Instruction Manual

Established Leaders in Valve Actuation

Publication P270E Issue 08/08

GPSA Series

Electric Actuators and Control Systems

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TABLE OF CONTENTS

General Information .............................................. 3-4

Product Specifications .............................................. 5

Component Indentification ...................................... 6

Major Dimensions .................................................... 7

Mechanical Setup .................................................... 8

DIP Switch Configuration ......................................... 9

Typical Wiring Diagram ............................................ 9

Actuator Setup .................................................. 10-11

Menu Overview .................................................... 12

Software Setup .................................................. 13-19

Control Schemes .................................................... 20

Troubleshooting Guide ........................................... 21

Due to wide variations in the terminal numberingof actuator products, actual wiring of this deviceshould follow the print supplied with the unit.

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GENERAL INFORMATIONINTRODUCTIONRotork Process Controls designs, manufactures, andtests its products to meet many national and interna-tional standards. For these products to operate withintheir normal specifications, they must be properlyinstalled and maintained. The following instructionsmust be followed and integrated with your safetyprogram when installing and using RPC products:

• Read and save all instructions prior to installing,operating and servicing this product.

• If you don’t understand any of the instructions,contact Rotork Process Controls for clarification.

• Follow all warnings, cautions and instructions markedon, and supplied with, the product.

• Inform and educate personnel in the proper installa-tion, operation and maintenance of the product.

• Install equipment as specified in Rotork ProcessControls installation instructions and per applicablelocal and national codes. Connect all products to theproper electrical sources.

• To ensure proper performance, use qualified person-nel to install, operate, update and maintain the unit.

• When replacement parts are required, ensure thatthe qualified service technician uses replacementparts specified by Rotork Process Controls. Substitu-tions may result in fire, electrical shock, other haz-ards, or improper equipment operation.

• Keep all product protective covers in place (exceptwhen installing, or when maintenance is beingperformed by qualified personnel), to preventelectrical shock, personal injury or actuator damage.

• Operation of actuator in an inappropriate fashionway cause harm or damege to unit or other equip-ment/surroundings

WARNINGBefore installing the actuator, make sure that it issuitable for the intended application. If you areunsure of the suitability of this equipment for yourinstallation, consult Rotork Process Controls priorto proceeding.

WARNING - SHOCK HAZARDInstallation and servicing must be performed onlyby qualified personnel.

WARNING - ELECTROSTATIC DISCHARGEThis electronic control is static-sensitive. To protectthe internal components from damage, nevertouch the printed circuit cards without usingelectrostatic discharge (ESD) control procedures.

RECEIVING/INSPECTIONCarefully inspect for shipping damage. Damage to theshipping carton is usually a good indication that it hasreceived rough handling. Report all damage immedi-ately to the freight carrier and Rotork Process Controls,Inc.

Unpack the product and information packet—takingcare to save the shipping carton and any packingmaterial should return be necessary. Verify that theitems on the packing list or bill of lading agree withyour own.

STORAGEIf the product will not be installed immediately, itshould be stored in a clean, dry area where the ambi-ent temperature is -13° to 131° F (-25 to 55° C). Theactuator should be stored in a non-corrosive environ-ment. The actuator is not sealed to NEMA 4 until theconduit entries are properly connected.

EQUIPMENT RETURNA Returned Goods authorization (RG) number isrequired to return any equipment for repair. This mustbe obtained from Rotork Process Controls. (Telephone:414/461-9200) The equipment must be shipped,freight prepaid, to the following address after the RGnumber is issued:

Rotork Process Controls, Inc.5607 West Douglas AvenueMilwaukee, Wisconsin 53218Attn: Service Department

To facilitate quick return and handling of your equip-ment, include:1. RG Number on outside of box2. Your Company Name, Contact Name, Phone/Fax3. Address4. Repair Purchase Order Number5. Brief description of the problem

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GENERAL INFORMATIONIDENTIFICATION LABELAn identification label is attached to each actuatorcover. When ordering parts, requesting information orservice assistance, provide all of the label information.

Rotork Process Control

GENERAL ACTUATOR DESCRIPTIONThe GPSA is a high precision linear actuator. It iscapable of producing 200 pounds of force over its 1.38inch stroke length at a speed of up to .13 inches persecond. At a speed of .25 inches per second the unit iscapable of producing 100 pounds of thrust.

It can utilize up to three input signals, independentlyconfigurable as either current (4-20 ma) or voltage(1-5 V) for control. Two dry contact inputs areavailable and may be configured to energize or de-energize on fault. The actuator provides three outputrelays which are configurable as to their trigger and toact as NO or NC. A position feedback signal is pro-vided via a 4-20ma transmitter, which is configurableas either internally powered or externally looppowered.

A two line, 16 character VFD display and rotaryswitches comprise the actuators HMI. This providesaccess for viewing and modifying changeableparameters and data feedback.

GPSA

1628 J 07120 / 50-60 / 1 / 0.5

95C 036051 - 1

GPSA-0100

MODEL NUMBER: GPSA

Actuator Series

SERIAL NUMBER: 1628 J 07

Year BuiltSequential NumberMonth Built

ABBREVIATIONS USED IN THIS MANUALA or Amps Ampereac Alternating Current° C Degrees CelsiusCW ClockwiseCCW Counterclockwisedc Direct Current° F Degrees FahrenheitG Earth GroundHz Hertzkg KilogramL Line (power supply)lbs Poundslbf. Lbs. ForceLVDT Linear Variable Differential TransformermA Milliampmfd Microfaradmm MillimetersN Newton (force)NEMA National Electrical Manufacturing Assoc.Nm Newton MeterNPT National Pipe ThreadPh PhasePL Position Limit SwitchP/N Part NumberRPM Revolutions per MinuteSEC SecondTL Thrust Limit SwitchVac Volts acVdc Volts dcVR Variable ResistanceW Watt

WARRANTY INFORMATIONWarranty: Subject to the following, Rotork Process Controls expresslywarrants the products manufactured by it as meeting the applicableRotork Process Controls product specifications and that such products arefree from defects in material and workmanship for a period of one (1)year from the date of delivery. The foregoing is the sole and exclusivewarranty made by Rotork Process Controls with respect to the products.Rotork Process Controls makes no other warranties, either express orimplied (including, without limitation, warranties as to merchantability orfitness for a particular purpose). The purchaser retains responsibility forthe application and functional adequacy of the offering. See RotorkProcess Controls’s General Conditions of Sale - Product, for completewarranty information.

ROTORK PROCESS CONTROLS

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SPECIFICATIONSInput Voltage: 100 - 240 Vac,+/- 20%, 47 - 66 Hz, 1 Phase

Power: 85 watts

Command Signal Inputs: 4-20 mA, 1-5 Vdc

Position Feedback Signal: 4-20 mA

Field Wiring Terminations: Plugable terminal block,wire size range 26-14 AWG

Command Signal Monitor: If the command signaldrops below 3.7 mA or above 20.3 mA the actuatorcan be programed to either lock in place or run to aposition (user selectable).

Current Limit: Automatic adjustment of the motorcurrent limit (internal to servo control).

Speed/Thrust: 0.25 in./sec. at 100 lbs. thrust0.13 in./sec. at 200 lbs. thrust

Stroke: Up to 1.38 in. (35 mm)Infinitely adjustable within range.

Weight: 23 lbs. (10.4 kg)

Conduit Entry: 3/4 NPT (4)

Handwheel: Push to engage, spring return on release.

Temperature Limits: -4° F to 150° F (-20° C to 65° C)

Enclosure: Explosion-proof for Class I, Division 1,Groups C and D. Dust ignition-proof for Class II,Division 1, Groups E, F and G. Type 4, indoor oroutdoor

Duty Cycle: Continuous unrestricted modulating duty

Position Accuracy: .5% of full range

ELECTRICAL SUPPLY REQUIREMENTS• An overcurrent protective device is required for the

supply power. Size the overcurrent device perrequirements of actuator for 125% of maximumrated load.

• Disconnect for the supply power is to be supplied bythe customer.

• Wire conductor type and size should match RotorkProcess Controls requirements, wiring diagrams andfollow local codes.

MAINTENANCE• Rotork Process Controls actuators are maintenance

free. It is recommended that you remove the coverand visually inspect the actuator for any irregularitieson an annual basis.

SPARE PARTS• Spare parts and spare parts lists can be obtained by

contacting the Rotork Process Controls ServiceDepartment.

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COMPONENT IDENTIFICATION

ManualOverrideHandwheel

Electronics

Actuator Cover

Actuator Base

MagneticFeedbackEncoder

Motor

Screw Nut

Screw Shaft

Output Shaft

Non-IntrusiveMomentarySwitches for Setupand Diagnostics

VacuumFluorescentDisplay

Conduit Entries(4 Total)

Explosion-ProofWindow

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MAJOR DIMENSIONS

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GeneralThe electrical installation, maintenance and use of theseactuators should be carried out in accordance with theNational Legislation and Statutory Provisions relating to thesafe use of this equipment, applicable to the site of installa-tion.

For the UK: Electricity at Work Regulations 1989 and theguidance given in the applicable edition of “IEEE WiringRegulations” should be applied. Also the user should be fullyaware of his duties under the Health and Safety act 1974.

For USA: NFPA70, National Electrical Code ® is applicable.

The basic wiring diagram is shown on page 9, however theactual wiring must follow the print supplied with the actuator.

Input PowerInput power, (100-240VAC ±20%), terminates at TB1 on thepower supply board. Live and Neutral must be connected toterminals 1 and 3 respectively. The power supply is auto-sensing therefore no switch settings are required for selectionof input voltage range.

The incoming power supply earth ground must be securelyconnected to the ground screw terminal located inside theactuator base.

Command WiringThe analog input signals are used for automatic positioning ofthe actuator. The assignment of each channel is as follows:

Proportional: J3-1 (+ve) and J3-2 (-ve)Process Variable: J3-3 (+ve) and J3-4 (-ve)Remote Setpoint or Remote Ratio: J3-5 (+ve) and J3-6 (-ve)

Consult ‘Control Setup’ section of this document for moreinformation. The input signal may be configured for voltage(1-5V) or current (4-20mA) and is achieved by use of dipswitches S1 – S3, see section titled ‘Setting the DipSwitches’. Each analog input channel is fully isolated.

MECHANICAL SETUP

RelaysThe GPSA provides 3 user configurable relays for position ormonitoring indication. The relays may be configured toenergize or de-energize on the assigned condition. Thecontacts are rated at 10mA to 5A, 250V AC, 30V DC. Therelays will de-energize under loss of power.

The connections are as follows:Relay 1: J1-7 Normally Closed

J1-8 Normally OpenJ1-9 Common

Relay 2: J1-4 Normally ClosedJ1-5 Normally OpenJ1-6 Common

Relay 3: J1-1 Normally ClosedJ1-2 Normally OpenJ1-3 Common

Contact InputsThe Contact Inputs provide an additional pair of isolatedinputs for specific control purposes, (see ‘Start-up Informa-tion’ section of this document). These inputs are activatedby connecting the corresponding pair of terminals together.Input SW should be wired to terminals J2-3 and J2-4. TheStand-by switch is wired to J2-5 and J2-6. Informationregarding the configuration of these switches can be found inthe ‘Start-up Information’ section of this document.

TransmitterA current loop transmitter provides a 4-20mA signal thatcorresponds to the measured position. This may be eitherloop powered or internally powered, (see the section titled‘Setting the Dip Switches’). In the internally powered mode,the feedback signal wires connect to terminals 2 (+ve) and 1(-ve) of J2 respectively. In the loop powered mode however,the signal wires connect to terminals 1 (+ve) and 2 (-ve) ofJ2 respectively. The transmitter is fully isolated.

Setting the Dip SwitchesThere are four dip switches situated on the main logic PCBthat are used for actuator configuration. They are locatedbehind the display near the display board standoffs. SwitchesS1 – S3 determine the type of command signal, (voltage orcurrent) used by the actuator, for analog inputs 1 – 3 respec-tively. Switch S4 is used to select between a loop poweredand internally powered current transmitter. It should benoted that the orientation of the transmitter’s terminals isdifferent for the two modes.

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DIP Switch Chart

Switch Switch Position Function

On (slide to the right) Current input selected for INPUT 1

Off (slide to the left) Voltage input selected for INPUT 1

On (slide to the right) Current input selected for INPUT 2

Off (slide to the left) Voltage input selected for INPUT 2

On (slide to the right) Current input selected for INPUT 3

Off (slide to the left) Voltage input selected for INPUT 3

On (slide to the right) Internally powered transmitter

Off (slide to the left) Externally loop powered transmitter

S1

S2

S3

S4

TYPICAL WIRING DIAGRAM

Due to widevariations

in the terminalnumberingof actuator

products, actualwiring should

follow the printsupplied withthe actuator.

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ACTUATOR SETUP

General

1) PowerUnit automatically senses 100 to 240 Vac input power.

2) Command CalibrationUnit is factory calibrated for input commands of both 4-20maand 1-5 Volts. There is no need for the customer calibrationof the input signals.

3) Auto/ManualThe unit can be operated in Manual or Automatic modes.See the Menu Hierarchy for the location of this user settableselection.

4) CalibrationThe unit may be calibrated in one of two modes (Zero/Spanor Characterize)

InterfaceA display and two selector knobs are used for a non-intrusivecustomer interface to the actuator. The unit provides amenuing system to access run modes, parameters,diagnostics and alarms. The ↑ and ↓ selections are used toscroll through the menu choices and status/parameter lists.These parameters are arranged in a tree structure which istraversed using the ↑ and ↓ knob selections.

Selecting the ↓ option will scroll down one entry in theparameter listing. The next parameter will be shown on thetop line of the display. Selecting ↑ will scroll back up to theprevious parameter in the list. Each menu listing is circular.The menu listings contain parameters and access toadditional menus of parameters. Menus are distinguished byusing only the top line of the display. When a menu isshown, selecting Enter takes the operator to that menu andagain the ↑ / ↓ selections are used to traverse it. Cancelmoves back to the previous menu.

Parameters use both display lines. A parameter’s name isshown on the top line and its current value is shown on thebottom line. When a parameter is shown (if it is updateable),selecting Enter will put that parameter in the update mode.

This is denoted by a “U” in the upper left hand corner of thedisplay. The ↑ / ↓ selections are now used to modify theparameter value. If the parameter has discrete settings, ↑ / ↓will cycle through the circular list of those settings. If theparameter is numeric, the ↑ / ↓ knob selections willincrement or decrement the parameter respectively.

When updating a numeric parameter value, holding a knobselection (↑ or ↓) will increase the amount of increment (↑)or decrement (↓) in use. Initially a parameter is updatedthrough its least significant digit. Holding the knob selectionthrough ten changes will advance the update one position tothe left for an additional ten updates. This process continuesuntil the knob is released. All numeric parameters haveminimum and maximum limits. The update of parameters iscircular. For example, incrementing a parameter past itsmaximum value will cause the value to loop around to itsminimum value and continue updating from that point.

Updating a parameter causes the unit to enter Manual Mode.The unit will remain in Manual Mode until the operatorreturns it to Automatic mode via the “AUTO/MAN CTRL”parameter.

Zero/Span – This option provides a 2-point calibration of theunit. This calibration is performed under the VALVE POSmenu via the following steps:1. Update the MAX POSITION parameter to reflect the

value of the maximum output position of the actuator.(ex. 100 %)

2. Select the CAL POINT 1 parameter. Use the ↑ / ↓ knobto run the actuator to the desired ZERO position. SelectEnter to save the current physical position of actuator asits ZERO point.

3. Continue to the CAL PT 1 VAL parameter and select it forupdate. This is the numeric value that is to be associatedwith the ZERO point (ex. 0 %). Update and select Enterto save this value

4. Continue to the CAL POINT 2 parameter. Use the ↑ / ↓knob to run the actuator to the desired SPAN position.Select Enter to save the current physical position ofactuator as its SPAN point.

5. Continue to the CAL PT 2 VAL parameter and note that itis automatically set to the MAX POSITION setting of step1. This is the numeric value that is associated with theSPAN point (ex 100 %). In a two-point calibration thisvalue is not updateable by the user.

6. The two-point calibration of the actuator is nowcompleted.

Cancel

Enter

Up

Down

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Characterization – This option provides for a 2 to 11 pointcalibration of the unit in order to characterize its output. Thiscalibration is performed under the VALVE POS menu via thefollowing steps:

1. Update the MAX POSITION parameter to reflect thevalue of the maximum output position of the actuator.(ex. 100 %)

2. Select the CAL POINT 1 parameter. Use the ↑ / ↓ knobto run the actuator to the desired ZERO position. SelectEnter to save the current physical position of actuator asits ZERO point.

3. Continue to the CAL PT 1 VAL parameter and select it forupdate. This is the numeric value that is to be associatedwith the ZERO point (ex 0 %). Update and select Enter tosave this value

4. Continue to the CAL POINT 2 parameter. Use the ↑ / ↓knob to run the actuator to the desired position. SelectEnter to save the current physical position of actuator asthe second calibration point.

5. Continue to the CAL PT 2 VAL parameter and select it forupdate. This is the numeric value that is associated withthe second calibration point (ex 10 %).

6. Continue to the CAL POINT 3 parameter. Use the ↑ / ↓knob to run the actuator to the desired position. SelectEnter to save the current physical position of actuator asthe third calibration point.

7. Continue to the CAL PT 3 VAL parameter and select it forupdate. This is the numeric value that is associated withthe third calibration point (ex 20 %).

8. Calibration points (up to 11) will be automaticallyavailable until the CAL PT X VAL parameter is set equal tothe MAX POSITION parameter value set in step 1. Whenthis occurs, calibration is considered complete; noadditional calibration points are provided.

ACTUATOR SETUP5) TransmitterThe unit may be configured to use either an internallypowered transmitter (S4 slid to the right, in line with thepainted line) or as externally loop powered (S4 slid to theleft, not in line with the painted line) The transmitter isfactory calibrated. User calibration is not required.

6) Loss of Command ActionThe unit may be configured to perform one of four actionswhen a loss of the command input signal occurs whilerunning under the automatic operation of the Open Loopcontrol mode:LOCK – Locks the unit in place at its current positionDRIVE to ZERO - The unit will drive to the ZERO positionset in calibrationDRIVE to SPAN - The unit will drive to the SPAN position setin calibrationDRIVE to POS - The unit will drive to a user positionspecified by the CMD LOS POS parameter

7) Loss of Process Variable Input ActionThe unit may be configured to perform one of four actionswhen a loss of the process variable input signal occurs underthe automatic operation of the Closed Loop control mode:LOCK - Lock the unit in place at its current positionDRIVE to ZERO - The unit will drive to the ZERO positionset in calibrationDRIVE to SPAN - The unit will drive to the SPAN position setin calibrationDRIVE to POS - The unit will drive to a user positionspecified by the PV LOS POS parameter

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1 POSITION GRPH2 POSITION3 AUTO/MAN CTRL4 MANUAL JOG (ONLY WHEN IN MANUAL MODE)5 “CMD POS” OR “PV SP STAT”*6 SETUP6.1 BASIC PARAMS

6.1.1 DEADBAND CNT6.1.2 LINEAR/ROTARY SPEED6.1.3 SPEED UNITS*6.1.4 ACTUATOR TYPE

6.2 CONTROL SETUP6.2.1 CONTROL MODE6.2.2 OPEN LOOP*

6.2.2.1 CMD UNITS6.2.2.2 CMD MAX6.2.2.3 CMD MIN6.2.2.4 CMD DAMP6.2.2.5 CMD LO ALRM6.2.2.6 CMD ALRM DB6.2.2.7 CMD LOS ACT6.2.2.8 CMD LOS POS*6.2.2.9 RATIO SET

6.2.3 CLOSED LOOP*6.2.3.1 PV UNITS6.2.3.2 PV MAX6.2.3.3 PV MIN6.2.3.4 PV DAMP6.2.3.5 PV HI ALRM6.2.3.6 PV LO ALRM6.2.3.7 PV ALRM DB6.2.3.8 PV LOS ACT6.2.3.9 PV LOS POS*6.2.3.10 PROPOR GAIN6.2.3.11 INTEGRAL TIME6.2.3.12 LOC/RMT SP6.2.3.13 SET POTNT*6.2.3.14 SP DEV ALARM

6.2.4 FEED FORWARD*6.2.4.1 CMD UNITS6.2.4.2 CMD MAX6.2.4.3 CMD MIN6.2.4.4 CMD DAMP6.2.4.5 CMD LO ALRM6.2.4.6 CMD ALRM DB6.2.4.7 PV UNITS6.2.4.8 PV MAX6.2.4.9 PV MIN6.2.4.10 PV DAMP6.2.4.11 PV HI ALRM6.2.4.12 PV LO ALRM6.2.4.13 PV ALRM DB6.2.4.14 PROPOR GAIN6.2.4.15 INTEGRAL TIME6.2.4.16 CMD CHNG TIME6.2.4.17 CMD-POS VARI6.2.4.18 CMD CHNG VAR6.2.4.19 CMD DEADBAND6.2.4.20 SETPOINT*6.2.4.21 SP DEV ALARM6.2.4.22 LOC/RMT SP

6.3 OUTPUT RELAYS6.3.1 R1 ASSIGN6.3.2 R1 FORM6.3.3 R2 ASSIGN6.3.4 R2 FORM6.3.5 R3 ASSIGN6.3.6 R4 FORM

6.4 CONTACT INPUTS6.4.1 INPUT SW ACTIVE6.4.2 INPUT CONFIG*6.4.3 INPUT SW SET6.4.4 OVREIDE SW ACT*6.4.5 OVRIDE CONFIG*

6.5 VALVE POS6.5.1 UNITS6.5.2 MAX POSITION6.5.3 CALIBRATE OPT6.5.4 ZERO-SPAN/CHARACTERIZE

6.5.4.1 CAL PT 1 VAL6.5.4.2 CAL PT 1 LOC6.5.4.3 CAL PT 2 VAL6.5.4.4 CAL PT 2 LOC

6.6 DEFAULTS6.6.1 SET CUST DFLT6.6.2 LOAD CUST DFLT6.6.3 LAOD FACT DFLT6.6.4 PASS PROTECT6.6.5 SET PASS6.6.6 ENCODER IN IT6.6.7 INVERT DISP6.6.8 LANG SELECT

7 STATUS7.1 ALARM

7.1.1 LIST OF CURRENT ALARMS7.2 FAULT HISTORY

7.2.1 LIST OF LAST 10 FAULTS7.3 AMP TEMP7.4 ACTUAT STATUS7.5 ACTUAT STARTS7.6 AMP STARTS7.7 SOFT VERSION

MENU OVERVIEW

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6.2.2 OPEN LOOP CONTROL PARAMETERS6.2.2.1 CMD UNITSThis is a four character label that will be displayed with theinput command and it’s associated parameters. It is entirelyconfigurable by the operator. When selected for update, thefirst of the four characters is highlighted. The ↑ / ↓ selectionsare used to scroll through the available characters: A-Z, a-z,space, -, % and /. Selecting Enter will set the displayed characterand continue to the next. When all four characters have beenset, the label is saved. At anytime prior to the final characterbeing set, Cancel may be selected and no change to the labelwill be made.

6.2.2.2 CMD MAXThis is the input reading that is to be associated with themaximum input signal of 20ma or 5V.

6.2.2.3 CMD MINThis is the input reading that is to be associated with theminimum input signal of 4ma or 1V.

6.2.2.4 CMD DAMPDampening is the amount of time over which the commandinput signal is averaged. The setting may range from 0seconds (no dampening) to 25 seconds. This is used tosmooth out rapid fluctuations of the input signal.

6.2.2.5 CMD LO ALRMThis is the level that signifies a low input command. Whenthe input command falls below this level, an alarm isgenerated.

6.2.2.6 CMD ALRM DBThis parameter determines when the CMD LO ALRM iscleared. The input command reading must rise above thealarm level by this amount in order for the system to clear anexisting low command alarm. The parameter may be setfrom 0.3% to 25% of the Input command range.

6.2.2.7 CMD LOS ACTThis is the action taken when the input command is lost. Itmay be configured asLOCK – actuator locks in place at its current positionDTZ – actuator drives to the Zero positionDTS – actuator drives to the Span positionDTP – actuator drives to a user selected position

6.2.2.8 CMD LOS POSThis is the position to which the actuator will drive when theCMD LOST ACT parameter is set to Drive To Position andthe signal is lost.

6.2.2.9 LOC/REM RADIOThis parameter configures whether the RATIO multiplier ofthe system is obtained locally when set to LOCAL, or if it isobtained from the input signal (on input pair number 3)when set to REMOTE.

SOFTWARE SETUP

Configuration6.1 Basic Parameters

6.1.1 DEADBANDThis adjustment establishes the servo sensitivity. It is factoryset but may be adjusted, if necessary, in the field. If theactuator begins to oscillate (rapidly adjusting around a singlepoint) the sensitivity can be decreased. Increase thedeadband parameter until the oscillation no longer occurs.Oscillation will reduce the life of the unit.

6.1.2 SPEEDLINEAR SPEEDThis is the speed at which the unit moves in a linear direc-tion. It may be set to either .13 or .25 inches/second.

ROTARY SPEEDThis is the selection to set the rotary speed of the actuator.It is adjustable between TBD. There are no units associatedwith this parameter other than those the operator desires touse. See SPEED UNITS parameter.

6.1.3 SPEED UNITSThis parameter is available only for rotary actuators. It is afour-character user programmable unit string to associate withthe speed parameter.

6.1.4 ACUATOR TYPEThis parameter configures the unit as linear or rotary.

6.2 Control Setup

6.2.1 CONTROL MODE SELECTIONThis selects the control mode that the actuator uses todetermine its output position:

6.2.2 OPEN LOOP: (See page 19 for diagram)In this mode the output position is directly proportional tothe input command provided on input terminal pair #1.

6.2.3 CLOSED LOOP: (See page 19 for diagram)This strategy is integral based and adjusts the output positionof the actuator based on the difference between a desiredlocal or remote Set Point (terminal pair #3) and the actualProcess variable signal on terminal pair #2. This adjustmentis added incrementally over a specified integral time. Theamount of the correction is continually calculated/updated.

6.2.4 FEED FORWARD: (See page 19 for diagram)This mode combines the control strategies of proportionaland process variable control mentioned above. The outputsetting is adjusted in proportion to the input command onterminal pair #1 and a correction factor is applied which isderived from the error between the desired local or remoteSet Point (terminal pair #3) and the actual input signal oninput terminal pair #2.

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SOFTWARE SETUP6.2.2.10 RATIO SETThis parameter is a Ratio Multiplier that is applied to theinput command signal. It ranges from .2 to 2. A setting of 1results in no change to the input command signal.

6.2.3 CLOSED LOOP CONTROL PARAMETERS6.2.3.1 PV UNITSThis is a four character label that will be displayed with theprocess variable and it’s associated parameters. It is entirelyconfigurable by the operator. When selected for update, thefirst of the four characters is highlighted. The ↑ / ↓ selectionsare used to scroll through the available characters: A-Z, a-z,space, -, % and /. Selecting Enter will set the displayed characterand continue to the next. When all four characters have beenset, the label is saved. At anytime prior to the final characterbeing set, Cancel may be selected and no change to the labelwill be made.

6.2.3.2 PV MAXThis is Process Variable reading that is to be associated withthe maximum input signal of 20ma or 5V, and local setpoint.

6.2.3.3 PV MINThis is Process Variable reading that is to be associated withthe minimum input signal of 4ma or 1V, and local setpoint.

6.2.3.4 PV DAMPDampening is the amount of time over which the ProcessVariable input signal is averaged. The setting may range from0 seconds (no dampening) to 25 seconds. This is used tosmooth out rapid fluctuations of the input signal.

6.2.3.5 PV HI ALRMThis is the Alarm level that signifies that the Process Variablesignal is too high. When the process variable input risesabove this level an alarm is generated.

6.2.3.6 PV LO ALRMThis is the Alarm level that signifies a Process Variable signalis too low. When the Process Variable input falls below thislevel an alarm is generated.

6.2.3.7 PV ALRM DBThis parameter determines when the Process Variable Highand Low Alarms are cleared. The Process Variable signalmust rise above the Low Alarm level by the Deadbandamount in order to clear a Process Variable Low Alarm. TheProcess Variable signal must fall below the Process VariableHigh Alarm level by this amount to clear a Process VariableHigh Alarm. The parameter may be set from 0.3% to 25% ofthe Process Variable signal range.

6.2.3.8 PV LOS ACTIONThis is the action taken when the Process Variable inputsignal is lost. It may be configured asLOCK – actuator locks in place at its current positionDTZ – actuator drives to the Zero positionDTS – actuator drives to the Span positionDTP – actuator drives to a user selected position

6.2.3.9 PV LOS POSThis is the position to which the actuator will drive when thePV LOS ACTION parameter is set to Drive To Position andthat signal is lost.

6.2.3.10 PROPOR GAINThis is the gain applied in the PI control loop of the ClosedLoop control scheme. It tells the actuator what percentageof the difference between the Set Point and the ProcessVariable signals to use as the step up or down. Thepercentage is equal to 100 divided by the PROPOR GAINsetting. It may be set from 0 to 255%. A gain setting of100% results in the step up or down being equal to thedifference of the two signals.

6.2.3.11 INTEGRAL TIMEThis is the time over which the correction of the PI controlloop is applied to the system. It ranges from 0 to 60minutes. The correction to be made to the system iscalculated and it is applied incrementally over the Integraltime. The correction and the size of its incrementalapplication is continually calculated and applied to thesystem. A setting of 0 minutes would apply any requiredcorrection immediately rather than spread out over a periodof time.

6.2.3.12 LOC/RMT SPThis parameter configures whether the Process Variable setpoint of the system is obtained locally (SP) when set toLOCAL, or if it is obtained from the input signal (on input pairnumber 3) when set to REMOTE.

6.2.3.13 SET POINTWhen LOC/RMT SP is set to LOCAL, this is the Local SetPoint Parameter that the system uses. It is only availablewhen REM SP is set to REMOTE.

6.2.3.14 SET POINT DEV ALRMThis is the percentage of the Process variable Signal by whichthe Set Point and the Process Variable signal may differbefore an alarm is triggered.

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SOFTWARE SETUP6.2.4 FEED FORWARD CONTROL PARAMETERS6.2.4.1 CMD UNITSThis is a four character label that will be displayed with theinput command and it’s associated parameters. It is entirelyconfigurable by the operator. When selected for update, thefirst of the four characters is highlighted. The ↑ / ↓ selectionsare used to scroll through the available characters: A-Z, a-z,space, -, % and /. Selecting Enter will set the displayed characterand continue to the next. When all four characters have beenset, the label is saved. At anytime prior to the final characterbeing set, Cancel may be selected and no change to the labelwill be made.

6.2.4.2 CMD MAXThis is the input reading that is to be associated with themaximum input signal of 20ma or 5V.

6.2.4.3 CMD MINThis is the input reading that is to be associated with theminimum input signal of 4ma or 1V.

6.2.4.4 CMD DAMPDampening is the amount of time over which the commandinput signal is averaged. The setting may range from 0seconds (no dampening) to 25 seconds. This is used tosmooth out rapid fluctuations of the input signal.

6.2.4.5 CMD LO ALRMThis is the level that signifies a low input command. Whenthe input command falls below this level, an alarm isgenerated.

6.2.4.6 CMD ALRM DBThis parameter determines when the CMD LO ALRM iscleared. The input command reading must rise above thealarm level by this amount in order for the system to clear anexisting low command alarm. The parameter may be setfrom 0.3% to 25% of the Input command range.

6.2.4.7 PV UNITSThis is a four character label that will be displayed with theprocess variable and it’s associated parameters. It is entirelyconfigurable by the operator. When selected for update, thefirst of the four characters is highlighted. The ↑ / ↓ selectionsare used to scroll through the available characters: A-Z, a-z,space, -, % and /. Selecting Enter will set the displayed characterand continue to the next. When all four characters have beenset, the label is saved. At anytime prior to the final characterbeing set, Cancel may be selected and no change to the labelwill be made.

6.2.4.8 PV MAXThis is Process Variable reading that is to be associated withthe maximum input signal of 20ma or 5V, and local set point.

6.2.4.9 PV MINThis is Process Variable reading that is to be associated withthe minimum input signal of 4ma or 1V, and local set point.

6.2.4.10 PV DAMPDampening is the amount of time over which the ProcessVariable input signal is averaged. The setting may range from0 seconds (no dampening) to 25 seconds. This is used tosmooth out rapid fluctuations of the input signal.

6.2.4.11 PV HI ALRMThis is the Alarm level that signifies that the Process Variablesignal is too high. When the process variable input risesabove this level an alarm is generated.

6.2.4.12 PV LO ALRMThis is the Alarm level that signifies a Process Variable signalis too low. When the Process Variable input falls below thislevel an alarm is generated.

6.2.4.13 PV ALRM DBThis parameter determines when the Process Variable Highand Low Alarms are cleared. The Process Variable signalmust rise above the Low Alarm level by the Deadbandamount in order to clear a Process Variable Low Alarm. TheProcess Variable signal must fall below the Process VariableHigh Alarm level by this amount to clear a Process VariableHigh Alarm. The parameter may be set from 0.3% to 25% ofthe Process Variable signal range.

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SOFTWARE SETUP6.2.4.14 PROPOR GAINThis is the gain applied in the PI control loop of the ProcessVariable control scheme. It tells the actuator whatpercentage of the difference between the Set Point and theProcess Variable signals to use as the step up or down. Thepercentage is equal to 100 divided by the PROPOR GAINsetting. It may be set from 0 to 255%. A gain setting of100% results in the step up or down being equal to thedifference of the two signals.

6.2.4.15 INTEGRAL TIMEThis is the time over which the correction of the PI controlloop is applied to the system. It ranges from 0 to 60minutes. The correction to be made to the system iscalculated and it is applied incrementally over the Integraltime. The correction and the size of its incrementalapplication is continually calculated and applied to thesystem. A setting of 0 minutes would apply any requiredcorrection immediately rather than spread out over a periodof time.

6.2.4.16 CMD CHANGE TIMEThis parameter controls the time period over which thecorrection factor caused by a change in the input commandis applied to the system during Feed Forward control. Forinstance, if the input command is changed by 25% and theCMD CHNG TIME parameter is set to 30 seconds; incre-mental changes will be made to the system each controlcycle to incorporate the correction over time so that it is fullyimplemented after 30 seconds.

6.2.4.17 CMD-POS VARIThis is the percent difference of input command and theposition that if exceeded will trigger a recalculation of thecorrection factor applied during Feed Forward Control.

6.2.4.18 CMD CHNG VARIThis is the percent difference of the current command andthe input command when the last correction factor wascalculated that if exceed will trigger a recalculation ofcorrection factor applied during Feed Forward control.

6.2.4.19 CMD DEADBANDThis is the amount the command may change withoutcausing the system to accumulate any error due to the inputcommand.

6.2.4.20 SET POINTWhen LOC/RMT SP is set to LOCAL, this is the Local SetPoint Parameter that the system uses. It is only availablewhen REM SP is set to REMOTE.

6.2.4.21 SET POINT DEV ALRMThis is the percentage of the Process variable Signal by whichthe Set Point and the Process Variable signal may differbefore an alarm is triggered.

6.2.4.22 LOC/RMT SPThis parameter configures whether the Process Variable setpoint of the system is obtained locally (SP) when set toLOCAL, or if it is obtained from the input signal (on input pairnumber 3) when set to REMOTE.

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SOFTWARE SETUP

6.3 Output RelaysThe actuator has three output relays that are configurable bythe user. They may be set to trigger on any one of thirteenfault/alarm or actuator conditions. They may also beconfigured as ENERG ON FLT or DEENERG ON FLT.

6.3.1 R1 ASSIGNThe Relay may be triggered upon any one of the followingconditions:

Fault Process Variable LowLocal Process Variable HighRemote Set Point Deviation LowManual Set Point Deviation HighAuto Command LowStall Valve Position High

Valve Position Low

When assigned to NONE, the relay will not trigger but is setto the state that was set up by the R1 CONFIG parameter.

6.3.2 R1 CONFIGThe output relay may be configured as ENERG ON FLT(energized on fault), relay closes on the fault condition orDEENERG ON FLT (de-energized on fault) relay opens onfault condition.

6.3.3 R2 ASSIGNSee Relay 1 Assignment, this operates in the same fashionbut on the second output relay.

6.3.4 R2 CONFIGSee Relay 1 Configuration, this operates in the same fashionbut on the second output relay.

6.3.5 R3 ASSIGNSee Relay 1 Assignment, this operates in the same fashionbut on the third output relay.

6.3.6 R4 CONFIGSee Relay 1 Configuration, this operates in the same fashionbut on the third output relay.

6.4 Contact InputsThe actuator is equipped with two contact inputs that maybe configured by the operator.

6.4.1 INPUT SW ACTIVESetting this parameter to YES enables input Switch 1. Whenactive, the INPUT CONFIG and INPUT SW SET parametersare also made accessible to the operator. If INPUT SWACTIVE is set to NO, no other Input switch 1 parameters areaccessible (not displayed) and switch 1 input is not used.

6.4.2 INPUT SW CONFIGWhen Input switch 1 is enabled this parameter configureswhether the switch is normally open (NORM OPEN), actionis taken when the contact closes or normally closed (NORMCLOSED), action is taken when the contact opens.

6.4.3 INPUT SW SETThe user has two options for actuator positioning when thisswitch is activated. It may be set to either LOCK (lock inplace) or DRVIE TO ZERO (run to the ZERO position) .

6.4.4 ORIDE SW SETSetting this parameter to YES enables the input standbyswitch. When active, the Override Switch Configuration isalso made accessible to the operator. If the ORIDE SW SET isset to NO, the Override Switch configuration parameter isnot accessible and the Override switch input is not used.

6.4.5 ORIDE SW CONFIGWhen ORIDE SW SET is set to YES this configures whetherthe switch is normally open (NORM OPEN), action is takenwhen the contact closes or normally closed (NORMCLOSED), action is taken when the contact opens.

When the override switch is activated the actuator will driveto the ZERO position and the lower line of the display willshow OVERRIDE at all times.

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SOFTWARE SETUP

6.5 Valve POSThe output position of the unit can be calibrated by the user.This calibration can be anywhere from two to eleven points.The actuator linearly interpolates between adjacentcalibration points to determine the setting for the output

6.5.1 UNITSThis is a four character label that will be displayed with theoutput position and it’s associated parameters. It is entirelyconfigurable by the operator. When selected for update, thefirst of the four characters is highlighted. The ↑ / ↓ selectionsare used to scroll through the available characters: A-Z, a-z,space, -, % and /. Selecting Enter will set the displayed characterand continue to the next. When all four characters have beenset, the label is saved. At anytime prior to the final characterbeing set, Cancel may be selected and no change to the labelwill be made.

6.5.2 MAX POSITIONThis is the maximum output position of the system, or thehighest desired output of the system.

6.5.3 CALIBRATE OPTThis parameter selects between a 2 point linear (Zero-Span)calibration and an up to eleven point (Characterize)calibration of the unit.

6.5.4 CAL POINT 1This is the actual position of the output shaft at the ZEROposition in A/D counts. When calibrating, adjust the output(using the ↑ / ↓ selections) to its ZERO position and thenselect Enter.

6.5.4.1 CAL PT 1 VALThis is the unit value associated with the ZERO position ofthe valve. The ↑ / ↓ selections are used to adjust it. Whenthe desired value is shown select Enter to save that value.

6.5.4.2 CAL POINT 2This is the actual position of the output shaft at the secondcalibration point in A/D counts. In a 2-point calibration thiswould be the Span position. When calibrating, adjust theoutput (using the ↑ / ↓ selections) to the desired position andthen select Enter.

6.5.4.3 CAL PT 2 VALThis is the unit value associated with the second calibrationpoint of the valve.

6.5.4.4 CAL POINT 3-11These are the actual positions of the output shaft atadditional calibration points.

CAL PT 3-11 VALThese are the unit value associated with the additionalcalibration points.

6.6 Defaults6.6.1 SET CUST DEFSThis option saves the current set up of the actuator topermanent memory. The user may then at a later time loadthese setting back into the actuator. Selecting Enter when theYES option is displayed will save the current settings as thecustomer defaults.

6.6.2 LOAD CUST DEFSThis allows the user to load the actuator with the last settingsof the customer defaults stored in memory.

6.6.3 LOAD FACT DEFSThis enables the user to return the actuator settings to thevalues they had when the actuator left the RPC factory.Pressing Enter when the Yes option is displayed will load theDefault Factory settings.

6.6.4 PASS PROTECTThis parameter enables and disables the unit’s passwordprotection. When password control is enabled, set to YES, apassword is required to change any parameter settings. Thepassword is a 4-letter code entered through use of the knobs↑ / ↓ and Enter.

Without the proper password, parameters are only viewable.Once a valid password is entered, the actuator will accept achange. If more than one parameter is to be modified, thenext parameter must be accessed within 30 seconds ofstoring the previous parameter or the password will need tobe reentered. Setting this parameter to NO disables thepassword protection.

6.6.5 SET PASSThis allows the customer to set their own password on theunit through the knobs. The password is a four letter code.Each of the four code letters may be set from A to Z by usingthe ↑ / ↓ selector to scroll through choices and then selectingEnter to lock in the selection. As the new password isentered it is shown on the screen so the user can verify thatthey have entered it correctly.

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7 Status

7.1 ALARMSThere are several conditions which will trigger an alarm onthe actuator. An alarm state is denoted by the icon of a bellbeing displayed in the lower left hand corner of the display.All alarms are self clearing. Should the condition that causedthe alarm no longer exist, the bell icon will be erased.

To see the specific alarm(s) in effect, the user looks at thismenu. When this menu is displayed selecting Enter willexpand the display to show the current alarms on the lowerline of the display. The upper line of the display will nowread ACTIVE ALARMS. If no alarms are active the lower lineof the display will show NONE. However, if an alarm isactive, the name of the alarm is shown. It is possible thatmore than one alarm may be active. Use the ↑ / ↓ knob toscroll through the list of active alarms. Possible alarms thatmay occur are:

StallLoss of Remote Set Point SignalLoss of Feedback Position SignalLoss of Command SignalLoss of Process Variable SignalProcess Variable HighProcess Variable LowSet Point Deviation HighSet Point Deviation LowCommand Low

7.2 FAULT HISTORYThis is a circular listing of the last 10 faults that have occurredin the actuator. The faults messages are preceded with anumber indicating where in the history each fault occurred. 0indicates the most recent error; a 1 is the error that occurredbefore error 0 and so on… The numbers increase as onelooks back into the fault history of the unit. A total of 10faults are stored. If this capacity is exceeded, the oldesterror is removed from the list and the most recent is addedto it

7.3 AMP TEMPThis is the current temperature of the unit in degrees C

7.4 ACT STATUSThis is a code to show the current state of the actuator.

7.5 ACT STARTSThis is the number of times since the last power up cyclethat the actuator has been moved in either direction. Thisvalue is not stored in permanent memory and is reset to zeroupon each Amplifier power cycle.

7.6 AMP STARTSThis is the number of times that the amplifier has beenpowered up. This count is saved in permanent memory.

7.7 SOFTWARE VERThis is the version number of the software that is currentlyloaded into the actuator. It is not user adjustable.

6.6.6 ENCODER INITNote this procedure invalidates the position configurationof the actuator. If performed improperly or incompletelythe changes will allow the actuator to run out of itsexpected range which could cause damage to the actuatorand/or to the devices to which it is connected. Thisprocedure should only be run in the event that the controlboard or feedback device has been replaced.

The GPSA is a precision actuator using a feedback device todetermine its position. The feedback devices are individuallycalibrated to the actuator in which they are used duringproduction at our factory. In the unlikely event that thecontrol board or feedback encoder needs to be replaced,they will need to be recalibrated as a pair. It is a simpleprocedure but it is important to ensure that once performed,the output position of the actuator is also recalibrated toensure safe and proper operation on the unit.

Selecting Enter will start the encoder recalibration procedure.The operator will then be asked if they want to recalibratethe encoder. If Enter is selected, the user will then be asked“ARE YOU CERTAIN”. Again, selecting Enter will proceedwith the calibration. The user is then directed to run theactuator to its center position. The arrow knob will positionthe actuator. The plate covering the output shaft should beremoved by unscrewing the 6 screws which hold it in place.Adjust the actuator so that the position indicator knob on theoutput shaft aligns with the middle two screw holes that heldthe cover plate in place. Up until this point (before thisselection of Enter), Cancel may be selected and no changewill be made to the actuator. Once the unit is positionedproperly selecting Enter will calibrate the encoder to theactuator’s center position. A flashing message is thendisplayed to remind the operator that they must recalibratethe output position of the unit. The encoder is nowcalibrated and the cover plate should be replaced.

IMPORTANT: It is now required to recalibrate the actuatorsoutput position via either the Zero-Span or Characterizecalibration procedures. Failure to recalibrate the actuatorsoutput position could cause damage to the actuator and/or tothe equipment to which it is connected.

6.6.7 INVERT DISPThis parameter allows the display and the Knob functions tobe “inverted” should the actuator be installed in a way thatwould result in the display being upside down. Setting thisparameter to YES will rotate the display 180 degrees.

6.6.8 LANG SELECTThis parameter selects the display language used by theactuator. A selection of English, Spanish, French or Germanmay be chosen.

SOFTWARE SETUP

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CONTROL SCHEMES (see page 12)

Command Signal

(Input #1)(Position)

Controller

Actuator Drive

Valve

Open Loop

GPSA Controller(Positioner Mode)

Actuator Output

Actuator Internal Position Feedback

Process Variable

Feedback(Input #2)

Controller

Actuator Drive

Valve

Closed Loop

GPSA Controller(Process Control

Mode)

Actuator Output

Local or Remote

PV Setpoint(Input #3)

PVSensor

Process Variable

Process Variable

Feedback(Input #2)

Controller

Actuator Drive

Valve

Feed Forward

GPSA Controller(Process Control

Mode)

Actuator Output

Local or Remote

PV Setpoint(Input #3)

PVSensor

Process Variable

Command Signal

(Input #1)

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TROUBLESHOOTING GUIDETrouble Possible Cause Remedy

Actuator will not power up. No display. a. No or low input power.b. Unit wired incorrectly.

a. Verify input power is between 100 and 240 Vac.b. Reference wiring diagram and ensure unit is wired properly.

Unit will not respond to command input.a. Command is wired to incorrect input.b. Command signal is configured incorrectly.c. Incorrect control mode is selected.

a. Ensure command is wired to appropriate input.b. Ensure proper command signal is configured (mA or Volts) through S1-S3.c. Ensure the correct control mode is selected.

Unit will not stroke to desired location.

a. Incorrect command signal sent.b. Calibration of actuator is incorrect.c. Actuator is physically prevented from moving to desired location.

a. Verify that the correct command signal is being sent.b. Repeat calibration procedure to ensure proper calibration.c. Ensure there are no mechanical interferences within the valve.

Actuator chatters in operation. Approaching the maximum output thrust of the actuator. Determine the cause of the excessive load and remove.

Actuator hunts in operation.a. Command signal is oscillating.b. Noise is present on command signal.c. Process variable is driving changing actuator position.

a. Verify command signal is not oscillating. Determine cause if present.b. Verify proper shielding is present, check for noise on command signal.c. Monitor the process variable feedback to determine if it is inducing the change.

Actuator delays before responding to a command change. CMD DAMP parameter is set to high. Verify the CMD DAMP parameter is set correctly.

Relay signal not received at control.a. Relay not configured to trip on desired event.b. Wiring to relay is incorrect.c. Unit is not in condition to trigger event.

a. Verify proper software event configuration.b. Verify correct wiring.c. Verify unit is in condition to trigger event.

Inputs not responding to discrete signals.a. Input not configured to trip desired event.b. Wiring to input is incorrect.c. Input is not present.

a. Verify proper trigger event for input.b. Verify unit is wired correctly.c. Verify input is present.

Position transmitter is not functioning.a. Loop/Internal power mode is incorrectly configured. S4 is incorrectly set.b. Unit is wired incorrectly.

a. Verify proper power mode is configured through S4.b. Reference wiring diagram and ensure unit is wired properly.

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www.rotork.com

UK head officeRotork Controls Limitedtel Bath 01225 733200fax 01225 333467email mail@rotork.co.uk

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As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change.

For the very latest version release, visit our website at www.rotork.com

The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and produced in the UK by Rotork Controls Limited. POWSH0808

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