) B. Target 1 (TARGET 1) C.
  • Page 59 Smart Positioner YT-3400 / 3450 series Product manual PST Introduction 8.9.1 Unlike FST (Full Stroke Test) where a valve such as an emergency shutoff valve is physically closed and opened in full, PST(Partial Stroke Test) is a method used to test a percentage of the possible failure of the valve by slightly closing and opening the valve when testing.
  • Page 60 Smart Positioner YT-3400 / 3450 series Product manual PST Mode (PST) 8.9.2 To run PST, select a PST mode. There are 3 mode for running PST. Mode Description PST OFF Stop PST Schedule. It’s a default mode PST NOW PST runs repeatedly by interval value Run PST immediately.
  • Page 61 Smart Positioner YT-3400 / 3450 series Product manual 8.9.3.1 Start Position (START PO) Sets start position when PST initiates. The position must be in between 0 and 100 %, and default value is 100 %. <+>/<-> → → → Press <+> or <->...
  • Page 62 Smart Positioner YT-3400 / 3450 series Product manual 8.9.3.4 Interval (INTERVAL) Interval time (days) between 1 PST and the next PST. The value must be between 1 ~ 365, and default value is 365 (days). <+>/<-> → → → Press <+> or <->...
  • Page 63 Smart Positioner YT-3400 / 3450 series Product manual 8.9.3.7 Latency (LATENCY) Latency for next movement after valve move. The value must be between 1 ~ 60 sec, and default value is 10 (sec). <+>/<-> → → → Press <+> or <->...

  • Page 64: View Mode (View)

    Smart Positioner YT-3400 / 3450 series Product manual View Mode (VIEW) 8.10 Displays various information of the positioner. <-> 3 seconds → → → Press <+> or <-> button if the above is not displayed. <-> <-> <-> → →...
  • Page 65 Smart Positioner YT-3400 / 3450 series Product manual bIAS 75 BIAS value when valve position is at 75 % Total used time duration. If a unit was used less than 1 hour, the time will not accumulate. 4.18 1’st row→”4.18” means 4hours and 18minutes.

  • Page 66: Error And Warning Code

    Smart Positioner YT-3400 / 3450 series Product manual Error and Warning Code Error or Warning code occur if there is a problem during Auto calibration or using the product. ➢ Error code : These are indicated if the positioner cannot be controlled, malfunctions or becomes imprecise.

  • Page 67: Error Code Which Is Displayed While Using The Product

    Smart Positioner YT-3400 / 3450 series Product manual ➢ Indicated when the feedback lever’s angle used is excessively small ➢ Re-install the positioner by during auto calibration. moving it towards the actuator RNG ERR ➢ when this error is detected, auto...

  • Page 68: Warning Code Which Can Be Checked From View Mode

    Smart Positioner YT-3400 / 3450 series Product manual ➢ Accumulated I value is I max or min’s limit. ➢ Degree of precision is low. ➢ Re-perform auto-calibration ➢ Indicated if valve’s friction is ➢ Check air regulator’s set pressure extremely high or set pressure of air and re-adjust to appropriate regulator has been changed.

  • Page 69: Main Software Map

    Smart Positioner YT-3400 / 3450 series Product manual Main Software Map Ver. 1.46...
  • Page 70 Product manual Manufacturer: Rotork YTC Limited Address: 81, Hwanggeum-ro, 89 Beon-gil, Yangchon-eup, Gimpo-si, Gyeonggi-do, South Korea Postal code: 10048 Tel: +82-31-986-8545 Fax: +82-70-4170-4927 Email: ytc.sales@rotork.com Homepage : http://www.ytc.co.kr Issued : 2021-08-19 Copyright © Rotork YTC Limited. All Rights Reserved. Ver. 1.46...

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