Rexa Manual x2 Iom 10-2014

Installation and Operation Manual
for the REXA Series 2 Xpac

IOM10/2014
Original Instructions
ISO 9001:2008
REXA ElectraulicActuation
Serial #____________________________
Model #___________________________
Application________________________
Tag # _____________________________
REXA
4 Manley Street
W. Bridgewater, MA 02379
(P) 508.584.1199
(F) 508.584.2525
Contents
FUNDAMENTAL SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . XI
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
When to Lock-Out/Tag-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Procedures: Lock-Out/Tag-Out. . . . . . . . . . . . . . . . . . . . . . . . . xvi
Education and Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
PRODUCT COMPLIANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIX
INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
ATEX Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . xxi
Declaration of Noise Emission. . . . . . . . . . . . . . . . . . . . . . . . . . xxii
Waiver of Translations Agreement. . . . . . . . . . . . . . . . . . . . . . xxiii
Waiver of Mains Supply Disconnect / Emergency Stop
Agreement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 About Rexa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Factory Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Actuator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
Figure 1.3 ID Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.1 Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 1.3.1 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Build Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4.1 Recommended Fluids and Lubricants . . . . . . . . . . . . . . 5
1.4.2 Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1.4.2-1 Linear Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 1.4.2-2 Rotary Actuators & Drives . . . . . . . . . . . . . . . . . . . . . . 6
Table 1.4.2-3 CSA Temperature Ratings . . . . . . . . . . . . . . . . . . . . . . 7
1.4.3 Relative Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.5 Transportation and Storage. . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Monthly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.1 Oil Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.2 Standard Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 1.6.2-4 External Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 1.6.2-1 Add oil indication . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 1.6.2-2 Full oil indication . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 1.6.2-3 Oil Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.3 Accumulator Fail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 1.6.3 Reservoir Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REXA Series 2 Xpac Installation and Operation Manual 10/14
ii Contents
1.6.4 Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 1.6.4-1 Castrol EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 1.6.4-2 Fill Valve with cover. . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 1.6.4-3 Fill the oil gun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 1.6.4-4 Purge the air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 1.6.4-5 Oil Pump Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 1.6.4-6 Fill Valve with Schrader fitting. . . . . . . . . . . . . . . . . 15
1.6.5 Overfilling, Oil Weeping & Thermal Expansion . . . . . . . 16
1.6.6 Air Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6.7 Reservoir Purging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 1.6.7-1 Reservoir Purging Ports . . . . . . . . . . . . . . . . . . . . . . 17
Figure 1.6.7-2 Full Indicator OKflush with front face . . . . . . . . . 18
1.6.8 Hydraulic System Purging. . . . . . . . . . . . . . . . . . . . . . . 18
Figure 1.6.8-1 Extend/CW and Retract/CCW Ports . . . . . . . . . . . . . 19
Figure 1.6.8-2 Bleed Kit (PN: K09275) . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Tool Requirements (Power Module Only) . . . . . . . . . . . . . . . . 20
1.8 Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.8.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.8.2 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 1.8.2-1 B Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 1.8.2-2 C Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 1.8.2-3 D, & D Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 1.8.2-4 C &D Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.8.3 Control Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 1.8.3 Typical Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . 27
Table 1.8.3-1 Control Enclosure Terminal Blocks . . . . . . . . . . . . . . 28
Table 1.8.3-2 Actuator Terminal Blocks . . . . . . . . . . . . . . . . . . . . . 28
1.8.4 Operational Summary. . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 1.8.4-1 Hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 1.8.4-2 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 DELIVERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Unpacking System, Lifting. . . . . . . . . . . . . . . . . . . . . . .
2.4 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Operational and Maintenance Clearances. . . . . . . . . . .
2.4.2 Hazards Due to Height. . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
32
32
32
32
33
3 ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Enclosure Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1 Control Enclosure Installation. . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 3 Electrical Installation Block Diagram . . . . . . . . . . . . . . . . . 36
3.2 Main Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 3.2 Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 3.2 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
iii
3.2.1 Supply Disconnect Device . . . . . . . . . . . . . . . . . . . . . . 38

3.2.2 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.3 Grounding Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.4 Main Power Supply Wiring. . . . . . . . . . . . . . . . . . . . . . . 40
3.2.5 Cordage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.6 Fuse Identification/Replacement . . . . . . . . . . . . . . . . . 42
3.3 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Feedback Cable (Stepper & Servo Motor Units) . . . . . . . . . . 44
Power Module Cable (Stepper Motor Units). . . . . . . . . . . . . . 44
Heater/Solenoid Cable (Servo Motor Units Only). . . . . . . . . . 45
Motor Resolver Cable (Servo Motor Units Only). . . . . . . . . . . 45
Motor Power Cable (Servo Motor Units Only) . . . . . . . . . . . . 46
Booster Cable (D,P9 and D,P40 Units Only). . . . . . . . . . . . . . 46
D,P9 (REXA P/N #P97117). . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
D,P40 (REXA P/N #P97882) . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.1 Cable Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 3.3.1 Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.2 Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Conduit and Conduit Fittings. . . . . . . . . . . . . . . . . . . . . . . . . 48
4 MECHANICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Pre-Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2 R Series (Rotary). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.1 Rotary Mounting (Fail in Place). . . . . . . . . . . . . . . . . . . 51
4.2.2 Rotary Mounting (Universal Spring Fail). . . . . . . . . . . . 52
Figure 4.2.2 Solenoid Override Position . . . . . . . . . . . . . . . . . . . . . . 52
4.2.3 Rotary Mounting Accumulator. . . . . . . . . . . . . . . . . . . 53
4.3 L Series (Linear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3.1 Linear Mounting (Fail in Place) . . . . . . . . . . . . . . . . . . . 55
4.3.2 Linear Mounting (Spring Fail) . . . . . . . . . . . . . . . . . . . . 56
Figure 4.3.2 Solenoid Override Position . . . . . . . . . . . . . . . . . . . . . . 57
4.3.3 Linear Mounting Accumulator. . . . . . . . . . . . . . . . . . . . 57
4.4 D Series (Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.1 Drive Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 4.4.1 Drive Base Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.2 Drive Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 4.4.2-1 Drive Arm Assembly Reference Drawing . . . . . . . . . 59
Figure 4.4.2-2 Drive Arm Alignment . . . . . . . . . . . . . . . . . . . . . . . 60
5 START-UP CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Inspection of Electronic Sub-Assembly Installation. . .
5.1.2 Inspection of Mechanical Actuator Installation. . . . . . .
5.2 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Lateral Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
61
61
62
62
63
iv Contents
5.2.2 Longitudinal Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 63

5.3 Initial Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.4 Rotary and Drive Spring Stops . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 5.4 Universal Spring Alignment . . . . . . . . . . . . . . . . . . . . . . 66
5.5 Cylinder End Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 5.5 Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5.1 End Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 5.5.1-1 Cylinder End Stops . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 5.5.1-2 End Stop Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Table 5.5.1 Stroke Adjustor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.5.2 R200000/R400000 End Stroke Adjustments. . . . . . . . 70
Figure 5.5.2 R200000/R400000 Stroke Adjuster . . . . . . . . . . . . . . 71
6 MODES OF OPERATION & CONTROL PARAMETERS . . . . . . . . . 72
Figure 6 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1 Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1.1 Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 6.1.1 Control Parameter Menus . . . . . . . . . . . . . . . . . . . . . . 74
6.1.2 Changing a Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.1.3 CALIBRATE Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1.4 CONTROL Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1.5 SPEED/ACCEL Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 6.1.5 Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hi Accel {High Acceleration}: Drive Type = Step . . . . . . . . . . 82
Hi Accel {High Acceleration}: Drive Type = Servo . . . . . . . . . 82
6.1.6 INPUTS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.1.7 DRIVES Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.1.8 OUTPUTS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1.9 CURRENT STATS Menu and
HISTORIC STATS Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.2 Auto Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2.1 Display Fields in Auto Mode. . . . . . . . . . . . . . . . . . . . . 99
6.2.2 Display Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.2.3 Parameter Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3 Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 6.3 Contacts Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A. MECHANICAL LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1.2 Linear Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.1.3 Linear Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Figure A.1 Linear Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.2 Rotary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.2.1 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . A-4
Figure A.2 Rotary Limit Switch Schematic . . . . . . . . . . . . . . . . . . A-5
A.2.2 Rotary Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

A.2.3 Rotary Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Figure A.2.3 Rotary Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . A-6
B. STEM CONNECTION & SEAT LOADING METHODS . . . . . . . . . B-1
B.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B.2 Elastic Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Figure B.2-1 Preloaded Coupling . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Figure B.2-2 Rated Load Coupling . . . . . . . . . . . . . . . . . . . . . . . B-2
B.3 Seat Loading Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Figure B.3 Seat Loading Cylinder . . . . . . . . . . . . . . . . . . . . . . . . B-3
B.3.1 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . B-4
B.3.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Table B.3.2 SLC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Figure B.3.2 SLC Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . B-5
B.4 Solenoid Auto-Seating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
B.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Figure B.5-1 SLC IndicatorSeated . . . . . . . . . . . . . . . . . . . . . . . B-7
Figure B.5-2 Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
C. ACCUMULATOR FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1.1 Trip Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Figure C.1.1-A Trip Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
C.1.2 Recharge Function. . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Figure C.1.2-B Recharge Condition . . . . . . . . . . . . . . . . . . . . . . . C-3
C.2 Accumulator Control Parameters. . . . . . . . . . . . . . . . . . . . C-4
DRIVES Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C.3 Recharging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
C.4 Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Figure C.4-1 Solenoid Manual Override Levers (Position A) . . . . . C-5
Figure C.4-2 Solenoid Manual Override Levers (Position B) . . . . . C-6
C.5 Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Figure C.5 Bypass Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
D. BOOSTER PUMP CONFIGURATION. . . . . . . . . . . . . . . . . . . . . .
D.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.2 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.2.1 Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.3 Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D.4 Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-1
D-1
D-1
D-2
D-2
D-2
E. PULSE OPERATING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

E.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
E.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Figure E.2-1 Contact Input Board Wiring Options . . . . . . . . . . . . E-2
Figure E.2-2 Contact Input Board Wiring Options . . . . . . . . . . . . E-2
E.3 Signal Input Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
vi Contents
ON state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OFF state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E.4 Pulse Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . .
E.5 Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-3
E-3
E-3
E-4
F. ERRORS AND ERROR DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . .

FB bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CS bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dir error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drv fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+15 fail or -15 fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pres bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pres low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Op Pres bad or Cl Pres bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Over Temp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slc Fb bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slc stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key bad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mem fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No inp bd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/D fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-1
F-1
F-2
F-2
F-2
F-3
F-3
F-3
F-4
F-4
F-4
F-5
F-5
F-5
F-6
F-6
F-6
F-7
G. SURGE CONTROL OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

G.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Figure G.1-1 Overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Figure G.1-2 Target position . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
Figure G.1-3 Undershoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
G.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
G.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Figure G.3-1 Surge Solenoid Connection . . . . . . . . . . . . . . . . . . .G-5
Figure G.3-2 Solenoid & Wet Trip Connection . . . . . . . . . . . . . G-6
Figure G.3-3 Solenoid & Dry Trip Connection . . . . . . . . . . . . . . G-7
H. BUILD NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Linear Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Rotary Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3
Electronic Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . H-4
Mounting Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Linear Series Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Rotary Series Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Drive Series Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Linear Fisher Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
K. FIELDBUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
Resource block: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-2
vii
Analog Output block (AO). . . . . . . . . . . . . . . . . . . . . . . . . . . K-2

Analog Input blocks (AI). . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3
Discrete Output block (DO). . . . . . . . . . . . . . . . . . . . . . . . . . K-4
Discrete Input block (DI). . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4
Transducer block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-5
X2 Actuator Configuration Parameters. . . . . . . . . . . . . . . . . K-5
Other X2 actuator parameters:. . . . . . . . . . . . . . . . . . . . . . . K-8
ERROR_BYTE1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-10
ERROR_BYTE2:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11
ERROR_BYTE3:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11
X2 Actuator Data Collection Parameters. . . . . . . . . . . . . . K-11
M. MANUAL OPERATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
M.1 Declutchable Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . M-1
Figure M.1-1 Handwheel Assembly . . . . . . . . . . . . . . . . . . . . . . . M-2
Figure M.1-2 Drill Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2
Figure M.1-3 Drill Drive with Drill . . . . . . . . . . . . . . . . . . . . . . . . . M-2
M.1.2 Declutchable Drill Drive . . . . . . . . . . . . . . . . . . . . . . M-2
M.2 Manual Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
Figure M.2 Manual Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . M-4
M.3 Fail Safe Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . M-4
Figure M.3 Solenoid Manual Override Levers (Position B) . . . . . . . M-5
N. DIGITAL COMMUNICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1
N.1 HART Field Device Specification. . . . . . . . . . . . . . . . . . . N-3
1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6
1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6
1.2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-6
1.3 Who should use this document?. . . . . . . . . . . . . . . . . . N-6
1.4 Abbreviations and definitions. . . . . . . . . . . . . . . . . . . . . N-6
1.5 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7
2. Device Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7
3. Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-7
4. Product Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8
4.1 Process Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8
4.2 Host interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-8
4.3 Local Interfaces, Jumpers And Switches . . . . . . . . . . . N-8
5. Device Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9
6. Dynamic Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9
7. Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9
7.1 Device Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-9
7.2 Additional Device Status (Command #48). . . . . . . . . . N-10
8. Universal Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-12
8.1 Supported Commands. . . . . . . . . . . . . . . . . . . . . . . . . N-12
9. Common-Practice Commands . . . . . . . . . . . . . . . . . . . . . . N-21
viii Contents
9.1 Supported Commands. . . . . . . . . . . . . . . . . . . . . . . . . N-21

9.2 Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-27
10. Device-Specific Commands . . . . . . . . . . . . . . . . . . . . . . . N-27
10.1 Supported Device Specific Commands. . . . . . . . . . . N-27
11. Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-28
12. Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29
12.1 Sampling Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29
12.2 Power-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29
12.3 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29
12.4 Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-29
12.5 Command Response Times. . . . . . . . . . . . . . . . . . . . N-30
12.6 Delayed-Response. . . . . . . . . . . . . . . . . . . . . . . . . . . N-30
12.7 Non-Volatile Memory. . . . . . . . . . . . . . . . . . . . . . . . . N-30
12.8 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30
12.9 Write Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30
12.10 Damping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-30
ANNEX A. Capability Checklist. . . . . . . . . . . . . . . . . . . . . . . . N-31
ANNEX B. Hart Interface Board Connection. . . . . . . . . . . . N-32
O. OUTPUT LOAD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
O.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
O.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
Table O.2 Adjustment Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-1
Figure O.2 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . O-2
O.3 Adjustment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-3
O.4 Spring Change: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-3
P. INTERCONNECT DIAGRAMS
& CONTROL ENCLOSURE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . P-1
D97904 Stepper Wiring Diagram . . . . . . . . . . . . . . . . . . . . . P-2
B Quick Connect Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
C Quick Connect Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
D97904-.5d D Servo Wiring Diagram. . . . . . . . . . . . . . . . . P-5
D Quick Connect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
D97904-D D Servo Wiring Diagram. . . . . . . . . . . . . . . . . . . . P-7
D Quick Connect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8
D97904-2D 2D Servo Wiring Diagram. . . . . . . . . . . . . . . . . . P-9
D97904-P9 D,P9 Servo Wiring Diagram . . . . . . . . . . . . . . . P-10
D97904-P40 D,P40 Servo Wiring Diagram . . . . . . . . . . . . . P-11
D97904-STEPACCUM Stepper with Accumulator Fail Opt. . P-12
D97904-.5DACCUM D Servo with Accumulator Fail Opt. . P-13
D97904-DACCUM D Servo with Accumulator Fail Opt . . . . . P-14
D97904-2DACC 2D Servo with Accumulator Fail Opt . . . . . . P-15
D97904-P9ACC D,P9 Servo with Accumulator Fail Opt. . . . P-16
D97904-P40ACC D,P40 Servo with Accumulator Fail Opt. . . P-17
ix
B and C-Pump Control Enclosure Drawing . . . . . . . . . . . . . .

P98492 Control Enclosure for Quick Connect Cables . . .
D and D-Control Enclosure Drawing (QCC) . . . . . . . . . . . . .
D and D-Pump Control Enclosure Drawing . . . . . . . . . . . . .
2D & DP9 Control Enclosure Drawing . . . . . . . . . . . . . . . . . . .
DP40 Control Enclosure Drawing. . . . . . . . . . . . . . . . . . . . . . .
P-18
P-19
P-20
P-21
P-22
P-23
Q. CONTACT INPUT OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1

Contact Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1
Q.1 Signal Input Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1
ON state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2
OFF state:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2
Q.2 1 Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-2
Figure Q.2-1 1 Cont Dry Input Board . . . . . . . . . . . . . . . . . . Q-3
Figure Q.2-2 1 Cont Wet Input Board . . . . . . . . . . . . . . . . . . Q-4
Q.3 2 Cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-4
Figure Q.3-1 2 Cont Dry Input Board . . . . . . . . . . . . . . . . . . Q-5
Figure Q.3-2 2 Cont Wet Input Board . . . . . . . . . . . . . . . . . . Q-6
R. REMOTE MANUAL CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . R-1
R.1 Remote Manual (RemoteMan). . . . . . . . . . . . . . . . . . . . . . . R-1
Figure R.1-1 Dry Contacts Input Board . . . . . . . . . . . . . . . . . . . R-2
Figure R.1-2 Wet Contacts Input Board . . . . . . . . . . . . . . . . . . R-3
S. SAFETY MANUAL FOR ESD SIL COMPLIANCE. . . . . . . . . . . . . S-1
S.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Figure S.1 Example Safety Instrumented Function . . . . . . . . . . . . . s-2
S.2 System Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
S.3 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
S.4 Safety Critical Components . . . . . . . . . . . . . . . . . . . . . . . . S-3
S.5 System Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-3
S.6 Site Acceptance Test Procedures. . . . . . . . . . . . . . . . . . . . S-4
S.7 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . S-5
T. POSITION TRANSMITTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1
T.1 Position Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2
Figure T.1-1
Figure T.1-2
Passive Position Transmitter Connections . . . . T-3

Active Position Transmitter Connections . . . . . T-4
U. ELECTRONIC RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1

U.1 Limit Switch Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1
U.2 Alarm and Warning Relay. . . . . . . . . . . . . . . . . . . . . . . U-1
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-2
Figure U-1 CPU Boards Electronic Relays . . . . . . . . . . . . . . . . . . U-3
V. LOCAL MODE INDICATION BOARD. . . . . . . . . . . . . . . . . . . . . . . V-1
Local Mode Indication Board. . . . . . . . . . . . . . . . . . . . . . . . . . . V-1
Figure V-1 Local Mode Indication Board . . . . . . . . . . . . . . . . . . . V-2
x Contents
W. ELECTRONIC UNIT RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . W-1

Table W-1 Electronic Unit Ratings . . . . . . . . . . . . . . . . . . . . . . . . W-3
X. REDUNDANT CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . X-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
X.1 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2
X.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2
X.2.1 User Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-2
X.2.2 Redundant Interconnections. . . . . . . . . . . . . . . . . . . . X-3
X.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-3
X.4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-4
X.5 CPU Set Up for MAIN and Backup. . . . . . . . . . . . . . . . . . . . X-4
X.6 Simultaneous CALIBRATE . . . . . . . . . . . . . . . . . . . . . . . . . . X-4
X.7 AUTO Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-6
X.8 Redundant High Speed Solenoids for Spring Fail Operation. . X-6
Figure X. Redundant Unit Interconnection Diagram . . . . . . . . . . . X-7
xi
Fundamental Safety Information
REXA actuators all produce extremely high forces, have hydraulic lines under
pressure and have dangerous electrical power input levels. In addition to these
standard characteristics, optional actuator constructions possess other hazards
such as coil and disk springs under compression and high pressure accumulator
bottles.
WARNINGS
Based on these hazards, the following could occur if this safety information is
not observed:

Serious physical injury
Death
Damage to actuator or other equipment
Always observe the safety information listed in this documentation.
Safety Considerations
xii
WARNING LABELS
Hazardous Voltage
Turn Off and Lock Out system power before servicing. Do Not
Operate this equipment from any power source that does not
match the voltage rating stamped on the equipment. Refer to
the manufacturers identification nameplate for operational
requirements.
General Warning
Refer to Installation Manual before servicing.
Attention
Important information provided. Do No Use this equipment for
any purpose not described in this manual.
Crush or Pinch Point Hazard
Turn Off and Lock Out system power before servicing.
Warn of Actuator movement if Spring Fail Unit.
Guard Warning
All Guards MUST be in place before operation. Failure to do so
may result in injury or damage to equipment.
Tripping, Slipping and Falling Hazards
These hazards can be avoided by cleaning spilled hydraulic oil in
a timely manner.

Airborne noise greater than 80 dB, ear protection suggested.
Using the actuator for uses other than what it is intended may result in
injury or death. Use the Actuator for its intended purpose ONLY.
Do not use the Actuator should it be damaged in shipping or installation.

Contact REXA, Inc.
REXA Series 2 Xpac Installation and Operation Manual 09/11 xiii
RESIDUAL RISKS
This section is to help identify the risks associated with the Actuator System.
These items are identified as:
ACTUATOR & DRIVEN DEVICE CONNECTION:
The point at which the actuator couples to the driven device poses
the risk of injury due to pinch or crush point. Use appropriate
Lock-Out/Tag-Out procedures when connecting Actuator to the
driven device.
MANUAL OVERRIDE HANDWHEEL ASSEMBLY:
The Manual Override Handwheel Assembly is to remain declutched until it is required. The Motor Shaft Cover MUST be in
place during normal operation. Failure to do so poses a risk of
injury.
MANUAL OVERRIDE HANDWHEEL ASSEMBLY:
When the Manual Override, Handwheel Assembly is used, adhere
to proper Lock-Out/Tag-Out procedures.
FEEDBACK COVER:
Feedback Cover MUST be in place during operation. Failure to do
so may result in injury. Use proper Lock-Out/Tag-Out procedures
before accessing feedback housing.
SHOCK HAZARD:
Wire Cover must be in place during operation. Use proper LockOut/Tag-Out procedures before removing cover.
SHOCK HAZARD:
Control Enclosure Cover must be closed during normal operation.
Failure to do so may result in injury. Use proper Lock-Out/Tag-Out
xiv
procedures before accessing Control Enclosure.

SHOCK HAZARD:
Hazardous voltage levels are present in the actuator. Only qualified
service and installation personnel should install or adjust this
device.
ALIGNMENT:
Ensure that the actuator shaft is in line with the valve plug stem.
Misalignment could damage the actuator and driven device or
cause injury to installation personnel.
AVOID ACCIDENTAL STARTING:
When installing the actuator, insure that line power to the unit is
shut off. When power is applied, the actuator may immediately
respond to the control signal. Inadvertent motion could damage
the actuator and driven device or cause injury to installation
personnel.
IMPORTANT:
When machining the control enclosure, thoroughly clean any metal
chips or residue from the enclosure before applying power.
HYDRAULIC OIL:
The standard oil used in REXA actuators or drives is Castrol
EDGE SAE 5W-50 motor oil. The introduction of other fluids may
cause damage to the unit.
SPRING UNDER TENSION:
REXA actuators, denoted by an E, R or U as the last character in
the model number, contain a spring under tension. Failure to
properly remove this force before disassembly can cause serious
injury to maintenance personnel. Contact REXA for disassembly
REXA Series 2 Xpac Installation and Operation Manual 09/11 xv
instructions.
RELIEVING INTERNAL PRESSURE:
When the electric power is off or the motor is not turning, hydraulic
pressure remains locked within the cylinder and/or accumulator.
This internal pressure must be relieved before disconnecting any
hydraulic fitting. Open the bypass cylinder (3/16 hex) located on
the power module for fail in place units and manually override all
solenoid valves that are closed.
Note: Reservoir lines may contain up to 60 psi (4 bar) that cannot be relieved.
Note: Accumulators will still contain up to 2000 psi (138 bar) of nitrogen gas that
cannot be relieved.
ACCUMULATOR FAIL OPTION:

REXA actuators denoted by an A as the last character in the model
number contain an accumulator charged with high-pressure
nitrogen. These actuators also have an automatic recharging cycle
for the accumulator. Failure to properly follow installation
instructions may cause serious injury to maintenance personnel
and/or damage to equipment.
NPT PLUG and CONDUIT CONNECTIONS:

During assembly, Loctite 767 compoundor its
equivalentmust be used on threads of all NPT plug and
conduit connections to ensure a watertight seal.
WHEN TO LOCK-OUT/TAG-OUT
Lock-out/Tag-out before servicing.
Most equipment is installed along with safe switches allowing the equipment
to be disabled for minor repair. In general, these switches provide adequate
xvi
protection for minor repair, which is routine, repetitive, and necessary to the
normal use of the equipment. Lock-Out/Tag-Out procedures shall be used for
the following situations.

Major repairs or overhaul.
When working alone, out of visual contact of the controlling switch.
Anytime there is danger of injury from an unexpected release of energy.
Any situation that threatens an employees safety.
Note: Always follow local & plant procedures.
PROCEDURES: LOCK-OUT/TAG-OUT
The following are minimum recommended procedures to be followed for
Lock-Out/Tag-Out:
1. Notify all affected areas and employees of the impending Lock-Out situation,
the reason for it, and estimated start and duration times.
2. Equipment shutdown and isolation: Place all switches in the off or
safe position. Disconnect sources of power, ensuring all sources of
both primary and secondary power to the equipment are interrupted.
3. Dissipate residual energy. Shutting down equipment does not mean
there is no energy left in it. Check for trapped pressure, compressed
spring or residual electricity in the system.
4. Lock-Out or Tag-Out all in-line points of control. In most cases, there
may be more than one place, or more than one lock, if several people
are working on the equipment.
5. Lock-Out verification: Take nothing for granted. Verify that the lockedout switch or control cannot be overridden. Test the equipment to
be certain that the locked-out switch is de-energized, and not simply
REXA Series 2 Xpac Installation and Operation Manual 09/11 xvii
malfunctioning. Test all control points and modes to be sure that the
equipment does not start.
6. Perform the work scheduled. Try to foresee all possible hazards. Ensure the new/repair work does not bypass the Lock-Out and reactivate
the system.
7. Lock and/or tag removal. All locks and tags are to be left in place
until all work is completely finished. This is especially true when more
than one employee is working on the equipment. A lock is never to be
removed except by the person who placed it there.
8. Equipment start-up. Make a final safety check before restarting equipment, to be certain it is safe to operate. Make sure of the following:
a) All tools and other items have been removed.
b) All machine guards are returned to their proper position. All electric,
hydraulic, pneumatic or other systems are properly reconnected.
c) All employees are clear of equipment.
Many of the Lock-Out/Tag-Out procedures appear to be common sense, and
they are. Following them will ensure safe operation calibration, maintenance
and repair of equipment and/or processes, without dangerous surprises or
injury.
EDUCATION AND DISCIPLINE

The key to worker safety is education. The purpose of this document is for
everyone to understand the importance of Lock-Out/Tag-Out and how to
recognize when it is in use. By educating all employees to the importance of
following proper safety procedures, we ensure a safer working environment. As
with all safety procedures, a fair uniform enforcement of discipline must be in
place. Employees are responsible for their own safety, the safety of their fellow
employees and the safety of the facility.
xix
Product Compliance
INFORMATION
Inclusion of the following symbols indicates that the supplied REXA actuator
complies with applicable standards:
For the U.S. and Canada: A CSA mark with the indicators C and
US means that the product is certified for both the U.S. and
Canadian markets, to the applicable U.S. and Canadian standards.
The REXA Actuator/Drive with Control Enclosure is certified by
CSA for use in General Locations per EN 61010-1 and for Hazardous Locations Class 1, Division 2, Groups A, B, C and D or Class
1, Division 1, Groups C and D.
mark indicates that the product is certified for European

markets, and complies to the standards listed in the
Declaration of Conformity.
Product Compliance
xx
Product Compliance
EC DECLARATION OF CONFORMITY
ACCORDING TO:
MACHINERY DIRECTIVE 2006/42/EC
EMC DIRECTIVE 2004/108/EC
PED DIRECTIVE 97/23/EC (APPLIES WHERE APPLICABLE)
We, REXA, Inc.,
Hereby declare under our sole responsibility, the following products to be in compliance
by design according to the relevant essential health and safety requirements and harmonized standards mentioned. The Technical File may be produced by our EU representative below. In case of alteration of the product, not agreed upon by us, this declaration
will lose its validity.
Manufactured:
4 Manley Street
West Bridgewater, MA 02379 USA
EU Authorized Representative:
Koso Kent Introl Limited
Armytage Road
Brighouse, West Yorkshire HD6 1QF
Contact: Brian Richmond (QHSE Director)
or Jonathan Lodge (Technical Director)
Telephone: +44(0)1484 710311
Fax: +44(0)1484 407407
Brand Name:
(REXA)
Product Description: X-Pac and X2 Series Electraulic (Self-Contained Electro-Hydraulic)

Actuator and Drive Systems
Models:
Linear, Rotary and Drive Units

Servo or Stepper Units
Applicable Directives:
Machinery Directive 2006/42/EC including Low Voltage Directive
EMC Directive 2004/108/EC
PED Directive 97/23/EC; applies where applicable, to accumulator
systems
Applicable Harmonized Standards:
Health/Safety: Machinery Directive 2006/42/EC Annex I, EN60204-1:2006, EN ISO
12100:2010, EN61310-1:1995, EN61310-2:1995, EN ISO 13850:2006,
IEC61010-1:2001
EMC:
EN61326-1:2006, EN61000-6 Part -2:2005 and -4:2007; EN55011:2007:

IEC61000-4-2:2008, IEC 61000-4-3:2010, IEC61000-4-4:2010,
IEC61000-4-5:2005, IEC61000-4-6:2008, IEC61000-4-8:2009,
IEC61000-4-11:2004
PED:
Directive 97/23/EC; designed as Sound Engineering Practice

Equipment
xxi
ATEX DECLARATION OF CONFORMITY

ACCORDING TO: DIRECTIVE 94/9/EC
We, REXA, Inc.,
Hereby declare under our sole responsibility, the following products to be in compliance
by design according to the relevant essential health and safety requirements and
harmonized standards mentioned. The Technical File may be produced by our EU
representative below. In case of alteration of the product, not agreed upon by us, this
declaration will lose its validity.
Manufactured:
4 Manley Street
West Bridgewater, MA 02379 USA
Armytage Road
Telephone: +44(0)1484 710311
Fax: +44(0)1484 407407
Brand Name:
(REXA)
Product Description: X-Pac and X2 Series Electraulic (Self-Contained Electro-Hydraulic)

Actuator and Drive Systems
Models:
Designation:
Linear, Rotary and Drive Units

Servo or Stepper Units
II 3G EEx nA II T3
-40C Ta 65C
Applicable Directives: ATEX Directive 94/9/EC

Machinery Directive 2006/42/EC including Low Voltage Directive
EMC Directive 2004/108/EC
PED Directive 97/23/EC; applies where applicable, to accumulator
systems
Applicable Harmonized Standards:
Health/Safety: ATEX Directive 94/9/EC including Annex I and II; Machinery Directive
2006/42/EC Annex I, EN60204-1:2006, EN ISO 12100:2010, EN613101:1995, EN61310-2:1995, EN ISO 13850:2006, IEC61010-1:2001
EMC:
EN61326-1:2006, EN61000-6 Part -2:2005 and -4:2007; EN55011:2007:

IEC61000-4-2:2008, IEC 61000-4-3:2010, IEC61000-4-4:2010,
IEC61000-4-5:2005, IEC61000-4-6:2008, IEC61000-4-8:2009,
IEC61000-4-11:2004
ATEX:
EN50021:1999
PED:
Directive 97/23/EC; designed as Sound Engineering Practice

Equipment
Product Compliance
xxii
Product Compliance
DECLARATION OF NOISE EMISSION

The REXA, Incorporated Model REXA Electraulic Actuator System Sound Pressure Levels
per EN ISO 11202 is as follows:
Model No: As above
Serial No: On Nameplate
Year of Construction: 2011
Operating
Idle
LpAm (Operator Position)
81 dB (A)
66 dB (A)
LpAm (Bystander Position)
84 dB (A)
67 dB (A)
Peak C-weighted instantaneous SPL in the

Operators position LpC peak
88 dB (c)
Sound power emitted where the equivalent

continuous A-weighted SPL exceeds 80 dB (A).
8.8 Bel
The average difference between the extraneous

noise level and the sound intensity level at each
measuring point is:
LpAm = 16 dB (A)
Ambient Correction Factor K3A calculated

according to EN ISO 11204 Appendix A.
4 dB (A)
Measurements were made at a height of 1.5 m and 1 m from the Operator Position and all
four sides of the equipment.
The figures quoted are emission levels and are not necessarily safe working levels. While
there is a correlation between the emission and exposure levels this cannot be used reliably
to determine whether or not further precautions are required.
Factors that influence the actual level of exposure of the workforce include characteristics
of the work room, the other sources of noise, etc. such as the number of machines and
other adjacent processes. Also, the permissible level of exposure can vary from country to
country.
This information, however, will enable the user of the machine to make a better evaluation
of the hazard and risk.
KOSO America
4 Manley Street
West Bridgewater, MA 02379
USA
xxiii
WAIVER OF TRANSLATIONS AGREEMENT

We, REXA, Inc.,
Hereby declare exclusion of the responsibility at the time of sale to provide translated
documentation of REXA products. This includes and is not limited to the following
documents:

Installation and Operation Manual (IOM)
Interconnect, layout and wiring schematics and drawings
Technical Service and Repair Manual
This document also waives the responsibility of translations of the following system
components and markings:

Human Machine Interface (HMI Keypad Display) textual read-out of system

parameters and status display
Modification of keypad display symbols to ISO characters
Internal labeling and identification symbols and statements
Individual wire and component marking identification is not required. The fully
assembled factory wired panel is only serviced by REXA personnel and not
the end user. However, end user terminations are readily identified.
Translations of the above mentioned may be made by the end user and/or the authorized
representative listed on this document. Any of which may be translated must bear the
statement Translation of Original Instructions within the document(s) header or footer.
Armytage Road
Telephone: +44(0)1484 710311
Fax: +44(0)1484 407407
Product Compliance
xxiv
Product Compliance
WAIVER OF
MAINS SUPPLY DISCONNECT / EMERGENCY STOP
AGREEMENT
We, REXA, Inc.,
Hereby declare it the responsibility of the installer of this equipment to provide a suitable
disconnect for the Control Panel supplying power to the system.
The disconnect must:

Be suitable for the Voltage and Full Load Ampere Rating of all downstream
equipment supplied by the Panel;
The supply disconnecting device shall be one of the following types:

o Switch-disconnector with fuses, in accordance with IEC 60947-3,
utilization category AC-23B or DC-23B
o As above, except one that has an auxiliary contact that in all cases
causes switching devices to break the load circuit before the opening of the main contacts of the disconnector.
o A circuit breaker suitable as an isolation device per IEC 60947-2
o Any other switching device in accordance with an IEC product
standard that also meets the isolation requirements of IEC 60947-1
and is appropriate for on-load switching of the largest motor or
other inductive loads;
Be approved for use as a disconnect for the country in which the system is
installed.
Be provided with a Lock-Out/Tag-Out capability in the Off (Down)

position.
The Handle must be RED in color to indicate it is suitable as an E-Stop

device.
If assistance is required in specifying an appropriate device, please contact our engineering
department for recommendations.
REXA Series 2 Xpac Installation and Operation Manual 08/14 1
1 General Information
1.1 ABOUT REXA

REXA is located in West Bridgewater, Massachusetts, USA. We manufacture,
sell and service the highest quality actuators and drives. The driving force of
these units is a self-contained electrically driven hydraulic pumping system, thus
the term Electraulic is coined. This Installation and Operation Manual is part
of REXAs continuing commitment to supply only the highest quality products
and services to our customers. Customer support is our top priority at REXA.
Please contact the factory if this manual or your Sales Representative fails to
provide required information.
1.2 FACTORY SUPPORT

REXA is a full service company. We have a fully staffed service department with
factory trained and certified service personnel for both factory and on site repair.
For repair, service, sales, warranty or parts order, you may contact the factory at
the following:
General Information
General Information
REXA
4 Manley Street
West Bridgewater, MA 02379
Phone: (508) 584-1199

Fax: (508) 584-2525
Web: www.rexa.com
Note: It is important to have the model code and build number for both the
electronics and the actuator in addition to the serial number for the actuator so we
can provide better service.
This information can be found on the metal tags on the actuator and on the front
panel of the electronics. Reference the sections below on Actuator Identification
for more detailed explanation.
1.3 ACTUATOR IDENTIFICATION

The model number, mechanical build number, electronics build number and
serial numbers are all used to identify an individual actuator and electronics.
The model number will provide a general description of the actuator and
electronics as a set. These numbers also provide the information required to
correctly define what sections of this manual applies to a particular actuator.
The build number provides more detailed information of the components used in
the construction of the actuator. Finally the serial number will allow the factory
to determine any special considerations or features your actuator may have that
make it unique.
Since most applications are custom, this is the only identification that fully
allows us to identify the unit. The factory requires these numbers whenever
service or information is requested. Supplying the model, both mechanical and
electrical build numbers, and the serial number will ensure the quickest and
most accurate response to your request. These numbers can be found on the
ID tags located on the actuator and on the serial tag on the electronics. Figure
1.3 shows a typical ID tag.
Figure 1.3 ID Tag
General Information
General Information
1.3.1 Model Number

The basic model number is a generic description of the actuator. Figure 1.3.1
shows a break down of the model number tree and how it works.
MODEL NUMBER
X2__
__ __ __ __ __ __ __ __-__

Thrust
Torque
Stroke

Rotation
Spring Fail Option

(Upon Power Loss)
Series 2
L Series Xpac Linear
R Series Xpac Rotary
D Series XPac Drive
R or D SERIES
L SERIES
Torque
Rotation
(lbfin) (degrees)
Thrust
(lb)
Strokes
(in inches)

2000

4000

5000
10000
15000
20000
30000
40000
50000
60000
80000
120000
.75, 2, 4 6, 8, 11
.75, 2, 4
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22
.75, 2, 4, 6, 8, 11, 16, 22

2500

5000
10000
20000
50000
100000
200000
400000
90, 120
90, 120
90, 120
90, 120
90, 120
90, 120
90, 120
90, 120
C1: CSA-Class 1, Div 1

Actuator Only
P: None Lock in Place
U: Universal (Rotary)
Actuator and Electronics
E: Extend (Linear)
R: Retract (Linear)
Actuator Only, Class 1, Div 2
A: Accumulator Failure
Electronics Only
C6: CSA- Class 1, Div 1
Actuator and Electronics
Power Modules
CA: CSA-Class 1, Div 2
B: Single B
Actuator Only
C: Single C
D: Single D
D: Single D
2C: Dual C Manifold
2D: Dual D Manifold
D,P9: Booster Pump
D,P40: Booster Pump
Model Numbers Examples:

X2L4000-4-C-P
Is a Linear L Series 2 Xpac with 4000 lb of thrust, stroke adjustable up to 4
inches, and C size power module. Lock in position upon loss of power.
X2R2500-90-B-U
A Rotary R Series 2 Xpac with 2500 lbfin of torque, rotation adjustable to
90 degrees, and B size Power module. Spring failure upon loss of power.
Figure 1.3.1 Model Number
Hazardous Area Code
1.3.2 Serial Number

Serial numbers are assigned to every job at REXA. Job specific information
as well as sales and engineering information are stored under a specific serial
number. A typical serial number will look like: C060000. The C06 indicates
the year of manufacture and the next four digits correspond to the unique order
number.
1.3.3 Build Number

The build number is a catalog number we use to designate in complete detail
the construction of the actuator. From this number all configurations can be
defined. There are two different categories of build numbers; one is for the
mechanical sub-assembly, and the second is for its corresponding electronics
sub-assembly. Within the mechanical sub-assembly there is a build number for
Rotary and Drive actuators, and a separate build number for Linear actuators.
The build numbers are shown in Appendix H.
1.4 GENERAL SPECIFICATIONS

1.4.1 Recommended Fluids and Lubricants
Intended Use
Specifications
Operating fluid, all REXA Actuators Castrol EDGE

SAE 5W-50 Motor Oil*
Anti-Seize Compound
Bostik Never-Seez or equivalent
O-ring Lubricant
Parker Super-O-Lube or equivalent
Thermal Grease
Thermalcote or equivalent
Molybdenum Disulfide Grease
Mobilgrease XHP 222 or equivalent
Parts Cleaner
ZEP BRAKE WASH or equivalent
Note: In special applications the type of oil used is system dependant and the user
should refer to the system documentation.
General Information
General Information
1.4.2 Operating Temperatures

The following is a general guideline; refer to Technical Memo TM19-2 for further
information.
Temperature Range
Table 1.4.2-1 Linear Actuators

Actuator
Construction
Type L Linear
Cylinder
Type C Linear
Cylinder
Installation
Requirements
Electronics
Temp. Range
Motor Type
Standard
High Temp.
-5F to +200F
-30F to +200F
-76F to +200F
-5F to +250F
(-20C to +93C)
(-34C to +93C)
(-60C to +93C)
(-20C to 121C)
+10F to +200F
-10F to +200F
-76F to +200F
-5F to +250F
(-12C to +93C)
(-23C to +93C)
(-60C to +93C) (-20C to 121C)
1
inch
thermal
Heat
tracing & 1 inch
None
None
insulation2
thermal insulation2
Separate Control Enclosure with CPU, motor driver, power supply, transient protection
and termination.
-40F to +140F (-40C to +60C)
-40F to +120F (-40C to +50C)
Stepper
Servo
1. High ambient temperatures affect oil viscosity which may affect actuator rated output.
2. These items are not supplied by REXA.
Temperature Range1
Table 1.4.2-2 Rotary Actuators & Drives

Actuator
Construction
Type R Rotary
or D Drive
Cylinder
Installation
Requirements
Electronics
Temp. Range
Motor Type
Standard
+10F to +200F
-10F to +200F
High Temp.
-76F to +200F
-5F to +250F
(-20C to
+121C)
Optional
Standard oil &
1 of thermal
Heat tracing & 1
High Temp.
cartridge heater
insulation2
therm2
Construction
Separate Control Enclosure with CPU, motor driver, power supply, transient protection
and termination.
-40F to +140F (-40C to +60C)
-40F to +120F (-40C to +50C)
Stepper
Servo
(-12C to +93C)
(-23C to +93C)
(-60C to +93C)
1. High ambient temperatures affect oil viscosity which may affect actuator rated output.
2. These items are not supplied by REXA.
Table 1.4.2-3 CSA Temperature Ratings

Power
Module
Operating Temperatures
Actuator
T-Code
Electronics
Duty*
Notes
Actuator/Elec Cycle
B 115V
-40F to +150F (-40C to +65C) -40F to +140F
(-40C to +60C)
T3/T3C
S1
B 230V
-40F to +150F (-40C to +65C) -40F to +104F
(-40C to +40C)
T3/T3C
S8
24V B
-40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3/T3C
S1
48V B
-40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/T3C
S1
24V C
-40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/TC3
S1
C 115V
-40F to +150F (-40C to +65C) -40F to +140F
(-40C to +60C)
T3/T3C
S1
C 230V
-40F to +150F (-40C to +65C) -40F to +104F
(-40C to +40C)
T3/T3C
S8
2C 115V
-40F to +150F (-40C to +65C) -40F to +140F
(-40C to +60C)
T3/T3C
S1
.5D 115V -40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/T3C
S1
.5D 230V -40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/T3C
S1
-40F to +150F (-40C to +65C) -40F to +131F
(-40C to +55C)
T3C/T3C
S1
-40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/T3C
S1
-40F to +150F (-40C to +65C) -40F to +150F
(-40C to +65C)
T3C/T3C
S1
2D
-40F to +150F (-40C to +65C) -40F to +131F
(-40C to +55C)
T3C/T3C
S1
D,P9**
-40F to +140F (-40C to +60C) -40F to +122F
(-40C to +50C)
T3C/T3C
S8
1, 3
D,P40**
-40F to +140F (-40C to +60C) -40F to +122F
(-40C to +50C)
T3C/T3C
S8
2, 3
D 230V
Dual .5D
115V
Dual .5D
230V
Notes
1. Duty cycle for D,P9 PM motor is S1, booster motor will remain S8.
2. Duty cycle for D,P40 PM motor is S1, booster motor will remain at S8.
3. CSA duty cycle tested at 31.8% for continuous operation at maximum load and speed.
4. Uses internal 240 to 120 Vac step-down transformer P98246.
5. Uses 48 Vdc to 72 Vdc converter.
6. Uses 24 Vdc to 165 Vdc converter.
**
Exclude from CSA Class 1, Div. 1, Groups C & D.
S1
Duty: Duty cycle S1 is defined as continuous operation at load.
General Information
General Information
S8
Duty: Duty cycle S8 is defined as periodic duty with rest period between operation, variable load/speeds.
*Duty Cycle definitions taken from IEC 60034-1 applies to all rotating electrical machines.
1.4.3 Relative Humidity

The equipment will operate correctly within an environment at 50% RH, +40C
(+104F). Higher RH may be allowed at lower temperatures.
Measures shall be taken by the Purchaser to avoid the harmful effects of
occasional condensation.
1.4.5 Transportation and Storage

This equipment will withstand, or has been protected against, transportation and
storage temperatures of 25C (13F) to +55C (+131F) and for short periods
up to +70C (+158F).
It has been packaged to prevent damage from the effects of normal humidity,
vibration and shock.
1.5 MAINTENANCE SCHEDULE

The REXA actuator requires minimal routine maintenance consisting primarily of
visual inspections. However, as with any mechanical device, components will
wear out. The frequency of use and the operating conditions are both factors
that will dictate the maintenance schedule. For additional information refer to
TM9-2. The following is a recommended list of visual inspections and their
frequency.
Note: With time and experience, a predictable schedule of maintenance and
replacement of seals may be developed.
Monthly
Check the oil indicator for proper oil level. Add oil if necessary following
the instructions in section 1.6.4. When oil is added, a visual inspection of
the actuator is needed to determine where the loss of oil occurred and the
necessary repair required.
Note: Ambient temperature swings will affect the oil indicator position.
Quarterly
Perform a visual inspection of the actuators for damage, oil leakage, obstruction
and hazards. Repair items found damaged during this inspection in accordance
with company procedures. During this inspection, check the following items at
a minimum:
Mounting hardware and fasteners are tight
Oil level is correct
Tubing and fittings are tight
Tubing is not touching or rubbing
Power module fasteners are tight
Actuator can hold position without re correcting
Oil leaks
Spring washer stack for damage (not all models)
Check for moisture ingression or contaminants under the feedback
housing, wire cover and in the electronics enclosure
Ground wire connectivity
Ensure the feedback signal on the actuator is stable
Inspect wiring for cuts, abrasions or tears
General Information
10
General Information
1.6 OIL
The REXA Xpac Actuator is a sealed, self-contained, hydraulic positioning
system in which oil is pumped from one side of a double acting cylinder to the
other. An internal oil reservoir provides a source of make up oil for thermal
expansion and is an integral component within the module. As the size of
the actuator cylinders increase so does the need for additional make up oil,
therefore larger systems will have external reservoir bottles in addition to the
standard internal reservoir.
A closed-loop hydraulic system means that the oil in the actuator is isolated
from the environment and immune to degradation with time as a result of
exposure to moisture and other atmospheric elements. Since the hydraulic
system is sealed and spring-loaded, it is also unaffected by the orientation in
which the actuator is applied.
A periodic, visual inspection of the REXA Xpac Actuator is required in order to
verify that the hydraulic system has not been compromised for any reason. Any
external signs of a major oil leak or repeated refilling of the unit will indicate
damage to the actuator that will require servicing of the unit and investigation for
a cause.
1.6.1 Oil Level Inspection

1.6.2 Standard Units
There is a reservoir indicator on the actuator body located on the same face as
the motor shown in Figures 1.6.2-11.6.2-3. It is used to display the oil level
within the actuator. The indicator is a silver rod with a scale beside it reading
HOT, OK and ADD. As the unit cools down and heats up the indicator
will move in and out. At 70F the indicators ideal position will be in the middle
of the OK region. The unit may be indicating near the ADD limit if the
ambient temperature is lower and will indicate in the HOT region if the ambient
temperature is elevated. The reservoir volume has been sized for 110F
temperature swings. Reference Figures 1.6.2-1 through 1.6.2-3 showing the
different indication levels.
Figure 1.6.2-1 Add oil indication
Figure 1.6.2-2 Full oil indication
11
Figure 1.6.2-3 Oil Expansion
Larger units will require additional make up oil and an external reservoir will be
plumbed in series with the internal reservoir. The internal reservoir will still show
the oil level however there is also an indicator rod in the external reservoir. At an
ambient condition of 70F it should be protruding out approximately 3- inches
as measured from the base of the bushing shown in Figure 1.6.2-4.
Figure 1.6.2-4 External Reservoir
General Information
12
General Information
1.6.3 Accumulator Fail

In an accumulator fail unit the reservoir contains oil for thermal expansion and
also provides oil to charge the accumulator system. There are two different style
accumulator reservoir bottles used depending on the size of the system. The
first type uses a visual indicator rod as shown in Figure 1.6.2-4 and is typically
used on smaller units. As the reservoir volume needs increase, a gas pressurized
reservoir bottle is used and a pressure gauge is provided (Figure 1.6.3) to show
the oil level.
Figure 1.6.3 Reservoir Gauge

In order to check the level of the oil in an accumulator system you must locate
the Auxiliary Reservoir Settings label shown below. This can be found on the
reservoir bottle.
Auxiliary Reservoir Settings
With the accumulator fully discharged, the accumulator
pressure gauge must read 0 PSI. Fill until Indicator Extension is
XXX "
Auxiliary Reservoir Settings

With the accumulator fully discharged, the accumulator
pressure must read 0 PSI. Fill until Reservoir pressure is
XXX 5 PSI
WARNING: Adding oil to the unit without verifying the

Accumulator is at 0 PSI before filling will cause damage
And potential injury or Death.
When accumulator is full @ XXX PSI. The indicator

Extension should be @ XXX "
WARNING: Adding oil to the unit without verifying the

Accumulator is at 0 PSI before filling will cause damage
And potential injury or Death.
When accumulator is full @ XXX PSI. The reservoir

Pressure should be @ XXX 5 PSI
13
1.6.4 Filling
If the addition of oil is required, it should be filled with Castrol EDGE SAE
5W-50 motor oil (Figure 1.6.4-1). In special applications the type of oil used is
system dependant and the user should refer to the system documentation. The
actuator does not need to be taken out of service when adding oil.
Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.
Figure 1.6.4-1 Castrol EDGE

REXA Xpac Actuators are filled through a standard Schrader-style Fill Valve
located on a face of the Reservoir Assembly. Use any oil gun equipped with a
Schrader-style fitting. The mating half of a Schrader-style fitting can be obtained
at any auto parts store, purchased through a REXA Sales Rep, or purchased
directly from REXAs Inside Sales Office. The following steps will guide a user to
successfully fill a REXA Xpac Actuator with oil:
NOTE: DO NOT OVERFILL THE RESERVOIR. While overfilling will not harm the
actuator on non-accumulator units, overfilling will force oil from the Thermal Expansion
Valve. Overfilling will also promote oil weeping from the relief valve due to thermal
expansion. If an accumulator unit is over filled, the reservoir can be over pressurized
and catastrophic seal damage can occur.
PROCEDURE (9 steps):
General Information
14
General Information
1. Locate and Remove the fill valve cover (Figure 1.6.4-2).
Figure 1.6.4-2 Fill Valve with cover.

2. Fill the oil gun with oil (Figure 1.6.4-3).
Figure 1.6.4-3 Fill the oil gun.

3. To purge any air out of the oil gun, line and fitting; first, pump the handle
a few times until the lever gets firm (Figure 1.6.4-4).
Figure 1.6.4-4 Purge the air.

4. Depress the small valve in the center of the Female Schrader fitting (on
15
the oil Pump) with a suitable device like a small screwdriver or punch
until you get clean, air-free oil (Figure 1.6.4-5).
Figure 1.6.4-5 Oil Pump Valve.

5. Attach the oil fill gun to the actuators Schrader fitting (Figure 1.6.4-6).
Figure 1.6.4-6 Fill Valve with Schrader fitting.

6. Add oil until the indicator is in the OK section of the scale (Figure
1.6.2-2). Reference the reservoir labels for correct filling of Accumulator
units.
7. Remove the oil gun from the Fill Valve.
8. Re-install the fill valve cover.
9. Drain and store the Fill Gun in a clean place for future use.
General Information
16
General Information
1.6.5 Overfilling, Oil Weeping & Thermal Expansion

All REXA Xpac Actuators contain a Thermal Expansion Valve located next to
the Schrader-style Fill Valve. If an actuator is overfilled with oil, it should be
expected that oil will purge out of the Thermal Expansion Valve. Simply wipe-off
whatever oil may be purged.
The Thermal Expansion Valve is built into every REXA Xpac Actuator in order to
allow the actuator to relieve the Thermal Reservoir of excess oil pressure due to
thermal expansion. Thermal expansion refers to the volumetric changes a fluid,
such as oil, experiences given changes in environmental temperature.
It is not uncommon to discover trace amounts of residual oil collected around
the Thermal Expansion Valve of an actuator if the unit has been overfilled.
This residual oil is typically the result of oil weeping from the relief valve as
the ambient temperature increases causing the oil to expand. As previously
mentioned, the actuator is a closed-loop hydraulic system, and any increase in
oil volume will be purged. On large oil volume actuators REXA adds an external
auxiliary reservoir in order to compensate for the greater volume of oil that may
expand due to increases in ambient temperature.
If the temperature is lowered, the reservoir indicator will retract as the oil volume
decreases. Oftentimes, users will mistake the indicator retraction as a sign
that the actuator has lost oil due to a service issue. If a user adds oil to the
actuator at this time, oil will likely purge out of the Thermal Expansion Valve
upon an eventual rise in ambient temperature. It is when oil is evidently leaking,
or collected in large amounts somewhere on, or dripping off, a REXA Xpac
Actuator that a service-related issue is likely, and oil filling is needed. For this
reason, we ask users to perform periodic inspections with ambient temperature
changes in mind.
1.6.6 Air Purging

As previously noted, all REXA Xpac Actuators are characterized by a closedloop, hydraulic system that is responsible for their distinguished reputation
as being unmatched in rigidity, precision and control. This is, in part, due to
17
the advantages of using hydraulics in place of pneumatic actuation. Air is a

compressible medium that results in many inherent disadvantages, such as poor
control and rigidity, when used in actuation.
In light of these facts, it is obvious that the presence of any air in the closedloop hydraulic system of a REXA Xpac Actuator is extremely disadvantageous
and detracts from performance of the actuator. Certain repair and replacement
procedures will involve exposing the internal hydraulic system to the outside
environment and may introduce unwanted air to the system. The presence of air
in the hydraulic system is likely to cause problems such as unstable positioning.
For this reason, whenever the closed-loop hydraulic system of a REXA
Xpac Actuator is opened to the atmosphere, it is imperative that necessary
steps are taken to remove any air from the system. When purging a REXA
Xpac Actuator of air, there are two main areas of concern: the reservoir, and the
hydraulic system.
1.6.7 Reservoir Purging
Figure 1.6.7-1 Reservoir Purging Ports

1. It is important to first identify if the reservoir has entrapped air. This
can be done by pressing in on the reservoir indicator. If it does not feel
stiff, there is air in the reservoir system.
Note: Be aware of external reservoirs or additional modules; press evenly on all
reservoirs to check for entrapped air.
General Information
18
General Information
2. Depending on the orientation of the actuator the highest purge point on

the module must be identified, as any entrapped air will migrate to the
highest point. Purge Port 1 and Purge Port 2 (Figure 1.6.7-1) are both
at corners of the reservoir volume and most likely will be the highest
points.
Note: Some modules will have auxiliary reservoirs attached and plugged ports
on those reservoir may be the highest points.
3. Slowly unthread the highest purge point fastener and have an oil catch
pan ready. It may not be necessary to fully remove these plugs as air
will purge out with a few threads still installed.
4. Retighten the plug before proceeding.
5. Refill to the correct oil level.
Note: Some actuator orientation will not allow for proper purging and the actuator
may need to be removed and re-orientated for purging, then re-installed. The
best position for purging is with purge port 1 facing up.
Figure 1.6.7-2 Full Indicator OKflush with front face
1.6.8 Hydraulic System Purging

NOTE: It is important to purge the reservoir before continuing.
To purge the actuator of air, it is recommended that you use the REXA bleed kit
(P/N: K09275) See Figure 1.6.8-2 for details.
19
1. Change the Max Man Spd to 30% or less. (Refer to section 6.1.5.)
2. Open the manual bypass to relieve internal pressure. (Refer to C.5.)
NOTE: Some units can have a solenoid instead of a manual bypass; ensure that
the solenoid is open before proceeding. (Refer to section 1.8.4.)
3. Locate the best available pressure ports to bleed air from the system.
The best position is the highest point that is accessible and will allow air
to escape the system. Keep in mind that the porting may be located on
the module, cylinder, manual hydraulic pump or SCL, etc.
4. Attach the REXA bleed kit (Figure 1.6.8-2) to the open ports Extend/CW
and Retract/CCW. Follow the hydraulic lines to differentiate between
pressure direction (Figure 1.6.8-1).
Figure 1.6.8-1 Extend/CW and Retract/CCW Ports

5. Run the actuator through its full stroke constantly pumping oil into the
reservoir. Do not let the reservoir run dry, or you will need to purge
the reservoir and start over.
General Information
20
General Information
Figure 1.6.8-2 Bleed Kit (PN: K09275)
1.7 TOOL REQUIREMENTS (Power Module Only)

All these common tools may be required during installation and maintenance.
Flashlight
Set of Flat Tip Screwdriver
Standard Set of Allen Wrenches Set of Combination Wrenches
Set of Picks
12 Channel Lock Pliers
3
16 Nut Driver
3 8 Nut Driver
Snap Ring Pliers
Needle Nose Pliers
Wire Strippers
Wire Cutter
Crimper
Digital Volt Meter
Oil Gun with Schrader Fill Assembly
Soft Blow Hammer
21
1.8 THEORY OF OPERATION

1.8.1 Overview
The REXA Xpac is a microprocessor controlled, self-contained, Electraulic
(electro-hydraulic) actuator or drive designed specifically for modulating service.
Hydraulic, electronic and mechanical technologies are combined to achieve
REXAs state-of-the-art line of actuators.
The patented Flow Match System is simply described as a highly efficient
method of pumping hydraulic fluid (motor oil Castrol EDGE SAE 5W-50) from
one side of a double acting cylinder to the other. Once the correct position
is reached, the motor shuts off. Power is not required to maintain actuator
position. The hydraulics are controlled by a dedicated microprocessor
contained within the control enclosure. Software designed for the Xpac allows
the user to set actuator operation parameters.
Note: Although Castrol Edge oil is recommended, oil of equal quality may be used.
The Xpac consists of two major components, the actuator (cylinder, feedback
and Electraulic power module) and the control enclosure. The actuator is installed
on the driven device, while the enclosure is remotely mounted. Connecting the
actuator and enclosure are the module cable and the feedback cable.
1.8.2 Actuator
The heart of the actuator is the Electraulic Power Module. Consisting of a motor,
gear pump, flow match valve (FMV), make-up oil reservoir, heater, thermostat
and bypass solenoid (spring fail units only), the Power Module delivers oil
at a nominal 2000 psi to a hydraulic cylinder. Four different size modules, B,
C, D and D, are available meeting hazardous area but non-explosion proof
requirements. For applications requiring hazardous area and explosion proof
approvals, two different power modules, C and D are available. The major
functional difference between the sizes is pumping volume and thus, the
maximum stroking speed of an actuator.
The B and C modules are driven with a stepper motor and therefore have a
slower frequency response then the D series modules which are driven with
General Information
22
General Information
servo motors. More detailed information on the frequency response and flow
rates can be found in product/technical memos. The only visible difference
among all 4 sizes of modules is the motor.
There are three types of hydraulic cylinders. On smaller size linear actuators
(thrust of 10000 lb or less and strokes of 6 inches or less), the L series cylinder
is manufactured from a solid block of aluminum. Larger size C series cylinders
are made of a fabricated tie-rod construction. The third type, used on rotary
(series R) and drive (series D) units, is a rack and pinion rotary design.
A position sensor, provides feedback position to the control electronics. The
feedback assembly is sealed in a NEMA 4X cover and mounted within or
adjacent to the cylinders. The connection of the position sensor is by direct
mechanical means.
The B and C modules shown in Figure 1.8.2-1&2 are the two sizes of stepping
motor modules. They both have cylindrical motor cases. The motor case
lengths are depicted in Figure 1.8.2-1&2 for module identification purposes.
With the exception of pump and motor size, these two modules share many of
the same components so both modules will be depicted on one rebuild diagram
for each of the applicable service sections.
Figure 1.8.2-1 B Module
23
Figure 1.8.2-2 C Module
General Information
24
General Information
The 1/2D and D modules shown in Figure 1.8.2-3 are the two sizes of servo
motor modules. They both have square case motors. The motor case lengths
are depicted in Figure 1.8.2-3 for module identification purposes. Again, with
the exception of pump and motor size, these two modules share many of the
same components so both modules will be depicted on one rebuild diagram for
each of the applicable service sections.
1/2D-Module
D-Module
Figure 1.8.2-3 D, & D Module
25
The C and D explosion proof modules shown in Figure 1.8.2-4 are two sizes
of power modules offered for applications requiring hazardous area and
explosion proof approvals. The motor case lengths are depicted in Figure
1.8.2-4 for module identification purposes. With the exception of pump, motor
size, and cover, these modules share many of the same componenets as the
non-explosion proof modules so both modules will be depicted on one rebuild
diagram for each of the applicable service sections.
C- Module
D-Module
Figure 1.8.2-4 C & D Module
General Information
26
General Information
1.8.3 Control Sub-Assembly

The control sub-assembly consists of the enclosure, Central Processing Unit
(CPU), Power Supply, Motor Drivers, Main Power Transient Suppression, and a
termination area.
The control sub-assembly also provides the user interface. The enclosure
mounted 2-line x 20 character/line Vacuum Fluorescent Display (VFD) and 5
button keypad will be the point for setup and calibration of the actuator as well
as visual feedback of actuator status. The Keypad and Display can be optionally
mounted inside the Control Enclosure should the installation warrant it.
The CPU consists of a microprocessor, an Analog-to-digital (A/D) converter, an
isolated 4-20 mA Position Transmitter, Electronic (PhotoMOS) limit switches,
as well as warning and alarm relays. The CPU will also accept optional I/O
interface boards.
The power supply develops DC voltages from the incoming AC Power. The
DC voltages, +5, +15, -15 and +24 Vdc, provide power to the CPU, actuator
feedback circuit, the optional interface boards as well as optional loop supply
(+24 Vdc) for the Position Transmitter.
The motor driver is the component that supplies power to the motor. It can
either be a DC Stepper Motor Driver or an AC Servo Motor Driver, depending
on the model actuator. The motor driver accepts command signals from the
CPU and provides DC Step Pulses (Stepper Motor) or Pulse Width Modulated
(PWM) DC Voltage (Servo Motor) to the module mounted motor to drive it in one
direction or the other. There is one motor driver for each power module.
Field wiring is terminated inside the control enclosure. Refer to Tables 1.8.3-1
and 1.8.3-2 for Terminal Block ratings.
27
Figure 1.8.3 Typical Control Enclosure

Standard Painted-Steel Enclosure Specifications
For Single Module Actuators:
UL 508 Types 12, 4
CSA Type 12, 4
Complies with NEMA Type 12 and 4
IEC 529, IP66 Construction

Refer to Appendix P for dimensions and alternative construction.
General Information
28
General Information
Table 1.8.3-1 Control Enclosure Terminal Blocks

MECHANICAL
Termination Torque
10 lbfin Max.
Operating Temperature
-40F to +221F
(-40C to +105C)
MATERIAL
Contact
Brass, Tin Plated
Screw
#6-32, Combo Head, with

SEMS Washer
Insulator Body
Polycarbonate, UL 94V-0,
Black
ELECTRICAL
Voltage Rating
300 Vac
Current Rating
20 Amp
Wire Range
12-24 AWG
Table 1.8.3-2 Actuator Terminal Blocks

MECHANICAL
Termination Torque
12 lbfin Max.
Operating Temperature
-40F to +250F
(-40C to +125C)
MATERIAL
Contact
Copper Alloy
Screw
Screw M3, Slotted
Insulator Body
Polyamide PA, UL 94V-2,

Gray
ELECTRICAL
Voltage Rating
300 Vac
Current Rating
20 Amp
Wire Range
10-28 AWG
29
1.8.4 Operational Summary

The CPU converts an incoming control signal into a target position. The current
position is determined through the feedback assembly mounted on the actuator.
The difference between the target and current position is the error. If the error
exceeds the user set deadband then the CPU will initiate corrective action by
starting the motor.
A reversible hydraulic pump is driven by the motor. The pump can pressurize
either side of a double acting cylinder through one of two sides of the Flow
Matching Valves, FMV-1 and FMV-2. Each FMV side is comprised of a ported
spool with an integral pilot operated check valve.
In the example in Figure 1.8.4-1; to move the cylinder piston to the left, the
pump turns in the direction to pressurize FMV-2 through port A2. The spool in
FMV-2 becomes unbalanced by the pressure differential and moves to the left,
lifting its check valve, opening port D2 to port B2 and port A2 to port E2.
High pressure fluid flows through Port E2 to the right side chamber of the
cylinder. Since the hydraulic circuit is closed, the same amount of oil that flows
into the right side of the piston must be extracted from the left side. This allows
oil movement without an active reservoir. This oil flows through the open check
valve of FMV-2 and into pump suction.
By rotating the pump in the opposite direction, the FMVs operate in reverse to
move the cylinder piston to the right. When the pump stops, both check valves
close, and the hydraulic oil is locked within the cylinder. Motor operation is not
required to maintain position.
Figure 1.8.4-1 Hydraulic schematic

General Information
30
General Information
Each actuator has an internal hydraulic bypass circuit. This circuit creates a
direct connection from one side of the hydraulic cylinder to the other. It is useful
for relieving internal pressure in the actuator and allowing an external load to
move the actuator. The nut labeled bypass on the actuator face as shown in
Figure 1.8.4-2 controls this circuit. Turning this bypass in all the way puts the
unit in its normal operation. Turning the bypass out 1 to 2 turns will open this
bypass circuit.
Note: This bypass nut is only on units without internal solenoids.
Each pressure gauge on the actuator has its own on/off isolation valve (Figure
1.8.4-2). This valve should remain off unless pressure is being read from the
gauge. This will protect the gauge from constant cycling, thus extending its life.
When closing this valve you will create an internal pressure trap in the gauge;
therefore, you should not expect to see 0 psi when off.
Gauge
Gauge
CW Off
CCW On
CW Off
CCW On
Bypass
CW Off
CCW On
Figure 1.8.4-2 Bypass
31
2 Delivery
2.1 RECEIPT
REXA makes every effort to package products to avoid damage in shipping.
Upon receipt inspect the crate and make note of any physical damage. If severe
damage is present, then consideration should be given to rejecting the shipment
and contacting the shipping company concerning in-transit damage claims.
2.2 STORAGE
If the actuator and control enclosure sub-assemblies are not immediately
installed, provisions for storage must be made. The equipment should not
be removed from the original containers and should be protected from the
elements. The ambient environment must be:
Cleanno airborne particles or contaminants.
Non Corrosiveminute quantities of gases can concentrate in a
confined area.
Dryrelative humidity must be sufficiently low to prevent moisture
condensation on chilled metal components.
Temperaturerecommended storage temperature is between
10F 120F (12C 50C).
Delivery
32 Delivery
2.3 UNPACKING
The REXA Xpac actuator is shipped filled with oil and ready to be installed.
It has been operated, tested and thoroughly inspected. After removing the
actuator from the packaging, inspect it for any signs of mechanical damage
that may have occurred during shipping. Immediately report any damage to the
factory.
Compare the contents to the packing list included with every shipment.
Immediately report any discrepancies to the factory.
2.3.1 Unpacking System, Lifting

If a piece of the system weighs between 4079 lb (1836 kg), the
manual must tell the installer that a two-man lift is required.
If a piece of the system weighs between 80 lb and 129 lb (36 kg59
kg), a three-man lift must be used.
Above 129 lb (59 kg), a machine assist must be used (forklift
or crane)
2.4 INSTALLATION REQUIREMENTS

2.4.1 Operational and Maintenance Clearances

Volts to Ground
0600
Condition 1
900 mm (3 ft)
Exposed live parts are on one side and no live or grounded parts are on the
other side of the working space. Or, exposed live parts on both sides are
effectively guarded by wood or other suitable insulating materials. Insulated
wire or insulated busbars operating at not over 300 V to ground shall not be
considered as live parts.
33
2.4.2 Hazards Due to Height

Use Safety Harness when working aloft above 1.8 m and consult Plant
Safety Policy for safety consciousness and harness requirements.
Delivery
35
3 Electrical Installation
CONTROL ENCLOSURE OVERVIEW
The Block Diagram (Figure 3) on the following page gives a general overview of
the Control Enclosure and Actuator installation.
Note: Not all actuators will have all the options shown in Figure 3.
3.1 CONTROL ENCLOSURE INSTALLATION

The Control Enclosure must be mounted in a location conducive to its operation.
Ideally, it should be mounted in a Control Room environment. The Control
Enclosure rating is as follows:

General Locations (Standard):

Environmental: NEMA 4 and 12, IP 66
Ambient Temperature: 40 to +130F (-40 to +55C)

Optional Construction:

Hazardous Locations: CSA Class 1, Div. 2, Groups A, B, C & D,
T3
Available Units: All units in Table 1.4.2-3 are available

Protection Method: Non-Incendive (non-sparking), limitation of

surface temperatures

Ambient Temperature: 40 to +104F (-40 to +40C)

Hazardous Locations: CSA Class 1, Div.1, Groups C & D, T3

Available Units: All units in Table 1.4.2-3 are available except

D-P9 AND D-P40

Protection Method: Explosion Proof and Intrinsically Safe

Ambient Temperature: Refer to Table 1.4.2-3
Electrical Installation
Figure 3 Electrical Installation Block Diagram
37
It is necessary to verify the enclosure door is closed tightly

and any openings added are sealed to comply with the
ratings given above.
Note: Reaffirm with units tagging the Control Enclosures intended location.
3.2 MAIN POWER

The Main Power requirements for the Control Enclosure/Actuator vary according
to model. The Main Power requirements are given as part of the Nameplate
Information attached to the lower left corner of the control enclosure as shown
in Figure 3.2. If no control enclosure is used, the nameplate will be attached to
the backplane on which the Electronics is mounted.
Figure 3.2 Control Enclosure

In general, the Main Power requirements are given in Table 3.2; however, the
Nameplate rating takes precedence.
38
Table 3.2 Power Requirements

Module Size
Incoming Voltage*
Maximum
Current
Required
VA
Rating
B Module
115 Vac 10%, 50/60 Hz
4.0 amp
500
C Module
115 Vac 10%, 50/60 Hz
8.5 amp
1100
D Module
115 Vac 10%, 50/60 Hz
20.0 amp
2400
D Module
230 Vac 10%, 1, 50/60 Hz
10.0 amp
2400
2D Module
230 Vac 10%, 1, 50/60 Hz
20.0 amp
4800
D,P9
230 Vac 10%, 3, 50/60 Hz
25.0 amp
9000
D,P40
230 Vac 10%, 3, 50/60 Hz
50.0 amp
21000
* If another voltage is to be used, an External Step Up/Down Transformer of the

proper size must be used.
3.2.1 Supply Disconnect Device

To comply with IEC 61010-1, Safety Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use, a supply disconnect device with the
proper rating MUST be installed. The supply disconnecting device:
a) Shall disconnect (isolate) the Control Enclosure/Actuator from the
supply when required.
b) Shall be included in the building installation.
c) Shall be in close proximity and within easy reach of the Control
Enclosure.
d) Shall be marked as the disconnecting device for the equipment.
Refer to the Nameplate Rating of the Control Enclosure sub-assembly for proper
sizing of the required disconnect device.
It is the responsibility of the installer of this equipment to provide a suitable
disconnect for the Control Panel supplying power to this equipment.
This disconnect must:
39
Be suitable for the Voltage and Full Load Ampere Rating of all downstream equipment supplied by the Panel;
The supply disconnecting device shall be one of the following types:
(a) Switch-disconnector with fuses, in accordance with IEC 60947-3,
utilization category AC-23B or DC-23B.
(b) As above, except one that has an auxiliary contact that in all cases
causes switching devices to break the load circuit before the opening of
the main contacts of the disconnector.
(c) A circuit breaker suitable as an isolation device per IEC 60947-2.
(d) Any other switching device in accordance with an IEC product
standard that also meets the isolation requirements of IEC 60947-1 and
is appropriate for on-load switching of the largest motor or other inductive loads.
Be approved for use as a disconnect for the country in which this equipment is installed.
Be provided with a Lock Out Tag Out capability in the Off (Down) position.
The Handle must be RED in color to indicate it is suitable as an E-Stop
device.
3.2.2 Grounding
Protective Earth Ground
A dedicated Protective Bonding Conductor (Protective Earth, PE) must be
provided. The conductor must be connected to the terminal labeled PE or
Protective bonding provides protection against electrical shock and
should be provided at both Control and Actuator.
40
3.2.3 Grounding Symbols

Protective Earthing
Safety Earth Ground
Noise Free (EMI) Ground
Frame/Chassis Ground
3.2.4 Main Power Supply Wiring

It is the responsibility of the Installer of this equipment to supply suitable main
power supply wiring. Consult the Manufacturers Identification Nameplate
on the Machine to determine Voltage and amperage requirements when
determining the wiring size (mm2).
The supply wiring must be approved for use in the country in which this
equipment is installed or bear the <HAR> Mark.
A separate bi-color ground wire that is green in color with a yellow stripe
must be run in the hard-pipe conduit along with the supply wiring.
The conduit must be grounded in accordance with the National wiring
rules of the country where installed.
The fittings installed where the service wiring enters the body of the panel
must not reduce the panel Ingress Protection rating.
3.2.5 Cordage
It is the responsibility of the Installer of this equipment to supply a suitable
length of heavy duty supply cordage. It should meet the following requirements:
It must be approved for use in the country in which this equipment is
installed or bear the <HAR> Mark.
The maximum length of the cordage should not exceed the values
established by the National Electric Code of the country in which it is
installed.
41
The outer jacketing of the cordage should be rated for exposure to water,
oil and other similar substances.
The Voltage and Ampere rating of this equipment, as noted on the
Manufacturers Identification Label, should be consulted when selecting
the proper size (mm2) of the cordage.
A suitable industrial style attachment plug should be selected for connecting to the branch circuit. As an alternative, the end that terminates
at the building supply source may be permanently connected in accordance with local wiring rules.
The supply cordage should be routed to the Control Cabinet in a manner
that does not allow it to be stepped on, pinched, subject to abrasion,
excessive bending, become a trip hazard or subject to other abuse.
Refer to REXA interconnect drawings for details of interconnect cable
requirements.
42
3.2.6 Fuse Identification/Replacement

Unit
Description
Main Fuse (V, A, IR, Class)
Branch Fuse(s)
B, 115 Vac
600V, 5A, SCR 200k, Class CC
none
B, 230 Vac
none
B, 24 Vdc
DC/DC; 250V, 2A, SCR 100,1/4x1/4 TD Glass Tube

Heater; 250V, 8A, SCR 200, 1/4x1/4 TD Glass Tube
Solenoid; 250V, 5A, SCR 200, 1/4x1/4 TD Glass Tube
B, 48 Vdc

C, 115 Vac
none
Dual C, 115 Vac
none
C, 24 Vdc
600V, 50A, SCR 300k, Class J

D, 115 Vac
none
D, 230 Vac
none
Full D, 230 Vac
none
Dual D, 230 Vac 600V, 20A, SCR 200k, Class CC
none
D,P9, 230 Vac
none
D,P40, 230 Vac
D; 600VAC, 10A, SCR 200k, Class CC

P40; 600VAC, 35A, SCR 200k, Class J
24/48
Vdc
Power
Supply
115 V Power
Supply
230 V Power Supply
Power
Supply
Fuse
Location
Description
Voltage
(V)
Amperage
(A)
SC I/R
(A)
43
Type
Size
F1
Triple Power suuply
250
35
GMC
5 20mm
F2
24 Vdc Supply
250
35
GMC
5 20mm
GMA
5 20mm
A15QS
Form 101
GMA
5 20mm
5 20mm
4
8
F3
Contact Input Board
250
35
F4
Trip Solenoid
150
100000
F5
Fail Solenoid
250
35
F6
Fail Solenoid
250
35
GMA
F7
Heater
250
35
GMA
5 20mm
F8
Heater
250
35
GMA
5 20mm
F1
Triple Power suuply
250
35
GMC
5 20mm
F2
24 Vdc Supply
250
35
GMC
5 20mm
F3
Contact Input Board
250
35
GMA
5 20mm
F4
Trip Solenoid
150
100000
A15QS
Form 101
F5
Fail Solenoid
250
100
GMA
5 20mm
F7
Heater
250
100
GMA
5 20mm
Branch
Fuse
Protection
DC/DC; 250V, 2A, SCR 100, Time Delay Glass Tube
3.3 CABLES
Each Actuator and Control Sub-Assembly are interconnected by a set of cables.
These cables are supplied by REXA. The following will help you identify the
cables.
44
Feedback Cable (Stepper & Servo Motor Units)

The Actuator Feedback Cable carries the Actuator Feedback signal to
the Control Sub-Assembly. The Feedback Cable (REXA P/N #P96192)
specifications are:
Cable Type:
3 Conductors #18 AWG 16/30 STRANDED TINNED

COPPER
Insulation:
COLOR CODE
1. RED

2. WHITE

3. BLACK
Jacket: GRAY
Cable O.D.:
0.230-0.250
Feedback Cable must be shielded.
Power Module Cable (Stepper Motor Units)

The Stepper Motor Actuators use a Power Module Cable to interconnect
between the Control Sub-Assembly and Actuator. The Power modules
function is to transfer motor power, Heater Power and Solenoid Power. The
Power Module Cable (REXA P/N #P96191X2) specifications are:
Cable Type:
4 TWISTED PAIR, 1 TWISTED TRIAD, #16 AWG 19/29

STRANDED TINNED COPPER
Insulation:
COLOR CODE

PAIR 1 RED WITH RED/BLACK

PAIR 2 GREEN WITH GREEN/BLACK

PAIR 3 BLUE WITH BLUE

PAIR 4 YELLOW WITH YELLOW

TRIAD BROWN & BROWN & GREEN/YELLOW
Jacket: GRAY
Cable O.D.:
0.50-0.55
If not using Power Module Cable Supplied by REXA, it is
important that the motor power conductors be twisted pairs
to avoid adverse effects of radiated noise from the cable.
45
Heater/Solenoid Cable (Servo Motor Units Only)

The Servo Motor Actuator uses a Heater/Solenoid Cable to interconnect
between the Control Sub-Assembly and Actuator. The cable supplies
power to the Power Module heater and Fail Safe Solenoid (for Spring Fail
units). There is also a Ground Conductor. The Heater/Solenoid Cable
(REXA P/N #P97335-X2) specifications are:
Cable Type:
1 TWISTED PAIR, 1 TWISTED TRIAD
Insulation:

COLOR CODE
PAIR 1 BLUE WITH BLUE
TRIAD BROWN & BROWN & GREEN/YELLOW
Jacket: GRAY
Cable O.D.:
0.4-0.45
Motor Resolver Cable (Servo Motor Units Only)

The Servo Motor Actuator uses a dedicated Motor Resolver Cable to
interconnect between the Control Enclosure and Actuator. The cable
supplies motor speed and position feedback to the Servo Amplifier. The
Resolver Cable (REXA P/N #P96399) specifications are:
Cable Type:
Power Limited Tray Cable (PLTC), 20 AWG (7/28) stranded,

tinned copper conductors, twisted pairs, individually shielded
plus an overall foil shield (100% coverage), PVC jacket.
Pairs:
1. RED paired with BLACK

2. GREEN paired with BLUE

3. BROWN paired with WHITE

4. ORANGE paired with YELLOW
Characteristics: Voltage Rating: 300 Volts

Temp. Rating: -30 C to +105 C

Flammability: Passes UL VW-1 Flame Test UL Type TC

Sunlight Resistant

Direct Burial

Indoor/Outdoor Use
Cable O.D.:
0.41 Max.
Resolver Cable must be shielded.
46
Motor Power Cable (Servo Motor Units Only)

The Servo Motor Actuator uses a dedicated Motor Power Cable to interconnect between the Control Enclosure and Actuator. The cable supplies power to the Servo Motor. The Servo Motor Power Cable (REXA P/N
#P96402) specifications are:
Cable Type:
UL Type TC, (Tray Cable), 4 conductor, overall foil shield, #14

AWG 4130 stranded tinned copper with #14 AWG drain
wire pulled under foil tape.
Conductors: 1. ORANGE
2. GRAY
3. BLUE
4. GREEN
Characteristics: Voltage Rating: 600 Volts

Temp. Rating: -30 C to +90 C

Flammability: Passes UL VW-1 Flame Test UL Type TC

Sunlight Resistant

Direct Burial

Indoor/Outdoor Use
Cable O.D.:
0.61
Motor Power Cable must be shielded.
Booster Cable (D,P9 and D,P40 Units Only)

The Booster Pump actuator uses a dedicated cable to interconnect
between the Control Enclosure and Booster Pump motor.
D,P9 (REXA P/N #P97117)

Cable Type:
4 CONDUCTOR, OVERALL FOIL SHIELD, 10 AWG
Insulation:

COLOR CODE
1. ORANGE
2. BLUE
3. GRAY
4. GREEN
Jacket: GRAY
Cable O.D.:
0.60-0.65
47
D,P40 (REXA P/N #P97882)

Cable Type:
4 CONDUCTOR, OVERALL FOIL SHIELD, 8 AWG
Insulation:

COLOR CODE: Black, labeled

1. ONE
2. TWO
3. THREE
4. FOUR
Jacket: BLACK
Cable O.D.:
0.70
3.3.1 Cable Lengths

The length of cabling between the Control Enclosure and Actuator is limited.
The following table gives the appropriate lengths for each type of cable and
whether the actuator is using a Stepper or Servo type motor.
It is important to adhere to the length limits and conductor
size for proper operation of the system.
Table 3.3.1 Cable Lengths

Cable
Used on Unit Type
Max. Length
Feedback Cable
Step or Servo
700 ft
Module Cable
Stepper
300 ft*
Motor Power Cable
Servo
700 ft
Resolver Cable
Servo
700 ft
Heater/Solenoid Cable
Servo
700 ft
* 300 ft limit is for 16 AWG Cable. Consult factory for longer lengths.
48
3.3.2 Cable Routing

Important for proper operation.
Cables between Control Enclosure and Actuator should be run in flex conduit,
rigid conduit or dedicated cable tray. It is important to separate Low level
signals from High Power cables. Please adhere to the following:

Actuator Feedback and Resolver cables can be in the same tray or

conduit.
If Feedback and Resolver cables are run with other equipment cables,
be sure those cables are signal level only. No high power Cables.
Power Module Cable(s) for Stepper Motor units can be in the same
conduit with each other, but must be separate from the Feedback Cable.
The Power Module cable is considered a High Power cable.
Motor Power Cable(s) (Servo Motors) must be in their own conduit or

tray. Failure to do so may cause the high frequency of the PWM
(Pulse Width Modulated) signal to affect surrounding equipment or
actuator operation.
Heater/Solenoid Cable can be in the same conduit or tray with other AC

signals.
3.4 CONDUIT AND CONDUIT FITTINGS

Conduit and Conduit fittings suitable for the environment must be used.
Failure to do so may cause ingress of contaminants or water into the
enclosure.
A removable gland plate is provided on the bottom of the Control

Enclosure. The gland plate can be removed to machine the appropriate
conduit openings. Be sure to reattach the gland plate securely with its
gasket in place.
49
Seal all conduit threads with Locktite 567 or equivalent to prevent

ingress of moisture.
Be sure fittings are tightened securely.
Must maintain IP66 for steel, IP67 for stainless and fiberglass electronics
enclosures, as well as actuator assembly.
For applications requiring hazardous and explosion proof systems, conduit

and conduit fittings must be properly installed to NEC (National Electrical Code) wire standards to meet the area classifications:

CSA Class I Division 1, Groups C and D; -40C to 65C; T3
ATEX II 2G EEX d IIB, T3, -40CTamb65C.
Follow the National Electrical Code (NEC) and appropriate Local Codes
for installation of Industrial equipment.
Refer to Appendix P for Interconnect Diagram.

WARNING: The position transmitter used in the REXA CPU is extremely
accurate and sensitive. Because of its high sensitivity, directly
shorting this circuit with an ammeter can cause damage to the
circuit. The load resistance of the DCS needs to be present
to protect this circuit from a direct short. Without the load
resistance (i.e., using an ammeter), premature failure of the
Position Transmitter may occur. Refer to the Troubleshooting and
Repair Manual for proper testing procedure.
50
Mechanical Installation
4 Mechanical Installation
The Xpac can operate any device requiring force and stroke or torque and
rotation. These include louvers, dampers, variable speed drives and valves.
While the instructions below are primarily focused on valves, they also apply to
any device that may be controlled by the Xpac.
4.1 PRE-INSTALLATION CHECKLIST

Before installation of the actuator, check for the following:
Ensure that the equipment was not damaged during shipping.
Confirm that the electronic sub-assembly number and actuator serial
number match.
Verify that there is sufficient clearance for installation.
Ensure that interconnect cables are present and are the proper length.
Make certain that all the necessary equipment, tools and personnel are
present for installation.
Ensure all hydraulic tube fittings are tight.
51
4.2 R SERIES (ROTARY)

Generally, R Series actuators are shipped with a four bolt mounting pattern
and stem connection. REXA can also provide custom mounting components to
adapt to the device being controlled. Contact your sales representative for more
details.
4.2.1 Rotary Mounting (Fail in Place)

The following operation requires the unit to be in the CLOSED position; If it is
not, use the handwheel or manual hydraulic pump. Refer to Appendix M, Manual
Operators, for information concerning the Handwheel or Manual Hydraulic
Pump. If the unit is not supplied wtih a Handwheel or Manual Hydraulic Pump,
the unit must be connected to the electronics and manual operation use to drive
it to the CLOSED position. Refer to Manual Mode in section 6.
a)
With the actuator separated from its mounting, rotate the driven device
to the closed position.
Note: Be aware that not all bolt patterns are square; refer to layout drawing for
reference.
b)
Place the mounting bracket on the driven device.
c)
Hand tighten fasteners.
d)
Install the shaft coupling if applicable. Confirm the correct position of

the shaft key position on both actuator and driven device.
Note: Be sure to use anti-seize compound on mating surfaces.
e)
Carefully install actuator to the assembly; hand tighten fasteners.
Note: If a discrepancy exists between mating connections, check orientation of

assembly components.
f)
Check alignment of assembly. Ensure that the actuator face and mounting bracket are parallel, with no gaps.
g)
Tighten fasteners in a star pattern.
52
4.2.2 Rotary Mounting (Universal Spring Fail)

The universal rotary spring package is a bolt on addition to the REXA R series
actuator. The unit may rotate in either a clockwise or counterclockwise direction
upon power loss. To complete this feature, a normally open solenoid valve is
installed in the power module and usually wired to the input power. Please refer
to Product Memo 4, Spring Fail, for additional information.
If the unit has a REXA solenoid valve it will have the toggle lever shown below.
Toggling this lever will override the function of the solenoid. If the unit has no
power and you need to use the Handwheel, Drill Drive or Manual Hydraulic
Pump the lever must be in the solenoid override position as shown in Figure
4.2.2.
CAUTION:
Make sure the toggle lever is returned to its normal position
when solenoid power is returned, or the spring fail function
will not operate properly.
Figure 4.2.2 Solenoid Override Position

The spring package will be pre loaded (compressed) to a specified torque
as indicated on the order. The pre loaded torque is set at an angle of 45 to
53
the spring axis. Installation of the driven device within 5 of this position is
acceptable.
Actuators are usually shipped in the fail position. Refer to Appendix M, Manual
Operators, for information concerning the Handwheel or Manual Hydraulic Pump.
CAUTION!
REXA actuators, denoted by an E, R or U in the model

number, contain a spring under tension.
a)
to the fail position.
reference.
b)
c)
d)

e) Carefully install actuator to the assembly; hand tighten fasteners.

f)
g) Tighten fasteners in a star pattern.
4.2.3 Rotary Mounting Accumulator

Fail mode operation uses a piston type accumulator with nitrogen gas on one
side of the piston and oil on the other. The accumulator is sized to provide full
rated output at end of stroke during fail mode.
54
The following operation requires the unit to be in the closed position; if it is not,
use the handwheel or manual hydraulic pump. Refer to Appendix M, Manual
Operators, for information concerning the Handwheel or Manual Hydraulic
Pump. If the unit is not supplied with a Handwheel or Manual Hydraulic Pump,
the unit must be connected to the electronics and manual operation used to
drive it to the closed position. Refer to Manual Mode in section 6.
a)
to the closed position.
reference.
b)
c)
d)

e)
Carefully install actuator to the assembly; hand tighten fasteners.

f)
g)
Tighten fasteners in a star pattern.
4.3 L SERIES (LINEAR)

REXA L series actuators utilize a sliding stem, piston-style cylinder. Mounting
to the driven device is typically done with a bolted yoke assembly. Stem
connections will vary by application. Refer to Appendix B for information on
Stem Connection & Seat Loading Methods.
55
4.3.1 Linear Mounting (Fail in Place)

Actuators are usually shipped in the retracted position. Refer to Appendix
M, Manual Operators, for information concerning the Handwheel or Manual
Hydraulic Pump. Refer to Appendix B, Stem Connections and Seat Loading
Methods.
CAUTION!
When mounting linear actuators, take care to avoid

mechanical misalignment that would cause side-load to the
actuator output shaft. Be sure that the driven device is
straight and true. Severe side-load will cause excessive
wear to both the actuator and driven device.
a)
to the retracted position.
b)
Retract the actuator stem to a position that will allow mounting the
actuator without contacting the valve stem. If the optional handwheel is
not available, the unit must be connected to the electronics and manual
operation used to drive it to the closed position. Refer to Manual Mode
in section 6.
c)
Place the actuator onto the driven devices mating surface and loosely
install the mounting hardware.
Note: Loose set up allows for float and self-alignment.
d)
Extend the actuator stem until the coupling contacts the valve stem.
e)
Thread the driven device stem into the coupling for a distance of at
least one and one half times the stem diameter and use a lock nut
against the coupling to prevent the stem from rotating out.
Note: There are wrench flats machined on the actuator stem for this purpose. No
damage will occur if the actuator stem is rotated.
f)
If the actuator is installed in a vertical position, manually stroke it to

allow the stem connection to self-align.
56
g)
Securely tighten the mounting connection. Visually inspect the stem for
any noticeable indication of bending.
For all other orientations, support the actuator in a manner that prevents any
noticeable indication of stem bending. Securely tighten the mating connection.
Manually stroke the actuator and carefully observe the stem for any evidence of
lateral (side to side) misalignment.
h) For verification, once the mounting hardware is tight and the actuator is
installed, de couple the actuator shaft. If any movement of the actuator
shaft can be seen during the process, loosen the mounting hardware,
realign the actuator and repeat steps f, g and h.
4.3.2 Linear Mounting (Spring Fail)

The spring fail option for linear actuators consists of a spring mounted
underneath the hydraulic cylinder and a normally open solenoid valve installed
on top of the power module. The spring can be specified to extend or retract
the stem upon power loss. It is not field reversible. The solenoid valve is usually
wired to the input power.
If the unit has a REXA solenoid valve it will have the toggle lever shown in
Figure 4.3.2. Toggling this lever will override the function of the solenoid. If the
unit has no power and you need to use the hand wheel, drill drive or manual
hydraulic pump the lever must be in the solenoid override position as shown
in Figure 4.3.2. Note that the REXA solenoid valve option is only available for
systems with B, C, 1/2D, and D power modules rated for hazardous but nonexplosion proof environments.
CAUTION:
Make sure the toggle lever is returned to its normal position
when solenoid power is returned, or the spring fail function
will not operate properly.
57
Figure 4.3.2 Solenoid Override Position
CAUTION!
REXA actuators, denoted by an E, R or U in the model

number, contain a spring under tension.
4.3.3 Linear Mounting Accumulator

Fail mode operation uses a piston type accumulator with nitrogen gas on one
side of the piston and oil on the other. The accumulator is sized to provide full
rated output at end of stroke during fail mode.
Actuators are usually shipped in the retracted position. Refer to Appendix
M, Manual Operators, for information concerning the Handwheel or Manual
Hydraulic Pump. Refer to Appendix B, Stem Connection and Seat Loading
Methods.
CAUTION!
When mounting linear actuators, take care to avoid

mechanical misalignment that would cause side-load to the
actuator output shaft. Be sure that the driven device is
straight and true. Severe side-load will cause excessive
wear to both the actuator and driven device.
58
a)
to the retracted position.
b)
Retract the actuator stem to a position that will allow mounting the
actuator without contacting the valve stem. If the optional handwheel is
not available, the unit must be connected to the electronics and manual
operation used to drive it to the closed position. Refer to Manual Mode
in section 6.
c)
Place the actuator onto the driven devices mating surface and loosely
install the mounting hardware.
Note: Loose set up allows for float and self-alignment.
d)
Extend the actuator stem until the coupling contacts the valve stem.
e)
Thread the driven device stem into the coupling for a distance of at least
one and one half times the stem diameter and use a lock nut against the
coupling to prevent the stem from rotating out.
Note: There are wrench flats machined on the actuator stem for this purpose. No
damage will occur if the actuator stem is rotated.
f)
If the actuator is installed in a vertical position, manually stroke it to allow

the stem connection to self-align.
g)
Securely tighten the mounting connection. Visually inspect the stem for
any noticeable indication of bending.
For all other orientations, support the actuator in a manner that prevents any
h) For verification, once the mounting hardware is tight and the actuator is
installed, de couple the actuator shaft. If any movement of the actuator
shaft can be seen during the process, loosen the mounting hardware,
realign the actuator and repeat steps f, g and h.
59
4.4 D SERIES (DRIVE)

By the addition of a rugged L-shaped mounting base, a lateral load bushing
and a lever arm, the R series actuator becomes an excellent drive. Applications
requiring long strokes or non-axial loaded rotary motion are effectively solved by
this unit. Traditionally, a drive-type actuator is used for DAMPER control.
4.4.1 Drive Mounting

The base of a REXA drive contains a four-hole mounting pattern. These holes
have been sized to accept the appropriate diameter bolt for the imposed load.
Table 4.4.1 lists the base hole, minimum bolt diameter and recommended
bolt torques. Standard bolting or threaded studs are acceptable, but material
strength must be an SAE Grade 8. Hardened load washers and lock washers
must be used. The Handwheel or Manual Hydraulic Pump is used to position
the Drive Arm.
Table 4.4.1 Drive Base Bolting

RECOMMENDED
Model
Hole
Min. Bolt
Bolt Torque

Diameter Diameter Minimum Maximum
D2500/5000
D10000/20000
D50000/100000
.56
.81
1.00
20 lbft
200 lbft
650 lbft
30 lbft
250 lbft
700 lbft
Note: Bolting to be SAE Grade 8.
4.4.2 Drive Arm

Connection to the driven device (linkage) is by means of the drive arm. Standard
arms are based upon actuator size. Each arm includes multiple connection
points. See Figure 4.4.2-1. Custom arms are available upon request.
Figure 4.4.2-1 Drive Arm Assembly Reference Drawing
60
The connecting link and other linkage should be selected to withstand the
maximum load imposed by the drive. This will vary depending upon the
effective length of the arm. The following equation should be used to determine
the minimum safe working load of the connecting linkage:
Load=
Rated Drive Torque

5
Effective Lever
For most installations, the optimum alignment of the drive arm and the driven
(damper) arm is when they are parallel to each other and perpendicular
to the connecting linkage at mid-rotation. Refer to Figure 4.4.2-2. This is
accomplished by a combination of linkage length and drive arm adjustments.
A slotted spline connection between the drive arm and shaft provides multiple
mating angles (5-10 intervals).
Figure 4.4.2-2 Drive Arm Alignment
61
5 Start-Up Considerations
5.1 START-UP CHECKLIST

At this time the actuator, electronics sub-assembly and driven device should
be installed. Before applying power to the unit and calibrating the actuator the
following items should be considered:
5.1.1 Inspection of Electronic Sub-Assembly Installation

Check the following:
Inspect incoming voltage connection.
Test for correct incoming voltage
Control signal connections are secure.
Outgoing signals are connected properly.
Interconnection cable wiring is correct at electronic sub-assembly,
actuator junction boxes and terminal blocks.
Feedback cables are connected and shielded properly at actuator/
electronics.
Start-Up Considerations
62
All ground wires are secured.

All electrical connections are tightened properly.
Conduit connections are secure and watertight with thread sealant.
Electronics are free of tools and debris.
Proper personnel has been notified for lock out/ tag out procedures.
5.1.2 Inspection of Mechanical Actuator Installation

Check the following:
Oil level is correct.
Motor and feedback wires are connected properly and securely.
Actuator mounting fasteners are tight.
Coupling/split clamp installed properly.
All conduit connections are secure and watertight with thread sealant.
All tools and equipment are clear of operating area.
Safety related covers and labels are installed and clearly marked.
Proper personnel has been notified for lock-out/tag-out procedures.
5.2 ALIGNMENT
Any noticeable bending of the actuator stem or driven device should be
immediately corrected. Not only will operation be impaired, but damage to the
actuator seals and bushings or driven device may occur. When mounting the
actuator to the driven device the actuator shafts and couplings MUST align
properly.
5.2.1 Lateral Alignment

Any misalignment needs to be corrected or it will reduce the life of the actuator
and cause damage to the driven device.
In most cases, lateral alignment is corrected by stroking the actuator with the
mounting or mating connection in a loosened condition. This will allow the
connection to self-align. If there is insufficient clearance, then the appropriate
bore diameters must be increased.
5.2.2 Longitudinal Alignment

LINEAR
Failure to reach full stroke is caused by a mechanical limitation within the
actuator or driven device. Incorrect yoke leg lengths or thread engagement
in the stem coupling may reduce the travel. In most cases, the required
adjustment is small and can simply be made by changing the length of thread
engagement of the stem coupling. Further adjustment can only be made by
changing the length of the yoke legs.
If the actuator is installed in a vertical position, manually stroke it to allow the
stem connection to self-align. Securely tighten the mounting connection.
Visually inspect the stem for any noticeable indication of bending.
For all other orientations, support the actuator in a manner so that there is no
ROTARY (<90 Rotation)
Failure to reach the full 90 rotation is usually not binding, but rather an installation
problem. With the actuator separated from the driven device, rotate the driven
device to the closed position. Move the actuator in the same direction until the
end of rotary piston travel is reached. The connections between the driven device
and the actuator should be within 2-4 degrees. If a large discrepancy exists
between the mating connections, the adapter may be incorrect.
64
DRIVE
Drive units can create an extraordinary amount of force. Any misalignment of
the drive/driven arms, or incorrect linkage arrangements, can cause damage to
the actuator or the driven device. All mechanical connections and stroke limits
should be set carefully and inspected.
5.3 INITIAL CALIBRATION

Refer to Section 5.4, Rotary and Drive Spring Stops, and Section 5.5,
Cylinder End Stops, prior to calibrating rotary or drive units with spring
or accumulator fail option.
Apply AC Power.
Line 2 will display the CALIBRATE menu header.
If not already in CALIBRATE, simultaneously press AUTO/MANUAL for 5
seconds.
Scroll down to Position Lo with the
arrow.
Press the ENTER ( ) key. = will begin
to flash. Value will change to current
actuator position.
Move the actuator with the or to
the Position that corresponds to
4.0 mA.
Refer to Appendix B, Stem Connection &
Seat Loading Methods.
Press the ENTER ( ) key to lock in
that value.
CAUTION!
The end point should not be set against a mechanical stop
without a spring coupling or damage will occur.
Note: If the actuator is stroked beyond the factory set cylinder limit, the display
will show CylEnd while the down key is held. If the enter key is pressed, the display
will show TooLow. Position Lo will need to be calibrated higher until this warning
goes away.
Scroll down to Position Hi with the
arrow.
Press the ENTER ( ) key to lock in that value.

Press the ENTER ( ) key. = will begin to flash. Value will change to
current actuator position.
Move the actuator with the
20.0 mA.
or
to the Position that corresponds to

CAUTION!
The end point should not be set against a mechanical stop
without a spring coupling or damage will occur.
Note: If the actuator is stroked beyond the factory set cylinder limit, the display
will show CylEnd while the up key is held. If the enter key is pressed, the display
will show TooHi. Position Hi will need to be calibrated lower until this warning goes
away.
Scroll down to Signal Lo with the
arrow.
Press the ENTER ( ) key. = will begin to flash.

Apply the actual 4.0 mA Control Signal from the DCS. The value in the
display will change; showing what is being read from the DCS.
Scroll down to Signal Hi with the
arrow.
Press the ENTER ( ) key. = will begin to flash.

Apply the actual 20.0 mA Control Signal from the DCS. The value in the
display will change; showing what is being read from the DCS.
66
The Actuator has now been calibrated. It is recommended at this point that
all Current Status be reset to 0. Refer to Current Status menu section for
procedure.
To enter the Auto mode:
Simultaneously press Auto ( ) and ENTER ( ).
Line 1 of the display will change to Auto followed by the Current
Status.
Line 2 will be blank.
When the keys are released
Line 2 will display the current Position.
5.4 ROTARY AND DRIVE SPRING STOPS

Spring stops provide the actuator the means to prevent over-travel during a
fail safe condition. If the driven device does not limit over-rotation or overtravel, spring stops can be utilized for this purpose by turning the spring stop
adjustment screw in or out to modify the actuators final fail position.
To install a Spring Fail unit, position the spring lever to the 45 location by
extending the spring stop as shown in Figure 5.4. Rotate the driven device to
the required failure position. Adjust the spring stop to allow mating of the shafts
and alignment of the mounting bolts.
Figure 5.4 Universal Spring Alignment
Once mounted, the spring stops should be adjusted to a position that transfers
torque onto the driven device at the fail position.
5.5 CYLINDER END STOPS

Cylinder end stops provide the actuator the means to prevent over-travel
during a fail safe condition. If the driven device does not limit over-rotation or
over-travel, cylinder end stops can be utilized for this purpose. These stroke
adjusters can reduce cylinder rotation 05 degrees.
2
3
Figure 5.5 Stroke Adjustment
CAUTION!
Ensure that there is no hydraulic pressure in the system prior

to cracking any hydraulic lines. All pressure gauges should
read 0 psi.
Note: Each actuator is tested and shipped from the factory with the thread seal
and jam nut lightly torquedenough to seal during factory acceptance testing.
This procedure assures that the sealing rubber is undamaged and will properly
seal once the stroke adjustor is fully adjusted in the field by the end user, and the
threaded elements are firmly tightened to full torque.
68
5.5.1 End Stop Adjustment

Counter Clockwise
Adjuster
Clockwise Adjuster
Figure 5.5.1-1 Cylinder End Stops

WARNING:
The Calibrated end points PL and PH must not be set with
the actuator against the cylinder end stop.
1. Position the actuator in the desired final fail position slightly beyond the
calibrated end stop. This can be done when calibrating PL and PH.
Note: Failure to follow this step will lead to a potential situation where the electronics
may try to drive the actuator beyond its physical limit, and a stall condition will
result.
2. Turn off the power breaker in the electronics.

3. Locate the correct stroke adjuster (refer to Figure 5.5.1-1).
4. Locate the hydraulic fitting (1) connected directly to the stroke adjuster
cylinder cap as shown in Figure 5.5. Loosen this fitting to allow oil to
escape during this adjustment process.
5. Loosen the jam nut (Figure 5.5.1-2) by turning counterclockwise. Back
off this jam nut 4 to 5 turns and move the countersunk washer away
from the thread seal and against the repositioned jam nut.
6. Using light oil and a small brush or squirt can, generously lubricate the
thread seal rubber and the threads of the adjustment screw.
7. Carefully pry the thread seal washer away from the end cap and then
pull and twist it back and forth to carefully slide it along the adjustment
screw threads to gain adjustment clearance.
8. The actuator stroke adjustment can now be made using the threaded
adjustment rod. This rod has a hollow hex in the end to allow easy
adjustment.
WARNING:
As the stroke adjusters are turned in, fluid will be displaced
and need to leak out of the system. Failure to exhaust fluid
will damage internal components of the actuator.
9. The actuator is shipped from the factory with this adjustment rod
threaded fully out to the end of travel to give the full rotation of the
actuator. The adjustment screw can only be rotated clockwise (inward)
from this shipped position.
Caution: A mechanical lock at the end of the threads restricts inadvertent
disassembly outward. Rotating the adjustment screw counterclockwise (outward)
from this end position may cause damage to the hardware.
Figure 5.5.1-2 End Stop Detail

10. Use an allen wrench drive inserted into the hollow hex adjustment screw
end to adjust the stroke adjustor. Rotate clockwise to decrease the
stroke of the actuator. Each stroke adjustor provides a minimum of 5
degrees of actuator rotation adjustment.
70
11. The number of adjustment screw rotations needed to achieve the 5 degree rotational adjustment of the actuator depends on the size (model)
of the actuator and the pitch of the adjustment thread on the adjustment
screw. The Table 5.5.1 shows this relationship.
12. After final positioning of the adjustment screw to achieve the desired
actuator rotation, readjust the position of the thread seal along the
adjustment screw threads to contact the end cap. Caution: use generous lubrication during this step to assure no damage to the rubber seal
by the threads.
13. Reposition the countersunk washer and the jam nut and torque the jam
nut to the requirements of the Table 5.5.1.
14. Tighten the hydraulic fitting that was loosened in step 4.
Table 5.5.1 Stroke Adjustor

Model
One Turn Adjustment Jam Nut Final Torque

(degrees)
(lbft)
R2500/R5000
3.3
50
R10000/R20000
2.0
150
R50000/R100000
2.0
300
R200000/R400000
1.2
375
5.5.2 R200000/R400000 End Stroke Adjustments

R200000/R400000 actuators do not use an external thread seal arrangement.
The seal is contained internally while the jam nut and adjustment screw drive is
located externally. Refer to Figure 5.5.2. An external drive square is provided
on the adjustment screw end and can be driven by using a standard wrench.
No special lubrication of the threads is needed during adjustment.
The unit is shipped from the factory with the stroke adjustor positioned at the
full outward position as described above. Adjustment is made by disconnecting
the hydraulic line to vent out any displaced fluid, loosening the jam nut several
turns counter clockwise and then using the square drive to position the adjustor
to provide the desired actuator stop position. The total adjustment range is 5
degrees minimum. Table 5.5.1 shows the adjustment achieved from one turn of
the adjustor.
The jam nut is repositioned after adjustment is complete and torqued to the final
tightness value specified.
Jam nut
Drive square
Adjustment
screw
Figure 5.5.2 R200000/R400000 Stroke Adjuster
72
Modes of Operation & Control Parameters
6 Modes of Operation & Control Parameters
The user interface is a 2-line, 20 character/line vacuum fluorescent emissive

display with a membrane keypad. The display may suffer phosphor burnout if
a static display is left on for a long period of time. To avoid this, the display is
dimmed after one hour of no keypad usage. The display may be turned back on
by pressing any key. If, while in Auto or Local Manual mode, an alarm condition
is detected, the entire display will blink on and off until acknowledged by an
operator pressing any key.
The electronics can be put into 3 different modes of operation. They are:
o Setup
o Automatic (Auto)
o Manual (Local Man, RemoteMan)
Each mode can be entered as shown in Figure 6:
Figure 6 Modes of Operation
6.1 SETUP MODE

The Setup mode is the means of setting the control parameters of the actuator
such as actuator span, speed, etc. Most parameters are factory set and provide
excellent actuator performance. However, some applications may require fine
tuning of the actuator.
The eight menus and accompanying control parameters are covered in the
following sections. To access and change the Control Parameters (See Figure
6.1.1), the electronics must be in the Setup mode.
Password protection of the Setup mode is optional. The default value of 0000
indicates no password is required. If any other value is set as the password, the
user will be prompted to enter it prior to entering the Setup mode.
6.1.1 Menu Navigation

To get the electronics in Setup mode, simultaneously press AUTO (
MANUAL ( ) for 5 seconds.
) and
Note: The actuator will no longer follow a control signal when in setup mode.
To scroll from column to column, you must have the column header in the
display and press ENTER ( ). This will scroll from left to right and then repeat.
To scroll up and down a column, use the
and
arrows.
X2 Control
Parameters
Menu
Only if
Flow Char = On
Only if
Sol. Seat = On
Requires
Special
Construction
Only if
Signal Type
= Analog
Signal Hi
Only if
Signal Type
= Analog
Signal Lo
Position Hi
Position Lo
CALIBRATE
CS 90% Pt
CS 10% Pt
Only if
Signal Type
= Analog or
Commun
Flow Char
Cal. Stroke
Sol. Seat
Seat Load
Seat Ld Cyl
Only if
Signal Type
= Analog or
Commun
Bumpless
NA if Signal
Type = 1 Cont
Min Mod
Max Hi Spd
Deadband
Accum Pres
Accum Dir
Rechrg Time
Warn Pres
Rechrg Pres
Accumulator
Surge Offpt
Only if
Surge Bkpt
= Off
Version
Close Pres
Open Pres
Password
00000
Xmitter
Hi
Xmitter
Low
Pos
Xmitter
SB - only if
Sig. Type = Analog
Accum. = No &
Booster Pump = Off
BP - only if
Drive Type = Servo
& Surge Bkpt = Off
Only if
Surge Bkpt
Off
See SB below
Surge Bkpt
See BP below
Boost Pump
Relay #2
Relay #1
Drive Type
Stall Time
OUTPUTS
DRIVES
Figure 6.1.1 Control Parameter Menus
Max Man Spd
Power On
Trip
Only if
Signal Type
= Commun
Shed Time
Only if
Signal Type
= Analog or
Commun
Failsafe
Only if
Signal Type
= Pulse
Pulse Inc
Only if
Signal Type
= Pulse
Pulse Dur
Signal Type
INPUTS
If 2-Speed =
Bkpt >> Lo
Up/Dn >> Dn
Only if
2-Speed
= Bkpt
Speed Bkpt
Max Dn Spd
Max Lo Spd
2-Speed
Lo Accel
Accel Bkpt
Hi Accel
Gain
If 2-Speed
= Up/Dn
Max UP Spd
SPEED/
ACCEL
CONTROL
Only if Accumulator = Yes

Last Error
Strokes x1k
Starts x1k
Over Temp
Low Oil
Strokes x1k
Starts x1k
Over Temp
Low Oil
Cl Pres bad
Op Pres bad
Op Pres bad
Cl Pres bad
Stall
SLC Stop
Direction
CS bad
Fb bad
SLC Fb bad
Shed Time
Pressure bd
Drive fault
A/D Fail
Mem Fail
HISTORIC
STATS
Stall
SLC Stop
Direction
CS bad
Fb bad
SLC Fb bad
Shed Time
Pressure bd
Drive fault
A/D Fail
Mem Fail
CURRENT
STATS
Errors will only be shown if they have occurred

Require special construction
Requires special construction
6.1.2 Changing a Parameter

To access and change a parameter, the Parameter ID must be visible on the
display, i.e. Position Lo. Pressing the button will cause the = sign to
blink. The parameter is now accessible to change. Use the
and
arrows
to change the value of the parameter. To accept the new value, press the
button. The = sign will stop flashing. When a value is entered for any
parameter, updating is briefly displayed.
Pressing the or arrow in parameters Position Lo and Position Hi will
cause the Actuator to move.
Parameters Signal Lo and Signal Hi cannot be changed by pressing the arrows.
An active 4-20 mA signal must be applied. The actual signal in milliamperes will
be displayed.
76
6.1.3 CALIBRATE Menu

The CALIBRATE menu consists of the following parameters:
Note: When changing Position Lo and Position Hi, the actuator will move.
Position Lo defines the actuator position corresponding to Signal

Lo setting. When Signal type is set to Contact Inputs, Position Lo defines the
actuator position corresponding to the Close Input.
Note: The span between Position Lo and Position Hi must be greater than 10%.
Position Hi defines the actuator position corresponding to the Signal Hi setting.

If the Signal type is set to Contact Inputs, Position Hi defines the actuator
position corresponding to Open Input.
Note: If a value for Position Lo is entered that is within 10.0% of the current
value of Position Hi, the value is accepted, and parameter Position Hi is displayed.
If the display shows the = blinking, it is ready to be set to a value more than
10.0% different than Position Lo. The menu will alternate between Position Lo
and Position Hi until a span greater than 10% is achieved. Similar action occurs
when setting Position Hi. While uncommon, if Driver Type (see Drives Menu) does
not match the actuator, a continuous loop between Position Hi and Position Lo
will occur.
Signal Lo is the Input Signal, typically 4 mA, that corresponds to Position Lo.
Signal Hi is the Input Signal, typically 20 mA, that corresponds to Position Hi.
Signal Lo and Signal Hi are only visible in the menu if Signal Type = Analog.
Range: 0.0 to 25.0 mA
Note: Unknwn appears if control signal failure occurs while calibrating.
Error appears, briefly, if an unacceptable value is entered. The unacceptable
value is rejected and the previous value is retained.
Note: If Failsafe does not = Off, input signal value must be greater than 2.5 mA
and the span must be greater than 3.8 mA. Refer to INPUTS menu.
Note: If Failsafe = Off, the span for Signal Hi must be greater than 3.8 mA or vice
versa.
Refer to INPUTS menu for Failsafe information.
Refer to section Initial Calibration (Start-Up Considerations) for additional

information on Position Lo, Position Hi, Signal Lo and Signal Hi settings.
78
6.1.4 CONTROL Menu

The CONTROL menu provides the following:
Deadband sets the maximum deviation allowed between Input Signal and
current position before actuator movement in Auto mode.
Units: % of calibrated stroke
Range: 0.05 to 5.00 % of calibrated stroke`
The deadband should not be set any smaller than the process requires. Check
to ensure the actuator is not reacting to noise in the control signal, but to
actual signal changes.
Min Mod {Minimum Modulating} defines a set-point in the actuator stroke

below which the actuator will not modulate. Min Mod sets the upper limit
of a no-modulating band with respect to Position Lo. This may be used to
minimize seat wear.
Not in menu if parameter Signal Type = 1 Cont.
Operational in both Auto and Local Man/RemoteMan
Units: % of calibrated stroke (Refer to INPUTS Menu.)
Range: Off or 0.1 to 99.9 % of calibrated stroke
Bumpless {Bumpless Transfer} sets the total time the actuator takes to travel
from its current position to a new target control position when the actuator is
switched from either Manual or Setup into Auto. This feature is designed as
a safeguard in the event the control signal was changed while the actuator
was not in Auto mode. When the unit is switched into Auto and the Bumpless
parameter is On, the actuator seeks the new target position at less than normal
speed. The actuator will take 100 small steps to reach the new target position in
the time set as the bumpless parameter. A delay will be defined between each
step until the actuator reaches the new target position.
This feature only appears in the menu if the incoming control signal parameter
Signal Type is set to Analog or Commun.

If Bumpless is set to any value other than Off when the actuator is switched
to Auto and the deviation between the incoming control signal and the
actuators current position is LESS than ten times the dead band parameter,
the operation of the actuator is the same as Bumpless = Off.
If Bumpless is set to any value other than Off when the actuator is switched
to Auto and the current deviation between the incoming control signal and
the actuators current position is GREATER than ten times the dead band
parameter, the operation of the actuator is to:
Divide the Bumpless time parameter by 100 to define the time interval
between actuator steps. These steps are how the actuator will track to
its new control position.
Divide the deviation between the current actuators position and the new
control signal position by 100. This defines the size of each step.
Once the actuator reaches the control signal set point the actuator will resume
normal operation.
Only in menu if Signal Type=Analog and Accumulator=No, and Booster Pump=
No.
See INPUTS and DRIVES menus.
Units: Seconds
Range: Off or, from 10 to 990 seconds
80
Seat Ld Cyl {Seat Load Cylinder}: Specifies whether or not the actuator employs
a seat load cylinder. This yes or no option is set at the factory.
Refer to Appendix B, Stem Connection & Seat Loading Methods, for additional
information.
Seat Load {Seat Load Switching}: Specifies that the actuator does not employ
a seat load cylinder (Off) or that a seat load cylinder is employed and the value
entered is the transition point at which the seat load cylinder is engaged/
disengaged via solenoid action.
Sol. Seat {Solenoid Seating}: Uses software to allow the stored energy of
a failsafe actuator to provide the seating force. Can only be used on linear
failsafe actuators where the fail direction is the same as the seating direction.
Replaces the elastic coupling and seat load cylinder for these applications.
Cal. Stroke {Calibrated Stroke}: When Sol. Seat = On, Cal. Stroke can be set
from .3" to 99.9" in one inch increments.
Flow Char {Flow Characterization}: The actuator is designed to have a linear
relationship between Control Signal and stroke (10% CS, 10% stroke, etc.) The
ability to modify this characteristic can assist in loop tuning or linearization of
a control scheme. Changing this actuator characteristic can have a profound
effect on the behavior of the control loop and should only be undertaken wtih
a thorough understanding of the effect. The stroke position can be modified
at 10% control signal intervals. The only restriction is that each stroke position
must be at least 2.5% from its neighbors.
CS 10% Pt thru CS 90% Pt {Control Signal 10% Point thru Control Signal
90% Point): When Flow Char= On, parameters CS 10% Pt thru CS 90% Pt
are added to the CONTROL menu. Each of these 9 parameters specifies
the desired actuator position when the Analog control signal is equal to the
corresponding point. Operation between Setpoints is linear.
Units: % of calibrated stroke
Range: CS 10% Pt: 2.5 to CS 90% Pt 97.5
Each calibrated stroke must be at elast 2.5% distant from the adjacent position.
Ex.; If CS 10% Pt= 2.5 when a 10% Control Signal is applied, the actuator will
travel 2.5% of calibrated stroke.
6.1.5 SPEED/ACCEL Menu

The SPEED/ACCEL menu displays the following:
Max Hi Spd {Maximum High Speed} specifies the maximum motor speed when
operating in the Auto mode when 2-Speed is set to Off or to Bkpt. This speed
parameter will go above 100%, but the output of a stepper module will be
reduced if setting it beyond this value. The motor may run into stall conditions.
Conversely, turning the speed down below 100% will allow the motor to make
more torque if a stalling condition exists. When running a stepper module near
the low temperature specification the speed may need to be lowered to avoid
occasional stalls
Max Up Spd {Maximum Up Speed} is in the menu when operating in Auto mode
when 2-Speed is set to Up/Dn. Max Up Spd specifies the maximum motor
speed when moving from Position Lo toward Position Hi.
Range: 5 to 125 % of actual motor speed, but no greater than Max Hi Spd.
Gain: In the Auto mode Gain is used to determine how motor speed is adjusted
as the actuator approaches the target position. The higher the Gain setting, the
closer the actuator will get to the target position before decelerating. The lower
the Gain setting, the further away the actuator will be from the target position
when it begins to decelerate. This value is typically factory set; however, it may
be changed should the application warrant it.
Range: 1 to 250
Figure 6.1.5 Gain
82
Hi Accel {High Acceleration}:

Drive Type = Step
Hi Accel defines the rate at which the motor speed will be increased or
decreased until maximum speed is achieved for all modes of operation. It may
be replaced by Lo Accel if dual acceleration is used in combination with Gain to
define the rate of motor speed decrease until it reaches the target position.
Hi Accel allows the actuator to use two separate acceleration rates. If the
actuator is to make a large move, increase the acceleration rate to get to
the new Setpoint as quickly as possible. If the actuator is modulating and
requires small step changes, a slower acceleration eliminates overshoot. The
acceleration breakpoint allows the value for Hi Accel for changes in Setpoint
that are greater than Accel Bkpt and Lo Accel for changes in Setpoint that are
less than Accel Bkpt value. Acceleration Breakpoint defines the maximum
deviation for which Lo Accel is used in place of Hi Accel. Set Hi Accel for large
changes and Lo Accel for small changes.
Hi Accel {High Acceleration}:

Drive Type = Servo
Hi Accel defines the rate at which motor speed will be increased until maximum
motor speed is reached for all modes of manual stroking.
(Manual stroking = Local Man, RemoteMan, and when setting Position Lo/Hi in
Setup mode.)
Range: Lo Accel to 99 (Can not be set below value set in Lo Accel)
Accel Bkpt {Acceleration Breakpoint} defines maximum deviation for which

Lo Accel is used in place of Hi Accel.
Note: If deviation between signal and position is < or = to Accel Bkpt, Lo Accel is
used in place of Hi Accel.
Note: If deviation between signal and position is > than Accel Bkpt, only Hi Accel
is used.
Range: 0.1 to 5.0

Note: If Lo Accel = Hi Accel or if Accel Bkpt = 0.1, dual acceleration is nullified.
Lo Accel {Low Acceleration} defines an optional low rate of acceleration for

small deviations (< Accel Bkpt) in Auto mode.
Range: 1 to Hi Accel (Can not be set above value set in Hi Accel)
2-Speed defines status of optional two speed operation.

Select: Off, Up/Dn or Bkpt
Default: Off
When 2-Speed = Off, Max Hi Spd specifies maximum motor speed when
operating in Auto.
When 2-Speed = Up/Dn, Max Dn Spd defines motor speed as unit moves
toward parameter Position Lo. Max Hi Spd is changed to Max Up Spd and
defines motor speed as unit moves toward parameter Position Hi.
Note: When operating in Auto, Local Man, or RemoteMan and traveling
toward the position specified by parameter Position Hi, Max Up Spd sets
the speed limit.
Note: When operating in Auto, Local Man, or RemoteMan and traveling
toward the position specified by parameter Position Lo, Max Dn Spd sets
the speed limit.
Note: When operating in Setup, Max Man Spd sets the speed limit.
When 2-Speed = Bkpt, Max Lo Spd and Speed Bkpt are added to the menu.
Note: Max Hi Spd defines motor speed between Spd Bkpt and Position Hi
Note: Max Lo Spd {Maximum Low Speed} defines maximum low speed
between Spd Bkpt and Position Lo.
Note: Speed Bkpt {Speed Breakpoint}: Provides a speed transition point.
84
Range: 0.1 to 99.9
Max Man Spd {Maximum Manual Speed} defines the maximum motor speed
when operating in Setup. Sets the maximum motor speed when operating in
Local Man or RemoteMan only if 2-speed = Off.
Range: 5 to 125 (but no greater than Max Hi Spd)
Default: 80
6.1.6 INPUTS Menu

The INPUTS menu consists of the following parameters:
Signal Type: Selects the main control signal(s) for the Auto mode. Allows
the user to define the type of control signal being sent to the actuator.
Select Analog, 1 Cont, 2 Cont, Pulse, or Commun.
Note: 1 Cont, 2 Cont and Pulse are only included in the Inputs menu if Contact/
Pulse Inputs Board is installed. Refer to Appendix E, Pulse Operating System, and
Appendix Q, Contact Input Options, for additional information.
When Signal Type = Analog, the main control signal is the 4-20 mA
analog input. This selection provides the full modulating capability of the
actuator.
When Signal Type = 1 Cont (one contact), two position operation
open/closed positionis selected. The applied signal defines actuator position.
If the Open input is active (powered), the actuator goes to Position Hi. If the
Open input is not active (un-powered), the actuator goes to Position Lo.
When Signal Type = 2 Cont (two contacts), manual modulation
operation is selected. The main input signals are the Main contacts Open and
Close inputs of the Contact Input Board. If both inputs are active or inactive,
the actuator remains in its current position. If only the Open input is active, the
actuator travels towards Position Hi. If only input Close is active, the actuator
travels towards Position Lo.
Note: Actuator will continue to move in desired direction as long as a signal is
present or until target is reached.
When Signal Type = Pulse, pulse operation is selected.
Pulse Dur {Pulse Duration} sets the minimum time that the Pulse Input must
remain active in order to be recognized as a valid signal. A continuous signal
may be measured as multiple pulses.
86
Ex.; With pulse Duration set at 50 milliseconds, a 100 millisecond pulse equals
two pulses.
Units: ms (milliseconds)
Range: 10 to 999 milliseconds
Pulse Inc {Pulse Increment} sets the amount of actuator travel for each valid
pulse received. It only appears in menu if Signal Type= Pulse
Range: 0.1 to 5.0 % of calibrated stroke
The input signals are the Main Contacts Open and Close inputs of the Contact
Input Board. If only input Open is active and meets the requirements of Pulse
Dur, the value set in Pulse Inc is added to (direct acting) or subtracted from
(reverse acting) the current position to become the new target position. The
actuator then seeks this new position. If only input Close is active and meets
the requirements of Pulse Dur, the value set in Pulse Inc is subtracted from
(direct acting) or added to (reverse acting) the current position to become the
new target position. The actuator then seeks this new position. If both inputs
are active or inactive, the actuator holds its current position.
Pulse input has the ability to control the actuator by an Open or Close pulse
signal. Each Input signal must meet the minimum pulse duration. For a period of
time it will be recorded as a number of pulses based on defined pulse duration.
Target position can be adjusted based on the number of pulses and defined
pulse increments. The motor will then move in desired direction until new target
position has been reached.
When Signal Type = Commun, the full modulating capability of the actuator is
also provided. However, the controlling signal is the Setpoint Parameter which
may be written via one of the communication interfaces( HART or Foundation
Field Bus ).
Note: When set to Commun, parameters Failsafe and Shed Time are
added to this menu.
Failsafe defines the position the actuator moves to via the motor if the Analog
control signal falls below 2.5 mA.
Only in menu if Signal Type = Analog.
Select:
Inplac: Actuator remains in current position.

0% to 100%: Actuator goes from 0% to % set.
Off: Used for zero based control signal, i.e., 0-20 mA. Off will appear above
a setting of 100%.
Default: Inplac.
Note: Local and Remote Manual will override the Failsafe position.
Shed Time specifies the maximum amount of time allowed between writes to
parameter Setpoint before the action specified in parameter Failsafe is taken.
When set to OFF, no action is taken.
Only in menu if Signal Type = Commun
Trip parameter defines the active state of the AUX CLOSE input on the
Contacts Inputs Board. This secondary input is used to override the main input
to cause actuator movement with the aid of a solenoid/spring package or with
an accumulator. This Failsafe position is factory configured to either calibrated
end, but not to both, and is not field reversible.
When Trip = Off, trip function is not used
When Trip = Unpwrd, and AUX CLOSE input is not powered, go to end point
(Trip = Logic )
When Trip = Pwrd, and AUX CLOSE input is powered, go to end point (Trip =
Logic I)
Note: Trip = Unpwrd/Trip = Pwrd is only selectable if Contact Inputs Board is installed.
88
Power On parameter defines the mode the Control Enclosure will be in when
Main Power is applied.
When Power On = Last, (the default), on power up or reset, the actuator will
return to its previous operating mode (Auto, Local or Setup).
When Power On = Local, on power up or reset, if the previous mode was Auto,
the actuator will enter Local mode instead.
6.1.7 DRIVES Menu

The DRIVES menu consists the following parameters:
Drive Type defines the type of motor, stepper or servo, provided with the power
module(s) and is factory set to Step or Servo.
Stall Time defines the maximum time, 1 to 50 Sec (seconds), allowed for the
actuator to travel 1% of calibrated stroke before a stall is assumed. If 1% travel
is not detected in the time set, the motor drive is stopped, the drive is reset
and a restart attempted. A maximum of five retries are allowed before a stall
error (alarmed) is declared.
Note: Stall Time also sets the point at which the Booster Pump will turn off.
Note: If Stall Time = 1-5 seconds, the Booster Pump will turn off 2.5% away
from the target position.
Note: If Stall Time = 6 -10 seconds, the Booster Pump will turn off 1.0%
away from the target position.
Note: If Stall Time > 10 seconds, the Booster Pump will turn off 0.5% away
from the target position.
Boost Pump: {Booster Pump Breakpoint} defines the minimum deviation,5.0 to

99.9% of calibrated stroke or Off, between current position and Control Signal
for the booster pump to turn on.
Note: Only in menu if Drive Type = Servo, and Surge Bkpt = Off.
Note: If no Boost Pump, Boost Pump = Off
Main Valves sets the maximum deviation allowed before the main valves are
opened. This is a special parameter; used only with actuators which use an
accumulator for all motive force (no power module).
90
Note: The main valve off point is set by parameter Stall Time.
Note: Main Valves is only visible in the Drives menu if Foundation field bus
is installed. Requires special construction.
Surge Bkpt {Surge Breakpoint} defines in % calibrated stroke the minimum

deviation between the current position and the new target set by the incoming
Control signal, required to operate the surge solenoid. When the deviation
exceeds the setting, the Surge Relay output is activated and kept active
until the current position matches the current control signal. The Surge Relay
controls a solenoid valve allowing the actuator to travel quickly in the surge
direction when activated.
Only in menu if Signal Type = Analog, Accumulator = No and Booster Pump =
No.
Note: Surge Bkpt is only included in the SPEED/ACCEL menu if Contact/
Pulse Inputs Board is installed.
Refer to Appendix G, Surge Control Option, for additional information.
Surge Offpt{Surge Offpoint} will only appear in the DRIVES manu when the
Surge Bkpt has a value other than off. Surge Offpt is defined in percentage
of calibrated stroke. This percentage will define a distance the actuator will
be away from its new target position when it changes the state of the surge
solenoid during a surge event. On system with high speed trips this will allow
the controller to change states of the solenoid to anticipate hitting the new
target position and eliminate overshoot during a surge event. With Surge Offpt
set to off the actuator will command the surge solenoid to change state when
it reaches its new target position during a surge event. This will result in some
overshoot of the new position as the actuator will continue to travel while the
solenoid changes states. Surge Offpt has a settable range of 0.1% up to 5%
less than the current Surge Break point value.
Accumulator defines whether or not an accumulator system is present,

Accumulator action is controlled by parameter Trip; refer to INPUTS menu.
Factory set to Yes or No.
If Accumulator = Yes, he following 5 parameters are in the menu.
Rechrg Pres {Recharge Pressure} adjusts the pressure level at which an

accumulator recharge cycle ends. Factory set in # (psi), from Warn Pres + 100
up to Warn Pres + 3000 psi.
Warn Pres {Warning Pressure} adjusts the pressure at which an accumulator low
pressure warning is issued. Factory set from 1000 psi up to Rechrg Pres - 100
psi.
Note: The Warning relay deactivates and the status display will indicate
Pres Low when the accumulator pressure drops below the value set in
Warn Pres.
Rechrg Time {Recharge Time} adjusts the maximum time allowed for a recharge
cycle to complete. A recharge cycle ends when either the Rechrg Pres setting
is reached or the Rechrg Time expires. In either case, the actuator resumes
tracking the control signal. Recharge Time is factory set.
Accum Dir {Accumulator Direction} defines the direction the accumulator will
cause the actuator to travel during a Trip. This parameter is factory set based
on information provided. This parameter is necessary to inform the CPU as to
which direction, Pos Lo (Position lo) or Pos Hi (Position Hi), to operate the motor
during a recharge cycle after a Trip.
Accum Pres {Accumulator Pressure}: This parameter cannot be set. It is the

live pressure reading from the accumulator pressure transducer.
Units: # (psi)
Range: 0 to 3000
Unknwn if pressure bad error
92
6.1.8 OUTPUTS Menu

The OUTPUTS menu consists of the following parameters:
Relay #1
Relay #2
Pos Xmitter
Xmitter Low
Xmitter Hi
Password
Version
Relay #1 defines the point in % of calibrated stroke at which relay output 1 is
active. The relay will be active when the actuator position is = or < the value set
in Relay #1
Relay #2 defines the point in % of calibrated stroke at which relay output 2 is

active. The relay will be active when the actuator position is = or > the value set
in Relay #2
Pos Xmitter {Position Transmitter} defines the action of the position transmitter
output as being direct acting, Dir or reverse acting, Rev.
When set to direct acting, a 4 mA output corresponds to Position Lo.
When set to reverse acting, a 4 mA output corresponds to Position Hi.
Xmitter Low {Transmitter Low} is the parameter to calibrate the Output zero of
the 4-20 mA Position Transmitter.
To calibrate the 4mA Zero, Set a digital multi-meter,
DMM, to read milliamps (mA) DC. Connect the
DMM to the Position Transmitter Output on the CPU.
Connect the Red lead of the DMM to the LOOP OUT
terminal. Connect the black lead of the DMM to LOOP
INT RTN terminal. Press Enter to access this setting.
The Value displayed on the REXA display corresponds to

Digital bits. Each increment or decrement of 4 bits and
will increment or decrement the current output by one
micro-amp (1 A). The acceptable range for Xmitter Lo
is 3.9 to 4.1 mA.
Note: The Position Transmitter will output the mA

signal that corresponds to the actuators current
position until the Enter button is pressed and the =
sign is flashing. When the = sign is flashing, the
output will change to the Zero or Lo Calibration
value.
Xmitter Hi {Transmitter Hi} is the parameter to calibrate the Output span of the
4-20 mA Position Transmitter.
To calibrate the 20 mA Span, Set a digital multi-meter,
DMM, to read milliamps (mA) DC. Connect the
DMM to the Position Transmitter Output on the CPU.
Connect the Red lead of the DMM to the LOOP OUT
terminal. Connect the black lead of the DMM to LOOP
INT RTN terminal. Press Enter to access this setting.
The Value displayed on the REXA display corresponds
to Digital bits. Each increment or decrement is steps
of 4 bits and will increment or decrement the current
output by one micro-amp (1 mA).
Note: The Position Transmitter will output the mA
signal that corresponds to the actuators current
position until the Enter button is pressed and the =
sign is flashing. When the = sign is flashing, the
output will change to the Span or Hi Calibration
value.
Note: Xmitter Hi and Xmitter Lo values are not
transmitted over the bus in Foundation Fieldbus
units.
94
Once the position transmitter calibration is complete, there is no need to recalibrate the transmitter for changes in actuator span. Changing the actuator
span will cause the transmitter span to automatically re-calibrate its output.
Password {Password} defines the password required to enter the
Setup mode in order to change any control parameters. The

default value of 0000 indicates no password is required. If a value
is entered into Password other than the default value, future entry
into Setup mode will require that the user enter the Password
value prior to gaining access to the Setup menus.
Version {Software version} displays the version of software.
Example:
Version X01_0_AA_xxxx
6.1.9 CURRENT STATS Menu and

HISTORIC STATS Menu
The CURRENT STATS and HISTORIC STATS menus both provide error counters
and usage indicators. The two menus provide identical information, the
difference being that the CURRENT STATS parameters can be reset to 0 in
the Setup mode where as the HISTORIC STATS cannot. Also, the CURRENT
STATS can be viewed (but not altered) in Auto mode. HISTORIC STATS can
only be viewed in Setup mode.
The error counters are provided as an aid to diagnosing a problem. They are
particularly useful in identifying intermittent problems since they record ALL
instances of detected errors, rather than just those which result in an alarmed
condition. They are also useful in identifying problems associated with actuator
tuning.
Note: Refer to the TS&R Manual for trouble shooting support.
The error counters generally operate in the Auto mode (inclusive of Local
Man/RemoteMan) only. Errors detected in Setup are not recorded. If the Auto
mode is entered from Setup with an existing error, the error is not counted. The
only exception to the Auto mode only rule is the Mem Fail counter which
operates only in Setup mode.
Usage indicators only record in Auto mode.
The CURRENT STATS error counters and usage indicators may be reset to zero
by the following;
While in Setup and the counter/indicator to be reset is on display:
Press (E)nter the equals sign begins blinking
Press (D)own the value field resets to zero
Press (E)nter the new count is now zero
Note: If the (U)p key is pressed prior to step 3, the old count is returned to the
display and will be retained if the (E)nter key is then pressed.
96
Mem fail indicates the number of times that the Setup parameter memory failed
to erase/write a parameter value properly.
A/D fail indicates the number of times the A/D converter failed to respond to a
command.
Drive fault indicates the number of times a drive fault was detected.
Pressure bd {Accumulator pressure bad} indicates the number of times that the
Accumulator pressure transducer was detected out of range. The transducer is
considered out of range if the 4-20 mA signal is less than 3 mA or greater than
21 mA.
Shed Time indicates the number of times that a Setpoint update did not occur
within the time set in parameter Shed Time.
SLC Fb bad {Seat Load Cylinder Feedback bad} indicates the number of times
that the feedback from the seat load cylinder (4-20mA) was below 2 mA.
Fb bad {Actuator feedback} indicates the number of times that the actuators
feedback was below 2 mA.
Cs Bad {Analog control signal bad} indicates the number of times the analog
control signal was below 2.5 mA
Direction {Direction error} indicates the number of times the motor was stopped
because the actuator was detected moving in the wrong direction.
SLC stop {Seat Load Cylinder stop} indicates the number of times the actuator
stopped at the Seated position of the seat load cylinder but the control signal
did not require the valve to be seated (control signal was > 0.2%)
Stall indicates the number of times the motor was stopped because the Stall
Time was reached prior to achieving 1% of travel.
Note: For units with a Seat Load Cylinder, Stall will indicate the number
of times the Seated position was reached while position of the main
cylinder was greater than 1% above Position Lo.
The following four counters support non-standard hardware configurations:
Op Pres bad indicates the number of times that the open side pressure
transducer was detected out of range. The transducer is considered out of
range if the 4-20 mA signal is less than 3 mA.
Cl Pres bad indicates the number of times that the close side pressure
transducer was detected out of range. The transducer is considered out of
range if the 4-20 mA signal is less than 3 mA.
Low Oil indicates the number of times the reservoir level switch detected a low
oil condition.
Over Temp indicates the number of times the oil temperature switch detected
an over temperature condition.
The following two parameters are usage counters; each indicates the number of
times an event counter reached a count of 1000. Event counters are located
in volatile memory. Each power-on/reset causes the loss of any partial 1000
counts. Entry into Setup followed by a return to Auto mode preserves partial
1000 counts.
Starts x1K indicates the number of times the motor was started while in Auto.
e.g., Starts x1K=2 is 2000 starts.
Strokes x1K indicates the number of times the actuator traveled a distance
equal to its calibrated stroke divided, by 1000.
e.g., Strokes x1K=2 is 2000 strokes.
98
Last Error is not a counter; it indicates the last error detected. May be manually
reset to None in Setup {press (E)nter while Last Error is on display}. It is
automatically reset to None from reset/power on. The following may appear in
the value field (field 6) if a Last Error occurs:
Fb bad
Cs bad
Dir er
Stall
DrvFlt
Pwr 15
PresBd
Shed
Op bad
Cl bad
Lo Oil
HiTemp
SLC Fb
SLCstp
ADfail
MemBad
6.2 AUTO MODE

Auto is the mode in which the actuator will automatically follow the control
signal. When the deviation between current position and control signal is
greater than the dead band setting, the actuator will move to decrease that error.
6.2.1 Display Fields in Auto Mode

Field 2 (Blank)
Field 1
Au t o
Po s i t i o n =
St a t u s : OK
Field 3
0.0%
Field 4
Field 5
Field 6
Field 1 displays the Operating mode.

Field 2 is left blank to separate Fields 1 and 3.
Field 3 displays the unit status.
Field 4 displays the parameter position or alternate.
Field 5 separates fields 4 and 6 with space = space.
Field 6 shows the value for the parameter.
100
6.2.2 Display Information

Auto (Field 1) indicates the unit is in Auto mode, standard operation.
AutoBt (Field 1) indicates Auto mode with Bumpless transfer in progress.
Refer to the CONTROL menu.
Automm (Field 1) refers to Auto mode with minimum modulating active.

Refer to the CONTROL menu.
AutoRchg (Field 1) indicates the unit is in Auto mode with accumulator

Recharge cycle in progress. Refer to the DRIVES menu.
AutoTrip (Field 1) indicates the unit is in Auto mode with the Trip input active.
Refer to the INPUTS menu.
Status:OK (Field 3) or an error/warning message indicates the status of the unit.

Refer to the CURRENT STATS menu.
Position (Field 4) identifies the value displayed in Field 6.

Value (Field 6): Low if current position is more than 0.5% below Position Lo

0.0 to 100.0 if current position is between Position Lo and

Position Hi
High if current position is more than 0.5% above Position Hi

Note: Lo or Hi value indicates overtravel past Position Hi or Position Lo settings;
typically due to spring/accumulator driven operation.
If set up for Reverse Acting:

Value (Field 6): Low if current position is more than 0.5% above Position Lo

0.0 to 100.0 if current position is between Position Lo and

Position Hi
High if current position is more than 0.5% below Position Hi
Position value may display the following in the situations stated:
Unknwn (Field 6) if the feedback signal from the actuator to the

Control enclosure is not present.
Seated (Field 6) if the seat load cylinder is at the seated position

6.2.3 Parameter Viewing
In Auto mode the Control Parameters may be viewed (but not altered) by using
the or keys.
The first press of the key displays the Live Control Signal; successive
presses of the key steps the display down through the CALIBRATE menu.
The first press of the key displays the current Deviation. Successive presses
of the key steps the display up through the CURRENT STATS menu. A
5-second timer reverts the display back to current position if no / key
presses are detected. Holding the key down holds the current parameter on
display indefinitely.
Control Sig {Live Control Signal} (Field 4) identifies the value of the analog
control signal. The display is 0 -100 % for easy comparison with
the position display.
Value (Field 6): None when parameter Signal does not equal Analog.

Low when current signal is more than 0.5% below Signal Lo.
0-100% Active 4-20 mA signal is applied and is in between

Signal Lo and Signal Hi.
High when current signal is more than 0.5% above Signal Hi.
Unknwn when control signal is not applied.
Deviation (Field 4): Identifies the value in Field 6 as the difference, in % of

calibrated stroke, between the actuators current position and the actuators
102
target position. The value is prefixed with - if the current position is less than
the target and with + if above the target position.
Value (Field 6): 0.0 to 99.9% of calibrated stroke

Unknwn when the feedback signal from the actuator to the

Control enclosure is not present.
6.3 MANUAL MODE

Local Man indicates the manual operation of the actuator locally through
the Control Enclosure keypad. Once the Local Manual mode is entered, the
current status will be displayed along with position.
To enable local control, the status must be active. The actuator may be stroked
throughout its calibrated range. To do so, press . The = sign in Field 5 will
begin blinking. Use the and keys to stroke the actuator. Pressing again
prevents operation of the unit with the / keys.
When stroking the actuator in Local Manual mode, parameter Max Man
Spd sets the maximum speed of travel.
While in the Local Manual mode (= sign not blinking), the
used to examine (but not change) any Setup parameter.
and
keys may be
RemoteMan allows manual operation from a remote-station control unit. The

actuator can be stroked throughout its calibrated range. Once the Remote
Manual mode is entered, the current status will be displayed along with Position.
The RemoteMan mode is only accessible if the Contacts Input board is installed.
Refer to Appendix R, Remote Manual Control and Appendix Q, Contact Input
Options.
Figure 6.3 Contacts Input Board
A-1
A. MECHANICAL LIMIT SWITCHES
The mechanical limit switches are independent devices installed on the yoke
of the linear units and in the feedback housing area of rotary or drive units.
Electrical connections are made directly to the switches independent of REXA
electronics. Position will be indicated regardless of actuator power status.
A.1 LINEAR
A.1.1 General Specifications
Quantity: 2 or 4
Type: Single Pole, Double Throw (SPDT), Form C.
Rating: 5 amp @ 24 Vdc, 0.5 amp @ 125 Vdc,

10 amp @ 110 Vac - resistive
Differential Travel (Hysteresis): 5/16

Environmental: NEMA 4, FM/CSA CL.I, DIV.1 & 2,

GRP. A, B, C & D.
Connection: -14 NPT, screw terminals
Appendix A
Mechanical Limit Switches
A-2
Optional DPDT Limit Switches

Quantity: 2 or 4
Type: Double Pole Double Throw (DPDT), Form CC

Differential Travel (Hysteresis):


GRP. A, B, C & D.
Connection: -14 NPT, screw terminals
A.1.2 Linear Wiring

Remove the access plate by unscrewing the four slotted screws on the bottom of
the unit. Thread the cable through the NPT fitting and connect to the appropriate Normally Open (NO), Normally Closed (NC) and Common (C) screw terminals.
The cable should be grounded in accordance with Local and National Electrical
Code. Make sure that the gasket is in place and tightly seal the cavity.
A.1.3 Linear Adjustment

Loosen the two mounting screws approximately 1 to 2 turns and slide the entire
switch to the required position. Securely retighten the screws.
Appendix A
A-3
Figure A.1 Linear Limit Switches
Appendix A
A-4
A.2 ROTARY
A.2.1 General Specifications
Quantity: 2 or 4
Type: Single Pole, Double Throw (SPDT)

Differential Travel (Hysteresis): 5


GRP. A, B, C & D (optional).
Connection: Within the feedback housing (-NPT) screw terminals
Optional DPDT Rotary Limit Switches

Quantity: 2
Type: Double Pole, Double Throw (DPDT), Hermetically Sealed
Rating: 0.3 amp @ 125 Vdc, 0.15 amp @ 250 Vdc,

10 amp @ 125 or 250 Vac
Differential Travel (Hysteresis): 5

Connection: Directly to screw terminal on the switch.
Appendix A
A-5
Figure A.2 Rotary Limit Switch Schematic
A.2.2 Rotary Wiring

Remove the cylinder feedback cover (over the cylinder pinion) by unscrewing.
Refer to Figure A.2.3. Take care to keep threads clean and free from damage.
Thread the cable through the NPT fitting and make connections directly
to the microswitches. Refer to Figure A.2. The cable should be grounded in
accordance with Local and National Electrical Code.
A.2.3 Rotary Adjustment

For adjustment, the switch cam can be relocated by loosening the set screw and
repositioning. Make sure that the O-ring gasket is in place and tightly seal the
cavity. (See Figure A.2.3)
Appendix A
A-6
Appendix A
Switch Cam
Set Screw
Figure A.2.3 Rotary Limit Switch
B-1
B. Stem Connection &

Seat Loading Methods
B.1 THEORY OF OPERATION
Actuators which must come up against a hard stop require a spring loaded
element between the actuator and driven device. This spring loaded element
provides a controlled loading without over stressing mating parts. Its purpose is
the same as torque limit switches found on gear motor actuators but without the
inherent adjustment difficulties and potential for faulty calibration.
B.2 ELASTIC COUPLING

For applications that extend or retract against a hard stop, linear Xpac actuators
are provided with an elastic coupling for connecting the driven device to the
actuator. The elastic coupling contains a set of disc springs which are precompressed to approximately 80% of the rated thrust for fail-in-place units and
50% of the rated thrust for spring fail actuators.
The coupling provides a visual indication of compression (seat load) and should
be compressed to its rated mark when the driven device is at the end of travel.
At that point, the load on the driven device is approximately the net rated output
Appendix B
Stem Connection & Seat Loading Methods
B-2
Appendix B
of the actuator. Lower rated couplings are available for applications that require
reduced seat load.
The force indicator on the elastic coupling is a pin captured in a slot on the
side of the coupling. As the coupling compresses, the pin slides in the slot. A
scribed line marks the rated output position.
Figure B.2-1 Preloaded Coupling
Figure B.2-2 Rated Load Coupling
Enclosed spring couplings (not shown) have a small telltale pin protruding
from the top or bottom. As the coupling compresses, the pin is drawn into the
coupling. When the pin is flush with the coupling, it is at its rated output.
Note: The output of each coupling may be verified through the pressure gauges.
Note: To translate pressure gauge readings into actuator output, use the following
formula:
Pressure gauge reading

actuator rated output = actual output
2000 psi
For additional output calculation data, refer to Appendix O.
B.3 SEAT LOADING CYLINDER

On larger size units the forces are too great to use a mechanical elastic coupling.
Instead, a smaller Seat Loading Cylinder (SLC) with a spring load is hydraulically
connected to the actuator cylinder as shown Figure B.3.
The Seat Loading Cylinder utilizes a pre-compressed load equivalent to 80%
(1600 psi) of the nominal working pressure (2000 psi). As the power module
B-3
pumps hydraulic fluid into the actuator cylinder, the output shaft will begin to
extend. Once the force on the extension shaft reached the preset 80% of the
actuators rated output, the pressure in the top of the actuator cylinder will reach
the limit that begins to compress the spring on the seat load cylinder. This will
occur when the driven device reaches its end of stroke. As the pressure builds
within the actuator cylinder, oil flows into the SLC, designated by the high
pressure flow arrow and retracts the SLC shaft. When the spring is compressed
to the full nominal working pressure, the position feedback of the SLC will trigger
the power module to shut off. The rated actuator output is now applied to the
driven device and retained within the cylinders by the Flow Matching Valves.
Seat Load Cylinder
Figure B.3 Seat Loading Cylinder
Appendix B
B-4
Appendix B
B.3.1 Mechanical Installation

The Seat Loading Cylinder is mounted to the side of the main cylinder at the
factory. All hydraulic piping and spring preload will be complete. Mechanical
installation is not required.
B.3.2 Electrical Installation

Operation of the Seat Loading Cylinder requires the connection of a feedback
cable between the SLC and the control enclosure. The standard cable consists
of a red, white and black wire and a tinned copper ground wire. Each individual
wire is 18 AWG. The feedback cable is not restricted by distance.
The SLC Feedback Connections are terminated inside the Control Enclosure at
the CPU Board Assembly, TB1, +15, SLC+ and SLC-. Refer to Figure B.3.4-1.
The feedback connection is made directly to the screw terminals on the
feedback printed circuit board. Remove the four cap screws cover using care
not to damage the internal components. Feed the cable through the inch
NPT opening. Wiring connection is made directly to the feedback printed circuit
board per Figure B.3.2. Replace the cover on the cylinder and securely fasten.
Refer to the Electrical Installation section.
Table B.3.2 SLC Connections

SLC inch NPT on cylinder (Screw Termination)
Signal name
Wire colors
Terminal
+15 Vdc
Red
15V
Feedback (+)
White
4-20
Feedback (-)
Black
GND
Figure B.3.2 SLC Feedback Board
B-6
B.4 SOLENOID AUTO-SEATING

For linear valve applications that require fail-safe in the same direction as the
seated position, the elastic coupling and seat load cylinder are considered
to be redundant and unnecessary. Using an elastic coupling on a spring fail
or accumulator fail REXA is like using a spring in series with another spring.
For these applications REXA handles the seat loading with software that
automatically controls the solenoid operation as the actuator positions close to
the seat. This control menu parameter is called Solenoid Seat (Sol. Seat).
The software concept is similar in operation to the Min Mod functionality.
Rather than use the motor to drive to the seat, once the actuator reaches a
position close to the seat the solenoid valve(s) open and the remaining travel is
accomplished by using the stored energy (spring or accumulator) to drive the
valve into the seat.
B.5 CALIBRATION
Operation of the actuator is the same as a unit with an elastic coupling. The
only difference is at the seated position. Instead of compressing a coupling,
the spring on the SLC is compressed until the indicator on the SLC leg is at the
seated point. See Figure B.5-1.
Position Lo is set by moving the stem to the corresponding low signal

position. If the signal low position is the SEAT position, the seat load cylinder
flag must line up with the SEAT indicator mark on the spring housing cover.
The SEAT indicator mark is factory set for each application. The preset
tension of the spring should not be changed without consulting the REXA
factory.
Appendix B
B-7
Figure B.5-1 SLC IndicatorSeated

With Position Lo on the display, press the (E)NTER key. = will begin to
blink. Using the Scroll Up and Scroll Down keys, position the actuator to the
desired point and press (E)NTER again. The displayed value will be recorded as
the Position Low endpoint.
Position Hi is set by moving the stem to the corresponding high signal

position. If the signal high position is the SEAT position, the seat load cylinder
flag must line up with the SEAT indicator mark on the spring housing cover.
The SEAT indicator mark is factory set for each application. The preset
tension of the spring should not be changed without consulting the REXA
factory.
With Position Hi on the display, press the (E)NTER key. = will begin to
blink. Using the Scroll Up and Scroll Down keys, position the actuator to the
desired point and press (E)NTER again. The displayed value will be recorded as
the Position Hi endpoint.
When calibration is complete, and before returning to AUTO mode, depress
the RESET button located on the right side of the REXA CPU board. This will
set the new seated value as the SLC target. See Figure B.5-2.
Appendix B
B-8
Appendix B
Reset Switch
Figure B.5-2 Reset Switch
C-1
C. Accumulator Fail
C.1 THEORY OF OPERATION

System operation is based on a piston type accumulator with nitrogen gas on
one side of the piston and oil on the other.
Appendix C
Accumulator
C-2
Accumulator
Appendix C
C.1.1 Trip Function

Refer to Figure C.1.1-A, Trip Condition, to follow the fluid flow path during a trip.
The arrows indicate the flow direction
Under a trip condition or loss of electric power, two solenoid valves open
simultaneously. One solenoid allows oil under pressure from the accumulator
to be released and enter the failure side of the actuator driving it in the fail
direction. The other solenoid allows the oil displaced from the opposite side of
the cylinder into an auxiliary reservoir. To control the fail speed a needle valve is
installed on the outlet of the second solenoid valve.
Auxiliary
Reservoir
Actuator Cylinder
Isolation Valve
Trip Solenoid
Power Module
Trip Speed
Control Valve
Port A (Unit will trip

on power loss)
A
Optional Plumbing
B
Port B (Unit will not
trip on power loss)
Trip Solenoid
Accumulator
Pressure Gauge
Accumulator Bottle
Auxiliary
Reservoir
Pre-charged Nitrogen Gas

Figure C.1.1-A Trip Condition
C-3
C.1.2 Recharge Function

Reference Figure C.1.2-B to follow fluid path during recharge.
When the trip condition ends or power is restored, a pressure transducer signals
the CPU of low pressure in the accumulator. This signal tells the CPU to run the
power module in the direction required to drive the actuator in the fail direction.
Since the actuator cylinder is already at the end of its travel, the oil being
pumped from the reservoir by the power module will be allowed to flow into the
accumulator. When the proper recharge pressure is reached, the CPU stops
the power module and closes the solenoid valves. Normal operation is now
resumed and the actuator will follow the control signal.
Auxiliary
Reservoir
Actuator Cylinder
Isolation Valve
Trip Solenoid
Port A (Unit will
trip on power loss)
Power Module
Trip Speed
Control Valve
Optional Plumbing
B
Port B (Unit will not
trip on power loss)
Trip Solenoid
Accumulator
Pressure Gauge
Accumulator Bottle
Pressure Transducer
Pre-charged Nitrogen Gas
Figure C.1.2-B Recharge Condition
Appendix C
Accumulator
C-4
Accumulator
C.2 ACCUMULATOR CONTROL PARAMETERS

Five parameters in the electronics are used to control accumulator functions.
These may be found under the Drives menu and are: Rechrg Pres,
Warn Pres, Rechrg Time, Accum Dr and Accum Pres.
DRIVES Menu
The DRIVES menu provides the following:
Drive Type
Stall Time
Boost Pump
Accumulator
Rechrg Pres
Warn Pres
Rechrg Time
Accum Dir
Accum Pres
Reference the DRIVES Menu in Modes of Operation & Control Parameters.
C.3 RECHARGING
The recharge cycle will only occur if:
1. The CPU is in the Auto mode when power is restored after a loss of
power or removal of trip signal,

And
2. The pressure transducer output is less than Rechrg Pres
If CPU is NOT in Auto mode when power is restored or trip signal removed, the
unit MUST be placed in Auto and the reset button pushed.
Appendix C
C-5
IMPORTANT!
All actuators are shipped in the failed or tripped condition.

The actuator may initially power up in Setup mode. With the
trip signal inactive (or not connected), put the actuator in
Auto then either press the reset button or cycle power off
and back on. The actuator will go through a fail cycle, a recharge cycle and then return to following the control signal.
If this operation is not performed, the actuator will follow the
control signal, but the accumulator will remain uncharged,
rendering the actuator incapable of performing a trip or fail
operation. However, a low pressure warning will indicate
insufficient pressure to perform a fail operation.
C.4 MANUAL OVERRIDE

Accumulator actuators with solenoid valves are supplied with manual override
levers. This feature enables a way to manually change states of the solenoid
valves with electrical power off or in trip mode. Units are shipped from the
factory with the solenoid override levers in position A (Figure C.4-1).
Figure C.4-1 Solenoid Manual Override Levers (Position A)

They must be in this position for normal operation of the actuator. To use the
handwheel during a power off or trip situation both solenoid override levers must
be moved to position B.
Appendix C
Accumulator
C-6
Accumulator
Figure C.4-2 Solenoid Manual Override Levers (Position B)

Once both overrides are moved to position B, the handwheel may be operated
in a normal manner (Refer to Appendix M, Manual Operators). After handwheel
use and prior to returning the actuator to normal service, (power restored or trip
signal removed) both solenoid override levers must be returned to position A.
NOTE: When returning the levers to the normal open position the actuator will
stroke in the trip direction.
It is recommended that both override levers be safety wired in position A when

the handwheel is not in use.
For operation of Manual Override, refer to Appendix M, Manual Operators.
WARNING!
After using the handwheel, the overrides must be returned to

the A position or the unit will not operate correctly when
power is restored or trip signal removed. If only one override
is returned to the A position after a trip, damage to the
power module may occur.
Appendix C
C-7
C.5 DISCHARGING
There will be times that it is necessary to fully discharge the oil-side of the
accumulator system; such as when maintenance is being performed. To
perform this task, do the following:
1. Remove power to the actuator.
2. If the unit is fail in place during power loss, place both solenoid valves in
position B as shown in Figure C.4-2.
3. Open the manual bypass located on the front face of the module. Refer
to Figure C.5.
4. Check to ensure that all the pressure gauges read 0 psi.
Gauge
Gauge
CW Off
CCW On
CW Off
CCW On
Bypass
CW Off
CCW On
Figure C.5 Bypass Drawing
Appendix C
Accumulator
D-1
D. Booster Pump Configuration
D.1 THEORY OF OPERATION

Booster Pump Configurations utilize an Xpac power module and a large
capacity Booster Pump. The power module provides fine positioning, while a
volume booster pump provides the speed for large or coarse position changes.
This dual pump operation allows REXA to extend its unique capabilities to very
high thrust or torque units and high-speed operation without sacrificing position
accuracy.
Two sizes of BOOSTER PUMPS are available: the P9 and the P40. The P9
is used in combination with the D size power module to provide 5 times the
capacity of a D size power module or 2.5 GPM. A P40 with D size power
module has the pumping capacity for 11 GPM.
D.2 MECHANICAL INSTALLATION

An Xpac with the Booster Pump Configuration has no special installation
procedure. Therefore, the standard installation should be followed.
Appendix D
Booster Pump
D-2 Booster Pump
Appendix D
D.2.1 Control Enclosure

The major electrical components are located in a NEMA 4 enclosure. They have
a wide temperature range (-40F to 120F1 [-40C to +49C]) and can be field
installed at a convenient location. Avoid areas subject to excessive vibration or
heat. To reduce the possibility of water incursion, we recommend that any fitting
be pointed downward.
1
Ambient temperature only. Direct solar heat load must be avoided.
D.3 ELECTRICAL INSTALLATION

The Xpac consists of two major components, the Electraulic actuator (cylinder
and power module) and the control enclosure. The actuator is installed on
the driven device, while the enclosure is remotely mounted. Connecting them
are the motor power, resolver, feedback and module cables. Some cables
may not be run within the same conduit or seal-tite flex hose. Preferred wiring
procedures recommend that power voltages (motor power and module cables)
be kept separate from low level signal lines (resolver and feedback cables). User
connections of electric power and control signals are made at the enclosure.
Refer to Appendix P, Interconnect Diagrams.
! Important !
Motor power and motor resolver cables for the power module and booster
pump motors must be shielded! The shield of each is connected to the
green ground screw on the back panel of the control enclosure only.
The motor resolver signals are low level voltages.
The motor resolver

cables must be kept separate from the motor power cables or any other
high power wiring. However, the resolver cables may be run with the
feedback cable or other low power conductors.
Failure to follow the above may inhibit the proper operation of the
actuator.
D.4 CONTROL PARAMETERS

Refer to DRIVES menu, Modes of Operation & Control Parameters.
E-1
E. Pulse Operating System
E.1 THEORY OF OPERATION

The pulse operating system allows the use of a voltage input signal instead of
the standard 4-20 mA signal. Pulses are not merely motor power commands,
but change the target position. The actuator will continue moving until the
actual position satisfies the target position. The motion (speed, acceleration,
resolution) of the unit will be in accordance with the values set during calibration.
To receive the pulses, a contact input board is mounted on the CPU. This board
accepts 3 or 4 wire signals in the range of 24 to 120 volts, AC or DC. The pulses
are interpreted by the CPU based on the values set for the two pulse control
parameter, Pulse Duration and Pulse Increment.
Refer to the CALIBRATE menu and the INPUTS menu for additional information.
E.2 INSTALLATION
Wiring for pulse input is performed at the contact inputs board located on top of
the CPU. Terminal block TB3 provides six terminals to connect the HIGH signal
and the LOW signal. Refer to Figure E.2-1, -2, for wiring options.
Appendix E
Pulse Operating System
E-2
Figure E.2-1 Contact Input Board Wiring Options
Figure E.2-2 Contact Input Board Wiring Options
Appendix E
E-3
E.3 SIGNAL INPUT RANGE

Voltage: OFF: 0 to 8 volts, AC or DC
ON: 22 to 120 volts, AC or DC
Undefined: 8 to 22 volts, AC or DC
Current: OFF: less than 1 mA
ON: 1.8 mA to 10 mA; proportional to voltage
Impedance: 12K ohms
Electromechanical or solid state switching devices may be used to activate the
control signal. The following points should be observed:
ON state:
Most AC and many DC solid state switching devices require a minimum current
flow in order to remain in the closed state. If this minimum current exceeds the
input signal current at the activation voltage, the current flow may be increased
by adding a shunt resistor across the input signal terminals of the pulse auxiliary
board.
OFF state:
The OFF state leakage current must be less than 1 mA. Diode clamps or RC
snubber networks placed across mechanical relays and the semiconductor
junctions of solid state switches will pass some current in the OFF state. If this
leakage exceeds 1 mA, a resistor added across the input signal terminals will
bypass the current.
E.4 PULSE CONTROL PARAMETERS

Refer to the CALIBRATE menu and INPUTS menu for additional information.
Appendix E
E-4
E.5 TUNING
On systems that utilize position feedback to control the pulse train, it is usually
necessary to tune the Pulse Increment to replicate the actuator speed. The ideal
Pulse Increment is determined by dividing the Pulse Duration (in seconds) by the
total stroking time and multiplying by 100%.
Duration
Pulse Increment
= Pulse

Stroke Time 100%
To allow for motor acceleration, round this value up to the next highest tenth of a
percent.
Appendix E
F-1
F. Errors and Error Displays
The following are the error messages which appear on line 1 in place of
Status:OK when one or more errors are detected. If more than one error
is active, each is displayed at 1 second intervals in a repeating fashion. All
errors are cleared by: 1. Cycling the main power; 2. Pushing the reset switch;
3. Entering the Setup mode; or 4. By means identified in the Cleared by
sections which follow. To fix some of these alarm code errors it may be
necessary to refer to the Trouble Shooting and Repair manual.
FB bad
Cause: The actuators main Feedback is below 2 mA; either (+) or (-) 15
fail is set, or A/D fail is set.
Indicators: Alarm and Warning opens.

FB bad is displayed.

Actuator will not move.
Cleared by: Self clearing when Feedback >2 mA, or when 15 fail or
A/D fail clears.
Appendix F
Errors and Error Displays
F-2
CS bad
Cause: The analog Control Signal is below 2.5 mA; either the (+) or (-) 15
fail is set, or A/D fail is set.
Indicators: Alarm and Warning relays open.

CS bad is displayed.

Actuator will move to Failsafe position.
Cleared by: Self clearing when Control Signal >2.5 mA, or when 15 fail
or A/D fail clears.
Stall
Cause: After five attempts the actuator was unable to move 1% of stroke
within the defined Stall Time.
The Seated position was reached on the Seat Load Cylinder while the
position of the main cylinder was greater than 1% above Position Lo.

Stall is displayed.

Cleared by: Any control signal change which effects movement in the
opposite direction of the stall will clear the stall error.
Dir error
Cause: The actuator was detected moving in the wrong direction.

Dir error is displayed.

Cleared by: Cleared by cycling main power on, by pushing the reset switch,
or entering the Setup mode.
Appendix F
F-3
Drv fault
Cause: At least one motor drive has detected a problem.
Indicators: Warning relay opens.

Drv fault is displayed.

The actuator may or may not continue normal operation
depending on actuator construction.
Cleared by: CPU will attempt to clear Drv fault error until fault condition is
corrected.
+15 fail or
-15 fail
Cause: The (+) or (-) 15 volt power supply is out of range if it exceeds a (+)
or (-) 10% error band.
(+/-)15 fail is displayed.

Cleared by: CPU will attempt to clear fail error until fault condition is corrected.
Pres bad
Cause: The accumulators pressure transducer {Accum Pres} is out of
range if the 4-20 mA signal is less than 3 mA or greater than 21
mA.

Pres bad is displayed.

Actuator continues to operate normally.
Cleared by: Cleared when transducer signal is greater than 3 mA or less
than 21 mA.
Appendix F
F-4
Pres low
Cause: The accumulator pressure {Accum Pres} is below the value set in
parameter Warn Pres.

Pres low is displayed.

Cleared by: Successful Accumulator recharge cycle.
Op Pres bad or
Cl Pres bad
Cause: The open or close pressure transducer is out of range. The transducer is considered out of range if the 4-20 mA signal is less than 3 mA..

Op or Cl Pres bad is displayed.

Actuator continues to operate normally in Auto mode..
Cleared by: Transducer signal being greater than 3 mA.
Low Oil*
Cause: The reservoir oil level switch indicates that the oil level is low.

Low Oil is displayed.

Actuator continues to operate normally but will not attempt a
recharge cycle.
Cleared by: Oil level returning to normal.

*Available on REXA MEGApac only. Contact factory for additional details.
Appendix F
F-5
Over Temp*
Cause: The oil temperature switch indicates an over temperature condition
exists.

Over Temp is displayed.

Actuator attempts to continue to operate normally.
Cleared by: Temperature returning to normal range.
*Available on REXA MEGApac only. Contact factory for additional details.
Slc Fb bad
Cause: The Feedback signal from the Seat Load Cylinder is less than 2 mA.

Slc Fb bad is displayed.

Cleared by: Self clearing when Feedback >2 mA.
Slc stop
Cause: The actuator has detected a Seated position from the seat load
cylinder feedback, but the main cylinder is more than 0.2% from its
Seated position.

Slc stop is displayed.

The actuator continues with normal operation; however, the
main cylinder may not seat properly.
Cleared by: Any control signal change which effects movement in the
opposite direction in which the stop occurred will clear the error.
Appendix F
F-6
Key bad
Cause: A bad reading of the key pad has occurred.

Key bad is displayed.

Cleared by: Self clearing with a valid keypad reading.
Mem fail
Cause: A memory location containing a Setup parameter value has failed to
erase/write.

Mem fail is displayed.

Cleared by: Only cleared by cycling main power or pushing the reset
switch.
No inp bd
Cause: 1. Signal Type is set to 1 Cont, 2 Cont, or Pulse when a contact
input board is not installed or is faulty.
2. Trip is not Off.
Indicators:

Alarm and Warning relays open.

No inp bd is displayed.
Unit will go to Setup mode.
Cleared by: Changing the Signals menu parameter(s), or (with power off)
installing the required board.
Appendix F
F-7
A/D fail
Cause: The A/D converter on the CPU Board has failed to respond.

A/D fail is displayed.

Cleared by: Self clears if/when A/D responds.
Appendix F
G-1
G. Surge Control Option
G.1 THEORY OF OPERATION

High speed operation in one direction during upset conditions can best be
handled with REXAs Surge Control Option. This option gives the actuator the
ability for fast operation in one direction. During normal movements actuator
stroking speed is determined by Power Module speed capabilities. To obtain
this second surge speed a coil spring drives the actuator when a solenoid valve
opens. Four additional components are added to the standard actuator:
Mechanical Spring - provides the force to move the actuator in the surge
direction.
Solenoid Bypass Valve - bypasses the actuators normal hydraulic circuit.
Solid State Relay - interfaces the CPU with the solenoid.
Needle Valve - allows adjustment in Surge Control speed
The CPU will pulse the solenoid through the electronic relay to allow
controlled high speed motion in the spring direction. Control of this feature is
accomplished with the Surge Breakpoint (SG) parameter in the Setup menu.
Appendix G
Surge Control Option
G-2
If the change in control signal is less than the Surge Breakpoint, the actuator
operates normally. If the change in control signal is greater than the Surge
Breakpoint (and in the surge motion direction), then the solenoid opens and the
actuator is driven by the spring to the new position.
If the actuator is overshooting during a surge event, the Surge Offpt parameter
can be used to eliminate this overshoot. Reference the Drive Menu section in
Modes of Operation & Control Parameters in the IOM for additional information
regarding setting the Surge Offpt parameter. Increasing this Surge Offpt
parameter will reduce the overshoot until the unit begins to slow down too much
prior to hitting its target position. Figure G.1-1 illustrates the overshoot from
a surge event. Increasing the Surge Offpt would be required to eliminate this
issue. Figure G.1-2 shows the expected results when the Surge Offpt parameter
is tuned properly. Figure G.1-3 shows an undershoot condition. Decreasing the
Surge Offpt percentage will reduce the undershoot.
Various configurations of the spring package may have been provided. The
spring may be installed to open or close the driven device. Fail-safe position
can either be lock in place or in the surge direction.
Figure G.1-1 Overshoot
Appendix G
G-3
Figure G.1-2 Target position
Figure G.1-3 Undershoot
Appendix G
G-4
G.2 INSTALLATION
The fast response solenoid is a 3-way configuration and piped external to the
hydraulic cylinder. An adjustable needle valve is in line with the solenoid to allow
custom adjustment of the surge speed to meet a particular installation.
The wires used for the surge solenoid are a pair of blue wires in the module
cable. Connection for the solenoid within the control enclosure is made to TB4
of the power supply assembly as shown in G.2-1.
Refer to Figures G.2-1,-2,-3.
G.3 CALIBRATION
Refer to the CONTROL menu for additional information.
Appendix G
G-5
Figure G.3-1 Surge Solenoid Connection
Appendix G
G-6
Figure G.3-2 Solenoid & Wet Trip Connection
Appendix G
G-7
Figure G.3-3 Solenoid & Dry Trip Connection
Appendix G
REXA Series 2 Xpac Installation and Operation Manual 04/13 H-1
H. Build Numbers
The build number is a catalog number REXA uses to designate in complete

detail the construction of the actuator. From this number all configurations can
be defined. There are two different categories of build numbers; one is for the
mechanical sub-assembly, and the second is for its corresponding electronics
sub-assembly. Within the mechanical sub-assembly there is a build number for
Rotary and Drive actuators, and a separate build number for Linear actuators.
Appendix H
Build Numbers
H-2
Build Numbers
Appendix H
LINEAR SERIES ACTUATOR

1 2 3 4 5 6 7 8 9 10
11
12
13
14 15
A
Actuator Type
L=REXA Block Cylinder
C=Commercial Cylinder
Output
C=2000 lbf (8896 N)
D=4000 lbf (17793 N)
E=5000 lbf (22241 N)
F=10000 lbf (44482 N)
G=15000 lbf (66723 N)
H=20000 lbf (88964 N)
I=30000 lbf (133447 N)
J=40000 lbf (177929 N)
M=60000 lbf (266893 N)
K=80000 lbf (355858 N)
L=120000 lbf (533787 N)
Z=Special
Actuator Stroke
A=.75" (.02 m)
B=2" (.05 m)
C=4" (.10 m)
D=6" (.15 m)
E=8" (.20 m)
F=11" (.28 m)
G=16" (.40 m)
H=22" (.56 m)
I=28" (.71 m)
J=36" (.91 m)
K=42" (1.07 m)
L=48" (1.22 m)
Z=Special
15
1
14
Power Module Size

B=B Module
C=C Module
D=D Module
F=D Module
G=2D Module
H=D,P9 Module
I=D,P40 Module
M=2C Xpac Module
Z=Special
Output Limit/Protection
C=37%-73% Total Output
D=74%-99% Total Output
E=100%-140% Total Output (Std)
Z=Special
13
12
11
10
Fail Safe Mode

P=Fail In Place (Std)
E=Fail Extend Low Spring Load
R=Fail Retract Low Spring Load
H=Fail Extend High Spring Load
B=Fail Retract High Spring Load
A=Accumulator Extend
M=Accumulator Retract
Z=Special
Fail Mode Speed

N=N/A (Std)
S=Standard Solenoid
H=High Speed Solenoid
E=Surge Control Extend
R=Surge Control Retract
Z=Special
Heater/Solenoid Voltage
A=120 Vac
B=240 Vac
C=125 Vdc
F= 48 Vdc
E=24 Vdc
G=12 Vdc
N=No Heater
Z=Special
Design
X2-A
X2-B
Z=Special
Construction
S=NEMA 4X, (Std)
T=NEMA 4X, TNEMEC Paint
C=NEMA 4X Class1/Div2
D=NEMA 4X, Class1/Div2, TNEMEC Paint
N=CE, IP66, ATEX Zone 2
Z=Special
Mechanical Switches
N=No Switches (Std)
A=2 SwitchesSPDT 4X Hi Temp
C=2 SwitchesSPDT Class1/Div2
E=4 SwitchesSPDT Class1/Div2
G=2 SwitchesDPDT Class1/Div2
J=4 SwitchesDPDT Class1/Div2
O=Oil Level
D=Oil Level & 2 SwitchesSPDT Cl1/Div2
F=Oil Level & 4 SwitchesSPDT Cl1/Div2
H=Oil Level & 2 SwitchesDPDT Cl1/Div2
K=Oil Level & 4 SwitchesDPDT Cl1/Div2
Z=Special
Seat Loading Method

N=None (Std)
S=Seat Load Cylinder
C=Elastic Coupling Extend
U=Elastic Coupling Retract
Z=Special
Cable Connections
S=Terminal Strip (Std)
Q=Quick Disconnect
Z=Special
Manual Override
H=Handwheel/Drill Drive
P=Manual Hydraulic Pump
N=None (Std)
Z=Special
Temperature Rating and Stem Boot

S=Standard 200F (93C) Temp Rating (Std)
H=High 250F (121C) Temp Rating
B=Standard 200F (93C) with Linear Stem Boot
T=High 250F (121C) with Linear Stem Boot
R=Standard 200F (93C) Remote Feedback
L=Standard 200F (93C) Remote Feedback with Stem Boot
Z=Special
The most common codes are shown above. However, the Xpac 2 is an engineered product and REXA practices a policy of continuous improvement. As
such, additional codes may be available or may be added without notice. Please contact the factory for information on any code not shown above.
H-3
ROTARY SERIES ACTUATOR

1 2 3 4 5 6 7 8 9 10
11
12
13
14 15
A
Actuator Type
R=Rotary Cylinder
D=Drive Unit
Output
C=2500 lbfin (282 Nm)
D=5000 lbfin (565 Nm)
E=10000 lbfin (1130 Nm)
F=20000 lbfin (2260 Nm)
G=50000 lbfin (5650 Nm)
H=100000 lbfin (11300 Nm)
I=200000 lbfin (22597 Nm)
J=400000 lbfin (45194 Nm)
Z=Special
14
13
2
12
Actuator Rotation
A=90 degree (Std)
B=180 degree
C=270 degree
D=280 degree
E=120 degree
Z=Special
3
11
Power Module Size

B=B Module
C=C Module
D=D Module
F=D Module
G=2D Module
H=D,P9 Module
I=D,P40 Module
M=2C Xpac Module
Z=Special
Fail Safe Mode

C=Clockwise Spring
R=Counter Clockwise Spring
A=Accumulator Clockwise
M=Accumulator Counter Clockwise
Z=Special
10
Fail Mode Speed

N=N/A (Std)
S=Standard Solenoid
H=High Speed Solenoid
E=Surge Control CW
R=Surge Control CCW
Z=Special
6
7
15
Design
X2-A
Z=Special
Output Limit/Protection
C=37%-73% Total Output
D=74%-99% Total Output
E=100%-140% Total Output (Std)
Z=Special
Construction
S=MEMA 4X, (Std)
T=NEMA 4X, TNEMEC Paint
C=NEMA 4X, Class1/Div2
D=NEMA 4X, Class1/Div2, TNEMEC Paint
Z=Special
Mechanical Switches
N=No Switches (Std)
C=2 SwitchesSPDT
E=4 SwitchesSPDT
G=2 SwitchesDPDT
O=Oil Level
D=Oil Level & 2 SwitchesSPDT
F=Oil Level & 4 SwitchesSPDT
H=Oil Level & 2 SwitchesDPDT
Z=Special
Seat Loading Method

N=None (Std)
Z=Special
Cable Connections
S=Terminal Strip (Std)
Q=Quick Disconnect
Z=Special
Manual Override
H=Handwheel/Drill Drive
P=Manual Hydraulic Pump
N=None (Std)
Z=Special
Temperature Rating
S=Standard 200F (93C) Temp Rating
R=Remote Feedback Std. Temp
Z=Special
Heater/Solenoid Voltage
A=120 Vac
B=240 Vac
C=125 Vdc
F=48 Vdc
E=24 Vdc
G=12 Vdc
N=No Heater
Z=Special
Appendix H
Build Numbers
H-4
Build Numbers
Appendix H
ELECTRONIC NUMBERING SYSTEM

1 2 3 4 5 6 7 8 9 10
11
12
13
14 15
A
Power Module Size
B=B Module
C=C Module
D=D Module
F=D Module
G=2D Module
H=D-P9 Module
I=D-P40 Module
M=2C Xpac Module
Z=Special
15
Design
A=X2
B=X2, Design 2
C=X2, Design 3
D=X2, Design 4
Z=Special
Power Supply
A=120 Vac
B=240/208 Vac
C=480 Vac
D=12 Vdc
E=24 Vdc Std 14to185F (-10to+85C)
F=48 Vdc
G=125 Vdc
I=240 Vac 3Phase
J=480 Vac 3Phase
K=380 Vac 3Phase
L=600 Vac 3Phase
Z=Special
14
13
2
Control Signal
G=Analog 4-20mA w/ Surge Sup. (Std)
P=Pulse Operating System
T=Two Position - 1 Signal
M=Manual - 2 Signal
J=Hart 420 mA w/ Surge Sup.
F=Foundation fieldbus
Z=Special
11, 12
10
3
Area Approvals
S=General Locations (Std)
C=CSA C1/D2 (B,C,D)
9
4
Enclosure Material
P=Painted Steel, NEMA 4 (Std)
S=304 Stainless Steel, NEMA 4X
F=Fiberglass, NEMA 4X
Z=Special
Controls
E=External (Std)
I=Internal
C=Int Controls
with Ext Buttons/Window
D=Int Controls
with Ext Buttons/No Window
Z=Special
Variations
N=None (Std)
T=Quick Release Connectors
U=Quick Release/Conform Coat
Electronics Supplied
Y=Yes
Z=Special
Software
AA=Standard Software (Std)
FA=Foundation Fieldbus
LA-Standard w/Auto Mode Ind.
Options
N=No Options (Std)
A=Accumulator System
S=Hydraulic Surge Option
L=Seat Load Cylinder
D=Accum. & Seat Load Cylinder
H=Surge & Seat Load Cylinder
Z=Special
Position Transmitter
A=Active 420mA
P=Passive 420mA (Std)
L=Active 4-20mA, Local Mode Ind.
M=Passive 4-20mA, Local Mode Ind.
Z=Special
Actuator Temperature Rating

S=Standard 200F (93C) Temp Rating
R=Remote Feedback Std 200F (93C)
Z=Special
Remote Manual Station

A=Basic Station
B=Basic Station with Display
C=Remote Station Compatibility
N=None (Std)
Z=Special
H-5
MOUNTING SYSTEMS
Linear Series Actuator
1 2 3 4 5 6 7 8 9
Actuator Type
N=No Mounting Hardware
C=Commercial Linear Cylinder
Output
C=2000 lbf (8896 N)
D=4000 lbf (17793 N)
E=5000 lbf (22241 N)
F=10000 lbf (44482 N)
G=15000 lbf (66723 N)
H=20000 lbf (88964 N)
I=30000 lbf (133447 N)
J=40000 lbf (177929 N)
M=60000 lbf (266893 N)
K=80000 lbf (355858 N)
L=120000 lbf (533787 N)
Z=Special
1
9
2
Actuator Stroke
A=.75" (.02 m)
B=2" (.05 m)
C=4" (.10 m)
D=6" (.15 m)
E=8" (.20 m)
F=11" (.28 m)
G=16" (.40 m)
H=22" (.56 m)
I=28" (.71 m)
J=36" (.91 m)
K=42" (1.07 m)
L=48" (1.22 m)
Z=Special
Valve Attachment
S=Down Seat Split Clamp
B=Up Seat Split Clamp
N=No Clamp
4
7
3
Certified Drawings
A= Actuator Outline
C=Control Enclosure Outline
E=Electrical Interconnect Schematic
O=Actuator & Interconnect
D=Actuator & Enclosure & Interconnect
N=No Certified Drawings
5
6
Packaging
D=Domestic (Std)
E=Export
Inspection Level
S=Standard Inspection
A=Advanced Inspection (Level II)
P=Premium Inspection (Level I)
Variations
N=No Factory Mount & Calibrate
A=L2000 Mount & Calibrate
B=L4K-L10K Mount & Calibrate
C=L15K & Up, Mount & Calibrate
Other Documentation
B=Bill of Materials
C=Certificate of Conformance
F=Final Inspection Report
A=All (BOM, COC & FIR)
N=No Other Documentation
Rotary Series Actuator

1 2 3 4 5 6 7 8 9
Actuator Type
R=Rotary Cylinder
Output
C=2500 lbin (282 Nm)
D=5000 lbin (565 Nm)
E=10000 lbin (1130 Nm)
F=20000 lbin (2260 Nm)
G=50000 lbin (5650 Nm)
H=100000 lbin (11300 Nm)
I=200000 lbin (22597 Nm)
J=400000 lbin (45194 Nm)
Z=Special
Actuator Rotation
A=90 Degrees (Std)
B=180 Degrees
C=270 Degrees
D=280 Degrees
E=120 Degrees
Z=Special
8
2
7
3
Valve Attachment
A=4" or less
B=6" to 10"
C=12" to 14"
D=16" to 20"
E=20" and up
4
5
Packaging
D=Domestic (Std)
E=Export
Inspection Level
Variations
A=Factory Mount & Cal 4" or Less
B=Factory Mount & Cal 6" to 10"
C=Factory Mount & Cal 12" to 14"
D=Factory Mount & Cal Over 16"
Other Documentation
B=Bill of Materials
Certified Drawings
A= Actuator Outline
Appendix H
Build Numbers
H-6
Build Numbers
Appendix H
Drive Series Mounting

1 2 3 4 5 6 7 8 9
Actuator Type
D=Drive Unit
Output
C=2500 lbin (282 Nm)
D=5000 lbin (565 Nm)
E=10000 lbin (1130 Nm)
F=20000 lbin (2260 Nm)
G=50000 lbin (5650 Nm)
H=100000 lbin (11300 Nm)
I=200000 lbin (22597 Nm)
J=400000 lbin (45194 Nm)
Z=Special
9
2
Actuator Rotation
A=90 Degrees (Std)
B=180 Degrees
C=270 Degrees
D=280 Degrees
E=120 Degrees
Z=Special
Valve Attachment
S=Standard Base & Arm
A=Standard Base & Custom Arm
B=Custom Base & Standard Arm
C=Custom Base & Custom Arm
4
5
Packaging
D=Domestic (Std)
E=Export
Inspection Level
Variations
N=No Linkage Kit
C=Custom Linkage Kit
Other Documentation
B=Bill of Materials
Certified Drawings
A= Actuator Outline
H-7
LINEAR FISHER MOUNTING

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Actuator Type
C=Commercial Linear Cylinder
Output
C=2000 lbf (8896 N)
D=4000 lbf (17793 N)
E=5000 lbf (22241 N)
F=10000 lbf (44482 N)
G=15000 lbf (66723 N)
H=20000 lbf (88964 N)
Z=Special
Actuator
Stroke
A=.75" (.02 m)
B=2" (.05 m)
C=4" (.10 m)
D=6" (.15 m)
E=8" (.20 m)
F=11" (.28 m)
G=16" (.40 m)
Z=Special
1
17
Revision
A=Current Rev
16
Variations
N=None
2
15
14
3
Valve Attachment
S=Down Seat Split Clamp
B=Up Seat Split Clamp
N=No Clamp
13
4
Certified Drawings
A= Actuator Outline
12
5
Other Documentation
B=Bill of Materials
11
10
6
Fail Safe Mode

E=Fail Extend Low Spring Load
R=Fail Retract Low Spring Load
H=Fail Extend High Spring Load
B=Fail Retract High Spring Load
A=Accumulator Extend
M=Accumulator Retract
Z=Special
9
7
8
Valve Stroke
A=" to 1"
B=1-18" to 1-78"
H=2" and up
Z=Special
Stem Height
A=4-"
B=6-316"
C=6-58"
D=8-78"
E=9-58"
Stem Thread
B=38"24
D="20
F="16
H=1"14
I=1-"12
Yoke Boss
A=2-18"
C=2-316"
E=3-916"
G=5"
Packaging
D=Domestic (Std)
E=Export
Inspection Level
Mount & Cal

A=L2000 Mount & Calibrate
B=L4K-L10K Mount & Calibrate
C=L15K & Up, Mount & Calibrate
Seat Loading Method

N=None (Std)
C=Elastic Coupling Extend
U=Elastic Coupling Retract
Z=Special
Appendix H
Build Numbers
K-1
K. Fieldbus
An Xpac Series 2 actuator is represented on a Fieldbus network as a group of

blocks through which the X2 actuator may be configured and operated. The
blocks include:

- One Resource block

- One Analog Output block
- One Discrete Output block
- Two Analog Input blocks
- One Discrete Input block
- One Transducer block
The Resource block and the Input/Output blocks are standard Fieldbus blocks
which implement the networking and control capability of a Fieldbus system.
The Transducer block is a custom block which is designed specifically to
connect an Xpac 2 actuator to a Fieldbus network. In a control application,
the Transducer block reads and writes process variables from the actuator and
passes these values to the network via the I/O blocks.
The Transducer block also provides access to all X2 actuator configuration
(Setup) parameters (excluding stroke calibration parameters). Any configuration
parameter which may be viewed or changed at the local Operators Panel may
also be viewed or changed over the Fieldbus network.
Appendix K
Fieldbus
K-2
Fieldbus
The Transducer block is also capable of gathering simultaneous data samples

of X2 actuator Position, Setpoint, and (if implemented) Differential Pressure,
and storing them for later retrieval. Two hundred samples of each variable are
gathered in 20 groups of 10 samples of each variable. Data gathering may
be initiated manually at any time, or automatically by a specified change in
Setpoint. The rate at which the samples are gathered may also be specified.
All blocks have many named parameters. The standard Fieldbus blocks
(Resource and I/O) contain only Fieldbus defined parameters which, in this
document, are written as FIELDBUS NAME (upper case lettering) and when
observed on a Fieldbus host are viewed in a similar manner. The Transducer
block also contains Fieldbus defined parameters which are written and viewed
as above. The Transducer block also contains X2 actuator specific custom
parameters which may be viewed on a host in one of two ways; either as a
default, software derived name or as a Device Description supplied name (noted
in brackets). In this document the custom parameters are written as DEFAULT
NAME {Device Description Name} wherever the names differ. Parameter
values where shown are in bold text
Resource block:
The Resource block provides device identification and some basic network
communications parameters.
There are no X2 actuator specific parameters in this block.
Analog Output block (AO)

The AO block accepts analog values from the network and writes the value
to the Transducers block parameter Setpoint to control positioning of the
X2 actuator.
The AO block also reads the Position of the X2 actuator from the
Transducer block and passes the value to the network.
To use this block:

- Set the AO block parameter CHANNEL to AO Setpoint.
Appendix K
REXA Series 2 Xpac Installation and Operation Manual 07/12 K-3
- Initialize the AO block parameter SHED_OPT (NormalShed_NormalReturn is sufficient).
- Set the Transducer block parameter CONTROL_CHANNEL {Positioner Control Method} to CH1- Analog Output
Analog Input blocks (AI)

The AI blocks read a process variable from the Transducer block and pass
the value to the network as an analog value.
To use AI1 blocks and propagate Actuator Position:

- Set the AI1 block parameter CHANNEL to Al1 Position.
- Set the AI1 block parameter L_TYPE to Indirect.
- Set the AI1 block parameter XD_SCALE:EU_100 to 100

:EU_0 to 0

:UNITS_INDEX to %.
- Set the AI1 block parameter OUT_SCALE:EU_100 to 100

:EU_0 to 0

:UNITS_INDEX to %.
To use AI2 blocks and propagate Actuator Differential Pressure (if the
feature is available):
Appendix K
- Set the AI2 block parameter CHANNEL to AI2 Differential Pressure.
- Set the AI2 block parameter L_TYPE to Direct.
- Set the AI2 block parameter XD_SCALE:EU_100 to 3000

:EU_0 to 0

:UNITS_INDEX to psi.
- Set the AI2 block parameter OUT_SCALE:EU_100 to 3000

:EU_0 to 0

:UNITS_INDEX to psi.
Fieldbus
K-4
Fieldbus
Discrete Output block (DO)

The DO block accepts discrete values from the network and forwards a
value of 0% or 100% to the Transducer block parameter Setpoint to control
positioning of the X2 actuator.
0x00 for a Setpoint of 0.0%
0x01 for a Setpoint of 100%
The DO block also reads the Position of the X2 actuator from the
Transducer block and passes the value to the FF network as a discrete
value.
0x00 if Position is less than 50.0%
0x01 if Position is equal to or greater than 50.0%
To use this block:

- Set the DO block parameter CHANNEL to DO Setpoint.
- Initialize the DO block parameter SHED_OPT (NormalShed_NormalReturn is sufficient).
- Set the Transducer block parameter CONTROL_CHANNEL {Positioner Control Method} to CH4- Discrete Output
Discrete Input block (DI)

The DI block reads the X2 actuator Position from the Transducer block and
passes the value to the FF network as a discrete value.
0x00 if Position is less than or equal to 5%
0x01 if Position is greater than 5% and less than 95%
0x03 if Position is greater than 95%
To use this block:

- Set the DI block parameter CHANNEL to DI Position.
Appendix K
Transducer block
The Transducer block links the XPac X2 actuator to the Input/Output
function blocks. It also provides access to all of the X2 actuators
configuration parameters. Other parameters which provide for control and
observation of the X2 actuator are also included.
All parameters may be viewed at any time. To change any parameter, the
block should be put in OOS (Out Of Service). To change any X2 actuator
configuration parameter, the X2 actuator must also be in Comm Setup
mode. The X2 actuators current mode may be viewed using parameter
MODE_STATUS {Mode\Status Byte}. The X2 actuators current mode
may be changed using parameter OPERATING_MODE {Operating Mode}.
X2 Actuator Configuration Parameters

The following lists all of the X2 actuators configuration parameters. Details
for each parameter may be found in the Setup section of this document.
All of the listed parameters will always be visible over a fieldbus network.
However, some parameters are not implemented in all X2 actuator Software
versions, and some parameters may not be usable due to the current
setting of other parameters. In either case, when a parameter is not usable
it will have a value of 1.#QNAN. Any attempt to modify such a parameter
will result in an error message.
CONTROL Menu
DEADBAND {Deadband}
Deadband
MIN_MODULATING {Minimum Modulating}
Min Mod
BUMPLESS {Bumpless Transfer}
Bumpless
SEAT_LOAD_CYLINDER {Seat Load Cylinder control} Seat Ld Cyl
Appendix K
SEAT_LOAD {Seat Load Switching}
Seat Load
SOLENOID_SEAT {Solenoid Seating}
Sol. Seat
CALIBRATED_STROKE {Calibrated Stroke}
Cal. Stroke
FLOW_CHAR {Flow Characterization}
Flow Char
FLOW_CHAR_CS_10 {CS 10% Pt} thru
CS 10% Pt thru
FLOW_CHAR_CS_90 {CS 90% Pt}
CS 90% Pt
Fieldbus
K-6
Fieldbus
Appendix K
SPEED/ACCEL Menu
MAX_HI_SPEED {Max Hi Speed}
Max Hi Spd
MAX_UP_SPEED {Max Up Speed}
Max Up Spd
GAIN {Gain}
Gain
HI_ACCEL {Hi Accel}
Hi Accel
ACCEL_BKPT {Accel Breakpoint}
Accel Bkpt
LO_ACCEL {Lo Accel}
Lo Accel
TWO_SPEED {2 Speed}
2-Speed
MAX_LO_SPEED {Max Lo Speed}
Max Lo Spd
MAX_DN_SPEED {Max Dn Speed}
Max Dn Spd
SPEED_BKPT {Speed Breakpoint}
Speed Bkpt
MAX_MAN_SPEED {Max Man Speed}
Max Man Spd
INPUTS Menu
SIGNAL_TYPE {Signal Type}
Signal Type
PULSE_DURATION {Pulse Dur}
Pulse Dur
PULSE_INCREMENT {Pulse Inc}
Pulse Inc
FAILSAFE {Failsafe}
Failsafe
SHED_TIME {Shed Time}
Shed Time
TRIP {trip}
Trip
POWER_ON {Power On}
Power On
DRIVES Menu
DRIVE_TYPE {Drive Type}
Drive Type
STALL_TIME {Stall Time}
Stall Time
BOOST_PUMP_BKPT {Boost Pump}
Boost Pump
MAIN_VALVE_BKPT {Main Valves}
Main Valves
SURGE_BREAKPOINT {Surge Breakpoint}
Surge Bkpt
ACCUMULATOR {Accumulator}
Accumulator
ACCUM_HI_PRES {Recharge Pres}
Rechrg Pres
ACCUM_LO_PRES {Warn Pres}
Warn Pres
RECHARGE_TIME {Rechrg Time}
Rechrg Time
ACCUM_FAIL_DIR {Fail Dir}
Accum Dir
ACCUM_PRES {Accum Pres}
Accum Pres
OUTPUTS Menu
RELAY_1 {Relay #1}
Relay #1
RELAY_2 {Relay #2}
Relay #2
POS_XMTR {Position Transmitter}
Pos Xmitter
Password {Password}
Password
OPEN_PRES {Open Pres}
Open Pres
CLOSE_PRES {Close Pres}
Close Pres
SOFTWARE_VERSION {Controller Software Version}
Version
CURRENT STATS and HISTORIC STATS Menus:
Appendix K
MEM_FAIL {Memory fail Error Count}
Mem fail
A/D_FAIL {A/D fail Error Count}
A/D fail
DRIVE_FAULT {Drive fault Error Count}
Drive fault
PRESSURE_BAD {Accumulator pressure bad}
Pressure bd
SHED_TIME_ERROR {Shed Time error}
Shed Time
SLC_FB_BAD {SLC Feedback bad}
SLC Fb bad
FB_BAD {Feedback bad}
Fb bad
CS_BAD {Control signal bad}
Cs bad
DIRECTION {Direction error}
Direction
SLC_STOP {SLC stop}
SLC stop
Fieldbus
K-8
Fieldbus
Appendix K
STALL {Stall}
Stall
CL_PRESS_BAD {Close Pres bad}
Cl Pres bad
OP_PRESS_BAD {Open Pres bad}
Op Pres bad
LOW_OIL {Low Oil}
Low Oil
OVERTEMP {Over Temp}
Over Temp
STARTS_X1K {Starts x1K}
Starts x1K
STROKES_X1K {Strokes x1K}
Strokes x1K
Other X2 actuator parameters:

CONTROL_CHANNEL {Positioner Control Method}: This parameter
specifies which output block is to provide the Setpoint to the Transducer block.

CH1-Analog Output: Selects the AO block as the Setpoint source.
CH4-Discrete Output: Selects the DO block as the Setpoint source.
OPERATING_MODE {Operating Mode}: This parameter is used to change

the mode of operation of the X2 actuator.

Auto mode: Switches the X2 actuator to Auto mode for Setpoint tracking.
Comm Setup mode: Switches the X2 actuator to a Setup mode for

configuration over the Fieldbus network.
Panel Setup mode and Panel Local mode: These modes are only
selectable at the X2 actuators local Operators Panel and cannot be
invoked over the Fieldbus network.
MODE_STATUS {Mode\Status Byte}: This parameter reports the current

mode of operation of the X2 actuator.

Auto mode: The X2 actuator is following the Setpoint input. No X2

actuator configuration parameter may be modified while in Auto mode.
In Comm Setup Mode: The X2 actuator is holding position. Any X2

actuator configuration parameter may be modified over the Fieldbus
network.
Panel Setup Mode: The X2 actuator is holding position. Any X2

actuator configuration parameter may be modified at the local Operators
Panel.
Manual Mode (either Local or Remote): The X2 actuator is holding

position but may be manually stroked at the local Operators Panel or
via a remote hand/auto station.
The Mode\Status Byte also reports the presence of the Contact Input Board
if it is installed in the X2 actuator, and reports active status of the Trip input
(override signal).
RESPONSE_CODE {Response Code}: When an X2 actuator configuration
parameter is written, a response code is issued as part of the return
message indicating the relative success or failure of the write operation.

Success: the data was accepted unconditionally.
Conditional success: the data sent was too large, too small or imprecise. The X2 actuator has corrected the data by rounding down, rounding up, or rounding off the value sent prior to writing.
Failure Not Available: The write attempt was rejected because the
parameter is not used in this version of the X2 actuator or the parameter
is currently not usable due to settings of other parameters. When a
parameter is not available it is displayed with a value of 1.#QNAN.
Failure Wrong Mode: The write attempt was rejected because the X2
actuator was not in Comm Setup Mode.
Failure No Contact: The write attempt was rejected because the

parameter requires use of the Contact Input Board which is not present
in the X2 actuator.
POSITION: This parameter reports the X2 actuators current position.

CONTROL_SIGNAL {Control Signal}: This parameter is not used with a
Fieldbus network and should be ignored.
Appendix K
Fieldbus
K-10 Fieldbus
Appendix K
TARGET_POS {Target}: This parameter reports the current target position

of the X2 actuator. Target position normally equals the Setpoint value
but may be modified by use of other parameters such as Flow Characterization, Minimum Modulating, Bumpless Transfer, etc.
SETPOINT: This parameter reports the current value of the X2 actuators
Setpoint input.
DIFF_PRESSURE: This parameter reports the current differential pressure
measured across the X2 actuators hydraulic cylinder(s). It may be
used to calculate thrust or torque by multiplying the value times the net
working area of the hydraulic cylinder(s). When the differential pressure
measuring feature is not implemented, this parameters value will be
1.#QNAN.
ERROR_BYTE1 (error_byte1},
ERROR_BYTE2 (error_byte2},
ERROR_BYTE3 (error_byte3}: These parameters report any error conditions detected within the X2 actuator.
ERROR_BYTE1:
main feedback failure
FB bad
seat load cylinder feedback failure
SlcFb bad
control signal failure
CS bad
actuator direction error
Dir error
-15 volt power supply failure
-15 fail
+15 volt power supply failure
+15 fail
seat load cylinder stall
Slc stop
actuator stall
Stall
ERROR_BYTE2:
motor drive fault
Drv fault
accumulator pressure transducer bad
Pres bad
accumulator requires recharge flag
Pres low
bad keypad
Key bad
eprom erase/program failure
Mem fail
pulse/contact board missing
No inp bd
A/D failure
A/D fail
CPU failure
CPU fail
ERROR_BYTE3:
open direction pressure transducer bad
Op Pres bad
close direction pressure transducer bad
Cl Pres bad
oil over temperature
Over Temp
low oil
Low Oil
shed time exceeded
Shed Time
X2 Actuator Data Collection Parameters

COLLECTION_MODE {collection _mode}: specifies the method of initiating data gathering. Select:

MANUAL for operator initiated gathering
AUTO for initiating on a change in Setpoint
COLLECTION_CONTROL {collection_control}: used to START a manually

initiated collection. STOP may be used to halt a collection prior to 200
samples of each parameter having been collected.
COLLECTION_DELTA_SP {collection_delta_sp}: when collection_mode
is AUTO, specifies the change in Setpoint required to initiate collection.
Appendix K
Fieldbus
K-12 Fieldbus
Once automatically initiated, collecting will continue until 200 samples of

each variable have been gathered.
COLLECTION_SAMPLE_RATE {collection_sample _rate}: specifies the
rate at which samples of each variable will be collected in samples per
second. Select 1, 2, 4, 5, 10, 20.
COLLECTION_INDEX {collection_index}: when reading the collected
variables, this specifies which group of 10 values to return. Select
Group 1 for the 1st 10 values, Group 2 for values 11 through 20, etc., up
to Group 20 for values 191 through 200. Unused samples or samples
read prior to gathering will read zero.
COLLECTION_SETPOINT {collection_setpoint},
COLLECTION_POSITION {collection_position},
COLLECTION_DIFF_PRESSURE {collection_diff_pressure}: when read,
these return 10 successive values of the named variable as specified by
the collection_index. When the Differential Pressure measuring feature
is not implemented, collection_diff_pressure will read 1.#QNAN.
Notes: Data collection parameters.
1. For each collection variable, the first sample of Group 1 is the value of the variable
immediately prior to the initiation of collection. The second sample is the value of
the variable one sample interval later. The third sample is the value of the variable
a second sample interval later, etc.
2. When collection mode is set to AUTO, the first two samples of the setpoint
variable show the change in setpoint which initiated the collection.
3. The variable differential pressure is collected using peak detection methods.
During a sampling interval, differential pressure is continuously monitored and the
largest value found during the sampling interval is reported as the value for that
interval.
4. The differential pressure peak detector runs continuously. Therefore, the first
sample of Group 1 for the collection variable differential pressure is the maximum
value detected since the end of the last collection period. This value is generally
not meaningful and can be discarded.
Appendix K
M-1
M. Manual Operators
The Xpac has two types of manual operators available: Declutchable

Handwheel/Drill Drive and Manual Hydraulic Pump. Since both options utilize
our hydraulic circuit for override operation, they will only function if the system is
in working order.
CAUTION:
Before attempting to operate any manual override feature,
make sure that the electric power is OFF.
M.1 DECLUTCHABLE HANDWHEEL

The handwheel is mounted to the motor output end of the actuator. To operate,
depress and turn the handwheel. One half-revolution may be required before
proper engagement, as the inside of the handwheel must engage with the
motor shaft. The handwheel will declutch by moving outwards when released.
Clockwise rotation of the manual operator will retract the stem on a linear unit
and clockwise rotate the shaft (looking at the feedback housing) on a rotary unit.
Appendix M
Manual Operators
M-2 Manual Operators
Appendix M
HANDWHEEL REVOLUTIONS
Linear
Rotary
(To move one inch per

1000 lb of rated thrust)
(90 of rotation/1000
lbin of rated torque)
~75
~200
C, D
~25
~65
~13
~33
Power Module
Figure M.1-1 Handwheel Assembly
Figure M.1-2 Drill Drive
Figure M.1-3 Drill Drive with Drill
M.1.2 Declutchable Drill Drive

The drill drive is part of the handwheel assembly that can be used on standard
B, C, 1/2D, and D power modules rated for hazardous but non-explosion proof
environments to drive the unit. The handwheel can be removed by simply
pulling on it to expose a 5/16 hex drive. To operate, connect an appropriate
drill to the 5/16 hex. Push the drive in and turn. One half-revolution may be
required before proper engagement, since the drive must contact a slot on the
end of the motor shaft. Clockwise rotation of the manual operator will retract
the stem on a linear unit and rotate the shaft clockwise (looking at the feedback
housing) on a rotary unit. The drive will declutch by moving outwards when
released.
Note: The actuators drive train and cylinder must be in proper working order to
operate handwheel/drill drive.
M-3
CAUTION:
Care must be taken to ensure the drill gun is limited to 2000
rpm. Running into a mechanical stop using a drill may
damage the actuator and potentially the equipment it is
attached to. As the actuator nears the end point, decrease
drill speed so damage doesnt occur.
M.2 MANUAL HYDRAULIC PUMP

The manual hydraulic pump can be installed on all units and needs only the
cylinder side of the hydraulic circuit and the FMV check valves to be in working
order. If the gear pump or suction check valves fail, the manual hydraulic pump
will still provide a means for manual operation.
To operate the manual hydraulic pump, insert lever into the piston assembly
and pump the handle up and down. To reverse the actuator direction, either
push in or pull out the black, direction control knob located on the bottom of the
assembly.
Note: It is not advisable to leave the lever in the piston assembly when the
hydraulic pump is not in use.
MANUAL HYDRAULIC PUMP SPEEDS (# of pumps)
Appendix M
Linear
Rotary
(To move one inch/1000 lb

of rated thrust)
(90 of rotation/1000 lbin

of rated torque)
~1
~2.5
Manual Operators
M-4 Manual Operators
Appendix M
Directional
control knob
Figure M.2 Manual Hydraulic Pump
M.3 FAIL SAFE UNIT OPERATION

Fail Safe units, Spring Return and Accumulator, utilize solenoid valves in the
fail safe operation. Upon loss of power these solenoids will change state. In
order for manual operation, solenoids must be in position B for normally open
solenoids. Manually override them so they appear as shown in Figure M.3.
Refer to Rotary Spring Fail and Linear Spring Fail sections under Mechanical
Installation for additional information.
WARNING!
After using the handwheel, the overrides must be returned to

their open position or the unit will not operate correctly
when power is restored or trip signal removed. If only one
override is returned to the open position after a trip, damage
to the power module may occur. Changing the override(s)
back may also cause the actuator to run to the fail safe
position.
M-5
Figure M.3 Solenoid Manual Override Levers (Position B)
Appendix M
Manual Operators
N-1
N. Digital Communications
N.1 HART FIELD DEVICE SPECIFICATION
Appendix N
Digital Communications
N-3
N.1 HART FIELD DEVICE SPECIFICATION
HART Field Device Specification:

REXA
Xpac Series X2 Rexa Electrohydraulic Actuator
Author: Larry Schoonover

REXA
Version 1.0
Appendix N
N-4 Digital Communications
Appendix N
TABLE OF CONTENTS
1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Who should use this document?. . . . . . . . . . . . . . . . . . . . . . .
1.4 Abbreviations and definitions . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
7
2. DEVICE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. PRODUCT OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. PRODUCT INTERFACES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Process Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Sensor Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Host interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Analog Input 1: Actuator Setpoint. . . . . . . . . . . . . . . . . .
4.3 Local Interfaces, Jumpers And Switches. . . . . . . . . . . . . . . .
4.3.1 Local Controls And Displays. . . . . . . . . . . . . . . . . . . . . .
4.3.2 Internal Jumpers And Switches. . . . . . . . . . . . . . . . . . .
8
8
8
8
8
8
8
8
5. DEVICE VARIABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. DYNAMIC VARIABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. STATUS INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 Additional Device Status (Command #48). . . . . . . . . . . . . . . 10
8. UNIVERSAL COMMANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.1 Supported Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9. COMMON-PRACTICE COMMANDS . . . . . . . . . . . . . . . . . . . . . . . 21
9.1 Supported Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Burst Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10. DEVICE-SPECIFIC COMMANDS . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1 Supported Device Specific Commands . . . . . . . . . . . . . . . 27
11. TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12. PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12.1 Sampling Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
N-5
12.2 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Self-Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 Command Response Times. . . . . . . . . . . . . . . . . . . . . . . . .
12.6 Delayed-Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.7 Non-Volatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.8 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.9 Write Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.10 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
29
30
30
30
30
30
30
ANNEX A. CAPABILITY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 31

ANNEX B. HART INTERFACE BOARD CONNECTION. . . . . . . . . . 32
Appendix N
1. INTRODUCTION
1.1 Scope
The Xpac Series X2 Rexa Electrohydraulic Actuator complies with HART
Protocol Revision 5.0. This document specifies all the device specific features
and documents HART Protocol implementation details. The HART functionality
of this Field Device is described sufficiently to allow its proper application in a
process and its complete support in HART capable Host Applications.
1.2 Purpose
This specification is designed to compliment other documentation (e.g., the
Xpac Series X2 Rexa Electrohydraulic Actuator Installation Manual) by providing
a complete, unambiguous description of this Field Device from a HART
Communication perspective
1.3 Who should use this document?

The specification is designed to be a technical reference for HART capable Host
Application Developers, System Integrators and knowledgeable End Users. It
also provides functional specifications (e.g., commands, enumerations and
performance requirements) used during Field Device development, maintenance
and testing. This document assumes the reader is familiar with HART Protocol
requirements and terminology.
1.4 Abbreviations and definitions

Abbreviations
ADC
Analog to Digital Converter
CPU
Central Processing Unit (of microprocessor)
EEPROM Electrically-Erasable Read-Only Memory
Appendix N
N-7
Definitions
Actuator
A field device whose primary purpose is to vary its output thus

affecting the connected process. An actuator typically uses the
4-20 mA Loop Current as a setpoint.
1.5 References
Hart Revision 5 specifications: HCF_SPEC-11, HCF_SPEC-54, HCF_SPEC-81,
HCF_SPEC-99, HCF_SPEC-127, HCF_SPEC-151, HCF_SPEC-183, HCF_SPEC307. Available from the HCF.
Xpac Series X2 Rexa Electrohydraulic Actuator Installation Manual, Available
from REXA.
2. DEVICE IDENTIFICATION
Manufacturer Name:
REXA
Model Name(s):
Manufacture ID Code:
222 (DE Hex)
Device Type Code: 128 (80 Hex)
HART Protocol Revision
5.0
Device Revision:
Number of Device Variables
None
Physical Layers Supported
FSK
Physical Device Category
Actuator
X2
3. PRODUCT OVERVIEW
The X2 is an electrohydraulic actuator that is powered separately from the
primary analog input signal. The actuator and its electronics do not draw
current from the circuit which is used only for HART signaling.
The X2 is configured using the pushbuttons on the front panel of the device.
The analogue input of this device is interpreted by the device as a setpoint. The
setpoint can be treated linearly or characterized according to user input. The
Appendix N
HART communication over the analog input is used primarily for monitoring of
position, signal, and cylinder differential pressure (may not be available on all
models).
4. PRODUCT INTERFACES
4.1 Process Interface
4.1.1 SENSOR INPUT CHANNELS
The X2 has sensors that measure actuator position, actuator differential
pressure, and analog input signal. The measurements from these sensors are
scaled by the device into engineering units and are available as variables using
HART communication.
Other sensors are available as options but are not available using HART
communication. These are described in the X2 manual.
4.2 Host interface

4.2.1 ANALOG INPUT 1: ACTUATOR SETPOINT
The two-wire 4-to-20mA current loop is connected to the X2 . Refer to the
Installation Manual for connection details.
4.3 Local Interfaces, Jumpers And Switches

4.3.1 LOCAL CONTROLS AND DISPLAYS
The local controls and displays are described in the X2 manual.
4.3.2 INTERNAL JUMPERS AND SWITCHES
This internal jumpers and switches are described in the X2 manual.
Appendix N
N-9
5. DEVICE VARIABLES
This Field Device does not expose any Device Variables.
6. DYNAMIC VARIABLES
Two Dynamic Variables are implemented.
Meaning
Units
PV
Position of the actuator
SV
Pressure differential
psi
7. STATUS INFORMATION
7.1 Device Status
Bit 4 (More Status Available) is set whenever any status bit is detected.
Command #48 gives further detail.
Appendix N
Appendix N
7.2 Additional Device Status (Command #48)

Command #48 returns 6 bytes of status data, with the following status
information:
Byte
Bit
0*
Meaning
Class
Invalid EEPROM state
Error
Invalid EEPROM write
Error
EEPROM write error
Error
Not used
Not used
Not used
Not used
Not used
Main feedback failure
Error
Seat load cylinder feedback failure
Error
Control signal failure
Error
Actuator direction error
Error
-15v supply failure
Error
15v supply failure
Error
Seat load cylinder stall
Warning
Actuator stall
Error
Motor drive fault
Warning
1**
Bad pressure reading
Warning
2**
Accumulator requires recharge
Warning
Bad keypad
Warning
EEPROM erase failure
Error
Pulse board missing
Error
A/D failure
Error
CPU failure
Error
1**
6**
2
N-11
0**
Open direction pressure bad
Error
1**
Close direction pressure bad
Error
2**
Temperature too high
Warning
3**
Low oil
Warning
Not used
Not used
Not used
Not used
Local manual control
Information
Remote manual control
Information
Not used
Not used
Not used
Not used
Not used
Not used
Not used
*Byte 0 refers to the HART interface board. The remaining bytes refer to the
controller board.
**Not available on all models.
Not used bits are always set to 0.
These bits are set or cleared by the self-test executed at power up, or following
a reset command. They are also set (but not cleared) by any failure detected
during continuous background self-testing.
Appendix N
8. UNIVERSAL COMMANDS
8.1 Supported Commands
Command Number: 0
Command Name: Read Unique Identifier
Command Type: Read
Sets Configuration Changed: no
Description: Returns the manufacturer and device information needed for
other communication with the device. This command can be sent using short
addressing (polling address) and thus can be used before knowing the full
device address.
Request: no data
Response:
Byte 0: u8 - Device code for expansion 254
Byte 1: u8 Manufacturers code 222 for Rexa
Byte 2: u8 Manufacturers device code 128 for this device
Byte 3: u8 Number of preambles required for this device default is 5
Byte 4: u8 Universal command revision 5 for this device
Byte 5: u8 Transmitter revision 1 for this device
Byte 6: u8 Software revision 1 for this device
Byte 7: u8 Hardware revision multiplied by 8 8 for this device (revision of 1)
Byte 8: u8 Flags 0 for this device
Bytes 9 11: u24 Device ID
Command Errors: none
Appendix N
N-13
Command Number: 1
Command Name: Read Primary Variable
Command Type: Read
Description: Returns the primary variable (position) and its units (%)
Request: no data
Response:
Byte 0: u8 Position units code 57 for this device which is the code for percent
Bytes 1-4: float Primary variable position for this device
Command Number: 2
Command Name: Read Current and Percent of Range
Command Type: Read
Description: Returns the input signal in mA and the signal as a percent of the
signal scale.
Request: no data
Response:
Bytes 0-3: float Input signal in mA
Bytes 4-7: float Input signal as a percent of range in percent
Appendix N
Command Number: 3
Command Name: Read Dynamic Variables
Command Type: Read
Description: Returns the primary variable (position), the secondary variable
(pressure differential) and the input signal. The units of the PV and SV are also
returned.
Request: no data
Response:
Bytes 0-3: float input signal in mA
Byte 4: u8 Units code of the primary variable 57 (percent) for this device
Bytes 5-8: float The primary variable - position for this device
Byte 9: u8 Units code of the secondary variable 6 (psi) for this device
Bytes 10-13: The secondary variable pressure differential for this device
Command Number: 6
Command Name: Write Polling Address
Command Type: Write
Sets Configuration Changed: yes
Description: Sets the polling address for the device.
Request:
Byte 0: u8 Polling address. Can be 0 to 15. Since this device is controlled by the 4-20 signal, only polling address 0 should be used.
Appendix N
N-15
Response:
Byte 0: u8 Polling address
Command Errors:
2 Invalid parameter if the polling address is greater than 15
Command Number: 11
Command Name: Read Unique Identifier Associated with Tag
Command Type: Read
Description: Returns device identification information if the device tag matches
the tag sent in this command.
Request:
Bytes 0-5: ascii The device tag which can be up to 8 text characters long.
Response: Note: the device only responds if the tag matches the tag saved in
the device. If the tag does not match, the device does not respond at all.
Byte 0: u8 - Device code for expansion 254
Byte 1: u8 Manufacturers code 222 for
Byte 2: u8 Manufacturers device code 128 for this device
Byte 3: u8 Number of preambles required for this device default is 5
Byte 4: u8 Universal command revision 5 for this device
Byte 5: u8 Transmitter revision 1 for this device
Byte 6: u8 Software revision 1 for this device
Byte 7: u8 Hardware revision multiplied by 8 8 for this device (revision of 1)
Appendix N
Byte 8: u8 Flags 0 for this device

Bytes 9 11: u24 Device ID
Command Number: 12
Command Name: Read Message
Command Type: Read
Description: Returns the message field saved in the device. The message
field can be up to 32 text characters long.
Request: no data
Response:
Bytes 0-23: ascii The message saved in the device up to 32 text characters long.
Command Number: 13
Command Name: Read Tag and Descriptor
Command Type: Read
Description: Returns the tag field, the descriptor field, and the date field. All of
these fields are user settable. These fields can be used in whatever manner the
user wants.
Request: no data
Appendix N
N-17
Response:
Bytes 0-5: ascii The tag, up to 8 text characters long
Bytes 6-17: ascii The descriptor, up to 16 text characters long
Bytes 18-20: u8 The date as 3 unsigned bytes. The first byte represents
the day of the month (1 to 31), the second byte the month (1 to 12), and
the third byte the year minus 1900 (e.g. 2006 would be 106).
Command Number: 14
Command Name: Read Primary Variable Sensor Information
Command Type: Read
Description: This command is included only for compatibility with certain DCS
systems. The data returned in this command is always constant.
Request: no data
Response:
Bytes 0-2: u24 Sensor serial number always 0 for this device
Byte 3: u8 units code 250 (not used) for this device
Bytes 4-7: float upper limit special code for not-a-number for this device
Bytes 8-11: float lower limit special code for not-a-number for this device
Bytes 12-15: float minimum span special code for not-a-number for this device
Appendix N
Command Number: 15
Command Name: Read Primary Variable Output Information
Command Type: Read
Description: This command is included only for compatibility with certain DCS
systems. The data returned in this command is always constant.
Request: no data
Response:
Byte 0: u8 - Alarm code 250 (not used) for this device
Byte 1: u8 - Transfer function 250 (not used) for this device
Byte 2: u8 - Primary variable units code 57 (percent) for this device
Bytes 3-6: float - Upper range always 100.0 for this device
Bytes 7-10: float - Lower range always 0.0 for this device
Bytes 11-14: float Damping value always 0.0 for this device
Byte 15: u8 Write protect code 250 (not used) for this device
Byte 16: u8 Private label code 250 (not used) for this device
Command Number: 16
Command Name: Read Final Assembly Number
Command Type: Read
Appendix N
N-19
Description: Returns the final assembly number stored in the device. This
number is user settable and can be used for whatever the user wants.
Request: no data
Response:
Bytes 0-2: u24 The final assembly number. The value can range from 0 to
16777215.
Command Number: 17
Command Name: Write Message
Command Type: Write
Description: Sets the message field in the device
Request:
Bytes 0-23: ascii The message field, up to 32 text characters.
Response:
Bytes 0-23: ascii The message field, up to 32 text characters.
Command Number: 18
Command Name: Write Tag and Descriptor
Command Type: Write
Appendix N
Description: Sets the tag field, the descriptor field and the date field in the device
Request:
Response:
Command Number: 19
Command Name: Write Final Assembly Number
Command Type: Write
Description: Sets the final assembly number in the device
Request:
16777215.
Appendix N
N-21
Response:
16777215.
9. COMMON-PRACTICE COMMANDS
9.1 Supported Commands
Command Number: 33
Command Name: Read Transmitter Variables
Command Type: Read
Description: Returns up to 4 variables specified from the list of variables. For
this device, possible variable codes are
0. Input Signal
1. Position
2. Pressure differential
Request: Note: fewer than 4 parameters can be sent and the response will be
correspondingly shortened
Byte 0: u8 the transmitter variable code for slot 0
Appendix N
Response:
Byte 0: u8 the variable code for slot 0
Byte 1: u8 the units code for the variable in slot 0
Bytes 2-5: float the value of the selected variable in slot 0
Command Errors:
2 Invalid parameter if the variable code is not 0, 1, or 2
Command Number: 38
Command Name: Reset Configuration Changed Flag
Command Type: Process
Sets Configuration Changed: yes (cleared)
Description: Clears the configuration changed flag for the HART master that
sent the command.
Appendix N
N-23
Request: no data
Response: no data
Command Number: 48
Command Name: Read Additional Status
Command Type: Read
Description: Returns the device specific status bytes. These bytes indicate:
Byte 0
Bit 0: Invalid EEPROM state
Bit 1: Invalid EEPROM write
Bit 2: EEPROM write error
Byte 1
Bit 0: Main feedback failure
Bit 1: Seat load cylinder feedback failure
Bit 2: Control signal failure
Bit 3: Actuator direction error
Bit 4: -15v supply failure
Bit 5: 15v supply failure
Bit 6: Seat load cylinder stall
Bit 7: Actuator stall
Appendix N
Byte 2
Bit 0: Motor drive fault
Bit 1: Bad pressure reading
Bit 2: Accumulator requires recharge
Bit 3: Bad keypad
Bit 4: EEPROM erase failure
Bit 5: Pulse board missing
Bit 6: A/D failure
Bit 7: CPU failure
Byte 3
Bit 0: Open direction pressure bad**
Bit 1: Close direction pressure bad**
Bit 2: Temperature too high**
Bit 3: Low oil**
Byte 4
Bit 0: Local manual control
Bit 1: Remote manual control
Byte 0 of the status codes refer to the HART interface board. The remaining
bytes refer to the controller board. Bits that apply to options that are not in the
delivered model will be set to 0.
**Not available on all models.
Request: no data
Appendix N
N-25
Response:
Bytes 0-4: u8 status data, each bit identifying the condition defined above.
Byte 5: u8 reserved
Byte 6: u8 operating mode 1 0 for this device
Byte 7: u8 operating mode 2 0 for in this device
Bytes 8-10: u24 analog output saturated 0 for this device
Bytes 11-13: u24 analog output fixed 0 for this device
Command Number: 107

Command Name: Write Burst Mode Variables
Command Type: Write
Description: Sets the variable codes that will be used in burst mode by
command 33.
Request: Note: Fewer than 4 variable codes may be specified by sending only
those needed.
Byte 0: u8 Variable code for slot 0
Response:
Appendix N

Command Errors:
2 Invalid parameter if any variable code is not 0, 1, or 2
Command Number: 108

Command Name: Write Burst Mode Command
Command Type: Write
Description: Sets which command will be used during burst mode
Request:
Byte 0: u8 Burst mode command number. Must be 1, 2, 3, or 33
Response:
Byte 0: u8 Burst mode command number. Must be 1, 2, 3, or 33
Command Errors:
2 Invalid parameter if the burst command is not 1, 2, 3, or 33
Command Number: 109

Command Name: Burst Mode Control
Command Type: Write
Appendix N
N-27

Description: Turns burst mode on or off
Request:
Byte 0: u8 Burst mode control. 0 turns burst mode off, 1 turns burst
mode on.
Response:
Byte 0: u8 Burst mode control.
Command Errors:
2 Invalid parameter if burst mode control is not 0 or 1
9.2 Burst Mode

This Field Device supports Burst Mode.
10. DEVICE-SPECIFIC COMMANDS

10.1 Supported Device Specific Commands
Command Number: 140

Command Name: Clear Status
Command Type: Process
Description: Clears the HART interface board status flags. Note however, that
persistent status conditions may immediately be set again after clearing.
Request: no data
Appendix N
Response: no data
11. TABLES
Command Types
Read returns data from the device
Write sends data to the device
Process sends a command to the device
Data Types
u8 unsigned byte (8 bit number)
s8 signed byte
u16 unsigned short integer (16 bits)
s16 signed short integer
u24 unsigned 24 bit integer
u32 unsigned long integer (32 bits)
s32 signed long integer
float IEEE floating point number
ascii packed ascii (see Hart foundation documentation for details)
Appendix N
N-29
12. PERFORMANCE
12.1 Sampling Rates
Typical sampling rates for HART are shown in the following table:
Primary position sensor sample
500 ms
Pressure differential
500 ms
Analog input signal (4-20 mA)
500 ms
12.2 Power-Up
On power up, the transmitter goes through a self-test procedure (see section
12.4), which takes approximately 2 seconds. During this period, the device will
not respond to HART commands other than HART command 0.
12.3 Reset
Command 42 (Device Reset) is not implemented. A device reset buttons is
available inside the housing, which resets the main electronics board and the
HART communications board.
12.4 Self-Test
The self-test procedure is executed at power up or after a device reset. The
self-test includes:
Microprocessor
Configuration storage eeprom
Analog-to-digital converter
Digital-to-analog converter
This self-test takes about 2 seconds. During self-test following power-up or
reset, the device will not respond to HART commands.
Appendix N
12.5 Command Response Times

Minimum
5 ms
Typical
20 ms
Maximum
150 ms
12.6 Delayed-Response
Delayed-response is not used.
12.7 Non-Volatile Memory

EEPROM is used to hold the devices configuration parameters. New data is
written to this memory immediately on execution of a write command.
12.8 Modes
The actuator can be in auto, manual, or setup modes, however these modes are
accessible only from the pushbuttons on the main panel. In setup mode, HART
communication is disabled.
12.9 Write Protection

Write protect is not available.
12.10 Damping
Damping is not used.
Appendix N
N-31
ANNEX A. CAPABILITY CHECKLIST

Manufacturer, model and revision
REXA, Xpac Series X2
Device type
Actuator
HART revision
5.0
Device Description available
No
Number and type of sensors
2 available from HART
Number and type of actuators
electrohydraulic
Number and type of host side signals
1: 4 - 20mA analog
Number of Device Variables
Number of Dynamic Variables
Mappable Dynamic Variables?
No
Number of common-practice commands 6
Appendix N
Number of device-specific commands
Bits of additional device status
24
Alternative operating modes?
Yes but not settable from HART
Burst mode?
Yes
Write-protection?
No
ANNEX B. HART INTERFACE BOARD CONNECTION
Appendix N
O-1
O. Output Load Protection
O.1 THEORY OF OPERATION

Each Xpac power module is equipped with two pressure limiting cartridges that
provide output load protection to the device the actuator is attached to. These
valves are located under the wire cover on the power module body as shown in
Figure O.2. The valve to the left controls the pressure in the extend or clockwise
direction.
O.2 IDENTIFICATION
Each valve has a pressure label sticker indicating its range of adjustment. The
range corresponds to the spring installed under the adjustment cap as noted in
Table O.2
Table O.2 Adjustment Range

Adjustment Range (psi)
Appendix O
Spring Color
750-1500
Purple
1500-2250
Orange
2250-3000
Brown (Std)
Output Load Protection
O-2
Appendix O
Standard springs are 22503000 psi unless specified otherwise. The limiting
cartridge is then factory set to 23002400 psi. To translate pressure into
actuator output, use the following formula:
Pressure Gauge Reading

2000 psi
)(
) [
Actuator Rated Output = Actual Output
The pressure gauge reading can be obtained from the corresponding pressure
gauge shown in Figure O.2. This value should be the delta between the two
gauges when calculating actual output.
Figure O.2 Pressure Relief Valve
O-3
O.3 ADJUSTMENT:
Loosen the lock nut while holding the adjustment cap in place.
While running the actuator in a hard stop, read the corresponding gauge
to the valve that is being adjusted.
Turn the adjustment cap CW to increase the relief pressure and CCW to
decrease the relief pressure.
Note: The adjustment cap does not have a hard stop and will unthread.
Tighten lock nut against the cap to 100 lbin (11 Nm) and test set
pressure.
O.4 SPRING CHANGE:

Loosen the lock nut.
Unthread the adjustment cap.
Replace the spring.
Replace the adjustment cap.
Follow the adjustment procedure (O.3), above.
Appendix O
REXA Series 2 Xpac Installation and Operation Manual 04/13 P-1
P. Interconnect Diagrams
& Control Enclosure Drawings
D97904 STEPPER WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . P-2
B QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
C QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-4
D97904-.5D D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . P-5
D QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . P-6
D97904-D D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . P-7
D QUICK CONNECT CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . P-8
D97904-2D 2D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . P-9
D97904-P9 D,P9 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . P-10
D97904-P40 D,P40 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . P-11
D97904-STEPACCUM STEPPER WITH ACCUMULATOR FAIL OPTION . . . . .P-12
D97904-.5DACCUM D SERVO WITH ACCUMLATOR FAIL OPTION . . . . . P-13
D97904-DACCUM D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . P-14
D97904-2DACC 2D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . P-15
D97904-P9ACC D,P9 SERVO WITH ACCUMLATOR FAIL OPTION . . . . . . . P-16
D97904-P40ACC D,P40 SERVO WITH ACCUMULATOR FAIL OPTION . . . . . P-17
B AND C-PUMP CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . P-18
B AND C CONTROL ENCLOSURE FOR QUICK CONNECT CABLES . . . . . . . . . P-19
D AND D CONTROL ENCLOSURE FOR QUICK CONNECT CABLES . . . . . . . P-20
D AND D PUMP CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . P-21
2D & D,P9 CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . . . . P-22
D,P40 CONTROL ENCLOSURE DRAWING . . . . . . . . . . . . . . . . . . . . . P-23
Appendix P
Interconnect Drawings
D97904 STEPPER WIRING DIAGRAM
B QUICK CONNECT CABLES
P-3
C QUICK CONNECT CABLES
P-4
D97904-.5D D SERVO WIRING DIAGRAM
P-5
D QUICK CONNECT CABLES
P-6
D97904-D D SERVO WIRING DIAGRAM
P-7
D QUICK CONNECT CABLES
P-8
D97904-2D 2D SERVO WIRING DIAGRAM
P-9
D97904-P9 D,P9 SERVO WIRING DIAGRAM
P-10
D97904-P40 D,P40 SERVO WIRING DIAGRAM
P-11
D97904-STEPACCUM STEPPER WITH ACCUMULATOR FAIL OPTION
P-12
D97904-.5DACCUM D SERVO WITH ACCUMULATOR FAIL OPTION
P-13
D97904-DACCUM D SERVO WITH ACCUMULATOR FAIL OPTION
P-14
D97904-2DACC 2D SERVO WITH ACCUMULATOR FAIL OPTION
P-15
D97904-P9ACC D,P9 SERVO WITH ACCUMULATOR FAIL OPTION
P-16
D97904-P40ACC D,P40 SERVO WITH ACCUMULATOR FAIL OPTION
P-17
B AND C-PUMP CONTROL ENCLOSURE DRAWING
P-18
P98492 CONTROL ENCLOSURE FOR QUICK CONNECT CABLES
P-19
D AND D CONTROL ENCLOSURE FOR QUICK CONNECT CABLES
P-20
D AND D PUMP CONTROL ENCLOSURE DRAWING
P-21
2D & DP9 CONTROL ENCLOSURE DRAWING
P-22
DP40 CONTROL ENCLOSURE DRAWING
P-23
REXA Series 2 Xpac - Installation and Operation Manual - 03/14
Q-1
Q. Contact Input Options
CONTACT INPUTS
Note: Refer to the INPUTS menu, Signal Type parameter in the Modes of Operation
& Control Parameters section.
Q.1 SIGNAL INPUT RANGE

Voltage: OFF: 0 to 8 volts, AC or DC
ON: 22 to 120 volts, AC or DC
Undefined: 8 to 22 volts, AC or DC
Current: OFF: less than 1 mA
ON: 1.8 mA to 10 mA; proportional to voltage
Impedance: 12K ohms
Electromechanical or solid state switching devices may be used to activate the
control signal. The following points should be observed:
Appendix Q
Contact Input Options
Q-2
ON state:
Most AC and many DC solid state switching devices require a minimum current
flow in order to remain in the closed state. If this minimum current exceeds the
input signal current at the activation voltage, the current flow may be increased
by adding a shunt resistor across the input signal terminals of the pulse auxiliary
board.
OFF state:
The OFF state leakage current must be less than 1 mA. Diode clamps or RC
snubber networks placed across mechanical relays and the semiconductor
junctions of solid state switches will pass some current in the OFF state. If this
leakage exceeds 1 mA, a resistor added across the input signal terminals will
bypass the current.
Q.2 1 CONT
The single contact (1 Cont) option of controlling the actuator is for ON/OFF
applications. A single dry contact or live voltage is applied to the Contact Inputs
Board.
The dry contact is biased by 120 Vac available from the Contact input board. A
live voltage, 24 to 120 Vac/Vdc, is supplied by the end user.
When Signal Type = 1 Cont (one contact), two position operation
open/closed positionis selected. The applied signal defines actuator position.
If the Open input is active (powered), the actuator goes to Position Hi. If the
Open input is not active (un-powered), the actuator goes to Position Lo.
Typical wiring schemes are shown in Figure Q.2-1, -2.
Appendix Q
Q-3
Figure Q.2-1 1 Cont Dry Input Board
Appendix Q
Q-4
Figure Q.2-2 1 Cont Wet Input Board
Q.3 2 CONT
The dual contact (2 Cont) option of controlling the actuator is for manual
modulation control, using two signals. Two dry contacts or two live voltages are
applied to the Contact Inputs Board.
The dry contacts are biased by 120 Vac available from the Contact input board
or live voltages, 24 to 120 Vac/Vdc, are supplied by the end user.
Appendix Q
REXA Series 2 Xpac - Installation and Operation Manual - 03/14 Q-5
When Signal Type = 2 Cont (two contacts), manual modulation

operation is selected. The main input signals are the Main contacts Open and
Close inputs of the Contact Input Board. If both inputs are active or inactive,
the actuator remains in its current position. If only the Open input is active, the
actuator travels towards Position Hi. If only input Close is active, the actuator
travels towards Position Lo.
Typical wiring schemes are shown in Figures Q.3-1, -2.
Figure Q.3-1 2 Cont Dry Input Board
Appendix Q
Q-6
Figure Q.3-2 2 Cont Wet Input Board
Appendix Q
R-1
R. Remote Manual Control
R.1 REMOTE MANUAL (RemoteMan)

The actuator may be equipped to connect to a remotely located manual station.
The basic station includes one Remote/Auto: two-position maintained switch,
and one Open/Off/Close: momentary spring-return-to-center switch. The two
position switch is used to alternate between Auto and RemoteMan (remote
manual) modes. In the RemoteMan mode, turning the momentary switch to
Open or Close will move the actuator in the open or close direction. The springreturn-to-center (off) will stop the actuator at the position when the switch is
released. As an additional option, a seven segment LED digital display may be
connected to the standard position transmitter to display actuator position at the
remote manual station.
RemoteMan allows the actuator to operate manually from a remote location.

Once the Remote Manual mode is entered, the current status will be displayed
along with Position.
The RemoteMan mode is only accessible if the Contacts Input board is
installed on top of the CPU. Typical wiring schemes are shown in Figure R.1-1, -2.
Appendix R
Remote Manual Control
R-2
The RemoteMan mode will be entered when the MAN Input of the Remote
Auto/MAN Inputs is activated. The actuator is then controlled by activating the
Open or Close Inputs of the Remote Auto/MAN Input.
Figure R.1-1 Dry Contacts Input Board
Appendix R
R-3
Figure R.1-2 Wet Contacts Input Board
Appendix R
S-1
S. Safety Manual for ESD SIL Compliance

S.1 GENERAL
This REXA actuator is a Type A device with a hardware fault tolerance
(HFT) of 0. The Rexa actuator has a safety trip function designed to meet
or exceed the requirements of IEC 61508 for a SIL 3 capable designed
process. The actuator has been designed and verified to withstand the
worst case expected environmental conditions listed in the IOM and
specification sheet.
This section of the manual covers the operating requirements for the end
user to ensure their system is operated in compliance with the operating
requirements needed to achieve safe operation of the equipment in
accordance to the rated SIL level. The time in which an actuator will
transition into a safe state is defined as the time required to trip on the
Rexa data sheet. This transition time must be reviewed against the process
safety time to insure this product is appropriate for the application.
Any deviation to the installation, operation or maintenance from this
appendix will void the IEC61508 SIL certification and may impact the
ability of the actuator to accomplish its safety function. All product failures
impacting functional safety should be reported back to Rexa. The FMEDA
report for failure rates, failure modes, and proof test information can be
found in the Rexa report KOS 13-10-03 R0001, titled FMEDA Rexa, Xpac.
Appendix S
Safety Manual for ESD SIL Compliance
S-2
An example of the system and application environment in which the

PRODUCT will be embedded once delivered is shown in the following
drawing.
Figure 1: Example Safety Instrumented Function

S.2 SYSTEM SET UP
In order to properly set up the ESD control system the following measures
must be taken:
1. The actuator needs to be calibrated to the driven device. Reference the
Mechanical and Electrical installation section of this manual.
2. The actuator end points need to be set. Reference the section of this
IOM on setting mechanical end stops.
S.3 SYSTEM OPERATION

The primary safety function of the actuator is to place the driven device in
the process safe position when input to the actuators solenoid valves is
de-energized. The safety function that carries the SIL certification is an ESD
trip function. This trip function is designed to ensure the actuator can be
stroked in one direction to
Appendix S
REXA Series 2 Xpac - Installation and Operation Manual - 03/14 S-3
either the full open or the full closed position. This function needs to be
controlled directly from the users SIS and not through the Rexa control
box. The ESD is certified for low demand fail safe applications.
3.1 The safety solenoids defined on the hydraulic schematic must be
wired directly into the main safety system. It is possible for the Rexa
controller to control these solenoids but in order to minimize the number of
components in the safety loop they must be wired directly into the safety
system for SIL applications.
3.2 Since the safety solenoids are controlled directly by the safety system
a trip relay must be installed to disable the Rexa electronics during a safety
event. This relay will insure the Rexa electronics cannot react to the safety
system taking control of the actuator.
3.3 This system has been designed to full stroke at rate which is shown
on the actuator data sheet provided to by REXA for this specific order.
3.4 The useful life of this actuator is 10 years based on the duty
cycle provided to REXA for this application. After recommended seal
maintenance the actuators useful product life is 20 years.
3.5 The REXA actuator is available in normally open or normally closed
ESD configurations.
3.6 A 24 hour mean time to repair should be assumed for safety
availability calculations.
S.4 SAFETY CRITICAL COMPONENTS

4.1 Definition - Some of the components on this actuator are identified
as safety critical. If the failure of any component would inhibit the safety
function of this Rexa actuator it is deemed a Safety critical component.
4.2 Only OEM supplied replacement parts can be used as suitable
replacement parts for any component identified as Safety critical.
4.3 This actuator was supplied to meet a strict number of specifications
and may not be modified in the field.
S.5 SYSTEM DIAGNOSTICS

5.1 Built into the Rexa CPU are numerous diagnostics that can be
found in the error codes section of this IOM. These error codes must be
Appendix S
S-4
monitored by the safety system through an alarm relay. The only critical
alarmed feature that would indicate the system may not perform its
intended trip function is the stall alarm.
5.1.1 Stall Alarm If the actuator fails to move 1%, within the adjustable
stall time setting, while positioning the alarm relay will open indicating an
alarm event.
5.1.2 Partial stroke testing is performed to verify the actuator is capable
of performing its intended safety function. The actuator shall be designed
to support proof test intervals of 1 year or greater while consuming less
than 40% of the allowable PFDavg for SIL 2 SIF applications when PST is
implemented. The control and design of this test should be in the scope
of the control system. The Rexa actuator will only follow the requested
change in position as defined by the control loop. This PST percentage to
activate needs to be calibrated within the scope of the plants SIS system.
During a partial stroke test the control system must monitor the position
transmitter to insure the actuator actually successfully performed this
function. The control room supervisor needs to review and sign off on the
results of the proof tests. This PST should be sufficient to achieve a greater
than 65% SFF (Safe Failure Fraction). Key points to review during this test:
5.1.3 Verification from the REXA position transmitter that the actuator
followed the change in the control position and performed its PST function.
5.1.4 Redundant verification from an optional PST limit switch can be
provided, this limit switch needs to be wired directly into the SIS system.
5.2 The test results are to be recorded and stored for the life of the
product.
5.3 In order to insure this system can maintain its as designed
functionality the maintenance section of this IOM must be strictly adhered
too.
S.6 SITE ACCEPTANCE TEST PROCEDURES

A cognizant engineering supporting the operation of the system is
responsible for assigning individuals to conduct and record automated
testing and proof testing of the equipment. The cognizant engineer is then
responsible for reviewing the results.
6.1 Run the actuator open and verify stroking times meet the
specification sheet.
Appendix S
S-5
6.2 Run the actuator close and verify stroking time meet the specification
sheet.
6.3 Perform an ESD trip and verify stroking time meet the specification
sheet.
6.4 Run the actuator to its PST position to verify position feedback and
the optional PST limit switch is functioning properly.
S.7 ENVIRONMENTAL REQUIREMENTS

7.1 The actuator has been designed and verified to withstand the worse
case environmental conditions as listed in this IOM.
Appendix S
T-1
T. Position Transmitter
Appendix T
T-2
Appendix T
T.1 POSITION TRANSMITTER

The position transmitter provides a two-wire 4-20 mA signal that is proportional
to actuator position. The transmitter's output is optically isolated from the
electronics. Both an active and passive transmitter are available. A passive
position transmitter is similar to other two-wire transmitters in that an external
dc power source is required. An active two-wire transmitter with its own 24 Vdc
power supply is available.
Note: Position feedback can be changed in the field from active to passive or
passive to active by rewiring the feedback as shown in Figures T.1-1 and T.1-2.
Refer to OUTPUTS Menu (6.1.8) in Modes of Operation & Control Parameters

for calibration procedures.
Passive
Resolution
Maximum External Load
Active
<0.1% of full stroke
1000 ohms @ 36 Vdc
700 ohms @24 Vdc
Minimum Supply Voltage
10 + (0.02 x RLOAD) Vdc
Maximum Supply Voltage
36 + (0.004 x RLOAD) Vdc
24 Vdc
(internal supply)
Also included with the transmitter is an Alarm Relay. Whenever the actuator is
unable to follow the applied control signal, the Alarm Relay will change state
(de-energize). See PM14 for additional details.
Alarm Relay:

Response: second of any "fail to operate condition"

Alarm Contacts: SPST

Rating: 1 amp @ 30 Vdc, 0.3 amp @ 120 Vac - resistive

Connection: Terminal strip on the auxiliary board
Figure T.1-1
Appendix T
T-3
Passive Position Transmitter Connections
T-4
Figure T.1-2
Active Position Transmitter Connections
Appendix T
U-1
U. ELECTRONIC RELAYS
Limit Switch, Alarm and Warning
ELECTRONIC RELAYS
The electronic limit, alarm and warning relays are located on the CPU board. All
wiring connections are made directly to this board at TB1 and TB5. An indicator
LED shows the status (energized-ON) of each relay.
Two of the relays are configured in the Setup Mode to activate upon user
defined stroke limits. The third relay is an alarm indicator and the fourth is a
warning indicator.
U.1 Limit Switch Relays

LED D4 will illuminate when the Relay 1 is active; indicating the actuator position
is at, or below, the value set in parameter Relay 1.
LED D5 will illuminate when the Relay 2 is active; indicating the actuator position
is at, or above, the value set in parameter Relay 2.
U.2 Alarm and Warning Relay

LEDs D6 and D7 on the CPU Board are always active and light when the
actuator operates normally without any error and is following the control signal.
Appendix U
Electronic Relays
U-2
Electronic Relays
Appendix U
Once the actuator detects an error, or is put into LOCAL or SETUP mode,
the Alarm and Warning Relays open and LEDs D6 and D7 will turn off.
When the CPU detects an error, which opens the Warning Relay only, LED D7
will turn off. The Warning relay is a signal from the control enclosure that means
the REXA CPU detects a problem but can still operate and follow the Control
Signal.
The Alarm relay is a signal from the control enclosure that means the REXA CPU
detects a problem, or is in LOCAL or SETUP modes, and cannot follow the
Control Signal.
GENERAL SPECIFICATIONS
Quantity:
4 (2 Limit, 1 Warning, 1 Alarm)
Type:
High Capacity PhotoMOS Relay
Rating:
1 amp @ 200 Vac/Vdc
Turn On time:
<3 mS
Differential Travel
0.1%
(Hysteresis):
Connection:
Terminal strip on the CPU board
U-3
CPU
PHOTOMOS
WARNING RELAY
RATING:
200 VAC/VDC, 1.0 AMP
PHOTOMOS
ALARM RELAY
RATING:
PHOTOMOS
LIMIT SWITCH RELAYS
RATING:
Figure U-1 CPU Boards Electronic Relays
Appendix U
Electronic Relays
V-1
V. Local Mode Indication Board
LOCAL MODE INDICATION BOARD

The Local Mode Indication Board is an optional circuit board mounted to the
CPU as shown in Figure V-1.
Appendix V
Local Mode Indication Board
V-2
Local Mode Indication Board
Figure V-1 Local Mode Indication Board

The Local Mode Indication board gives an independent Solid State relay closure
when the CPU is in the Auto mode, and LED D1 will illuminate. When the
CPU is put into one of the Local operation modeswhether it is Setup
mode, Local Man mode or Remote Man modethe contact will open,
and LED D1 will turn off. The relay will not trigger when an Error code occurs.
The relay is the Photo-Mos type, SPST with a rating of 200 Vac @ 1 Amp.
Appendix V
REXA Series 2 Xpac - Installation and Operation Manual - 07/12 W-1
W. Electronic Unit Ratings
Appendix W
Electronic Unit Ratings
Appendix W
Voltage
24VDC max
Relays
Warning
Alarm
Limit Switches
Voltage
36VDC max
36VDC max
24VDC - 120VAC/VDC
1-5VDC
Voltage Amps
24VDC 4-20mA
Amps
4-20mA
Voltage
Amps
200VAC/VDC
1.0A
200VAC/VDC
1.0A
200VAC/VDC
1.0A
Position Transmitter Output
Feedback Out
Control Signal
Standard 4-20mA control signal
Optional 10 - 50mA
Pulse control signal ( 1 or 2 contacts)
Low Coltage control
Amps
4-20mA
10-50mA
1A
20mA
Customer Input @ Circuit Breaker

Motor Power
Voltage Input Phase Input Fuse
Volts
Amps
B, 24VDC
24VDC
20A
95VDC
6.3A
B, 48VDC
48VDC
15A
72VDC
6.3A
B, 115VAC
115VAC 10%
1
5A
170VDC
6.3A
B, 230VAC
230VAC 10%
1
5A
170VDC
6.3A
C, 24VDC
24VDC
50A
165VDC
6.3A
C, 115VAC
115VAC 10%
1
10A
170VDC
6.3A
Dual C, 115VAC 115VAC 10%
1
15A
170VDC
6.3A
1/2D, 115VAC
115VAC 10%
1
20A
160VDC
6.0A
1/2D, 230VAC
230VAC 10%
1
10A
280VDC
6.5A
Full D, 230VAC 230VAC 10%
1
10A
280VDC
7.5A
Dual D
230VAC 10%
1
20A
280VDC
7.5A
D, P9
230VAC 10%
3
25A
280VDC, 340VDC 7.5A, 22.0A
D, P40
230VAC 10%
3
50A
280VDC, 340VDC 7.5A, 55.0A
= N/A with CSA
Electronic Unit
Table W-1 Electronic Unit Ratings

Fail Solenoid
Volts
Amps
24VDC
5A
48VDC
2A
125VDC
1A
125VDC
1A
24VDC
5A
125VDC
2A
125VDC
2A
125VDC
2A
246VDC
1A
246VDC
1A
246VDC
1A
246VDC
1A
246VDC
1A
Circle Seal Solenoid

Volts
Amps
24VDC
5A
48VDC
5A
115VAC
5A
115VAC
5A
24VDC
5A
115VAC
5A
115VAC
5A
115VAC
5A
115VAC
5A
115VAC
5A
115VAC
5A
115VAC
5A
115VAC
5A
Serial number contains date of manufacture

information.
Electronics Enclosure Nameplate
Heater Power
Volts
Amps
24VDC
8A
48VDC
5A
115VAC
2A
230VAC
1A
24VDC
8A
115VAC
2A
115VAC
2A
115VAC
2A
230VAC
1A
230VAC
1A
230VAC
1A
230VAC
1A
230VAC
1A
W-3
Electronic Unit Ratings
X-1
X. Redundant Construction
INTRODUCTION
The modular construction of the Xpac allows the duplication of the critical
components without a major redesign or sacrificing operational characteristics.
Two Power Modules, two complete control electronics and two feedback
assemblies are used to operate a single hydraulic cylinder. Each module
operates from its own controls and feedback. Wiring and setup are the same as
for any standard REXA Actuator.
One module is designated as main and the other as backup. In this manner, the
operation of the main system is indicated to the backup system via the Main
systems Alarm relay Output. The functional difference between the modules is
strictly in the response to a change in control signal.

The Backup is sixteen times less sensitive than the Main, up to a

maximum of 5%.
For instance, setting the dead band of each module to 0.1% would mean that
the backup module is at 1.6%. A control signal change of less than 1.6% would
result in only the main module taking action to change position. A change
greater than 1.6% would have both modules operating. Regardless of the
Appendix X
Redundant Construction
X-2
change, positioning would still be 0.1% resolution. If the main module cannot
respond (indicated by the alarm), then the backup module will automatically
revert to fine control and position to the 0.1% setting.
This configuration has a redundancy of 90%. The only major component not
duplicated is the hydraulic cylinder which is unlikely to suffer a catastrophic
failure. Any size module can be upgraded. An R is added to the model number
to indicate this enhancement (L2000-2-2BR-P).
X.1 MECHANICAL INSTALLATION

Mounting and installation procedures for the actuator or drive are the same as
for a standard unit. The location of the mounting holes and shaft connections
are not affected.
X.2 ELECTRICAL INSTALLATION

The two control electronics can be installed in a single enclosure or two
separate enclosures. In either case, there are two complete sets which function,
for the most part, independently.
Wiring is accomplished as two separate units. Each Power Module and
feedback circuit is connected to a single electronics.
However, the Alarm relay of the Main Control Enclosure is connected to the Aux
Contacts Open Input of the Backup Control Enclosure.
X.2.1 User Connections

Electrical power and control signal are wired in the conventional manner.
However, consideration should be given to maintaining the redundancy down to
the following user connections:
Power should be brought from two sources.
Appendix X
X-3
A single 4-20mA control signal is looped through both electronics.
X.2.2 Redundant Interconnections

The Alarm relay of the Main electronics is connected to the Auxiliary Open
Contact of the Backup electronics. When the Backup detects the Main is in the
alarm state via this input, (Contact Input = no voltage detected), the Backup
switches to its normal deadband setting until the alarm condition is cleared.
X.2.2.1 Alarm Indication

The alarm relay is used to indicate the online status of the Main Power
Module. Power for the alarm is obtained from the Backup Actuator Main
AC power.
X.3 OPERATION
The operation is substantially unchanged from a standard unit. However,
some mention should be made to the interaction of two independent Power
Modules on the same cylinder. Both CPUs are looking at the actual position
and comparing this to the target position set by the control signal. If the target
position for one module is satisfied but not for the other, then one module will
reposition the actuator. If the repositioning causes the first module to move
outside of its target, then it will move the actuator back. This action would occur
with the same signal and low dead band settings (< 0.5%). Such operation is
alleviated by simultaneous calibration and the backup units deadband having
an internal setting sixteen times that of the main unit.
Another extraordinary condition will happen if one module is put into LOCAL
MAN and moved manually. The other unit will continue to track the control
signal and move the actuator back. Placing both CPUs in LOCAL MAN and
moving only one remedies this situation.
Appendix X
RedundantConstruction
X-4
Appendix X
X.4 WIRING
CALIBRATE
Wiring is accomplished as two separate units. A Power Module and feedback

circuit is connected to a single electronics.
X.5 CPU SET UP FOR MAIN AND BACKUP

Each CPU is set as either the MAIN or BACKUP when shipped from the factory
as a complete unit. However, in the case where a CPU needs to be replaced,
the CPU must be set to either be the MAIN or BACKUP. This is accomplished in
the CONTROL menu, parameter Function, as shown.
The parameter Function = Backup can only be selected if the Contact
Inputs Board, P/N S97713, is installed. If the CPU is put into Auto mode when
Backup is selected and no input board is present, the error No inp bd will
be displayed and the CPU will revert back to the Setup mode.
CONTROL
SPEED /
ACCEL
Function
Deadband
INPUTS
Min Mod
DRIVES
Bumpless
OUTPUTS
Surge
Bkpt
CURRENT
STATS
HISTORIC
STATS
Seat Ld
Cyl
Flow Char
Se t u p
No i n p b d
Fu n c t i o n = Ba c ku p
X.6 SIMULTANEOUS CALIBRATE

Both CPUs should be calibrated at the same time on a step by step basis.
Follow the procedure indicated in Section 5.3. With the exception of the
X-5
Position Lo, Position High, all values in the SETUP Parameters should be
identical.
Position Lo and Position HI should be set at the same time.

1. Access parameter Position Lo on both the Main and Back Up
electronics, so that the = is flashing.
2. Operate the actuator, using the Main electronics, to the position that
corresponds to 4 mA.
3. The % position value should change on both Control electronics.
4. The value on the Main electronics may be slightly different than the Back
Up. That is acceptable.
5. Lock the value into Position Lo on the Main and Back Up by
pressing Enter and stopping the = from flashing.
6. Access parameter Position Hi on both the Main and Back Up
electronics, so that the = is flashing.
7. Operate the actuator, using the Main electronics, to the position that
corresponds to 20 mA.
8. The value on the Main electronics may be slightly different than the Back
Up. That is acceptable.
9. Lock the value into Position Hi on the Main and Back Up by pressing Enter and stopping the = from flashing.
10. Again, Position Lo and Position Hi of the Main Control
enclosure may have slightly different values than the Back Up values;
however, the physical position of the actuator is the same.
Appendix X
RedundantConstruction
X-6
X.7 AUTO MODE DISPLAY

When in Auto mode, the CPU operating as the MAIN will display Auto-Main, and
the CPU operating as the BACKUP will display Auto-Bkup. When there is no
voltage present on the Backups Auxiliary Open input, (Main is in Alarm state),
the display on the Backup will change to Auto-Main until the alarm on the main
is cleared.
X.8 REDUNDANT HIGH SPEED SOLENOIDS

FOR SPRING FAIL OPERATION
Some actuators may be equipped with redundant hi-speed solenoids to offer a
mechanical spring fail on loss of Main AC power.
Each solenoid is connected to its respective Control electronics.
The two solenoids are hydraulically connected in series with one another. Under
normal operation, the solenoid valves are closed. This allows the actuator to
operate with the motor and pump.
When Main AC Power is removed from BOTH Main and Back Up Control
electronics, both solenoids will open, causing the spring to move the actuator to
the Fail Safe position.
Note: Because the solenoids are hydraulically connected is series, if Main power
to only one Controller is removed, the actuator will not travel to the fail position.
Rather, it will maintain normal operation with the motor and pump. In addition,
should solenoid become defective, the remaining solenoid allows for normal
operation.
Appendix X
X-7
Figure X. Redundant Unit Interconnection Diagram

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Installation and Operation Manual

for the REXA Series 2 Xpac

Figure 1.3 ID Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.1 Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REXA Series 2 Xpac Installation and Operation Manual 10/14

REXA Series 2 Xpac Installation and Operation Manual 10/14

3.2.1 Supply Disconnect Device . . . . . . . . . . . . . . . . . . . . . . 38

REXA Series 2 Xpac Installation and Operation Manual 10/14

5.2.2 Longitudinal Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 63

REXA Series 2 Xpac Installation and Operation Manual 10/14

A.2.2 Rotary Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

E. PULSE OPERATING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

REXA Series 2 Xpac Installation and Operation Manual 10/14

F. ERRORS AND ERROR DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . .

G. SURGE CONTROL OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

REXA Series 2 Xpac Installation and Operation Manual 10/14

Analog Output block (AO). . . . . . . . . . . . . . . . . . . . . . . . . . . K-2

REXA Series 2 Xpac Installation and Operation Manual 10/14

9.1 Supported Commands. . . . . . . . . . . . . . . . . . . . . . . . . N-21

REXA Series 2 Xpac Installation and Operation Manual 10/14

B and C-Pump Control Enclosure Drawing . . . . . . . . . . . . . .

Q. CONTACT INPUT OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1

Passive Position Transmitter Connections . . . . T-3

U. ELECTRONIC RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1

REXA Series 2 Xpac Installation and Operation Manual 10/14

W. ELECTRONIC UNIT RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . W-1

REXA Series 2 Xpac Installation and Operation Manual 10/14

REXA Series 2 Xpac Installation and Operation Manual 09/11

Fundamental Safety Information

Serious physical injury

Damage to actuator or other equipment

Always observe the safety information listed in this documentation.

Airborne noise greater than 80 dB, ear protection suggested.

Do not use the Actuator should it be damaged in shipping or installation.

REXA Series 2 Xpac Installation and Operation Manual 09/11

REXA Series 2 Xpac Installation and Operation Manual 09/11 xiii

procedures before accessing Control Enclosure.

REXA Series 2 Xpac Installation and Operation Manual 09/11

REXA Series 2 Xpac Installation and Operation Manual 09/11 xv

ACCUMULATOR FAIL OPTION:

NPT PLUG and CONDUIT CONNECTIONS:

Major repairs or overhaul.

When working alone, out of visual contact of the controlling switch.

Anytime there is danger of injury from an unexpected release of energy.

Any situation that threatens an employees safety.

Note: Always follow local & plant procedures.

REXA Series 2 Xpac Installation and Operation Manual 09/11

REXA Series 2 Xpac Installation and Operation Manual 09/11 xvii

EDUCATION AND DISCIPLINE

REXA Series 2 Xpac Installation and Operation Manual 09/11

mark indicates that the product is certified for European

Product Description: X-Pac and X2 Series Electraulic (Self-Contained Electro-Hydraulic)

Linear, Rotary and Drive Units

EN61326-1:2006, EN61000-6 Part -2:2005 and -4:2007; EN55011:2007:

Directive 97/23/EC; designed as Sound Engineering Practice

REXA Series 2 Xpac Installation and Operation Manual 09/11