REXA • 4 Manley Street • W. Bridgewater, MA 02379 • (P) 508.584.1199 • (F) 508.584.

2525
Troubleshooting and Repair Manual
for the REXA Series 2 Xpac
TS&R 06/10
Serial #____________________________
Model #___________________________
Application________________________
Tag # _____________________________
REXA Electraulic™ Actuation
06/10 i
Contents
Fundamental SaFety InFormatIon
WARNINGS xv
Warning Labels xvi
Residual Risks xvi
When to Lock-Out/Tag-Out xix
Procedures: Lock-Out/Tag-Out xx
Education and Discipline xxi
1. General InFormatIon
11 Factory Support 1
12 Actuator Identifcation 1
1.2.1 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.2 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.3 Build Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
13 General Specifcations 4
1.3.1 Recommended Fluids and Lubricants. . . . . . . . . . . . . . . . . 4
1.3.2 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
14 inspection schedule 6
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Problem IdentIFICatIon
What is the problem? 9
21 Interface issues 12
Resolutions 12
2.1.1 I forgot my Password; how do I get into Setup? . . . . . . . 12
2.1.2 Warning relay open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.3 Alarm relay open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.4 Error code in display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FB bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CS bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mot stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dir error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ii REXA X2 Series TS&R Manual
Drv fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
+15 fail or -15 fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pres bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pres low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SlcFb bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Slc stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Key bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mem fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
No inp bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A/D fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CPU fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.5 Motor driver fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.6 No display, unusual display . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.7 Actuator will not respond to HART command . . . . . . . . . . 20
2.1.8 Actuator will not respond to FF command. . . . . . . . . . . . . 21
2.1.9 Actuator will not respond to Pulse command. . . . . . . . . . . 21
2.1.10 Actuator will not respond to Analog command . . . . . . . . 21
2.1.11 Actuator will not respond to 1 Cont (On/Off) command 22
2.1.12 Actuator will not respond to 2 Cont
(Manual Control) command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
22 Accessories 23
2.2.1 External push buttons don’t work. . . . . . . . . . . . . . . . . . . . 23
2.2.2 Internal Keypad buttons don’t work . . . . . . . . . . . . . . . . . . 23
2.2.3 Drill Drive / Hand wheel doesn’t work. . . . . . . . . . . . . . . . . 24
2.2.4 Manual Hand Pump doesn’t work . . . . . . . . . . . . . . . . . . . 25
2.2.5 Gauges don’t work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.6 Pressure Limiting Protection not working . . . . . . . . . . . . . 25
2.2.7 Torque or thrust data not accurate (from transducers) . . 26
2.2.8 Mechanical limit switches not functioning. . . . . . . . . . . . . 26
23 Control Issues 27
2.3.1 Actuator moves to wrong position . . . . . . . . . . . . . . . . . . . 27
2.3.2 Actuator “hunting” (dithering during control) . . . . . . . . . . . 27
2.3.3 Actuator “drifts” away from applied load . . . . . . . . . . . . . . 28
2.3.4 Position Feedback doesn’t match actual position . . . . . . 28
2.3.5 How do I test my 4-20 mA Position Transmitter? . . . . . . 28
2.3.6 No position feedback signal . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.7 Electrical Limit Switches don’t function . . . . . . . . . . . . . . . 29
2.3.8 Actuator will not seat, I can not get full travel. . . . . . . . . . 29
06/10 iii
2.3.9 Actuator does not meet stroke speed requirements . . . . 30
2.3.10 Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.11 Only one module on 2D or 2C units functions . . . . . . . . 30
2.3.12 Surrounding equipment disrupted by Actuator operation. . 31
2.3.13 Servo Motor turning at low RPM when
not commanded to move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.14 Actuator slows down and “resets” before getting to target
position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.15 Actuator overshoots target position and returns . . . . . . 32
2.3.16 I have many errors logged in historical stats . . . . . . . . . 32
24 Fail Safe Issues 33
2.4.1 Accumulator will not recharge. . . . . . . . . . . . . . . . . . . . . . . 33
2.4.2 Actuator does not recover after fail safe event . . . . . . . . 33
2.4.3 Unit will not move to fail position . . . . . . . . . . . . . . . . . . . . 34
2.4.4 Actuator does not meet failsafe speed requirements . . . 35
2.4.5 Hydraulic surge system not functioning . . . . . . . . . . . . . . 36
2.4.6 Unit moves to the wrong position for trip. . . . . . . . . . . . . . 36
2.4.7 No Accumulator Pressure reading on Display, but there is
pressure on gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.8 Solenoid is extremely hot to the touch . . . . . . . . . . . . . . . 37
25 Oil Leaks 38
2.5.1 External oil leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5.2 The oil indicator is low, but no oil is visible / Repeated Reservoir
flling, no visual oil leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5.3 Reservoir relief leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
26 Miscellaneous 39
2.6.1 Water in Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.2 Cylinder binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
27 Calibration 40
2.7.1 Setting PL or PH and the unit reads “too high” or “too low” . 40
2.7.2 Will not accept PL or PH value. . . . . . . . . . . . . . . . . . . . . . 40
2.7.3 Will not accept SL or SH value. . . . . . . . . . . . . . . . . . . . . . 40
3. troubleShootInG
31 Accumulator low/bad pressure 41
Press bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Press Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
32 Drive Fault 44
3.2.1 B CSA drive fault IMS Driver. . . . . . . . . . . . . . . . . . . . . . . . 44
iv REXA X2 Series TS&R Manual
B Stepper Driver IMS Style with separate Power Supply: . 44
Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Stepper Motor:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Stepper Drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.2 B CSA drive fault Potted Drive . . . . . . . . . . . . . . . . . . . . . . 48
Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Stepper Motor:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Stepper driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.3 C drive fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stepper Motor:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stepper driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.4 Servo Motor Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2.5–A Input/Output signals from CPU to Driver . . . . . . . . . . .55
3.2.5–B Input/output signals from CPU to Dual D Drivers . . . . 56
3.2.5–C Input/output signals from CPU to Servo Driver with Booster
Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.6 Driver Fault code identifcation. . . . . . . . . . . . . . . . . . . . . . 57
REXA Omega Series Fault Codes (specifc to the Omega drive LED
display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2.7 Actuator “run away” when unit is powered up . . . . . . . . . 60
3.2.8 Servo Motor resistance readings . . . . . . . . . . . . . . . . . . . . 62
3.2.9 DC Bus Voltage check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.10 REXA Omega Drive Motor Wiring . . . . . . . . . . . . . . . . . . 63
33 Seat Loading Cylinder Problems 64
3.3.1 SLC reads Seated before actuator is on valve seat . . . . 64
3.3.2 SLC Feedback bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.3.3 SLC Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
34 Feedback Bad 66
35 Mot stall 70
3.5.1 Motor stall hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
High pressure stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Low/no pressure stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.5.2 Motor stall electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
36 Direction Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
06/10 v
REXA Electronics: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
37 +/- 15 Vdc Fail 75
38 Hart Interface 76
CS problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
No Digital communication is taking place . . . . . . . . . . . . . . . . . . 76
39 Foundation Fieldbus 78
No Digital communication is taking place . . . . . . . . . . . . . . . . . . 78
310 Pulse Control Signal 80
311 Control Signal 84
3.11.1 If actuator Position does not match Control Signal Input (Control
Signal Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.11.2 CS Bad reading (Control signal is less than 2.5 mA) . . 85
3.11.3 Control Signal “dithering” or noisy . . . . . . . . . . . . . . . . . . 86
3.11.4 Actuator travels to Position Lo or Position Hi when CS Bad error
occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.11.5 CS Bad error does not appear when Control Signal drops below
2.5 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
312 Contact Input Signal 88
313 Display Problems 94
3.13.1 Ribbon Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.13.2 Control Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
314 Pressure Relief Valves 96
315 Control Issues 98
3.15.1 Actuator Hunting – Electrical Noise . . . . . . . . . . . . . . . . 98
Electrical Noise on the Control Signal . . . . . . . . . . . . . . . . . . 98
Electrical Noise on the Actuator Feedback Signal . . . . . . . . 99
3.15.2 Actuator Torque / Thrust requirements . . . . . . . . . . . . . 100
3.15.3 Actuator drifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.15.4 Position Transmitter Calibration. . . . . . . . . . . . . . . . . . . 102
3.15.5 Electrical Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . 104
Do the solid state relays have leakage current when they are
off? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.15.6 Too High/Too Low on display . . . . . . . . . . . . . . . . . . . . . 106
316 Trip Signal 107
3.16.1 Fail direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.16.2 No trip on loss of power. . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.16.3 No trip on loss of control signal . . . . . . . . . . . . . . . . . . . 108
3.16.4 No trip on loss of trip signal . . . . . . . . . . . . . . . . . . . . . . 108
vi REXA X2 Series TS&R Manual
317 WATER INGRESS 110
3.17.1 Module / Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.17.2 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.e. eleCtrICal rePaIr
4E1 Ground Loops 113
4.E.1.1 What is a Ground Loop? . . . . . . . . . . . . . . . . . . . . . . . . 113
4.E.1.2 Why Ground Anyway? . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.E.1.3 Solutions (or a Single Ground is a Good Ground) . . . 114
4.E.1.4 Causes of Ground Potential Differences. . . . . . . . . . . 116
4.E.1.5 Ground loops and REXA Equipment . . . . . . . . . . . . . . 116
4.E.1.6 What fxes a ground loop?. . . . . . . . . . . . . . . . . . . . . . . 117
4E2 COMPONENT REPLACEMENT 118
4E3 Power Supply Assembly 122
4.E.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
4.E.3.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
4E4 CPU Assembly 129
4.E.4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.E.4.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4E5 Contact In / Relay Out Assembly 137
4.E.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.E.5.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4E6 Stepper Motor Drive (Std B&C) 142
4.E.6.1 Removal (STD B&C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.E.6.2 Replacement (STD B&C) . . . . . . . . . . . . . . . . . . . . . . . 143
4E7 CSA B Stepper Driver 144
4.E.7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.E.7.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4E8 CSA C Stepper Motor Drive 147
4.E.8.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.E.8.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4E9 1/2 D, D Servo Motor Drive 149
4.E.9.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.E.9.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4E10 VFD Display Assembly (External) 153
4.E.10.1 Removal of the External VFD Display: . . . . . . . . . . . 153
4.E.10.2 Replacement of the display assembly: . . . . . . . . . . . 154
4E11 VFD Display Assembly (Internal) 155
06/10 vii
4.E.11.1 Removal of the Internal Display Assembly . . . . . . . . 155
4.E.11.2 Replacement of the Display Assembly: . . . . . . . . . . . 156
4E12 Replacing Surge Suppressor 158
4.E.12.1 Removal of Control Signal Surge Suppressor . . . . . 158
4.E.12.2 Replacement of Control Signal Surge Suppressor:. 159
4.E.12.3 Removal of the AC Surge Suppressor: . . . . . . . . . . . 159
4.E.12.4 Replacement of the AC Power Surge Suppressor: . 160
4E13 Replacing Hart® Interface Assembly (S97695) 162
4.E.13.1 Removal of the Hart Interface Assembly . . . . . . . . . 162
4.E.13.2 Replacement of the Hart Interface Assembly: . . . . . 163
4E14 Replacing Fieldbus Assembly 164
4.E.14.1 Removal of the Foundation Fieldbus Assembly. . . . 164
4.E.14.2 Replacement of the Foundation Fieldbus Assembly 165
4E15 Replacing EMI / RFI Filter 166
4.E.15.1 Removal of the Filter:. . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.E.15.2 Replacement of the Filter: . . . . . . . . . . . . . . . . . . . . . . 167
4E16 Replacing Remote Mounted Feedback Board 168
4.E.16.1 Removal of Feedback Board . . . . . . . . . . . . . . . . . . . 168
4.E.16.2 Replacement of Feedback Board. . . . . . . . . . . . . . . . 169
4E17 Replacing Fuses (Single Pole, Double Pole, 3 Phase) 170
4.E.17.1 Removal of a Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4.E.17.2 Replacement of a Fuse . . . . . . . . . . . . . . . . . . . . . . . . 171
4E18 Replacing External Switch 172
4.E.18.1 Removal of External Switch . . . . . . . . . . . . . . . . . . . . 172
4.E.18.2 Replacement of External Switch . . . . . . . . . . . . . . . . 173
4.m. meChanICal rePaIr
4M1 Component Identifcation 175
4M2 Overview 178
4M3 Power Module Removal 181
4.M.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4M4 Reservoir Rebuild (All Size Modules) 183
4.M.4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.M.4.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 184
4.M.4.3 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4M5 Module Motor Replacement or Seal Replacement 185
4.M.5.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.M.5.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 186
viii REXA X2 Series TS&R Manual
4.M.5.3 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4M6 Fill and Overfll Valves 188
4.M.6.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.M.6.2 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4M7 Pressure Limiting Valve 189
4.M.7.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.M.7.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 190
4.M.7.3 Re-assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4M8 Drive Train Removal 191
4.M.8.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.M.8.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 192
4.M.8.3 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4.M.8.4 Drive Train Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.M.8.5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.M.8.6 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 194
4.M.8.7 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4M9 Suction Check Valve 196
4.M.9.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.M.9.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 196
4.M.9.3 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4M10 Standard Manifold Rebuild 197
4.M.10.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.M.10.2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . 198
4.M.10.3 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4M11 Solenoid 199
4.M.11.1 Disassembly (Solenoid Cover). . . . . . . . . . . . . . . . . . 199
4.M.11.2 Cleaning and Inspection (Solenoid Cover). . . . . . . . 200
4.M.11.3 Re-Assembly (Solenoid Cover) . . . . . . . . . . . . . . . . . 200
4.M.11.4 Disassembly (Solenoid Manifold) . . . . . . . . . . . . . . . 202
4.M.11.5 Cleaning and Inspection (Solenoid Manifold) . . . . . 203
4.M.11.6 Re-Assembly (Solenoid Manifold) . . . . . . . . . . . . . . . 203
4M12 Solenoid Set up 205
4M13 Solenoid Testing 207
4M14 High Speed Solenoids 209
4.M.14.1 Description of Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.M.14.2 Equipment Requirement . . . . . . . . . . . . . . . . . . . . . . . 209
4.M 14.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.M 14.4 Cleaning and Examination of Parts. . . . . . . . . . . . . . 210
06/10 ix
4.M 14.5 Initial Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4.M 14.6 Adjustment and Final Assembly. . . . . . . . . . . . . . . . . 211
4.M 14.7 Final Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4M15 HAND WHEEL / DRILL DRIVE 213
4.M.15.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.M.15.2 Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4M16 Hand Pump 214
4.M.16.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.M.16.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4M17 Commercial Linear Cylinders 216
4.M.17.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.M.17.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4M18 REXA Linear Cylinders 220
4.M.18.1 Cylinder Removal Procedure for All REXA Block
Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.M.18.2 L500 and L2 000 Cylinder Rebuild Procedure For ¾ Inch, 2
Inch, 4 Inch and 6 Inch Stroke Units. . . . . . . . . . . . . . . . . . . . . . 222
A. Feedback Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.M.18.2-A.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.M.18.2-A.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 223
B. Bushing Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.M.18.2-B.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.M.18.2-B.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 225
4.M.18.2-B.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 225
C. Shank Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.M.18.2-C.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.M.18.2-C.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 227
4.M.18.2-C.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.M.18.3 L4 000 Cylinder Rebuild Procedure for ¾ Inch, 2 Inch and 4
Inch Stroke Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
A. Feedback Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.M.18.3-A.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.M.18.3-A.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 230
B. Bushing Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4.M.18.3-B.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.M.18.3-B.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 232
4.M.18.3-B.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 232
C. Shank Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
x REXA X2 Series TS&R Manual
4.M.18.3-C.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.M.18.3-C.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 234
4.M.18.3-C.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.M.18.4 L10 000 Cylinder Rebuild Procedure for 2 Inch and 6 Inch
Stroke Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
A. Feedback Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.M.18.4-A.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.M.18.4-A.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 237
B. Top Bushing Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.M.18.4-B.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.M.18.4-B.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 239
4.M.18.4-B.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 239
C. End Cap Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.M.18.4-C.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.M.18.4-C.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 241
4.M.18.4-C.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 241
D. Shank Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.M.19.4-D.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.M.18.4-D.2 Cleaning and Inspection . . . . . . . . . . . . . . . . 243
4.M.18.4-D.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4M19 Rotary Cylinder 245
4.M.19.1 Assembly and Disassembly Procedures . . . . . . . . . 246
4.M.19.1- A Inspection & Replacement
of End Cap Seals (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.M.19.1- B. Inspection & Replacement of Wear Rings (4), Piston
Seals (5) and Cylinder O-Ring (8). . . . . . . . . . . . . . . . . . . . . 246
4.M.19.1- C. Inspection and Replacement of Pinion and Bearing
Retainer O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.M.19.1- D. Complete Disassembly of Cylinder . . . . . . . . 248
4.M.19.1- E. Reassembly of Cylinder . . . . . . . . . . . . . . . . . 248
4M20 Rotary Feedback 249
4.M.20.1 Identifcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Contacting potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.M.20.2 Contacting Potentiometer . . . . . . . . . . . . . . . . . . . . . . 249
4.M.20.2- A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.M.20.2- B Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.M.20.3 Non - Contacting Potentiometer . . . . . . . . . . . . . . . . . 251
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.M.20.3-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
06/10 xi
4.M.20.3-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.M.20.4 Retroftting with Contacting or
Non-Contacting Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 252
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.M.20.4-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.M.20.4-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.M.20.4-B1 Contacting Potentiometer . . . . . . . . . . . . . . . 253
4.M.20.4-B2 Non - Contacting Potentiometer. . . . . . . . . . . 253
4M21 - Linear Feedback 254
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Identifcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.M.21.1 Contacting Linear Potentiometer . . . . . . . . . . . . . . . . 255
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.M.21.1-A Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.M.21.1-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.M.21.2 Non - Contacting Linear Potentiometer/Retroft . . . . 256
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.M.21.2-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4.M.21.2-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.M.21.3 Non -Contacting Linear Potentiometer . . . . . . . . . . . 258
4.M.21.3-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.M.21.3-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4M22 Elastic Coupling 261
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Identifcation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.M.22.1 Open Spring Compression (Downseating) Load Type Elastic
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.M.22.1-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.M.22.1-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.M.22.2 Closed Spring Tension (Upseating) Load Type Elastic
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.M.22.2-A Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
4.M.22.2-B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
4 M23 Seat Load Cylinder 266
4.M.23.1 Removal from Actuator . . . . . . . . . . . . . . . . . . . . . . . . 266
4.M.23.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.M.23.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.M.23.4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
xii REXA X2 Series TS&R Manual
4.M.23.5 Re-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4M24 Booster Pump 269
4.M.24.1 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.M.24.1.A Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.M.24.1.B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.M.24.2 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.M.24.2.A Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.M.24.2.B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.M.24.3 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.M.24.3.A Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.M.24.3.B Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4M25 Transducer 273
Identifcation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.M.25.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.M.25.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4M26 External reservoir and accumulator bottle 275
Reservoir Identifcation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Accumulator Identifcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.M.26.1 Disassembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.M.26.2 Reassembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
aPPendIx a
List of Recommended Tools
TK-2, the Standard Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
TK-3, the Tube Bending Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
TK-4, the Bleed Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
aPPendIx b
Returning the Actuator for Repair
B.1 Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1
aPPendIx C
Circuit Schematics
D97904 — Stepper Wiring Diagram . . . . . . . . . . . . . . . . . . . . C.2
D97904-.5d — ½D Servo Wiring Diagram . . . . . . . . . . . . . . . C.3
D97904-D — D Servo Wiring Diagram . . . . . . . . . . . . . . . . . . C.4
D97904-2D — 2D Servo Wiring Diagram . . . . . . . . . . . . . . . . C.5
D97904-P9 — D,P9 Servo Wiring Diagram. . . . . . . . . . . . . . . C.6
06/10 xiii
D97904-P40 — D,P40 Servo Wiring Diagram. . . . . . . . . . . . . C.7
D97904-STEPACCUM — Stepper w/ Accumulator Fail Option. . C.8
D97904-.5DACCUM — ½D Servo w/ Accumulator Fail Option. . C.9
D97904-DACCUM — D Servo with Accumulator Fail Option . . C.10
D97904-2DACC — 2D Servo with Accumulator Fail Option . . . C.11
D97904-P9ACC — D,P9 Servo with Accumulator Fail Option . C.12
D97904-P40ACC — D,P40 Servo w/ Accumulator Fail Option C.13
aPPendIx d
Cable Specifcations
X2 Module Cable Specifcation . . . . . . . . . . . . . . . . . . . . . . . . D.1
Feedback Cable Specifcations . . . . . . . . . . . . . . . . . . . . . . . . D.2
Solenoid Cable Specifcations . . . . . . . . . . . . . . . . . . . . . . . . . D.3
HEATER/SOLENOID Cable Specifcations . . . . . . . . . . . . . . . D.4
D –Pump Motor Cable Specifcations. . . . . . . . . . . . . . . . . . . . D.5
Resolver Cable Specifcations. . . . . . . . . . . . . . . . . . . . . . . . . D.6
P40 Motor Cable Specifcations. . . . . . . . . . . . . . . . . . . . . . . . D.7
aPPendIx e
Parameter Sheet
aPPendIx F
Field Service Memo
X2 Troubleshooting and Repair Manual
Safety Information – 06/10 xv
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:
• Damage to actuator or other equipment
• Serious physical injury
• Death
always observe the safety information listed in this documentation.
• Airborne noise is less than 60 dB.
• All Guards MUST be in place before operation. Failure to do
so may result in injury or damage to equipment.
• Use the Actuator for its intended purpose ONLY. Using the
actuator for uses other than what it is intended may result in
injury or death.
• Do not use the Actuator should it be damaged in shipping or
installation. Contact REXA.
Fundamental Safety Information
Safety Information (06/10)
xvi REXA X2 Series TS&R Manual
WARNING LABELS

Hazardous Voltage
Turn Off and Lock Out system power before
servicing.

General Warning
Refer to Installation Manual before servicing.

Attention
Important information provided.

Crush or Pinch Point Hazard
Turn Off and Lock Out system power before
servicing.
Warn of Actuator movement if Spring Fail Unit.
RESIDUAL RISKS
This section is to help identify the risks associated with the Actuator
System. These items are identifed 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.
X2 Troubleshooting and Repair Manual
Safety Information – 06/10 xvii

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 Lock-Out/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 procedures before accessing
Control Enclosure.

SHOCK HAzARD:
Hazardous voltage levels are present in the actuator.
Only qualifed 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 person-
nel.
Safety Information (06/10)
xviii REXA X2 Series TS&R Manual

AVOID ACCIDENTAL STARTING:
When installing the actuator, insure that line power to
the unit is shut off. When power is applied, the actua-
tor 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 Syntec® SAE 5W-50 motor oil. The introduc-
tion of other fuids 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 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
ftting. 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.
X2 Troubleshooting and Repair Manual
Safety Information – 06/10 xix
Note: Accumulators will still contain up to 2 000 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 compound—or its
equivalent—must be used on threads of all NPT
plug and conduit connections to ensure a
watertight seal.
WHEN TO LOCK-OUT/TAG-OUT
Most equipment is installed along with safe switches allowing
the equipment to be disabled for minor repair. In general, these
switches provide adequate 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.
Safety Information (06/10)
xx REXA X2 Series TS&R Manual
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 verifcation: Take nothing for granted. Verify that
the locked-out switch or control cannot be overridden. Test
the equipment to be certain that the locked-out switch is
de-energized, and not simply 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 fnished. This is especially
true when more than one employee is working on the equip-
ment. A lock is never to be removed except by the person
who placed it there.
8. Equipment start-up. Make a fnal safety check before
restarting equipment, to be certain it is safe to operate.
Make sure of the following:
X2 Troubleshooting and Repair Manual
Safety Information – 06/10 xxi
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.
X2 Troubleshooting and Repair Manual
General Information – 06/10 1
1. General Information
11 FACTORy SUPPORT
REXA is a full service company. We have a fully staffed service
department with factory trained and certifed 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:
REXA Phone: (508) 584-1199
4 Manley Street Fax: (508) 584-2525
West Bridgewater, MA 02379 Web: www.rexa.com
Note: It is important to have the model number and build code
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 Identifcation for a more detailed explanation.
12 ACTUATOR IDENTIFICATION
The model number, mechanical build code, electronics build code
and serial numbers are all used to identify an individual actuator and
electronics.
2 REXA X2 Series TS&R Manual
General Information (06/10)
The model number will provide a general description of the actuator
and electronics as a set. The model number also provides the
information required to correctly defne what sections of this manual
applies to a particular actuator. The build code 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 identifcation
that fully allows us to identify the unit. The factory requires these
numbers whenever service or information is requested. Supplying
the model number, both mechanical and electrical build codes,
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 1.2-1 and 1.2-2 shows typical ID tags.
Figure 1.2-1 Mechanical ID Tag
W.BRIDGEWATER MASSACHUSETTS
MODEL
SERIAL NO.
MAX. THRUST LBS
MAX. TRAVEL
INCHES
VOLTS
AMPS Hz
ONE OR MORE OF THE FOLLOWING U.S. PATENTS APPLY
4.557.180 4.625.513 4.696.163 4.766.728
Figure 1.2-2 Electronics ID Tag
ACTUATOR IDENTIFICATION
General Information – 06/10 3
X2 Trouble Shooting and Repair Manual
121 Model Number
The basic model number is a generic description of the actuator.
Figure 1.2.1 shows a break down of the model number tree and how
it works.
L SERIES
Thrust Strokes
(lb) (in inches)
500 –.75, –2
2 000 –.75, –2, –4 –6, –8, –11
4 000 –.75, –2, –4
5 000 –.75, –2, –4, –6, –8, –11, –16, –22
8 000 –.75, –2, –4, –6
10 000 –.75, –2, –4, –6, –8, –11, –16, –22
15 000 –.75, –2, –4, –6, –8, –11, –16, –22
20 000 –.75, –2, –4, –6, –8, –11, –16, –22
30 000 –.75, –2, –4, –6, –8, –11, –16, –22
40 000 –.75, –2, –4, –6, –8, –11, –16, –22
50 000 –.75, –2, –4, –6, –8, –11, –16, –22
60 000 –.75, –2, –4, –6, –8, –11, –16, –22
80 000 –.75, –2, –4, –6, –8, –11, –16, –22
120 000 –.75, –2, –4, –6, –8, –11, –16, –22
R or D SERIES
Torque Rotation
(lbf·in) (degrees)
600 –90, –120
1 200 –90, –120
2 500 –90, –120
5 000 –90, –120
10 000 –90, –120
20 000 –90, –120
50 000 –90, –120
100 000 –90, –120
200 000 –90, –120
Power Modules
B: Single B
C: Single C
½D: Single ½D
D: Single D
2C: Dual C Manifold
2D: Dual D Manifold
D,P9: Booster Pump
D,P40: Booster Pump
Spring Fail Option
(Upon Power Loss)
P: None - Lock in Place
U: Universal (Rotary)
E: Extend (Linear)
R: Retract (Linear)
A: Accumulator Failure
MODEL NUMBER
X2__ __ __ __ __ – __ __ – __ – __
Thrust - Stroke
Torque - Rotation
Series 2
L Series – Xpac Linear
R Series – Xpac Rotary
D Series – Xpac Drive
Model Numbers — Examples:
X2L4000-4-C-P
Is a Linear L Series 2 Xpac with 4 000 lb of thrust, stroke adjustable up to 4
inches, and C size power module. Lock in place upon loss of power.
X2R2500-90-B-U
A Rotary R Series 2 Xpac with 2 500 lbf·in of torque, rotation adjustable to 90
degrees, and B size power module. Spring failure upon loss of power. .
Figure 1.2.1 Model Number
ACTUATOR IDENTIFICATION
4 REXA X2 Series TS&R Manual
General Information (06/10)
122 Serial Number
Serial numbers are assigned to every job at REXA. Job specifc
information as well as sales and engineering information are stored
under a specifc serial number. A typical serial number will look like:
C0600000. The C06 indicates the year of manufacture and the next
fve digits correspond to the unique order number.
123 Build Code
The build code is a catalog number we use to designate in complete
detail the construction of the actuator. From this number all
confgurations can be defned. There are two different categories
of build numbers; one is for the mechanical sub-assembly, and the
second is for it’s 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 of the IOM.
13 GENERAL SPECIFICATIONS
131 Recommended Fluids and Lubricants
INTENDED USE SPECIFICATIONS
Operating oil, standard Castrol SYNTEC® SAE 5W-50 Motor Oil
Operating oil, biodegradable EnviroLogic® 3100 Series Hydraulic Fluid
Anti-Seize Compound Bostik Never-Seez® or equivalent
O-ring Lubricant Parker Super-O-Lube or equivalent
Thermal Grease Thermalcote™ or equivalent
Molybdenum Disulfde Grease Mobilgrease® XHP 222 or equivalent
Parts Cleaner zEP® BRAKE WASH or equivalent
ACTUATOR IDENTIFICATION
General Information – 06/10 5
X2 Trouble Shooting and Repair Manual
132 Operating Temperatures
The following is a general guideline; refer to Technical Memo TM19-2
for further information.
Table 1.3.2-1 Linear Actuators *
T
e
m
p
e
r
a
t
u
r
e

R
a
n
g
e
¹
Actuator
Construction
Standard High Temp.
Type L Linear
Cylinder
-5 °F to +200 °F -30 °F

to +200 °F -76 °F to +200 °F -5 °F to +250 °F
(-20 °C to +93 °C) (-34 °C to +93 °C) (-60 °C to +93 °C)
(-20 °C to
121 °C)
Type C Linear
Cylinder
+10 °F to +200 °F -10 °F to +200 °F -76 °F to +200 °F -5 °F to +250 °F
(-12 °C to +93 °C) (-23 °C to +93 °C) (-60 °C to +93 °C)
(-20 °C to
121 °C)
Installation
Requirements
None
1 inch thermal
insulation
2
Heat tracing &
1 inch thermal
insulation
2
None
Electronics
Temp. Range
Separate Control Enclosure with CPU, motor driver, power supply, transient
protection and termination.
-40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C)
Motor Type Stepper Servo
1. High ambient temperatures affect oil viscosity which may affect actuator rated output.
2. These items are not supplied by Rexa.
* all CSa electronics, mechanical stepper units and servo units are rated -40 °F to +104 °F
(-40 °C to +40 °C).
Table 1.3.2-2 Rotary Actuators & Drives *
T
e
m
p
e
r
a
t
u
r
e


R
a
n
g
e
1
Actuator
Construction
Standard High Temp.
Type R Rotary
or D Drive
Cylinder
+10 °F to +200 °F -10 °F to +200 °F -76 °F to +200 °F -5 °F to +250 °F
(-12 °C to +93 °C) (-23 °C to +93 °C) (-60 °C to +93 °C)
(-20 °C to
+121 °C)
Installation
Requirements
Standard oil &
cartridge heater
1” of thermal
insulation
2
Heat tracing & 1”
therm
2
Optional
High Temp.
Construction
Electronics
Temp. Range
Separate Control Enclosure with CPU, motor driver, power supply, transient
protection and termination.
-40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C)
Motor Type Stepper Servo
1. High ambient temperatures affect oil viscosity which may affect actuator rated output.
2. These items are not supplied by Rexa.
* all CSa electronics, stepper units and servo units are rated -40 °F to +104 °F
(-40 °C to +40 °C).
GENERAL SPECIFICATIONS
6 REXA X2 Series TS&R Manual
General Information (06/10)
14 INSPECTION 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 (see below). 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 the IOM, 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 fttings 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)
INSPECTION SCHEDULE
General Information – 06/10 7
X2 Trouble Shooting and Repair Manual
• Check for moisture ingression or contaminants under the feed-
back 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
Maintenance Schedule
Items such as seals, O-rings, wear bands, bushings, seats and
valves will from time to time need to be replaced. Since factors such
as pressure, actuator travel, contaminants, temperature and output
all play a role in determining how frequently preventive maintenance
is required, this document should only be used as a guide. Actual
maintenance history logs for the specifc application should be
generated for a better indicator of when preventive maintenance is
required.
For example, a linear cylinder seal for a 2 000 lb thrust actuator will
wear out three times faster if the cycle stroke is six inches vs. two
inches and, conversely, will last four times longer if the stroke is half
inch vs. two inches. Seal life is also dictated by the pressure the
seal is holding. As the pressure increases, so do the forces between
the seals and the rods and bores they are sealing. As these forces
increase so do the friction forces between these components
causing a seal under pressure to exhibit more wear than one under
less pressure. It is important to understand the application and
its infuence on the actuators’ components when determining the
frequency of preventive maintenance for each unit.
The soft goods — or seals — in each REXA actuator have been
selected to provide a design life of at least 1,000,000 cycles or
10,000,000 dither cycles. This equates to four years of service in a
typical process control system. Seal design life estimates are based
on the following assumptions:
The actuator will only be loaded to its full output during 5% of its
total travel — this is the case in 90% of control applications when
the actuator is seating a valve.
INSPECTION SCHEDULE
8 REXA X2 Series TS&R Manual
General Information (06/10)
If the full load of the actuator is required over a greater percent-
age of the stroke, then required maintenance will be increased.
Excessive loads — such as those exhibited when a cylinder
“dead ends”— can cause excessive stress and premature wear.
INSPECTION SCHEDULE
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 9
WHAT IS THE PROBLEM?
21 INTERFACE ISSUES
2.1.1 I forgot my Password; How do I get into Setup?
2.1.2 Warning relay open
2.1.3 Alarm relay open
2.1.4 Error code in display
2.1.5 Motor driver fault
2.1.6 No display, unusual display (ex., letters missing, sections
burnt out, etc)
2.1.7 Actuator will not respond to HART command
2.1.8 Actuator will not respond to FF command
2.1.9 Actuator will not respond to Pulse command
2.1.10 Actuator will not respond to Analog command
2.1.11 Actuator will not respond to 1 Cont (On/Off) command
2.1.12 Actuator will not respond to 2 Cont (Manual Control)
command
22 ACCESSORIES
2.2.1 External push buttons not functioning
2.2.2 Keypad buttons not functioning
2. Problem Identifcation
Problem Identifcation (06/10)
10 REXA X2 Series TS&R Manual
PROBLEM IDENTIFICATION
2.2.3 Drill Drive / Hand Wheel not functioning
2.2.4 Manual hand pump not functioning
2.2.5 Gauges not functioning
2.2.6 Pressure limiting protection not working
2.2.7 Torque or thrust data not accurate (from transducers)
2.2.8 Mechanical Limit Switches not functioning
23 CONTROL ISSUES
2.3.1 Actuator moves to wrong position
2.3.2 Actuator “hunting” (dithering during control)
2.3.3 Actuator “drifts” away from applied load
2.3.4 Position feedback doesn’t match actual position
2.3.5 How do I test my 4-20 mA Position Transmitter?
2.3.6 No position feedback signal
2.3.7 Electrical limit switches don’t function
2.3.8 Actuator will not seat
2.3.9 Actuator does not meet stroke speed requirements
2.3.10 Booster Pump does not turn on
2.3.11 Only one module on a 2D or 2C units functions
2.3.12 Surrounding equipment disrupted by Actuator operation
2.3.13 Servo Motor turning at low RPM when not commanded
to move
2.3.14 Actuator slows down and “resets” before getting to target
position
2.3.15 Actuator overshoots target position and returns.
2.3.16 I have many errors logged in historical stats
24 FAIL SAFE ISSUES
2.4.1 Accumulator will not recharge
2.4.2 Actuator does not recover after fail safe event
2.4.3 Unit will not move to fail position
2.4.4 Actuator does not meet fail safe speed requirements
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 11
2.4.5 Hydraulic surge not functioning
2.4.6 Unit moves to the wrong position for trip
2.4.7 No Accumulator Pressure reading on Display, but there is
pressure on gauge
2.4.8 Solenoid is extremely hot to the touch
25 OIL LEAKS
2.5.1 External oil leaks
2.5.2 Reservoir relief dumps oil
2.5.3 The oil indicator is low, but no oil is visible / Repeated
Reservoir flling, no visual oil leaks
26 MISCELLANEOUS
2.6.1 Water in unit. (Feedback, Module, Motor, electronics)
2.6.2 Cylinder binding
27 CALIBRATION
2.7.1 Setting PL or PH and unit reads “too high” or “too low”
2.7.2 Will not accept PL or PH value
2.7.3 Will not accept SL or SH value
PROBLEM IDENTIFICATION
Problem Identifcation (06/10)
12 REXA X2 Series TS&R Manual
21 INTERFACE ISSUES
RESOLUTIONS
211 I forgot my Password; how do I get into Setup?
Parameter Password has been added to the Outputs menu following
parameter Pos Xmitter. If a value (other than the default value of
00000) is entered into Password, future entry into Setup mode will
require the user to enter the Password value. Contact factory if you
lost your password.
212 Warning relay open
WARNING: The output is in the “alarm” state when the actuator
detects a problem but can otherwise continue to operate.
Detectable problems include:
– Accumulator low or bad pressure detected during “normal
operation” or following a failed recharge cycle. (See TS&R
section 31, Accumulator low/bad pressure.)
– Drive fault active. Multiple drive units can usually continue to
operate (with reduced performance) when one motor driver is
bad, so a “warning” is issued. (See TS&R section 32, Drive
Fault active.)
– Seat Load Cylinder reached its “Seated” position but the
valve was not required to be seated (SLC stop). (See TS&R
section 331, SLC reads Seated before actuator is on valve
seat.)
213 Alarm relay open
The CPU board has two solid state relay “alarm” outputs; an ALARM
and WARNING. The output is in the “alarm” state whenever the
actuator is unable to follow the control signal/control scheme as
defned in the Signals menu. An “alarm” occurs if the actuator is
switched to Local Manual but not Remote Manual. An alarm relay
change may be followed by an error code. (See Error code section.)
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 13
214 Error code in display
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 in a round-robin
fashion at approximately 1 second intervals. All errors are cleared
by power-on/reset or by entry into Setup mode in addition to the
means identifed below as “Cleared by”. Any error identifed as being
detected in “All” modes will persist until corrected.
FB bad
Meaning: The actuator’s main feedback is below 2 mA or either (+)
or (-) 15 fail is set or A/D fail is set.
Detected modes: All.
Actuator response in Auto mode: Freeze - no movement.
Cleared by: Self clearing when feedback greater than 2 mA or
when 15 fail or A/D fail clears.
Alarm/warning: Alarm
(See TS&R section 34, Feedback Bad.)
CS bad
Meaning: The analog control signal is below 2.5 mA or either the
(+) or (-) 15 fail is set or A/D fail is set.
Detected modes: All.
Actuator response in Auto mode: Defned by Failsafe parameter
(See IOM section 616, INPUTS Menu.)
Cleared by: Self clearing when control signal > 2.5 mA or when 15
fail or A/D fail clears.
Alarm/warning: Alarm
(See TS&R section 311, Control Signal Bad.)
INTERFACE ISSUES
Problem Identifcation (06/10)
14 REXA X2 Series TS&R Manual
Mot stall
Meaning: Five attempts to move the actuator 1% of stroke in the
time set in parameter Stall Time have failed (See IOM section 617,
DRIVES Menu), or the “Seated” position was reached on the Seat
Load Cylinder and the position of the main cylinder was greater than
1% above Position Lo.
Detected modes: Auto mode only.
Actuator response in Auto mode: Freeze in place – no movement
in stall direction.
Cleared by: Any control signal change which requires actuator
movement in the direction opposite to that in which the stall
occurred. One retry is allowed for each signal reversal. One
additional retry is allowed for each successful motor start/stop until
fve retries are “in the bank”.
Alarm/warning: Alarm
(See TS&R section 35, Mot stall.)
Dir error
Meaning: The actuator was detected moving in the wrong direction
on two successive motor starts.
Detected modes: Auto mode only.
Actuator response in Auto mode: Freeze – no movement.
Cleared by: Only cleared by power-on/reset or entry into Setup.
Alarm/warning: Alarm
(See TS&R section 36, Direction Error.)
Drv fault
Meaning: One or more motor drives has detected a problem which
could not be cleared with a drive reset. Will also appear when a
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 15
fault/reset board does not have drive fault jumpers installed (in
positions where a motor drive is not connected).
Detected modes: Auto mode only.
Actuator response in Auto mode: The actuator attempts to
continue normal operation.
Cleared by: A drive reset is attempted when the fault is initially
detected. If the fault does not clear on the frst reset attempt, the
Drv fault error is set. Additional drive resets (spaced at 10 second
intervals) occur until the fault clears. See Alarms, above, for
additional information.
Alarm/warning: Warning
(See TS&R section 32, Drive Fault.)
+15 fail or -15 fail
Meaning: The (+) or (-) 15 volt power supply is out of range by (+)
or (-) 10% error band.
Detected modes: All.
Actuator response in Auto mode: Freeze – no movement. Also
sets Fb fail and, if applicable, Cs fail.
Cleared by: Self clears if the supply returns to within a (+) or (-) 5%
error band.
Alarm/warning: Alarm
(See TS&R section 37, +/-15VDC Fail.)
Pres bad
Meaning: The accumulator’s pressure transducer is out of range.
The transducer is considered out of range if the 4 to 20 mA signal is
less than 3 mA or greater than 21 mA.
Detected modes: All.
INTERFACE ISSUES
Problem Identifcation (06/10)
16 REXA X2 Series TS&R Manual
Actuator response in Auto mode: The actuator continues with
normal operation.
Cleared by: Transducer signal greater than 3 mA or less than 21 mA.
Alarm/warning: Warning
(See TS&R section 31, Accumulator low/bad pressure.)
Pres low
Meaning: The accumulator pressure is below the value set in
parameter Warn Pres.
Detected modes: All.
Actuator response in Auto mode: The actuator continues with
normal operation.
Cleared by: Successful recharge cycle.
Alarm/warning: Warning
(See TS&R section 31, Accumulator low/bad pressure.)
SlcFb bad
Meaning: The feedback signal from the seat load cylinder is less
than 2 mA.
Detected modes: All.
Actuator response in Auto mode: Freeze – no movement.
Cleared by: Self clearing when feedback is greater than 2 mA.
Alarm/warning: Alarm
(See TS&R section 332, SLC Feedback bad.)
Slc stop
Meaning: The actuator has stopped at the “Seated” position of the
seat load cylinder, but the control signal is greater than 0.2% (i.e.,
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 17
the seat load cylinder has reached the “Seated” position, but the
control signal did not request it).
Detected modes: Auto mode only.
Actuator response in Auto mode: The actuator continues with
normal operation.
Cleared by: Any control signal change which requires actuator
movement in the direction opposite to that in which the stop occurred.
Alarm/warning: Warning
(See TS&R section 333, SLC stop.)
Key bad
Meaning: A bad reading of the key pad has occurred.
Detected modes: All.
Actuator response in Auto mode: The keypad reading is ignored
and the actuator continues with normal operation.
Cleared by: Self clearing with a valid keypad reading.
Alarm/warning: Warning
Mem fail
Meaning: A memory location containing a Setup parameter value
has failed to erase/write.
NoTE: The memory locations containing error counters are not checked.
Detected modes: Setup mode only.
Actuator response in Auto mode: N/A
Cleared by: Only cleared by power-on/reset or by re-entry into
Setup and reprogramming all parameters. Press Enter button to open
parameter (“=” will fash); then press Enter again to write in new value.
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18 REXA X2 Series TS&R Manual
Alarm/warning: Alarm until cleared
No inp bd
Meaning: One or more of the parameters in the Signals menu is
selected and the required Contact Inputs Board is not installed (or
failed to respond when read).
– Signal Type is set to 1 Cont, 2 Cont, or Pulse
– Trip is not set to Off
Detected modes: All.
Actuator response in Auto mode: Freeze in place and go to
Setup mode. When Setup mode is entered the frst incorrect
parameter (as listed above) will be on display.
Cleared by: Changing the Signals menu parameter(s) to match the
installed boards, or (with power off) installing the required board(s).
Alarm/warning: Alarm
A/D fail
Meaning: The A/D converter on the CPU Board has failed to
respond.
Detected modes: All
Actuator response in Auto mode: Freeze - no movement. Also
sets Fb fail and (if applicable) Cs fail.
Cleared by: Self clears if/when A/D responds.
Alarm/warning: Alarm
CPU fail
Meaning: The CPU has detected an unexpected interrupt.
Detected modes: All.
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 19
Actuator response in Auto mode: The actuator continues with
normal operation.
Cleared by: Only cleared by power-on/reset or by entry into Setup
mode.
Alarm/warning: Alarm
215 Motor driver fault
A motor driver has detected a problem and sent an error code to
the CPU.
The drive fault is relayed to the CPU through the fault input terminal
(TB3 for stepper, TB6 for servo). The fault input is 5 Vdc, and is
only present when there is a problem. Actuators with more than one
drive use an additional fault/reset board that is separate of the CPU.
The purpose of this board is to use one fault signal for both drives,
allowing the actuator to operate with 1 driver while the other is faulted.
REXA actuators use two styles of motor driver, Stepper and Servo.
To identify which driver you have, you must frst locate the model
number on the REXA identifcation tag located on the Electronics
enclosure, or the actuator. (See photos below.)
Photo 2.1.5-1 Electrical ID Tag Photo 2.1.5-2 Mechanical ID Tag
Located in the Model number of the REXA is the module type. An
example would be an X2L2000-4-C-P. The module type determines
which style of driver you have. In this example, the driver type is
C. (Refer to TS&R section 12 for additional actuator identifcation
information.)
INTERFACE ISSUES
Problem Identifcation (06/10)
20 REXA X2 Series TS&R Manual
Once the drive type is determined go to the corresponding section:
TS&R 321, B CSA drive fault IMS Driver
322, B CSA drive fault Potted Drive
323, C drive fault
324, Servo motor driver
325, Dual unit drive fault
326, Booster unit drive fault
216 No display, unusual display
(ex, letters missing, sections burnt out, etc)
The REXA display is a vacuum fuorescent emissive display with
keypad. The display could burn out if left on for long periods of time.
To avoid this, the display is dimmed after one hour of no keypad use,
but may be turned back on by pressing any key.
If the 14 position ribbon cable between the CPU and display comes
loose or is plugged in backwards, the display will go out. The power
indicator light may remain on, but the display will be blank.
If the 5 Vdc input from the Quad Power Supply is lost, the display will
go blank.
(See TS&R section 4E10 for repair/replacement of the display.)
217 Actuator will not respond to HART command
REXA actuators have an optional HART interface board that allows
them to communicate through the HART 5.0 protocol. When this
optional board is installed a two-wire 4 to 20 mA current loop runs
between the control station and the REXA actuator. This analog line
is attached to the HART BOARD and landed on connector TB1 to
pins CS+ and CS-. If the actuator is not responding to this control
signal, reference TS&R section 311, Control Signal Bad.
Through the universal HART command two dynamic variables (PV
position of the actuator and SV differential pressure in the actuator)
are transferred back to the control system. If these two variables
are not being sent back, reference TS&R section 27, Calibration.
If these variables are being sent back but the values are incorrect,
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 21
reference the troubleshooting section on the transducers—TS&R
section 38, HART Interface.
218 Actuator will not respond to FF command
REXA actuators have an optional FoUndatIon Fieldbus interface
board. When this optional board is installed a two wire connection
from the control station to the REXA actuator is used for communica-
tion. This connection is attached to the Foundation Fieldbus inter-
face board.
If connection to the REXA actuator cannot be established, reference
TS&R section 39, FoUndatIon Fieldbus.
If connection is established, reference other symptom section to
complete troubleshooting.
219 Actuator will not respond to Pulse command
REXA actuators have an optional contact input board that allows the
actuator to communicate through Pulse commands. The communi-
cation is established by either a 3 or 4 wire signal that carries AC or
DC voltages that ranges from 24 V to 120 V. These voltage pulses
are interpreted by the REXA controller in accordance with the setup
parameters Pulse Duration and Pulse Increment.
If the actuator will not respond to the Pulse signals or the desired
position is not being achieved, reference TS&R section 310, Pulse
Control Signal.
2110 Actuator will not respond to Analog command
REXA actuators have a standard analog control scheme built into
the main CPU board that allows the actuator to position using a
two-wire 4 to 20 mA current loop. If the actuator is not following a
change in the analog control signal current or is reading a CS bad
in the display, reference TS&R section 311, Control Signal Bad.
INTERFACE ISSUES
Problem Identifcation (06/10)
22 REXA X2 Series TS&R Manual
2111 Actuator will not respond to
1 Cont (On/Off) command
REXA actuators have an optional contact input board that allows
the actuator to be controlled through a single contact using the bias
voltage from the Contact Input board, or a distinct voltage signal.
The control is a 2 wire signal that carries AC or DC voltages that
range from 24V to 120V. This voltage is interpreted by the REXA
controller in accordance with the setup parameter Signal Type = 1
Cont.
If the actuator will not respond to the Contact signals, reference
TS&R section 312, Contact Input Signal.
2112 Actuator will not respond to
2 Cont (Manual Control) command
REXA actuators have an optional contact input board that allows
the actuator to be controlled through 2 contacts using the bias
voltage from the Contact Input board, or 2 distinct voltage signals.
The control is a 3 or 4 wire signal that carries AC or DC voltages
that ranges from 24 V to 120 V. This voltage is interpreted by the
REXA controller in accordance with the setup parameter Signal
Type = 2 Cont.
If the actuator will not respond to the Contact signals, reference
TS&R section 312, Contact Input Signal.
INTERFACE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 23
22 ACCESSORIES
221 External push buttons don’t work
The Electrical sub-assembly is equipped with an external door-
mounted, 5 button membrane switch and display assembly.
The switches interface with the Actuator (whether it is setup in
calibration, local control, or scroll through parameters) while in the
Auto mode.
 If the actuator is powered up in Auto mode without pushing
any buttons, the display will dim to half intensity. The frst
button push will “wake up” the display to full intensity. The
button must be pushed a second time to activate its function.
 A menu or parameter may not be accessible in the current
mode of operation. See IOM section 6, Modes of Operation
and Control Parameters.
 To access modes of operation, 2 buttons must be pressed
simultaneously. (See IOM section 6, Modes of Operation
and Control Parameters.)
 The ribbon cable connecting the membrane switch assembly
to the interface circuit board may be disconnected. See
TS&R section 313, Display Problems.
 If you are trying to Calibrate Signal Lo and Signal Hi with
the buttons, see IOM section 6, Modes of Operation and
Control Parameters.
 +5 Vdc internal to the Control enclosure may be too low.
(Contact the REXA factory.)
222 Internal Keypad buttons don’t work
The Electrical sub-assembly is optionally equipped with an internal,
CPU mounted, 5-button keypad switch and display assembly. The
switches are used to interface with the Actuator (whether it be setup
in calibration, local control, or scroll through parameters) while in the
Auto mode.
ACCESSORIES
Problem Identifcation (06/10)
24 REXA X2 Series TS&R Manual
 If the actuator is powered up in Auto mode without pushing
any buttons, the display will dim to half intensity. The frst
button push will “wake up” the display to full intensity. The
button must be pushed a second time to activate its function.
 A menu or parameter may not be accessible in the current
mode of operation. (See IOM section 6, Modes of Opera-
tion and Control Parameters.)
 To access modes of operation, 2 buttons must be pressed
simultaneously.
 If you are trying to move the actuator in Local or Calibrate
mode and the actuator will not move, see TS&R section
315, Control Issues.
 Are you trying to Calibrate Signal Lo and Signal Hi with the
buttons? (See IOM section 6, Modes of Operation and
Control Parameters.)
 +5 Vdc internal to the Control enclosure may be too low.
(Contact the REXA factory.)
223 Drill Drive / Hand wheel doesn’t work
The handwheel is mounted to the actuator’s motor. To operate, you
must engage the handwheel by pushing the handwheel toward the
motor; the hand wheel / drill drive is disengaged via internal spring.
One half-revolution may be required for proper engagement. The
handwheel will declutch by moving outwards when the spring is
released.
 The hand wheel can take several turns before you see
movement from the actuator. (See IOM Appendix M, sec-
tion M.1.2, Declutchable Handwheel.)
 Servo units do not allow for operation of the handwheel
while the actuator is powered up. A holding current is pres-
ent to prevent movement of the motor.
 Units with solenoids and accumulator systems must have
the override handles locked to operate the handwheel. (See
IOM Appendix M, section M.3.)
ACCESSORIES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 25
 If the Manual bypass valve is open, the hand wheel will not
operate.
224 Manual Hand Pump doesn’t work
The Manual hand pump is a piston style pressure device with
directional knob located underneath the assembly. The hand pump
assembly requires reservoir fuid to operate.
 Make sure the directional knob is in the up or down position.
 The hand pump can take several pumps before you see
movement from the actuator (See IOM Appendix M2,
Manual Hydraulic Pump.)
 Units with solenoids and accumulator systems must have
the override handles locked to operate the hand pump.
(See IOM Appendix M2, Manual Hydraulic Pump.)
 If the Manual bypass valve is open, the hand pump will not
operate.
225 Gauges don’t work
Most REXA units have several gauges installed. Module gauges
show cylinder pressure, and some units are equipped with reservoir
gauges (accumulator units). The power module gauges have shut
off valves located beneath the gauge. If the gauge is not reading,
ensure gauge isolation valves are open. If the gauge is still not
reading, you may have a bad gauge, and it should be replaced.
226 Pressure Limiting Protection not working
(unit building too much pressure)
The REXA pressure limiting valves are located on the power module
underneath the motor junction cavity cover. The valves are factory
set per specifcation. If the valves are tightened (CW rotation) then
the internal pressure of the REXA unit will increase. The valves are
adjustable and can be reset in the feld.
CAUTION: If the actuator is connected to the
driven device during adjustment, the equipment
can become damaged
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Problem Identifcation (06/10)
26 REXA X2 Series TS&R Manual
(See TS&R section 314, Pressure Limiting Valves.)
227 Torque or thrust data not
accurate (from transducers)
Some REXA units are equipped with pressure transducers to relay
internal pressure electronically.
Accumulator units use the pressure transducer to relay accumulator
charge pressure, Hart or Fieldbus units use pressure transmitters to
relay cylinder pressure as well.
The pressure transmitter is loop powered and sends a 4 to 20 mA
signal. See TS&R section 235, How do I test my 4-20 mA Position
Transmitter, for additional information.
228 Mechanical limit switches not functioning
REXA actuators have optional independent mechanical limit
switches to provide redundant indication of the actuator's position.
These limit switches are wired directly from the actuator cylinder
to the DCS and are independent of the REXA electronics. Switch
ratings and specifcations can be found in Appendix A, Mechanical
Limit Switches of the Installation and Operation Manual.
For repair/replace information on the switches for a rotary actuator,
reference IOM Appendix, section A2, Rotary.
For repair/replace information on the switches for a linear actuator
reference IOM Appendix, section A1, Linear.
ACCESSORIES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 27
23 CONTROL ISSUES
231 Actuator moves to wrong position
The REXA unit moving to the wrong position could be caused by:
 Control signal loss
– The REXA unit may be programmed to move open,
closed or in place on loss of control signal. (See
TS&R section 3151, Actuator Hunting–Electrical
Noise.)
 Wiring errors
– Incorrect wiring of the motor can cause incorrect or
interrupted motor phase pulses causing the motor to
travel briefy in the wrong direction. Check wiring per
your REXA drawing.
– Incorrect wiring of the feedback can cause the actua-
tor to travel in the wrong direction. Check wiring per
your REXA drawings.
 Manual bypass or Solenoid
– If the bypass valve or solenoid is open, the REXA unit
cannot build pressure. It is possible for the process
or driven device to push the actuator in the wrong
direction if these pressure relieving devices are open.
232 Actuator “hunting” (dithering during control)
The occurrence known as “hunting” can be caused by several
different issues.
Electrical noise issues:
If the REXA feedback or control signal is constantly in fux
the cabling may be installed incorrectly. (See TS&R section
3151, Actuator Hunting–Electrical Noise.)
Gain/acceleration settings may be incorrect. Every REXA
unit is tuned per power module and cylinder combination.
CONTROL ISSUES
Problem Identifcation (06/10)
28 REXA X2 Series TS&R Manual
Additional tuning may be required for faster pumps/motors and
smaller cylinders.
233 Actuator “drifts” away from applied load
The REXA actuator is designed and specifed to meet the required
thrust or torque per a specifc application. If the actuator is pushed
by the process, then the following steps should be taken:
 Confrm your actuator has the required thrust or torque to
overcome the process requirements. The actuator’s model
number will determine the rated thrust or torque. (See
TS&R section 3152, Actuator Torque/Thrust requirements,
for additional information.)
 Ensure bypass and solenoid valves are shut and tight.
 Ensure Pressure limiting valves are set correctly per the
unit’s specifcation. (See TS&R section 314, Pressure
Limiting Valves, for more information.)
 A damaged or failed piston seal can cause the REXA cylin-
der to lose internal pressure. (See TS&R section 3153,
Actuator drifting, for additional information.)
234 Position Feedback doesn’t match actual position
The REXA’s position transmitter output is digitally calibrated by the
CPU during programming of the high and low positions. If your
transmitter needs further calibration, see TS&R section 3156,
Position Transmitter calibration.
235 How do I test my 4-20 mA Position Transmitter?
See TS&R section 31, Press bad, step #4.
236 No position feedback signal
The REXA position transmitter is capable of transmitting a 4 to 20
mA output by using loop or internal power. Refer to your wiring
diagram for proper termination information.
CONTROL ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 29
237 Electrical Limit Switches don’t function
The REXA Control enclosure is equipped with two single-pole,
single-throw, solid state relays that give limit indication. The position
of that indication is set by parameters Relay #1 and Relay #2 in the
Outputs menu, (IOM section 6.1.8). Refer to your wiring diagram
for proper termination points. The relays are confgured to be “open
contact” when Main power is not applied. Also, the contact for Relay
#1 will be open when actuator position is above the position given by
parameter Relay #1, and will close when below the set point. The
contact for Relay #2 will be open when actuator position is below the
position given by parameter Relay #2 and will close when above the
set point.
 If relays are not operating, be sure the actuator is above
(Relay #2) or below (Relay #1) set points.
 Is the corresponding LED for each relay illuminating? If yes,
check wiring terminations.
 Is the actuator position within the Relay set point, including
deadband?
 The relays should have no more than 1.5 W resistance
when the contact is closed. If it is greater (or the contact
measures open when it should be closed), refer to TS&R
section 3155, Electrical Limit Switches.
238 Actuator will not seat, I can not get full travel
The REXA actuator is designed and specifed to meet the required
travel for a specifc application. If the actuator can not fully stroke
the driven device, the following steps should be taken:
 Confrm your actuator has the required travel or rotation for
the application. (See TS&R section 3152, Actuator torque/
thrust requirements, for additional information.)
 All REXA actuators have adjustable pressure limiting valves.
Ensure that your actuator is generating enough pressure to
overcome the process requirements. See TS&R section
314, Pressure Relief Valves, for adjustment procedures.
CONTROL ISSUES
Problem Identifcation (06/10)
30 REXA X2 Series TS&R Manual
 For TOO HIGH or TOO LOW indication on the display, see
TS&R section 3156, Too High/Too Low on display.
 Ensure no mechanical restriction or binding is causing the
actuator to stop travel.
Rotary units
– Some rotary units have adjustable travel stops.
Rotary SPRING FAIL stop may need to be set.
Linear units
– Engagement of valve stem into elastic coupling may
be too deep. Check engagement and make changes
if required. The engagement of the valve stem into
the actuator should be 1.5 times the diameter of the
stem. If the stem engagement can not be corrected,
contact your local REXA representative.
– Packing arrangement or anti-rotation may be interfer-
ing with actuator stroke.
239 Actuator does not meet stroke speed requirements
The REXA actuator is designed to meet a specifc speed
requirement. Refer to TS&R 3152, Actuator torque/thrust
requirements, for stroke times for your equipment. If your actuator
is not meeting these requirements, you may need to adjust the HS
setting in the parameter menu. (See IOM section 61, Setup Mode,
for additional information.)
2310 Booster Pump
Booster Pumps are an optional accessory installed on some
actuators. They are used to increase the speed of the actuator.
Booster pumps will turn on when the desired change in position is
greater than the “Boost Pump” setting under the drives menu. To
adjust this parameter, reference section 617 in the IOM.
2311 Only one module on 2D or 2C units functions
REXA units with specifc speed requirements sometimes use
multiple modules to meet that specifcation. Dual module units
CONTROL ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 31
require 2 sets of motors, drivers and cables. Refer to your specifc
wiring diagram to make sure you have the correct interconnect
for your actuator. For redundant units, a separate electronics is
required. If an error code is displayed on either driver, see TS&R
section 32, Drive Fault.
2312 Surrounding equipment
disrupted by Actuator operation
Some REXA actuators use large motors that require high voltage
and current. If the cables for the REXA actuator are run close to
surrounding equipment or control cables, it is possible for noise to be
induced onto the control lines of this equipment.
2313 Servo Motor turning at low RPM
when not commanded to move
When the actuator reaches its set point, the motor will come to a
complete stop. The FMV holds the load in place which allows the
power consumption of the unit to be very low. Since there are no
moving components, it extends the life of the actuator. If the motor
continues to rotate after the actuator has reached its new position,
reference TS&R section 3151, Actuator Hunting — Electrical
Noise.
2314 Actuator slows down and “resets”
before getting to target position
Within the actuator CPU there is a timer that will shut down the
motor and cause the system to reset if the actuator is not achieving
a certain speed. There are numerous reasons why the actuator may
be having a speed issue, and they range from tuning to having an
actuator that is undersized for a given load.
 The "Gain" setting may be too low. This will cause the motor
to slow down too much before it reaches the set point.
 If the actuator pressure is above 2400 psi when this is
occurring, reference TS&R 314, Pressure Relief Valves.
CONTROL ISSUES
Problem Identifcation (06/10)
32 REXA X2 Series TS&R Manual
2315 Actuator overshoots target position and returns
If the actuator does not slow down as it approaches the new
target position, it will likely overshoot its new position. Within the
sophisticated control scheme of the REXA electronics there are
tuning parameters that will allow this overshoot to be tuned out.
 The "Gain" setting may be too high. Refer to the IOM
section 6, Control Parameters, to ensure parameters are
correct.
2316 I have many errors logged in historical stats
The REXA electronics will keep a running count of error codes to
log the problems the system encounters. This count is stored under
the current stats and historical stats menus. The current stats can
be reset in the setup menu, but the historical stats are a permanent
running counter.
Reference the error codes section to determine possible root
causes. Close monitoring of the unit should be performed to
determine the root cause of these failures. Reference the specifc
error codes section for more information.
CONTROL ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 33
24 FAIL SAFE ISSUES
241 Accumulator will not recharge
The REXA accumulator system is self contained and does not
require external equipment to recharge the system after a trip. If
your accumulator is not recharging:
 Ensure that the parameter ACCUM DIR (accumulator fail
direction) is set to the proper end. (See IOM section C2,
Accumulator Control Parameters for additional details.)
 The system requires additional oil to charge the accumula-
tor; this oil is pulled from the reservoir system. There is a
shut off valve located between the reservoir and the accu-
mulator. This valve must remain OPEN.
 Some accumulator systems are designed to have more
than one fail per recharge cycle. The accumulator system
will only go through a recharge cycle if the pressure in the
system requires.
 Some accumulator systems use an external trip signal to
activate the fail condition. (See IOM section C11, Trip
Function, for additional information.)
 The accumulator system uses two external solenoids to
operate the accumulator system. The REXA CPU controls
power to the solenoids as defned during manufacturing of
the system. For information on the solenoids see TS&R
section 4M11.
242 Actuator does not recover after fail safe event
Some REXA actuators are equipped with a failsafe system when
necessary. Several different failsafe systems are available:
Control signal fail
– Check your FAILSAFE parameter setting. (See IOM
section 616, Inputs menu)
– Some control systems use a 0 to 20 mA input signal;
in this situation, the FAILSAFE parameter needs to be
FAIL SAFE ISSUES
Problem Identifcation (06/10)
34 REXA X2 Series TS&R Manual
set to OFF. Less than 2.5 mA is a valid signal for 0 to
20 mA systems.
Spring assist fail & Surge systems
– Spring fail units have an electrical solenoid in place
of the manual bypass. This solenoid assembly may
need to be adjusted to operate properly. (See TS&R
repair section 4M10-11 for information.)
– Surge systems have a trip input function that may
need to be reset to continue normal operation. (See
IOM section 616, Inputs menu, for additional infor-
mation.)
Accumulator system fail
– Some accumulator systems have trip input function
that may need to be reset to continue normal opera-
tion. (See Appendix C in the IOM for additional
information.)
243 Unit will not move to fail position
Some actuators have spring fail or accumulator systems to move the
driven device to a previously specifed position upon loss of power
or trip activation signal. The REXA standard system fails in place on
loss of power and can be programmed to fail to a specifed position
on loss of control signal. For additional information on the loss of
control signal function, see IOM section 6, Control Parameters.
If your equipment is spring fail or accumulator system design,
it will be indicated on the model number of the actuator. (See
TS&R section 12, Actuator ID, for information on REXA's model
numbering system.)
If your actuator has an –E, –R or –U in the model number, you have
a mechanical spring installed to fail the actuator upon activation of a
failsafe event (loss of power or trip signal).
If your actuator has an –A in the model number, you have an
accumulator system to fail the actuator upon activation of a failsafe
event (loss of power or trip signal).
FAILSAFE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 35
Before troubleshooting the failsafe system, make
sure your solenoid manual overrides are in the
correct position for failsafe event, and all shut off
valves are in the open position
Standard REXA internal solenoid identifcation, section 4M11.
High speed solenoid identifcation, section 4M14.
Also, ensure no mechanical restrictions are
preventing the actuator from reaching fail
position
Trip input functions have additional parameters to determine the
proper fail position and trip input functions. (See IOM section 616,
Inputs Menu, for additional information.)
244 Actuator does not meet failsafe speed requirements
The REXA actuator is designed to meet the required fail speed for
a specifc application. If the actuator can not fully stroke the driven
device in the time specifed, the following steps should be taken:
Spring fail units:
– Standard solenoid (module mounted) units have no
speed adjustment. To increase the fail speed of a
standard internal REXA solenoid, please contact your
REXA representative.
– High speed solenoid units have a needle valve
installed in line with the solenoid. Turn the needle
valve CCW to increase fail speed, CW to reduce fail
speeds.
Accumulator systems:
– Some accumulator systems have a needle valve
installed in line with the solenoid. Turn the needle
valve CCW to increase fail speed, CW to reduce fail
speeds.
– Some accumulator systems have a fow metering
valve installed in line with the accumulator system.
Adjust the metering valve to increase fow speed.
FAILSAFE ISSUES
Problem Identifcation (06/10)
36 REXA X2 Series TS&R Manual
– To further increase the speed of the accumulator
system fail speed, please contact your REXA repre-
sentative.
245 Hydraulic surge system not functioning
Hydraulic surge system uses a solenoid valve and spring to achieve
fast motion in one direction. This surge operation only occurs
with a change in the control signal input as defned by the Surge
Breakpoint parameter in the setup menu. Reference Appendix G in
the IOM for more information on setting the surge function correctly.
246 Unit moves to the wrong position for trip
REXA actuators can be confgured to fail to either end position or
stay in its last position. The fail-to-end position is achieved either by
the use of a coil spring or a pressurized accumulator bottle and can
be triggered by a loss of power, control signal or independent trip
signal.
 If the actuator trips to the wrong end, reference TS&R sec-
tion 3161, Fail Direction.
 If the actuator does not trip on loss of power, reference
TS&R section 3162, No trip on loss of power.
 If the actuator doesn’t trip on loss of control signal, see
TS&R section 3163, No trip on loss of control signal.
 If the actuator doesn’t trip on loss of trip signal, reference
TS&R section 3164, No trip on loss of trip signal
247 No Accumulator Pressure reading on
Display, but there is pressure on gauge
The REXA CPU constantly monitors the accumulator pressure. The
data is used to send a warning alarm if the pressure drops to a level
that a full fail safe trip can not be completed. This data is also used
during an accumulator recharge to determine the maximum pressure
the accumulator will be charged to. Reference Appendix C in the
IOM for more details on setting up an accumulator system.
FAILSAFE ISSUES
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 37
248 Solenoid is extremely hot to the touch
REXA uses high quality, aircraft-grade low leak solenoid valves to
control our trip functions. These solenoids can be either energized
all the time or only during a failsafe event. If the unit has solenoids
that are energized continuously, these valves will be hot to the touch.
Typically they will have a 60 °F (16 °C) temperature rise during
normal operation. If the solenoid valves are measured to have a
higher temperature rise, reference TS&R 4M11, Solenoids.
FAILSAFE ISSUES
Problem Identifcation (06/10)
38 REXA X2 Series TS&R Manual
25 OIL LEAKS
251 External oil leaks
Under normal operating conditions the REXA actuator will not
use additional make-up oil. The REXA unit may show signs of oil
weeping shortly after installation. When the actuator is exposed
to an increase in temperature, the reservoir may weep slightly until
equilibrium is met. If the reservoir continues to weep or leak oil,
please contact your local REXA representative.
252 The oil indicator is low, but no oil is visible /
Repeated Reservoir flling, no visual oil leaks
When the oil level indicator is below the scribe mark, refer to IOM
section 16, Oil, for flling instructions. If the cycle of retracting
and flling continues, the actuator could be leaking internally.
The actuator will continue to function as long as the oil level is
maintained, contact your local REXA representative.
253 Reservoir relief leaks oil
The actuators reservoir pressure relief valve is set between 40 and
120 psi depending on the design of the equipment. Upon installation
it is normal for the equipment to weep some oil from the reservoir
pressure relief valve during temperature changes. If the leak
persists, please contact your local REXA representative.
OIL LEAKS
X2 Troubleshooting and Repair Manual
Problem Identifcation – 06/10 39
26 MISCELLANEOUS
261 Water in Module
The REXA power module is rated to meet the requirements of
NEMA 4X. It is important to see if the location of where the water is
entering can be identifed. Typically the largest root cause of water
getting into the unit is from improper installation of the conduit and
not using pipe thread sealant during installation.
 First check the conduit ftting to insure they are tight and
pipe sealant has been used.
 For water in the module wire cavity or under the rotary hous-
ing, reference TS&R 3171, Module/Motor.
 For water under a linear feedback housing, reference TS&R
section 3172, Electronics.
262 Cylinder binding
Most mechanical restrictions are an application or mounting-related
problem. Binding will be indicated by erratic motion, noticeable
bending of the actuator stem or driven device, slower speed or
restricted travel. These issues should be corrected immediately as
they have the potential to shorten the life of the actuator bushings or
valve packing.
If you suspect you are having binding issues, please call the factory
for assistance.
MISCELLANEOUS
Problem Identifcation (06/10)
40 REXA X2 Series TS&R Manual
CALIBRATION
27 CALIBRATION
271 Setting PL or PH and the unit
reads “too high” or “too low”
When calibrating a REXA actuator, the end points are recorded as
Position Lo and Position High. If during the set up procedure PL
or PH is being set to a point that is too close to the mechanical end
stop, the display will read “too high” or “too low”. (Reference TS&R
3156, Too High/Too Low on display.)
 If the actuator feedback changes when the unit runs, refer-
ence TS&R 3151, Actuator Hunting—Electrical Noise.
 If the actuator feedback doesn’t change when stroking the
actuator, reference TS&R 362, Feedback.
 If the feedback only changes during a portion of the actua-
tors stroke, reference TS&R 362, Feedback.
272 Will not accept PL or PH value
When calibrating a REXA actuator the end points are recorded as PL
and PH. If during the set up procedure PL or PH are set too close
together (within 10% of each other) the values will not be accepted.
 If the actuator feedback changes when the units is being run
reference TS&R 3151, Actuator Hunting—Electrical Noise.
 If the actuator feedback doesn’t change when stroking the
actuator reference TS&R 362, Feedback.
 If the feedback only changes during a portion of the actua-
tors stroke reference TS&R 362, Feedback.
273 Will not accept SL or SH value
The REXA actuator will allow calibration of the incoming control
signal for precision control. The actuator will record the two control
signal inputs that correspond to the low travel end points. If during
the set up procedure SL or SH are out of range, they will not be
accepted. (Reference TS&R 311, Control signal calibration.)
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 41
31 ACCUMULATOR LOW/BAD PRESSURE
Press bad
This error appears when the CPU does not receive an analog signal
from the pressure transmitter.
1. Ensure the wiring to the Transmitter is correct according to
the drawing. It should be as follows.
CPU Transmitter
+15V RED
Acc+ BLACK
Shield should be landed at both the Electronic enclosure
back panel and at the Transmitter terminal strip at the
actuator.
2. Check the CPU by simulating a 4 to 20 mA signal; this can
be done by removing the wires connected to the Transmit-
ter and directly applying a 4 to 20 mA signal generator (see
photos). Connect the positive end of your signal generator
to Acc+ and the negative end to Acc-.
3. Troubleshooting
Troubleshooting (06/10)
42 REXA X2 Series TS&R Manual
3. Begin by scrolling to the “Accum Pres” parameter under the
Drives menu. Apply the recommended signal and take note
of the display reading.
Signal (mA) Display (#)
4 0
8 750
12 1500
16 2250
20 3000
If these readings are correct, then the CPU is good.
If these readings do not match, replace the CPU. (See
TS&R 4E4.)
4. If the CPU is working properly, the problem may be with the
Pressure Transmitter.
To test the Pressure Transmitter:
a.) Disconnect Pressure Transmitter Cable at the actuator
junction box.
b.) Connect current source as shown; red lead to red,
black lead to black.
c.) Turn dial on current source to full output (clockwise)
d.) Display should read mA signal that corresponds to
pressure
4 mA = 0 psi
16.8 mA = 2400 psi
20.0 mA = 3000 psi
e.) Pressure will not change as you move dial on current
source as the current source is fxed (based on the
pressure reading of the pressure transducer).
f.) The mA reading should correspond to pressure on the
pressure gauge
0.00667 mA per 1 psi
2400 psi*0.00667 = 16 mA
If these readings don’t match or no loop power can be
sourced, then the Pressure Transmitter is bad. (See
TS&R 4M25, Pressure Transducer Repair.)
ACCUMULATOR LOW/BAD PRESSURE
Photo 3.1-2
Signal generator
Photo 3.1-3
Red and black leads
Photo 3.1-1
Acc+ and Acc-
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 43
Press Low
The “Press Low” error occurs when the accumulator pressure is
below the warning pressure value (under the Drives menu).
1. Start by initializing a re-charge cycle. Once a re-charge
cycle has begun and display reads “Auto-Rchg”, scroll up
using the up arrow 15 times till display reads “Accum Pres”.
2. Hold down the Enter Key and observe the Accumulator
Pressure rising. This pressure should begin around 1900
lb because that is the pre-charge pressure of the Nitrogen
on the other side of the Piston Accumulator. The increase
in Pressure should be a steady rise of pressure until the
pressure has reached the recharge pressure value under
the Drives menu. There should be a 200 psi differential
between the “Rechrg Pres” and the “Warn Pres” values.
3. If the accumulator has started its recharge cycle and the
“Accum Pres” is at 1900 lb (or very close to the initial
pressure), allow the Actuator to perform its recharge cycle to
determine if the problem has been solved.
If you notice that the accumulator has started its recharge
cycle much lower than the 1900 lb, stop the recharge cycle
by holding down the AUTO & MANUAL buttons at the same
time. This will take the Actuator out of its re-charge cycle
and back into setup mode for further evaluation of the
problem.
4. Look at the Accumulator Pressure gauge located at the
Actuator. This pressure should match what you see under
the Drives Menu “Accum Pres”. If the gauge is reading
higher than what the transmitter shows, (between 1 900 and
2 400), go back to the Pressure Bad section and perform
the same checks to determine if the problem is in the CPU
or Transmitter. Repair or return the defective component if a
problem is found.
5. If the Accumulator gauge and pressure Transmitter are both
reading the same value (1 700 psi or below), then there was
a loss of Nitrogen from the Accumulator bottle. (See TS&R
4M26, Replacing Accumulator Bottle.)
ACCUMULATOR LOW/BAD PRESSURE
Troubleshooting (06/10)
44 REXA X2 Series TS&R Manual
32 DRIVE FAULT
Photo 3.2 B stepper driver external power supply
321 B CSA drive fault IMS Driver
B Stepper Driver IMS Style with separate Power Supply:
The REXA B motor driver with external power supply is the frst
version of CSA approved stepper driver. It was used from 2005 to
2009 and only on a few model REXA units. There is no fault relay
for this version driver. A jumper wire is installed on the CPU board
between FLT+/FLT- disabling this feature. The IMS style driver does
not have the logic I/O to enable this feature.
Interconnecting Cabling:
To test the cabling, remove the cable from the actuator and
electronics. Verify the integrity of the cable by checking each wire
to ensure there are no line breaks or shorts. Use a DMM to test
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 45
the cables. If a problem is found with the interconnecting cables,
replace the cable and recheck the unit for problems.
Stepper Motor:
The REXA Stepper module uses a 4 pole, brushless DC
electromagnetic stepper motor. A sequence of voltage inputs from
the driver module creates movement. If the sequence is interrupted
by a loss of current, a short to ground or to another phase, a driver
fault can result. To check the integrity of the motor, use a DMM to
read the resistance between each motor phase.
Phase A
Wire pair Green (phase A) and Green/Black (phase A-)
Phase B
Wire pair Red (phase B) and Red/Black (phase B-)
The motor resistance must be 0.3 ohms between each phase wire
(A/A-, B/B-). A reading of 0.6 or higher, or 0.1 or lower means the
motor is bad and must be replaced. See section TS&R 4M5 to
replace the B motor.
DRIVE FAULT
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46 REXA X2 Series TS&R Manual
Stepper Drive:
The version 1 CSA X2 REXA actuator uses an IMS Stepper module
driver to create motor movement. Some versions of REXA use an
AMCI potted drive explained in the following sections. See photos to
verify the style driver installed.
Photo 3.2.1-2
Version 2 CSA Driver
Photo 3.2.1-1
Version 1 CSA Driver
For version 1 drive continue on; version 2 drivers please skip to
TS&R section 322, B CSA drive fault Potted Drive
The version 1 CSA IMS driver sends a 60 Vdc square wave pulse
signal to the motor to create movement. The frequency of these
pulses is proportional to the High Speed setting in the Speed/ACC
menu. The IMS style driver uses power from the separate motor
power supply to drive the motor.
The motor power supply uses the incoming power supply to power
the motor/driver combination. Verify the incoming power at the
power supply board TB1 located underneath the CPU board.
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 47
Figure 3.2.1 Power supply board
The driver must have a supply of 60 Vdc from this module. To verify
the motor power supply voltage read the red/black output wires
coming from the large blue capacitor. If the 60 Vdc is not present,
change the power supply module. If the 60 Vdc is present, change
the motor driver. (See TS&R section 4E3 for instructions on
the power supply module or TS&R section 4E6−4E9 for driver
replacement.) If the power supply and driver voltages are correct,
continue on to the CPU.
CPU signals to the driver:
The stepper driver converts signals from the CPU to physical
movement by the motor. The direction and speed of the motor is
determined by input from the CPU.
DRIVE FAULT
Troubleshooting (06/10)
48 REXA X2 Series TS&R Manual
Place the actuator in the Local mode to continue these checks. To
read these signals, place a DMM on the terminals indicated. In the
Local mode, attempt to move the motor.
1. Direction: The TB3 terminals, Dir- and Dir +. is the output to
the driver that determines direction of motor movement. In
LOCAL mode:
a.) Press the Down button, 0 Vdc should be present,
motor direction should be counterclockwise.
b.) Press the UP button, 5 Vdc should be present, motor
direction should be clockwise.
If the voltage is not consistent when pressing the up/down buttons
on the display, change the CPU. (See TS&R section 4E4.)
2. Enable: The TB3 terminal ENA+ and ENA-, sends a 5 Vdc
signal to the driver to enable the drive to send the pulses
to the motor. If the 5 Vdc is not present during movement
(present on both directions), change the CPU. (See TS&R
section 4E4.)
3. Step pulse: TB3 terminals STP-, STP+. The pulse output to
the drive is 10 microseconds wide. This is too fast to read
via a DMM. An oscilloscope can measure the pulses.
400 pulses = 1 revolution of motor movement.
If the pulses are not present, change the CPU. (See TS&R section
4E4.)
322 B CSA drive fault Potted Drive
A drive fault can be caused by damage to the motor, driver or its
interconnecting cables. The frst step to determine the problem is
to identify what part of the assembly is at fault.
DRIVE FAULT
Photo 3.2.2 Potted drive
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 49
Interconnecting Cabling:
A drive fault can be caused by a short or wire break in the cable
run. To test the cabling, remove the cable from the actuator and
electronics. Verify the integrity of the cable by checking each
wire to ensure there are no line breaks or shorts. Use a DMM
or MEG device to test the cables. If a problem is found with the
interconnecting cables, replace the cable and recheck the unit for
problems.
Stepper Motor:
The REXA Stepper module uses a 4 pole, brushless DC
electromagnetic stepper motor. A sequence of voltage inputs
from the driver module creates movement. If the sequence is
interrupted by a loss of current, a short to ground or to another
phase, a driver fault can result. To check the integrity of the motor,
use a DMM to read the resistance between each motor phase.
Phase A
Wire pair Green (phase A) and Green/Black (phase A-)
Phase B
Wire pair Red (phase B) and Red/Black (phase B-)
The motor resistance must be 0.3 ohms between each phase wire
(A/A-, B/B-). A reading of 0.6 or higher, or 0.1 or lower means the
motor is bad and must be replaced. See TS&R section 4M5 to
replace the B motor.
Stepper driver:
The version 2 CSA AMCI potted driver sends a 160 Vdc square
wave pulse signal to the motor to create movement. The frequency
of these pulses is proportional to the High Speed setting in the
Speed/ACC menu. The potted AMCI drive receives a 5 Vdc signal
from the CPU through a N/O switch internal to the drive. If there
is a problem with the driver the switch changes state and the CPU
initiates a driver fault. Any failure to the driver will change the state
of this switch. A motor fault (as indicated above) or loss of input or
DRIVE FAULT
Troubleshooting (06/10)
50 REXA X2 Series TS&R Manual
output power is recognized as a driver fault. Place the REXA unit in
the Local mode to perform the following checks:
 Check incoming power to the drive. TB1 on the driver is the
incoming power. Place a DMM on these terminals to verify
the power input. If no voltage is present, there is a problem
with the input power, or the motor thermostat has changed
state.
 The motor thermostat is located on the actuator internal
to the stepper motor. This switch is triggered at 350 °F
(~180 °C). If the motor is allowed to cool (less than 300 °F
[~150 °C]) the thermostat interlock will reset and power will
be restored to the drive.
 If the 110 Vac power is present and the motor temperature is
below 300 °F (~150 °C), check the output of the driver to the
motor. As stated above, the driver sends a 160 Vdc square
wave pulse to the motor.
 In Local mode, run the motor in either direction and check
the output of the driver on TB2 terminals (A/A- and B/B-).
If no output is present, the driver has failed and must be
replaced. See TS&R sections 4E6-4E9 for information
on driver replacement.
CPU signals to the driver:
The stepper driver converts signals from the CPU to movement
by the motor. The direction and speed of the pulses is sent to the
driver in steps. The CPU frst determines direction and then the
drive is enabled. After that the pulse speed is sent to the driver. To
determine if the driver is faulty, you must frst check the CPU output.
1. Direction: TB3 terminals Dir- and Dir +. The direction is
determined with high or no voltage on these terminals. In
LOCAL mode:
a.) Press the Down button, 0 Vdc should be present,
motor direction should be counterclockwise.
b.) Press the UP button, 5 Vdc should be present, motor
direction should be clockwise.
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 51
If the voltage is not consistent when pressing the up/down buttons
on the display, change the CPU. (See TS&R section 4E4.)
2. Enable: TB3 terminal ENA+. The CPU sends a 5 Vdc
signal to enable the drive to send the pulses to the motor. If
the 5 Vdc is not present during movement, change the CPU.
(See TS&R section 4E4.)
3. Step pulse: TB3 terminals STP-, STP+. An oscilloscope
can measure the pulses.
400 pulses = 1 rpm of motor movement
If the pulses are not present, change the CPU. (See TS&R section
4E4.)
323 C drive fault
A drive fault can be caused by damage to the motor, driver or its
interconnecting cables. The frst step in determining the problem is
to identify what part of the assembly is at fault.
Interconnecting Cabling:
A drive fault can be caused by a short or wire break in the cable
run. To test the cabling, remove the cable from the actuator and
electronics. Verify the integrity of the cable by checking each
wire to ensure there are no line breaks or shorts. Use a DMM
or MEG device to test the cables. If a problem is found with the
interconnecting cables, replace the cable and recheck the unit for
problems.
Stepper Motor:
The REXA Stepper module uses a 4 pole, brushless DC
electromagnetic stepper motor. A sequence of voltage inputs from
the driver module creates movement. If the sequence is interrupted
by a loss of current, a short to ground or to another phase, a driver
fault can result. To check the integrity of the motor, use a DMM to
read the resistance between each motor phase.
DRIVE FAULT
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52 REXA X2 Series TS&R Manual
Phase A
Wire pair Green (phase A) and Green/Black (phase A-)
Phase B
Wire pair Red (phase B) and Red/Black (phase B-)
The motor resistance must be 0.3 ohms between each phase wire
(A/A-, B/B-). A reading of 0.6 or higher or 0.1 or lower, means the
motor is bad and must be replaced. See TS&R section 4M5 to
replace the B motor.
Stepper driver:
The REXA C electronics use an AMCI drive to send a 160 Vdc
square wave pulse signal to the motor to create movement. The
frequency of these pulses is proportional to the High Speed setting
in the Speed/ACC menu. The AMCI drive receives a 5 Vdc signal
from the CPU through an N/O switch internal to the drive. If there
is a problem with the driver the switch changes state and the CPU
initiates a driver fault. Any failure to operate condition will change
the state of this switch. A motor fault (as indicated above) or loss
of input or output power is recognized as a driver fault. Place the
REXA unit in Local mode to perform the following checks:
 Check incoming power to the drive. TB1 on the driver is the
incoming power. Place a DMM on these terminals to verify
the power input. If no voltage is present, there is a problem
with the input power, or the motor thermostat has changed
state.
 The motor thermostat is located on the actuator internal
to the stepper motor. This switch is triggered at 350 °F
(~180 °C). If the motor is allowed to cool (under 300 °F
[~150 °C]), the thermostat interlock will reset and power will
be restored to the drive.
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 53
 If the 110 Vac power is present and the motor temperature is
below 300 °F (~150 °C), check the output of the driver to the
motor. As stated above, the driver sends a 160 Vdc square
wave pulse to the motor. In the Local mode, run the motor
in either direction and check the output of the driver on TB2
terminals (A/A- and B/B-). If no output is present, the driver
has failed and must be replaced. See TS&R sections
4E6-4E9 for information on the driver replacement.
CPU signals to the driver:
The stepper driver converts signals from the CPU to movement
by the motor. The direction and speed of the pulses is sent to the
driver in steps. The CPU frst determines direction and then the
drive is enabled. After that the pulse speed is sent to the driver. To
determine if the driver is faulty you must frst check the CPU output.
1. Direction: TB3 terminals Dir- and Dir+. The direction is
determined with high or no voltage on these terminals. In
LOCAL mode:
a.) Press the Down button; 0 Vdc should be present,
motor direction should be counterclockwise.
b.) Press the UP button; 5 Vdc should be present, motor
direction should be clockwise.
If the voltage is not consistent when pressing the up/down buttons
on the display, change the CPU. (See TS&R section 4E4.)
2. Enable: TB3 terminal ENA+. The CPU sends a 5 Vdc
signal to enable the drive to send the pulses to the motor. If
the 5 Vdc is not present during movement, change the CPU.
(See TS&R section 4E4.)
3. Step pulse: TB3 terminals STP-, STP+. The pulse output to
the drive is 10 microseconds wide. This is too fast to read
via a normal meter. An oscilloscope can pick up the pulses.
400 pulses = 1 revolution of motor movement.
If the pulses are not present change the CPU. (See TS&R section
4E4.)
DRIVE FAULT
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54 REXA X2 Series TS&R Manual
324 Servo Motor Driver
REXA Omega Series Servo Motor Driver
This section covers the troubleshooting of the REXA Omega series
servo driver. All Omega series drivers operate identically regardless
of the motor and driver type. The part numbers and input/output
voltages may differ, but the troubleshooting is the same. To
troubleshoot the Omega series driver, it is recommended that the
REXA CPU be placed in the Local mode.
REXA’s Omega series Digital PWM Brushless Servo Amplifer
offers the latest in high performance DSP control of brushless
servo motors. The REXA unit operates in the VELOCITY Mode
confguration. In this mode of operation, the servo driver module
generates a tachometer signal which is used to close a velocity loop
specifc to the version of software loaded onto the driver and the
corresponding motor type. The control of the velocity loop is via the
REXA CPU. The signal from the CPU is an analog +/-3 Vdc signal.
The slope and amplitude of this signal controls the acceleration,
speed, and deceleration of the motor. See REXA Series 2 XPAC
IOM Section 6 CPU control parameters for tuning details.
Table 3.2.4 Servo motor driver
Features: Characterization
Digital current loops Current loop bandwidths up to 3 kHz.
Digitally tuned
All parameters set digitally. No potentiometers to adjust
DSP control for the ultimate in high performance.
Silent operation 12.5KHz PWM standard.
Complete isolation Complete optical isolation between signal and power stage.
Fault protection
Short from output to output, short from output to ground,
amplifer RMS over current, amplifer under/over voltage,
amplifer over temperature, motor over temperature.
RS-232
High speed (115.2 K baud) serial communication interface
for set up and tuning.
Non-volatile memory
All parameters and positions are stored in non-volatile
memory for reliability.
Status indicator 7-segment display indicates amplifer status and diagnostics.
The REXA Omega drive is pre-programmed at the factory for the
specifc motor on the actuator ordered.
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 55
Troubleshooting the Omega driver begins with the outputs from CPU
to the driver. To initiate motor movement, the CPU sends signals to
the driver:
These signals are common for all models of Omega drive:
325–A Input/Output signals from CPU to
Driver (TB6 STANDARD MOTOR)
ENABLE OUT: Blue wire—Signal to driver from CPU to
engage movement; 0 Vdc during normal operation, 5 Vdc
present during fault or reset condition.
FAULT IN: Red wire—Signal from driver to CPU to indicate
problem with driver, motor or cabling; 0 Vdc during normal
operation, 5 Vdc during fault condition.
+15V: No connection (15 Vdc available for logic power, not
used on Omega Drive).
GND: Black wire—optically isolated ground for driver logic.
MOT-/+: Green wire with Black ground—Analog signal from
CPU to driver to indicate operation speed, +3 Vdc /-3 Vdc (1
mV = 1 RPM of motor speed).
A MAX Hi Speed of 100% = 2.4 mV between these
terminals, actual motor speed is 2 400 RPM.
Figure 3.2.5–A Terminal block 6 Standard Motor
DRIVE FAULT
Troubleshooting (06/10)
56 REXA X2 Series TS&R Manual
325–B Input/output signals from CPU to
Dual D Drivers (TB6 STANDARD MOTOR)
Both drivers are terminated together as the above single driver at the
TB6 terminal block, with the exception of the fault input. A separate
board (fault/reset board) is used to have one incoming fault signal
from both drivers.
FAULT IN: Signal from driver to CPU to indicate problem;
0 Vdc during operation, 5 Vdc during fault condition.
Figure 3.2.5–B Fault/reset board for Dual D and Booster Drivers
325–C Input/output signals from CPU to
Servo Driver with Booster Driver (TB6 & TB7
Standard and Booster motor terminals)
For units with Booster pump option, the Servo driver is terminated as
standard single input. The Booster driver is terminated to TB7. The
input and output signals have the same value for booster and servo
motors. The drivers share a fault/reset board for common fault input
to the CPU (same as Figure 3.2.5–B, above).
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 57
Figure 3.2.5–C Standard motor and booster motor termination
326 Driver Fault code identifcation
When a driver fault code is sent to the CPU (5 Vdc present on
FAULT IN) from a driver, it will have a corresponding code on the
driver display. While in AUTO mode, the CPU will send a “reset”
signal to the driver in an attempt to clear the fault. The CPU will
continue to send reset signals (approximately every 3 seconds) until
the condition is corrected (until the fault is cleared). Removing the
unit from AUTO mode will stop the reset signal and allow you to view
the error code on the Omega display.
A diagnostic LED display is provided on each Omega driver, it is a
7- segment LED display. The drive generates Hall sensors and when
the driver and motor are operating normally, one of the outer six
segments is lit. Each of the six outer segments represents one of
the six Hall states in a commutation cycle of a motor. During motor
movement the display will show an O, all six segments lit (one at a
time) in the direction the motor is turning.
DRIVE FAULT
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58 REXA X2 Series TS&R Manual
REXA Omega Series Fault Codes (specifc
to the Omega drive LED display)
The fault codes below are shown on the drivers display when the
CPU is not sending a reset signal to the driver. A description of the
error code and possible causes are listed below:
Fault code = S Immediate short code. (Electronic Circuit Breaker,
high speed)
– Motor phase line to line short, or line to ground (direct short)
– Electronic “noise” on resolver cable (interference)
– Bad motor power cable
– Seized or shorted motor
Fault code = L Secondary short code, (Low speed ECB tripped)
– Green and Blue Resolver wires reversed or loose
– Motor seized
– Incorrect motor connected to driver
– Any driver, Red and Black wires reversed or loose
For low and high speed short codes, be sure to inspect motor and
cable integrity by use of a multi or MEG meter. Test for a short from
phase to phase or from phase to ground. Also, inspect for wrong
connection; i.e., blue and green wires swapped.
Fault code = E Resolver error
– Resolver line break
– Resolver cable electrical noise (interference)
To correct the resolver error code, inspect cable connections and/
or damage or corrosion to the cables. Be sure to separate resolver
(signal) cables from high power cables and other power sources (at
least 3 meters [~10']).
Fault code = H Driver Over-temperature (upper case H)
– Omega driver temperature is too high (185 °F [85 °C])
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 59
An H error code indicates the ambient temperature (at electronics
enclosure) is too high for the driver to operate (ambient temperature
range for Omega drivers -40 °F to +150 °F [-40 to +65 °C]).
This is a recoverable error. The ambient temperature for the
electronics must be brought back below the 150 °F (65 °C) threshold
in order to keep the 185 °F (85 °C) temperature switch on the driver
heat sink from opening. Since high temperatures will shorten the
life of electrical components; the electronics should be installed in a
controlled environment.
Fault code = h Motor over temperature (lower case h).
– Motor temperature is over thermostat set point (340 °F [170 °C])
The thermostat located in the motor has changed state. This is a
normally closed switch. If the temperature of the motor is below
340 °F (170 °C), check thermostat cable connections (yellow/orange
resolver wires).
Fault code = b Over Voltage fault.
– Incoming power is over 252 Vac input power
Check incoming power supply. Refer to actuator specifcation sheet
for power requirements.
Fault code = ≡ (three horizontal bars). Power on commutation
failed.
– Driver unable to zERO motor position on start up
Wiring errors (resolver/motor) can cause commutation errors. Check
all motor and resolver wiring at every termination; specifcally, white/
brown motor reference pair.
Fault code = = (two horizontal bars). Invalid Hall state detected.
Invalid Hall state is internal to the Omega driver. The drive has
failed and will need to be replaced.
DRIVE FAULT
Troubleshooting (06/10)
60 REXA X2 Series TS&R Manual
Fault code = 1 EEPROM checksum failed.
Checksum failure is internal to Omega driver; the write cycle has
been interrupted or incorrect data has been written. Recycling
power may recover the drive, if not, the drive must be replaced.
Fault code = C Clamp condition active.
The REXA CPU has disabled the driver (fault relay) this will
be followed by a reset signal from the CPU. There must be a
corresponding condition for the CPU to clamp the driver. Check
for drive faults, power problems (low or high incoming power) and
resolver or control cable problems.
Fault code = F Foldback condition active.
A foldback error is a warning that an unusual amount of current is
needed to move the motor. During this condition in which unusually
high current is detected, the power supply shuts down to protect the
system. This can be caused by a shorted motor (see S error checks),
or an open or incorrectly wired red/black resolver pair (cosine pair).
Fault code = O This is a status indication of normal operation, the
motor is moving.
Fault code = 8 Reset code
The CPU has sent a reset signal to the driver. (See TS&R section
321, CPU signals to the driver.)
Fault code = U. Driver power supply, bus Under Voltage
The incoming power supply is low; check incoming power.
327 Actuator “run away” when unit is powered up
Upon power up, some units can “run away” from the current position
even if in the Local mode. When wired incorrectly, units with multiple
drivers and motors can move without command. The cause of this
can be due to wiring problems between driver/motor pair when either a
motor or resolver cable is connected to the incorrect driver/motor pair.
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 61
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Table 3.2.7 is for reference when
dealing with a unit that moves
without command.
DRIVE FAULT
Troubleshooting (06/10)
62 REXA X2 Series TS&R Manual
328 Servo Motor resistance readings
Check motor resistance.
Table 3.2.8 Servo motor resistance
Resistance Inductance DC_Bus
Glentek_Full_D 1.4 Ohms 6.5 mH 280 V
Glentek_Half_D_120 .77 Ohms 3.25 mH 160 V
Glentek_Half_D_240 .77 Ohms 3.25 mH 280 V
Kollmorgen_Full_D 2.48 Ohms 38 mH 280 V
Kollmorgen_Half_D_120 2.34 Ohms 25 mH 160 V
Kollmorgen_Half_D_240 2.34 Ohms 25 mH 280 V
Replace motor if readings are not as noted above; replace driver if
readings are correct.
329 DC Bus Voltage check
The DC Bus Voltage = 1.414 × AC line voltage. This voltage cannot
be measured with a multimeter. An Oscilloscope is the best method
to measure the Phase to Phase voltage at the motor. A REXA Omega
Maestro program on a PC can also read this voltage (contact the
REXA service department). The picture below is 100 V per division
(5 v/d × a 20X probe), 295 V is the DC Bus voltage for 208 Vac/3-
phase. For 240 Vac units, this voltage would be 340 V, and a 120
Vac unit would have 170 V DC Bus Voltage.
Figure 3.2.9 DC Bus voltage
DRIVE FAULT
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 63
3210 REXA Omega Drive Motor Wiring
Most installation problems are with wiring. The following shows
standard motor power module:
Table 3.2.10 Motor wire color and function chart.
COLOR FUNCTION
RED COSINE
BLACK COSINE GROUND
BLUE SINE
YELLOW SINE GROUND
RED / WHITE REFERENCE
YELLOW / WHITE REFERENCE GROUND
GREEN RESOLVER SHIELD
BLUE PHASE R
GRAY PHASE S
ORANGE PHASE T
GREEN MOTOR CASE GROUND
WHITE TEMPERATURE SWITCH
WHITE TEMPERATURE SWITCH
Standard Servo Motor Wiring at the Power Module
Photo 3.2.10-1 Motor Power
(from enclosure side)
Photo 3.2.10-2 Motor Resolver
(from enclosure side)
DRIVE FAULT
Troubleshooting (06/10)
64 REXA X2 Series TS&R Manual
33 SEAT LOADING CyLINDER PROBLEMS
The SLC acts as a mechanical elastic coupling. Instead of a
mechanical coupling, the internal hydraulic pressure of the actuator
(2 000 psi) is used to show that the valve is in its seated position.
Refer to the IOM Appendix B, Figure B.3, for Loading Methods.
331 SLC reads Seated before actuator is on valve seat
Use the pressure gauges to verify that the pressure is above 2 000
psi. This will happen when the actuator is driven into its mechanical
stop (not the valve seat). The split clamp will need to be adjusted.
 Remove the split clamp and drive the valve to its seated
position.
 Drive the actuator to its seated position. Move the actuator
back open approximately ¼".
 Install the split clamp by lining up the valve shaft threads
and the actuator shaft threads.
 Calibrate the actuator in Setup (PL & PH).
If the actuator is at 50% stroke and reading seated:
 Try to drive the actuator open then back closed in Local
mode.
 If the unit still cannot go further than 50%, remove the split
clamp and stroke the actuator completely closed and open,
building pressure (2 000 to 2 300) on both gauges.
 If the proper pressure is obtained, the valve shaft is stuck or
something is keeping it from going closed.
332 SLC Feedback bad
Verify the wires are all connected at the enclosure and actuator (Red
+15, White SLC+ & Black SLC-).
SEAT LOADING CyLINDER
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 65
Simulate a 4 to 20 mA signal at the enclosure on SLC+ and SLC-. If
the error goes away, the problem is at the actuator or the actuator
cable.
 Land the wires back and remove the FB cover on the SLC.
Remove the white and black wire and simulate a 4 to 20 mA
signal.
– If the error goes away, the cables are good.
Two other components to check are the FB board and pot.
 Look to see if the red LED light is on the FB board; if not,
check to see if the red and black wires can display 15 Vdc.
– If the 15 Vdc is present and there is no LED light,
change the feedback board (see TS&R section
4E16, Remote Mounted Feedback Board).
 Check the pot by using an Ohm meter. Using the orange
and black wires to do so, you should read 0 to 5 000 ohms.
333 SLC Stop
SLC stop is simply the valve seat. In order to correctly connect the
valve shaft and actuator shaft follow these steps:
 Make sure both shafts line up perfectly.
 Drive the valve to its seated position.
 Drive the actuator to its seated position. Move the actuator
back open approximately ¼". Install the split clamp by lining
up the valve shaft threads and the actuator shaft threads.
 Calibration of the actuator can be done in Setup (PL & PH).
SEAT LOADING CyLINDER
Troubleshooting (06/10)
66 REXA X2 Series TS&R Manual
34 FEEDBACK BAD
When dealing with feedback issues it is always necessary to ensure
you have proper supply voltage to the electronics and that all the
wiring is properly landed. The supply voltage is proportional to the
CPU power supply. If the actuator’s incoming power supply is low,
high or unstable, the CPU power will also be affected.
The REXA feedback system begins with a potentiometer located on
the mechanical assembly, cabling that carries the signal from the
actuator to the electronics and the CPU which interprets and reports
the position indication. The CPU operating voltage is provided by
the Quad Power supply. The QPS is converting the incoming power
to various dc voltages to operate CPU, display, the actuator internal
feedback and the position transmission back to the operating control
system.
Check all connections to ensure the landed wiring is not pinched
down on the wire insulation, preventing a good connection.
If the actuator display reads FEEDBACK BAD, the following steps
should be taken:
 Check wiring on a non-contacting feedback
 Your wiring should be as follows: Red wire (supply voltage)
is the +15 Vdc, White wire (4 to 20 mA signal) is the FB+,
and the Black wire (reference) is FB-.
 The shield should be landed at the electronics and not at the
actuator.
 These connections should be checked at every termination
and junction box at every point between the CPU and the
potentiometer.
 Refer to your wiring diagram for additional information.
To check the Quad power supply voltages see the diagram in
Figure(s) 3.4–1, 2 or 3.
FEEDBACK BAD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 67
Figure 3.4-1 CPU voltage
Once all CPU voltages are confrmed and wiring has been
inspected, the next step to resolve the FEEDBACK BAD error is
to simulate a feedback signal directly to the CPU board. This will
determine if the problem is with the CPU or with the potentiometer.
FEEDBACK BAD
Troubleshooting (06/10)
68 REXA X2 Series TS&R Manual
Figure 3.4-2 QPS 120 V
Figure 3.4-3 QPS 240 V
FEEDBACK BAD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 69
 Place the actuator in Local mode, and remove the + and –
FB wires. With a 4 to 20 mA source send a signal directly
into the CPU at terminal 1 FB+/-.
 If the CPU can register and report a feedback signal, then
the problem lies in the potentiometer assembly. Replace the
potentiometer. (Refer to TS&R section 4M20.)
 If after simulating the feedback signal there is no change in
feedback status, the problem lies with the CPU. (See TS&R
section 4E4, CPU Assembly.)
Some actuators may come with a separate feedback circuit board.
The feedback circuit board is not needed for most standard products
(non-contacting potentiometer send a direct 4 to 20 mA signal
to the CPU board). For units with a feedback board, additional
terminations may result in a feedback bad error.
FEEDBACK BAD
Troubleshooting (06/10)
70 REXA X2 Series TS&R Manual
35 MOT STALL
Problem:
Mot stall means that fve attempts to move the actuator 1%
of stroke in the time set in Stall Time (See IOM section 6, Modes
of Operation and Control Parameters) have failed or, with a Seat
Load Cylinder, the “Seated” position was reached on the Seat Load
Cylinder and the position of the main cylinder was greater than 1%
above Position Lo.
In both situations, the actuator cannot match actuator position to
control signal input. A stall error can be caused by multiple systems;
the frst step in troubleshooting the stall error is to identify the cause.
The actuator will need to be removed from service but may not need
to be completely removed from the installation.
If possible, isolate the actuator from the process and place the unit
in the Local mode for troubleshooting. Follow the steps below to
identify if the stalling problem is mechanical or electronic:
1. Check oil level. See IOM section 164 for oil flling instruc-
tions. If flling the system with oil solves the stalling problem,
the unit can be put back into service. It should be closely
monitored and serviced as soon as possible. See TS&R
section 25, Oil Leaks, to locate a possible oil leak.
2. Check hydraulic system pressure. See TS&R section 31
for system pressure troubleshooting.
3. Check output of driver.
4. Check motor resistance.
Solution:
351 Motor stall hydraulic
A stall error can be caused by high system pressure or low system
pressure. The actuator will only generate enough pressure to
overcome the process forces. It is not unusual for the actuator to
operate well below the rated 2 000 psi system pressure. With the
MOT STALL
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 71
unit in Local mode, stroke the actuator and observe the pressure
gauges. If the actuator will not stroke via electronics, skip to section
3.5.2.
Use the handwheel/drill drive to confrm the mechanical
system is operating.
For Servo units, the system power must be off to operate
with handwheel.
For accumulator system handwheel operation see IOM
Appendix C, section C4, Manual Override.
For spring fail system, see IOM section M3.
If the system builds pressure quickly and can not move, skip
to TS&R section 31.
If the system builds no pressure, skip to TS&R section 3.1.
High pressure stall
A “high pressure” stall indicates the actuator either has to build
too much pressure to operate the driven device, or the system is
working too hard and can not follow the control signal. If one of the
pressure gauges is over 2 200 psi, the actuator is operating at its
limit. Some possible causes of this may be binding in the linkage,
hitting against a mechanical stop (cylinder limit, blockage in valve
etc.).
To resolve a high pressure stall, remove the linkage and
stroke the actuator to see if it will operate normally.
If the actuator can stroke with no problems while not con-
nected to the driven device, then the problem lies in the
linkage.
If the system still stalls while not connected to the driven
device, check your calibrated low and high positions. See
IOM section 6, Modes of Operation and Control Parameters
for additional calibration information.
If the problem persists please contact your local REXA
representative.
MOT STALL
Troubleshooting (06/10)
72 REXA X2 Series TS&R Manual
Low/no pressure stall
A “low pressure” stall can be any situation where the actuator
can not build enough pressure to move the driven device. A low
pressure stall can be caused by an open solenoid (see TS&R
section 4M11) or manual bypass (see IOM Appendix C and M), a
failed suction check valve, improperly adjusted pressure relief valves
or damaged cylinder piston seal.
– First verify the manual bypass and solenoid levers are in the
correct position.
– Then verify the adjustable pressure relief valves have
been set properly. See TS&R section 4M7 for additional
information on the adjustable pressure relief valves.
– If the unit will operate in one direction only, the suction check
valves need to be replaced. See TS&R section 4M9 for
information regarding suction check valve replacement.
– If the unit can not build pressure in either direction, the
piston may be worn and must be replaced. This will require
the unit be taken out of service for repair.
352 Motor stall electronic
Electronic stall problems can be caused by the driver, cabling,
speed/acceleration parameter settings or the motor itself. To confrm
and replace the failed component, it is best to verify the operation of
each component before replacing parts.
– Stall errors can be caused by a loose or corroded connec-
tion. Verify the system wiring for loose/corroded and correct
connections at every termination from the motor, through all
junction boxes, cabling and then to the driver.
– Gain and acceleration settings can cause motor stalls by
operating too slow when nearing the actuators set point.
Refer to IOM section 615 for additional information on
gain/acceleration settings.
– Refer to TS&R section 32, Drive Fault, for troubleshooting
motor and driver components.
MOT STALL
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 73
36 DIRECTION ERROR
Wiring is the most common cause for the motor not to move (or
move in the wrong direction). For both stepper and servo units it is
essential that the motor is ground at the power module and at the
REXA electronics.
– For stepper units make sure the motor is wired correctly at
the power module and the REXA stepper electronics. Refer
to TS&R Appendix C for wiring schematic.
– For servo units, make sure that the motor wires and resolver
wires are wired correctly at the power module and the REXA
stepper electronics. Refer to TS&R Appendix C for wiring
schematic.
REXA Electronics:
Ensure the position high and position low is correctly calibrated.
Refer to IOM section 6, Modes of Operation and Control
Parameters.
Make sure the deadband is calibrated according to the application.
Refer to IOM section 6, Modes of Operation and Control
Parameters.
Feedback:
– Make sure the feedback wires are wired correctly and
properly shielded at the actuator as well as ground at the
REXA electronics. Refer to TS&R Appendix C for feedback
wiring schematic.
Mechanical
Bypass:
– Make sure that the bypass is closed by turning the bypass
plug clockwise. If the bypass is opened while the actuator
is in auto mode and/or in actuation, a direction error will be
indicated on the display and the motor will stall as a result.
DIRECTION ERROR
Troubleshooting (06/10)
74 REXA X2 Series TS&R Manual
Solenoid:
– Make sure the lever on the solenoid is in its correct posi-
tion according to the application; this applies to the power
module solenoid and/or high speed solenoids.
Hand Pump:
There are many ways the hand pump can cause a direction error:
– If the pump is being stroked while the actuator is running in
the opposite direction of which the pump was stroked, then a
direction error will be indicated.
– If the actuator is static in auto mode while the pump is
stroked in any direction, a direction error will be indicated.
– If the direction knob on the pump is stuck in-between both
pump directions, then the system will act as a bypass and
cause a direction error to be indicated.
DIRECTION ERROR
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 75
+/- 15 VDC FAIL
37 +/- 15 VDC FAIL
If you receive this error, please contact your local REXA
representative.
Troubleshooting (06/10)
76 REXA X2 Series TS&R Manual
38 HART INTERFACE
NoTE: Setup issues are not covered in this trouble shooting section and
can be found in Appendix N of the IOM.
CS problem
If the actuator is receiving a CS bad error, remove both analog wires
and hook them directly into the CS+ and CS- located on the CPU
board.
To identify the CPU board, reference TS&R section 4E2. The
location of the CS+ and CS- on the CPU is shown in Photo 3.8-1. If
the CS bad error continues, reference TS&R section 311, CS BAD.
If the problem goes away, replace the HART interface board. (See
TS&R 4E13.)
No Digital communication is taking place
Under normal operation (when there is digital communication) the
CD, RX, TX, RTS LEDs located on the HART board will fash in
succession repeatedly. These LEDs are shown on the lower right
side of the board Photo 3.8-2.
If all the lights are out this means there is no digital signal being sent
to the REXA system. Troubleshoot the incoming control line with a
HART compatible hand held device to determine if there is a digital
signal to the REXA input lines. If this can be confrmed, replace the
Hart board (see TS&R 4E13).
If only the CD, RX and RTS lights are fashing in succession and the
TX light stays off, then check the software version installed in the
CPU. This is identifed as Version located under the outputs menu
in set up mode. Below is a list of software that is compatible with
HART (at the time this manual was written).
HART INTERFACE
Photo 3.8-1
CPU CS+ and CS-
Photo 3.8-2
HART board
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 77
X01_9_AV
XB1_6_AX
XB0_7_AX
XS0_4_BB
X01_9_AV
XR5_3_AQ
XA0_4_AV
XT1_3_AY
XT2_3_BA
XC0_1_BE
XD0_0_BF
XM0_2_Az
If the software installed is not listed above, record the actuator serial
number and contact the REXA factory to determine the correct
software version for the application.
HART INTERFACE
Troubleshooting (06/10)
78 REXA X2 Series TS&R Manual
39 FOUNDATION FIELDBUS
NoTE: Setup issues are not covered in this trouble shooting section and
can be found in Appendix K of the IOM.
No Digital communication is taking place
Under normal operation (when there is digital communication) the
3.3 V, Rx and Tx LEDs located on the FoUndatIon Fieldbus adapter
card will fash in succession repeatedly at a rate of 20 fashes / sec.
These LEDs are shown on the lower right corner as seen in Photo
3.9.
– If the 3.3 V and the Tx LEDs are on and the Rx fashes very
faintly, then check the software version installed in the CPU.
This is identifed as Version located under the outputs menu in
set up mode. Below is a list of software versions compatible with
FoUndatIon Fieldbus (at the time this manual was written).
XR3_1_AJ
XR4_0_AG
X02_7_AW
XA1_5_AW
XM1_0_BG
XM2_0_BH
– If the software installed is not listed above, record the actua-
tor serial number and contact the REXA factory to determine
the correct software version for the application.
– If all three LEDs remain on, this indicates the wrong soft-
ware has been installed in the CPU, and there is no digital
signal being received from the DCS.
FOUNDATION FIELDBUS
Photo 3.9
Foundation Fieldbus
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 79
– If the Rx and 3.3 V remain on this indicates the digital signal
from the DCS is not being received. Troubleshoot the
incoming control line with a Foundation Fieldbus compatible
hand held device to determine if there is a digital signal to
the REXA input lines. If this can be confrmed replace the
Foundation Fieldbus board. (Reference TS&R section
4E14 for replacement procedures.)
FOUNDATION FIELDBUS
Troubleshooting (06/10)
80 REXA X2 Series TS&R Manual
310 PULSE CONTROL SIGNAL
Some applications use a Pulse Control signal rather than a 4 to 20
mA modulating signal to position the actuator. The Pulse signal
should have amplitude of 24–120 volts, with a minimum duration of
10 ms and maximum duration of 999 ms.
If Signal Type = Pulse cannot be accessed in the INPUTS menu:
– For the Signal Type parameter to display Pulse in the
INPUTS menu, you must have the appropriate circuit board
assembly installed. The circuit board is mounted atop the
CPU as shown below.
Assembly for
Pulse Input
CPU
Assembly
Photo 3.10 Pulse control circuit board
PULSE BOARD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 81
If actuator will not move when pulses are applied or moves in wrong
direction:
– Verify signals, open and close, are connected as shown in
the following drawings.
TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
MC
MO
D
8
D
7
LED’s “ON” when
Signal is present
MC = Close input
MO = Open input
TB4
OPEN CLOSE
Figure 3.10-1 Pulse Signal Input – Using Active Voltage Signals
Or
TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
OPEN
RELAY
CLOSE
RELAY
MC
MO
D
8
D
7
LED’s “ON” when Signal is
present
MC = Close input
MO = Open input
TB3
Jumper must be in
place for Dry Contact
operation
Figure 3.10-2 Pulse Signal Input – Using REXA Relays & Bias Voltage
PULSE BOARD
Troubleshooting (06/10)
82 REXA X2 Series TS&R Manual
If Pulse input Signals are NOT polarity sensitive.
– Verify Signal Type = Pulse in the INPUTS menu
– Verify the signal amplitude is 24 V or greater, not to exceed
120 V.
– Verify Actuator is in “Auto” mode. Pulse control will not
operate the actuator in Local or Setup modes.
– Verify that parameter Pulse Dur (Pulse duration) is equal
to or just slightly less than the minimum pulse width being
applied. For example, if a control pulse of 100 ms is being
applied, Pulse Dur should be set to 95 ms to be sure the
pulse is read by the input.
– Verify that the number of pulses being applied command
the actuator to move beyond its deadband setting. For
example, Pulse Dur = 100 ms and Pulse Inc (Pulse Incre-
ment) =0.1%. For every valid 100 ms pulse, the actuator
will move 0.1% in the commanded direction. However, if the
parameter Deadband = 0.5%, the actuator will not move until
5 successive pulses are given to command a move outside
the 0.5% deadband.
– Verify the LED’s MC and MO illuminate when a pulse is
applied.
Are both LEDs on when no pulses are applied? This indicates
leakage current, typical of solid state devices, coming from the
control system. The input board is interpreting both inputs as active
(due to this leakage current) and the actuator will not move. 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
must be added across the input signal terminals and will bypass the
current.
– Verify the circuit board is seated properly on the CPU mating
24-pin connector.
PULSE BOARD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 83
– Verify the inputs with a known good source. Disconnect all
wires from the DCS to the input board. If a jumper is pres-
ent, remove it. Using a handheld current device, apply a 20
mA signal between the CLOSE–CLOSE inputs. The actuator
should travel toward positioned defned by parameter Posi-
tion Lo and the MC LED should illuminate. Now apply the
signal between the OPEN–OPEN terminals. The actuator
should travel toward the position defned by parameter Posi-
tion Hi. If this operation is successful, re-check the incoming
signals from the DCS.
CAUTION: 120 Vac is present on the PWR OUT
and PWR RTN terminals
If all the above do not solve the problem or the LEDs' MC and
MO are not illuminating, the Contact In/Relay Out board must be
replaced per TS&R section 4E5.
If actuator moves beyond target position when pulses are applied:
– Verify Signal Type = Pulse and not 1 Cont or 2 Cont.
– Verify pulse duration and pulse increment settings are set to
values determined by your application.
– Verify the number of pulses being given. Multiple pulses
may be read by the input. Pulse Dur may need to be
adjusted to a higher value so that fraction of a pulse is not
interpreted as a valid pulse.
One long pulse is interpreted as multiple Pulses. For example, with
Pulse Dur = 100 ms and Pulse Inc = 0.1% and a pulse 500 ms in
duration is applied, the actuator will move 0.5%, as the 500 ms pulse
is interpreted as fve, 100 ms pulses.
PULSE BOARD
Troubleshooting (06/10)
84 REXA X2 Series TS&R Manual
311 CONTROL SIGNAL
The Control Signal is typically a 4 to 20 mA modulating signal which
commands the actuator to travel to a set point.
3111 If actuator Position does not match Control
Signal Input (Control Signal Calibration)
Calibrate the DCS’s 4 to 20 mA control signal to the actuator control
enclosure. The default values for parameters Signal Lo and Signal
HI are 4.0 mA and 20.0 mA, respectively. If the DCS control signal
is slightly different than these values, actuator position will not match
incoming control signal. Parameters Signal Lo and Signal Hi cannot
be changed by pressing the arrows. An active 4 to 20 mA signal
must be applied.
– Using the DCS control signal, access Signal Lo in the
Calibrate menu and press the enter button for the “=”to
fash. Apply the signal that corresponds to command the
actuator to travel to Position Lo, typically 4.0 mA. The actual
current input will be displayed in mA and may vary slightly
from the default value. Lock this value in by pressing the
enter (

) button, stopping the “=” from fashing.
– Apply the signal that corresponds to command the actuator
to travel to Position Hi, typically 20.0 mA. The actual cur-
rent input will be displayed in mA and may vary slightly from
the default value. Lock this value in by pressing the enter
(

) button, stopping the “=” from fashing. The actuator
position should now match the control signal input when in
“aUto” (

) mode.
NoTE: Unknwn appears if control signal failure occurs while calibrating.
Error appears, briefy, 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 IOM section
6.1.6, INPUTS Menu.)
NoTE: If Failsafe = Off, the span for Signal Hi must be greater than 3.8
mA or vice versa.
CONTROL SIGNAL BAD
Photo 3.11-1
Signal Lo
Photo 3.11-2
Signal Hi
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 85
3112 CS Bad reading (Control signal is less than 25 mA)
– Verify Signal Type = Analog in the INPUTS menu
– Verify Control Signal is greater than 2.5 mA
– Verify the polarity of the applied Control Signal. The control
signal input is polarity protected and current will not fow if
the polarity is not correct.
– If the polarity is correct, be sure the 4 to 20 mA loop from the
Control system is operating.
Using an ammeter, and again verifying polarity, vary the 4 to 20 mA
current from the control system and confrm that it is correct. If it
is not correct, the hand held current source can be used until the
control system problem is resolved. If at any time the DCS control
signal is suspect, use a handheld current source to verify operation
of the actuator.
If the Control signal is correct from the control system, verify that the
Control signal surge suppressor is not damaged. Do so by applying
the control signal directly to the CPU board, bypassing the surge
suppressor. Remove the wires on the CPU CS+ and CS- inputs
that connect to the suppressor before applying the signal. Apply
the known good control signal while in parameter Signal Lo and the
“=” is fashing. Vary the signal. If the input matches the Control
signal input, you have verifed the Control Signal surge suppressor is
defective and must be replaced. (Refer to TS&R section 4E12 for
Control Signal Surge Suppressor replacement.)
CONTROL SIGNAL BAD
Troubleshooting (06/10)
86 REXA X2 Series TS&R Manual
Photo 3.11-3
CPU connections
CPU Control
Signal Input
Control Signal
Surge
Suppressor
CS+ Input,
Middle
Terminal of
CS Surge
Suppressor
CS− Input
Top Terminal
of CS Surge
Suppressor
If the CPU still does not read the Control Signal, reconnect the
Control Signal surge suppressor wires to the CS+ and CS− inputs.
Apply the control signal to the surge suppressor input. Using a
Digital Voltmeter, measure the dc voltage across the CS+ and CS−
inputs on the CPU board.
The dc voltage should vary between 1.3 Vdc (for 4 mA input) to
4.0 Vdc (for 20 mA) input. If the voltage varies with change in
Control Signal but the display still reads CS Bad, the CPU must be
replaced. Replace the CPU. (Reference TS&R section 4E4, CPU
Assembly.)
3113 Control Signal “dithering” or noisy
If the Control Signal from the DCS is varying at a high frequency on
the REXA display, it may be contributed to a noisy signal or dithering
built into the control system.
CONTROL SIGNAL BAD
Photo 3.11-5
DC voltage for 4 mA
Photo 3.11-4
Digital voltmeter connections
Photo 3.11-6
DC voltage for 20 mA
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 87
Verify that the control signal cable from the DCS is a shielded, signal
type cable and the shield is landed to ground at the DCS only. In
addition, be sure this signal cable is segregated from high voltage
cables as they may induce voltage onto the signal causing it to vary.
Some control systems have a built in “dither signal” to operate with
older actuators to always have them move. Be sure this function is
disabled in your control system.
Should the above not remedy the problem, use a handheld current
source to drive the control signal input.
– If the signal becomes quiet and the display is steady, you
have verifed the problem is with the incoming control signal
and not the actuator input.
– If the display still varies with a steady input signal, the CPU
must be replaced per TS&R section 4E4.
3114 Actuator travels to Position Lo or
Position Hi when CS Bad error occurs
Verify the Failsafe parameter is set to the appropriate setting.
Failsafe defnes 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.
Close: Actuator goes to Position Lo.
Open: Actuator goes to Position Hi.
Off: Used for zero based control signal (i.e., 0 to 20 mA).
3115 CS Bad error does not appear when
Control Signal drops below 25 mA
– Verify Signal Type = Analog
– Verify Failsafe does not = Off
CONTROL SIGNAL BAD
Troubleshooting (06/10)
88 REXA X2 Series TS&R Manual
312 CONTACT INPUT SIGNAL
Some applications use a Contact Input signal rather than a 4 to 20
mA modulating signal to position the actuator. The Contact Input
signal should have amplitude from 24 to 120 V. There are two types
on Contact signal inputs.
The frst is a single contact, or ON/OFF signal. This is strictly for two
position control of the actuator. When the signal is present on the
OPEN input, the actuator will travel toward position as defned by
parameter Position Hi. When the signal is not present, the actuator
will travel toward the position defned by parameter Position Lo.
The second is two contacts, or “Manual” control of the actuator. The
actuator will travel toward Position Lo as long as the “Close” Input
is active. The actuator will travel toward Position Hi as long as the
“Open” input is active. If neither input is active, the actuator will
remain at the current position. If both inputs are active, the actuator
will remain at the current position.
If Signal Type = 1 Cont or 2 Cont, the CS Bad error code will not
be displayed in Auto mode. CS Bad only applies to a 4 to 20 mA
Control Signal
If Signal Type = 1 Cont or 2 Cont cannot
be accessed in the INPUTS menu
For the Signal Type parameter to display 1 Cont or 2 Cont in
the INPUTS menu, you must have the appropriate circuit board
assembly installed. The circuit board P/N is S97713, and is
mounted atop the CPU as shown in Photo 3.12-1.
CONTACT INPUT BOARD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 89
CPU
Assembly
Assembly
S97713
for Pulse Input
Photo 3.12-1 Contact input board
Using 1 Cont, actuator will not move
– Verify the single contact is connected in one of the confgu-
rations shown below.

TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
ON = OPEN
OFF = CLOSE
MO
D
7
LED “ON” when
Signal is present
MO = Open input
24-120
VAC/VDC
TB3
Figure 3.12-1 1 Contact Signal Input
– Using an Active Voltage Signal
Or
CONTACT INPUT BOARD
Troubleshooting (06/10)
90 REXA X2 Series TS&R Manual

TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
ON/OFF
RELAY
MO
D
7
LED “ON” when Signal is
present
MO = Open input
MINIMUM CONTACT
RATING
120 VAC, 10mA
TB3
Jumper must be in
place for Dry Contact
operation
Figure 3.12-2 1 Contact Signal Input
– Using Relay and Bias Voltage from REXA
Contact Input signal is NOT polarity sensitive.
– Verify Signal Type = 1 Cont in the INPUTS menu
– Verify the signal amplitude is 24 V or greater, not to exceed
120 V.
– Verify Actuator is in “Auto” mode. 1 Cont control will not
operate the actuator in Local or Setup modes.
– Verify circuit board is seated properly on the CPU mating
24-pin connector.
– Verify the inputs with a known good source. Disconnect
all wires from the DCS to the input board. If a jumper is
present, remove it. Using a handheld current device, apply
a 20 mA signal between the OPEN–OPEN inputs. The
actuator should travel toward the position defned by param-
eter Position Hi, and the MO LED should illuminate. Now
remove the signal. The actuator should travel toward the
position defned by parameter Position Lo. If this operation
is successful, re-check the incoming signals from the DCS.
CAUTION: 120 Vac is present on the PWR OUT
and PWR RTN terminals
CONTACT INPUT BOARD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 91
– If all the above do not solve the problem or the LED MO is
not illuminating, the Contact In/Relay Out board must be
replaced per TS&R section 4E5.
Using 1 Cont, actuator always runs toward
Position Hi even when no signal is applied
Are the LEDs on when no signal is applied? This indicates leakage
current, typical of solid state devices, coming from the control
system. The input board is interpreting the input as active due
to this leakage current, and the actuator will not move. 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 must be added
across the input signal terminals to bypass the current.
Using 2 Cont, actuator will not move
– Verify the 2 signals are connected in one of the confgura-
tions shown below.

TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
MC
MO
D
8
D
7
LED’s “ON” when
Signal is present
MC = Close input
MO = Open input
TB4
24-120
VAC/VDC
24-120
VAC/VDC
CLOSE
Figure 13.2-3 2 Contact Signal Input – Using an Active Voltage Signal
CONTACT INPUT BOARD
Troubleshooting (06/10)
92 REXA X2 Series TS&R Manual
Or

TB6
CONTACT INPUT BOARD
ASSEMBLY NO. S97713
OPEN RELAY
CLOSE
RELAY
MC
MO
D
8
D
7
LED’s “ON” when Signal is
present
MC = Close input
MO = Open input
TB3
Jumper must be in
place for Dry Contact
operation
Figure 13.2-4 2 Contact Signal Input
– Using Relays & Bias Voltage from REXA
Contact Input signal is NOT polarity sensitive.
– Verify Signal Type = 2 Cont in the INPUTS menu
– Verify the signal amplitude is 24 V or greater, not to exceed
120 V.
– Verify Actuator is in “Auto” mode. 2 Cont control will not
operate the actuator in Local or Setup modes.
– Verify the circuit board is seated properly on the CPU mating
24-pin connector.
– Verify the LED’s MC and MO illuminate when a signal is
applied.
Are both LEDs on when no signal is applied? This indicates current
leakage —typical of solid state devices—coming from the control
system. The input board is interpreting both inputs as active due
to this leakage current, and the actuator will not move. The OFF
state leakage current must be less than 1 mA. Diode clamps or
RC snubber networks placed across mechanical relays and the
CONTACT INPUT BOARD
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 93
CONTACT INPUT BOARD
semiconductor junctions of solid state switches will pass some
current in the OFF state.
– If this leakage exceeds 1 mA, a resistor must be added
across the input signal terminals to bypass the current.
Verify the inputs with a known good source. Disconnect all wires
from the DCS to the input board. If a jumper is present, remove
it. Using a handheld current device, apply a 20 mA signal between
the CLOSE–CLOSE inputs. The actuator should travel toward the
position defned by parameter Position Lo, and the MC LED should
illuminate. Apply the signal between the OPEN–OPEN terminals.
The actuator should travel toward the position defned by parameter
Position Hi. If this operation is successful, re-check the incoming
signals from the DCS.
CAUTION: 120 Vac is present on the PWR OUT
and PWR RTN terminals
– If all the above do not solve the problem, or the LEDs MC
and MO are not illuminating, the Contact In/Relay Out board
must be replaced per TS&R section 4E5.
Using 2 Cont, actuator moves to Position
Lo when OPEN signal is removed
– Verify CLOSE signal is not active
– Verify Signal Type = 2 Cont and NOT 1 Cont.
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94 REXA X2 Series TS&R Manual
DISPLAy PROBLEMS
313 DISPLAy PROBLEMS
3131 Ribbon Connector
The ribbon cable connecting the membrane switch assembly to the
interface circuit board may be disconnected.
Ribbon cable is disconnected
– When the ribbon cable is connected, the keypad display on
the front of the enclosure will show the green power LED
illuminated, and the display should read SETUP. If these
two conditions are not present, the ribbon cable may be
disconnected.
– Check that the ribbon cable is secured into CPU board
connector P7 and the latches are closed so the cable can
not pull out. The pink stripe on the ribbon cable should be
facing Pin 1 of connector P7. The other end of the ribbon
cable connecting to the display interface board should also
be checked. The pink stripe on the ribbon cable should be
facing Pin 1 on connector P1 of the display interface board
with latches securely locking the ribbon cable in place.
Is power transmitting from CPU to the display?
– When there is no power, the VFD display will have no
read-out, and the green LED on the keypad will not be
illuminated.
– Before replacing CPU board, check +5 Vdc is present from
Power Board. Measure dc voltage at terminal TB2 on CPU
board. Measure the dc voltage with a DMM between Pin 6
(+5 Vdc) and Pin 7 (Ground). A +5 Vdc should be present;
if not, Power Board needs to be replaced. (See TS&R
section 4E3 to replace Power board.)
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 95
DISPLAy PROBLEMS
– On CPU connector P7, disconnect the ribbon cable while
powered. The exposed gold plated pins of the connectors
can be measured to check if power is being output from
CPU to the display. Measure the dc voltage with a DMM
between Pin 2 (+5 Vdc) and Pin 14 (Ground). +5 Vdc should
be present. If not, CPU board may need replacement. See
TS&R section 4E4 to replace CPU board.
– If +5 Vdc is present at TB2 on the CPU and at connector P7
and the display is still not functioning, then the ribbon cable
should be replaced.
If +5 Vdc power is present from above, but still no display read-out:
External Display
– If the Green power LED is illuminated on the keypad display,
but the VFD readout is not present, then the VFD display
needs to be replaced. (See TS&R section 4E10).
Internal Display
– If the read-out is not present on the VFD display, but the
push buttons work on the display interface board, then the
VFD needs to be replaced. (See TS&R section 4E11.)
3132 Control Issues
Trying to move the actuator in Local or Calibrate mode and the
actuator will not move
– Ensure the keypad display green power LED is illuminated.
– Ensure that the Ribbon Cable (with blue connectors from the
display interface to the keypad) has not come loose and is
seated properly.
– Reset the Electronics by pushing SW1 on the CPU board.
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96 REXA X2 Series TS&R Manual
PRESSSURE RELIEF VALVES
314 PRESSURE RELIEF VALVES
If the unit is creating more pressure than the application requires, the
following steps should be taken to rectify this problem:
– Unscrew the adjustment cap on the pressure relief valve and
check if the spring color is the correct color for the applica-
tion (see IOM Appendix O). The wrong color spring can
provide more or less pressure for the application.
If the spring in the pressure relief valve bonnet is correct, reapply the
cap adjustment but do not tighten.
– Run the unit to see if the application is still building pressure
on the pressure relief valve side that has been worked on.
If the actuator does not build pressure, the pressure relief valve is
performing as designed. Pressure is not building because the valve
stem is allowing fuid back into the system.
– Refer to IOM Appendix O to reset the pressure relief valve
to its factory setting.
NoTE: This process should be done to both pressure relief valves.
If the actuator continues to build pressure, unbolt the pressure
relief valve bonnet from the power module (Refer to TS&R 4M7,
Pressure Limiting Valve).
If the valve stem is loose in the bonnet hole, check for contaminants
in the pressure relief valve cavity.
– Place the pressure relief valve bonnet back into the pressure
limiting cartridge cavity and refer to IOM Appendix O to
reset the pressure relief valve.
– If the pressure relief valve continues to build too much pres-
sure, refer to TS&R 4M7.
If the valve stem is tight/stuck in the bonnet hole, order a pressure
relief valve replacement kit.
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 97
– Reinstall as referenced in TS&R 4.M.7, and refer
to Appendix O in the IOM to reset the pressure
relief valve.
PRESSURE RELIEF VALVES
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98 REXA X2 Series TS&R Manual
315 CONTROL ISSUES
3151 Actuator Hunting – Electrical Noise
The actuator will not stop moving around its target position. This is
referred to as “hunting” for position. There are many different factors
that may cause the actuator to hunt for position; one is electrical
noise.
Electrical Noise on the Control Signal
If the actuator is in “auto” mode and the display is fuctuating greater
than the deadband setting AND the motor is turning, the cause may
be electrical noise on the incoming control signal.
To determine if the control signal is unstable, you can observe the
incoming control signal by using the Up or Down arrows to view
parameter “Control Sig”. If the mA is fuctuating, the Control Signal
is noisy.
– Ensure the Control Enclosure has a solid earth ground
connection. (Refer to TS&R section 4E1.)
– Ensure the control signal cable from the DCS is a
shielded cable.
– Ground the shield of the Control signal cable at the
DCS end only.
– Ensure that the DCS does not have a built-in “dither”
signal on the control signal output. This is found on
some older control system/actuator combinations.
– Using a handheld current source, apply a 4 to 20 mA
signal into the Control Signal input while observing
the parameter Control Sig. If the display is steady, try
operating the actuator with the hand-held device. If
the actuator operates properly with the hand-held, the
DCS signal is noisy and should be checked.
CONTROL ISSUES
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 99
Electrical Noise on the Actuator Feedback Signal
If the actuator is in “auto” mode and the display is fuctuating greater
than the deadband setting AND the motor is turning, the cause may
be electrical noise on the feedback signal from the actuator.
The feedback signal from the actuator is a 4 to 20 mA loop which
tells the CPU the actuator position. If this loop is noisy, the
actuator may “hunt” to fnd the target position. To determine if the
feedback signal is unstable, you can observe the actuator
feedback signal in the “setup” mode.
– Place the actuator into setup mode.
– Access the “deadband” parameter in the Control
menu.
– Increase the deadband by 0.5%.
– Place actuator into “Auto” mode
 Does the actuator stop hunting? If so, the problem is most
likely noise. If not, noise may not be the issue.
– In the “Calibrate” menu, scroll down to parameter
Position Lo.
– Record the value for Position Lo.
– Press the “enter” button. The “=” will fash.
– The value for Position Lo will indicate the current
position of the actuator.
DO NOT PRESS ENTER.
 If the display is fuctuating, the feedback signal from the
actuator is noisy.
– Press the reset button on the upper right corner of the
CPU. This will exit parameter Position Lo and default
back to its previous value.
– Ensure that the Control Enclosure has a solid earth
ground connection. (Refer to TS&R section 4E1)
– Ensure the feedback signal cable from the actuator is
a shielded cable.
CONTROL ISSUES
Troubleshooting (06/10)
100 REXA X2 Series TS&R Manual
CONTROL ISSUES
– Ground the shield of the feedback signal cable at the
control enclosure end only.
– Ensure the Feedback cable is in a signal level tray
or conduit. Having the Feedback cable in a tray or
conduit with high voltage cable can cause the signal
to be noisy due to induced voltage on the feedback
signal from neighboring cables.
– Ensure the Green/Yellow ground wire in the module
cable is terminated at both actuator and control
enclosure. This wire equalizes the ground potential
at the control enclosure and actuator, thus eliminating
possible current fow on the feedback cable shield.
 Faulty Feedback Device?
If the actuator is hunting or dithering for position, and feedback
and control signal noise have been ruled out, it is possible that
the actuator feedback device is faulty. The feedback device may
have a random spot within its stroke in which the feedback signal
is intermittent, giving the appearance of a noisy signal. The linear
actuator uses a conductive plastic potentiometer with a 4 to 20
mA feedback board, and the rotary and drive actuators use a non-
contacting device that transmits a 4 to 20 mA signal. Refer to TS&R
section 34 to troubleshoot feedback devices.
3152 Actuator Torque / Thrust requirements
REXA Actuators and Drives are a self contained Electraulic™ device
that utilizes a reversible hydraulic pump, driven by the motor, to
pressurize either side of a double acting cylinder.
The output thrust / torque of each cylinder is based on an internal
pressure of 2 000 psi. That 2 000 psi pressure multiplied by the
effective area of the cylinder equates to the output thrust / torque.
Each X2 REXA standard power module is shipped from the factory
with 2 pressure gauges; one to monitor each side of the cylinder.
The simplest way to ensure your actuator is producing the specifed
amount of torque / thrust is to observe the pressure gauges during
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 101
operation. The gear pump will only produce as much pressure as
needed to overcome the process forces. If the actuator is producing
from 0 to 2 200 psi without producing a stall error then it is operating
within specifcations. If the actuator stalls out or fails to produce over
2 000 psi then consult TS&R section 351.
3153 Actuator drifting
Actuator “drifts” away from applied load.
If your actuator is being “pushed” by the process, resolving this
problem can be diffcult and may require that the unit be removed
from service.
The REXA actuator is designed to operate on 2 000 psi internal oil
pressure. At 2 000 psi the cylinder is at its rated output. Each REXA
unit has been designed to meet a specifc application’s thrust or
torque requirement. If your REXA unit is operating above the 2 000
psi limit, you may have an undersized cylinder for your application.
Every REXA X2 power module has adjustable pressure relief valves
to protect the actuator from over-pressurizing. If these relief valves
are shut off or not operating properly, the unit may build too much
pressure and damage itself or the surrounding equipment. To
verify the cylinder output, see the serial tag located on the electrical
CONTROL ISSUES
Troubleshooting (06/10)
102 REXA X2 Series TS&R Manual
or mechanical assembly. Refer to TS&R section 12, Actuator
Identifcation, for additional information. Please contact your local
REXA representative if you believe your cylinder is undersized.
If your actuator is correctly sized and still drifting away from the load,
with the pressure gauges ON run the actuator in the direction of the
load to see if internal pressure can be built.
– If no pressure builds but motor is turning, check the
Manual bypass and / or override solenoids.
– If pressure builds but immediately drifts down, check
the pressure relief valve setting. (See TS&R section 3.14.)
– If pressure builds but drifts down slowly, the unit may
have a leaking piston seal or problem with the fow
matching valve. Contact your REXA representative.
3154 Position Transmitter Calibration
Xmitter Low {Transmitter Low} is the parameter to calibrate the
Output zero of the 4 to 20 mA Position Transmitter.
To calibrate the 4 mA zero, connect a DMM to the Position
Transmitter Output on the CPU. Set the DMM to read milliamperes
(mA). 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 will change the current output by one micro-
amp (1 μA). The acceptable range for Xmitter Lo is 3.9 to 4.1 mA.
Photo 3.15.4-2
DMM connection
Photo 3.15.4-3
DMM display
CONTROL ISSUES
Photo 3.15.4-1
Xmitter Low readout
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 103
NoTE: The Position Transmitter will output the mA signal that corresponds
to the actuator's current position until the Enter button is pressed and the
“ =” sign is fashing. When the “ =” sign is fashing, 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, connect a DMM to the Position
Transmitter Output on the CPU. Set the DMM to read milliamperes
(mA). 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 change the current output by
one micro-amp (1 μA).
NoTE: The Position Transmitter will output the mA signal that
corresponds to the current position of the actuator until the Enter button
is pressed and the “ =” sign is fashing. When the “ =” sign is fashing, the
output will change to the “Span” or Hi Calibration value.
Photo 3.15.4-4
Xmitter Hi readout
Photo 3.15.4-5
DMM display
NoTE: Xmitter Hi and Xmitter Lo values are not transmitted over the bus
in Foundation Fieldbus units.
Once the position transmitter calibration is complete, there is
no need to re-calibrate the transmitter for changes in actuator
span. Changing the actuator span will cause the transmitter to
automatically re-calibrate its output.
CONTROL ISSUES
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CONTROL ISSUES
3155 Electrical Limit Switches
The Electrical Sub-Assembly is equipped with two SPST 1 Form
A PhotoMos relays that are confgured as electronic limit switches.
The termination points for these relays are located on the CPU
board assembly at TB5, Relay 1 and Relay 2. The relays close
based on the value of parameters RELAY #1 and RELAY #2 in the
OUTPUTS menu. Refer to IOM Section 618.
LED, D5 LED, D4
Terminal Block TB5
with Relay 1 and
Relay 2 Connections
Photo 3.15.5-1 Terminal Blaock TB5
Electrical limit switch rating = 200 Vac/Vdc, 1 A
Can the electrical Limit Switches be confgured
Normally Open or Normally Closed?
– No. The relays are SPST, solid state devices with
a Normally Open contact only. The relay contact is
“open” when power is off or the relay is not within the
“active” range determined by actuator stroke.
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 105
Do the solid state relays have leakage
current when they are off?
– The leakage current in the “off” state should be
no greater than 10 mA. If it is greater, the relay is
defective and the CPU should be replaced per TS&R
section 4E4.
If RELAY 1 does not give a closed contact indication:
 Is the actuator stroke below the value set in parameter
Relay#1?
– If no, bring the actuator to within the active range of
Relay #1 or adjust parameter Relay #1.
 Is the LED D4 lit?
– If No, replace the CPU Board according to section
4.E.4
– LED D4 is lit, but I do not have a closed contact.
Confrm the actuator is within the active range for
Relay #1. Using an ohmmeter, measure the resis-
tance across the terminals at TB5 for Relay 1. The
“on” resistance of the relay should be approximately
0.7 Ω but no greater than 1.1 Ω.
If the resistance is greater than 1.1 Ω or an open
circuit, the relay is faulty and the CPU should be
replaced per TS&R section 4E4.
RELAY 2 does not give a closed contact indication
 Is the actuator stroke below the value set in parameter
Relay #2?
– If not, bring the actuator to within the active range of
Relay #2 or adjust parameter Relay #2.
 Is the LED D5 lit?
– If No, replace the CPU Board according to TS&R
section 4E4.
– LED D5 is lit, but I do not have a closed contact.
CONTROL ISSUES
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106 REXA X2 Series TS&R Manual
CONTROL ISSUES
– Confrm the actuator is within the active range for
Relay #2. Using an ohmmeter, measure the resis-
tance across the terminals at TB5 for Relay 2. The
“on” resistance of the relay should be approximately
0.7 Ω but no greater than 1.1 Ω.
– If the resistance is greater than 1.1 Ω or an open
circuit, the relay is faulty and the CPU should be
replaced per TS&R section 4E4.
3156 Too High/Too Low on display
The display reads Too Low or Too Hi, and you cannot calibrate your
high / low position.
The actual physical mechanical travel, of the REXA cylinder is
recorded in the CPU. To prevent the unit from hitting the cylinder
end during operation an electrical “cushion” is added.
– Back the actuator away from the cylinder end until the
CPU allows the value to be set. If possible, disengage
the driven device linkage slightly to allow the actuator
more room to travel. If no changes can be made that
will satisfy proper safe operation, contact your local
REXA representative.
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 107
TRIP SIGNAL
316 TRIP SIGNAL
REXA actuators can be confgured to fail to either end position or
stay in its last position. The fail to end position is achieved by either
the use of a coil spring or a pressurized accumulator bottle. It can be
triggered by a loss of power, control signal or independent trip signal.
3161 Fail direction
The Fail direction is factory confgured—based on information
provided—to fail to either calibrated end, but not both, and is not
feld reversible.
Please contact your REXA representative.
3162 No trip on loss of power
The actuator does not trip on loss of power reference.
 If equipped with a high-speed solenoid, ensure the solenoid
override levers are both in Position A for normal actuator
operation. Refer to IOM Appendix C, section C4, Manual
Override.
– Ensure the Accumulator bottles are charged and the
Shutoff valves are in their proper position. Refer to
IOM Appendix C, Accumulator Fail.
 If equipped with a REXA solenoid, a bypass control toggle
lever will be present on the power module. Ensure that the
lever is in its ‘normal position’. Refer to IOM section C4,
Manual Override.
– Check software settings for Trip option and / or
Accumulator option under Inputs menu. Refer to IOM
section 6, Modes of Operation and Control Param-
eters, for proper setting when using Trip function to fail
on loss of power.
– Check fuses on triple power supply board with DMM.
Fuses F5, F6 are for REXA spring fail solenoid. Fuse
F4 is for High-Speed solenoids, and Fuse F3 is for
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108 REXA X2 Series TS&R Manual
TRIP SIGNAL
Contact Input Board. Using a DMM, a good fuse will
measure close to zero Ohms or show continuity. A
blown fuse is an open circuit or will read infnity on the
meter. See TS&R section 4E17 to replace blown
fuses on Triple Power Supply.
3163 No trip on loss of control signal
The actuator doesn’t trip on loss of control signal.
If Analog control signal falls below 2.5 mA, the actuator should
move to fail safe position via motor.
– Check that the Failsafe option is enabled. Refer to
IOM section M3, Failsafe Unit Operation.
– Ensure the Accumulator bottles are charged and the
Shutoff valves are in their proper position. Refer to
IOM Appendix C, Accumulator Fail.
NoTE: Local and Remote Manual mode will override Failsafe position
3164 No trip on loss of trip signal
The actuator doesn’t trip on loss of trip signal reference
– Check that the trip signal (24–120 Vac/Vdc) is wired
to the correct terminals of the contact input board.
Ensure that any required jumpers are in place. Check
that the Trip option and/or Accumulator option is
enabled. Refer to IOM Appendix C, Accumulator Fail.
– Check fuses on triple power supply board with DMM.
Fuses F5, F6 are for REXA spring fail solenoid. Fuse
F4 is for High-Speed solenoids, and Fuse F3 is for
Contact Input Board. Using a DMM, a good fuse will
measure close to zero Ohms or show continuity. A
blown fuse is an open circuit or will read infnity on the
meter. See TS&R section 4E17 to replace blown
fuses on Triple Power Supply.
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 109
TRIP SIGNAL
 If equipped with high-speed solenoids, ensure the solenoid
override levers are both in Position A for normal actuator
operation. Refer to IOM section C4, Manual Override.
– Ensure the Accumulator bottles are charged and the
Shutoff valves are in their proper position. Refer to
IOM Appendix C, Accumulator Fail.
 If equipped with a REXA solenoid, a bypass control toggle
lever will be present on the power module. Ensure that the
lever is in its ‘normal position’. Refer to IOM section C4,
Manual Override.
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110 REXA X2 Series TS&R Manual
WATER INGRESS
317 WATER INGRESS
3171 Module / Motor
The Mechanical Sub Assembly (MSA) of the REXA Actuator is
designed to thrive in the most hostile ambient environments. The
MSA is rated NEMA 4X (protection against rain, snow, hose directed
water and corrosion resistant). When properly installed your MSA
should provide years of weather tight operation.
The MSA has multiple conduit entries. Each of the entries ship from
the factory with a stainless steel plug installed with sealant around
the threads to eliminate the possible ingress of water. If a plug is
removed and replaced with a conduit ftting both local and National
Electrical Codes (NEC) must be complied with to ensure proper
installation and sealing.
The MSA also has a wire terminal cover that allows access to the
module terminal strips. This cover incorporates an O-ring to form
the seal against the environment. The ¼ inch bolts used to hold
the cover on should be torqued to 120 lb·in to ensure the proper
pressure on the O-ring.
Each motor should be equipped with either a hand wheel or a motor
cover on the back end of the motor. These items are equipped with
an O-ring to make sure the motor is sealed from any elements. If
the back end of the motor is left unsealed, water or other elements
may cause damage to the motor or wire terminals.
3172 Electronics
The Electrical Sub Assembly (ESA) of the REXA actuator, although
typically remote mounted from the MSA, is also rated for outdoor
use. The standard steel enclosure is rated NEMA 4 (protection
against rain, snow and hose directed water). When properly
installed your ESA should give you years of weather tight operation.
The closing mechanism on the ESA is a single point quarter turn
latch that requires the use of a tool for opening. When properly
X2 Troubleshooting and Repair Manual
Troubleshooting – 06/10 111
closed the cover is compressed against the gasket to form a seal
against the environment.
All electrical connections to the ESA should be made at the gland
plate found at the bottom of the enclosure. The gland plate can be
removed, drilled for the different entry points, and then re-installed
with the gasket in place. When installing conduit fttings both local
and National Electrical Code (NEC) must be complied witih to
ensure proper installation and sealing.
WATER INGRESS
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 113
4.E. Electrical Repair
4E1 GROUND LOOPS
4E11 What is a Ground Loop?
A Ground Loop can be present in a system when points nominated
as Grounds are at different potentials, and there is more than one
electrical path connecting these Grounds, and signal lines are
connected in such a way that circulating ground currents are able to
fow through one or more signal conductors.
The resulting current that fows in the loop can be very large — in
extreme cases hundreds of amps — but is more commonly less
than 500 mA. The voltage drop along the wire that is part of the
measurement circuit is impressed on the signal voltage thus causing
the error. Because this current is variable, it cannot be "calibrated
out."
4E12 Why Ground Anyway?
Three reasons for grounding measurement systems:
● The frst is safety. Should a high voltage accidentally come
into contact with the measurement system, the measure-
ment system would become dangerous. A grounded
114 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
GROUND LOOPS
measurement system would cause a fuse to "open" thus
rendering the system safe.
● The second reason for grounding is to ensure the measuring
system is operating within its operating voltage range. If the
system were not grounded, the system could be charged to
high voltage levels by static electricity or insulation leakage.
At some point, the system's insulation would break down,
possibly causing measurement errors in the process.
● A third reason grounds may be introduced into a system
is due to sensor needs. For example, to obtain the best
possible thermal contact and response time, a thermocouple
may be welded to the object of interest — hence grounding
the thermocouple. Another example is the pH electrode — it
is in electrical contact with the fuid being measured.
4E13 Solutions (or a Single Ground is a Good Ground)
1 Eliminate the loop
The simplest and most effective method to avoid ground
loop problems is to ensure the measurement system is
connected to a single ground point. Eliminate the loop.
However, this is not always possible as sensors must some-
times be grounded; communications links with computers
introduce additional grounds, or electrical safety demands
multiple grounds. But there are solutions:
2 Use Differential Inputs
The use of differential inputs (as opposed to single ended
inputs) is effective in overcoming ground loop errors as no
current passes down the two measurement wires. However,
differential inputs are only as good as their common mode
rating. If the ground voltage difference exceeds the rating
the errors will be introduced.
3 Shield Grounds
If shielded wires are used, the shielding should be grounded
at one end of the cable only, preferably the measurement
system end. If grounded at both ends, ground current will
fow through the shield and inductively induce noise into
the signals wires (which should be twisted to minimize this
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 115
GROUND LOOPS
effect). Also, it is possible that injecting the loop current
into the shield connection points may cause errors in the
measuring device or the sensor.
4 Isolation at the sensor
If possible, electrically isolate all the wiring associated with
the sensor from the area in which the sensor is installed.
This may need to include power supplies. The preferred
grounding point is at the measuring device.
Sometimes it is not possible to isolate the sensors or its
wiring. In these cases it is necessary to isolate at the
measuring device by providing a fully isolated input for that
sensor. If there is only one such sensor in the system, it
may be possible to use its ground as the system's ground.
5 Isolation at the measuring device input
Providing isolation at each of the measuring device's inputs
is the best but most expensive solution. Typically such
isolation will double the equipment cost. Also, isolation has
its limitations — speed and accuracy are often sacrifced to
contain the costs.
6 Isolation at the measuring device output
In small systems a cost effective solution is to provide
isolation at the measuring devices output interface such as
RS232, Ethernet, USB or modem.
7 Isolation (foating) of the measuring device
An unconventional but occasionally practical method of
isolation in a small setup is to isolate the entire measuring
device by allowing it to operate off batteries. The method
can provide almost any level of isolation required, but if used
to isolate very high voltages, extreme care must be taken
against forgetful contact.
The simple rule still applies — a single ground is a good ground.
Sometimes you may have no choice where the ground may be
placed (as with a grounded thermocouple grounded for good thermal
contact and response time), but remove ALL other grounds.
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GROUND LOOPS
4E14 Causes of Ground Potential Differences
Understanding the cause of ground potential differences can be of
some help in minimizing their impact on the measuring system and
also in negating effects such as corrosion.
● Electric trains and trams —
Electric traction systems often use the tracks as a the return
path for the current drawn from overhead power lines.
● Ground returns in electrical power systems
● Ground returns in marine power plants
● Lightning strike
● Galvanic corrosion prevention systems
● Inductively induced currents
Figure 4.E.1.4 Ground Loop
4E15 Ground loops and REXA Equipment
● Related to signal wires (Feedback, pressure transmitter)
● Earth ground connection between actuator and electronics
● Signs of ground loop problems:
– Noisy/unstable feedback, control or pressure transmit-
ter signal
– High voltage measurement between Earth Ground
and Neutral conductors at the control enclosure power
input.
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 117
GROUND LOOPS
4E16 What fxes a ground loop?
Typically, a ground loop is fxed by cleaning up the interconnecting
wiring to have:
● Shields terminated at ONE end of the cable only
● Shields connected to the backplane of the electronics
enclosure
● AC Ground from the AC source brought to the control enclo-
sure and actuator rather than ground to building steel only
● Good earth ground connections
● Trial and error… ground loops can be diffcult to solve and
require patience and thorough site evaluation. Every instal-
lation is different; take it one step at a time
118 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E2 COMPONENT REPLACEMENT
CAUTION: MAKE SURE THE UNIT
IS TURNED OFF AND POWER IS
DISCONNECTED BEFORE REPLACING
ANy COMPONENTS!
Note: Assumed starting position is facing the upright
electronic unit with the enclosure door open.
STANDARD AND CSA B/C-PUMP CONTROL ENCLOSURE
Figures 4.E.2-1&2 Standard and CSA
B/C-Pump Control Enclosure
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 119
Figures 4.E.2-3&4 D-Pump Control Enclsure
D-PUMP CONTROL ENCLOSURE
120 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
Figures 4.E.2-5&6 1/2D-Pump Control Enclsure
1/2 D-PUMP CONTROL ENCLOSURE
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 121
Figures 4.E.2-7&8 2D-Pump Control Enclsure
2D-PUMP CONTROL ENCLOSURE
122 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E3 POWER SUPPLy ASSEMBLy
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Figure 4.E.3-1 Stepper Power Supply Assembly
Photo 4.E.3-1
Power Supply Assembly
(Stepper)
POWER SUPPLy ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 123
Figure 4.E.3-2 Servo Power Supply Assembly
4E31 REMOVAL
1. Remove the CPU board per TS&R section 4E41.
2. Remove the wires from the green connector at the top left of
the Power Supply, TB5.
Figure 4.E.3.1-1 TB5 Power Supply
3. Remove the AC power wires from the “Power In/Motor
Power” terminal, TB1.
POWER SUPPLy ASSEMBLy
124 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
Figure 4.E.3.1-2 TB1 Power Supply
4. Remove any Motor wires that may be connected into the
“Motor In” terminal, TB3.
Figures 4.E.3.1-3,4 TB3 “Motor In” Terminal
POWER SUPPLy ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 125
5. Remove any Resolver wires that may be connected to the
“Motor Resolver” terminal, TB7.
Figure 4.E.3.1-5 TB7 “Motor Resolver” terminal
6. Remove any wires that may be connected to TB2 and TB3.
Figure 4.E.3.1-6 TB2 & 3
POWER SUPPLy ASSEMBLy
Note: All mounting hardware and
wires that were removed will be
required for the replacement of the
power supply.
126 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
7. Remove the Screws (6-32 x 0.25”) and Standoffs (6-32 x
1.75" with 6-32 x 0.625") used to secure the power supply,
the standoffs will require a ¼ nut driver for removal. Make
sure all wires have been removed from the power supply.
Remove the power supply from the control enclosure.
Figure 4.E.3.1-7 Power Supply and “Standoffs”
POWER SUPPLy ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 127
4E32 REPLACEMENT
1. Install the replacement power supply using the 6-32 x 0.5"
standoffs mounted to the control enclosures panel. Use the
Screws (6-32 x 0.25") and the Standoffs (6-32 x 1.75" with
6-32 x 0.625") that were removed from the old power supply.
Figure 4.E.3.2-1 Power Supply placement
2. Reconnect the motor cable wires to the “Motor In” terminal
on the power supply, TB3.
Figure 4.E.3.2-2,3 TB3 motor cable wire connections
POWER SUPPLy ASSEMBLy
128 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
3. Reconnect the AC power wires to the “Power In/Motor
Power” terminals, TB1.
4. Reconnect the DC power wires to TB5.
5. Reconnect any Resolver wires to the “Motor Resolver”
terminal TB7.
6. Reconnect any wire that may have been connected to
terminal TB2 and TB8.
7. Replace the CPU board per TS&R section 4E42.
POWER SUPPLy ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 129
4E4 CPU ASSEMBLy
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.
Figure 4.E.4 CPU Assembly drawing
CPU ASSEMBLy
130 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E41 Removal
1. Remove the Ribbon Cable connected to the “To Display
Interface” connector, Location P7.
Figure 4.E.4.1-1 P7, TB2 Ribbon Cable & Wire Connections
2. Remove the DC Power wires connected to the “Power In”
connector, Location TB2.
3. Remove any Stepper Driver Logic wiring connected to Loca-
tion TB3 (Stepper Units Only).
Figure 4.E.4.1-2 TB3, Stepper Driver Wiring
CPU ASSEMBLy
Photo 4.E.4.1-1
Ribbon connection
Photo 4.E.4.1-2
TB2 connections
Photo 4.E.4.1-3
TB3 connections
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 131
4. Remove any Servo Driver Logic wiring connected to the
“Standard Motor” connector, Location TB6 (Servo Units
Only).
5. Remove any Booster Driver Logic wiring connected to the
“Booster Motor” connector, Location TB7 (Booster Units
Only).
6. Remove the DC Power wires connected to Location TB8.
Figure 4.E.4.1-3 TB6, TB7 & TB8 Wire Connections
CPU ASSEMBLy
132 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
7. Make a note of all wires that are connected to Location TB1,
write the location of each wire down if necessary. Remove
all wires connected to TB1.
Figure 4.E.4.1-4 TB1 Wire Connections
Photo 4.E.4.1-4
TB1 Connections Terminal
CPU ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 133
8. Make a note any wires that may be connected to Locations
TB4 & TB5, write the location of each wire down if neces-
sary. Remove all wires connected to TB4 & TB5.
9. Remove the 6-32 x 0.25" Phillips head screws (8 pcs.) that
mount the CPU. This hardware will be required for installing
the new CPU Board.
Figure 4.E.4.1-5 Screw Location, CPU Board
10. Remove the CPU.
CPU ASSEMBLy
134 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E42 Replacement
1. Install the replacement CPU Board to the Standoffs using
the 6-32 x 0.25" hardware removed from the old CPU Board.
Figure 4.E.4.2-1 Screw Location, CPU Board
2. Reconnect the Ribbon Cable to the “To Display Interface”
connector, Location P7. The Red Stripe on the Ribbon
Cable should be oriented to Pin 1 at connector P7.
Figure 4.E.4.2-2 Cable to P7 and TB2 wire connections
CPU ASSEMBLy
Photo 4.E.4.2-1
Ribbon Connector
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 135
3. Reconnect the DC Power wires to the “Power In” connector,
Location TB2.
4. Reconnect any Stepper Driver Logic wiring that was con-
nected to Location TB3 (Stepper Units Only).
Figure 4.E.4.2-3 TB3 connections drawing
5. Reconnect any Servo Driver Logic wiring to the “Standard
Motor” connector, Location TB6 (Servo Units Only).
6. Reconnect any Booster Driver Logic wiring to the “Booster
Motor” connector, Location TB7 (Booster Units Only).
7. Reconnect the DC Power wires to Location TB8.
Figure 4.E.4.2-4 Connections to TB6, TB7 & TB8 drawing
CPU ASSEMBLy
Photo 4.E.4.2-2
DC Power Connections
Photo 4.E.4.2-3
TB3 connections
136 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
8. Reconnect all wires that were removed from Location TB1.
Figure 4.E.4.2-5 CPU connections at TB1
CPU ASSEMBLy
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 137
Photo 4.E.5.1-1
TB2 Contact Wires
4E5 CONTACT IN / RELAy OUT ASSEMBLy
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.
Figure 4.E.5 Contact In/Relay out board drawing
4E51 Removal
1. Remove the wires connected to location TB2.
Figure 4.E.5 .1-1 TB2 wiring drawing drawing
CONTACT IN / RELAy OUT ASSEMBLy
Photo 4.E.5
Contact Board
138 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
2. Remove any other wires that may be screwed into the
contact boards terminals, and note their location for later
replacement.
Figure 4.E.5.1-2 TB3, TB1 & TB6 drawing
3. Remove any Jumpers installed at locations TB3, TB1 &
TB6; make a note of their location as these jumpers will be
required for the new board.
Figure 4.E.5.1-3 Jumper location drawing
CONTACT IN / RELAy OUT ASSEMBLy
Photo 4.E.5.1-2
Jumper locations
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 139
4. Remove the 6-32 x 0.25" Phillips head screws (6 pcs.) that
secure the Contact board. This hardware will be required for
installing the replacement board.
Figure 4.E.5.1-4 Screw location drawing
5. Unplug the 24-pin female connector on the contact board
(location P1) from the 24-pin male connector on the CPU
board (location P1). Tag the board as defective and com-
pletely remove from the control enclosure.
Photo 4.E.5.1-3
Board removal
CONTACT IN / RELAy OUT ASSEMBLy
140 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E52 Replacement
1. Secure the replacement board to the mounting Standoffs
using the 6-32 x 0.25" Phillips head screws (6 pcs.). Be
sure to line up connector P1 on the Contact board with
connector P1 on the CPU.
Figure 4.E.5.2-1 Screw placement drawing
2. Replace any 2 Position Jumpers removed from locations
TB3, TB1 & TB6. Refer to any notes taken during the
removal process.
Figure 4.E.5.2-2 TB3, TB1 & TB6 locations
CONTACT IN / RELAy OUT ASSEMBLy
Photo 4.E.5.2-1
Contact board placement
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 141
3. Reconnect the wires that were installed at location TB2.
Figure 4.E.5.2-3 TB2 connection drawing
4. Refer to your notes and reconnect any additional wires that
may have been installed to the Contact Board.
Figure 4.E.5.2-4 Contact In/Relay out drawing
CONTACT IN / RELAy OUT ASSEMBLy
Photo 4.E.5.2-2
TB2 Wiring connections
142 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E6 STEPPER MOTOR DRIVE (STD B&C)
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.
4E61 Removal (STD B&C)
1. Disconnect the AC Power connector (Left), the Motor Power
connector (Middle) and the Driver Logic connector (Right).
Figure 4.E.6.1-1 Standard B/C power connections drawing
2. Locate the four driver mounting screws and nylon washers
on the top of the control enclosure. Remove this hardware
using a 1/8" Allen wrench. This hardware will be required
to install the replacement driver. Tag the driver as defective
and completely remove from control enclosure.
Figure 4.E.6.1-2 Mounting screw location
STD B/C STEPPER MOTOR DRIVER
Photo 4.E.6.1-1
Stepper Motor Drive
Photo 4.E.6.1-2
Motor Connectors
Photo 4.E.6.1-3
Enclosure mounting screws
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 143
4E62 Replacement (STD B&C)
1. Apply a thin layer of thermal coat to the back of the driver.
2. Mount the replacement driver to the top of the control
enclosure using the four screws and nylon washers that
were removed from the defective driver.
Figure 4.E.6.2-1 Mounting screw location
a.) Plug the AC Power (left), Motor Power (middle) and
Driver Logic (right) connectors into the driver in their
respective locations.
Figure 4.E.6.1-1 Standard B/C power connections drawing
STD B/C STEPPER MOTOR DRIVER
Photo 4.E.6.2-3
Stepper Motor Drive
Photo 4.E.6.2-1
Thermal Coat
Photo 4.E.6.2-2
Mounted Driver
144 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E7 CSA B STEPPER DRIVER
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.
4E71 Removal
1. Locate the B CSA Driver and disconnect the motor cable from
location P1.
Figure 4.E.7.1-1 CSA B stepper driver drawing
2. Locate the four driver mounting screws and nylon washers
on the top of the control enclosure. Remove this hardware
using a 1/8" Allen wrench. This hardware will be required
to install the replacement driver. Tag the driver as defective
and completely remove from control enclosure.
CSA B STEPPER MOTOR DRIVE
Photo 4.E.10.
CSA B stepper motor in enclosure
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 145
Figure 4.E.7.1-2 Mounting diagram
4E72 Replacement
1. Apply a thin layer of thermal coat to the driver mounting
plate.
2. Mount the replacement driver to the top of the control
enclosure using the four screws and nylon washers that
were removed from the defective driver.
Figure 4.E.7.2-1 Mounting diagram
3. Reconnect the Motor cable to location P1 on the Driver.
CSA B STEPPER MOTOR DRIVE
Photo 4.E.7.1-2
CSA B exterior mounting
146 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
Figure 4.E.7.2-2 CSA B stepper driver drawing
CSA B STEPPER MOTOR DRIVE
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 147
4E8 CSA C STEPPER MOTOR DRIVE
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E81 Removal
1. Disconnect the power connector (Left), the motor connector
(Middle) and the logic connector (Right).
Figure 4.E.8.1-1 Power connections drawing
2. Locate the four driver mounting screws and nylon washers
on the top of the control enclosure. Remove this hardware
using a 1/8" Allen wrench. This hardware will be required
to install the replacement driver. Tag the driver as defective
and completely remove from control enclosure.
Figure 4.E.8.1-2 Enclosure mounting drawing
CSA C STEPPER MOTOR DRIVE
Photo 4.E.8.1-3
Mounting screws
Photo 4.E.8.1-2
Cables disconnected
Photo 4.E.8.1-1
Power connections
148 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E82 Replacement
1. Apply a thin layer of thermal coat to the bottom of the driver.
2. Mount the replacement driver to the top of the control
enclosure using the four screws and nylon washers that
were removed from the defective driver.
Figure 4.E.8.2-1 Enclosure mounting location
3. Plug the AC Power (left), Motor Power (middle) and Driver
Logic (right) connectors into the Driver in their respective
locations.
Figure 4.E.8.2-2 Cable connections
CSA C STEPPER MOTOR DRIVE
Photo 4.E.8.2-1
Therma coat
Photo 4.E.8.2-2
Stepper motor attached
to enclosure
Photo 4.E.8.2-3
Cables connected
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 149
4E9 1/2 D, D SERVO MOTOR DRIVE
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.
Figure 4.E.9-1 Servo Motor Driver
Photo 4.E.9-1 Servo Motor Driver
SERVO MOTOR DRIVE
150 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E91 Removal
1. Cut away any wire ties that may be securing any cables to
the tie down bases applied to the Servo Driver.
Figure 4.E.9.1-1 Tie down bases
2. Disconnect the “Controller I/O” and “Resolver Feedback”
cables by loosening the two thumb screws on each cable.
Unplug the “Motor Output” connector and remove the Green/
Shield wire from the ground Screw. Unplug the “AC Input”
connector.
Figure 4.E.9.1-2 Servo drive cable connections
SERVO MOTOR DRIVE
Photo 4.E.9.1-1
Cable tie downs
Photo 4.E.9.1-2
Servo drive cable connections
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 151
3. Remove the four 8-32 x 0.50" Philips head screws securing
the Driver to the panel. This hardware will be required to
install the replacement drive. Tag the Driver as defective
and completely remove from the control enclosure.
Figure 4.E.9.1-3 Servo driver & panel drawing
4E92 Replacement
1. Secure the replacement Driver to the panel using the 8-32
x 0.50" Phillips head screws removed from the defective
driver.
Figure 4.E.9.2-1 Servo driver & panel drawing
SERVO MOTOR DRIVE
Photo 4.E.9.1-3
Mounting screws
Photo 4.E.9.2-1
Screw placement
152 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
2. Reconnect the “Resolver Feedback” and “Controller I/O”
cables. Plug in the “Motor Output” connector and secure
the Green/Shield wire to the ground screw. Plug in the “AC
Input” connector.
Figure 4.E.9.2-2 Servo Motor Drive Connections
SERVO MOTOR DRIVE
Photo 4.E.9.2-2
Servo Motor Drive Connections
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Electrical Repairs – 06/10 153
4E10 VFD DISPLAy ASSEMBLy (EXTERNAL)
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.*
4E101 Removal of the External VFD Display:
The External Display Assembly is mounted to the cover of the
control enclosure.
1. Disconnect the Ribbon Cable from the Display Interface
connector P1.
2. Remove the 10 screws that secure the External Display to
the enclosure’s cover.
3. Tag the Display as defective and completely remove it from
the cover of the control enclosure.
Figure 4.E.10.1-1 VFD Removal Drawing
EXTERNAL VFD DISPLAy
Photo 4.E.10
VFD Display
Photo 4.E.10.1-1
Ribbon Cable Position
Photo 4.E.10.1-2
Screw Removal
154 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E102 Replacement of the display assembly:
1. Apply the gasket to the bezel then place thru the cut-out
on the outside of the enclosure cover. Secure the Keypad
mounting plate assembly to the bezel using the hardware
provided.
2. Connect the ribbon cable to the back of the display assem-
bly location P1. The red stripe on the ribbon cable should
be orientated to pin 1 on connector P1.
Figure 4.E.10.2-1 VFD Replacement Drawing
Photo 4.E.10.2-3
Connected VFD Display
EXTERNAL VFD DISPLAy
Photo 4.E.10.2-1
Bezel & display (front view)
Photo 4.E.10.2-2
Bezel & display (back view)
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 155
4E11 VFD DISPLAy ASSEMBLy (INTERNAL)
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.*
Figure 4.E.11-1 Internal VFD Display Assembly Drawing
4E111 Removal of the Internal Display Assembly
1. Disconnect the ribbon cable from connector P1 of the
Display Interface Board.
2. Remove the six 6-32 x 0.25" screws used to secure the
Display Interface Board.
3. Tag this Board assembly as defective and completely
remove from control enclosure.
Figure 4.E.11.1-1 Internal VFD Removal Drawing
INTERNAL VFD DISPLAy
Photo 4.E.11.1-1
Ribbon Cable
Photo 4.E.11-1
VFD Display Assembly
Photo 4.E.11.1-2
Mounting Screws
Photo 4.E.11-2
Internal Display Interface
156 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4 Remove the Internal Display Mounting Bracket from the
CPU Board by removing the three 6-32 x 0.375" screws.
Figure 4.E.11.1-3 VFD Removal Drawing
4E112 Replacement of the Display Assembly:
1. Secure the Internal Display Mounting Bracket to the CPU
Board. The Bracket will be secured to three of the four
Standoffs using the 6-32 x 0.375" screws provided. Install
the 6-32 x 0.375" standoffs to the Bracket in the 6 places
shown below.
Figure 4.E.11.2-1 VFD Replacement Drawing
INTERNAL VFD DISPLAy
Photo 4.E.11.1-3
Mounting Bracket
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Electrical Repairs – 06/10 157
2. Install the 6-32 x .5625 standoffs into the front side of the
Display Interface Board; secure the standoffs using 6-32
Hex Nuts in the 4 places shown below. Secure the Display
Interface Board to the six standoffs installed on the Mounting
Bracket using 6-32 x 0.25" screws provided.
Figure 4.E.11.2-2 VFD Replacement Drawing
3. Reconnect the Ribbon Cable to connector P1 on the Display
Interface Board. Ensure the red stripe on the ribbon cable
is orientated to Pin 1. Secure the VFD Display Board to the
four standoffs installed on the Display Interface Board using
the 6-32 x .25” screws provided. Ensure that the 14 pin fe-
male connector on the VFD Display Board seats properly on
the 14-pin male connector on the Display Interface Board.
Figure 4.E.11.2-4 VFD Replacement Drawing
INTERNAL VFD DISPLAy
Photo 4.E.11.2-1
Internal VFD Diplay Assembly
Photo 4.E.12.2-2
Internal VFD Diplay Assembly
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4E12 REPLACING SURGE SUPPRESSOR
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
Note: Assumed starting position is facing the upright electronic unit
with the enclosure door open.*
CONTROL SIGNAL SURGE SUPPRESSOR
4E121 Removal of Control Signal Surge
Suppressor (Photo 4E121-1):
1. Disconnect output wires from the Suppressor. (Photo
4.E.12.1-2)
2. Using a long length fat screwdriver, reach down into the
enclosure and place the fat head into the release latch on
the Suppressor. (Photo 4.E.12.1-3)
3. Pull the screw driver downward to release the latch and the
Suppressor should pop up off of the Din Rail. (Photo 4.E.12.1-4)
4. You can now remove the Suppressor. (Photo 4.E.12.1-5)
Photo 4.E.12.1-4
Suppressor Released
Photo 4.E.12.1-5
Suppressor Removed
Photo 4.E.12.1-2
output Wires
Photo 4.E.12.1-3
Release Latch
SURGE SUPPRESSOR
Photo 4.E.12.2-1
Replacement Suppressor
Photo 4.E.12.1-1
Signal Surge Suppressor
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Electrical Repairs – 06/10 159
4E122 Replacement of Control
Signal Surge Suppressor:
1. Locate the replacement Suppressor. (Photo 4.E.12.2-1)
2. Place the Suppressor into position between the two end stops
and snap it into place on the DIN Rail. (Photo 4.E.12.2-2)
3. Replace the wires into their respective locations and screw
them in. (Photo 4.E.12.1-2)
4. The Control Signal Surge Suppressor is now replaced.
Photo 4.E.12.2-2
Position Suppressor
Photo 4.E.12.2-3
Suppressor Replaced
AC SURGE SUPPRESSOR
(STD B, C, 1/2D, D, 2D, DP9, DP40)
4E123 Removal of the AC Surge Suppressor:
1. Make sure that the power to the unit is off. Open the fuse
holder to ensure that no power comes on while you are
working on the unit. (Photo 4.E.12.3-1)
2. Locate the AC Power Surge Suppressor. (Photo 4.E.12.3-2)
3. Unscrew the power input wires from the Surge Suppressor.
(Photo 4.E.12.3-3)
Photo 4.E.12.3-3
Input wires
Photo 4.E.12.3-2
AC Power Surge Suppressor
SURGE SUPPRESSOR
Photo 4.E.12.3-1
Fuse
160 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
HART® INTERFACE
4. Unscrew the power output wires from the Surge Suppressor.
(Photo 4.E.12.3-4)
5. Now all power wires are removed from the Surge Suppres-
sor. (Photo 4.E.12.3-5)
6. Place a long, narrow fat head screw driver in the release
latch of the Surge Suppressor. (Photo 4.E.12.3-6)
7. Push down and towards the Suppressor to release it from
the Din Rail.
8. Remove the Surge Suppressor.
9. The AC Power Surge Suppressor is now removed. (Photo
4.E.12.3-7)
Photo 4.E.12.3-7
Unit with AC Surge
Suppressor removed
Photo 4.E.12.3-6
Release latch
Photo 4.E.12.3-4
output wires
Photo 4.E.12.3-5
All power wires removed
4E124 Replacement of the AC Power Surge Suppressor:
1. Locate the replacement Surge Suppressor. (Photo 4.E.12.4-
1)
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 161
2. Screw the 3 power input wires back into the Surge Suppres-
sor. (From left to right: Blue, Green (GND), Brown) (Photo
4.E.12.4-2)
3. Screw the 3 power output wires into the Surge Suppressor.
(From left to right: Blue, Green (GND), Brown)
(Photo 4.E.12.4-2)
4. The power wires are now reconnected.
5. The Surge Suppressor is now replaced.
6. Close the fuse block (Photo 4.E.12.3-1) and return power to
the unit. If the unit powers up normally, the Surge Protector
was successfully replaced.
Photo 4.E.12.4-1
AC Surge Suppressor
Photo 4.E.12.4-2
Input and output wires
HART® INTERFACE
162 REXA X2 Series TS&R Manual
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4E13 REPLACING HART® INTERFACE
ASSEMBLy (S97695)
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E131 Removal of the Hart Interface
Assembly (See Photo 4E131-1)
1. Remove the Control Signal wires from the board. (Photo
4.E.13.1-2) These wires are gray and gray/white and are
screwed into the two terminals (CS- & CS+) on top of the
board. (Photo 4.E.13.1-3)
Photo 4.E.13.1-3
Terminals CS- and CS+
Photo 4.E.13.1-2
Control signal wires
2. Unscrew these terminals and remove the wires.
3. Remove the Phillips head mounting screws from the four
corners of the Hart board and set aside for mounting the
replacement. (Photo 4.E.13.1-4)
Photo 4.E.13.1-5
Removal from standoffs
and CPU pins
Photo 4.E.13.1-4
Mounting screws
HART® INTERFACE
Photo 4.E.13.1-1
HART interface assembly
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 163
4. Lift the Hart board up to remove it from the standoffs and to
disconnect it from the CPU pins. (Photo 4.E.13.1-5) It may
be necessary to wiggle the board forward and back slightly
while lifting in order to make its removal easier.
5. The Hart Interface Assembly is now removed. (Photo
4.E.13.1-6)
Photo 4.E.13.2-1
Hart interface board
Photo 4.E.13.1-6
Hart interface board removed
4E132 Replacement of the Hart Interface Assembly:
1. Locate the replacement board. Make sure that your replace-
ment board has been pre-programmed before you install it.
(Photo 4.E.13.2-1)
2. Place the Hart board on top of the CPU board. The con-
nector on the bottom of the board should match up perfectly
with the pins on the CPU board. (Photo 4.E.13.1-5)
3. Firmly push the board down so that it rests on the 4 stand-
offs at the corners. (Photo 4.E.13.2-2)
4. Secure the Hart board to the standoffs with the 4 screws set
aside during removal. (Photo 4.E.13.1-4)
5. Reconnect the control signal wires. Place the gray/white
wire under the ‘CS+’ terminal and turn the screw to clamp
the wire in. Place the gray wire under the ‘CS-’ terminal and
turn the screw to clamp the wire in.
6. Return power to the unit and check for proper functionality.
HART® INTERFACE
Photo 4.E.13.2-2
Hart board on standoffs
164 REXA X2 Series TS&R Manual
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4E14 REPLACING FIELDBUS ASSEMBLy
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E141 Removal of the Foundation
Fieldbus Assembly (Photo 4E141-1)
Photo 4.E.14.1-1
Foundation Fieldbus Assembly
1. Remove the signal wires coming from the Foundation
Fieldbus that are screwed into the Signal Input terminal
(unlabeled) (Photo 4.E.14.1-2).
2. Using a small fat-head screwdriver unscrew the wires from
the terminal.
3. Unscrew the entire assembly from the CPU mounted
standoffs setting aside the 4 Phillips-head screws to be used
in the replacement. (Photo 4.E.14.1-3,4).
4. Slowly remove the assembly from the CPU by pulling
upwards.
5. It may be necessary to wiggle the assembly up and down
while pulling in order to ensure that the pins on the top of the
CPU and the connector on the bottom of the assembly aren’t
bent or damaged. (Photo 4.E.14.1-5).
FOUNDATION FIELDBUS
Photo 4.E.14.1-2
Signal Wires
Photo 4.E.14.1-3
Mounted Standoffs
Photo 4.E.14.1-4
Mounting Screws
Photo 4.E.14.1-5
CPU pins
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 165
4E142 Replacement of the Foundation
Fieldbus Assembly (Photo 4E142-1)
Photo 4.E.14.2-1
Foundation Fieldbus
1. Ensure that the power is off to the unit and the Foundation
Fieldbus.
2. Carefully place the replacement assembly on top of the CPU
and standoffs, being sure to properly line up the pins on
the CPU and the connector on the bottom of the Fieldbus
Assembly. (Photo 4.E.14.2-2)
3. Firmly press the assembly down so that it is seated atop the
standoffs and is snugly ftted with the pins.
4. Mount the assembly to the standoffs. Using the 4 Phillips-
head screws that had been set aside, screw them into the
four corners of the assembly and into the threaded standoff
holes. (Photo 4.E.14.2-3)
5. Connect the two signal wires. These wires are non-polar,
so it makes no difference which wires you screw into which
terminal as long as one wire goes into each terminal. (Photo
4.E.14.1-2)
6. Return power to the electronics unit and to the Foundation
Fieldbus.
FOUNDATION FIELDBUS
Photo 4.E.14.2-2
Pins
Photo 4.E.14.2-3
Threaded standoff holes
166 REXA X2 Series TS&R Manual
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4E15 REPLACING EMI / RFI FILTER
Photo 4.E.15
EMI/RFI Filter, bracket & wires
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E151 Removal of the Filter:
1. Pull the fuse holder open to make sure that no power goes
to the unit while it is being serviced. (Photo 4.E.15.1-1)
2. Locate the Filter and remove the power input wires to the
Filter. Needle nose pliers may be needed to remove the
connectors, as the connections are very secure. (Photo
4.E.15.1-2)
Photo 4.E.15.1-2
Detached input wires
Photo 4.E.15.1-1
open fuse holder
3. Remove the power output wired to the Filter. Again, use
needle nose pliers if necessary. (Photo 4.E.15.1-3)
EMI / RFI FILTER
Photo 4.E.15.1-3
Detached output wires
Photo 4.E.15.1-5
Bracket, flter removed
Photo 4.E.15.1-4
Bracket screw removal
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 167
4. Use a fat head screwdriver to remove the two screws that
mount the Filter to the bracket. Set the screws aside for the
replacement process. (Photo 4.E.15.1-4)
5. Remove the Filter. (Photo 4.E.15.1-5)
4E152 Replacement of the Filter:
1. Use the mounting screws, mount the replacement Filter to
the bracket. (Photo 4.E.15.1-4,5)
2. Reconnect the 3 power input wires to the right side of the
flter. The Green/Yellow (GND) wire connects to the left pin,
The Blue (Neutral) wire connects to the top right pin and the
Brown (Line) wire connects to the bottom right pin. (Photo
4.E.15.2-1)
3. Give the wires a light tug to make sure the connections are
secure.
4. Reconnect the 2 power output wires to the left side of the
flter. The Blue (Neutral) wire connects to the top pin and
the Brown (Line) wire connects to the bottom pin. (Photo
4.E.15.2-2)
5. The flter replacement is complete (Photo 4.E.15.2-3); close
the fuse holder (Photo 4.E.15.1-1) and return power to the
unit.
6. If the unit starts up and initializes properly the replacement is
complete.
Photo 4.E.15.2-3
Complete Filter replacement
EMI / RFI FILTER
Photo 4.E.15.2-1
Three power input wires
Photo 4.E.15.2-2
Two power output wires
168 REXA X2 Series TS&R Manual
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4E16 REPLACING REMOTE
MOUNTED FEEDBACK BOARD
Photo 4.E.16
Feedback Board
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E161 Removal of Feedback Board
1. Using a small fat head screwdriver, remove the feedback
wires (White, Red & Black) from the Feedback Board
terminals TB1 & TB2. (Photo 4.E.16.1-1,2)
Photo 4.E.16.1-1
Feedback wires at TB1 & TB2
Photo 4.E.16.1-2
Feedback Board wires removed
2. Locate and remove the 2 Phillips head screws used to
mount the Feedback Board to the mounting plate. (Photo
4.E.16.1-3)
3. Set these screws aside, as they will be needed to mount the
replacement Feedback Board.
4. Remove the Feedback Board from the mounting plate.
(Photo 4.E.16.1-4)
REMOTE MOUNTED FEEDBACK BOARD
Photo 4.E.16.1-3
Feedback mounting screws
Photo 4.E.16.1-4
Feedback mounting plate
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 169
4E162 Replacement of Feedback Board
Photo 4.E.16.2-1
Feedback Board
1. Using the screws that were previously set aside, mount
the new Feedback Board to the mounting plate. (Photo
4.E.16.1-4)
2. Using the small fat head screwdriver, screw the wires into
their respective locations. The wires from the CPU screw
into Feedback Board terminal TB2 and the wires from the
actuator screw into terminal TB1.
Note: The labels on the terminals dictate which wire goes to which
terminal. (W-White, R-Red & B-Black) (Photo 4.E.16.2-2)
3. Power up the unit and check the display to make sure it
does not read a feedback error (Fb bad).
4. The Feedback Board is now successfully replaced.
Photo 4.E.16-2
Feedback Board reconnected
REMOTE MOUNTED FEEDBACK BOARD
170 REXA X2 Series TS&R Manual
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4E17 REPLACING FUSES (SINGLE
POLE, DOUBLE POLE, 3 PHASE)
Photo 4.E.17-1
Single pole 120 Vac
Photo 4.E.17-2
Double pole 240 Vac
Photo 4.E.17-4
CE approved Single pole 120 Vac
Photo 4.E.17-3
3-phase 240+ Vac
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E171 Removal of a Fuse
1. Locate and pull open the fuse holder to reveal the fuse(s)
inside and note its placement in the holder. (Photos
4.E.17.1-1, 2, 3, 4)
Note: The placement of the fuse(s) differs. With a Bussman fuse holder
the fat end of the fuse will go in frst and the nipple end will be facing out.
With a Ferraz Shawmut fuse holder the nipple end goes in frst and the
fat end is facing out. If the fuse in use is CE Approved, both ends will be
fat and it may be inserted either way. (Photos 4.E.17.1-1,2,3,4)
2. Remove the fuse(s) from the fuse holder. It may sometimes
be necessary to use needle nose pliers or a similar tool to
remove the fuse
FUSES
Photo 4.E.17.1-4
open CE single pole
Photo 4.E.17.1-3
open 3-phase
Photo 4.E.17.1-2
open double pole
Photo 4.E.17.1-1
open single pole
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 171
3. Note the amperage before discarding the spent fuse.
Ensure that the replacement fuse(s) are of the same amper-
age and voltage rating. Do not confuse the spent fuse with
the functioning replacement fuse.
4E172 Replacement of a Fuse
1. Locate and ensure that the amperage and voltage ratings
are the same as the fuse that is being replaced.
2. Position the replacement fuse in the holder the same way
that the previous fuse was installed. (See Photo 4.E.17.1-1,
2 & 3.)
3. Close the fuse holder. (See Photo 4.E.17.2-2, 3 & 4.)
4. Return power to the unit.
5. If the unit powers up properly then the fuse replacement
was successful and is now complete.
Photo 4.E.17.2-1
Fuse
Photo 4.E.17.2-2
Fuse insertion
Photo 4.E.17.2-3
Fuse placement
Photo 4.E.17.2-4
Completed fuse replacement
FUSES
172 REXA X2 Series TS&R Manual
Electrical Repairs (06/10)
4E18 REPLACING EXTERNAL SWITCH
Photo 4.E.18
External switches
CAUTION: MAKE SURE THE UNIT IS TURNED
OFF AND POWER IS DISCONNECTED BEFORE
REPLACING ANy COMPONENTS!
4E181 Removal of External Switch
1. Open the enclosure door to access the wiring to the switch
you wish to replace. “OFF/OPEN/CLOSE” is now on the left
and “MAN/AUTO” is now on the right. (Photo 4.E.18.1-1)
2. Locate the correct switch and unscrew the wires from the
back. (Photo 4.E.18.1-2 or 3 )
3. Close the enclosure door and loosen the large bolt— se-
cures the switch to the control box—with an adjustable
wrench. Finish unscrewing the bolt by hand. (Photo
4.E.18.1-4)
4. Remove the bolt and the aluminum switch label. (Photo
4.E.18.1-5)
5. Remove the Switch.
Photo 4.E.18.1-4
Switch bolt
Photo 4.E.18.1-5
Switch label and bolt
Photo 4.E.18.2-1
Switch assemebly
Photo 4.E.18.1-1
Interior switch wiring
Photo 4.E.18.1-2
open/off/Closed wiring
Photo 4.E.18.1-3
Man/Auto wiring
SWITCHES
X2 Troubleshooting and Repair Manual
Electrical Repairs – 06/10 173
4E182 Replacement of External Switch
1. Remove the bolt from the new switch assembly. (Photo
4.E.18.2-1)
2. Place the switch inside of the notched hole in the enclosure
door. (Photo 4.E.18.2-2)
3. Place the switch position label over the switch handle.
(Photo 4.E.18.1-5)
4. Place the bolt over the switch handle and hand tighten the
bolt while lining up and straightening the switch and label.
5. Using an adjustable wrench, tighten the bolt just enough to
lock the switch and label securely in place.
6. Open the enclosure door to access the switch wiring.
7. Wire the replacement switch as indicated in the Wiring
Diagram, Figure 4.E.18.2-5 . (Also see “OFF/OPEN/
CLOSE” Switch, Photo 4.E.18.2-3 or “MAN /AUTO,” Photo
4.E.18.2-4.)
8. Power up the electronics and test each switch that was
replaced to make sure that it is wired correctly and is
operational.
Figure 4.E.18.2-5 Switch wiring diagram
OPEN CLOSE
OFF
MAN AUTO
Front View
P97630
Back View
P97630
N.O. N.O.
N.C. N.C.
N.O. N.O.
N.C. N.C.
N.O. N.O.
N.C. N.C.
N.O. N.O.
N.C. N.C.
Front View
P98144
Back View
P98144
NOTE: THERE IS A RED JUMPER WIRE
INSTALLED BY THE VENDOR ON
SWITCH P97630 THAT WILL NEED TO BE
REMOVED.
Photo 4.E.18.2-2
Notched enclosure hole
Photo 4.E.18.2-4
Manual /Auto wiring
Photo 4.E.18.2-3
open/off/Closed wiring
SWITCHES
X2 Troubleshooting and Repair Manual
Mechanical Repairs – 06/10 175
4M1 COMPONENT IDENTIFICATION
MOTOR
CYLINDER
COVER
ACCUMULATOR
JUNCTION BOX
Figure 4.M.1-1 REXA Linear Cylinder
Component Identifcation
4.M. Mechanical Repair
176 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
ROTARY
MOTOR
ROTARY
MOTOR
Figure 4.M.1-2 REXA Rotary Cylinder
with Spring Fail
Figure 4.M.1-3 REXA Rotary Cylinder
Fail in Place
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 177
ROTARY
ACCUMULATOR
JUNCTION BOX
HIGH SPEED
MOTOR
HIGH SPEED
SOLENOID
Figure 4.M.1-4 REXA Rotary Cylinder
with Accumulator Package
178 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M2 OVERVIEW
All REXA Xpac actuators consist of a motor, a pumping system
and a housing assembly referred to as the Power Module. There
are many different confgurations of REXA Xpac actuators. Two
characterizing features are the size and number of Power Modules.
All REXA Power Modules have many common parts and repair
procedures.
The details for identifying all REXA models by our labeling system
can be found in the Section 1.2.1 of this manual. Also, please note
that each actuator will have at least one power module, but in some
cases there are multiple power modules on one actuator assembly.
To visually identify the size of the power module, see Figures 4.M.2-
1, 2, 3 & 4. The key identifying features are the shape and length of
the motor.
"
16
7
2
Figure 4.M.2-1: B Power Module
POWER MODULE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 179
5"
Figure 4.M.2-2: C Power Module
8
1
2
"
Figure 4.M.2-3: ½ D Power Module
POWER MODULE
180 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
"
8
7
9
Figure 4.M.2-4: D Power Module
NoTE: With the exception of pump and motor sizing, all REXA Power
Modules share many of the same components encountered during a
rebuild. For this reason, we will refer to rebuilding only one module in
this guide, and point out the differences between different-sized Power
Modules as needed.
POWER MODULE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 181
4M3 POWER MODULE REMOVAL
CAUTIoN: All external loads must be removed
from the actuator before any service is performed
NoTE: Tag and Lock-Out the unit for repair in accordance with local
procedures. Repair of the power module will require removing the unit
from service.
It may be possible for certain repairs to be performed without
removing the units from the installation site. Extra hazards may
result from this type of repair and are not covered in the scope of this
manual. Consult the factory for further information.
NoTE: Due to the large number of custom applications of REXA
actuators this manual doesn’t show the exact steps to removing the
power module but rather the general procedure that should be followed.
4M31 Removal
1. Ensure that all pressure gauges read zero before discon-
necting any pressure lines. One way to do this is by turning
the bypass counterclockwise.
NoTE: On some modules the dual gauges on the module may not read
zero, but it is safe to proceed if they are both reading equal values.
2. Ensure that power has been turned off to the unit.
3. An oil drain bin should be ready to catch any oil that may
drain from disconnecting lines.
4. Disconnect the external conduit and wiring running to the
power module.
NoTE: Oil is under low pressure in the reservoir and will squirt out when
reservoir plugs are removed.
5. Disconnect either reservoir plug with the oil drain pan
underneath. (Refer to Figure 4.M.3.1.) The reservoir should
pull in forcing out oil from the removed port. If the reservoir
does not pull in it may be necessary to push it in.
POWER MODULE
182 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
Figure 4.M.3.1 Power Module
6. Re-install the reservoir port plug.
7. Disconnect any external plumbing to the module, pressure
and reservoir parts.
8. Remove the mounting screws from the module. This should
allow you to completely remove the module for repair.
9. Place the module over the oil drain pan and remove the
lower reservoir plug on the module.
10. Remove the upper reservoir plug on the module; this will
allow the remaining oil to drain from the lower port.
POWER MODULE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 183
4M4 RESERVOIR REBUILD (ALL SIzE MODULES)
Parts Required: Reservoir Seal Kit
Kit to include: Cover Seal, Cover O-ring
and Reservoir Piston O-ring

CAUTION: Spring under compression, 20 lb
pre-load
NoTE: All B, C, 1/2D and D size modules share the same reservoir
components and rebuild procedures.
Resevoir Scale
Retaining Ring
Reservoir Cover
Cover O-Ring
Cover Seal
Reservoir Spring
Reservoir Piston O-Ring
Reservoir Piston
Indicator Assembly
Upper Reservoir/
Drain Port
Lower Reservoir/
Drain Port
Figure 4.M.4 Reservoir Rebuild
4M41 Disassembly
CAUTION: Use care when removing the retaining
ring as this releases pre-loaded spring and cover
1. Make sure actuator has been drained of oil and both drain
plugs have been removed.
2. Remove the reservoir scale.
3. Remove the retaining ring. It may be necessary to tap in on
the reservoir cover to allow the retaining ring to release.
4. Use two 6-32 screws and thread them into the two tapped
holes in the reservoir cover.
RESERVOIR
184 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
5. Pull the reservoir cover off using the two 6-32 screws. While
doing so, be cautious; the reservoir has a spring load.
6. Remove the spring.
7. Remove the reservoir indicator piston assembly by pulling
on the indicator.
8. Remove and discard the cover O-ring from the reservoir
cover. Remove and discard the cover seal from the reser-
voir cover. Remove and discard the reservoir piston O-ring.
4M42 Cleaning and Inspection
1. Clean all components in a solvent/parts washer to remove
all dirt and contaminants.
2. Clean out the reservoir cavity and be careful not to introduce
any contaminants to the system.
3. Inspect reservoir bore for scratches. If they are deep
enough to be felt, replace power module body.
4. If a full rebuild is being performed proceed to the removal
sections for the relevant motor before re-assembly.
4M43 Re-Assembly
1. Lubricate the two new O-rings and the new cover seal.
2. Slide the new reservoir piston O-ring over reservoir piston
indicator assembly.
3. Slide reservoir assembly back into the reservoir cavity.
4. Drop the reservoir spring over the indicator on the reservoir
assembly.
5. Install the new cover O-ring in the O-ring groove on the
outside of the cover.
6. Fit the new cover seal into the reservoir cover groove.
NoTE: The O-ring side of the seal must face away from the module body.
7. Re-install the reservoir cover and retaining ring. It is neces-
sary to hold the reservoir spring compressed while installing
the retaining ring.
RESERVOIR
EXTERNAL
Figure 4.M.4.3:
Inner motor seal
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 185
4M5 MODULE MOTOR REPLACEMENT
OR SEAL REPLACEMENT
Parts Required: Appropriate Motor Seal Kit
Kit to include 2 motors seals and the motor gasket
NoTE: All modules share similar motor mounting procedures and
components. For simplicity the diagram below shows a B Module.
Motor Washers
Motor Gasket
Outer Motor Seal
Inner Motor Seal
Motor Wire Hole
Wire Cover
Motor Screws
Motor
Figure 4.M.4 Motor Replacement
4M51 Disassembly
1. Ensure the actuator has been drained of oil and top drain
plug has been removed.
2. Remove the four screws holding the wire cover on.
3. Locate and disconnect the motor wires from the terminal
block under wire cover.
4. Remove the four motor screws and four lock washers.
5. Pull the motor straight out.
NoTE: It may be necessary to lightly tap the sides of the motor with a
rubber mallet to break the seal between the motor and module body.
MOTOR / SEAL REPLACEMENT
186 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
6. Peel off the motor gasket and remove both motor seals.
These three items can be thrown out after you have located
the replacement parts in your rebuild kit.
4M52 Cleaning and Inspection
1. Clean off the motor face and casting face. Remove any
remaining gasket material and sealant.
2. If a full rebuild is being performed proceed to the removal
sections for the relevant power train before re-assembly.
4M53 Re-Assembly
1. Coat both new motor seals with petroleum jelly and insert as
shown below into the module. Seal will not function properly
if installed backwards.
EXTERNAL
Figure 4.M.5.3 Motor Seals
2. Apply sealant on boss of the motor area of the module, and
around the motor and mounting through-holes.
3. Place the gasket on the motor after installing sealant.
4. Orientate the motor shaft so that it engages with the pump
coupling in the module.
5. Feed the wires into the motor wire hole on the module and
slide the motor back into place. The motor should sit fush
to the casting. Turn the motor shaft back and forth to ensure
it is aligned with the pump coupling.
MOTOR / SEAL REPLACEMENT
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 187
CAUTION: Do not force the motor in place or
tighten the mounting screws before turning the
motor shaft, or damage will occur
6. Apply blue Loctite® and install the four motor washers.
Torque the screws in place to 50 lb·in.
7. Re-wire the motor to match the wire colors. For detailed
wiring diagram, refer to Appendix P of the IOM.
8. Reinstall the wire cover and torque the screws in place to 50
lb·in.
MOTOR / SEAL REPLACEMENT
188 REXA X2 Series TS&R Manual
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4M6 FILL AND OVERFILL VALVES
Note: All B, C, 1/2D and D size modules share the same external valves
replacement procedures.
Fill Valve
Reservoir Overfill
Valve
Figure 4.M.6 External Valves
4M61 Disassembly
1 Remove the reservoir overfll valve and the fll valve.
2 Clean out any sealant that may be left.
4M62 Re-Assembly
1 Coat the threads of the new overfll valve and the fll valve
with thread sealant.
2 Screw both valves in place as shown above.
FILL / OVERFILL VALVES
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 189
4M7 PRESSURE LIMITING VALVE
Table 4.M.7
Parts List
Item Description Qty Item Description Qty
1 Valve Bonnet 1 7 Quad Ring 1
2 Valve Stem 1 8 Star Washer 1
3 Spring Seat 1 9 Valve Seat Retainer 1
4 Spring 1 10 Cap Lock Nut 1
5 Spring Cap 1 11 O-ring - 106 1
6 O-ring - 015 1 12 Valve Seat 1
5
10
4
3
1
7
8
2
6
9
11
12
FIGURE 4.M.7 PRESSURE LIMITING VALVE
NoTE: If the power module is still attached to the actuator system then
make sure all pressure is relieved by turning the bypass counter clockwise.
Refer to Figure 4.M.1-1: Linear Cylinder Component Identifcation. Not
doing so may result in damage to unit and or injury to self.
4M71 Disassembly
1. Loosen the spring cap (5) by turning the cap lock nut (10)
clockwise and remove both items.
2. Remove the spring (4) and the spring seat (3).
3. Remove the valve bonnet (1) from the pressure relief cavity
of the power module. On the power module side, remove
the valve stem (2) and O-ring (6).
4. Using a pick, remove the star washer (8) and the quad ring
(7) from the power module side of the pressure relief.
PRESSURE LIMITING VALVE
190 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
5. Using an allen wrench, remove the valve seat retainer (9).
6. Using a pick, remove the O-ring (11) inside the power
module along with the valve seat (12).
7. The pressure relief O-rings (6 & 11) and quad ring (7) can be
thrown out after you have located the replacement parts in
your rebuild kit.
4M72 Cleaning and Inspection
1. Clean all components in a brake wash to remove dirt and
contaminants.
2. Clean out pressure relief cavity and be careful not to intro-
duce any contaminants into the system
3. Inspect for any metal fles or gall marks in the pressure relief
cavity
4M73 Re-assembly
1. Lubricate the new O-rings (6 & 11) and quad ring (7) before
reinstalling.
2. Install the valve seat (12) and O-ring (11) into the power
module cavity.
3 Using an allen wrench, place the valve seat retainer (9) into
the cavity and torque to 25 lb•in.
4 Install the quad ring (7) and star washer (8) into the power
module side of the valve bonnet (1).
5 Apply multi-purpose grease to the tip of the valve stem (2)
and insert the valve stem (2) into the power module side of
the valve bonnet (1).
6 Install the O-ring (6) onto valve bonnet (1) and insert the
valve bonnet (1) into the power module. Torque the valve
bonnet (1) to 25 lb•in.
7 Insert the spring seat (3) and spring (4) inside the valve
bonnet (1). Install the cap lock nut (10) and spring cap (5) to
the outside of the valve bonnet (1).
NoTE: Refer to IOM Appendix O for adjustment range (psi) and spring
color.
PRESSURE LIMITING VALVE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 191
4M8 DRIVE TRAIN REMOVAL
Parts Required: Module Rebuild Kit
NoTE: All B, C, 1/2D and D size modules share the same rebuild
procedures. Only the pump internals and coupling shafts are different.
Drive Train
Pressure O-Rings
Pump Coupling
Drive Train
Reservoir O-Ring
Drive Train
Pressure Gages
Drive Train Mounting
Screws
Washers
Solenoid O-Ring
Solenoid Wire Hole
Wire Cover
Figure 4.M.8 Drive Train
4M81 Disassembly
1. Ensure the oil has been drained from the module prior to
disassembling the power train.
2. For spring fail units only:
a.) Remove four screws holding wire cover on.
b.) Disconnect two white solenoid wires.
2. Remove the four drive train mounting screws and lock
washers.
3. Pull the power train assembly straight out.
DRIVE TRAIN
192 REXA X2 Series TS&R Manual
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4. Remove the drive train pressure O-rings, wire cavity O-rings
and drive train reservoir O-ring.
5. Remove the pump coupling.
4M82 Cleaning and Inspection
1. Clean out the inside of the module body. It is best if the
reservoir and the motor are completely removed and the
body can be completely sprayed out with contact cleaner.
2. Proceed with the drive train rebuild prior to assembly if
performing a full rebuild.
4M83 Re-Assembly
1. Drop the pump coupling shaft into the shaft hole in the
module. The B, C, and D shafts can be installed either side
frst because they are symmetrical. The ½ D shaft will only
go in one way. Check the ft of the shaft to the pump for
correct orientation.
2. Place the new O-rings into the O-ring grooves of the
module. Place a few dabs of petroleum jelly or grease over
the O-ring to hold it in place.
3. Align the pump shaft orientation to the coupling so they mate
up during installation. Slide the power train assembly back
into the module. It is necessary to rotate the motor shaft to
allow the pump coupling to align properly.
CAUTION: Do not force the drive train in place or
tighten the mounting screws before turning the
motor shaft, or damage will occur!
4. Apply blue Loctite® on the drive train screws and install the
four lock washers. Torque screws in place to 190 lb·in.
5. For spring fail only:
a.) Feed solenoid wires into the module.
b.) Reconnect both wires to the terminal strip under the
wire cover. There is no polarity, so either wire can go
to either solenoid terminal.
c.) Reinstall wire cover. Torque wire cover bolts to 50 lb·in.
DRIVE TRAIN
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 193
4M84 Drive Train Rebuild
Parts Required: Module Rebuild Kit
NoTE: All B, C, 1/2 D and D size modules share the same rebuild
procedures. Only the pump internals and coupling shafts are different.
Figure 4.M.8.4 Drive Train Rebuild
4M85 Disassembly
1. Remove the four 1/4-20 pump mounting bolts and lock
washers. Do not remove the #10-32 pump screws hold-
ing the pump together!
2. Separate the pump from the rest of the assembly. Place
it driven shaft up. Take extreme care to protect the drive
shaft of the pump once it is unbolted. Laying it on its output
shaft will cause damage and it will need to be replaced. The
pumps are not serviceable and should never be opened
or cleaned.
DRIVE TRAIN
194 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
3. Remove both pump O-rings from the face of the fow match
valve (FMV).
4. Remove the four 1/4-20 fow match valve screws and lock
washers.
CAUTION: There are check balls and springs
between the two faces Be careful not to lose
these components while separating the fow
match valve from the manifold
5. Remove the four O-rings from the fow match valve face.
4M86 Cleaning and Inspection
1. The outer surfaces of these components can be cleaned in
solvent. Extreme care must be taken to ensure no contami-
nants enter the pump or fow match valve during cleaning.
2. Turn the pump shaft 360°. It should be free to turn with
no binding felt. Replace pump if the shaft will not turn or
binding is felt.
3. Continue to the suction check valve replacement and
manifold rebuild before reassembly if a full rebuild is being
preformed.
4M87 Re-Assembly
1. Place new O-rings into the O-ring groove of the fow match
valve face. Place a few dabs of petroleum jelly over the
O-ring to hold them in place.
2. Insert a check ball then a check spring into each hole on the
fow match valve.
3. Align the fow match valve to the manifold as shown in Fig-
ure 4.M.8.4. The gauges are on the top side along with the
corner cutouts of the fow match valve. Apply blue Loctite®
on the fow match screws and install the 4 lock washers.
Torque the 4 screws in place to 100 lb·in.
DRIVE TRAIN
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 195
Figure 4.M.8.7 Flow Match Valve Face
4. Align the pump to the fow match valve as shown Figure
4.M.8.7. Note the location of the pump driven shaft. Apply
blue Loctite® on the pump screws and install the four lock
washers. Torque the screws in place to 100 lb·in.
DRIVE TRAIN
196 REXA X2 Series TS&R Manual
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4M9 SUCTION CHECK VALVE
Parts Required: Suction Check Rebuild Kit
NoTE: All B, C, 1/2 D and D size modules share the same rebuild
procedures.
Figure 4.M.9 Suction Check Valve
4M91 Disassembly
1. Unthread the suction check valve.
2. Remove the suction check valve O-ring
3. Remove the suction check ball and the suction check spring
from the fow match body.
4M92 Cleaning and Inspection
1. The suction check cavity can be cleaned with brake wash
but care must be taken not to introduce any contaminants
into the valve.
4M93 Re-Assembly
1. Slide the new suction check spring into the valve cavity of
the fow match valve.
2. Set a new suction ball onto the spring.
3. Install a new suction check O-ring into the groove on the
suction check. Thread in the suction check valve and torque
to 250 lb·in.
SUCTION CHECK VALVE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 197
4M10 STANDARD MANIFOLD REBUILD
Parts Required: Module Rebuild Kit
NoTE: All B, C, 1/2 D and D size modules share the same rebuild
procedures; however, slow speed spring fail units are different. High
temperature units also share the same procedure; however, high
temperature kits are available with different materials.
Figure 4.M.10 Manifold
4M101 Disassembly
1. Unthread the six bypass plate screws.
2. Remove the bypass plate.
3. Unthread all three bypass plugs from the bypass plate.
4. Remove the four face O-rings from the gauge manifold.
MANIFOLD
198 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
5. Remove the gauges—if they are being replaced—at this
time. If the unit is a high temperature unit it will not have
gauges installed…the ports will be plugged.
4M102 Cleaning and Inspection
Clean the bypass plate and the gauge manifold with brake
wash. Ensure no contaminants are allowed to enter the
ports of the gauge manifold.
4M103 Re-Assembly
1. Install new bypass plug O-rings into the O-ring groove of
the bypass plug. Lubricate the O-rings with petroleum jelly.
Repeat this for all three plugs. Be careful to avoid sliding
the O-ring over the threads of the bypass plug, which can
cause damage to the O-ring.
Figure 4.M.10.3 o-ring Grooves
2. Thread the three bypass plugs into the bypass plate. Once
the hex protrudes through the plate enough, use a hex head
screw driver and thread the plug until it bottoms into the
plate.
NoTE: If this is not done, the plugs will keep this plate from mounting
properly in the following steps.
3. Install the four face O-rings into the O-ring grooves of the
gauge manifold. Use petroleum jelly or grease to hold the
O-rings in place.
4. Align the bypass plate with the gauge manifold, apply blue
Loctite® on the bypass plate screws and install the washers.
Torque to 50 lb·in.
MANIFOLD
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 199
4M11 SOLENOID
Parts Required: Solenoid Rebuild Kit
NoTE: All B, C, 1/2 D and D size modules share the same rebuild
procedures. High temperature units also share the same procedure;
however, high temperature kits are available with different materials.
Figure 4.M.11 Solenoid Cover
4M111 Disassembly (Solenoid Cover)
1. Remove the cover mounting screws and washers.
2. Remove the solenoid cover and cover O-ring.
3. Remove the two toggle mounting screws and O-rings
4. Remove the three face O-rings.
5. Remove the plunger return spring, plunger and plunger
O-ring.
6. Tap out the Pivot Pin in order to remove the toggle assem-
bly, cam guide, spring washers and spring holder.
SOLENOID
200 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M112 Cleaning and Inspection (Solenoid Cover)
Clean all components with brake wash.
4M113 Re-Assembly (Solenoid Cover)
1. Locate the three new spring washers from the rebuild kit.
Install them onto the spring holder as shown below. Note
the “bow” location of the spring washers in the diagram,
installing the springs in the wrong orientation will cause the
bypass not to function.
Figure 4.M.11.3-1 Spring Washers
2. Install the Cam guide over the springs and onto the spring
holder as shown above.
3. Place the spring assembly into the mounting block, spring
holder side frst.
Figure 4.M.11.3-2 Toggle Assembly
SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 201
4. Align the toggle assembly as shown above into the mounting
block; note the location of the Lock-Out hole. Press the new
pivot pin in place.
5. Lubricate the new O-rings. Slide the plunger O-ring over the
small diameter of the plunger, and down to the frst shoulder
as shown below.
Figure 4.M.11.3-3 Plunger
6. Slide the plunger return spring over the plunger as shown
above and install the plunger adjustment screw into the
bottom of the plunger until tight.
7. Insert the plunger assembly into the mounting block as
shown below.
Figure 4.M.11.3-4 Mounting Block
8. Place the three face O-rings into the O-ring grooves of the
mounting block. Coat the O-rings with petroleum jelly to
hold them in place during assembly.
9. Continue onto the setup, TS&R section 4M12.
SOLENOID
202 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M114 Disassembly (Solenoid Manifold)
Solenoid Nut
Washer
Plunger O-Ring
Soleniod Plunger
Bypass O-Ring
Plunger Spring
Gauge
Gauge Manifold
Face O-Ring
Bypass Plug
Soleniod Plate
Washer
Solenoid Plate Screw
Solenoid
Solenoid Adjustment
Screw
Solenoid O-Ring
Solenoid Wire
Figure 4.M.11.4 Solenoid Manifold
NoTE: Mark position of solenoid wires on terminal strip. There is no
polarity, so either wire can go to either solenoid terminal.
1. Ensure power is off. Remove solenoid wire from terminal
strip.
2. Remove the solenoid plate screws and the solenoid plate.
3. Locate and remove all four face O-rings and the plunger
spring.
4. Remove the solenoid plunger and the plunger O-ring.
SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 203
5. Unthread both bypass plugs from the solenoid plate.
6. Remove both bypass O-rings from the bypass plugs.
7. Remove the solenoid nuts, solenoid O-rings and the solenoid.
8. If the solenoid is being replaced remove the solenoid adjust-
ment screw.
4M115 Cleaning and Inspection (Solenoid Manifold)
Clean all components with brake wash.
4M116 Re-Assembly (Solenoid Manifold)
1. Install the solenoid adjustment screw into the solenoid if a
new solenoid is being installed.
2. Place the solenoid O-rings into the grooves on the solenoid
plate. Coat the O-rings with petroleum jelly or grease to
hold them in place.
3. Install the solenoid so that the two mounting studs slide
through the O-ring holes. Thread solenoid wires through
solenoid manifold.
4. Install the washers and solenoid nuts to hold the solenoid in
place.
5. Install new bypass plug O-rings into the O-ring groove of
the bypass plug. Lubricate O-rings with petroleum jelly.
Repeat this for both plugs. Be careful to avoid sliding the
O-ring over the threads of the bypass plug which can cause
damage to the O-ring.
Figure 4.M.11.6-1 Bypass Plug
6. Thread both bypass plugs into the solenoid plate. Once
the hex protrudes through the plate enough, use a hex
head screw driver and thread the plug in until it bottoms into
SOLENOID
204 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
the plate. If this is not done the plugs will keep this plate
from mounting properly later in the following steps. Feed
solenoid wires through solenoid plate and engage manifold
according to Figure 4.M.11.4.
7. Install the four face O-rings into the O-ring grooves of the
gauge manifold. Use petroleum jelly to hold the O-rings in
place.
8. Coat the plunger O-ring with petroleum jelly for lubrication.
Slide this O-ring over the solenoid plunger as shown below.
Slide the plunger spring over the solenoid plunger as shown
below.
Figure 4.M.11.6-2 Solenoid Manifold Plunger
9. Insert the solenoid plunger assembly into the center hole
of the solenoid plate. It will slide in O-ring side frst. Feed
solenoid wires through power module to heater cavity junc-
tion box. Terminate accordingly.
10. Making sure the plunger spring stays in place, align the
solenoid plate to the gauge manifold, apply blue Loctite® on
the solenoid plate screws and install the washers. Torque to
50 lb·in.
SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 205
4M12 SOLENOID SET UP
1. Press in on the solenoid plunger and measure the gap
between the plunger and solenoid body using feeler gauges.
The gap should measure 0.015 inches. If this measurement
is out of specifcation it will be necessary to remove the
plunger and readjust the solenoid adjustment screw.
Photo 4.M.12-1
Plunger Gap
Photo 4.M.12-2 Plunger
2. Toggle the cover / latch assembly into the latched position
shown below (the lever in the vertical position).
Figure 4.M.12-1 Cover/Latch Assembly
3. Remove plunger adjusting screw, apply blue Loctite®, and
replace screw. Re-apply power to the actuator.
4. With the solenoid energized, place the cover/latch assembly
over the solenoid, aligning the notch in the cover with the
solenoid wires.
a.) Measure the gap between the bottom of the cover and
the solenoid mounting plate. The gap should measure
.020 inches. The best way to measure the gap is to
SOLENOID
206 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
insert one .020 feeler gauge under one edge of the
cover and press down on the cover directly over the
gauge. Now insert the other .020 feeler gauge under
the cover directly opposite the frst gauge as shown
below.
Photo 4.M.12-3 Cover/Mounting Plate
b.) Adjust the gap to .020 inches by removing the cover
and turning the screw directly in the center of the
cover cavity in or out until the desired gap is achieved.
Re-adjust as required to achieve the proper gap.
c.) Place the lever in the unlatched position and attach
the cover.
d.) Remove the cover and re-set the gap in step b.
e.) Reinstall the cover with the lever in the unlatched
position.
NoTE: A Padlock with 3/16″ diameter shank may be used in place of the
tethered pin to prevent unauthorized toggling of the lever.
f.) Install the tethered pin to lock the handle in place.
SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 207
4M13 SOLENOID TESTING
1. Stroke the unit against the spring until the end of stroke is
reached. Remove power to trip the solenoid. The actuator
should begin to move immediately, except in the case of a B
module Class 1 Division 2 which can take up to 10 seconds
to begin moving.
2. Reapply power to the actuator and immediately stroke the
unit fully against the spring. Solenoid must re-engage im-
mediately upon power up. If it does not, proceed to the next
step for adjustment of the solenoid open travel stop.
SetUp of the open Stop
a.) Remove the cover/latch assembly. Back out the
adjustment screw in the cover cavity ¼ turn and
retest. Continue to adjust at ¼ turn intervals and
retest as required until the re-latching of the solenoid
is immediate.
Figure 4.M.13 Latching Cover
VerIfIcatIon of ManUal latchIng operatIon
b.) In LOCAL mode stroke the actuator against the spring
to the end of travel. Record current position. Manu-
ally latch the solenoid and turn power off.
c.) Observing the CPU display may test rotary units drift.
No drift is to be allowed for 5 minutes.
SOLENOID
208 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
HIGH SPEED SOLENOID
Figure 4.M.14-2 High SpeedSolenoid Layout
Table 4.M.14 Solenoid Cutaway
ID
No.
Description
ID
No.
Description
1 Screws 13 Electrical connector
2 Set screw 14 O-ring
3 Spring pad 15 Set screw
4 Springs 16 Coil housing
5 Armature 17 Coil Assembly
6 O-ring 18 Spring pads
7 Backup rings 19 Socket head screws
8 O-rings 20 Valve body
9 Poppet 21 Seat assemblies
10 O-rings 22 Cage
11 Backup rings 23 Guide
12 Retainer 24 Set screw
25 Locking pad
Figure 4.M.14-1 Solenoid Cut-away
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 209
4M14 HIGH SPEED SOLENOIDS
This section describes installation of Repair Kit Parts and
subsequent testing on this solenoid valve. The repair kit allows
users of solenoid valve to update the subject valve to the latest
confguration at their own discretion.
Installation of Repair Kit Parts into existing solenoid valves is
available. However, for those valve users choosing to perform their
own installation, the following information is provided.
4M141 Description of Valve
1. Solenoid valve is a 3 way, 2 position solenoid valve.
2 When the solenoid coil is de-energized the NO port is
connected to the COM port, and the NC port is closed.
Sealing force on the NC seat is provided by springs within
the solenoid assembly. When the solenoid coil is energized
the NC port is connected to the COM port, and the NO port
is closed. Sealing force on the NO seat is provided by the
energized solenoid coil.
4M142 Equipment Requirement
1. Regulated pressure source, 0 to 3 000 psig clean air.
2. Electric power supply to match solenoid voltage, 2 amperes
minimum.
3. Torque wrench, audible adjustable, 5 to 150 lb·in.
4. Torque wrench, dial style, memory pointer, 0 to 30 lb·in.
5. Pressure transducer, fast response, 0 to 3 000 psig.
4M 143 Disassembly
1. Remove four socket head screws (19) securing solenoid
assembly to valve body (20). Orient whole unit with solenoid
below valve body when pulling two sections apart as there
are loose parts within solenoid.
HIGH SPEED SOLENOID
210 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
2. After completing above procedure, note relative distance
between armature (5) and valve body for later use. Remove
armature from poppet. Hold armature while turning poppet
counterclockwise utilizing slot in opposite end of poppet from
armature.
3. Loosen set screw (24) 2 to 3 turns. Do not remove set
screw or locking pad (25) unless replacement is necessary.
Remove retainer (12).
4. To remove internal valve components, push against
threaded end of poppet until components can be removed
from valve body. Check inside valve body for possibility of
an O-ring remaining, and remove.
5. Discard all items from valve for which replacement parts are
included in the Repair Kit.
4M 144 Cleaning and Examination of Parts
1. Clean metal valve components using commercial cleaning
solvents or detergent solutions. DO NOT wash solenoid
assembly.
2. Visually inspect all metal parts for nicks, scratches, or
other damage that can affect valve performance. Examine
the bores in valve body (20) and guide (23) for nicks and
scratches that can affect a-ring sealing.
4M 145 Initial Assembly
1. O-rings are lightly lubricated with Monsanto MCS 352 or
BAC 5001 or DAC ACO-DPM 5073.
2. Assemble cage (22), seat assemblies (21), O-rings (8),
backup rings (7), O-rings (10). Guide (23), and backup rings
(11) onto poppet (9) with the exception of one O-ring (10) used
on seat assembly nearest threaded end of poppet. Place this
one O-ring into its fnal location within valve body (20).
3. Insert poppet and associated components into valve body.
Using 3/8 hex wrench secure retainer (12). Torque retainer
8 to 10 lb·ft. Tighten set screw (24) to secure retainer.
HIGH SPEED SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 211
5. Apply small amount of anti-seize compound to threads on
poppet (9). Thread armature assembly (5) onto poppet to
approximate location of preceding section 4.M.14.3, step #2.
6. Remove four screws (1) securing electrical connector (13).
Raise connector suffciently to access space beneath.
Using 5/64 hex wrench, turn set screw (15) 3 to 4 turns
counterclockwise, from electrical connector end.
7. Assemble spring pad (3), springs (4), and spring pads (18)
into coil assembly (17). While aligning pin extending from
coil assembly with hole in armature assembly, place valve
body assembly onto coil housing (16). Pin must align with
hole to avoid damage. Secure coil housing (16) to valve
body (20) (orientation optional) using four cap screws (19).
Torque 55 to 57 lb·ft.
4M 146 Adjustment and Final Assembly
1. Cap COM port. Connect air pressure source to NO port
NC port open to atmosphere. Energize solenoid coil via
electrical connector pins A and B, polarity optional, with
approximately 24 Vdc. Turn poppet (9) counterclockwise
until air just starts to fow from NC port. Then turn poppet
clockwise until air fow just ceases. DE•ENERGIzE COIL.
Turn poppet an additional 1/8 to 1/4 turn clockwise.
2. Using 5/64 hex wrench, turn set screw (15) clockwise until
solenoid pull-in voltage is 70% of rated voltage.
3. NC port open to atmosphere with muffer. Increase air
pressure at NO port to 3 000 psig. Cycle valve ffteen times
minimum using 70% of the valves rated voltage. Valve
operation shall be sharp and without hesitation.
4M 147 Final Tests
1. Cap COM port. Connect air pressure source to NO port.
NC port open to atmosphere. Energize solenoid coil via
electrical connector pins A and B. Turn poppet (9) counter-
clockwise until air just starts to fow from NC port. Then turn
HIGH SPEED SOLENOID
212 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
poppet clockwise until air fow just ceases. DE-ENERGIzE
COIL. Turn poppet an additional 1/8 to 1/4 turn clockwise.
2. Using 5/64 hex wrench, turn set screw (15) until solenoid
pull-in voltage is nearly 70% of rated voltage. Turn clock-
wise to increase voltage, counterclockwise to lower voltage.
3. Secure electrical connector (13) to coil housing (16) with
four screws (1). 2 Torque screws 8 to 10 inch-pounds.
4. Pull-In Voltage Test
a.) Cap NO port. NC port open to atmosphere with muf-
fer. Apply 3000 psig air to COM port. Starting at zero
volts, gradually increase voltage to solenoid until valve
actuates. Valve shall actuate at or below 70% of rated
voltage. Remove pressure and voltage.
5. External Leakage and Proof Pressure Test
a.) Cap NO and NC ports. Solenoid coil de-energized.
Apply 4500 psig air to COM port for one (1) minute.
There shall be no signs of external leakage or dam-
age.
b.) Cap NO and NC ports. Energize solenoid coil with
24 Vdc. Apply 4500 psig air to COM port for one (1)
minute. There shall be no signs of external leakage or
damage. Remove pressure and voltage.
6. Internal Leakage Test
a.) Cap NO port. Solenoid coil de-energized. Apply
3000 psig air to COM port. Leakage at NC port not
to exceed 1 bubble in 2 minutes. Reduce pressure to
zero.
b.) Cap NC port. Energize solenoid coil with 24 Vdc.
Apply 3000 psig air to COM port. Leakage at NO port
not to exceed 1 bubble in 2 minutes. Reduce pres-
sure to zero.
7. Testing completed.
HIGH SPEED SOLENOID
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 213
4M15 HAND WHEEL / DRILL DRIVE
Parts Required: Hand Wheel Kit
Figure 4.M.15 Handwheel/Drilldrive
4M151 Disassembly
1 Refer to Figure 4.M.15 and remove the hand wheel from the
back end of the motor by unscrewing the housing.
2 Remove the spring.
3 Remove the O-ring.
4M152 Re-Assembly
1 Replace the spring.
2 Replace the O-ring.
3 Screw hand wheel back onto the end of the motor.
HANDWHEEL / DRILLDRIVE
214 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
MANUAL HAND PUMP
4M16 HAND PUMP
The manual hydraulic pump 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.
Photo 4.M.16 Manual Hand Pump
4M161 Removal
1. Turn off power to the unit. Open bypass and confrm that
there is no internal pressure.
2. Clamp the oil reservoir. Refer to TS&R Appendix F for
information on indicator clamping.
3. Place an oil drain pan under the hand pump.
4. Remove any tubing connected to the hand pump and
mounting plates.
5. Unscrew the bolts that connect the hand pump to the mount-
ing plate.
6. Remove the mounting plate from the hand pump.
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 215
4M162 Replacement
1. Attach the mounting plate to the new hand pump.
2. Replace hand pump and mounting plate assembly to the
original position.
3. Re-attach the tubing to the hand pump.
4. Unclamp oil reservoir and bleed the unit.
5. To operate the hand pump, insert lever into the piston
assembly and pump the handle up and down.
6. To reverse the direction of the pump either push in or pull
out on the black knob located on the bottom of the pump.
NoTE: It is not advisable to leave the lever in the piston assembly when
the hydraulic pump is not in use.
MANUAL HAND PUMP
216 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
COMMERCIAL LINEAR CyLINDERS
4M17 COMMERCIAL LINEAR CyLINDERS
The cylinder consists of a double rod end through shaft cylinder.
There are two bushings with seals, a wiper, shank, piston disk,
piston seals and cylinder body. The sizes range from 2 000 –10 000
lb greater than 6˝ stroke and greater than 10 000 lb with almost any
stroke size required.
Figure 4.M.17 Commercial Linear Cylinder
Table 4.M.17 Parts List
Item
No Description Qty
Item
No Description Qty
1 Head, Ported, Non-cushioned 1 41 Lipseal, Gland 2
7 Cap, Ported Non-cushioned 1 42 Lipseal, Piston 2
14 Gland 2 43 Backup Washer, Gland 2
15 Cylinder Body 1 44 Backup Washer, Piston 2
17 Piston Body, Lipseal Type 1 45 O-ring, Gland to Head Seal 2
19 Tie Rod 4 47 O-ring, Cylinder Body End Seal 2
23 Tie Rod Nut 4 57 Piston Rod 1
27 Retainer 2 60 Piston Rod Extension 1
40 Wiper Seal, Gland 2
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 217
4M171 Disassembly
NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local
procedures. Repair of the cylinder will require removing the unit from
service.
Seals Replacement
CAUTION: While assembling and disassembling
the cylinder, be aware of oil discharging from
unprotected ports
1. Clamp the reservoir piston to prevent oil from discharging
from power module when removing. Remove tubing feeding
the cylinder.
2. Remove the fasteners holding the feedback arm to the
cylinder shaft. Remove all plates, fasteners and legs as
necessary to free the cylinder from the assembly. Remove
the cylinder from the unit.
3. Loosen and remove the four tie rod nuts (23).
4. Remove the retainer plate (27).
5. Remove the bronze gland (14) on the retainer plate (27) by
unscrewing counter clockwise.
NoTE: Residual oil will drain at this point.
6. Remove the cap assembly (7).
7. Remove the piston and piston rod assembly (57, 17, 60).
Photo 4M.17.1-4: Cap/Head
Assembly

Photo 4M.17.1-5: Piston Rod
Assembly
COMMERCIAL LINEAR CyLINDERS
Photo 4.M.17.1-1: Retainer Plate
Photo 4M.17.1-2: Tools for gland
removal and installation
Photo 4M.17.1-3: Parker tool for
gland removal
218 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
8. Remove the cylinder body (15).
9. Remove the head assembly (1). Tie rods may be left
installed in the retainer.
10. Remove the seals from the piston disk (17) and inspect the
disk for wear and damage. Replace as necessary.
11. Inspect the cylinder body (15) for wear and damage. Re-
place as necessary.
12. Remove the seals (40, 41 & 43) from the glands (14) and
inspect the gland for wear and damage. Replace as neces-
sary.
13. Remove and discard the following O-rings: two glands
to head seals (45) and two cylinder body end seals (47).
Inspect the O-ring seating surface for damage. Replace as
necessary.
NoTE: Lubricate all surfaces, seals and O-rings prior to assembly.
4M172 Reassembly
1. Place one new set of piston lipseals (42) and back-up
washer (44) on one side of the piston disk with the open end
toward the shaft end.
2. Slide the piston disk assembly (57, 17, 60) into the cylinder
body (14). Slide the piston disk assembly to the end of the
body to expose the seal groove with no seals. Do not slide
the piston disk assembly all the way out of the cylinder body.
3. Place the other new piston lipseal (42) and back-up washer
(44) on the piston disk. Slide the piston disk assembly (57,
17, 60) back into the cylinder body (15).
4. With both glands, install new wiper seal (40), gland lipseal
(41) and gland backup washer (43) into the gland.
5. Install new cylinder body end seal O-ring (47) into head (1)
and cap (7). Also install new gland to head seal (45).
6. Install gland (14) to retainer (27). Ensure that the gland
is installed only two turns. If required, install tie rods to
retainer so that the tie rod ends are fush to the retainer.
COMMERCIAL LINEAR CyLINDERS
Photo 4M.17.1-6: Cylinder Body
Photo 4M.17.1-7: Piston Disk
Assembly
Photo 4M.17.1-8: Piston disk with
one set of seals into cylinder
Photo 4.M.17.1-9: Piston disk
ready for second set of seals
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 219
7. Install head (1) to retainer (27). Slip the cylinder body (15)
with piston disk assembly (57, 17, 60) over the tie rods (19)
and onto the head.
8. Install cap (7) to cylinder body (15).
9. Install retainer plate (27) to cap (7).
10. Thread the tie rod nuts onto the tie rods. Torque the tie rod
nuts (23) in accordance with Table 4.M.17.2.
11. Tighten gland (14) so that the top of the gland to the retainer
is 0.25".
12. Install power module, tubing and feedback items. Install unit
to valve.
Table 4.M.17.2 ToRQUE (lb·ft)
Size
Cylinder
Bore
Rod
Size
Tie Rod
(lb·ft)
L2 000 1.5" 1" 18
L5 000 2.5" 1.75" 45
L10 000 3.25" 2" 120
L15 000 4" 2.5" 131
L20 000 4" 1.75" 131
L40 000 6" 3" 528
L60 000 7" 3" 800
L80 000 8" 3.5" 1 168
COMMERCIAL LINEAR CyLINDERS
Photo 4M.17.1-10: Gland and
Seals
Photo 4M.17.1-11: Head/Cap Seals
Photo 4M.17.1-12: Head/Cap Seals
220 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M18 REXA LINEAR CyLINDERS
The current linear block cylinder line consists of fve models. These
models can reach force outputs up to 10 000 lb. Each of these
models comes in different stroke options typically 2″, 4″ and 6″. To
identify the model/size of your cylinder reference the model number.
The frst digit will be an L signifying it is a linear stroke. The next
three to fve digits before the dash is the thrust output. For more
details on Model numbering refer to TS&R section 1.2.1. You can
also confrm the output by measuring the shank diameter and
reference the table below.
Shank Diameter Cylinder Size
9/16″ L500
9/16″ L2 000
1″ L4 000
1-5/16″ L10 000
4M181 Cylinder Removal Procedure
for All REXA Block Cylinders
NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local
procedures. Repair of the linear cylinder will require removing the unit
from service.
Due to the large number of custom applications of REXA actuators
this manual doesn’t show the exact steps to separate the power
module but rather the general procedure that should be followed.
1. Remove any external loads or springs attached to the unit
before attempting any service. In some cases the power will
be needed to remove these loads.
CAUTION: Failure to properly remove loads on the
actuator can result in injury or death
2. Clamp the reservoir indicator to prevent oil from draining out
of the power module when disconnecting tubing. Be careful
not to damage indicator.
REXA LINEAR CyLINDERS
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 221
3. Clean the module thoroughly. It is important that no con-
taminants enter the internals of the actuator.
4. Remove the power module from the cylinder.
5. Remove the cylinder from its mounting.
REXA LINEAR CyLINDERS
222 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M182 L500 and L2 000 Cylinder Rebuild Procedure
For ¾ Inch, 2 Inch, 4 Inch and 6 Inch Stroke Units
PARTS REQUIRED: Cylinder Seal Kit
A Feedback Removal
14
16
13
15
9
5
7
6
3
11
17
10
8
4
2
12
1
9
Figure 4.M.18.2-A L500 & 2 000 Feedback Removal
Table 4.M.18.2-A
Parts List
Item Description Qty Item Description Qty
1 Cylinder Body 1 10 Anti-Rotation Rod 1
2 Bracket, Circuit Board Mounting 1 11 Retaining Ring 1
3 Potentiometer 1 12 Circuit Board Assembly 1
4 Spring Washers 2 13 Cover. Cylinder 1
5 #10-32 Shldr Scr 1 14 SHCS #10-32 × .75 4
6 Feedback Arm 1 15 O-ring Viton - 150 1
7 Hex Nut Std #4-40 (SS) 1 16 #10 Lock Washer 4
8 Roll Pin (Spring 1 17 Anti-Vibration Tape Foam 1
9 SCR Pan HD SL #6-32NC 4
4M182-A1 Disassembly
1. Refer to Figure 4.M.18.2-A and remove the 4 SHCS (14)
and lock washers (16).
L500 - L2 000 LINEAR CyLINDERS
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 223
2. Remove the feedback cover (13) and O-ring (15). The
O-ring can be thrown out once the replacement is identifed
from the rebuild kit.
3. Record all termination points. Disconnect all wires con-
nected to the circuit board (12)
4. Remove the 2 SCR pan head screws (9) to remove the
circuit board (12).
5. Remove the 2 SCR pan head screws (9) to remove the
circuit board bracket (2)
6. Remove the shoulder screw (5) and hex nut (7). Remove
the 2 spring washers (4). While holding the potentiometer
(3) rod, unscrew the feedback arm (6).
7. Remove the retaining ring (11), anti rotation rod (10), and
the potentiometer (3).
8. Proceed to bushing rebuild Section B to continue disassembly.
4M182-A2 Reassembly
1. Apply the bottom of the potentiometer with anti-vibration
foam (17) then slide the potentiometer (3) into the poten-
tiometer (3) hole in the cylinder (1). Ensure that the cable
slides into its slot. Snap the retaining ring (11) into the ring
groove above the pot.
2. Screw the feedback arm (6) onto the potentiometer (3).
Thread the hex nut (7) on. Anytime the pot is removed you
will need to adjust the pot height.
3. Align the 2 spring washers (4) to the end of the shank.
Thread the potentiometer (3) into the feedback arm (6) over
the spring washers (4). Install the shoulder screw (5).
4. Screw in the anti rotation rod (10).
5. Align the circuit board bracket (2) with its mounting hole on
the cylinder and install the two SCR pan HD SL (9).
6. Rewire all wires back to the circuit board (12).
7. Install a new O-ring (15) into the cover (13). Petroleum jelly
can be used to prevent the O-ring from falling out.
L500 - L2 000 LINEAR CyLINDERS
224 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
8. Place the cylinder cover (13) with the O-ring (15) back over
the cylinder and install the 4 SHCS (14) with washers (16).
B Bushing Rebuild
3
2
6
4
5
7
1
8
Figure 4.M.18.2-B L500 & 2 000 Bushing Rebuild
Table 4.M.18.2-B
Parts List
Item Description Qty
1 Cylinder Body 1
2 Bushing 2
3 Rod Wiper 2
4 Rod Seal 2
5 Bushing End Cover 2
6 O-ring Viton - 026 2
7 SCR Flat HD Hex #4-40 8
8 Nylon Tipped Set Screw 4
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
L500 - L2 000 LINEAR CyLINDERS
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 225
4M182-B1 Disassembly
NoTE: To prevent damage, use a dead blow hammer or soft face mallet.
1. Refer to Figure 4.M.18.2-B and remove the two set screws
(8).
2. Using a spanner wrench, remove the bushing. (2).
3. Lightly tap the opposite end of the shaft to force the bushing
out.
4. Use a pick to remove the rod wiper (3) and O-ring (6).
These items can be thrown out once the replacement parts
are located from the rebuild kit.
5. Use an allen wrench to remove the 4 SCR fat HD HEX (7)
from the bushing end cover (5) and remove the rod seal (4).
6. Repeat steps 1-5 on the opposite end.
NoTE: If there is a spacer sleeve on the piston rod it needs to be
reassembled on the same side or damage and improper operation may
result.
4M182-B2 Cleaning and Inspection
1. Clean the bushings (2) in solvent and dry.
2. Inspect the bushing (2) bore for damage. If any visual
marks can be felt in the bushing (2) bore then the bushing
(2) will need to be replaced.
3. Continue to section C to complete disassembly.
4M182-B3 Reassembly
1. Install the new rod wiper (3) with the pointed edge out. In-
stall the new O-ring (6) into the O-ring groove on the outside
of the bushing (2).
2. Install the new rod seals (4) into the seal groove. The open
side must face the cylinder body. Installing these backwards
will cause the seals to fail.
3. Lubricate the O-ring (6) and seals (3 & 4) prior to installation.
L500 - L2 000 LINEAR CyLINDER
226 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4. Place the bushing end cover (5) back over the end of the
bushing (2) and bolt the 4 hex head screws (7) back into the
bushing (2).
5. Slide the bushing (2) into the cylinder body (1).
6. Tighten with spanner wrench.
7. Place Loctite® onto the two set screws (4) and install into
the cylinder body. Turn the screws 1-¼ turns once you feel
the screw contact the bushing (2).
8. Slide the piston assembly into the cylinder bore. Ensure the
orientation of the output end. Lightly tap the assembly in if
necessary.
9. Repeat steps 1- 7 for the opposite end of the cylinder.
10. Go back to the feedback reassembly in Section A to com-
plete the rebuild.
C Shank Rebuild
Table 4.M.18.2-C
Parts List
Item Description Qty
1 Piston Seal 2
2 Shank 1
3 Piston 1
4 Split Ring Retainer 1
5 Split Ring 4
6 Retaing Ring 1
7 O-ring Viton - 22 1
2
5
7
1
3
4
6
Figure 4.M.18.2-C L500 & 2 000 Shank Rebuild
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
L500 - L2 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 227
4M182-C1 Disassembly
1. Refer to Figure 4.M.18.2-C and remove the retaining ring
(6). Care must be taken not to scratch the shaft fnish.
2. Slide the split ring retainer (4) off exposing the frst set of
split rings (5).
3. Separate the split rings (5) and slide the piston disk (3) off.
The second set of split rings (5) should now fall off.
4. Remove the O-ring (7) from the piston shank (2) and both
piston seals (1) from the piston disk (3). These three items
can be thrown out once you have located the new replace-
ments from your rebuild kit.
4M182-C2 Cleaning and Inspection
1. Clean the piston shaft (2), piston (3), split ring retainer (4),
split rings (5) and the retaining rings (6) in brake wash and
dry. Ensure no residue or contaminants remain.
2. Inspect the piston shaft (2) for scratches. If you can detect
scratches by running your fnger nail around the shaft
then the shaft will need to be replaced. Reference Table
4.M.18.2-C when ordering replacement parts.
3. Inspect the piston disk (3) for any burs around the outer
surface that would scratch into the cylinder bore. If burs are
found replace the piston disk.
4. Clean the cylinder bore in brake wash and dry. Be very
cautious not to get contaminants into the ports. If any
contaminates get into the system they could cause drifting
problems.
5. Inspect the bore for wear or scratches. If the anodizing
has worn through or any scuff marks can be felt replace the
cylinder body. Ensure any new cylinders have ball plugs
installed before reassembly.
L500 - L2 000 LINEAR CyLINDER
228 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M182-C3 Reassembly
1. Lubricate the new O-ring. Slide the O-ring (7) into the O-ring
groove of the shank (2). O-ring groove is located between
the two identical split ring grooves.
2. Slide the new piston seals (1) into the piston disk (3).
Note: The O-ring side of the seals must face away from each other.
Improper orientation will cause the seals to leak.
3. Install one set of split rings (5) into the lower split ring slot of
the shank (2).
4. Slide the piston (3) on from the top insuring the counter bore
fts over the split ring (5).
5. Install the second set of split rings (5) into the upper slot on
the shank (2).
6. Slide the split ring retainer (4) over the second set of split
rings (2).
Note: The split ring retainer can only go on one way and should set
fush to the piston disk (3).
7. Install the retaining ring (6).
8. Lubricate the new piston seals (4). Go to the bushing
rebuild reassembly Section B to continue the rebuild.
L500 - L2 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 229
4M183 L4 000 CyLINDER REBUILD PROCEDURE
FOR ¾ INCH, 2 INCH AND 4 INCH STROKE UNITS
PARTS REQUIRED: Cylinder Seal Kit
A Feedback Removal
8
16
9
7
14
11
4
3
15
10
2
1
13
12
6
5
17
Figure 4.M.18.3-A L4 000 Feedback Removal
Table 4.M.18.3-A
Parts List
Item Description Qty Item Description Qty
1 L4,000 Cylinder Body 1 10 Spring Washers 1
2 Potentiometer 1 11 #10-32 Shldr Scr 1
3 Retaining Ring 1 12 Circuit Board Assembly 1
4 Feedback Takeoff Arm 2 13 SCR Pan HD SL #6-32NC 1
5 Bracket, Circuit Board Mounting 1 14 Hex Nut Std #4-40 (SS) 4
6 SBCHS ¼-20 1 15 Anti-Rotation Rod 1
7 O-ring Viton - 156 1 16 SHCS .25-20 4
8 L4,000 Cylinder Cover 1 17 Anti-Vibration Tape Foam 1
9 Spring Lock Washer 4
L4 000 LINEAR CyLINDER
230 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M183-A1 Disassembly
1 Refer to Figure 4.M.18.3-A and remove the 4 ¼-20 screws
(16) and the 4 lock washers (9).
2 Remove the cylinder cover (8) and O-ring (7). The O-ring
can be thrown out once the replacement is identifed from
the rebuild kit.
3 Disconnected all wires to the circuit board (12) and remove
the 2 SCR pan head screws (13) to remove the circuit board
(12)
4 Remove the SBHCS ¼-20 (6) to remove the circuit board
bracket (5)
5 Remove the shoulder screw (11) and hex nut (14). Remove
the 2 spring washers (10). While holding the potentiometer
(2) rod, unscrew the feedback arm (4).
6 Remove the retaining ring (3), anti-rotation rod (15) and the
potentiometer (2).
7 Jump to bushing rebuild Section B to continue disassembly.
4M183-A2 Reassembly
1 Reapply anti-vibration tape foam (17) to the base of the
potentiometer (2) and slide the potentiometer (2) into the
potentiometer hole in the cylinder (1). Ensure the cable
slides into its slot. Snap the retaining ring (3) into the ring
groove above the potentiometer (2).
2 Screw the feedback arm (4) onto the potentiometer (2).
Thread the hex nut (14) on.
3 Align the 2 spring washers (10) to the end of the shank.
Spin the feedback arm (4) over the spring washers (10) and
line up the holes. Install the SH shoulder screw (11).
4 Screw in the anti-rotation rod (15).
5 Align the circuit board bracket (5) at a 45° from the edge and
install the SBHCS SS screw (6).
L4 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 231
6 Align the circuit board (12) with its mounting hole on the
circuit board bracket (5) and install the 2 SCR pan head
screw (13).
7 Rewire all connecting wires to the circuit board (12).
8 Install a new O-ring (7) into the cover (8). Petroleum jelly
can be used to hold the O-ring from falling out.
9 Install the 4 SHCS SS ¼-20 (16) and the 4 lock washers (9).
B Bushing Rebuild
3
5
6
2
4
1
Figure 4.M.18.3-B L4,000 Bushing Rebuild
Table 4.M.18.3-B
Parts List
Item Description Qty
1 L4 000 Cylinder Body 1
2 O-ring Viton - 133 2
3 Rod Wiper 2
4 Nylon Tipped Set Screw ¼-20 4
5 L4 000 Bushing 2
6 Rod Seal 2
L4 000 LINEAR CyLINDER
232 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
4M183-B1 Disassembly
NoTE: To prevent damage, use a dead blow hammer or soft face mallet.
1. Stroke the cylinder by striking it with a dead blow hammer
from end to end with the open SAE ports over an oil drain
bucket. Read caution above.
2. Refer to Figure 4.M.18.3-B and remove the two set screws
(4).
3. Use a spanner wrench to remove the bushing (5).
4. Lightly tap the opposite end of the shaft to force the bushing
(5) out.
5. Use a pick to remove the rod wiper (3), O-ring (2) and
the rod seal (6). These items can be thrown out once the
replacement parts are located from the rebuild kit
6. Repeat steps 2-5 on the opposite end.
NoTE: If there is a spacer sleeve on the piston rod, it needs to be
reassembled on the same side or damage and improper operation may
result.
4M183-B2 Cleaning and Inspection
1. Clean the bushings (5) in brake wash and dry.
2. Inspect the bushing (5) bore for damage. If any visual
marks can be felt by touch in the bushing (5) bore then the
bushing (5) will need to be replaced.
3. Continue to Section C to complete disassembly.
4M183-B3 Reassembly
1. Lubricate the O-ring (2) and seals (3 & 6) prior to installation.
L4 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 233
2. Install the new rod wiper (3) with the pointed edge out. In-
stall the new O-ring (2) into the O-ring groove on the outside
of the bushing (5).
3. Install the new rod seals (6) into the seal grooves. The
O-ring side must face the cylinder body. Installing these
backwards will cause the seals to fail.
4 Slide the bushing (5) into the cylinder body (1).
5 Screw in the bushing (5) into the cylinder body (1) and
tighten with spanner wrench.
6 Use Loctite® on the 2 set screws (4) and install it into the
cylinder body (1). Turn the screws 1 turn once you feel the
nylon bottom contact the bushing retainer.
7 Slide the piston assembly into the cylinder bore (observe the
orientation of the output end).
8 Repeat steps 1- 6 for the opposite end of the cylinder.
9 See the feedback reassembly Section A to complete the
rebuild.
C Shank Rebuild
Table 4.M.18.3-C
Parts List
Item Description Qty
1 Piston Seal 2
2 Shank 1
3 Piston 1
4 Split Ring Retainer 1
5 Split Ring 4
6 Retaing Ring 1
7 O-ring Viton - 22 1
2
5
7
1
3
4
6
Figure 4.M.18.3-C L4 000 Shank Rebuild
L4 000 LINEAR CyLINDER
234 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
CAUTION: While assembling and disassembling
the cylinder, be aware of oil discharging from
unprotected ports
4M183-C1 Disassembly
1. Refer to Figure 4.M.18.3-C and remove the retaining ring
(6). Care must be taken not to scratch the shaft fnish.
2. Slide the split ring retainer (4) off exposing the frst set of
split rings (5).
3. Separate the split rings (5) and slide the piston disk (3) off.
The second set of split rings (5) should now fall off.
4. Remove the O-ring (7) from the piston shank (2) and both
piston seals (1) from the piston disk (3). These three items
can be thrown out once you have located the new replace-
ments from your rebuild kit.
4M183-C2 Cleaning and Inspection
1. Clean the piston shaft (2), piston (3), split ring retainer (4),
split rings (5) and the retaining rings (6) in solvent and dry.
Ensure no residue or contaminants remain.
2. Inspect the piston shaft (2) for scratches. If you can detect
scratches with your fnger then the shaft (2) will need to
be replaced. Reference Table 4.M.18.3-C when ordering
replacement parts.
3. Inspect the piston disk (3) for any burs around the outer
surface that would scratch into the cylinder bore. If burs are
found replace the piston disk.
4. Clean the cylinder bore in brake wash and dry. Be very
cautious not to get contaminants into the ports. If any
contaminates get into the system they could cause drifting
problems.
5. Inspect the bore for wear or scratches. If the anodizing has
worn through or any scuff marks can be felt replace the cyl-
inder body. Reference Figure 4.M.18.3-C. Ensure that any
new cylinders have ball plugs installed before reassembly.
L4 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 235
4M183-C3 Reassembly
1. Lubricate all O-rings and seals prior to assembly. Slide the
new O-ring (7) into the O-ring groove of the shank (2).
2. Slide the new piston seals (1) into the piston disk (3). Note
the O-ring side of the seals must face away from each other.
Improper orientation will cause the seals to leak.
3. Install one set of split rings (5) into the lower split ring slot of
the shank (2).
4. Slide the piston (3) on from the top insuring the counter bore
fts over the split ring (5).
5. Install the second set of split rings (5) into the upper slot on
the shank (2).
6. Slide the split ring retainer (4) over the second set of split
rings (5).
Note: The split ring retainer can only go on one way and should be
fush to the piston disk (3).
7. Install the retaining ring (6).
8. Go to the bushing rebuild reassembly and feedback reas-
sembly to complete the rebuild.
L4 000 LINEAR CyLINDER
236 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M184 L10 000 CyLINDER REBUILD PROCEDURE
FOR 2 INCH AND 6 INCH STROKE UNITS
PARTS REQUIRED: Cylinder Seal Kit
A Feedback Removal
3
9
2
8
14
6
11
7
13
4
10
15
12
16
5
17
1
Table 4.M.18.4-A
Parts List
Item Description Qty Item Description Qty
1 Cylinder Body 1 10 Retaining Ring 1
2 #10 Lock Washer 4 11 Hex Nut Std #4-40 (SS) 1
3 SHCS #10-32 × .75 4 12 BHCS SS 0.25 × 20 1
4 Potentiometer 1 13 Spring Washers 2
5 Bracket, Circuit Board Mounting 1 14 #10-32 Shldr Scr 1
6 Feedback Arm 1 15 Anti-Vibration Tape Foam 1
7 Anti-Rotation Rod 1 16 Circuit Board Assembly 1
8 O-ring Viton - 150 1 17 SCR Pan HD SL #6-32NC 2
9 Cover, Cylinderr 1
Figure 4.M.18.4-A L10 000 Feedback Removal
L10 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 237
4M184-A1 Disassembly
1. Refer to Figure 4.M.18.4-A and remove the 4 SHCS ¼-20
screws (3) and lock washers (2).
2. Remove the cover (9) and O-ring (8). The O-ring can be
thrown out once the replacement is identifed from the
rebuild kit.
3. Mark termination points and disconnect all wires going to the
circuit board (16). Remove the 2 pan head (17) to remove
the circuit board (16).
4. Remove the BHCS SS ¼-20 (12) screw from the circuit
board bracket (5).
5. Remove the shoulder screw (14) and hex nut (11). Remove
the 2 spring washers (13). Hold the potentiometer (4) rod
and unscrew the feedback arm (6).
6. Remove the retaining ring (10), anti-rotation rod (7) and the
potentiometer (4).
7. Continue to bushing rebuild to continue disassembly.
4M184-A2 Reassembly
1. Apply anti-vibration tape foam (15) to the base of the
potentiometer (4) and slide the potentiometer (4) into the
potentiometer hole in the cylinder (1). Ensure the cable
slides into its slot. Snap the retaining ring (10) into the ring
groove above the potentiometer (4).
2. Screw the feedback arm (6) onto the potentiometer (4).
Thread the hex nut (11) on.
3. Align the 2 spring washers (13) to the end of the shank.
Spin the feedback arm (6) over the spring washers (13) and
line up the holes. Install the SH shoulder screw (14).
4. Screw in the anti-rotation rod (7).
5. Align the circuit board bracket (5) at a 45° from the edge and
install the BHCS SS screw (12).
L10 000 LINEAR CyLINDER
238 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
6. Align the circuit board (16) with its mounting hole on the
circuit board bracket (5) and install the 2 SCR pan head
screw (17).
7. Rewire all connecting wires to the circuit board (16).
8. Install a new O-ring (8) into the cover (9). Petroleum jelly
can be used to prevent the O-ring from falling out.
9. Install the 4 SHCS ¼-20 (3) and the 4 lock washers (2).
B Top Bushing Rebuild
Table 4.M.18.4-B
Parts List
Item Description Qty
1 L10 000 Cylinder Body 1
2 L10 000 Cylinder Bushing 1
3 Rod Wiper 2
4 SQB Rod Seal 2
5 Lockwasher 8
6 SHCS SS ¼-20 8
7 O-ring Viton - 029 1
8 Rod Buffer 2
3
6
5
2
7
4
8
1
Figure 4.M.18.4-B L10 000 Top Bushing Rebuild
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
4M184-B1 Disassembly
NoTE: To prevent damage, use a dead blow hammer or soft face mallet.
L10 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 239
1. Stroke the cylinder by striking it with a dead blow hammer
from end to end with the open SAE ports over an oil drain
bucket. Read caution above.
2. Refer to Figure 4.M.18.4-B and remove the four ¼-20
screws (6) and four lock washers (5).
3. Screw two of the ¼-20 screws (6) into the threaded holes of
the bushing (2) to force it out.
4. Use a pick to remove the rod wiper (3), O-ring (7) the SQB
rod seal (4), and the rod buffer seal (8). These items can be
thrown out once the replacement parts are located from the
rebuild kit.
4M184-B2 Cleaning and Inspection
1. Clean the bushing (2) in brake wash and dry.
2. Inspect the bushing (2) bore for damage. If any visual
marks can be felt by touch in the bushing (2) bore then the
bushing (2) will need to be replaced.
3. Continue to Section C to complete disassembly.
4M184-B3 Reassembly
1. Lubricate the O-ring and seals prior to installation.
2. Install the new rod wiper (3) with the pointed edge out. In-
stall the new O-ring (7) into the O-ring groove on the outside
of the bushing (2).
3. Install the new SQB rod seal (4) and rod buffer (8) into the
seal grooves. The open side of the SQB rod seal (4) must
face the cylinder body. Installing these backwards will cause
the seals to fail.
4. After the end cap and shaft sections have been completed,
slide the bushing (2) over the shank and into place. Ensure
the screw holes line up. Install the four ¼-20 screws (6) and
four lock washers (5). Use blue Loctite on the screws and
torque to 100 lb•in.
L10 000 LINEAR CyLINDER
240 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
5. Slide the piston assembly into the cylinder bore. Lightly tap
the assembly in if necessary. Note the orientation of the
shank, output end goes in last.
6. Go back to the end cap rebuild reassembly in Section C to
continue the rebuild.
C End Cap Rebuild
6
5
7
2
3
4
9
1
8
Table 4.M.18.4-C
Parts List
Item Description Qty
1 L10 000 Cylinder Body 1
2 L10 000 Cylinder Bottom Cylinder end Cap 1
3 Rod Wiper 2
4 SQB Rod Seal 2
5 Lockwasher 8
6 SHCS SS ½-13 8
7 O-ring Viton - 040 1
8 O-ring Viton - 047 1
9 Rod Buffer 2
Figure 4.M.18.4-C End Cap Rebuild
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
4M184-C1 Disassembly
1. Refer to Figure 4.M.18.4-C and remove the eight ½ - 13
screws (6) and eight lock washers (5).
L10 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 241
NoTE: To prevent damage, use a dead blow hammer or soft face mallet.
2. Lightly tap on the opposite end of the shaft to drive the end
cap (2) out. The Shaft assembly should also come out;
reference the Shaft Rebuild in Section D for rebuild.
NoTE: If there is a spacer sleeve on the piston rod, it needs to be
reassembled on the same side or damage and improper operation may
result.
3. Use a pick to remove the rod wiper (3), O-ring (7 & 8), and
SQB rod (4) and rod buffer (9) seals. These items can be
thrown out once the replacement parts are located from the
rebuild kit.
4M184-C2 Cleaning and Inspection
1. Clean the end cap in brake wash and dry.
2. Inspect the end cap (2) for damage. If any visual marks can
be felt, then the end cap (2) will need to be replaced.
3. Continue to the Piston Shank Rebuild in Section D before
reassembly.
4M184-C3 Reassembly
1. Lubricate O-rings and seals prior to installation.
2. Install the new rod wiper (3) with the pointed edge out.
Install the new O-rings (7 & 8) into the appropriate O-ring
grooves.
3. Install the new SQB rod (4) and rod buffer (9) seals into the
seal grooves. The open side of the SQB rod seal (4) must
face the cylinder body. Installing these backwards will cause
the seals to fail.
4. Slide the end cap (2) over the piston rod and back into
the cylinder (1). Use 2 of the SHCS SS 1/2-20 screws (6)
without washers to pull it back into place.
5. Install the eight ½ - 13 screws (6) and eight lock washers
(5). Use Blue Loctite® on the screws and torque to 65 lb•ft.
L10 000 LINEAR CyLINDER
242 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
6. Go to the Feedback Rebuild Reassembly in Section A to
fnish the rebuild.
D Shank Rebuild
Table 4.M.18.4-D
Parts List
Item Description Qty
1 Piston Seal 2
2 Shank 1
3 Piston 1
4 Split Ring Retainer 1
5 Split Ring 4
6 Retaing Ring 1
7 O-ring Viton - 22 1
2
5
7
1
3
4
6
Figure 4.M.18.4-D L10 000 Shank Rebuild
CAUTION: While assembling and disassembling
the cylinder, beware of oil discharging from
unprotected ports
4M194-D1 Disassembly
1 Refer to Figure 4.M.18.4-D and remove the retaining ring
(6). Care must be taken not to scratch the fnish of the
shank.
2 Slide the split ring retainer (4) off exposing the frst set of
split rings (5).
3 Separate the split rings (5) and slide the piston disk (3) off.
The second set of split rings should now fall off.
4 Remove the O-ring (7) from the shank (2) and both piston
seals (1) from the piston disk (3). These three items can be
thrown out once you have located the new replacements
from your rebuild kit.
L10 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 243
4M184-D2 Cleaning and Inspection
1. Clean the piston shaft (2), piston (3), split ring retainer (4),
split rings (5) and the retaining rings (6) in solvent and dry.
Ensure no residue or contaminants remain.
2. Inspect the piston shaft (2) for scratches. If you can detect
scratches by running your fnger nail around the shaft (2)
then the shaft (2) will need to be replaced.
3. Inspect the piston disk (3) for any burs around the outer
surface that would scratch into the cylinder bore. If burs are
found replace the piston disk (3).
4. Clean the cylinder bore in brake wash and dry. Be very
cautious not to get contaminants into the ports. If any
contaminates get into the system they could cause drifting
problems.
5. Inspect the bore for wear or scratches. If the anodizing
has worn through or any scuff marks can be felt, replace
the cylinder body. Ensure the new cylinder has ball plugs
installed before reassembly.
4M184-D3 Reassembly
1. Lubricate the new O-ring.
2. Slide the new O-ring (7) into the O-ring groove of the shank
(2). Slide the new piston seals (1) into the piston disk (3).
NoTE: The O-ring side of the seals must face away from each other.
Improper orientation will cause the seals to leak.
3. Install one set of split rings (5) into the lower split ring slot of
the shank (2).
4. Slide the piston (3) on from the top insuring the counter bore
fts over the split ring (5).
5. Install the second set of split rings (5) into the upper slot on
the shank (2).
6. Slide the split ring retainer over (4) the second set of split
rings (5).
L10 000 LINEAR CyLINDER
244 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
NoTE: The split ring retainer can only go on one way and should set
fush to the piston disk (3).
7. Install the retaining ring (6).
8. Lubricate the new piston seals (1).
9. Go to end cap rebuild reassembly, top bushing rebuild reas-
sembly and feedback reassembly to complete.
L10 000 LINEAR CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 245
4M19 ROTARy CyLINDER
The actuator consists of a pinion and one or two racks located
within the housing. Pressurization of alternate cylinder port(s)
result in shaft rotation. The gear chamber is flled with Moly grease
containing a minimum Molybdenum Disulfde (MSO2) content of 3%.
In the event that maintenance is required, the following steps should
be used as a guide:
Figure 4.M.19 Rotary Cylinder
ROTARy CyLINDER
Table 4.M.19 Parts List
Item
no.
description
Qty
Single
rack
double
rack
1* O-ring Pinion 2 2
2 Housing 1 1
3 Rack Bearing 1 2
4* Wear Ring 2 4
5* Piston Seal 2 4
5a* Back-up Ring 2 4
6 Nylon Slug 2 4
7 Rack Bolt 2 4
8* O-ring Cylinder 2 4
9* O-ring end Cap 2 4
10 Tie Rod Nut 8 16
11 end Cap 2 4
12 Cylinder Tube 2 4
13 Tie Rod 8 16
14* O-ring, Rack Bolt 2 4
15*
Back-up Ring,
Rack Bolt
2 4
16 Piston 2 4
17 Rack 1 2
18 Relief Valve 1 1
19 Locking Screw 1 1
20 Drive Screw 4 4
21 Name Plate 1 1
22 Bearing 2 2
23 Pinion 1 1
24*
O-ring, Bearing
Retainer
1 1
25 Bearing Retainer 1 1
1. Item with an asterisk denote items supplied
with seal kit
2. Item 5a applies to Viton O-rings only.
246 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M191 Assembly and Disassembly Procedures
NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local
procedures. Repair of the rotary actuator will require removing the unit
from service.
4M191- A Inspection & Replacement
of End Cap Seals (9)
1. Open the manual bypass to relieve internal pressure, check
gauges before proceeding.
2. Remove the actuator from the driven device.
3. Clamp the actuators reservoir piston (some units may have
external reservoirs) and remove the hydraulic tubing feeding
the cylinder.
4. Remove all fasteners, feedback, mounting, and motor/
pump assemblies as necessary to free the cylinder from the
assembly.
5. Remove the tie rod nuts/bolts (10) from the tie rods (13).
6. Pull end cap (11) free from the cylinder tube (12).
7. Inspect and/or replace end cap O-ring (9). Lubricate the
seal and end cap with 5W-50 oil before re-installing.
8. Replace end cap(s) (11) on cylinder tube (12) and assemble
tie rod nuts (10) to tie rods (13).
9. Torque the tie rod nuts/bolts per the Torque Table.
4M191- B Inspection & Replacement of Wear Rings
(4), Piston Seals (5) and Cylinder O-Ring (8)
1. Perform steps A1 and A2.
2. For 50 000 lb·in and greater models:
a.) Remove Rack bolt (7).
b.) Screw two threaded rods into the tapped holes in
piston (16) and pull free from cylinder tube (12).
3. For models less than 50,000 lb·in:
ROTARy CyLINDER
Photo 4.M.19.1-A-1
Tie rod nuts/bolts
Photo 4.M.19.1-A-2
End cap o-ring
Photo 4.M.19.1-B-1
Rack bolt .
Photo 4.M.19.1-B-2
Cylinder tube
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 247
a.) Pull cylinder tube (12) free from housing (2).
b.) Remove Rack bolt (7).
4. Inspect piston (16) and replace piston seal (5).
5. Inspect and/or replace wear ring (4), (used on R2 500 lb·in
and above actuators only).
6. Inspect and/or replace cylinder O-ring (8).
7. Place cylinder tube (12) over rack and press in housing (2).
8. Slide piston (16) with piston seal and wear rings assembled
onto it, into the cylinder tube (12), until it contacts the rack
(17).
CAUTION: Nylon slug (6) is designed to prevent
rack bolt from vibrating loose during operation
Ensure that it is on the rack bolt (7); replace if
required
9. Replace rack bolt (7) and torque per the torque table.
10. Replace end cap (11) and tie rod nuts (10), torque per Table
4.M.19: Torque.
4M191- C Inspection and Replacement of
Pinion and Bearing Retainer O-Rings
CAUTION: Berfore beginning, make match marks
to enable re-establishment of correct timing
Failure to loosen the lock screw will damage
threads on the bearing retainer
1. Loosen lock screw (19).
2. Using a spanner wrench, remove the bearing retainer (25)
by turning counter-clockwise. Remove the bearing retainer
O-ring (24).
3. Remove upper bearing (22), pinion (23) and lower bearing
(22).
4. Inspect and/or replace pinion O-ring (1) located at the “front”
or blind-side of the housing (2).
ROTARy CyLINDER
Photo 4.M.19.1-B-3
Piston
Photo 4.M.19.1-B-4
Cylinder o-ring
Photo 4.M.19.1-C-1
Match Marking
Photo 4.M.19.1-C-2
Lock Screw
248 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
5. Reinstall lower bearing (22), pinion (23) making sure match
marks line up, and upper bearing.
6. Inspect and/or replace bearing retainer O-ring (24).
7. Apply Moly grease to bearing retainer threads (25) and
reinstall into housing (2).
8. Torque bearing retainer (25) per the torque table.
9. Install and tighten locking screw per Table 4.M.19: Torque.
4M191- D Complete Disassembly of Cylinder
1. Perform steps B1 through B3.
2. Perform steps C1 through C3.
CAUTION: Make match marks to re-establish
correct timing
3. Push the rack (17) from either end to remove from housing.
4M191- E Reassembly of Cylinder
1. Perform C4 through C10. Refll gear chamber with Moly
Grease.
2. Perform B4 through B10.
Table 4M19: Torque (lb·ft)
Size
Tie Rod
Nut (10)
Rack
Bolt (7)
Bearing
Retainer
(25)
Locking
Screw
(19)
R600/R1200 6 3 15 2
R2500/R5000 15 15 30 4
R10,000/R20,000 30 40 100 4
R50,000/R100,000 130 130 250 15
R200,000/R400,000 525 360 500 15
ROTARy CyLINDER
Photo 4.M.19.1-B-4
Cylinder o-ring
Photo 4.M.19.1-C-5
Upper Bearing
Photo 4.M.19.1-C-4
Bearing Retainer o-ring
Photo 4.M.19.1-C-3
Bearing Retainer
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 249
4M20 ROTARy FEEDBACK
The rotary feedback assembly consists of a housing containing
either a contacting or non-contacting potentiometer. The
potentiometer is coupled to the rotary cylinder by means of a spring
clip and transmits the actuator position to the CPU.
4M201 Identifcation
Contacting potentiometer
When removing the rotary feedback housing cover you will see
the potentiometer mounted with three wires (orange, brown,
and red) coming out of the potentiometer housing and going to
a terminal block. (Photo 4.M.20-2)
Non-contacting potentiometer
When removing the rotary feedback housing cover you will see
the potentiometer mounted with a black cable coming out of the
potentiometer housing and four wires (white, brown, green, and
a shield) going to a terminal block. (Photo 4.M.20-3)
4M202 Contacting Potentiometer
Any adjustments to the rotary potentiometer will require removing
the unit from service. Tag-Out and Lock-Out the unit for repair in
accordance with local procedures. If the actuator has a spring fail
option, take note of the CPU display when the actuator is in the
failed position.
4M202- A Disassembly
1. Put the electronics into the “SETUP” mode and under
calibration, scroll down to either “PL” or “PH”, depending on
which end of the travel. If the actuator is somewhere in the
middle, either position may be selected.
ROTARy FEEDBACK
Photo 4.M.20-1
Feedback housing cover
Photo 4.M.20-2
Contacting Potentiometer
Photo 4.M.20-3
Non-contactingPotentiometer
250 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
2. Record the reading from the display before disconnecting
power. If no reading is present, then move the actuator to
either the full open or full closed position. A record of this
number has been recorded on the data sheet inside the
electronics enclosure.
3. Disconnect the incoming power.
4. Unscrew the cover of the feedback housing to expose the
potentiometer. (Photo 4.M.20-1)
5. Disconnect the three wires coming from the potentiometer.
(Photo 4.M.20.2-1)
6. Loosen the upper set screw on the potentiometer shaft
coupling. (Photo 4.M.20.2-2)
7. Remove the two screws holding the potentiometer to the
mounting plate and remove the old potentiometer. (Photo
4.M.20.2-3)
4M202- B Reassembly
1. Reinstall the new potentiometer into position on the mount-
ing plate and bolt the two screws to the mounting plate.
2. Reattach the potentiometer shaft to the shaft coupling and
tighten the upper set screw.
3. Rewire the three wires to the terminal strip as labeled.
4. zip-tie the three wires to the post of the potentiometer
mounting plate.
5. Screw the feedback housing cover back on and tighten
securely.
6. Reconnect incoming power to the unit.
7. For calibration refer to IOM section 6, Modes of Operation
and Control Parameters.
Photo 4.M.20.2-3
Mounting plate screws
Photo 4.M.20.2-2
Potentiometer shaft coupling
ROTARy FEEDBACK
Photo 4.M.20.2-1
Contacting Potentiometer
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 251
4M203 Non - Contacting Potentiometer
General
Any adjustments to the rotary potentiometer will require removing
the unit from service. Tag-Out and Lock-Out the unit for repair in
accordance with local procedures. If the actuator has a spring fail
option, take note of the CPU display when the actuator is in the
failed position.
4M203-A Disassembly
1. Put the electronics into the “SETUP” mode and under
calibration, scroll down to either “PL” or “PH”, depending on
which end of the travel. If the actuator is somewhere in the
middle, either position may be selected.
2. Record the reading from the display before disconnecting
power. If no reading is present, then move the actuator to
either the full open or full closed position. A record of this
number has been recorded on the data sheet inside the
electronics enclosure.
3. Disconnect the incoming power.
4. Unscrew the cover of the feedback housing to expose the
potentiometer. (Photo 4.M.20-1)
5. Disconnect the four wires coming from the potentiometer.
(Photo 4.M.20.3-1)
6. Loosen the upper set screw on the potentiometer shaft
coupling. (Photo 4.M.20.3-2)
7. Remove the two screws holding the potentiometer to the
mounting plate and remove the old potentiometer. (Photo
4.M.20.3-3)
4M203-B Reassembly
1. Reinstall a new potentiometer on the mounting plate and
bolt the two screws to the mounting plate.
Photo 4.M.20.3-3
Mounting plate screws
Photo 4.M.20.3-2
Upper set screw
ROTARy FEEDBACK
Photo 4.M.20.3-1
Non-contactingPotentiometer
252 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
2. Reattach the potentiometer shaft to the shaft coupling and
tighten the upper set screw.
3. Rewire the three wires to the terminal strip as labeled.
4. zip-tie the three wires to the post of the potentiometer
mounting plate.
5. Screw the feedback housing cover back on and tighten
securely.
6. Reconnect incoming power to the unit.
7. For calibration refer to IOM section 6, Modes of Operation
and Control Parameters.
4M204 Retroftting with Contacting or
Non-Contacting Potentiometer
General
Any adjustments to the rotary potentiometer will require removing
the unit from service. Tag-Out and Lock-Out the unit for repair in
accordance with local procedures. If the actuator has a spring fail
option, take note of the CPU display when the actuator is in the
failed position.
4M204-A Disassembly
1. Put the electronics into the “SETUP” mode and under
calibration, scroll down to either “PL” or “PH”, depending on
which end of the travel. If the actuator is somewhere in the
middle, either position may be selected.
2. Record the reading from the display before disconnecting
power. If no reading is present then move the actuator to
either the full open or full closed position. A record of this
number has been recorded on the data sheet inside the
electronics enclosure.
3. Disconnect the incoming power.
4. Unscrew the cover of the feedback housing to expose the
potentiometer. (Photo 4.M.20-1)
Photo 4.M.20.4-2
Pan head screws
Photo 4.M.20.4-1
Feedback board wiring
ROTARy FEEDBACK
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 253
5. Disconnect all wires going to the feedback board. (Photo
4.M.20.4-1)
6. Remove the feedback board by unscrewing the two nylon
pan head screws. (Photo 4.M.20.4-2)
7. Loosen the upper set screw on the potentiometer shaft
coupling. (Photo 4.M.20.4-3)
8. Remove the two screws holding the potentiometer to the
mounting plate and remove the old potentiometer. (Photo
4.M.20.4-4)
4M204-B Reassembly
4M204-B1 Contacting Potentiometer
Refer to contacting potentiometer reassembly.
NoTE: During reassembly, replace feedback board with the terminal
strip as pictured.
4M204-B2 Non - Contacting Potentiometer
Refer to non - contacting potentiometer reassembly.
NoTE: During reassembly, replace feedback board with the terminal
strip as pictured.
Photo 4.M.20.4-3
Upper set screw
Photo 4.M.20.4-4
Mounting screws
ROTARy FEEDBACK
254 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M21 - LINEAR FEEDBACK
General
Depending on the type of actuator application, there are three
different types of linear potentiometers; each type is designated to
a particular application. Note, in some cases the steps maybe the
same if retroftting a contacting potentiometer to a non-contacting
potentiometer.
Identifcation
REXA Linear Cylinder Potentiometer
The REXA block cylinder is equipped with a contacting
potentiometer located inside the cylinder block. For the
disassembly and reassembly of the REXA block cylinder refer
to TS&R 4M18.
Contacting Linear Potentiometer
Typically, contacting linear potentiometers are on applications
that have a 23-inch stroke or less; but some applications use
a non-contacting potentiometer. To determine whether the
potentiometer is contacting or non-contacting, observe the
color of the marker. The contacting potentiometer uses a black
marker which slides on the sensor track.
Non-contacting Linear potentiometer
Non-contacting linear potentiometers are usually on
applications that are over 23-inch stroke, but in some 23-inch
stroke or less applications a non-contacting potentiometer is
utilized. To determine whether the potentiometer is contacting
or non-contacting, observe the color of the marker. The non-
contacting potentiometer uses a yellow marker which slides on
the sensor track.
LINEAR FEEDBACK
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 255
4M211 Contacting Linear Potentiometer
General
Any adjustments to the linear potentiometer will require
removing the unit from service. Tag-Out and Lock-Out the unit
for repair in accordance with local procedures. If the actuator
has a spring fail option, take note of the CPU display when the
actuator is in the failed position.
4M211-A Disassembly
1. Put the electronics into “SETUP” mode and under calibra-
tion, scroll down to either “PL” or “PH”, depending on which
end of the travel. If the actuator is somewhere in the middle,
either position may be selected.
2. Record the reading from the display before disconnecting
power. If no reading is present, then move the actuator to
either the full open or full closed position. A record of this
number has been recorded on the data sheet inside the
electronics enclosure.
3. Disconnect all the wires attached to the feedback board.
4. Unscrew the 2 SHCS and the set screw from the anti-
vibration bracket and then remove the bracket.
5. Remove the anti-rotation rod.
6. Unscrew the shoulder screw from the cylinder shaft.
7. Detach the anti-rotation arm from the marker coupling.
8. Remove the sensor track by unscrewing the 4 SHCS from
the 2 sensor brackets and removing the track from the
potentiometer bracket.
4M211-B Reassembly
1. Attach the sensor track to the potentiometer bracket (wires
should be on the top of the sensor) using the 2 sensor
brackets and the 4 SHCS.
2. Attach the anti-rotation arm to the marker coupling.
LINEAR FEEDBACK
256 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
3. Reinsert the shoulder bolt and feedback spacer.
4. Screw the anti-rotation rod back into position through the
designated hole in the anti-rotation arm.
5. Place the anti-vibration bracket back into position and screw
in the 2 SHCS and set screw.
6. Rewire the sensor wires to the feedback board according to
the wire schematic.
7. For calibration refer to IOM section 6, Modes of Operation
and Control Parameters.
4M212 Non - Contacting Linear Potentiometer/Retroft
General
Any adjustments to the linear potentiometer will require removing
the unit from service. Tag-Out and Lock-Out the unit for repair in
accordance with local procedures. If the actuator has a spring fail
option, take note of the CPU display when the actuator is in the
failed position.
4M212-A Disassembly
1. Put the electronics into “SETUP” mode and under calibra-
tion, scroll down to either “PL” or “PH”, depending on which
end of the travel. If the actuator is somewhere in the middle,
either position may be selected.
2. Record the reading from the display before disconnecting
power. If no reading is present, then move the actuator to
either the full open or full closed position. A record of this
number has been recorded on the data sheet inside the
electronics enclosure.
3. Disengage all the wires connecting to the feedback board.
Unscrew the 2 pan head screws and remove the feedback
board.
4. Unscrew the 2 SHCS and the set screw from the anti-
vibration bracket and then remove the bracket.
LINEAR FEEDBACK
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 257
5. Remove the anti-rotation rod.
6. Unscrew the shoulder screw from the cylinder shaft.
7. Detach the anti-rotation arm from the marker coupling.
8. Remove the sensor track by unscrewing the 4 SHCS from
the 2 sensor brackets and removing the track from the
potentiometer bracket.
4M212-B Reassembly
1. Attach the sensor track to the potentiometer bracket (wires
should be on the top of the sensor) using the 2 sensor
brackets and the 4 SHCS.
2. Attach the anti-rotation arm to the marker coupling. Note the
replacement retroftting sensor; the marker will be yellow.
3. Reinsert the shoulder bolt and feedback spacer.
4. Screw the anti-rotation rod back into position through the
designated hole in the anti-rotation arm.
5. Place the anti-vibration bracket back into position and screw
in the 2 SHCS and set screw.
6. Mount the terminal strip in the location where the feedback
board was mounted.
7. Rewire the sensor wires to terminal strip as labeled or view
wiring schematic.
8. For calibration refer to IOM section 6, Modes of Operation
and Control Parameters.
LINEAR FEEDBACK
258 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M213 Non -Contacting Linear Potentiometer
Photo 4.M.21.3-1 Non-contacting potentiometer cover
4M213-A Disassembly
1. Run the actuator so that the cylinder is at its end stop.
2. Turn off power to the unit.
3. Unscrew the fourteen pan head screws to remove the two
piece non-contacting potentiometer cover (Photo 4.M.21.3-1).
4. Disconnect the non-contacting potentiometer wires from the
terminal strip inside the junction box. Remove the cable
from the junction box. (Photo 4.M.21.3-2)
5. Loosen the hex nut on the magnet sensor to disengage the
coupling from the feedback tie rod (Photo 4.M.21.3-3).
6. Remove the magnet sensor from the sensor track. This can
be done by sliding the magnet sensor down to the bottom of
the sensor track.
7. At the top of the sensor track, remove the sensor tie rod
guide by unscrewing the two 1/4-20 hex bolt and washers
(Photo 4.M.21.3-4).
8. Unscrew the four 10-32 SHCS and lock washers and remove
the sensor track mounts and track (Photo 4.M.21.3-5).
Photo 4.M.21.3-5
Sensor track & mounts
Photo 4.M.21.3-4
Sensor tie rod guide
Photo 4.M.21.3-3
Magnet sensor
Photo 4.M.21.3-2
Terminal strip /wire connections
LINEAR FEEDBACK
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 259
4M213-B Reassembly
1. Reinstall the four 10-32 SHCS and lock washer to the
brackets for the sensor track.
2. Mounting the sensor track onto the brackets. Once aligned,
tighten the 10-32 SHCS on the brackets.
3. Three inches from the top of the sensor track, reinstall the
tie rod guide by installing the two hex head bolts and wash-
ers to clamp down the feedback tie rod guide to the sensor
track.
4. Reinstall the sensor magnet by sliding the sensor magnet
onto the sensor track with the coupling facing the feedback
tie rod.
5. Reengage the magnet sensor coupling to the feedback tie
rod and tighten the hex nut.
6. Rewire the non-contacting potentiometer cables to the junc-
tion box as shown Photo 4.M.21.3-2 or in wiring schematic.
7. Make sure there is a loop before any wire hole entries as
shown in Photos 4.M.21.3-6 and 7. Use zip-ties to secure
the cable.
8. Reinstall the two piece non-contacting sensor cover and
reinstall the fourteen pan head screws as shown in Photo
4.M.21.3-1.
Photo 4.M.21.3-6
LINEAR FEEDBACK
260 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
LINEAR FEEDBACK
Photo 4.M.21.3-7
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 261
ELASTIC COUPLING
4M22 ELASTIC COUPLING
General
The elastic coupling is used to apply a controlled load at the seated
position with linear (L series) actuators. The elastic coupling is
attached to the actuator between the stem and the driven device.
Some valves are down seating and require a compression coupling.
Valves that are up seating require a tension coupling.
NOTE: An arbor or hydraulic press will be required to disassemble the
elastic coupling. Ensure the press is in good working order and has
suffcient force to handle the loads in the elastic couplings.
Identifcation
REXA offers two types of elastic couplings. One has an open frame
construction, which is the downseating coupling. See Photo 4.M.22-
1. The second type has a closed frame construction, and is the
upseating style. See Photo 4.M.22-2.
Photo 4.M.22-1
Downseating coupling
Photo 4.M.22-2
Upseating couplling
262 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M221 Open Spring Compression
(Downseating) Load Type Elastic Coupling
Table 4.M.22.1 Parts List
Item Qty Description
1 10 Spring Washers
2 1 Spring Stop
3 1 Actuator Stem Adapter
4 1 Load Pin
5 1 #8-32 Set Screw
6 1 Stroke Indicator
7 1 Spacer
Figure 4.M.22.1
NOTE: Repair of the elastic coupling will require removing the unit from
service. Tag-Out and Lock-Out the unit for repair in accordance with
local procedures.
4M221-A Disassembly
1. Remove any external loads from the actuator. The pressure
gauges both should read zero.
2. Remove the elastic coupling from the valve stem and actua-
tor shaft by unthreading it from each end, or removing the
split clamp from the valve end.
3. Remove the set screw (5) located in the thread hole of the
actuator stem adapter (3).
ELASTIC COUPLING
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 263
4. Compress the elastic coupling until the load pin (4) moves to
the center of the hole in the actuator stem adapter (3). This
removes the internal spring load from the load pin (4).
5. Push the load pin (4) out of the assembly.
6. Slowly release the pressure on the coupling and note the
arrangement of the spring washers (1).
7. Replace or modify components as necessary.
4M221-B Reassembly
1. Reassemble by placing the stroke indicator (6), spacer (7),
spring washer (1) stack and actuator stem adapter (3) over
the spring stop (2).
2. Line up the spring stop (2) hole with the actuator stem
adapter (3) slot. Compress the spring washers (1) until the
hole and slot line up.
3. Insert the load pin (4) into the hole. Make sure the fat on
the pin is facing the set screw hole.
4. Slowly release the pressure on the spring washers (1).
5. Install the set screw using a thread lock.
ELASTIC COUPLING
264 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M222 Closed Spring Tension (Upseating)
Load Type Elastic Coupling
Table 4.M.22.2 Parts List
Item Qty Description
1 1 Stem Adapter
2 1 Upper Cap
3 1 Stroke Indicator Disc
4 1 Lower Cap
5 8 Disc Spring
6 1 Spacer
7 8 Socket Hd Cap Screw
8 8 Lockwasher - Hi Collar
9 1 Travel Indicator
10 1 Spring
Figure 4.M.22.2
NOTE: Repair of the elastic coupling will require removing the unit from
service. Tag-Out and Lock-Out the unit for repair in accordance with
local procedures.
ELASTIC COUPLING
Photo 4.M.22.2-2
Top plate against load
Photo 4.M.22.2-1
Indicator pin
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 265
ELASTIC COUPLING
4M222-A Disassembly
1. Remove any external loads from the actuator. The both
pressure gauges should read zero.
2. Remove the elastic coupling from the valve stem and actua-
tor shaft by unthreading it from each end, or removing the
split clamp from the valve end.
NOTE: Do not damage the indicator pin during this procedure. Use shims
or provide the press base plate with proper clearance holes. See Photo
4.M.22.2-1 for reference.
3. Place coupling in press, use tube stock to hold the top plate
against the load. See Photo 2.M.22.2-2 for reference.
4. Remove bolts holding the coupling assembly together.
5. Slowly release the pressure on the coupling.
6. Remove the top plate, stem adaptor, cylindrical wall and
note the arrangement of the spring washers. Also remove
the seating indicator and spring which is under the stem
adaptor.
7. Replace or modify components as necessary.
4M222-B Reassembly
1. Reassemble by placing the stroke indicator, indicator spring,
spring washer stack, cylindrical wall and actuator stem
adapter onto the valve step adapter.
2. Line up top plate with bolt holes in valve stem adaptor.
3. Compress the elastic coupling until all the parts ft together
then tighten the loading bolts in a start pattern.
4. Install the set screw using a thread lock.
NOTE: Coupling design may differ on some models. Please contact
REXA for details if your coupling differs from the designs described
above. Have serial and model number ready before contacting the
factory.
266 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4 M23 SEAT LOAD CyLINDER
The Seat Load Cylinder (SLC) is a hydraulic cushion that replaces
the elastic coupling on larger REXA Actuators. This procedure will
take you through the removal, disassembly and repair of the SLC.
Caution: Spring under tension; take care when
removing hydraulic lines and mechanical spring
4M231 Removal from Actuator
1. Place the REXA actuator in the Set Up or Local mode.
2. Power the REXA unit down and follow local Lock-out/Tag-out
procedures.
3. Open manual bypass and pressure gauge isolation valves.
4. Verify system pressure is relieved; shut off isolation valves
on both hydraulic lines connecting the SLC.
NoTE: Record the termination of the feedback wiring.
5. Remove SLC feedback cover, disconnect wires and conduit
from the assembly.
6. Leaving the isolation valves connected to the actuator,
remove hydraulic lines from the SLC.
7. While supporting the SLC assembly, remove the bolts hold-
ing the SLC to the mounting plate.
4M232 Disassembly
1. Remove shoulder bolts (19) from the spring button.
2. Remove screws (16) holding spring tube (1) to cylinder
assembly.
3. Slide spring tube (1) off of the assembly.
NoTE: Record the spring pre-compression length before proceeding.
4. Holding the stem extension (5) still, remove jam nuts (8)
relieving the spring pressure.
SEAT LOAD CyLINDER
Photo 4.M.23
Seat Load Cylinder
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 267
Table 4.M.23.2 Parts List
5. Remove coil spring (3, 4) and spring buttons (7, 6). Some
SLC assemblies have more than one spring.
6. The stem extension (5) has a tack weld holding the exten-
sion to the hydraulic cylinder. Cover all open hydraulic ports
and carefully grind weld away to remove extension from
hydraulic cylinder.
7. Remove mounting plates (9) and adaptor port (10) from
cylinder assembly.
3/8-16 THRU
8X
Figure 4.M.23.2 SLC
SEAT LOAD CyLINDER
268 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M233 Repair
REXA SLC assemblies come in L2 000 and L4 000 cylinder sizes.
Refer to section 4.M.18 to repair the hydraulic cylinder assembly.
4M234 Reassembly
1. Replace mounting plates (9) and adaptor port (10) to
cylinder assembly.
2. Thread stem extension (5) onto hydraulic cylinder stem.
Use high grade thread locker to prevent the unthreading of
shafts.
3. Install coil spring (3,4) and spring buttons (7,6).
4. Holding the cylinder stem (5) still, thread jam nuts (8) onto
the stem extension (5). Use an anti-seize compound to
prevent the assembly from galling.
5. Tighten jam nuts (8) until the spring is compressed to the
proper length.
6. Install spring tube (1) and tube mounting bolts (16).
7. Install shoulder bolts (19) into the spring button.
4M235 Re-Installation
1. Re-install the SLC onto the mounting plate on the REXA
unit.
2. Connect hydraulic lines.
3. Replace SLC feedback cover, connect conduit and feedback
wiring.
4. Close manual bypass and purge system of air.
5. Verify operation of the SLC system. System pressure at the
seated position should be 2 000 psi. Adjust spring tension
as needed.
SEAT LOAD CyLINDER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 269
4M24 BOOSTER PUMP
4M241 Motor
NoTE: P9 and P40 size modules share similar motor mounting
procedures and components
Figure 4.M.24.1 Booster Pump drawing (P40 shown)
BOOSTER PUMP
270 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
Table 4.M.24.1 Parts List
4M241A Disassembly
1. Ensure that the power has been turned off from the unit.
2. Disconnect as necessary any conduit and wires to the motor
from the terminal block
3. Ensure the actuator has been drained of oil and top drain
plug has been removed.
4. Remove set screw from coupling (2).
5. Remove the four motor bolts and four lock washers.
6. Pull motor straight out.
4M241B Reassembly
1. Orientate the motor shaft so that it engages with the pump
coupling.
CAUTION: DO NOT FORCE THE MOTOR IN
PLACE OR TIGHTEN THE MOUNTING SCREWS
BEFORE TURNING THE MOTOR SHAFT OR
DAMAGE WILL OCCUR!
BOOSTER PUMP
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 271
2. Apply blue Loctite on motor bolts and install the four motor
washers.
3. Replace set screw in the coupling (2).
4. Reconnect wires. Refer to IOM Appendix D for more
information.
4M242 Pump
4M242A Disassembly
1. Confrm that all pressure gauges read zero before discon-
necting any pressure lines.
2. Ensure the actuator has been drained of oil and top drain
plug has been removed.
NoTE: An oil drain bin should be ready to catch any oil that may drain
from disconnecting lines.
3. Disconnect tubing from the pump.
4. While supporting the pump, remove set screw from coupling
(2).
5. Remove two bolts (12) and two lock washers.
6. Remove pump.
4M242B Reassembly
1. Engage replacement pump with mounting bracket and
coupling.
2. Apply blue Loctite on pump screws and install the motor
washers.
3. Replace set screw in coupling.
4. Reconnect tubing, tighten adapters (19) and refll actuator
with oil.
5. Before running motor, prime the pump by turning the cou-
pling by hand approximately 5 rotations. This will move the
oil throughout the pump and manifold.
BOOSTER PUMP
272 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
BOOSTER PUMP
4M243 Manifold
4M243A Disassembly
1. Confrm that all pressure gauges read zero before discon-
necting any pressure lines
2. Ensure the actuator has been drained of oil and top drain
plug has been removed.
NoTE: An oil drain bin should be ready to catch any oil that may drain
from disconnecting lines.
3. Disconnect tubing from the manifold.
4. While supporting the manifold, remove four mounting bolts
and take manifold off of mounting bracket.
4M243B Reassembly
1. Secure the new manifold to the mounting bracket with the
four mounting bolts.
2. Reconnect tubing, tighten adapters (19) and refll actuator
with oil.
3. Before running motor, turn the coupling by hand approxi-
mately 5 rotations. This will move the oil throughout the
pump and manifold.
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 273
TRANSDUCER
4M25 TRANSDUCER
Identifcation
Below is a typical installation of a pressure transducer on a REXA
actuator. The ¼" stainless steel tubing going to the transducer is the
fuid side. The large, NPT wire end of the transducer threads into
the transducer wiring box shown below.
Transducer
Transducer
wiring box
Figure 4.M.25 Transducer
CAUTION: The REXA pressure transducer may
have up to 2 500 psi of fuid pressure connected to
it Care must be taken during this repair
4M251 Disassembly
1. If the unit is an accumulator fail system, then the unit must
be in its fail safe position and the accumulator in its trip
state.
2. Open the manual bypass by turning the “Bypass” hex
counterclockwise on the power module’s front face. With
the accumulator in the trip state this will drain the accumula-
tor pressure to 0 psi.
NoTE: Ensure that the high pressure accumulator gauge located on the
gauge block reads 0 psi before proceeding.
274 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
3. Turn off electrical power to the unit.
4. Close the manual override levers on the accumulator sole-
noids for accumulator fail units only. Refer to IOM Appendix
C, section C.4 for more details.
5. Remove the cover from the transducer wiring box and
disconnect both leads going to the transducer.
6. Disconnect the ¼″ hydraulic ftting from the base of the
transducer after placing an oil catch pan under the unit.
7. Unthread the transducer from the transducer wiring box.
4M252 Reassembly
1. Apply thread sealant to the threads on both ends of the
transducer. Thread the transducer into the transducer wiring
box.
2. Reconnect the ¼" hydraulic ftting to the base of the trans-
ducer.
3. Re-wire the transducer into the transducer wiring box. Refer
to Appendix P of the IOM for interconnect wiring diagrams.
4. Re-install the transducer wiring box cover.
5. Turn on electrical power to the unit.
TRANSDUCER
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 275
4M26 EXTERNAL RESERVOIR AND
ACCUMULATOR BOTTLE
Reservoir Identifcation
REXA uses two types of reservoir bottles depending on the oil
volume required for the system. The frst type is a spring loaded
piston cylinder. It is identifed by the gray body and stainless
indicator rod protruding out one end. Depending on the system it
may have one or two hydraulic lines coming off of the end cap.
CAUTION: The REXA reservoir is a pressure
vessel that typically may have up to 60 psi of fuid
pressure Care must be taken during this repair
The second type of reservoir is a low pressure accumulator bottle.
These are typically painted black and there will be two hydraulic
ports side by side on one end cap as shown in Photo 4.M.26-2.
Any bottles having only one hydraulic port to the end cap is not a
reservoir but is a high pressure fail safe accumulator. There are
some units that will not have hydraulic lines to both of these ports
but both ports will be present if it is a reservoir.
CAUTION: The REXA accumulator bottle is a
pressure vessel that typically may have up to 2 500
psi of fuid pressure Care must be taken during
this repair
Accumulator Identifcation
REXA uses piston type accumulator bottles for all the accumulator
fail units. An accumulator fail actuator will have both an accumulator
and a reservoir bottle. The accumulator bottle can be identifed by
having only one hydraulic port located in the end cap as shown in
Photo 4.M.26-3. Following the hydraulic line from the bottle will lead
you to a pressure gauge indicating the pressure in the accumulator
bottle.
Photo 4.M.26-1
Piston cylinder
Photo 4.M.26-2
Accumulator bottle
Photo 4.M.26-3
Hydraulic port
EXTERNAL RESERVOIR / ACCUMULATOR BOTTLE
276 REXA X2 Series TS&R Manual
Mechanical Repair (06/10)
4M261 Disassembly:
1. If the unit is an accumulator fail system, then the unit must
be in the fail safe position and the accumulator fail in the trip
state.
2. Open the manual bypass by turning the “Bypass” hex
counterclockwise on the power module’s front face. With
the accumulator in the trip state this will drain the accumula-
tor pressure to 0 psi.
NoTE: Ensure that the high pressure accumulator gauge located on the
gauge block reads 0 psi before proceeding.
3. Close the manual override levers on the accumulator
solenoids for accumulator fail units only. Refer to IOM
Appendix C, section C4 for more details.
4. For accumulator replacement – The bottle can now be safely
removed, continue on for reservoir replacement.
5. On most reservoir bottles there will be a ¼-turn isolation
valve. Close this isolation valve so that the handle is
perpendicular to the valve body.
6. Clamp the reservoir power module indicator. See TS&R
Appendix F for information on indicator clamping.
7. Attach the REXA bleed kit to one of the open purge ports on
the power module body. Refer to IOM section 167 for port
identifcation.
8. Place an oil catch pan under the bleed kit port; open the
reservoir ¼-turn valves, remove the REXA indicator clamp
and open the ¼-turn valve on the purge kit. This will allow
the system oil to drain.
9. Close off the ¼-turn valves going to the reservoir. The
reservoir can now be safely removed.
EXTERNAL RESERVOIR / ACCUMULATOR BOTTLE
X2 Troubleshooting and Repair Manual
Mechanical Repair – 06/10 277
4M262 Reassembly:
1. Replace appropriate bottle.
2. Remove the bleed assembly.
3. Open up all isolating ball valves
4. Reference section 1.6 of the IOM for re-flling the actuator.
EXTERNAL RESERVOIR / ACCUMULATOR BOTTLE
X2 Troubleshooting and Repair Manual
Appendix A – 06/10 A1
REXA offers three tool kits which provide the needed tools to rebuild power modules, control enclosures
and most cylinders: the Standard Tool Kit (TK-2); the Tube Bending Kit (TK-3), and the Bleed Kit with Oil
Gun (TK-4). Actuator Bleed Kit (K09275) and Oil Gun (S03082) are also available.
TK-2, the Standard Tool Kit
The standard tool kit is contained in a rugged, high-visibility tool case which features convenient
removable pallets and a combinatyion lock for optimal security. The kit contains the following:
Description Qty Item #
Hex Key Set, Ball End 13 pcs TOOL-0001
Pick Set 4 pcs. TOOL-0002
Side Cutter/Needle Nose Pliers 1 ea. TOOL-0003
Stranded Wire Stripper/Cutter 1 TOOL-0004
Tongue and Groove 12" Channellock Pliers 1 TOOL-0005
Adjustable Wrench Set 3 pcs. TOOL-0007
Retaining Ring Pliers 2 pcs. TOOL-0008
Nut Driver Set 7 pcs. TOOL-0009
Screw Driver Set 8 pcs. TOOL-0010
Mini Screw Driver Set 2 pcs. TOOL-0011
Combination Wrench Set 9 pcs. TOOL-0012
Strap Wrench Set 2 pcs. TOOL-0013
2 lb. Rubber Hammer 1 TOOL-0014
Mag Lite 2D Flashlight 1 TOOL-0015
Feeler Gauge 1 TOOL-0016
Hacksaw with Blade 1 TOOL-0017
Utility Knife 1 TOOL-0018
Tool Case 1 TOOL-0019
Photo A-1 Tool kit (TK-2)
Appendix A
List of Recommended Tools
Appendix A (06/10)
A2 REXA X2 Series TS&R Manual
TK-3, the Tube Bending Kit
The tubing kit contains the following:
Description Qty Item #
¼" Tube Bender 1 TOOL-0020
3
⁄ 8" Tube Bender 1 TOOL-0021
Tube Cutter 1 TOOL-0022
Tube Deburring Tool 1 TOOL-0023
Photo A-2 Tube Bending Kit
(TK-#)
TK-4, the Bleed Kit
The bleed kit contains the following:
Description Qty Item #
Schrader Oil Gun Assembly 1 S03082
Bleed Kit 1 K09275
Photo A-3 Bleed Kit (TK-4)
X2 Troubleshooting and Repair Manual
Appendix B – 06/10 B1
This section contains information on how to return a faulty actuator for repair or replacement.
B1 Return Procedure
1. Call REXA at (508) 584-1199 during regular business hours to get a Returned Materials
Authorization Number (RMA#).
Note: Do not attempt to return materials or other equipment without a valid RMA number. Returns
received without a valid RMA number are not accepted and are returned to sender.
2. REXA is not responsible or liable for damage resulting from improper packaging or
shipment.
3. Ship the actuator to:
REXA
4 Manley Street
W Bridgewater, MA 02379
Attn: Repair Dept, RMA#
4. REXA will determine the failure and cost to repair. No work will be performed without your
authorization. A minimum charge for diagnostic evaluation will apply.
Appendix B
Returning the Actuator for Repair
KOSO AMERICA, INC.
4 Manley Street
W. Bridgewater, MA 02379
Tel.: 508.584.1199
Fax: 508.584.2525
ELECTRAULIC™ ACTUATION
DATE: SERIAL # RETURN SHIPPING VIA: CUSTOMER P.O.# Commission/Installation Date
(REXA use only)
SECTIONS  THRU  MUST BE COMPLETED BEFORE AN
RMA WILL BE ISSUED.
Date Received Date Evaluated Date Scheduled
 BILLING ADDRESS  SHIPPING ADDRESS
Company:______________________________________ Company:_______________________________________
Address:_______________________________________ Address:________________________________________
_______________________________________________ ________________________________________________
_______________________________________________ ________________________________________________
Contact:_______________________________________ Contact:________________________________________
Tel:____________________ Fax:___________________ Tel:____________________ Fax:____________________
e-mail:_________________________________________ e-mail:__________________________________________
 ITEM(S) BEING RETURNED
 Actuator  Electronics
 Other:____________________
Include photo of problem & installation.
Electronics: supply voltage_________ control signal__________
Last error: ________ Number of: ________ starts × 1k ______ strokes × 1k ______
Fb bad _______ Dir error _______
Cs bad _______ Drv fault _______ *Drive display location
Stall _______ *Drive display ______
 PROBLEM / FAILURE DESCRIPTION (Give detailed description(s) to the following questions on a separate
sheet of paper and attach to this form to ensure conclusive findings):
1. Date and time of failure? 5. How was the failure diagnosed?
2. When did the issue first begin? What were the
characteristics of this event, and what actions
were taken?
6. Have there been any recent site shutdown or restarts on
the installation or associated equipment?
3. Describe the operational conditions at the time. 7. Any normal or special maintenance procedures
performed over the life of the unit? What was the reason
and when (compared to failure date)?
4. Describe what failed…and how. 8. What application/function does the actuator perform?
Action Requested:  repair  troubleshoot / advise  refurbish Requested Return Date:______________
Prepared By:____________________________________ Representative:_______________________________________
Notes:
1. Completing this form will ensure a faster and less costly turn around.
2. Before shipping the unit, make certain that the unit is properly cleaned to prevent injury to
factory technicials while unpacking (due to hazardous substances on unit). If unit requires
additional cleaning prior to receipt, turn arouond time and cost of order will increase.
3. Package the actuator properly and correctly to prevent damage during shipping. KOSO
AMERICA is not responsible for damage during shipping.
4. A miinimum 2 hour diagnostic charge will apply to all non-warranty evaluations.
5. REXA RMA number must appear on all packages.
RETURN MATERIALS AUTHORIZATION
ENVIRONMENTAL CONDITION:
Ambient Temperature_________
Location:  inside  outside
REP
%
BC
REXA
Electraulic
Actuators & Drives
KOSO America
4 Manley Street
W. Bridgewater, MA 02379
Tel: 508•584•1199
Fax: 508•584•2525
BILLING ADDRESS
PREPARED BY: _________________________ REPRESENTATIVE: ________________________
SHIPPING ADDRESS
DATE: SERIAL # CUSTOMER P.O. # WORK ORDER # (for REXA use only) RETURN
SHIPPING
VIA:
PROBLEM/FAILURE DESCRIPTION:
ACTION REQUESTED: † REPAIR † TROUBLESHOOT/ADVISE † REFURBISH
REQUESTED
RETURN DATE: _________________
SECTIONS n THRU q MUST BE COMPLETED
BEFORE AN RMA WILL BE ISSUED.
NOTES:
REP
%
BC
Company: ________________________________
Address: _________________________________
_________________________________________
Contact: __________________________________
Tel: ________________ Fax: _______________
_________________________________________
e-mail: ___________________________________
n o
ITEM(S) BEING RETURNED
† ACTUATOR † ELECTRONICS † OTHER _________________
Model No.: ________________________________
Electronics: SUPPLY VOLTAGE __________ CONTROL SIGNAL ___________
ENVIRONMENTAL CONDITION:
Ambient Temperature _________
Location: † inside † outside
p
q
v03
Company: ________________________________
Address: _________________________________
_________________________________________
Contact: __________________________________
Tel: ________________ Fax: _______________
_________________________________________
e-mail: ___________________________________
Date Received Date Evaluated Date Scheduled
COMPLETING this form will ensure a faster and less costly turn around on repair of the actuator.
BEFORE SHIPPING the actuator, make certain that the unit is properly cleaned to prevent injury to
factory technicians while unpacking (due to hazardous substances on unit). If unit requires additional
cleaning prior to repair, turn around time and cost of repair will increase.
PACKAGE THE ACTUATOR PROPERLY and correctly to prevent damage during shipping.
KOSO AMERICA is not responsible for damage during shipping.
A MINIMUM 4 HOUR LABOR or 2 hour diagnostic charge will apply to all non-warranty repairs.
REXA RMA number must appear on all packages.
1.
2.
3.
4.
5.
return materIalS authorIZatIon
X2 Troubleshooting and Repair Manual
Appendix C – 06/10 C1
D97904 — STEPPER WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.2
D97904-.5D — ½D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.3
D97904-D — D SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4
D97904-2D — 2D SERVO WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.5
D97904-P9 — D,P9 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.6
D97904-P40 — D,P40 SERVO WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.7
D97904-STEPACCUM — STEPPER WITH ACCUMULATOR FAIL OPTION. . . . . . . . . . . . .C.8
D97904-.5DACCUM — ½D SERVO WITH ACCUMLATOR FAIL OPTION. . . . . . . . . . . . . . .C.9
D97904-DACCUM — D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . . . . . . . . . C.10
D97904-2DACC — 2D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . . . . . . . . . . C.11
D97904-P9ACC — D,P9 SERVO WITH ACCUMLATOR FAIL OPTION. . . . . . . . . . . . . . . . C.12
D97904-P40ACC — D,P40 SERVO WITH ACCUMULATOR FAIL OPTION. . . . . . . . . . . . . C.13
Appendix C
Circuit Schematics
C
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X2 Troubleshooting and Repair Manual
Appendix D – 06/10 D1
X2 MODULE CABLE SPECIFICATION
CABLE TYPE: 4 Twisted pair, 1 twisted triad
CONDUCTORS: #16 AWG 19/29 Stranded Tinned Copper
CABLING: 4 Twisted pair, 1 twisted triad, wrap with an aluminum/mylar tape (foil side
in). Pull in a #16 AWG tinned copper drain wire under this tape.
JACKET: Gray PVC
FILLER: As required
INSULATION: Color Coded PVC
Pair 1. Red with Red/Black
Pair 2. Green with Green/Black
Pair 3. Blue with Blue
Pair 4. Yellow with Yellow
Triad Brown and Brown and Green/Yellow
RATINGS: Voltage rating; 600 volts
Temp rating; -20 °C to +105 °C (-4 °F to +220 °F)
Flammability; Passes UL VW-1 fame test
LABELING: Label PVC jacket with company name and note (Repeat ever 1.0');
REXA P96191-X2 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE
SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIP-
MENT BY AT LEAST 1 METER
APPROX. O.D. 0.5 – .625"
Appendix D
Cable Specifcations
Appendix D (06/10)
D2 REXA X2 Series TS&R Manual
FEEDBACK CABLE SPECIFICATIONS
CABLE TYPE: 3 Conductor
CONDUCTORS: #18 AWG 16/30 Stranded Tinned Copper
CABLING: 3 Conductors together and wrap with an aluminum/mylar tape (foil side in).
Pull in same AWG tinned copper drain wire over this tape.
JACKET: Gray PVC
FILLER: As required
INSULATION: Color Coded PVC
1. Red
2. White
3. Black
CHARACTERISTICS: Voltage rating; 600 volts
Temp rating; -20 °C to +105 °C (-4 °F to +220 °F)
Flammability; Passes UL VW-1 fame test
LABELING: Label PVC jacket with company name and note (Repeat ever 1.0');
REXA P96192 ! ATTENTIoN ! – LoW VoLTAGE CABLE – MUST BE
SEPARATED FRoM HIGH VoLTAGE CABLES AND HIGH VoLTAGE
EQUIPMENT BY AT LEAST 1 METER
APPROX. O.D. 0.230 – .250"
X2 Troubleshooting and Repair Manual
Appendix D – 06/10 D3
SOLENOID CABLE SPECIFICATIONS
CABLE TYPE: 3 Conductor
CONDUCTORS: #16 AWG 19/29 Stranded Tinned Copper
CABLING: 3 Conductors pulled in a PVC jacket.
JACKET: Gray PVC
FILLER: As required
INSULATION: Color Coded PVC
Blue
Blue
Green/Yellow
CHARACTERISTICS: Voltage rating; 600 volts
Temp rating; -20 °C to +105 °C (-4 °F to +220 °F)
Flammability; Passes UL VW-1 fame test
LABELING: Label PVC jacket with company name and note (Repeat ever 1.0');
REXA P97981 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE
SEPARATED FRoM HIGH SIGNAL LEVEL CABLES AND SENSITIVE
EQUIPMENT BY AT LEAST 1 METER
APPROX. O.D. 0.25 – .275"
Appendix D (06/10)
D4 REXA X2 Series TS&R Manual
HEATER/SOLENOID CABLE SPECIFICATIONS
CABLE TYPE: 1 Twisted pair, 1 twisted triad
CONDUCTORS: #16 AWG 19/29 Stranded Tinned Copper
CABLING: 1 Twisted pair, 1 twisted triad
JACKET: Gray PVC
FILLER: As required
INSULATION: Color Coded PVC
Pair 1. Blue with Blue/Black
Triad Black and White and Green/Yellow
CHARACTERISTICS: Voltage rating; 600 volts
Temp rating; -20 °C to +105 °C (-4 °F to +220 °F)
Flammability; Passes UL VW-1 fame test
LABELING: Label PVC jacket with company name and note (Repeat ever 1.0');
REXA P97335 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE
SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIP-
MENT BY AT LEAST 1 METER
APPROX. O.D. 0.4 – 0.45"
X2 Troubleshooting and Repair Manual
Appendix D – 06/10 D5
D – PUMP MOTOR CABLE SPECIFICATIONS
CABLE TYPE: UL type TC (tray cable), 4 conductor, overall foil shield
CONDUCTORS: #14 AWG 41×30 Stranded Tinned Copper
CABLING: 4 Conductors together and wrap with an aluminum/polyester tape (foil side
in), 100% coverage. Pull in a #14 (41/30) AWG tinned copper drain wire
under this tape.
JACKET: Gray PVC
FILLER: As required
INSULATION: Color Coded PVC / Nylon
1. Orange
2. Blue
3. Gray
4. Green
CHARACTERISTICS: UL type TC
Voltage rating; 600 volts
Temp rating; -20 °C to +90 °C (-4 °F to +195 °F)
Flammability; Passes UL VW-1 fame test
Sunlight resistant
Direct burial
Indoor/outdor use
LABELING: As required by UL for TC type cable
Label PVC jacket with company name and note (Repeat ever 1.0');
REXA P96402-14 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE
SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIP-
MENT BY AT LEAST 1 METER
APPROX. O.D. 0.60 – 0.61"
Appendix D (06/10)
D6 REXA X2 Series TS&R Manual
RESOLVER CABLE SPECIFICATIONS
CABLE TYPE: Power Limited Tray Cable, 20 AWG pairs stranded (7/28) tinned copper
conductors, twisted pairs, PVC Insulation, Indiviually shielded plus an
overall foil shield (100% coverage), PVC Jacket
CONDUCTORS: #20 AWG 7/28 Stranded Tinned Copper Conductors, Colored PVC insula-
tion, 300 volt, 105 °C (220 °F)
CABLING: 4 Twisted Pairs, Min 2 twist/inch:
Pair 1: Red paired with Black
Pair 2: Green paired with Blue
Pair 3: Brown paired with White
Pair 4: Orange paired with Yellow
Inner SHEILDING (per pair): ALULMINUM FOIL-Polyester TAPE, 100% coverage, Foil Fac-
ing IN with a 22 AWG (7/30) tinned copper DRAIN WIRE pulled over the
tape
Outer SHEILDING: ALULMINUM FOIL-Polyester TAPE, 100% coverage, Foil Facing OUT with
a 22 AWG (7/30) tinned copper DRAIN WIRE pulled over the tape
INSULATION: Color Coded PVC, 0.016" WALL NOM.
JACKET: Gray PVC, 0.053" WALL NOM.
FILLER: As required
CHARACTERISTICS: Voltage rating; 300 volts
Temp rating; -30 °C to +105 °C (-22 °F to +220 °F)
Flammability; Passes UL VW-1 fame test
UL type PLTC
Sunlight resistant
Direct burial
Indoor/outdor use
LABELING: UL File #…20 AWG TYPE PLTC 105 °C 300 V (UL)
Label PVC jacket with company name and note;
REXA P98272 ! ATTENTIoN ! – LoW VoLTAGE CABLE – MUST BE
SEPARATED FRoM HIGH VoLTAGE CABLES AND EQUIPMENT BY
AT LEAST 1 METER
APPROX. O.D. 0.40 – 0.42"
X2 Troubleshooting and Repair Manual
Appendix D – 06/10 D7
P40 MOTOR CABLE SPECIFICATIONS
DESCRIPTION: Cable, 4/C 8 AWG shielded
CONDUCTORS:
Wire Size & Type: 8 AWG (7×24/30) tinned copper, 10-0100-253
Insulation Type: PVC 105C, 60-0600-34
Nom. Ins. Thickness: 0.036
Conductor diameter: 0.237
Tolerance: .008"
Colors: Orange, Blue, Gray, Green
Covering Each conductor covered with clear nylon
Insulation Type: Clear Nylon, 60-0875-02
Nom. Ins. Thickness 0.007
Conductor diameter 0.250
Tolerance: (+/-) .009"
ASSEMBLY:
Core Cabling: 4/C Cable around fller
Filler: Gray or White fbrillated polypropylene (center)
Lay direction: Left
Binder: Fleece tape (100% coverage, 35% min. overlap)
Shield 1
Shield: Aluminum/polyester (100% coverage, 35% min. overlap, foil facing
outward)
Drain Wire: 10 AWG stranded tinned copper (in contact with foil and
TC shield (0.120 O.D.)
Note: Drain wire may be parallel
Shield 2
Type: Braid Ends; 8
Material: Tinned copper carriers; 48
Required coverage: 90% minimum coverage Angle; 37.25
AWG: #34, 10-0100-14 Pics/Inch; 4.60
JACKET: Gray PVC
Material type: Tube Black, PVC, Oil, water & sunlight resistant, 60-0600-34, Nom.
jacket thickness–0.060
Note: outer jacket will show evidence of the underlying wire form. Apperance will worsen with addition of
drain wire.
(continued)
Appendix D (06/10)
D8 REXA X2 Series TS&R Manual
Cable diameter: 0.764
Note: O.D. will increase by 0.120" on major diameterl
Tolerance: (+/-) .028"
Print: Ink jet white
Legend: REXA p/n P97882 ! ATTENTIoN ! – HIGH VoLTAGE CABLE –
MUST BE SEPARATED FRoM SIGNAL LEVEL CABLES AND
SENSITIVE EQUIPMENT BY AT LEAST 1 METER
Ratings: 105C; Voltage rating of conductors is equivalent to SAB 08610804
(UL)/c(UL) 600v; UL-AWM: 1000 V; cable not UL/CSA rated
Tests misc.:
Test 1: Continuity Put Ups; Bulk
Test 2: Short Reels; Wood
Test 3: Physical.dimensional weight; 478 lb/mft
Approvals: UL/CSA; None
X2 Troubleshooting and Repair Manual
Appendix E – 06/10 E1
Appendix E
Parameter Sheet
Appendix E – 06/10 E3
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X2 Troubleshooting and Repair Manual
Appendix F – 06/10 F1
Appendix F
Field Service Memo
F3
Field Service Memo
KOSO AMERICA
4 Manley Street
W. Bridgewater, MA 02379
Tel: 508.584.1199
Fax: 508.584.2525
Electraulic™
Actuators
& Drives
FSM/I-C - April 30, 2008
Indicator Clamping
In the past it has been said that for simple maintenance procedures clamping of the aluminum X1 reservoir
indicator is recommended to avoid draining of the actuator's oil. This is an acceptable procedure for the X1
power module because the reservoir indicator is aluminum, which will not corrode and also does not pass
through any seals.
An issue arises when this same procedure is performed on either an X2 power module or any REXA actuator
(X1 or X2) with an external auxiliary reservoir. The X2 reservoir indicator should not be clamped as you can
damage the stainless finish. The X2 reservoir indicator passes through a seal and damage to the indicators’
finish will result in the seal tearing while the indicator passes in and out. A tear in the indicator seal will allow
water and other elements to enter the power module's electrical connection area. A similar issue exists
with both X1 and X2 units which utilize an external auxiliary reservoir. The oil level indicator on an external
reservoir is chrome plated and equally susceptible to damage. Once the finish on the indicator has been
compromised there is a potential for corrosion. To avoid this we continue to recommend that these oil
indicators not be clamped and that the oil be drained to complete maintenance and repairs.
However, it is our understanding that certain simple procedures become far less time consuming if oil is not
drained from the unit. For situations like this we recommend that all possible precautions be taken to ensure
the integrity of the oil level indicators’ finish. A simple step must be taken to protect the oil level indicator.
For this we recommend use of a rubber hosing to shield the indicator from the teeth of the clamping device.
Please observe the photos below depicting this clamping procedure with a pair of vise grips. Following this
procedure correctly will prevent the need to drain the oil during simple actuator maintenance or repair and
will also adequately protect the finish of the indicator.

Contents
Fundamental SaFety InFormatIon
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Warning .Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi Residual .Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi When .to .Lock-Out/Tag-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Procedures: . .Lock-Out/Tag-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . xx Education .and .Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

1. General InFormatIon
1 .1 . .Factory .Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1 .2 . .Actuator .Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.2.1 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2.2 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2.3 Build Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 .3 . .General .Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 1.3.1 Recommended Fluids and Lubricants . . . . . . . . . . . . . . . . . 4 1.3.2 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 .4 . .inspection .schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. Problem IdentIFICatIon
What .is .the .problem? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 2 .1 . . .Interface .issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.1 I forgot my Password; how do I get into Setup? . . . . . . . 12 2.1.2 Warning relay open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.3 Alarm relay open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.4 Error code in display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FB bad CS bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Mot stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dir error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 06/10

i

Drv fault

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

+15 fail or -15 fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pres bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pres low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SlcFb bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Slc stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Key bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Mem fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 No inp bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 A/D fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CPU fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.1.5 Motor driver fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.1.6 No display, unusual display . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.1.7 Actuator will not respond to HART command . . . . . . . . . . 20 2.1.8 Actuator will not respond to FF command . . . . . . . . . . . . . 21 2.1.9 Actuator will not respond to Pulse command . . . . . . . . . . . 21 2.1.10 Actuator will not respond to Analog command . . . . . . . . 21 2.1.11 Actuator will not respond to 1 Cont (On/Off) command 22 2.1.12 Actuator will not respond to 2 Cont (Manual Control) command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2 .2 . . .Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2.2.1 External push buttons don’t work . . . . . . . . . . . . . . . . . . . . 23 2.2.2 Internal Keypad buttons don’t work . . . . . . . . . . . . . . . . . . 23 2.2.3 Drill Drive / Hand wheel doesn’t work . . . . . . . . . . . . . . . . . 24 2.2.4 Manual Hand Pump doesn’t work . . . . . . . . . . . . . . . . . . . 25 2.2.5 Gauges don’t work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.2.6 Pressure Limiting Protection not working . . . . . . . . . . . . . 25 2.2.7 Torque or thrust data not accurate (from transducers) . . 26 2.2.8 Mechanical limit switches not functioning . . . . . . . . . . . . . 26 2 .3 . . .Control .Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.3.1 Actuator moves to wrong position . . . . . . . . . . . . . . . . . . . 27 2.3.2 Actuator “hunting” (dithering during control) . . . . . . . . . . . 27 2.3.3 Actuator “drifts” away from applied load . . . . . . . . . . . . . . 28 2.3.4 Position Feedback doesn’t match actual position . . . . . . 28 2.3.5 How do I test my 4-20 mA Position Transmitter? . . . . . . 28 2.3.6 No position feedback signal . . . . . . . . . . . . . . . . . . . . . . . . 28 2.3.7 Electrical Limit Switches don’t function . . . . . . . . . . . . . . . 29 2.3.8 Actuator will not seat, I can not get full travel. . . . . . . . . . 29

ii

REXA X2 Series TS&R Manual

2.3.9 Actuator does not meet stroke speed requirements . . . . 30 2.3.10 Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.3.11 Only one module on 2D or 2C units functions . . . . . . . . 30 2.3.12 Surrounding equipment disrupted by Actuator operation . . 31 2.3.13 Servo Motor turning at low RPM when not commanded to move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.3.14 Actuator slows down and “resets” before getting to target position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.3.15 Actuator overshoots target position and returns . . . . . . 32 2.3.16 I have many errors logged in historical stats . . . . . . . . . 32 2 .4 . . .Fail .Safe .Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2.4.1 Accumulator will not recharge. . . . . . . . . . . . . . . . . . . . . . . 33 2.4.2 Actuator does not recover after fail safe event . . . . . . . . 33 2.4.3 Unit will not move to fail position . . . . . . . . . . . . . . . . . . . . 34 2.4.4 Actuator does not meet failsafe speed requirements . . . 35 2.4.5 Hydraulic surge system not functioning . . . . . . . . . . . . . . 36 2.4.6 Unit moves to the wrong position for trip. . . . . . . . . . . . . . 36 2.4.7 No Accumulator Pressure reading on Display, but there is pressure on gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 2.4.8 Solenoid is extremely hot to the touch . . . . . . . . . . . . . . . 37 2 .5 . . .Oil .Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.5.1 External oil leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.5.2 The oil indicator is low, but no oil is visible / Repeated Reservoir filling, no visual oil leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.5.3 Reservoir relief leaks oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2 .6 . .Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.6.1 Water in Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.6.2 Cylinder binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2 .7 . .Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.7.1 Setting PL or PH and the unit reads “too high” or “too low” . 40 2.7.2 Will not accept PL or PH value . . . . . . . . . . . . . . . . . . . . . . 40 2.7.3 Will not accept SL or SH value . . . . . . . . . . . . . . . . . . . . . . 40

3. troubleShootInG
3 .1 . .Accumulator .low/bad .pressure . . . . . . . . . . . . . . . . . . . . . . . . 41
Press bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Press Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3 .2 . .Drive .Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.2.1 B CSA drive fault IMS Driver. . . . . . . . . . . . . . . . . . . . . . . . 44
06/10

iii

B Stepper Driver IMS Style with separate Power Supply: . Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Drive: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 B CSA drive fault Potted Drive . . . . . . . . . . . . . . . . . . . . . . Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper Motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepper driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 44 45 46 47 48 49 49 49 50

3.2.3 C drive fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Interconnecting Cabling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Stepper Motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Stepper driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 CPU signals to the driver: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3.2.4 Servo Motor Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 3.2.5–A Input/Output signals from CPU to Driver . . . . . . . . . . . 55 3.2.5–B Input/output signals from CPU to Dual D Drivers . . . . 56 3.2.5–C Input/output signals from CPU to Servo Driver with Booster Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 3.2.6 Driver Fault code identification . . . . . . . . . . . . . . . . . . . . . . 57 REXA Omega Series Fault Codes (specific to the Omega drive LED display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3.2.7 Actuator “run away” when unit is powered up . . . . . . . . . 60 3.2.8 Servo Motor resistance readings . . . . . . . . . . . . . . . . . . . . 62 3.2.9 DC Bus Voltage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3.2.10 REXA Omega Drive Motor Wiring . . . . . . . . . . . . . . . . . . 63 3 .3 . .Seat .Loading .Cylinder .Problems . . . . . . . . . . . . . . . . . . . . . . . 64 3.3.1 SLC reads Seated before actuator is on valve seat . . . . 64 3.3.2 SLC Feedback bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 3.3.3 SLC Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 3 .4 . .Feedback .Bad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 3 .5 .Mot .stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 3.5.1 Motor stall hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 High pressure stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Low/no pressure stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3.5.2 Motor stall electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 3 .6 .Direction .Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

iv

REXA X2 Series TS&R Manual

. . . . . . . . . . . . . .13 .2 CS Bad reading (Control signal is less than 2. . . . . . . . . . . .1 Fail direction . . . .REXA Electronics: . . . . . . . . . . .Signal . . . .15. . . . . .15.4 Actuator travels to Position Lo or Position Hi when CS Bad error occurs . . . . . . . .Pulse . .5 CS Bad error does not appear when Control Signal drops below 2. . . . . . . . . . . . . . . 85 3. . . . . . . . . . . 102 3. . . . . . .6 Too High/Too Low on display . . . . . . . . . . . . . . . .3 Actuator drifting . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .Problems . 98 3. . . . . . . . . . . . . . . . . .12 . . . . . . . . . . . . . . . . . . .5 mA . . . . . . .3 No trip on loss of control signal . . . . . . . . . . . . . . . . 75 3 . 108 06/10 v . . . . . . . . . . .1 Ribbon Connector . .15. 101 3. . . . . 84 3. . . . . . . . 98 Electrical Noise on the Actuator Feedback Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . .11. . . . 94 3. . .Contact . . . . . . 99 3. . . . 84 3. .+/. 86 3. . . . . . . . . . . . . . . . . . . . .16. . . . . .2 Control Issues . . .11. . . . . . . . . . . . . 104 Do the solid state relays have leakage current when they are off? . . . . . . . . .11 . .15 . . . . . . . . . . . . . . . . . . . . . . . .Control .Fieldbus . . . . . . . 76 3 . 80 3 . . . . . . . . . . . . . . .8 . . . . . . . . . . . . . . . . .Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 . . . . . 107 3. . . . . . 88 3 . . . . . . . . . .Pressure . . . . . . . . . . . . . . . . . .13. . . . . 105 3. . . . . . . . 87 3. . . . . . . . . . . . . . . . . . . . 78 No Digital communication is taking place . . . . . . . . . . . . . . . . . . . . . . . 76 No Digital communication is taking place .11. . . . . . . .7 . . . . . . . . . . . . . . . . . . . . . . . 94 3. . . . . . . . . . . . .Signal . . . .3 Control Signal “dithering” or noisy . . . . . . . . . 76 CS problem . . . . . . . . . .15. . . . . . . . . . 78 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 3 . . . . . . . . . . . . . . . .16. . . . . . . . . . . 100 3. . . . . . . . . 96 3 . . . .11. . . .Trip . 98 Electrical Noise on the Control Signal . . . . . . . . . . .Fail . . .11. . . .16 . . . . . . 87 3 . . . . . . . . . . . . . . .Valves . . . . . . . . . . . . .Control . . . . .Signal . . . . . . . . . 107 3. . . .Input . . . . . . . . . . . . . . . . . . . .Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3 . . . . . . . . . . . . . . .5 Electrical Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . .10 .16. . . . . . . .4 Position Transmitter Calibration .Interface . 107 3. . . . . . . . . . . . . . . .5 mA) . . .4 No trip on loss of trip signal . . . . . .1 If actuator Position does not match Control Signal Input (Control Signal Calibration) . . 108 3. . .15. . . . . . . . . . . . . . . . . . . . . . . . .1 Actuator Hunting – Electrical Noise . . . . 73 Mechanical . . .16.13. .2 Actuator Torque / Thrust requirements . . . . . . . . . . . . . .14 . . . . . . . . . . . . .9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foundation . . . . . . . . . . . . . . . .Display . . . . . . . . .Vdc .Signal . . . . . .Hart . .2 No trip on loss of power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control .15. . . . . 73 3 . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .7. . . 147 4. .17 . . . . . . . . . .E. . . .1 Module / Motor . . . . . . . . . . . . . . . . . . . . . . . . .2 Electronics . . . . . . 113 4. . . .2 Why Ground Anyway? . . . . . . 113 4./ . . . . . . . . . . . . .1. .E. . .e. . . . . . . . . . .(Std . . . . . .10 . . 147 4. . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . 144 4. . . . . . . . . . 150 4. . . . . . . . . .11 . . .Stepper .Contact . . . . . 137 4. . . . . .CSA .Display . . . . . . .E. . . . .2 Replacement . . . . . . . .E. . . . . . .6. . . . .VFD . . . . . . . . . 130 4. . . . . .CPU . . . . . 151 4 .E . . .5 . .Drive . . . . . . . . . . . . . . . .6 . . . . . . . . . . .10. . . . . . . . . . . . .Display . . . . . . .1 Removal . . . . . . . . . . . . . . . . .Drive . . . . . 153 4.2 Replacement . .E.1 Removal .3 Solutions (or a Single Ground is a Good Ground) . . . . . . . . 116 4. . . .5. . . . . . .E.Assembly . . . . . . . . .8 . . . . .Ground . . .7. .2 Replacement . . . . . 142 4.E . 137 4.Supply . . 116 4. . . . . . .1 . . .E. .Servo . eleCtrICal rePaIr 4 . . . . . . . . . . . . . . . . . . .1. . . . .Relay . .B . . . . .Motor . . . . .COMPONENT . . 117 4 . . . . .1. .1 Removal . . . . . . . . . .5 Ground loops and REXA Equipment . . . . . . . . .10.E .Assembly . . . . . . . . .3 . . . . . 118 4 . . . . . . . . . . . . . . . . . . .2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly . . 153 4. .7 . . . . 149 D 4. . . . . .Motor . . . . . . . . . . .WATER . . . . . . . . . . . . . .Stepper . . . . . . .E . . . . . . . 142 4. . . . . . .1. . . . . . . . . . . . .2 Replacement of the display assembly: . .E. . . . . . . . .E . . . . . .E. . . . .Out . . 154 4 . . . . . . . . . . . . . . . . . .E. 113 4. . . 110 3. . . . . . . .E. . . . . . .Loops . .Assembly .9.6. .In . . . . . . . . . . . . . .4 Causes of Ground Potential Differences . . . . .17. .2 Replacement . . . . . . . . . . . . 140 4 . 129 4. . . .8. . . . .D . . . . . . . .4. . . . . . . . . .C . . .E. . . . . . . . . . .(Internal) . 114 4. . . . .E . . . . .1 Removal . . .3.E. . . . . . .REPLACEMENT . . . . . . .E . . . 155 vi REXA X2 Series TS&R Manual . . . . . . .Power . .Drive .1 Removal of the External VFD Display: . . . .2 Replacement . . . . . . . . . . . .E. . . .9.VFD . . . . .3.E. . . . . . . . . . . . . .E. . . . . .INGRESS . .1 What is a Ground Loop? . . 134 4 .Assembly . . 144 4. . . .Motor . 110 3. . . . . . . . . . . . . . . .E. . . . . . 143 4 . . .4 . .E. . . . .1 Removal . . . . . . . . . . . . . . . .1/2 . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 4. . . . . . .E. . .E . . . . . . . . .E .6 What fixes a ground loop?. . . . . . . . . 110 4. . . . . .E. . . . . . . . . . . . . . . . . . . . . . . 145 4 .4. . . . . . . . .1 Removal (STD B&C) . . . . . .Driver . . . . . . . . .3 . .17. . . . . . . . . . . . . . . . . . 122 4. . .CSA . . . .Stepper . . .E .E. . .1. . . . . . . . . . 148 4 . . . . . .E . . . . . . . . .9 . . 127 4 . . . .2 Replacement . . . . .1 Removal . . . . .2 Replacement (STD B&C) . .B&C) . .(External) . . . . . . . . . . . . . . . .E. . .8. . . . . .

. . .13. .2 Cleaning and Inspection . . . . . 162 4. . . . . . . . .1 Removal of the Foundation Fieldbus Assembly . . . . . .E. 164 4. . .Module . . . . .M .EMI ./ . . . . . . . . .3. . .Replacing . 184 4. . . . . . . . . .4. . . . . .2 Replacement of the Filter: . .Replacing .Modules) . .15.E .E .Motor . . . . . . .Replacing . . .E . . . . .Overview . . . . . .14. . .Replacing . . . . .18. . . . . .Seal .E. . . . .Mounted . . .Power . . . . . . 185 4. . . . . .Removal . . . . . 183 4. . . . .M. .Component . . . . . . . . . . .12. . . . . . .12. 168 4. . . .M. . . . . . . . . . . . . .Identification . . .E. . .Filter . 166 4. . . .5. . . . . .E . . . . . . . . . . . 172 4. . . . . .2 Replacement of Control Signal Surge Suppressor:.Hart® . . . . 170 4. . . . . . . . . . . .11. . . . . . . . . . . . . 164 4. . .1 Disassembly . . . . . . . . .E. 172 4. . . . .1 Removal of the Internal Display Assembly .Rebuild . . . . . . . 171 4 . . . . . . . . . . . . . . . . . . .Module . . . .M. . . . . . . .E.Replacement .1 Removal of Feedback Board . . .4 . . 186 06/10 vii . 175 4 . . .17 . . . . .E. . . . . . . . . . . . . .16. . . . . . .m. .1 Removal of the Filter: . 168 4.12. .Assembly .15 .(S97695) .18 . .or . . . .1 Removal of Control Signal Surge Suppressor . . . . . . .Feedback . . . . 173 4. . .Replacement . 167 4 . . . .E. 170 4. . . . .Reservoir . . . . .2 Cleaning and Inspection . . . . .M . . . . .1 Removal . . . 185 4. . . . . . . .E . . .(All . . . . . . . .M . .M.Switch . . . .4. . . . . . .Suppressor . . . 162 4. . . . . . . .RFI . meChanICal rePaIr 4 . . . .Interface . .2 Replacement of the Display Assembly: .14. .Replacing . . . .17. .1 Removal of the Hart Interface Assembly . . . .1 Disassembly . . . . . .15. . . . . . . . . .2 Replacement of External Switch . . . . . .4 Replacement of the AC Power Surge Suppressor: . . . . .E. . . . . .E .1 Removal of a Fuse . . . . . . . . . . . . . . .16 . . . . . .E. . .Replacing . . . . . . . . .3 Re-Assembly . .11.Double . . . . . . . . .4. . . . . . . 163 4 .E .13. .3 Removal of the AC Surge Suppressor: . . . . . . . . . .Pole.16. .E. . . . . .Fieldbus .E. . . . 155 4.Phase) .3 . . . . . . . . .2 Replacement of Feedback Board. . . . 166 4.Replacing . . .Surge .1 . 184 4 .17. . . . . . . . . .2 Replacement of the Hart Interface Assembly: . . . 158 4.12.Remote . . . . . . . . .E. . . . . . .2 Replacement of a Fuse .14 . . . . .5. . . . .M. . .E. . . . . .12 . .E. . . . . . . . . . . .Pole.2 Replacement of the Foundation Fieldbus Assembly 165 4 . . . . .13 .3 . . 160 4 . . . . . . . . . .1 Removal of External Switch . . . . . .E. . . . . 181 4. . . . . . . . . . . . .E. 159 4. .E. . . .M . . . . 156 4 . . . . . . . .(Single .Assembly . .External . . . 178 4 . . . . 169 4 .E. . . . . . . . .5 . . . . . . . . . 181 4 . . . . . . . . . . . . . 183 4. . . . . 159 4. .4. . 158 4.M. . . . .Size .2 . . . . . . .Board . . . . . . . . .M .Fuses .18. .

. . . . . . . . . . . . 198 4 .11. . .1 Description of Valve . . . . . .2 Cleaning and Inspection . . . . . . . . 197 4. . . . . . . . . . . . . . . .M. . .8 . . . . . 189 4. . . . . . 188 4. . . . . . .4. . . . . . . . .M. .13 . . . . . . . . . .8. .Pressure . . . .M. . . . . . .M. . . 209 4. . 200 4.10 .1 Disassembly . . . .Valve . . . .M. . . . . . . . . .M. . . .Solenoids . . .8. . . . . . . . .8. .10. 198 4. . . . . . . . . . . .M . . . . . .M. . . .7. . . . . . . . . . .2 Cleaning and Inspection . . . . . . . . . . .M 14. . . . . . . . . . . . . . . .Limiting . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . .M. . . . . . . . . . . . . . . . . . . . . . .M. . . . . . . . . .Valve . .M. . . . .Manifold .14. . . . . . . . . .M.9 . . .2 Equipment Requirement .M. . . . . . . . .7 . . . . . 199 4. . 203 4. . . . . . .M. . . .Solenoid . .High . . . . . . 188 4 . . . . . . . .1 Disassembly . . .3 Disassembly .1 Disassembly . . . . . . . . . . . 205 4 . . . .M . . . . . . . . . 209 4. . . .Check . . . . . . .Set . . . . . .M 14. . . . . . . . . . . . . . . . . . . . .8. . 203 4 . . . .11. . . . . 199 4. . . . . . . . . . . . . . . 196 4. . . 192 4. . . . . . . . 209 4. .7. . . . . . . 207 4 . . . . . 197 4.M. . .M. . . . . . . . . . . . . . . . . .5. . .12 . . . . .M. . . . . . . . 186 4 . . . . . . . .11. . . . . 194 4. 196 4. . . .7 Re-Assembly . . . . . .Overfill . .M. .4 Disassembly (Solenoid Manifold) .M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4 Drive Train Rebuild . . .10. . . . . . . .8. . . . . . . . . . . . .2 Cleaning and Inspection (Solenoid Cover) . 209 4. . . . . . . . . . . .3 Re-assembly . . . . . . . . . . . . . . . .5 Cleaning and Inspection (Solenoid Manifold) . . . .8. .3 Re-Assembly . . . . .Suction .Removal . . . . . . . .Fill . . . . . . . . . . .M. . . . . . . .M. . . . . . . . . . . . . . . . . . . . .M. . .M. .Train . . . . 191 4. . . .Rebuild . .2 Cleaning and Inspection . . . . . .9. . . . . . . . . . . . . . . . 190 4. . .M. . .M . . . . . . . . . . . . . . . . .Speed . . . . . . . .Drive . . . . . . . .6. . . . .and . . . . . . . . . . . . . .M. . .Solenoid . 188 4. . . . . . . . . . . . 200 4.Testing . .up . . . . .Standard . . . . . . . . .14 . . .3 Re-Assembly (Solenoid Cover) . . . . . . . . . . . . . .6 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 4 . . . . 210 viii REXA X2 Series TS&R Manual .11. . . . . . . . . . . . . . .2 Re-Assembly . . . . . . . . . . . . . . .M. . .11. . . . . . . . . . 191 4. . . . . . . . . . . . . . . . .M. . . . . . . .9. . . 192 4. . . 202 4. 190 4 . . . .11. . . . . . .Valves . . . . . . .1 Disassembly (Solenoid Cover) . . 193 4.M . . . . . . . 196 4 . . . .2 Cleaning and Inspection . . 189 4. . . . . . . . . . . . . . . . . . . . . . .3 Re-Assembly . . . . . . . . .8. . . . . . . . . .3 Re-Assembly . . .M . . . . . . . . . . . . . . . . . . . . . .M . . .6 Re-Assembly (Solenoid Manifold) . . . . . . . . .3 Re-Assembly . . . . . 196 4. . . . . .5 Disassembly . . . . . . . . . . . . .6. . . . . 193 4. . . . . . . .M. . .1 Disassembly . . . . . .14. . . .M . . . .M . .6 . . . . . .M . . . . . . . . . . . . .1 Disassembly . . . . . . . . . . . .4 Cleaning and Examination of Parts . . . . . . . . . . . . . . . . . . . . .Solenoid . . . . . . . . . .11 . . . . . . .10. . . .

. . . . .M. . . . . . . .18. . . .M 14.2-B. . . . . . . . . . . . . . . 223 B.18. . . . . . . . . . .2 Reassembly . . . . . . . . . . . . . . . . . . . 233 06/10 ix . . .1 Disassembly . . . . . . . . . . . . . . . .2 L500 and L2 000 Cylinder Rebuild Procedure For ¾ Inch. .M. .18. . . . . . . . 218 4 . . . . . . . 222 4. . . 232 4.18. . . . . . . . . . . . .DRILL . . . . . .M. . . . .18.M. . . . . . .1 Removal .7 Final Tests . . . . . 225 4. . . .M . . . . . . . . 227 4. . .18. . . . . . . .M. .M. . . . . . . . . . . Bushing Rebuild. . . .Cylinders . .18. . . .16. . . . . . . . . . . . . . . . . . . . . . . .5 Initial Assembly . . . . . . . . . . . 230 B. . . . 230 4.18. . . . .M . . . . . . . . . . . . . . . .Cylinders . . . . . . 222 4. . . .15 . . . . . . . . . . . . 228 4. . . .18.15. . . . . . . . .3-A. . .Hand . . . . .3 Reassembly . . . . . . . . . . . . . . . . . . . .17. . . . . . . . . . . . . . . . . .1 Disassembly .M. . . . .3-A. . . . . . . . . . . . . . . 232 4. .M. . . . .2-C. . . . . . . .HAND . . .2 Reassembly . . . . . . . . . . . . .2 Cleaning and Inspection . . . . . 220 4.15. . . . . . . . . . . . . . . . . . . . . . 210 4. . . Bushing Rebuild.1 Disassembly . . . . . . . 225 C. .M. . . . .REXA . . .18. . . . . .1 Disassembly . . .18. . . . . . . . . . . . . . . . . . . . . . . . . . 229 4. . . . . . . 226 4. . . . .16. . . . . . . . . . . . . . . . . . . . . . . .M.Linear . . . . . . . . . . . . . 214 4. . .M.M. . . . . . . .M. . . .M. . . . . .M.17 . . . . . . . . . .18. . . . . . . . . . . . .DRIVE . . .Linear . . . . . . .3-B. . . . 2 Inch. . . . . . . . . . . . . . . . . 4 Inch and 6 Inch Stroke Units. . . . . . . . . . . . . . . . . .M 14. . . . . . . . . . . . . . . . . . . . . . . . . . .M 14. . . . 216 4. .1 Disassembly . . . 232 C. . . Feedback Removal . . . . . . . . . . . . . . . .16 . . . . . . . . . . . 214 4. . . . . . . .M. . . . . . . . . . . .M. . . .1 Cylinder Removal Procedure for All REXA Block Cylinders . . 2 Inch and 4 Inch Stroke Units . . .18. . . . . . . . . . . . . . . . . Shank Rebuild. . . . . 211 4 . . . . . . . . . . . . . . .3 L4 000 Cylinder Rebuild Procedure for ¾ Inch. 227 4. . . . . .M. . . . . . .Pump . . . 213 4. . . . . . . 222 A. . . . . . . . . .18. . . .M. . . . . . 220 4. . . . . . . .2 Cleaning and Inspection . . . . . . .WHEEL . . . . .18. . . . . .2-C. . . . . . . . . . . . . . . . .1 Disassembly . . 215 4 . . . . . . .3-B. . . . . . . . . . . . . . . . .M . . . . . . . . . . . . .6 Adjustment and Final Assembly . . . . . . .2 Replacement . . . . . . . . . . ./ . . . . .3 Reassembly . . . . . . . . . . . . . . . . .4. 213 4. . .2 Re-Assembly .17. . . . . . . . . .M. . . . . . Shank Rebuild . . . . . . . . . . . . . .18. . . 217 4. . . . . . . . . . .M . . . . . . . . . . . . . . Feedback Removal. . . . . . .3-B. . .M. . . . .M. .2-A. . . . . . . . . . . . . .2-B. . . 224 4. . . . . . . . .2 Cleaning and Inspection . . . . 211 4.2-A. . . . . . . . . . . . .2-B. . . . . . . . 213 4 . . 229 A. . . . . . . . . . . . .18 . . . . . . . . . . . . . . . .2 Reassembly . . . . . . . . . . . . . . .Commercial . . . . . . . . . . . . . . . . . . 225 4. 231 4. . .1 Disassembly . . . . . . . . .3 Reassembly . . . .2-C. .

. 234 4. . . . . . . . . . . .1 Disassembly . . . . . . . .M. End Cap Rebuild . . . . . . . . . . . . . . . . . . . . . .4-D. . . . . . . . .1 Disassembly . . . . . . . .2.4-C. . . 251 x REXA X2 Series TS&R Manual . . .1 Disassembly . . . . . . . . . . . . .4-A. . . . . .2 Cleaning and Inspection . . . .3 Reassembly . 249 Contacting potentiometer . .C. .18. . . . . . . . . . . . . . . . .4-A. . .B Reassembly .Rotary . . . . . .3-C.2 Cleaning and Inspection . .4. . . . . . . . .M. . 235 4. . . . . . .D. . .18. . . . . . . . . .20. . . . . . .2 Cleaning and Inspection . . . .M . . . . . . .M . . . . . . . . . .M. . . .19. . .M. .2 Cleaning and Inspection . .M. . . . . 241 D. . . . . . . . 242 4. . . . . . . . . . . Shank Rebuild . . Complete Disassembly of Cylinder . . .1. . . . . . 239 C. . . . . . . . . . . . . . . . . .A Disassembly .M. . .3 Reassembly . . . . . . . 246 4. .Feedback . . . . . . . 243 4. 237 B. . . . . . . . .20. . . .M. . . .M. . .3 Reassembly . . . . . . . . 248 4 . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Identification . . . . . . . . . . .4-B. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18. .2. . 250 4.18. . .4-B. . . . . . . . . . 249 4. . . . . . . Inspection & Replacement of Wear Rings (4). Top Bushing Rebuild .18. . . . . . . . . . . .M.M. . . . .M. . .M. .20.M. . . 249 4. . . . . .M. . . . . .M. . . . . . . . . . . . . . . . . . . . . . . .3-C. Feedback Removal . . . . . . . 238 4. . . . . . . . . . . . . . .19. . . . . . . . .1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M. . . . . . .Rotary . 242 4. . .20 . . . . . . . . . . . . . . . . . . . . 251 General . . . . . . . . . . . . . . . .M. . .18. . . . . 249 4. . .19. 241 4. .2 Reassembly . . . . . . . .18. . .4-C. . . . . .19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-B. . . . . . . . . . . . . . . . . . . .1. .4 L10 000 Cylinder Rebuild Procedure for 2 Inch and 6 Inch Stroke Units .1 Assembly and Disassembly Procedures . . . . . .1 Disassembly .4-C. . . . .M. . . 246 4. . . . . . . .M. . . .20.M. . . . . . . . . . . . . . .18. . . . . . .18.4-D. . . . . . . . . . 247 4. . . . . . . . 240 4. . . . . . . . . . . . . . . . . . . . . . . .M. . . . . . . . . . . . . . . . . . . . . . . . . . . 243 4 . 234 4. . . . . . . . . .Contacting Potentiometer . . . . . .3 Non .4-D. 245 4. . . . . .3-C. 249 4. . . . . . . . .18. .M. . . . 246 4. . . . . .18. . . . . .2 Contacting Potentiometer .3-A Disassembly . 236 A.19 . . . . . .Cylinder . .B. . . . . . . . . . . . . . .18.A Inspection & Replacement of End Cap Seals (9) . . . . . 248 4. . . . . . . . . . . . . . . . . . . . . . . . . . .19. . .19.3 Reassembly . . . . . . .1. . . . . . 237 4. . . . . . .19. . . . . . . . .M. . . . . . . .M. . 238 4. 236 4.M.E. .18. . . . . . . . . . . 240 4.18. . .20. . .1. . . 251 4. . . . . . . . Inspection and Replacement of Pinion and Bearing Retainer O-Rings . . . 239 4. . . . . . . . . Reassembly of Cylinder . . . . . . . . . . . . . . . . . . . . . .M. . . .M. . . .20. . . . Piston Seals (5) and Cylinder O-Ring (8). . . . . . . . .

. . . . . . . .M. . . . . .2-B Reassembly . . . .23 . .Linear . . . . . . . . . . . . . . . . . . .M. . . . . . . . . . . . . . . . . . .M. . . . . . . . .. . . . . .21. . . . . . . .M. . . . . . . . . . . . . . . . . . . . .22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20. . . . . . . . . . . . . . .M. . . . .21. . . . . . . . . . . . . . . . . . . . . . . . .Elastic . . . . .4-A Disassembly . . .3-A Disassembly . . 264 4. . . . . . . . . . . . . . . .4-B Reassembly . . . . . . . . . . . . . . . . .Feedback . . . . . .Coupling . . . . . .M. . . . . . . . . . . . . . . . . . . 265 4. . . . . . . . . . . . . . . .2 Non . . . . . . . . . . . . . . . . . . . . . . .20. . . .1-A Disassembly . .Cylinder .21.M. . . . . . . . . . . . . . . . .4-B2 Non . .4. . . . . . . . . . . . . . . .M. . . .1-B Reassembly . . . . . . . . . .M. . . . .3 Repair . . . . . . . . . . . . . . . . . . . . . . . . 261 General . . 266 4. . . 262 4. . . . . . .M. . . . . . . . . . . . . . . 258 4. . 256 General . . . . . . . . . . . . . . . .3-B Reassembly . . .M. . . . . . . . . . . . . . . . . . .M. . 265 4 . . . . . . . . . . . . . . . . .M . . . . . . . .M. .20. . . . . . . .22. . . . 261 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M. . .2-A Disassembly . . . . . . . . . . . 251 4. . . . . . 266 4. . . .2 Disassembly . . .M. . . . . . .20. . . . .M. . . . . . . . . . . . .23. . .2-B Reassembly . . . . . .23. 254 4. 253 4 . . . . . . . .1 Contacting Linear Potentiometer . . .M. . . .M. . . . . . . . . . . . . . . . . . . . .M. . . . . .M. . 256 4. . . . . . . . .22 . . . . . . . . . . . . . . . . 255 4. .1 Removal from Actuator . . . . . . . . 266 4. . .20. . . . .21. 254 Identification . . . .2 Closed Spring Tension (Upseating) Load Type Elastic Coupling . . . . . . . . .1-A Disassembly . . . . . . . . . .M . . . . . .Seat . . .1-B Reassembly . . . . . . . . . . . . .21. .3 Non -Contacting Linear Potentiometer . . . . . . . 255 4. . . . . . . . . . . . . .M. .M . . . . . . 256 4. . . . . . .Contacting Linear Potentiometer/Retrofit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21. . 268 06/10 xi . .21.2-A Disassembly . . . . .22. . . .4 Retrofitting with Contacting or Non-Contacting Potentiometer . . . . . . . 263 4. . .4-B1 Contacting Potentiometer . . . . . . . .23. . . . . . . . . . . . . . . . . .M. . . . .23. . .22. . . . . . . . . 258 4. . .21 . . . . . .M. . . . 255 4. . . . . . . . . . . . . . 254 General . . . . . . . . . . . . . . 252 4. . 255 General . . . . . . . . . . . . . .21. . . . . . . . . . . . . . . .1 Open Spring Compression (Downseating) Load Type Elastic Coupling . . .22. . . . . . . . . . . . . . . . . . . . . . . . . . 268 4. . . 259 4 . . . . 262 4.3-B Reassembly . . . . . . . . . . . . . . .20. . . . . . . . . . . . . . . . . .22. . . . . . . . . . . 253 4. . 253 4. . . . . . . . . . .Contacting Potentiometer . . . . 257 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 4.Load . . . . . . . . 261 Identification . . . . . .4 Reassembly . .. . . . . . . . . . . . . . .M. . . . .M. . . . . . . . .21. . . . .

. . . . . .Booster . . . . . . . . . . . . . . .24.M. .M. .A. .M . . . . . . . . .3. . . . . . 274 4 . . . .1. . . . . . .A. . . . 271 4. . . . . . 275 4.reservoir . .6 xii REXA X2 Series TS&R Manual . . . 273 4. . . . . . 272 4. .25. . . . . . . .M. .24 .5 D97904-P9 — D. . . . . . . . . . . . .24.24. . . . . . . the Tube Bending Kit . . . . . . . . . . . . . . .Transducer . . . . . . . . . . .24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. . . . . . . . 275 Reservoir Identification . . . . . . . 269 4. . . . . . . . . . . . . . . . .24. . . . . . . . . . . . . . 273 Identification . . C. . . . . .2 Pump . . . . . . .M. .3. . . .Recommended .24. . . . 269 4. . .Pump . . . . . . . . . . . . . . . . . . .Actuator . . . . . C. .M. . . . . .24. 271 4. . . . . . . . . . . . .2. . . . . .M . . . . . . . .M. . . . . . . .A Disassembly . . . . . . . .1 aPPendIx C Circuit . . . . . . . . . . . . . .4. . . . 268 4 . . . . .M. . .1 Disassembly . . . . .A Disassembly . C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Reassembly: . . . . . . . . . .26. . . . .3 Manifold . . . . . . the Bleed Kit .2 D97904-. . . . . . . . . . . . . . . . the Standard Tool Kit . .accumulator . . . . . . .2. . . . . . . . . . . . . . . 273 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. . . . . . . . . .5 Re-Installation . . . . . . . . . . . .Tools TK-2. . . . . . . . . . . . . . . . . . . . . . . . .Repair B. . . . . . 275 Accumulator Identification . . . . . . . . .A. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 D97904-D — D Servo Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . .B Reassembly . . . . . . . . . . .1 TK-3. . . . . . . . . . .4 D97904-2D — 2D Servo Wiring Diagram . . . . . .External . . . 272 4 . .Schematics D97904 — Stepper Wiring Diagram . . . . . . . . . .M. . . . .B Reassembly . . . . . . . . . . . . .25 . . .M. . . .2 aPPendIx b Returning . . . . . . . . . .24. 277 aPPendIx a List . . . . . . . . . . . . 270 4. . . . . . . . . . . . .M. . . .25. .M . . . .1 Return Procedure . . . . .M. . .B Reassembly . . . . . . . .23. . . . . . . . . . .of . . . . . . . . . .2 Reassembly . . . . . . . . . . . . .A Disassembly .M. .26 . . . . . . . .and . . . . . . . . . . . . . .26. .the . . . . . . .for . . . . . . . .2 TK-4. . . .M. . 271 4. . . 272 4. . . . .5d — ½D Servo Wiring Diagram . . . . . . . 270 4. . . . . . . . . . . . .24. . .M. . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P9 Servo Wiring Diagram. . . . . . . . . . . . . . .bottle . . . . . . .1 Disassembly: . .B. 276 4. . . . . .1 Motor . . .

. . . . . . . .D97904-P40 — D. .2 Solenoid Cable Specifications . . . . . . . . . . . . D. . . . . . . . . .6 P40 Motor Cable Specifications. . .1 Feedback Cable Specifications .8 D97904-. . . . . . D. . . .5 Resolver Cable Specifications . . . . . . . . . .Service . . . . . . D. . . C. . . . . .9 D97904-DACCUM — D Servo with Accumulator Fail Option . . D. .5DACCUM — ½D Servo w/ Accumulator Fail Option.10 D97904-2DACC — 2D Servo with Accumulator Fail Option . .13 aPPendIx d Cable . . . . . C. . . . . . . .11 D97904-P9ACC — D. D. . . . . . . . .Specifications X2 Module Cable Specification .4 D –Pump Motor Cable Specifications. . . . D. . . . . D. . . .7 D97904-STEPACCUM — Stepper w/ Accumulator Fail Option. . . .P40 Servo w/ Accumulator Fail Option C. . . . . . . . . . . . . . . C. . . . . . . . . . . . . . . C. . . . . . . .P9 Servo with Accumulator Fail Option . . .Memo 06/10 xiii . .Sheet aPPendIx F Field . . . . .3 HEATER/SOLENOID Cable Specifications . . . . . . . . . . . . . . . . . . . C. .12 D97904-P40ACC — D. . . . . .P40 Servo Wiring Diagram. .7 aPPendIx e Parameter . C. . . . . .

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Contact REXA. • • • Airborne noise is less than 60 dB. • Safety Information – 06/10 xv . WARNINGS Based on these hazards.X2 Troubleshooting and Repair Manual Fundamental Safety Information REXA actuators all produce extremely high forces. 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. 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. have hydraulic lines under pressure and have dangerous electrical power input levels. the following could occur if this safety information is not observed: • • • Damage to actuator or other equipment Serious physical injury Death always observe the safety information listed in this documentation. Failure to do so may result in injury or damage to equipment. Do not use the Actuator should it be damaged in shipping or installation. All Guards MUST be in place before operation.

or .Warning Refer to Installation Manual before servicing. . RESIDUAL .Voltage .Safety Information (06/10) WARNING . 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.Point . . .Pinch . Use appropriate Lock-Out/Tag-Out procedures when connecting Actuator to the driven device. . Warn of Actuator movement if Spring Fail Unit.LABELS . The Motor Shaft Cover MUST be in place during normal operation. xvi REXA X2 Series TS&R Manual . . Failure to do so poses a risk of injury. MANUAL OVERRIDE HANDWHEEL ASSEMBLY: The Manual Override Handwheel Assembly is to remain declutched until it is required.RISKS This section is to help identify the risks associated with the Actuator System. servicing. General .Crush . Turn Off and Lock Out system power before .Hazardous .Hazard Turn Off and Lock Out system power before . servicing. .Attention Important information provided.

Only qualified service and installation personnel should install or adjust this device. Handwheel Assembly is used. Use proper Lock-Out/Tag-Out procedures before removing cover. SHOCK HAzARD: Hazardous voltage levels are present in the actuator. ALIGNMENT: Ensure that the actuator shaft is in line with the valve plug stem. SHOCK HAzARD: Control Enclosure Cover must be closed during normal operation. Safety Information – 06/10 xvii . Use proper Lock-Out/Tag-Out procedures before accessing feedback housing. FEEDBACK COVER: Feedback Cover MUST be in place during operation. SHOCK HAzARD: Wire Cover must be in place during operation. Failure to do so may result in injury.X2 Troubleshooting and Repair Manual MANUAL OVERRIDE HANDWHEEL ASSEMBLY: When the Manual Override. Misalignment could damage the actuator and driven device or cause injury to installation personnel. adhere to proper Lock-Out/Tag-Out procedures. Use proper Lock-Out/Tag-Out procedures before accessing Control Enclosure. Failure to do so may result in injury.

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. R or U as the last character in the model number. Failure to properly remove this force before disassembly can cause serious injury to maintenance personnel. hydraulic pressure remains locked within the cylinder and/or accumulator. SPRING UNDER TENSION: REXA actuators denoted by an E. the actuator may immediately respond to the control signal.Safety Information (06/10) AVOID ACCIDENTAL STARTING: When installing the actuator. RELIEVING INTERNAL PRESSURE: When the electric power is off or the motor is not turning. Inadvertent motion could damage the actuator and driven device or cause injury to installation personnel. Contact REXA for disassembly instructions. The introduction of other fluids may cause damage to the unit. contain a spring under tension. Note: Reservoir lines may contain up to 60 psi (4 bar) that cannot be relieved. IMPORTANT: When machining the control enclosure. When power is applied. xviii REXA X2 Series TS&R Manual . thoroughly clean any metal chips or residue from the enclosure before applying power. This internal pressure must be relieved before disconnecting any hydraulic fitting. HYDRAULIC OIL: The standard oil used in REXA actuators or drives is Castrol Syntec® SAE 5W-50 motor oil. insure that line power to the unit is shut off.

these switches provide adequate protection for minor repair. Anytime there is danger of injury from an unexpected release of energy. In general.as the last character in the model number contain an accumulator charged with high-pressure nitrogen. • • • • Major repairs or overhaul.TO . Any situation that threatens an employees safety. Lock-Out/Tag-Out procedures shall be used for the following situations. which is routine. Note: Always follow local & plant procedures.LOCK-OUT/TAG-OUT Most equipment is installed along with safe switches allowing the equipment to be disabled for minor repair. . . These actuators also have an automatic recharging cycle for the accumulator. WHEN . Failure to properly follow installation instructions may cause serious injury to maintenance personnel and/or damage to equipment. When working alone. REXA actuators denoted by an A . out of visual contact of the controlling switch. NPT PLUG and CONDUIT CONNECTIONS: During assembly.ACCUMULATOR FAIL OPTION: . and necessary to the normal use of the equipment. Loctite® 767 compound—or its equivalent—must be used on threads of all NPT plug and conduit connections to ensure a watertight seal.X2 Troubleshooting and Repair Manual Note: Accumulators will still contain up to 2 000 psi (138 bar) of nitrogen gas that cannot be relieved. Safety Information – 06/10 xix . repetitive.

Ensure the new/repair work does not bypass the Lock-Out and reactivate the system. All locks and tags are to be left in place until all work is completely finished.Safety Information (06/10) PROCEDURES: . Verify that the locked-out switch or control cannot be overridden. if several people are working on the equipment. 2. Disconnect sources of power. or more than one lock. Make a final safety check before restarting equipment. A lock is never to be removed except by the person who placed it there. Equipment shutdown and isolation: Place all switches in the “off” or “safe” position. Notify all affected areas and employees of the impending LockOut situation. and estimated start and duration times. Equipment start-up. Lock-Out verification: Take nothing for granted. Check for trapped pressure. 3. Perform the work scheduled. 6. Test the equipment to be certain that the locked-out switch is de-energized. Shutting down equipment does not mean there is no energy left in it. This is especially true when more than one employee is working on the equipment. and not simply malfunctioning. ensuring all sources of both primary and secondary power to the equipment are interrupted. the reason for it. . Test all control points and modes to be sure that the equipment does not start. Lock and/or tag removal. 8. 4.LOCK-OUT/TAG-OUT The following are minimum recommended procedures to be followed for Lock-Out/Tag-Out: 1. compressed spring or residual electricity in the system. Lock-Out or Tag-Out all in-line points of control. there may be more than one place. Try to foresee all possible hazards. 5. to be certain it is safe to operate. Make sure of the following: xx REXA X2 Series TS&R Manual . In most cases. Dissipate residual energy. 7.

maintenance and repair of equipment and/or processes. c) All employees are clear of equipment. All electric. Following them will ensure safe operation calibration.DISCIPLINE The key to worker safety is education. Safety Information – 06/10 xxi . we ensure a safer working environment. 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. EDUCATION . and they are. hydraulic. the safety of their fellow employees and the safety of the facility. without dangerous surprises or injury. Many of the Lock-Out/Tag-Out procedures appear to be common sense. a fair uniform enforcement of discipline must be in place. By educating all employees to the importance of following proper safety procedures.AND .X2 Troubleshooting and Repair Manual a) All tools and other items have been removed. Employees are responsible for their own safety. pneumatic or other systems are properly reconnected. As with all safety procedures. b) All machine guards are returned to their proper position.

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MA 02379 Phone: (508) 584-1199 Fax: (508) 584-2525 Web: www.rexa. For repair.X2 Troubleshooting and Repair Manual 1. .FACTORy . you may contact the factory at the following: REXA 4 Manley Street West Bridgewater. General Information – 06/10 1 . Reference the sections below on Actuator Identification for a more detailed explanation. warranty or parts order.2 . mechanical build code.com Note: It is important to have the model number and build code for both the electronics and the actuator in addition to the serial number for the actuator so we can provide better service. We have a fully staffed service department with factory trained and certified service personnel for both factory and on site repair. service. General Information 1 . 1 . electronics build code and serial numbers are all used to identify an individual actuator and electronics.SUPPORT REXA is a full service company.IDENTIFICATION The model number. sales. This information can be found on the metal tags on the actuator and on the front panel of the electronics. .ACTUATOR .1 .

These numbers can be found on the ID tags located on the actuator and on the serial tag on the electronics. TRAVEL AMPS VOLTS LBS INCHES Hz ONE OR MORE OF THE FOLLOWING U.625.728 Figure 1. (06/10) Figure 1. Since most applications are custom. and the serial number will ensure the quickest and most accurate response to your request.766. The build code provides more detailed information of the components used in the construction of the actuator.180 4. Supplying the model number. Figure 1.S.2-2 Electronics ID Tag 2 REXA X2 Series TS&R Manual . both mechanical and electrical build codes. this is the only identification that fully allows us to identify the unit. The model number also provides the information required to correctly define what sections of this manual applies to a particular actuator.2-1 Mechanical ID Tag W. THRUST MAX.696. The factory requires these numbers whenever service or information is requested.2-2 shows typical ID tags.557.BRIDGEWATER MASSACHUSETTS MODEL SERIAL NO.2-1 and 1. Finally the serial number will allow the factory to determine any special considerations or features your actuator may have that make it unique.163 4. PATENTS APPLY 4.513 4.General Information ACTUATOR . MAX.IDENTIFICATION The model number will provide a general description of the actuator and electronics as a set.

Series – Xpac Rotary D . –11. –11. –16. and C size power module.Series – Xpac Drive . . –120 –90. –2. –16. and B size power module. –2. –22 Model Numbers — Examples: X2L4000-4-C-P Is a Linear L Series 2 Xpac with 4 000 lb of thrust.2.IDENTIFICATION 1 .Fail .P9: Booster Pump D. –16. –6. –120 –90. –22 –. –22 –. –120 –90. stroke adjustable up to 4 inches. –16.__ . . . –11..X2 Trouble Shooting and Repair Manual ACTUATOR . –2.Series – Xpac Linear R . . –11. –6.2 . . –4.SERIES Torque (lbf·in) 600 1 200 2 500 5 000 10 000 20 000 50 000 100 000 200 000 Rotation (degrees) –90.__ . –120 Power . –6. Lock in place upon loss of power. –8. –120 –90. –8.75. –11 –. –22 –.Model .75. –8. .75.1 Model Number General Information – 06/10 3 .Number The basic model number is a generic description of the actuator. –22 –.75.75.__ . –11. –6. (Upon Power Loss) P: None .75. –16.SERIES Thrust (lb) 500 2 000 4 000 5 000 8 000 10 000 15 000 20 000 30 000 40 000 50 000 60 000 80 000 120 000 Strokes (in inches) –.75. –22 –.2. –4. –4. Torque . –8.__ . .75. –2. Rotation Spring . –8. –4. –4. –2.75. –120 –90.or . –120 –90.Modules B: Single B C: Single C ½D: Single ½D D: Single D 2C: Dual C Manifold 2D: Dual D Manifold D. –6. . –8. –6. –2. –4 –. –4. –2. –16. –2 –. –11. –16. –16.2 L . . Thrust . Figure 1. . –11. –16. –4. –8. –120 –90. .75. . –6. –22 –. –6. –6. –22 –.75. Stroke .1 shows a break down of the model number tree and how it works. –6 –. –22 –. –6.__ .– .__ . –8. –8. –4.1 . MODEL . –11.D . rotation adjustable to 90 degrees.NUMBER X2__ . –8. .. –4. –8. Figure 1. . –11.__ . X2R2500-90-B-U .__ Series .P40: Booster Pump L .Lock in Place U: Universal (Rotary) E: Extend (Linear) R: Retract (Linear) A: Accumulator Failure R . .75.Option . –4 –6.75. –22 –. –4.75. A Rotary R Series 2 Xpac with 2 500 lbf·in of torque. –2.– . –2. –2. –2. Spring failure upon loss of power. . –120 –90. –4. –16. –2. –2.– . –11.

(06/10) 1 .Number Serial numbers are assigned to every job at REXA.Build . . 1 .and .3 .1 .2 . Within the mechanical sub-assembly there is a build number for Rotary and Drive actuators. A typical serial number will look like: C0600000.Serial .GENERAL .Recommended . Job specific information as well as sales and engineering information are stored under a specific serial number. .Lubricants Intended Use Operating oil.IDENTIFICATION 1 . . and a separate build number for Linear actuators.3 .General Information ACTUATOR . one is for the mechanical sub-assembly.2 .Code The build code is a catalog number we use to designate in complete detail the construction of the actuator.Fluids . There are two different categories of build numbers. The C06 indicates the year of manufacture and the next five digits correspond to the unique order number.2 . . biodegradable Anti-Seize Compound O-ring Lubricant Thermal Grease Molybdenum Disulfide Grease Parts Cleaner Specifications Castrol SYNTEC® SAE 5W-50 Motor Oil EnviroLogic® 3100 Series Hydraulic Fluid Bostik Never-Seez® or equivalent Parker Super-O-Lube or equivalent Thermalcote™ or equivalent Mobilgrease® XHP 222 or equivalent zEP® BRAKE WASH or equivalent 4 REXA X2 Series TS&R Manual .3 . and the second is for it’s corresponding electronics sub-assembly.SPECIFICATIONS 1 . From this number all configurations can be defined. The build numbers are shown in Appendix H of the IOM. standard Operating oil.

High ambient temperatures affect oil viscosity which may affect actuator rated output. High ambient temperatures affect oil viscosity which may affect actuator rated output. motor driver. Range Motor Type (-20 °C to +121 °C) Optional Standard oil & 1” of thermal Heat tracing & 1” High Temp. transient protection and termination. Actuator Construction Temperature Range¹ Type L Linear Cylinder Type C Linear Cylinder Installation Requirements Electronics Temp.3. motor driver. -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C) Stepper Servo 1. These items are not supplied by Rexa.SPECIFICATIONS 1 . -76 °F to +200 °F (-60 °C to +93 °C) -76 °F to +200 °F (-60 °C to +93 °C) -5 °F to +250 °F (-20 °C to 121 °C) -5 °F to +250 °F (-20 °C to 121 °C) (-34 °C to +93 °C) -10 °F to +200 °F (-23 °C to +93 °C) 1 inch thermal insulation 2 Heat tracing & 1 inch thermal None insulation 2 Separate Control Enclosure with CPU.2-2 Rotary Actuators & Drives * Standard +10 °F to +200 °F (-12 °C to +93 °C) -10 °F to +200 °F (-23 °C to +93 °C) -76 °F to +200 °F (-60 °C to +93 °C) High Temp. * all CSa electronics. These items are not supplied by Rexa. power supply. refer to Technical Memo TM19-2 for further information.2 . 2.Operating .2-1 Linear Actuators * Standard -5 °F to +200 °F (-20 °C to +93 °C) +10 °F to +200 °F (-12 °C to +93 °C) None -30 °F to +200 °F ‡ High Temp. .3 . Temperature Range1 Actuator Construction Type R Rotary or D Drive Cylinder Installation Requirements Table 1. transient protection and termination. * all CSa electronics. Range Motor Type Table 1. 2 2 cartridge heater insulation therm Construction Separate Control Enclosure with CPU. General Information – 06/10 5 . 2. -40 °F to +140 °F (-40 °C to +60 °C) -40 °F to +120 °F (-40 °C to +50 °C) Stepper Servo 1. power supply. stepper units and servo units are rated -40 °F to +104 °F (-40 °C to +40 °C).3.X2 Trouble Shooting and Repair Manual GENERAL . mechanical stepper units and servo units are rated -40 °F to +104 °F (-40 °C to +40 °C).Temperatures The following is a general guideline. -5 °F to +250 °F Electronics Temp.

General Information INSPECTION . oil leakage. section 1.SCHEDULE 1 . components will wear out. (06/10) Monthly Check the oil indicator for proper oil level. a visual inspection of the actuator is needed to determine where the loss of oil occurred and the necessary repair required. During this inspection. . a predictable schedule of maintenance and replacement of seals may be developed. The frequency of use and the operating conditions are both factors that will dictate the maintenance schedule (see below). Quarterly Perform a visual inspection of the actuators for damage.6. as with any mechanical device. NoTE: With time and experience. When oil is added. The following is a recommended list of visual inspections and their frequency. Add oil if necessary following the instructions in the IOM.INSPECTION . obstruction and hazards.SCHEDULE The REXA actuator requires minimal routine maintenance consisting primarily of visual inspections. 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) 6 REXA X2 Series TS&R Manual . NoTE: Ambient temperature swings will affect the oil indicator position. Repair items found damaged during this inspection in accordance with company procedures.4. However.4 .

As the pressure increases. this document should only be used as a guide. contaminants. a linear cylinder seal for a 2 000 lb thrust actuator will wear out three times faster if the cycle stroke is six inches vs. As these forces increase so do the friction forces between these components causing a seal under pressure to exhibit more wear than one under less pressure.000 cycles or 10. This equates to four years of service in a typical process control system. temperature and output all play a role in determining how frequently preventive maintenance is required. The soft goods — or seals — in each REXA actuator have been selected to provide a design life of at least 1. two inches. Actual maintenance history logs for the specific application should be generated for a better indicator of when preventive maintenance is required. For example. conversely. O-rings.X2 Trouble Shooting and Repair Manual INSPECTION .000. It is important to understand the application and its influence on the actuators’ components when determining the frequency of preventive maintenance for each unit. wear bands. actuator travel. seats and valves will from time to time need to be replaced. abrasions or tears Maintenance . Since factors such as pressure.SCHEDULE • Check for moisture ingression or contaminants under the feedback housing. will last four times longer if the stroke is half inch vs. Seal design life estimates are based on the following assumptions: The actuator will only be loaded to its full output during 5% of its total travel — this is the case in 90% of control applications when the actuator is seating a valve.000. two inches and.Schedule Items such as seals. Seal life is also dictated by the pressure the seal is holding.000 dither cycles. wire cover and in the electronics enclosure • Ground wire connectivity • Ensure the feedback signal on the actuator is stable • Inspect wiring for cuts. bushings. so do the forces between the seals and the rods and bores they are sealing. General Information – 06/10 7 .

Excessive loads — such as those exhibited when a cylinder “dead ends”— can cause excessive stress and premature wear. then required maintenance will be increased.General Information INSPECTION . (06/10) 8 REXA X2 Series TS&R Manual .SCHEDULE If the full load of the actuator is required over a greater percentage of the stroke.

2.1.IS .1.6 No display.2 . Problem Identification WHAT . etc) 2.1.1 I forgot my Password.9 Actuator will not respond to Pulse command 2.8 Actuator will not respond to FF command 2.1..1.4 Error code in display 2.2 Keypad buttons not functioning Problem Identification – 06/10 9 .1. . sections burnt out.ISSUES 2.5 Motor driver fault 2.1. How do I get into Setup? 2.INTERFACE .12 Actuator will not respond to 2 Cont (Manual Control) command 2 .PROBLEM? 2 .3 Alarm relay open 2.1 External push buttons not functioning 2.2.THE .ACCESSORIES 2. unusual display (ex.1.11 Actuator will not respond to 1 Cont (On/Off) command 2.1.X2 Troubleshooting and Repair Manual 2.2 Warning relay open 2.7 Actuator will not respond to HART command 2.1.1 . letters missing.10 Actuator will not respond to Analog command 2. .1.1.

3.3.3 .2.6 No position feedback signal 2.13 Servo Motor turning at low RPM when not commanded to move 2.3.3.12 Surrounding equipment disrupted by Actuator operation 2.4 Actuator does not meet fail safe speed requirements 10 REXA X2 Series TS&R Manual .ISSUES 2.3.3.3 Actuator “drifts” away from applied load 2.3.4 Position feedback doesn’t match actual position 2.FAIL .14 Actuator slows down and “resets” before getting to target position 2.7 Torque or thrust data not accurate (from transducers) 2.3.4 .2.16 I have many errors logged in historical stats 2 .3.2.3.6 Pressure limiting protection not working 2.5 Gauges not functioning 2.2.4.CONTROL .8 Mechanical Limit Switches not functioning (06/10) 2 .Problem Identification PROBLEM .1 Accumulator will not recharge 2.4.2 Actuator does not recover after fail safe event 2.2 Actuator “hunting” (dithering during control) 2.11 Only one module on a 2D or 2C units functions 2.3.3.3 Unit will not move to fail position 2.3. .15 Actuator overshoots target position and returns.9 Actuator does not meet stroke speed requirements 2.2.10 Booster Pump does not turn on 2. .3.ISSUES 2.1 Actuator moves to wrong position 2.4. 2.2.3.4 Manual hand pump not functioning 2.5 How do I test my 4-20 mA Position Transmitter? 2.3 Drill Drive / Hand Wheel not functioning 2.SAFE .IDENTIFICATION 2.7 Electrical limit switches don’t function 2.3.8 Actuator will not seat 2.4.

5 .1 External oil leaks 2.3 The oil indicator is low.7 .3 Will not accept SL or SH value Problem Identification – 06/10 11 .8 Solenoid is extremely hot to the touch 2 .4. (Feedback. .4.X2 Troubleshooting and Repair Manual PROBLEM .7.5 Hydraulic surge not functioning 2.1 Setting PL or PH and unit reads “too high” or “too low” 2.2 Reservoir relief dumps oil 2.LEAKS 2.6. .7 No Accumulator Pressure reading on Display.5. .6 .2 Will not accept PL or PH value 2.6 Unit moves to the wrong position for trip 2.1 Water in unit.7. but there is pressure on gauge 2. Module.4.5.MISCELLANEOUS 2.5. no visual oil leaks 2 .IDENTIFICATION 2. Motor. but no oil is visible / Repeated Reservoir filling.4. electronics) 2.6.2 Cylinder binding 2 .CALIBRATION 2.OIL .7.

.1 .my .3 . section .TS&R . (See . section . An “alarm” occurs if the actuator is switched to Local Manual but not Remote Manual.3 .) – Drive fault active.2 . .1. If a value (other than the default value of 00000) is entered into Password. Multiple drive units can usually continue to operate (with reduced performance) when one motor driver is bad. .(See Error code section.1 .Alarm . Contact factory if you lost your password. . Detectable problems include: – Accumulator low or bad pressure detected during “normal operation” or following a failed recharge cycle.Warning .Password.get .3 .) 12 REXA X2 Series TS&R Manual .Setup? . The output is in the “alarm” state whenever the actuator is unable to follow the control signal/control scheme as defined in the Signals menu.) – Seat Load Cylinder reached its “Seated” position but the valve was not required to be seated (SLC stop).I .do . (06/10) 2 .relay .open WARNING: The output is in the “alarm” state when the actuator detects a problem but can otherwise continue to operate.how .ISSUES RESOLUTIONS 2 . .) 2 .3 .2.I .forgot . .1 . Accumulator low/bad pressure.1 .open The CPU board has two solid state relay “alarm” outputs. (See . so a “warning” is issued. Drive Fault active.1 . Parameter Password has been added to the Outputs menu following parameter Pos Xmitter.3 . .1. future entry into Setup mode will require the user to enter the Password value.Problem Identification INTERFACE .ISSUES 2 .section .into . (See TS&R .INTERFACE .TS&R . an ALARM and WARNING. An alarm relay change may be followed by an error code. SLC reads Seated before actuator is on valve seat.relay .

is set or A/D . fail .section .X2 Troubleshooting and Repair Manual INTERFACE .fail .no movement.section .Alarm (See TS&R . Any error identified as being detected in “All” modes will persist until corrected.6.code . . All errors are cleared by power-on/reset or by entry into Setup mode in addition to the means identified below as “Cleared by”.ISSUES 2 . Detected modes: All.) Cleared by: Self clearing when control signal > 2. Alarm/warning: .fail .1 .fail . Control Signal Bad.5 mA or when 15 .clears.in .is set. each is displayed in a round-robin fashion at approximately 1 second intervals. Alarm/warning: .display The following are the error messages which appear on line 1 in place of Status: .3 . FB bad Meaning: The actuator’s main feedback is below 2 mA or either (+) or (-) 15 . . Actuator response in Auto mode: Freeze .is set or A/D fail is set.fail .fail .or A/D .4 .11.clears.5 mA or either the (+) or (-) 15 fail . Cleared by: Self clearing when feedback greater than 2 mA or when 15 . Actuator response in Auto mode: Defined by Failsafe parameter (See .3 .1 .) Problem Identification – 06/10 13 . INPUTS Menu. Feedback Bad. Detected modes: All.Error .section .Alarm (See TS&R .OK when one or more errors are detected.6 .) CS bad Meaning: The analog control signal is below 2.A/D .IOM .or . If more than one error is active.4.

Alarm .) Dir error Meaning: The actuator was detected moving in the wrong direction on two successive motor starts. One additional retry is allowed for each successful motor start/stop until five retries are “in the bank”. (See TS&R .section .6. Actuator response in Auto mode: Freeze – no movement.6 . . Actuator response in Auto mode: Freeze in place – no movement in stall direction.ISSUES (06/10) Mot stall Meaning: Five attempts to move the actuator 1% of stroke in the time set in parameter Stall Time have failed (See IOM . Detected modes: Auto mode only. . Direction Error. Alarm/warning: .) Drv fault Meaning: One or more motor drives has detected a problem which could not be cleared with a drive reset. DRIVES Menu). Cleared by: Any control signal change which requires actuator movement in the direction opposite to that in which the stall occurred.Problem Identification INTERFACE .section . Alarm/warning: .section .5. Mot stall. Detected modes: Auto mode only. One retry is allowed for each signal reversal.1 . Will also appear when a 14 REXA X2 Series TS&R Manual . Cleared by: Only cleared by power-on/reset or entry into Setup.7.Alarm (See TS&R . or the “Seated” position was reached on the Seat Load Cylinder and the position of the main cylinder was greater than 1% above Position Lo.3 .3 .

Also sets Fb .3 .Warning .section .ISSUES fault/reset board does not have drive fault jumpers installed (in positions where a motor drive is not connected). Alarm/warning: .) Pres bad Meaning: The accumulator’s pressure transducer is out of range. Problem Identification – 06/10 15 . Cleared by: Self clears if the supply returns to within a (+) or (-) 5% error band. The transducer is considered out of range if the 4 to 20 mA signal is less than 3 mA or greater than 21 mA.7.fail . if applicable. Alarm/warning: .fail. . +/-15VDC Fail.2. Actuator response in Auto mode: The actuator attempts to continue normal operation. (See TS&R . Meaning: The (+) or (-) 15 volt power supply is out of range by (+) or (-) 10% error band.fault . Additional drive resets (spaced at 10 second intervals) occur until the fault clears. Cleared by: A drive reset is attempted when the fault is initially detected. Detected modes: All.) +15 fail . If the fault does not clear on the first reset attempt. Detected modes: Auto mode only.3 . for additional information.error is set. See Alarms.Alarm (See TS&R .-15 fail .X2 Troubleshooting and Repair Manual INTERFACE . .and. above. the Drv .section . Detected modes: All. Actuator response in Auto mode: Freeze – no movement. Cs . Drive Fault.or .

3 .1. . Detected modes: All. Cleared by: Successful recharge cycle. Alarm/warning: . SLC Feedback bad.section .. Cleared by: Transducer signal greater than 3 mA or less than 21 mA. Actuator response in Auto mode: Freeze – no movement.) (06/10) Pres low Meaning: The accumulator pressure is below the value set in parameter Warn Pres.) SlcFb bad Meaning: The feedback signal from the seat load cylinder is less than 2 mA.ISSUES Actuator response in Auto mode: The actuator continues with normal operation.3 . .e. 16 REXA X2 Series TS&R Manual .Warning (See TS&R . Accumulator low/bad pressure.2% (i.3 .section .Problem Identification INTERFACE .3 . .Warning (See TS&R . Actuator response in Auto mode: The actuator continues with normal operation. Detected modes: All. Accumulator low/bad pressure.) Slc stop Meaning: The actuator has stopped at the “Seated” position of the seat load cylinder. Cleared by: Self clearing when feedback is greater than 2 mA. Alarm/warning: .section .Alarm (See TS&R .1. but the control signal is greater than 0. Alarm/warning: .2.

Alarm/warning: . but the control signal did not request it). Cleared by: Self clearing with a valid keypad reading.ISSUES the seat load cylinder has reached the “Seated” position.X2 Troubleshooting and Repair Manual INTERFACE .3 . SLC stop. Problem Identification – 06/10 17 . Detected modes: Setup mode only.3. .) Key bad Meaning: A bad reading of the key pad has occurred. then press Enter again to write in new value. Cleared .Warning (See TS&R . Actuator response in Auto mode: The actuator continues with normal operation. Alarm/warning: Warning Mem fail Meaning: A memory location containing a Setup parameter value has failed to erase/write. Actuator response in Auto mode: N/A Cleared by: Only cleared by power-on/reset or by re-entry into Setup and reprogramming all parameters.section . Press Enter button to open parameter (“=” will flash).by: Any control signal change which requires actuator movement in the direction opposite to that in which the stop occurred. Detected modes: All. NoTE: The memory locations containing error counters are not checked.3 . Detected modes: Auto mode only. Actuator response in Auto mode: The keypad reading is ignored and the actuator continues with normal operation.

Alarm/warning: .fail. . .Alarm A/D fail Meaning: The A/D converter on the CPU Board has failed to respond. – Signal Type is set to 1 Cont.no movement. 2 Cont.and (if applicable) Cs . Detected modes: All. Detected modes: All Actuator response in Auto mode: Freeze . .Problem Identification INTERFACE . 18 REXA X2 Series TS&R Manual . Cleared by: Changing the Signals menu parameter(s) to match the installed boards. or Pulse – Trip is not set to Off Detected modes: All.until . Alarm/warning: .fail .cleared (06/10) No inp bd Meaning: One or more of the parameters in the Signals menu is selected and the required Contact Inputs Board is not installed (or failed to respond when read).Alarm . Cleared by: Self clears if/when A/D responds.ISSUES Alarm/warning: . Also sets Fb . Actuator response in Auto mode: Freeze in place and go to Setup mode. or (with power off) installing the required board(s).Alarm CPU fail Meaning: The CPU has detected an unexpected interrupt. When Setup mode is entered the first incorrect parameter (as listed above) will be on display.

Actuators with more than one drive use an additional fault/reset board that is separate of the CPU.1 .1. the driver type is C. In this example. and is only present when there is a problem. (Refer to TS&R .section .X2 Troubleshooting and Repair Manual INTERFACE . Cleared by: Only cleared by power-on/reset or by entry into Setup mode. . The purpose of this board is to use one fault signal for both drives. or the actuator. The module type determines which style of driver you have. Alarm/warning: . The fault input is 5 Vdc.driver . An example would be an X2L2000-4-C-P.Motor . (See photos below.ISSUES Actuator response in Auto mode: The actuator continues with normal operation.5-1 Electrical ID Tag Photo 2. REXA actuators use two styles of motor driver.5 .1. TB6 for servo). you must first locate the model number on the REXA identification tag located on the Electronics enclosure. Stepper and Servo.2 for additional actuator identification information. To identify which driver you have. The drive fault is relayed to the CPU through the fault input terminal (TB3 for stepper.) Photo 2.Alarm 2 .) Problem Identification – 06/10 19 . allowing the actuator to operate with 1 driver while the other is faulted.fault A motor driver has detected a problem and sent an error code to the CPU.1 .5-2 Mechanical ID Tag Located in the Model number of the REXA is the module type.

Driver .C .IMS .drive . .drive .letters .drive .Actuator . 20 REXA X2 Series TS&R Manual .will . (ex .No .TS&R . . If the 14 position ribbon cable between the CPU and display comes loose or is plugged in backwards.Dual .2 . .fault (06/10) 2 .unit . When this optional board is installed a two-wire 4 to 20 mA current loop runs between the control station and the REXA actuator.fault .7. the display is dimmed after one hour of no keypad use. Control Signal Bad.section .fault . .Problem Identification INTERFACE .Booster . If these two variables are not being sent back.Potted .5. .11.1.2 .drive . If these variables are being sent back but the values are incorrect.display .fault .drive . the display will go blank. To avoid this.etc) The REXA display is a vacuum fluorescent emissive display with keypad.B .2 .out.. Calibration. reference TS&R .) 2 .2 .CSA .2 .motor . the display will go out.unusual . . The power indicator light may remain on.2. .Drive 3 .4. Through the universal HART command two dynamic variables (PV position of the actuator and SV differential pressure in the actuator) are transferred back to the control system.burnt . If the 5 Vdc input from the Quad Power Supply is lost. .4 .command REXA actuators have an optional HART interface board that allows them to communicate through the HART 5.driver . 3 .6 . 3 . reference TS&R . but the display will be blank. This analog line is attached to the HART BOARD and landed on connector TB1 to pins CS+ and CS-. If the actuator is not responding to this control signal. . . but may be turned back on by pressing any key.3 . . . 3 .E .missing.0 protocol.B .1 .fault .6. .unit .Servo .7 .3.3 . The display could burn out if left on for long periods of time. .1 .10 for repair/replacement of the display.2 .respond . .sections . 3 . (See .section .ISSUES Once the drive type is determined go to the corresponding section: TS&R .HART .display.not .section .2 .CSA .to . .

3 .will .Actuator . section .Pulse . 2 .Analog .not . 2 .to . If the actuator will not respond to the Pulse signals or the desired position is not being achieved.3 .command REXA actuators have an optional FoUndatIon Fieldbus interface board.command REXA actuators have an optional contact input board that allows the actuator to communicate through Pulse commands. If connection to the REXA actuator cannot be established. .section .not .section . .section . 2 .8.respond .1 .FF .9 . The communication is established by either a 3 or 4 wire signal that carries AC or DC voltages that ranges from 24 V to 120 V.to .not . reference TS&R .X2 Troubleshooting and Repair Manual INTERFACE . Pulse Control Signal. If the actuator is not following a change in the analog control signal current or is reading a CS . FoUndatIon Fieldbus.8 . If connection is established.will . reference TS&R .Actuator .1 . Control Signal Bad.respond .command REXA actuators have a standard analog control scheme built into the main CPU board that allows the actuator to position using a two-wire 4 to 20 mA current loop.ISSUES reference the troubleshooting section on the transducers—TS&R .respond . reference TS&R .1 . These voltage pulses are interpreted by the REXA controller in accordance with the setup parameters Pulse Duration and Pulse Increment.Actuator .bad in the display.9.3 . reference other symptom section to complete troubleshooting.3 . This connection is attached to the Foundation Fieldbus interface board.will . Problem Identification – 06/10 21 .11.to .10. HART Interface. When this optional board is installed a two wire connection from the control station to the REXA actuator is used for communication.10 .

section . .section . or a distinct voltage signal.command .Cont .to . The control is a 3 or 4 wire signal that carries AC or DC voltages that ranges from 24 V to 120 V. reference TS&R . The control is a 2 wire signal that carries AC or DC voltages that range from 24V to 120V. 1 .will .11 .ISSUES 2 .(Manual . or 2 distinct voltage signals. This voltage is interpreted by the REXA controller in accordance with the setup parameter Signal Type = 1 Cont. 2 .Problem Identification INTERFACE .respond . reference TS&R .to . REXA actuators have an optional contact input board that allows the actuator to be controlled through a single contact using the bias voltage from the Contact Input board. . REXA actuators have an optional contact input board that allows the actuator to be controlled through 2 contacts using the bias voltage from the Contact Input board.Actuator .12.command . (06/10) 2 .1 . If the actuator will not respond to the Contact signals. This voltage is interpreted by the REXA controller in accordance with the setup parameter Signal Type = 2 Cont.Actuator .1 . . Contact Input Signal.Control) .not .12 .will . Contact Input Signal.Cont . If the actuator will not respond to the Contact signals.respond .3 .3 .12.not .(On/Off) . 22 REXA X2 Series TS&R Manual .

buttons .  If the actuator is powered up in Auto mode without pushing any buttons.don’t .  To access modes of operation. see . The switches are used to interface with the Actuator (whether it be setup in calibration. Modes of Operation and Control Parameters. The button must be pushed a second time to activate its function. or scroll through parameters) while in the Auto mode. 2 buttons must be pressed simultaneously. (See IOM .  A menu or parameter may not be accessible in the current mode of operation.Internal . (Contact the REXA factory. the display will dim to half intensity.section . See TS&R .1 .)  The ribbon cable connecting the membrane switch assembly to the interface circuit board may be disconnected.3 .13.X2 Troubleshooting and Repair Manual ACCESSORIES 2 . .push .section . local control.2 .don’t . 5 button membrane switch and display assembly. CPU mounted. . .work The Electrical sub-assembly is optionally equipped with an internal.buttons .) . Modes of Operation and Control Parameters. The first button push will “wake up” the display to full intensity. The switches interface with the Actuator (whether it is setup in calibration.2 .IOM . 2 . or scroll through parameters) while in the Auto mode. 5-button keypad switch and display assembly.  If you are trying to Calibrate Signal Lo and Signal Hi with the buttons.6.External . .Keypad . Modes of Operation and Control Parameters.ACCESSORIES 2 . Display Problems.6. See IOM .work The Electrical sub-assembly is equipped with an external doormounted.2 . local control.section .6.  +5 Vdc internal to the Control enclosure may be too low. Problem Identification – 06/10 23 .2 . .section .

3.Drill .Drive . Declutchable Handwheel.Appendix .6.  Units with solenoids and accumulator systems must have the override handles locked to operate the handwheel. section M.  A menu or parameter may not be accessible in the current mode of operation.  +5 Vdc internal to the Control enclosure may be too low. Modes of Operation and Control Parameters.  If you are trying to move the actuator in Local or Calibrate mode and the actuator will not move. (See IOM .6. the hand wheel / drill drive is disengaged via internal spring. One half-revolution may be required for proper engagement.  Are you trying to Calibrate Signal Lo and Signal Hi with the buttons? (See IOM . (Contact the REXA factory.Hand . (See IOM .1.Problem Identification ACCESSORIES  If the actuator is powered up in Auto mode without pushing any buttons. .)  To access modes of operation. The button must be pushed a second time to activate its function.wheel .2 . section M. Modes of Operation and Control Parameters. (See IOM .work The handwheel is mounted to the actuator’s motor.) .section .Appendix .  The hand wheel can take several turns before you see movement from the actuator. the display will dim to half intensity. 3 .section .)  Servo units do not allow for operation of the handwheel while the actuator is powered up.) (06/10) 2 . you must engage the handwheel by pushing the handwheel toward the motor. 2 buttons must be pressed simultaneously.doesn’t . To operate./ . The handwheel will declutch by moving outwards when the spring is released. see TS&R . A holding current is present to prevent movement of the motor.M. The first button push will “wake up” the display to full intensity.15.) 24 REXA X2 Series TS&R Manual .section .2. Control Issues.3 .M.

 Units with solenoids and accumulator systems must have the override handles locked to operate the hand pump. the hand pump will not operate.Gauges . .2 .working . .much .work The Manual hand pump is a piston style pressure device with directional knob located underneath the assembly. you may have a bad gauge. 2 . Problem Identification – 06/10 25 . . (See IOM .Pump .If .) .don’t .)  If the Manual bypass valve is open.X2 Troubleshooting and Repair Manual ACCESSORIES  If the Manual bypass valve is open. Manual Hydraulic Pump. 2 .2 . . can . If the valves are tightened (CW rotation) then the internal pressure of the REXA unit will increase. The valves are adjustable and can be reset in the field.Appendix .Hand .M .5 . Module gauges show cylinder pressure.too .the .become . If the gauge is not reading.during .not .device .  Make sure the directional knob is in the up or down position. 2 . and it should be replaced. The hand pump assembly requires reservoir fluid to operate. the hand wheel will not operate. The power module gauges have shut off valves located beneath the gauge.4 . .6 .2. and some units are equipped with reservoir gauges (accumulator units).connected .Appendix .work Most REXA units have several gauges installed.Protection . .actuator .Pressure .2. (unit . driven .the .2 .Limiting .pressure) The REXA pressure limiting valves are located on the power module underneath the motor junction cavity cover.building . ensure gauge isolation valves are open.Manual .  The hand pump can take several pumps before you see movement from the actuator (See IOM . The valves are factory set per specification. Manual Hydraulic Pump.adjustment. If the gauge is still not reading.doesn’t . CAUTION: .to .equipment .damaged .the .M .is . .

7 .A .transducers) Some REXA units are equipped with pressure transducers to relay internal pressure electronically. . accurate . for additional information.thrust . reference .Torque .2.not .switches .2 . .2 . Linear. 2 . Rotary.or . The pressure transmitter is loop powered and sends a 4 to 20 mA signal.8 .A .3 . Pressure Limiting Valves. See TS&R . For repair/replace information on the switches for a rotary actuator.Mechanical .not .Appendix.) (06/10) 2 .(from .3 . .functioning REXA actuators have optional independent mechanical limit switches to provide redundant indication of the actuator's position.section . 26 REXA X2 Series TS&R Manual .14.IOM . .limit . Hart or Fieldbus units use pressure transmitters to relay cylinder pressure as well.data .section . How do I test my 4-20 mA Position Transmitter.1. These limit switches are wired directly from the actuator cylinder to the DCS and are independent of the REXA electronics. Mechanical Limit Switches of the Installation and Operation Manual. Accumulator units use the pressure transducer to relay accumulator charge pressure.section . For repair/replace information on the switches for a linear actuator reference .2 .IOM .5.Problem Identification ACCESSORIES (See TS&R .Appendix. Switch ratings and specifications can be found in Appendix A.section .

(See TS&R .  Wiring errors – –  Manual bypass or Solenoid – 2 . Every REXA unit is tuned per power module and cylinder combination.3 .2 .CONTROL . Actuator Hunting–Electrical Noise.ISSUES 2 .1.position The REXA unit moving to the wrong position could be caused by:  Control signal loss – The REXA unit may be programmed to move open.3 .section . Incorrect wiring of the feedback can cause the actuator to travel in the wrong direction. If the bypass valve or solenoid is open. (See TS&R .15 . Check wiring per your REXA drawing. Problem Identification – 06/10 27 .15 . the REXA unit cannot build pressure.“hunting” . . .1 .Actuator . . It is possible for the process or driven device to push the actuator in the wrong direction if these pressure relieving devices are open.3 .) Gain/acceleration settings may be incorrect.moves . Electrical noise issues: If the REXA feedback or control signal is constantly in flux the cabling may be installed incorrectly.to .control) The occurrence known as “hunting” can be caused by several different issues. 3 .X2 Troubleshooting and Repair Manual CONTROL .ISSUES 2 . closed or in place on loss of control signal.section .(dithering .Actuator . Actuator Hunting–Electrical Noise.) Incorrect wiring of the motor can cause incorrect or interrupted motor phase pulses causing the motor to travel briefly in the wrong direction. Check wiring per your REXA drawings.wrong .1. .3 .during .

match . .load The REXA actuator is designed and specified to meet the required thrust or torque per a specific application.3 .feedback . 2 .4-20 . (See TS&R .4 . then the following steps should be taken:  Confirm your actuator has the required thrust or torque to overcome the process requirements.actual .bad. (See TS&R .Position .1.“drifts” . If the actuator is pushed by the process. Pressure Limiting Valves. .applied .doesn’t .3 .section .)  A damaged or failed piston seal can cause the REXA cylinder to lose internal pressure.section .Feedback .3 .2.3 . .3 . .3 .3 .position .my .section .away .3 .Position .15 .5 .No . Actuator Torque/Thrust requirements.mA . for more information.Transmitter? . See TS&R .Problem Identification CONTROL .6. (See TS&R .15 .section .  Ensure Pressure limiting valves are set correctly per the unit’s specification. Position Transmitter calibration. 28 REXA X2 Series TS&R Manual .ISSUES Additional tuning may be required for faster pumps/motors and smaller cylinders. step #4.)  Ensure bypass and solenoid valves are shut and tight.do .) 2 .14.section .Actuator . see TS&R . Press .How . for additional information. for additional information. 2 .3.test .3 . The actuator’s model number will determine the rated thrust or torque.I . (06/10) 2 .from .3 .position The REXA’s position transmitter output is digitally calibrated by the CPU during programming of the high and low positions. Actuator drifting.15 .signal The REXA position transmitter is capable of transmitting a 4 to 20 mA output by using loop or internal power.6 . If your transmitter needs further calibration. Refer to your wiring diagram for proper termination information.

The REXA actuator is designed and specified to meet the required travel for a specific application.not . . 3 . and will close when below the set point.3 .get . Electrical Limit Switches.section .3 . Pressure Relief Valves. The contact for Relay #2 will be open when actuator position is below the position given by parameter Relay #2 and will close when above the set point. the following steps should be taken:  Confirm your actuator has the required travel or rotation for the application.Switches .Limit .function The REXA Control enclosure is equipped with two single-pole.14. be sure the actuator is above (Relay #2) or below (Relay #1) set points.I . refer to TS&R . for additional information.)  All REXA actuators have adjustable pressure limiting valves.Actuator .15 .seat. See TS&R . (See TS&R . single-throw. If the actuator can not fully stroke the driven device. Ensure that your actuator is generating enough pressure to overcome the process requirements.3 .not .8 . section .don’t . If it is greater (or the contact measures open when it should be closed). solid state relays that give limit indication.X2 Troubleshooting and Repair Manual CONTROL .3 .1. (IOM section 6. The position of that indication is set by parameters Relay #1 and Relay #2 in the Outputs menu.8).7 .will .Electrical .can . for adjustment procedures.2.5 W resistance when the contact is closed. the contact for Relay #1 will be open when actuator position is above the position given by parameter Relay #1.ISSUES 2 .  If relays are not operating.travel . Problem Identification – 06/10 29 . . 2 .5. check wiring terminations.  Is the corresponding LED for each relay illuminating? If yes.  Is the actuator position within the Relay set point. including deadband?  The relays should have no more than 1. Actuator torque/ thrust requirements.section . Also. . Refer to your wiring diagram for proper termination points.full . The relays are configured to be “open contact” when Main power is not applied.15 .

requirements The REXA actuator is designed to meet a specific speed requirement.Actuator . . If the stem engagement can not be corrected.module .3 .3 .9 .in .section .  Ensure no mechanical restriction or binding is causing the actuator to stop travel. Engagement of valve stem into elastic coupling may be too deep. Rotary SPRING FAIL stop may need to be set. Too High/Too Low on display.Booster .5 times the diameter of the stem. (06/10) Linear units – – 2 .Pump . Booster pumps will turn on when the desired change in position is greater than the “Boost Pump” setting under the drives menu.6.Problem Identification CONTROL .15 . . They are used to increase the speed of the actuator.) 2 .or . To adjust this parameter. you may need to adjust the HS setting in the parameter menu. If your actuator is not meeting these requirements. 2 . Refer to TS&R .Only .6 .not .on . Setup Mode. Rotary units – Some rotary units have adjustable travel stops. Packing arrangement or anti-rotation may be interfering with actuator stroke.2. for additional information. reference section .1 .functions REXA units with specific speed requirements sometimes use multiple modules to meet that specification.speed . Dual module units 30 REXA X2 Series TS&R Manual . for stroke times for your equipment.3 . see TS&R . The engagement of the valve stem into the actuator should be 1.stroke .meet .the .ISSUES  For TOO HIGH or TOO LOW indication on the display.3 . Check engagement and make changes if required.units . .6 .3 .7 .15 .1. Actuator torque/thrust requirements. (See IOM section .10 .IOM.11 . contact your local REXA representative.2C .2D .one . Booster Pumps are an optional accessory installed on some actuators.does .

and .Actuator . There are numerous reasons why the actuator may be having a speed issue.at .2.X2 Troubleshooting and Repair Manual CONTROL .Actuator .turning .to . .3 .ISSUES require 2 sets of motors. before .3 . . Pressure Relief Valves. Drive Fault.section .12 .Surrounding .target .  The "Gain" setting may be too low.  If the actuator pressure is above 2400 psi when this is occurring.not . If the cables for the REXA actuator are run close to surrounding equipment or control cables. . Refer to your specific wiring diagram to make sure you have the correct interconnect for your actuator. If an error code is displayed on either driver. . it is possible for noise to be induced onto the control lines of this equipment.by . a separate electronics is required.Servo .3 .low . If the motor continues to rotate after the actuator has reached its new position.move .getting .1. reference TS&R . it extends the life of the actuator. reference TS&R .15 .13 . when .3 .RPM . Actuator Hunting — Electrical Noise.slows . For redundant units. This will cause the motor to slow down too much before it reaches the set point.position . and they range from tuning to having an actuator that is undersized for a given load. section .14. Since there are no moving components. The FMV holds the load in place which allows the power consumption of the unit to be very low. 2 .3 .3 .operation Some REXA actuators use large motors that require high voltage and current. Problem Identification – 06/10 31 .to . see TS&R .“resets” .down . 2 . Within the actuator CPU there is a timer that will shut down the motor and cause the system to reset if the actuator is not achieving a certain speed. disrupted .Motor .equipment . the motor will come to a complete stop. drivers and cables.commanded . 2 . When the actuator reaches its set point.14 .

32 REXA X2 Series TS&R Manual .in .stats The REXA electronics will keep a running count of error codes to log the problems the system encounters.3 .and . Reference the specific error codes section for more information. (06/10) 2 .15 . section . but the historical stats are a permanent running counter.I . Close monitoring of the unit should be performed to determine the root cause of these failures. Refer to the IOM .3 .6.historical .returns . Reference the error codes section to determine possible root causes.  The "Gain" setting may be too high.errors . The current stats can be reset in the setup menu.overshoots . This count is stored under the current stats and historical stats menus.Actuator .many . . . Within the sophisticated control scheme of the REXA electronics there are tuning parameters that will allow this overshoot to be tuned out. If the actuator does not slow down as it approaches the new target position.Control Parameters.ISSUES 2 . to ensure parameters are correct.Problem Identification CONTROL .16 . it will likely overshoot its new position. .logged .target .have .position .

6 .)  The system requires additional oil to charge the accumulator.after . section . section .will .X2 Troubleshooting and Repair Manual FAIL .recover .fail .not .4 .event .1 .4 . (See IOM .2.1 .2 .SAFE .M .C . Inputs menu) Some control systems use a 0 to 20 mA input signal. For information on the solenoids see TS&R . If your accumulator is not recharging:  Ensure that the parameter ACCUM . . The REXA CPU controls power to the solenoids as defined during manufacturing of the system. Some REXA actuators are equipped with a failsafe system when necessary.Actuator .6.does . . for additional information. . Accumulator Control Parameters for additional details.4 .)  The accumulator system uses two external solenoids to operate the accumulator system.not . The accumulator system will only go through a recharge cycle if the pressure in the system requires.C .11.section .1. .4 . this oil is pulled from the reservoir system.recharge The REXA accumulator system is self contained and does not require external equipment to recharge the system after a trip.safe .IOM .SAFE .  Some accumulator systems are designed to have more than one fail per recharge cycle. Several different failsafe systems are available: Control signal fail – – Check your FAILSAFE parameter setting.ISSUES 2 . (See IOM .FAIL . in this situation. Trip Function.Accumulator .  Some accumulator systems use an external trip signal to activate the fail condition.DIR (accumulator fail direction) is set to the proper end.1 . There is a shut off valve located between the reservoir and the accumulator. 2 . This valve must remain OPEN. (See .ISSUES 2 .section . the FAILSAFE parameter needs to be Problem Identification – 06/10 33 .

1 . for additional information.section .fail .6. 34 REXA X2 Series TS&R Manual .in .) Some accumulator systems have trip input function that may need to be reset to continue normal operation.section .IOM for additional information. you have an accumulator system to fail the actuator upon activation of a failsafe event (loss of power or trip signal). .Unit . –R or –U in the model number.) (06/10) – Accumulator system fail – 2 .will . If your actuator has an –A in the model number.5 mA is a valid signal for 0 to 20 mA systems.the .1 .4 . For additional information on the loss of control signal function.) Surge systems have a trip input function that may need to be reset to continue normal operation.6 . Less than 2. Inputs menu. This solenoid assembly may need to be adjusted to operate properly. (See TS&R . (See Appendix .2.4 . it will be indicated on the model number of the actuator.section .position Some actuators have spring fail or accumulator systems to move the driven device to a previously specified position upon loss of power or trip activation signal. you have a mechanical spring installed to fail the actuator upon activation of a failsafe event (loss of power or trip signal). .) If your actuator has an –E.3 .M . see IOM .to . Control Parameters.10-11 for information.6.Problem Identification FAILSAFE .C .section . repair . Actuator ID. (See TS&R .move . The REXA standard system fails in place on loss of power and can be programmed to fail to a specified position on loss of control signal. for information on REXA's model numbering system.ISSUES set to OFF. If your equipment is spring fail or accumulator system design. (See IOM .not . Spring assist fail & Surge systems – Spring fail units have an electrical solenoid in place of the manual bypass.

section . Some accumulator systems have a needle valve installed in line with the solenoid.your .off .mechanical .Actuator . valves . position . Before .the . .6 .position . preventing .manual .the . . Turn the needle valve CCW to increase fail speed.failsafe .the . (See IOM .are . Turn the needle valve CCW to increase fail speed.position . Standard REXA internal solenoid identification.restrictions .make .are .does .the .in . Some accumulator systems have a flow metering valve installed in line with the accumulator system.X2 Troubleshooting and Repair Manual FAILSAFE .and . CW to reduce fail speeds.open .1 .failsafe .fail .M . section 4 .all . Trip input functions have additional parameters to determine the proper fail position and trip input functions. . Also.speed . – Accumulator systems: – – Problem Identification – 06/10 35 .shut .system.4 .6.meet .solenoid . Inputs Menu. CW to reduce fail speeds. sure .event. . correct .overrides .from . .actuator . High speed solenoid units have a needle valve installed in line with the solenoid.are .ISSUES . If the actuator can not fully stroke the driven device in the time specified.troubleshooting .M . High speed solenoid identification.requirements The REXA actuator is designed to meet the required fail speed for a specific application.reaching . for additional information. section 4 .failsafe . Adjust the metering valve to increase flow speed. To increase the fail speed of a standard internal REXA solenoid.) 2 .for .no .4 .11.ensure . the following steps should be taken: Spring fail units: – Standard solenoid (module mounted) units have no speed adjustment. please contact your REXA representative.14.not .in .

the .Hydraulic . This surge operation only occurs with a change in the control signal input as defined by the Surge Breakpoint parameter in the setup menu. .3 . The fail-to-end position is achieved either by the use of a coil spring or a pressurized accumulator bottle and can be triggered by a loss of power.section .  If the actuator doesn’t trip on loss of trip signal. please contact your REXA representative.G .section .for .Unit . .16 .No .section .Problem Identification FAILSAFE .position . No trip on loss of control signal.3 .IOM for more information on setting the surge function correctly.reading . .4 .C .5 .is . Display. IOM for more details on setting up an accumulator system.in .  If the actuator doesn’t trip on loss of control signal.Pressure .ISSUES – To further increase the speed of the accumulator system fail speed.in . The REXA CPU constantly monitors the accumulator pressure. reference TS&R .surge .moves .to .7 .on .4.pressure .3 .16 . . Reference Appendix . This data is also used during an accumulator recharge to determine the maximum pressure the accumulator will be charged to.  If the actuator trips to the wrong end.not .gauge . the . 36 REXA X2 Series TS&R Manual . .trip REXA actuators can be configured to fail to either end position or stay in its last position. see TS&R .3.1. No trip on loss of trip signal 2 .the .2.16 .section . (06/10) 2 .system .functioning Hydraulic surge system uses a solenoid valve and spring to achieve fast motion in one direction.on . Fail Direction.  If the actuator does not trip on loss of power.4 . 2 . reference TS&R . Reference Appendix .4 .wrong . The data is used to send a warning alarm if the pressure drops to a level that a full fail safe trip can not be completed.3 .but .Accumulator .6 .there . control signal or independent trip signal. No trip on loss of power. reference TS&R .16 .

is .8 . If the unit has solenoids that are energized continuously. reference TS&R .4 .ISSUES 2 . Solenoids. Typically they will have a 60 °F (16 °C) temperature rise during normal operation.touch .11.4 .to . If the solenoid valves are measured to have a higher temperature rise. Problem Identification – 06/10 37 . .Solenoid .extremely .X2 Troubleshooting and Repair Manual FAILSAFE . REXA uses high quality.M .the .hot . these valves will be hot to the touch. aircraft-grade low leak solenoid valves to control our trip functions. These solenoids can be either energized all the time or only during a failsafe event.

Repeated . The REXA unit may show signs of oil weeping shortly after installation.5 . the actuator could be leaking internally. the reservoir may weep slightly until equilibrium is met.leaks .low.6.5 . If the reservoir continues to weep or leak oil. (06/10) 2 . refer to IOM .Reservoir . Oil. When the actuator is exposed to an increase in temperature.no .3 .LEAKS 2 .but . If the leak persists. contact your local REXA representative.no . please contact your local REXA representative.LEAKS 2 . The actuator will continue to function as long as the oil level is maintained./ . 2 . If the cycle of retracting and filling continues.oil .leaks Under normal operating conditions the REXA actuator will not use additional make-up oil. for filling instructions.filling.is . .oil .Reservoir .visible . Upon installation it is normal for the equipment to weep some oil from the reservoir pressure relief valve during temperature changes.relief .oil The actuators reservoir pressure relief valve is set between 40 and 120 psi depending on the design of the equipment.External .2 .The . .visual .5 .OIL . .oil .1 .1 .5 . . .is .oil .indicator .Problem Identification OIL .leaks When the oil level indicator is below the scribe mark. section . 38 REXA X2 Series TS&R Manual . . please contact your local REXA representative. .

noticeable bending of the actuator stem or driven device.in .6 .1.binding Most mechanical restrictions are an application or mounting-related problem.Water . Binding will be indicated by erratic motion. Module/Motor. If you suspect you are having binding issues.  First check the conduit fitting to insure they are tight and pipe sealant has been used.17 . 2 .2. .17 . .Module The REXA power module is rated to meet the requirements of NEMA 4X. reference TS&R . section . It is important to see if the location of where the water is entering can be identified. please call the factory for assistance. .1 .  For water in the module wire cavity or under the rotary housing.6 .X2 Troubleshooting and Repair Manual MISCELLANEOUS 2 .MISCELLANEOUS 2 .2 . Problem Identification – 06/10 39 . Electronics.Cylinder .3 . slower speed or restricted travel. Typically the largest root cause of water getting into the unit is from improper installation of the conduit and not using pipe thread sealant during installation. reference TS&R .6 .3 . These issues should be corrected immediately as they have the potential to shorten the life of the actuator bushings or valve packing.  For water under a linear feedback housing.

If during the set up procedure PL or PH are set too close together (within 10% of each other) the values will not be accepted.low” When calibrating a REXA actuator.not .accept .unit . (Reference TS&R .) 40 REXA X2 Series TS&R Manual .1. The actuator will record the two control signal inputs that correspond to the low travel end points.15 . .7 . (06/10) 2 . Too High/Too Low on display. reference TS&R . Feedback.3 .SH .6.  If the feedback only changes during a portion of the actuators stroke reference TS&R .or .2.1 .7 .high” .PL .15 .Will .and .15 .  If the actuator feedback doesn’t change when stroking the actuator reference TS&R .or .  If the feedback only changes during a portion of the actuators stroke.not . 3 . Feedback. reference TS&R .3 . . Actuator Hunting—Electrical Noise.2.3 .1.3 .11. 2 .“too . Feedback. reads .or . Control signal calibration.2.3 . If during the set up procedure PL or PH is being set to a point that is too close to the mechanical end stop.or . Actuator Hunting—Electrical Noise.)  If the actuator feedback changes when the unit runs. the display will read “too high” or “too low”.3 . they will not be accepted.TS&R .SL .Problem Identification CALIBRATION 2 .  If the actuator feedback changes when the units is being run reference . the end points are recorded as Position Lo and Position High. . If during the set up procedure SL or SH are out of range.Setting .7 .3 .7 .2 . reference TS&R .6 .PL .PH .“too .value The REXA actuator will allow calibration of the incoming control signal for precision control.3 .6 . Feedback. .PH .CALIBRATION 2 .value When calibrating a REXA actuator the end points are recorded as PL and PH.Will .accept . (Reference TS&R .  If the actuator feedback doesn’t change when stroking the actuator.the .6 .6 .2.

Troubleshooting 3 . CPU +15V Acc+ Transmitter RED BLACK Shield should be landed at both the Electronic enclosure back panel and at the Transmitter terminal strip at the actuator. this can be done by removing the wires connected to the Transmitter and directly applying a 4 to 20 mA signal generator (see photos). Check the CPU by simulating a 4 to 20 mA signal.ACCUMULATOR .1 .X2 Troubleshooting and Repair Manual 3. Connect the positive end of your signal generator to Acc+ and the negative end to Acc-. 1. Ensure the wiring to the Transmitter is correct according to the drawing.LOW/BAD . It should be as follows.PRESSURE Press bad This error appears when the CPU does not receive an analog signal from the pressure transmitter. Troubleshooting – 06/10 41 . 2. .

) Disconnect Pressure Transmitter Cable at the actuator junction box.) c.PRESSURE 3. Pressure Transducer Repair.Troubleshooting .) 4. then the Pressure Transmitter is bad.(#) 0 750 1500 2250 3000 If these readings are correct. red lead to red. If the CPU is working properly. The mA reading should correspond to pressure on the pressure gauge 0.25. Connect current source as shown.1-1 Acc+ and Acc- Photo 3.ACCUMULATOR . To test the Pressure Transmitter: a. Apply the recommended signal and take note of the display reading.) Photo 3.) f.4 .00667 mA per 1 psi 2400 psi*0. the problem may be with the Pressure Transmitter.) b. (See TS&R .00667 = 16 mA If these readings don’t match or no loop power can be sourced.) Photo 3.0 mA = 3000 psi Pressure will not change as you move dial on current source as the current source is fixed (based on the pressure reading of the pressure transducer).4 .1-3 Red and black leads 42 REXA X2 Series TS&R Manual . black lead to black.(mA) 4 8 12 16 20 (06/10) Display . replace the CPU. Begin by scrolling to the “Accum Pres” parameter under the Drives menu. If these readings do not match. (See TS&R .M .) d. Signal .LOW/BAD .4.E . then the CPU is good. Turn dial on current source to full output (clockwise) Display should read mA signal that corresponds to pressure 4 mA = 0 psi 16.8 mA = 2400 psi 20.1-2 Signal generator e.

26. This pressure should match what you see under the Drives Menu “Accum Pres”. If the gauge is reading higher than what the transmitter shows. This pressure should begin around 1900 lb because that is the pre-charge pressure of the Nitrogen on the other side of the Piston Accumulator.Bad section and perform the same checks to determine if the problem is in the CPU or Transmitter. Repair or return the defective component if a problem is found. 1. go back to the Pressure . 3.ACCUMULATOR . If you notice that the accumulator has started its recharge cycle much lower than the 1900 lb. Hold down the Enter Key and observe the Accumulator Pressure rising. Once a re-charge cycle has begun and display reads “Auto-Rchg”. This will take the Actuator out of its re-charge cycle and back into setup mode for further evaluation of the problem. Look at the Accumulator Pressure gauge located at the Actuator. 5. allow the Actuator to perform its recharge cycle to determine if the problem has been solved. Start by initializing a re-charge cycle. Replacing Accumulator Bottle. (between 1 900 and 2 400).X2 Troubleshooting and Repair Manual . If the Accumulator gauge and pressure Transmitter are both reading the same value (1 700 psi or below). then there was a loss of Nitrogen from the Accumulator bottle. scroll up using the up arrow 15 times till display reads “Accum Pres”. 2. stop the recharge cycle by holding down the AUTO & MANUAL buttons at the same time. 4. There should be a 200 psi differential between the “Rechrg Pres” and the “Warn Pres” values. (See TS&R .M .PRESSURE Press Low The “Press Low” error occurs when the accumulator pressure is below the warning pressure value (under the Drives menu). The increase in Pressure should be a steady rise of pressure until the pressure has reached the recharge pressure value under the Drives menu. 4 . If the accumulator has started its recharge cycle and the “Accum Pres” is at 1900 lb (or very close to the initial pressure).LOW/BAD .) Troubleshooting – 06/10 43 .

Style . . Interconnecting .1 .drive . .CSA . A jumper wire is installed on the CPU board between FLT+/FLT.Stepper . (06/10) Photo 3.2 B stepper driver external power supply 3 .FAULT 3 .Supply: The REXA B motor driver with external power supply is the first version of CSA approved stepper driver.fault .Driver B .disabling this feature. There is no fault relay for this version driver. Verify the integrity of the cable by checking each wire to ensure there are no line breaks or shorts. The IMS style driver does not have the logic I/O to enable this feature.separate .DRIVE .IMS .2 .IMS .with . Use a DMM to test 44 REXA X2 Series TS&R Manual .Cabling: To test the cabling.FAULT .Driver .Power . It was used from 2005 to 2009 and only on a few model REXA units.2 . remove the cable from the actuator and electronics.B .Troubleshooting DRIVE .

If a problem is found with the interconnecting cables. Stepper .1 or lower means the motor is bad and must be replaced. brushless DC electromagnetic stepper motor.3 ohms between each phase wire (A/A-. A sequence of voltage inputs from the driver module creates movement. a short to ground or to another phase. To check the integrity of the motor. use a DMM to read the resistance between each motor phase.X2 Troubleshooting and Repair Manual .6 or higher. B/B-).5 to replace the B motor.4 . Phase A Wire pair Green (phase A) and Green/Black (phase A-) Phase B Wire pair Red (phase B) and Red/Black (phase B-) The motor resistance must be 0. A reading of 0. Troubleshooting – 06/10 45 .Motor: The REXA Stepper module uses a 4 pole. If the sequence is interrupted by a loss of current. a driver fault can result.DRIVE .FAULT the cables. replace the cable and recheck the unit for problems. See section TS&R . or 0.M .

2.1-1 Version 1 CSA Driver Photo 3.1-2 Version 2 CSA Driver For version 1 drive continue on. B CSA drive fault Potted Drive The version 1 CSA IMS driver sends a 60 Vdc square wave pulse signal to the motor to create movement. (06/10) Photo 3.section . Verify the incoming power at the power supply board TB1 located underneath the CPU board.FAULT Stepper . The frequency of these pulses is proportional to the High Speed setting in the Speed/ACC menu.Drive: The version 1 CSA X2 REXA actuator uses an IMS Stepper module driver to create motor movement. version 2 drivers please skip to TS&R .3 .Troubleshooting DRIVE .2 . 46 REXA X2 Series TS&R Manual .2. The IMS style driver uses power from the separate motor power supply to drive the motor. Some versions of REXA use an AMCI potted drive explained in the following sections. The motor power supply uses the incoming power supply to power the motor/driver combination. See photos to verify the style driver installed.2.

signals .) If the power supply and driver voltages are correct.section . If the 60 Vdc is not present. (See TS&R .the .E .9 for driver replacement.E .2.X2 Troubleshooting and Repair Manual . change the power supply module.E .section . Troubleshooting – 06/10 47 . To verify the motor power supply voltage read the red/black output wires coming from the large blue capacitor.4 . The direction and speed of the motor is determined by input from the CPU. CPU . If the 60 Vdc is present. change the motor driver.3 for instructions on the power supply module or TS&R .1 Power supply board The driver must have a supply of 60 Vdc from this module.to .FAULT Figure 3.6−4 . continue on to the CPU.4 .DRIVE .driver: The stepper driver converts signals from the CPU to physical movement by the motor.

4. Step pulse: TB3 terminals STP-. 5 Vdc should be present.4. attempt to move the motor. (See TS&R .4. (See TS&R .2.Potted .Drive A drive fault can be caused by damage to the motor.2 .CSA . 0 Vdc should be present. Photo 3. The pulse output to the drive is 10 microseconds wide. change the CPU. (See TS&R .) 3 . If the 5 Vdc is not present during movement (present on both directions). section .fault . Dir. Enable: The TB3 terminal ENA+ and ENA-. To read these signals.drive . change the CPU. In (06/10) LOCAL mode: a.2 . If the pulses are not present. In the Local mode.E .and Dir +.B . motor direction should be clockwise.4 . change the CPU. This is too fast to read via a DMM.) 3. 400 pulses = 1 revolution of motor movement.E .2 Potted drive 48 REXA X2 Series TS&R Manual .FAULT Place the actuator in the Local mode to continue these checks. place a DMM on the terminals indicated.section . Direction: The TB3 terminals. The first step to determine the problem is to identify what part of the assembly is at fault. motor direction should be counterclockwise. 4 . sends a 5 Vdc signal to the driver to enable the drive to send the pulses to the motor.) 2.) b.4 . 1. . driver or its interconnecting cables.E .) Press the Down button. is the output to the driver that determines direction of motor movement. Press the UP button. If the voltage is not consistent when pressing the up/down buttons on the display.section . STP+.Troubleshooting DRIVE . An oscilloscope can measure the pulses.

The potted AMCI drive receives a 5 Vdc signal from the CPU through a N/O switch internal to the drive.M .X2 Troubleshooting and Repair Manual .Motor: The REXA Stepper module uses a 4 pole.3 ohms between each phase wire (A/A-. Stepper . B/B-). The frequency of these pulses is proportional to the High Speed setting in the Speed/ACC menu. use a DMM to read the resistance between each motor phase. A motor fault (as indicated above) or loss of input or Troubleshooting – 06/10 49 . See TS&R .6 or higher. Stepper .FAULT Interconnecting . Use a DMM or MEG device to test the cables. replace the cable and recheck the unit for problems. If the sequence is interrupted by a loss of current.Cabling: A drive fault can be caused by a short or wire break in the cable run. Phase A Wire pair Green (phase A) and Green/Black (phase A-) Phase B Wire pair Red (phase B) and Red/Black (phase B-) The motor resistance must be 0. If a problem is found with the interconnecting cables. a driver fault can result. a short to ground or to another phase. To check the integrity of the motor.driver: The version 2 CSA AMCI potted driver sends a 160 Vdc square wave pulse signal to the motor to create movement. Verify the integrity of the cable by checking each wire to ensure there are no line breaks or shorts. remove the cable from the actuator and electronics. brushless DC electromagnetic stepper motor.5 to replace the B motor. or 0. Any failure to the driver will change the state of this switch.DRIVE .4 .1 or lower means the motor is bad and must be replaced. To test the cabling. A sequence of voltage inputs from the driver module creates movement. A reading of 0. If there is a problem with the driver the switch changes state and the CPU initiates a driver fault.section .

and Dir +. If the motor is allowed to cool (less than 300 °F [~150 °C]) the thermostat interlock will reset and power will be restored to the drive. run the motor in either direction and check the output of the driver on TB2 terminals (A/A.6-4 .) Press the Down button. Press the UP button.FAULT output power is recognized as a driver fault. To determine if the driver is faulty.  The motor thermostat is located on the actuator internal to the stepper motor. As stated above. In LOCAL mode: a.  In Local mode. check the output of the driver to the motor.the . The CPU first determines direction and then the drive is enabled.  If the 110 Vac power is present and the motor temperature is below 300 °F (~150 °C). there is a problem with the input power.and B/B-). See TS&R . motor direction should be counterclockwise.4 . TB1 on the driver is the incoming power.E .sections .signals . (06/10) CPU . 1.9 for information on driver replacement. the driver sends a 160 Vdc square wave pulse to the motor. If no voltage is present. motor direction should be clockwise. This switch is triggered at 350 °F (~180 °C).E .) b. or the motor thermostat has changed state. Direction: TB3 terminals Dir. 0 Vdc should be present. The direction and speed of the pulses is sent to the driver in steps.driver: The stepper driver converts signals from the CPU to movement by the motor.Troubleshooting DRIVE . 5 Vdc should be present. 50 REXA X2 Series TS&R Manual . If no output is present. The direction is determined with high or no voltage on these terminals.to . Place a DMM on these terminals to verify the power input. Place the REXA unit in the Local mode to perform the following checks:  Check incoming power to the drive. you must first check the CPU output. the driver has failed and must be replaced. After that the pulse speed is sent to the driver.

(See TS&R .section .fault A drive fault can be caused by damage to the motor. remove the cable from the actuator and electronics. Step pulse: TB3 terminals STP-.FAULT If the voltage is not consistent when pressing the up/down buttons on the display. An oscilloscope can measure the pulses. change the CPU. If the 5 Vdc is not present during movement.) 3. STP+.4 .) 3 .Cabling: A drive fault can be caused by a short or wire break in the cable run.C .section .3 . The first step in determining the problem is to identify what part of the assembly is at fault. 4 . If the sequence is interrupted by a loss of current. change the CPU. Enable: TB3 terminal ENA+. a short to ground or to another phase. a driver fault can result.drive . Troubleshooting – 06/10 51 . (See TS&R .4 .DRIVE . If a problem is found with the interconnecting cables. 400 pulses = 1 rpm of motor movement If the pulses are not present.E . change the CPU. Use a DMM or MEG device to test the cables. driver or its interconnecting cables. Verify the integrity of the cable by checking each wire to ensure there are no line breaks or shorts. A sequence of voltage inputs from the driver module creates movement. (See TS&R . Interconnecting .E .E . .Motor: The REXA Stepper module uses a 4 pole. brushless DC electromagnetic stepper motor. The CPU sends a 5 Vdc signal to enable the drive to send the pulses to the motor. Stepper .X2 Troubleshooting and Repair Manual . replace the cable and recheck the unit for problems. To test the cabling.2 .4.4.) 2. To check the integrity of the motor.4. use a DMM to read the resistance between each motor phase.section .

Place the REXA unit in Local mode to perform the following checks:  Check incoming power to the drive. If the motor is allowed to cool (under 300 °F [~150 °C]).5 to replace the B motor. The AMCI drive receives a 5 Vdc signal from the CPU through an N/O switch internal to the drive. Place a DMM on these terminals to verify the power input. If there is a problem with the driver the switch changes state and the CPU initiates a driver fault.  The motor thermostat is located on the actuator internal to the stepper motor. 52 REXA X2 Series TS&R Manual .section . A reading of 0. (06/10) Stepper .driver: The REXA C electronics use an AMCI drive to send a 160 Vdc square wave pulse signal to the motor to create movement. there is a problem with the input power. If no voltage is present.6 or higher or 0. A motor fault (as indicated above) or loss of input or output power is recognized as a driver fault. See TS&R . TB1 on the driver is the incoming power. or the motor thermostat has changed state. the thermostat interlock will reset and power will be restored to the drive. The frequency of these pulses is proportional to the High Speed setting in the Speed/ACC menu.Troubleshooting DRIVE . means the motor is bad and must be replaced. This switch is triggered at 350 °F (~180 °C). B/B-).4 . Any failure to operate condition will change the state of this switch.M .3 ohms between each phase wire (A/A-.1 or lower.FAULT Phase A Wire pair Green (phase A) and Green/Black (phase A-) Phase B Wire pair Red (phase B) and Red/Black (phase B-) The motor resistance must be 0.

If the voltage is not consistent when pressing the up/down buttons on the display. In the Local mode.section . After that the pulse speed is sent to the driver. See TS&R . CPU . STP+.DRIVE . 4 . Step pulse: TB3 terminals STP-. The pulse output to the drive is 10 microseconds wide.9 for information on the driver replacement.E . The direction and speed of the pulses is sent to the driver in steps.) 2. motor direction should be clockwise. the driver has failed and must be replaced. Enable: TB3 terminal ENA+. run the motor in either direction and check the output of the driver on TB2 terminals (A/A.6-4 . Press the UP button. The direction is determined with high or no voltage on these terminals. An oscilloscope can pick up the pulses.section . 0 Vdc should be present.FAULT  If the 110 Vac power is present and the motor temperature is below 300 °F (~150 °C).) 3.) b.sections .to .X2 Troubleshooting and Repair Manual . As stated above. change the CPU.and Dir+.E . The CPU sends a 5 Vdc signal to enable the drive to send the pulses to the motor. (See TS&R . (See TS&R .E . the driver sends a 160 Vdc square wave pulse to the motor.and B/B-). This is too fast to read via a normal meter.signals .driver: The stepper driver converts signals from the CPU to movement by the motor. The CPU first determines direction and then the drive is enabled.4. (See TS&R . 5 Vdc should be present. If the 5 Vdc is not present during movement. 4 .) Press the Down button. In LOCAL mode: a.the . motor direction should be counterclockwise.) Troubleshooting – 06/10 53 .E .E . check the output of the driver to the motor.4 .4. change the CPU. If the pulses are not present change the CPU.4.4 . If no output is present. To determine if the driver is faulty you must first check the CPU output.section . Direction: TB3 terminals Dir. 400 pulses = 1 revolution of motor movement. 1.

motor over temperature.6 CPU control parameters for tuning details. speed. All parameters set digitally. 54 REXA X2 Series TS&R Manual . To troubleshoot the Omega series driver.Omega . The slope and amplitude of this signal controls the acceleration. REXA . and deceleration of the motor. Complete optical isolation between signal and power stage. 7-segment display indicates amplifier status and diagnostics. High speed (115. All Omega series drivers operate identically regardless of the motor and driver type. the servo driver module generates a tachometer signal which is used to close a velocity loop specific to the version of software loaded onto the driver and the corresponding motor type. amplifier RMS over current. it is recommended that the REXA CPU be placed in the Local mode.2.Motor .Driver .Motor . REXA’s Omega series Digital PWM Brushless Servo Amplifier offers the latest in high performance DSP control of brushless servo motors. The signal from the CPU is an analog +/-3 Vdc signal.Series .Servo . The control of the velocity loop is via the REXA CPU.4 Servo motor driver Features: Digital current loops Digitally tuned Silent operation Complete isolation Fault protection RS-232 Non-volatile memory Status indicator Characterization Current loop bandwidths up to 3 kHz. See REXA Series 2 XPAC IOM . All parameters and positions are stored in non-volatile memory for reliability. The part numbers and input/output voltages may differ.2 K baud) serial communication interface for set up and tuning. amplifier over temperature. In this mode of operation. 12.FAULT 3 . but the troubleshooting is the same.Servo . Short from output to output.2 .5KHz PWM standard. short from output to ground. Table 3.4 .Troubleshooting DRIVE .Section . The REXA unit operates in the VELOCITY Mode configuration. amplifier under/over voltage. (06/10) The REXA Omega drive is pre-programmed at the factory for the specific motor on the actuator ordered.Driver This section covers the troubleshooting of the REXA Omega series servo driver. No potentiometers to adjust DSP control for the ultimate in high performance.

Driver .4 mV between these terminals. To initiate motor movement.STANDARD . GND: Black wire—optically isolated ground for driver logic.(TB6 . +3 Vdc /-3 Vdc (1 mV = 1 RPM of motor speed). A MAX Hi Speed of 100% = 2.2. Figure 3. FAULT .5–A . not used on Omega Drive).to . 0 Vdc during normal operation. motor or cabling.FAULT Troubleshooting the Omega driver begins with the outputs from CPU to the driver. +15V: No connection (15 Vdc available for logic power. 5 Vdc during fault condition.X2 Troubleshooting and Repair Manual .OUT: Blue wire—Signal to driver from CPU to engage movement.from .DRIVE .Input/Output . MOT-/+: Green wire with Black ground—Analog signal from CPU to driver to indicate operation speed. 5 Vdc present during fault or reset condition. 0 Vdc during normal operation.IN: Red wire—Signal from driver to CPU to indicate problem with driver.5–A Terminal block 6 Standard Motor Troubleshooting – 06/10 55 .CPU .MOTOR) ENABLE .2 . the CPU sends signals to the driver: These signals are common for all models of Omega drive: 3 . actual motor speed is 2 400 RPM.signals . .

.STANDARD .signals . The drivers share a fault/reset board for common fault input to the CPU (same as Figure 3. the Servo driver is terminated as standard single input. A separate board (fault/reset board) is used to have one incoming fault signal from both drivers.Driver .2 .IN: Signal from driver to CPU to indicate problem.Input/output . 0 Vdc during operation.to .terminals) For units with Booster pump option.Troubleshooting DRIVE .5–B.D .5–B .signals .5–B Fault/reset board for Dual D and Booster Drivers 3 .with .TB7 .to .(TB6 . 5 Vdc during fault condition. Standard . Dual .from . .FAULT 3 .CPU . Servo . The input and output signals have the same value for booster and servo motors.CPU .5–C .MOTOR) Both drivers are terminated together as the above single driver at the TB6 terminal block. The Booster driver is terminated to TB7. FAULT .(TB6 .Input/output .Drivers .2.2.from .motor .and . with the exception of the fault input.2 . above).Booster .Driver . 56 REXA X2 Series TS&R Manual .& .Booster . . (06/10) Figure 3.

Each of the six outer segments represents one of the six Hall states in a commutation cycle of a motor.segment LED display. one of the outer six segments is lit. it is a 7. all six segments lit (one at a time) in the direction the motor is turning. Troubleshooting – 06/10 57 . The drive generates Hall sensors and when the driver and motor are operating normally.DRIVE .FAULT Figure 3.code . it will have a corresponding code on the driver display.2 . . A diagnostic LED display is provided on each Omega driver. During motor movement the display will show an O.2.X2 Troubleshooting and Repair Manual . The CPU will continue to send reset signals (approximately every 3 seconds) until the condition is corrected (until the fault is cleared).Driver . While in AUTO mode. the CPU will send a “reset” signal to the driver in an attempt to clear the fault.Fault .5–C Standard motor and booster motor termination 3 .identification When a driver fault code is sent to the CPU (5 Vdc present on FAULT IN) from a driver.6 . Removing the unit from AUTO mode will stop the reset signal and allow you to view the error code on the Omega display.

Codes .= .Fault .Secondary short code.drive .= . Be sure to separate resolver (signal) cables from high power cables and other power sources (at least 3 meters [~10']). to . Also. Fault . Test for a short from phase to phase or from phase to ground. . i.code . .Omega .= . inspect for wrong connection. . .Omega . . .code . high speed) – Motor phase line to line short.(specific .E ..H .Immediate short code. or line to ground (direct short) – Electronic “noise” on resolver cable (interference) – Bad motor power cable – Seized or shorted motor Fault . blue and green wires swapped.the . (Electronic Circuit Breaker. A description of the error code and possible causes are listed below: . be sure to inspect motor and cable integrity by use of a multi or MEG meter.Resolver error – Resolver line break – Resolver cable electrical noise (interference) To correct the resolver error code. Fault . Red and Black wires reversed or loose For low and high speed short codes. (Low speed ECB tripped) – Green and Blue Resolver wires reversed or loose – Motor seized – Incorrect motor connected to driver – Any driver.e.code .Driver Over-temperature (upper case H) – Omega driver temperature is too high (185 °F [85 °C]) (06/10) 58 REXA X2 Series TS&R Manual . .code .L .Troubleshooting DRIVE . .FAULT REXA .LED . inspect cable connections and/ or damage or corrosion to the cables.S .display) The fault codes below are shown on the drivers display when the CPU is not sending a reset signal to the driver.= .Series . Fault .

= . .code .code . Troubleshooting – 06/10 59 . This is a normally closed switch. . This is a recoverable error.= failed.= . . . Fault . Power on commutation – Driver unable to zERO motor position on start up Wiring errors (resolver/motor) can cause commutation errors. The ambient temperature for the electronics must be brought back below the 150 °F (65 °C) threshold in order to keep the 185 °F (85 °C) temperature switch on the driver heat sink from opening. the electronics should be installed in a controlled environment.= . Refer to actuator specification sheet for power requirements. white/ brown motor reference pair. Check all motor and resolver wiring at every termination. check thermostat cable connections (yellow/orange resolver wires). Invalid Hall state is internal to the Omega driver. If the temperature of the motor is below 340 °F (170 °C).Over Voltage fault.(two horizontal bars).code . Fault . The drive has failed and will need to be replaced.X2 Troubleshooting and Repair Manual . Fault .Motor over temperature (lower case h). Since high temperatures will shorten the life of electrical components.= . .≡ (three horizontal bars).h . Fault . specifically. – Motor temperature is over thermostat set point (340 °F [170 °C]) The thermostat located in the motor has changed state. – Incoming power is over 252 Vac input power Check incoming power supply.b .code .FAULT An H error code indicates the ambient temperature (at electronics enclosure) is too high for the driver to operate (ambient temperature range for Omega drivers -40 °F to +150 °F [-40 to +65 °C]).DRIVE . Invalid Hall state detected.

U.powered .O . units with multiple drivers and motors can move without command. This can be caused by a shorted motor (see S error checks). 60 REXA X2 Series TS&R Manual .8 . .FAULT Fault .Troubleshooting DRIVE . 3 .code . . bus Under Voltage The incoming power supply is low.Foldback condition active.= .) Fault .C .1.Actuator .7 . the write cycle has been interrupted or incorrect data has been written. . the power supply shuts down to protect the system.Reset code The CPU has sent a reset signal to the driver.when . . When wired incorrectly. .= .code . some units can “run away” from the current position even if in the Local mode.Clamp condition active. if not. Fault .= .F . CPU signals to the driver.TS&R .This is a status indication of normal operation. . . Check for drive faults.1 . Checksum failure is internal to Omega driver. The REXA CPU has disabled the driver (fault relay) this will be followed by a reset signal from the CPU.= .“run .up Upon power up.= . . Fault . check incoming power. . Driver power supply.= .code . or an open or incorrectly wired red/black resolver pair (cosine pair). Fault .2 .is . the motor is moving. Recycling power may recover the drive.away” . EEPROM checksum failed. During this condition in which unusually high current is detected.code . A foldback error is a warning that an unusual amount of current is needed to move the motor. the drive must be replaced.code .code . Fault . power problems (low or high incoming power) and resolver or control cable problems.unit . (See .section . There must be a corresponding condition for the CPU to clamp the driver. The cause of this can be due to wiring problems between driver/motor pair when either a motor or resolver cable is connected to the incorrect driver/motor pair. (06/10) 3 .2 .

UP: MOTOR RESOLVER . COSINE RTN. 5. and motor’s resolver feedback cables COSINE RTN and COSINE. RUN . THE . If motor’s power cables are properly connected to amplifier. and if the velocity loop is closed.Troubleshooting – 06/10 Table 3. If motor’s power cables are properly connected to amplifier. In the Control Panel window.FAULT 61 .2. and motor’s resolver feedback cable REFERENCE RTN line is not connected to the amplifier.PROBABLE . If motor’s power cables phase S. .MOTOR .RUN .7 is for reference when dealing with a unit that moves without command.POWER .TO . SINE and SINE RTN.CABLE . then there is one possibility that the motor would run away upon powerup.PIN . then the motor would run away upon power up.LIST .FOR . T and R are connected to amplifier’s phase R. respectively. and motor’s resolver feedback cable are properly connected. respectively.A .DRIVE . 2.7 Motor Run Away.CAUSES .AWAy — YES YES YES YES Table 3.OUT MOTOR’S .OF .UPON . then the motor would run away upon power up. then the motor would run away upon power up.FOLLOWING .PIN . respectively. That is: in Motion Maestro and the amplifier are set to run in current mode.AWAy . X2 Troubleshooting and Repair Manual 3. and motor’s resolver feedback cables REFERENCE RTN and REFERENCE are connected to amplifier’s REFERENCE and REFERENCE RTN. SINE RTN AND SINE are connected to amplifier’s COSINE.FEEDBACK PHASE S PHASE T PHASE S PHASE S PHASE S PHASE T PHASE R PHASE T PHASE T PHASE T COSINE COSINE COSINE COSINE COSINE RTN COSINE RTN COSINE RTN COSINE RTN COSINE RTN COSINE SINE SINE SINE SINE SINE RTN SINE RTN SINE RTN SINE RTN SINE RTN SINE REFERENCE REFERENCE REFERENCE REFERENCE RTN REFERENCE REFERENCE RTN REFERENCE RTN OPEN REFERENCE REFERENCE RTN MOTOR .IS . S and T.OUT PHASE R PHASE S PHASE R PHASE R PHASE R 1.2. then the motor would run away upon power up. 4. if the sign of the current command and the sign of the Actual Velocity (RPM) do not match. AMPLIFIER’S . If motor’s power cables are properly connected to amplifier. then the motor would run away upon power up. If all the motor’s cables are properly connected to the amplifier.

Troubleshooting
DRIVE .FAULT
3 .2 .8 . .Servo .Motor .resistance .readings
Check motor resistance. Table 3.2.8 Servo motor resistance
Resistance Glentek_Full_D Glentek_Half_D_120 Glentek_Half_D_240 Kollmorgen_Full_D Kollmorgen_Half_D_120 Kollmorgen_Half_D_240 1.4 Ohms .77 Ohms .77 Ohms 2.48 Ohms 2.34 Ohms 2.34 Ohms Inductance 6.5 mH 3.25 mH 3.25 mH 38 mH 25 mH 25 mH DC_Bus 280 V 160 V 280 V 280 V 160 V 280 V

(06/10)

Replace motor if readings are not as noted above; replace driver if readings are correct.

3 .2 .9 . .DC .Bus .Voltage .check
The DC Bus Voltage = 1.414 × AC line voltage. This voltage cannot be measured with a multimeter. An Oscilloscope is the best method to measure the Phase to Phase voltage at the motor. A REXA Omega Maestro program on a PC can also read this voltage (contact the REXA service department). The picture below is 100 V per division (5 v/d × a 20X probe), 295 V is the DC Bus voltage for 208 Vac/3phase. For 240 Vac units, this voltage would be 340 V, and a 120 Vac unit would have 170 V DC Bus Voltage.

Figure 3.2.9 DC Bus voltage

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.DRIVE .FAULT
3 .2 .10 . .REXA .Omega .Drive .Motor .Wiring
Most installation problems are with wiring. The following shows standard motor power module: Table 3.2.10 Motor wire color and function chart.
COLOR RED BLACK BLUE YELLOW RED / WHITE YELLOW / WHITE GREEN BLUE GRAY ORANGE GREEN WHITE WHITE FUNCTION COSINE COSINE GROUND SINE SINE GROUND REFERENCE REFERENCE GROUND RESOLVER SHIELD PHASE R PHASE S PHASE T MOTOR CASE GROUND TEMPERATURE SWITCH TEMPERATURE SWITCH

Standard Servo Motor Wiring at the Power Module

Photo 3.2.10-1 Motor Power (from enclosure side)

Photo 3.2.10-2 Motor Resolver (from enclosure side)

Troubleshooting – 06/10

63

Troubleshooting
SEAT .LOADING .CyLINDER
3 .3 . .SEAT .LOADING .CyLINDER .PROBLEMS
The SLC acts as a mechanical elastic coupling. Instead of a mechanical coupling, the internal hydraulic pressure of the actuator (2 000 psi) is used to show that the valve is in its seated position. Refer to the .IOM .Appendix .B, Figure B.3, for Loading Methods.

(06/10)

3 .3 .1 . .SLC .reads .Seated .before .actuator .is .on .valve .seat
Use the pressure gauges to verify that the pressure is above 2 000 psi. This will happen when the actuator is driven into its mechanical stop (not the valve seat). The split clamp will need to be adjusted.  Remove the split clamp and drive the valve to its seated position.  Drive the actuator to its seated position. Move the actuator back open approximately ¼".  Install the split clamp by lining up the valve shaft threads and the actuator shaft threads.  Calibrate the actuator in Setup (PL & PH). If the actuator is at 50% stroke and reading seated:  Try to drive the actuator open then back closed in Local mode.  If the unit still cannot go further than 50%, remove the split clamp and stroke the actuator completely closed and open, building pressure (2 000 to 2 300) on both gauges.  If the proper pressure is obtained, the valve shaft is stuck or something is keeping it from going closed.

3 .3 .2 . .SLC .Feedback .bad
Verify the wires are all connected at the enclosure and actuator (Red +15, White SLC+ & Black SLC-).

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SEAT .LOADING .CyLINDER
Simulate a 4 to 20 mA signal at the enclosure on SLC+ and SLC-. If the error goes away, the problem is at the actuator or the actuator cable.  Land the wires back and remove the FB cover on the SLC. Remove the white and black wire and simulate a 4 to 20 mA signal. – If the error goes away, the cables are good.

Two other components to check are the FB board and pot.  Look to see if the red LED light is on the FB board; if not, check to see if the red and black wires can display 15 Vdc. – If the 15 Vdc is present and there is no LED light, change the feedback board (see TS&R .section . 4 .E .16, Remote Mounted Feedback Board).

 Check the pot by using an Ohm meter. Using the orange and black wires to do so, you should read 0 to 5 000 ohms.

3 .3 .3 . .SLC .Stop
SLC stop is simply the valve seat. In order to correctly connect the valve shaft and actuator shaft follow these steps:  Make sure both shafts line up perfectly.  Drive the valve to its seated position.  Drive the actuator to its seated position. Move the actuator back open approximately ¼". Install the split clamp by lining up the valve shaft threads and the actuator shaft threads.  Calibration of the actuator can be done in Setup (PL & PH).

Troubleshooting – 06/10

65

Troubleshooting
FEEDBACK .BAD
3 .4 . .FEEDBACK .BAD .
When dealing with feedback issues it is always necessary to ensure you have proper supply voltage to the electronics and that all the wiring is properly landed. The supply voltage is proportional to the CPU power supply. If the actuator’s incoming power supply is low, high or unstable, the CPU power will also be affected. The REXA feedback system begins with a potentiometer located on the mechanical assembly, cabling that carries the signal from the actuator to the electronics and the CPU which interprets and reports the position indication. The CPU operating voltage is provided by the Quad Power supply. The QPS is converting the incoming power to various dc voltages to operate CPU, display, the actuator internal feedback and the position transmission back to the operating control system. Check all connections to ensure the landed wiring is not pinched down on the wire insulation, preventing a good connection. If the actuator display reads FEEDBACK BAD, the following steps should be taken:  Check wiring on a non-contacting .feedback . . .  Your wiring should be as follows: Red wire (supply voltage) is the +15 Vdc, White wire (4 to 20 mA signal) is the FB+, and the Black wire (reference) is FB-.  The shield should be landed at the electronics and not at the actuator.  These connections should be checked at every termination and junction box at every point between the CPU and the potentiometer.  Refer to your wiring diagram for additional information. To check the Quad power supply voltages see the diagram in Figure(s) 3.4–1, 2 or 3.

(06/10)

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FEEDBACK .BAD

Figure 3.4-1 CPU voltage Once all CPU voltages are confirmed and wiring has been inspected, the next step to resolve the FEEDBACK BAD error is to simulate a feedback signal directly to the CPU board. This will determine if the problem is with the CPU or with the potentiometer.

Troubleshooting – 06/10

67

Troubleshooting FEEDBACK .4-2 QPS 120 V Figure 3.BAD (06/10) Figure 3.4-3 QPS 240 V 68 REXA X2 Series TS&R Manual .

) Some actuators may come with a separate feedback circuit board.section .E . (See TS&R .4 . With a 4 to 20 mA source send a signal directly into the CPU at terminal 1 FB+/-. For units with a feedback board.4. The feedback circuit board is not needed for most standard products (non-contacting potentiometer send a direct 4 to 20 mA signal to the CPU board). Replace the potentiometer.)  If after simulating the feedback signal there is no change in feedback status.BAD  Place the actuator in Local mode.X2 Troubleshooting and Repair Manual FEEDBACK . section . additional terminations may result in a feedback bad error. and remove the + and – FB wires. the problem lies with the CPU.20. Troubleshooting – 06/10 69 . (Refer to TS&R .  If the CPU can register and report a feedback signal. CPU Assembly. then the problem lies in the potentiometer assembly.M .4 .

STALL Problem: Mot stall . A stall error can be caused by high system pressure or low system pressure. In both situations. the first step in troubleshooting the stall error is to identify the cause. If filling the system with oil solves the stalling problem.3 . Modes of Operation and Control Parameters) have failed or.section . Check motor resistance. It is not unusual for the actuator to operate well below the rated 2 000 psi system pressure. with a Seat Load Cylinder.MOT . . section . 4.6. See TS&R . A stall error can be caused by multiple systems. See IOM . (06/10) Solution: 3 .6 .hydraulic .stall . 3. Check hydraulic system pressure.4 for oil filling instructions. to locate a possible oil leak.Motor . the unit can be put back into service. the actuator cannot match actuator position to control signal input. Check oil level. The actuator will only generate enough pressure to overcome the process forces.section .5.5 . Check output of driver.1 for system pressure troubleshooting. See TS&R .2 .1 . isolate the actuator from the process and place the unit in the Local mode for troubleshooting. Oil Leaks.section .Troubleshooting MOT . The actuator will need to be removed from service but may not need to be completely removed from the installation. If possible.5 .STALL 3 . It should be closely monitored and serviced as soon as possible. With the 70 REXA X2 Series TS&R Manual . the “Seated” position was reached on the Seat Load Cylinder and the position of the main cylinder was greater than 1% above Position Lo.means that five attempts to move the actuator 1% of stroke in the time set in Stall Time (See IOM . . Follow the steps below to identify if the stalling problem is mechanical or electronic: 1. 2.1 .

For spring fail system. Manual Override.C.section . blockage in valve etc.2. the actuator is operating at its limit.3. then the problem lies in the linkage.IOM . For accumulator system handwheel operation see IOM .M . Modes of Operation and Control Parameters for additional calibration information. If the actuator will not stroke via electronics. skip to TS&R . check your calibrated low and high positions. Use the handwheel/drill drive to confirm the mechanical system is operating. remove the linkage and stroke the actuator to see if it will operate normally.5. High .X2 Troubleshooting and Repair Manual MOT .1. skip to section 3. skip to TS&R section 3. To resolve a high pressure stall.4.C . If one of the pressure gauges is over 2 200 psi.section . hitting against a mechanical stop (cylinder limit. Some possible causes of this may be binding in the linkage.STALL unit in Local mode. See IOM .section . If the actuator can stroke with no problems while not connected to the driven device. If the system builds pressure quickly and can not move. If the problem persists please contact your local REXA representative. .pressure .).6. the system power must be off to operate with handwheel. If the system still stalls while not connected to the driven device. stroke the actuator and observe the pressure gauges.1.section . see . Appendix .3 . Troubleshooting – 06/10 71 . For Servo units. or the system is working too hard and can not follow the control signal. If the system builds no pressure.stall A “high pressure” stall indicates the actuator either has to build too much pressure to operate the driven device.

2. Refer to TS&R . for troubleshooting motor and driver components.section .5 . Gain and acceleration settings can cause motor stalls by operating too slow when nearing the actuators set point.pressure . cabling. Drive Fault. through all junction boxes. Electronic stall problems can be caused by the driver. a failed suction check valve. improperly adjusted pressure relief valves or damaged cylinder piston seal.stall A “low pressure” stall can be any situation where the actuator can not build enough pressure to move the driven device.and . the suction check valves need to be replaced. This will require the unit be taken out of service for repair. Verify the system wiring for loose/corroded and correct connections at every termination from the motor.M .C .3 . it is best to verify the operation of each component before replacing parts. – Stall errors can be caused by a loose or corroded connection.IOM . Refer to .section . the piston may be worn and must be replaced.STALL Low/no .M).5 for additional information on gain/acceleration settings.7 for additional information on the adjustable pressure relief valves.stall .section . A low pressure stall can be caused by an open solenoid (see TS&R . section .section .electronic . To confirm and replace the failed component. See TS&R . If the unit will operate in one direction only.2 .9 for information regarding suction check valve replacement.6 .Troubleshooting MOT .11) or manual bypass (see IOM .4 . – – 72 REXA X2 Series TS&R Manual .4 .M .1 .4 . – – First verify the manual bypass and solenoid levers are in the correct position. cabling and then to the driver.Motor . speed/acceleration parameter settings or the motor itself. If the unit can not build pressure in either direction. (06/10) – – 3 .Appendix .M . Then verify the adjustable pressure relief valves have been set properly. See TS&R .

DIRECTION . Ensure the position high and position low is correctly calibrated.Appendix .C for wiring schematic.Appendix . Make sure the deadband is calibrated according to the application. Modes of Operation and Control Parameters.section .6.C for feedback wiring schematic. Feedback: – Make sure the feedback wires are wired correctly and properly shielded at the actuator as well as ground at the REXA electronics. Refer to TS&R .C for wiring schematic.ERROR 3 .Appendix .X2 Troubleshooting and Repair Manual DIRECTION . Mechanical Bypass: – Make sure that the bypass is closed by turning the bypass plug clockwise.6 . Troubleshooting – 06/10 73 . Refer to IOM .6. Refer to IOM . . If the bypass is opened while the actuator is in auto mode and/or in actuation. – For stepper units make sure the motor is wired correctly at the power module and the REXA stepper electronics. Refer to TS&R . For servo units. make sure that the motor wires and resolver wires are wired correctly at the power module and the REXA stepper electronics. For both stepper and servo units it is essential that the motor is ground at the power module and at the REXA electronics. Modes of Operation and Control Parameters. a direction error will be indicated on the display and the motor will stall as a result. – REXA . Refer to TS&R .Electronics: .section .ERROR Wiring is the most common cause for the motor not to move (or move in the wrong direction).

If the actuator is static in auto mode while the pump is stroked in any direction. – – 74 REXA X2 Series TS&R Manual . then a direction error will be indicated.Troubleshooting DIRECTION . (06/10) Hand Pump: There are many ways the hand pump can cause a direction error: – If the pump is being stroked while the actuator is running in the opposite direction of which the pump was stroked. this applies to the power module solenoid and/or high speed solenoids. then the system will act as a bypass and cause a direction error to be indicated. a direction error will be indicated. If the direction knob on the pump is stuck in-between both pump directions.ERROR Solenoid: – Make sure the lever on the solenoid is in its correct position according to the application.

VDC . please contact your local REXA representative.VDC .FAIL 3 ...7 .15 .+/. Troubleshooting – 06/10 75 . .15 .X2 Troubleshooting and Repair Manual +/.FAIL If you receive this error.

E . If only the CD. RX and RTS lights are flashing in succession and the TX light stays off.communication . If this can be confirmed.4 .on the CPU is shown in Photo 3.8-1.4 . CS BAD.3 . To identify the CPU board. Photo 3. The location of the CS+ and CS.INTERFACE NoTE: Setup issues are not covered in this trouble shooting section and can be found in Appendix N of the IOM.) Photo 3. If the actuator is receiving a CS bad error. RTS LEDs located on the HART board will flash in succession repeatedly.13.2.is . replace the Hart board (see TS&R . (See TS&R . If the problem goes away.taking . Troubleshoot the incoming control line with a HART compatible hand held device to determine if there is a digital signal to the REXA input lines. reference TS&R . This is identified as Version located under the outputs menu in set up mode. then check the software version installed in the CPU.section . replace the HART interface board. These LEDs are shown on the lower right side of the board Photo 3.INTERFACE 3 .11. (06/10) CS .8-2 HART board 76 REXA X2 Series TS&R Manual . If all the lights are out this means there is no digital signal being sent to the REXA system.problem . RX. Below is a list of software that is compatible with HART (at the time this manual was written).13).Digital .Troubleshooting HART .8-1 CPU CS+ and CS- No .located on the CPU board.4 .E .8-2.section .HART .8 . remove both analog wires and hook them directly into the CS+ and CS.place Under normal operation (when there is digital communication) the CD. reference TS&R . If the CS bad error continues.E . . TX.

X2 Troubleshooting and Repair Manual HART . record the actuator serial number and contact the REXA factory to determine the correct software version for the application. Troubleshooting – 06/10 77 .INTERFACE X01_9_AV XB1_6_AX XB0_7_AX XS0_4_BB X01_9_AV XR5_3_AQ XA0_4_AV XT1_3_AY XT2_3_BA XC0_1_BE XD0_0_BF XM0_2_Az If the software installed is not listed above.

(06/10) No . record the actuator serial number and contact the REXA factory to determine the correct software version for the application.place Under normal operation (when there is digital communication) the 3.9.3 V. – If the 3.FIELDBUS NoTE: Setup issues are not covered in this trouble shooting section and can be found in Appendix K of the IOM. Rx and Tx LEDs located on the FoUndatIon Fieldbus adapter card will flash in succession repeatedly at a rate of 20 flashes / sec. XR3_1_AJ XR4_0_AG X02_7_AW XA1_5_AW XM1_0_BG XM2_0_BH – If the software installed is not listed above.FOUNDATION .Digital .3 V and the Tx LEDs are on and the Rx flashes very faintly.is .9 Foundation Fieldbus This is identified as Version located under the outputs menu in set up mode. Below is a list of software versions compatible with FoUndatIon Fieldbus (at the time this manual was written). . If all three LEDs remain on.9 .communication . and there is no digital signal being received from the DCS. then check the software version installed in the CPU. – 78 REXA X2 Series TS&R Manual .taking . Photo 3. this indicates the wrong software has been installed in the CPU.Troubleshooting FOUNDATION .FIELDBUS 3 . These LEDs are shown on the lower right corner as seen in Photo 3.

Troubleshoot the incoming control line with a Foundation Fieldbus compatible hand held device to determine if there is a digital signal to the REXA input lines.E . 4 .FIELDBUS – If the Rx and 3.14 for replacement procedures. If this can be confirmed replace the Foundation Fieldbus board. (Reference TS&R .X2 Troubleshooting and Repair Manual FOUNDATION .) Troubleshooting – 06/10 79 .section .3 V remain on this indicates the digital signal from the DCS is not being received.

Assembly for Pulse Input (06/10) CPU Assembly Photo 3. .Troubleshooting PULSE . with a minimum duration of 10 ms and maximum duration of 999 ms.SIGNAL Some applications use a Pulse Control signal rather than a 4 to 20 mA modulating signal to position the actuator. The Pulse signal should have amplitude of 24–120 volts. The circuit board is mounted atop the CPU as shown below.CONTROL .10 . you must have the appropriate circuit board assembly installed.PULSE .10 Pulse control circuit board 80 REXA X2 Series TS&R Manual .BOARD 3 . If Signal Type = Pulse cannot be accessed in the INPUTS menu: – For the Signal Type parameter to display Pulse in the INPUTS menu.

10-1 Pulse Signal Input – Using Active Voltage Signals Or OPEN RELAY CLOSE RELAY TB3 LED’s “ON” when Signal is present MC = Close input MO = Open input D8 MC D7 MO Jumper must be in place for Dry Contact operation CONTACT INPUT BOARD ASSEMBLY NO.X2 Troubleshooting and Repair Manual PULSE . LED’s “ON” when Signal is present MC = Close input MO = Open input D8 MC OPEN CLOSE D7 MO CONTACT INPUT BOARD ASSEMBLY NO. are connected as shown in the following drawings.BOARD If actuator will not move when pulses are applied or moves in wrong direction: – Verify signals. S97713 TB6 Figure 3. open and close. S97713 TB4 TB6 Figure 3.10-2 Pulse Signal Input – Using REXA Relays & Bias Voltage Troubleshooting – 06/10 81 .

Verify that parameter Pulse Dur (Pulse duration) is equal to or just slightly less than the minimum pulse width being applied.Troubleshooting PULSE . (06/10) – – Are both LEDs on when no pulses are applied? This indicates leakage current. typical of solid state devices. 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. The OFF state leakage current must be less than 1 mA. For example. Verify the LED’s MC and MO illuminate when a pulse is applied. Verify that the number of pulses being applied command the actuator to move beyond its deadband setting. Verify Actuator is in “Auto” mode. If this leakage exceeds 1 mA. if a control pulse of 100 ms is being applied. The input board is interpreting both inputs as active (due to this leakage current) and the actuator will not move. – – – – Verify Signal Type = Pulse in the INPUTS menu Verify the signal amplitude is 24 V or greater. coming from the control system. For every valid 100 ms pulse.1%. – Verify the circuit board is seated properly on the CPU mating 24-pin connector. a resistor must be added across the input signal terminals and will bypass the current.BOARD If Pulse input Signals are not polarity sensitive. Pulse Dur should be set to 95 ms to be sure the pulse is read by the input.1% in the commanded direction.5%. the actuator will not move until 5 successive pulses are given to command a move outside the 0. not to exceed 120 V.5% deadband. However. 82 REXA X2 Series TS&R Manual . if the parameter Deadband = 0. Pulse control will not operate the actuator in Local or Setup modes. For example. the actuator will move 0. Pulse Dur = 100 ms and Pulse Inc (Pulse Increment) =0.

5.1% and a pulse 500 ms in duration is applied. The actuator should travel toward positioned defined by parameter Position Lo and the MC LED should illuminate. Verify the number of pulses being given.Vac .on . One long pulse is interpreted as multiple Pulses. For example. Using a handheld current device. If actuator moves beyond target position when pulses are applied: – – – Verify Signal Type = Pulse and not 1 Cont or 2 Cont.E .120 . re-check the incoming signals from the DCS. with Pulse Dur = 100 ms and Pulse Inc = 0. If all the above do not solve the problem or the LEDs' MC and MO are not illuminating.PWR . Troubleshooting – 06/10 83 .4 . Disconnect all wires from the DCS to the input board. . If a jumper is present.the . apply a 20 mA signal between the CLOSE–CLOSE inputs. and .BOARD – Verify the inputs with a known good source.present .is . Verify pulse duration and pulse increment settings are set to values determined by your application. Pulse Dur may need to be adjusted to a higher value so that fraction of a pulse is not interpreted as a valid pulse.terminals . Now apply the signal between the OPEN–OPEN terminals. 100 ms pulses. as the 500 ms pulse is interpreted as five.PWR . If this operation is successful. the Contact In/Relay Out board must be replaced per TS&R .OUT .RTN . The actuator should travel toward the position defined by parameter Position Hi. CAUTION: .X2 Troubleshooting and Repair Manual PULSE .section . the actuator will move 0. Multiple pulses may be read by the input. remove it.5%.

typically 20. .0 mA and 20. NoTE: If Failsafe does not = Off. actuator position will not match incoming control signal.Calibration) Calibrate the DCS’s 4 to 20 mA control signal to the actuator control enclosure.5 mA and the span must be greater than 3. The actuator position should now match the control signal input when in “aUto” ( ) mode.Position . (06/10) 3 . Apply the signal that corresponds to command the actuator to travel to Position Hi.BAD 3 . . (Refer to IOM section 6. Lock this value in by pressing the enter ( ) button.1 .11 .) NoTE: If Failsafe = Off.1. The actual current input will be displayed in mA and may vary slightly from the default value. Signal .(Control . typically 4. briefly. input signal value must be greater than 2.11-1 Signal Lo NoTE: Unknwn appears if control signal failure occurs while calibrating. Error appears.0 mA.8 mA or vice versa.Troubleshooting CONTROL .CONTROL .Signal .  – Photo 3. access Signal Lo in the Calibrate menu and press the enter button for the “=”to flash. the span for Signal Hi must be greater than 3. if an unacceptable value is entered.match . Apply the signal that corresponds to command the actuator to travel to Position Lo. Parameters Signal Lo and Signal Hi cannot be changed by pressing the arrows.does .SIGNAL .6.0 mA.Control . The actual current input will be displayed in mA and may vary slightly from the default value. stopping the “=” from flashing.11-2 Signal Hi 84 REXA X2 Series TS&R Manual . The unacceptable value is rejected and the previous value is retained.0 mA.8 mA. If the DCS control signal is slightly different than these values.11 . Photo 3. INPUTS Menu. stopping the “=” from flashing.actuator .not .If . Lock this value in by pressing the enter ( ) button. – Using the DCS control signal.Input . The default values for parameters Signal Lo and Signal HI are 4.SIGNAL The Control Signal is typically a 4 to 20 mA modulating signal which commands the actuator to travel to a set point. respectively. An active 4 to 20 mA signal must be applied.

Remove the wires on the CPU CS+ and CS. Vary the signal.BAD 3 .inputs that connect to the suppressor before applying the signal.12 for Control Signal Surge Suppressor replacement. the hand held current source can be used until the control system problem is resolved.5 . Apply the known good control signal while in parameter Signal Lo and the “=” is flashing.) Troubleshooting – 06/10 85 . If it is not correct. bypassing the surge suppressor.mA) – – – Verify Signal Type = Analog in the INPUTS menu Verify Control Signal is greater than 2. – Using an ammeter. The control signal input is polarity protected and current will not flow if the polarity is not correct.is . If at any time the DCS control signal is suspect. (Refer to TS&R .than . If the polarity is correct.2 . Do so by applying the control signal directly to the CPU board.reading . you have verified the Control Signal surge suppressor is defective and must be replaced.(Control .less .section .signal .Bad .4 . be sure the 4 to 20 mA loop from the Control system is operating.SIGNAL . and again verifying polarity.X2 Troubleshooting and Repair Manual CONTROL . use a handheld current source to verify operation of the actuator.E . If the Control signal is correct from the control system.11 . If the input matches the Control signal input.5 mA Verify the polarity of the applied Control Signal. verify that the Control signal surge suppressor is not damaged.2 . vary the 4 to 20 mA current from the control system and confirm that it is correct. .CS .

3 .SIGNAL .Control .3 Vdc (for 4 mA input) to 4. The dc voltage should vary between 1.11-3 CPU connections If the CPU still does not read the Control Signal. Photo 3. Apply the control signal to the surge suppressor input. the CPU must be replaced.Signal .E .or . CPU Assembly.) Photo 3.BAD (06/10) CPU Control Signal Input Control Signal Surge Suppressor CS+ Input.0 Vdc (for 20 mA) input. (Reference TS&R . measure the dc voltage across the CS+ and CS− inputs on the CPU board. reconnect the Control Signal surge suppressor wires to the CS+ and CS− inputs.11 .4 .“dithering” . If the voltage varies with change in Control Signal but the display still reads CS Bad.11-4 Digital voltmeter connections Photo 3.4. Using a Digital Voltmeter. Replace the CPU.noisy If the Control Signal from the DCS is varying at a high frequency on the REXA display.section . . Middle Terminal of CS Surge Suppressor CS− Input Top Terminal of CS Surge Suppressor Photo 3.11-6 DC voltage for 20 mA 86 REXA X2 Series TS&R Manual .Troubleshooting CONTROL . it may be contributed to a noisy signal or dithering built into the control system.11-5 DC voltage for 4 mA 3 .

be sure this signal cable is segregated from high voltage cables as they may induce voltage onto the signal causing it to vary.does . you have verified the problem is with the incoming control signal and not the actuator input.4 .Bad .when .Bad . Off: Used for zero based control signal (i. Be sure this function is disabled in your control system. If the display still varies with a steady input signal.5 . . Failsafe defines the position the actuator moves to via the motor if the Analog control signal falls below 2.5 mA. Close: Actuator goes to Position Lo.e.SIGNAL . – 3 .occurs Verify the Failsafe parameter is set to the appropriate setting.error . – If the signal becomes quiet and the display is steady.travels .section . signal type cable and the shield is landed to ground at the DCS only.Actuator .to .appear . the CPU must be replaced per TS&R .5 .CS .11 . Should the above not remedy the problem. Select: Inplac: Actuator remains in current position.E .below .. Only in menu if Signal Type = Analog. – – Verify Signal Type = Analog Verify Failsafe does not = Off Troubleshooting – 06/10 87 . In addition.error .Signal .not . Some control systems have a built in “dither signal” to operate with older actuators to always have them move.drops .BAD Verify that the control signal cable from the DCS is a shielded. Position .2 . Control .11 .or .Position .4.4 .Lo .CS . Open: Actuator goes to Position Hi.Hi . use a handheld current source to drive the control signal input.when .mA . 3 .X2 Troubleshooting and Repair Manual CONTROL . . 0 to 20 mA).

Troubleshooting CONTACT . the actuator will travel toward position as defined by parameter Position Hi.2 . or ON/OFF signal.Cont .12-1. you must have the appropriate circuit board assembly installed.1 . This is strictly for two position control of the actuator. or “Manual” control of the actuator.= . If neither input is active.Cont . the CS Bad error code will not be displayed in Auto mode.in . the actuator will remain at the current position. If Signal Type = 1 Cont or 2 Cont. The actuator will travel toward Position Lo as long as the “Close” Input is active.menu For the Signal Type parameter to display 1 Cont or 2 Cont in the INPUTS menu. the actuator will travel toward the position defined by parameter Position Lo.12 . and is mounted atop the CPU as shown in Photo 3.Signal . The Contact Input signal should have amplitude from 24 to 120 V. CS Bad only applies to a 4 to 20 mA Control Signal (06/10) If .cannot .INPUTS . If both inputs are active. There are two types on Contact signal inputs. When the signal is present on the OPEN input. The circuit board P/N is S97713.CONTACT .INPUT .accessed . 88 REXA X2 Series TS&R Manual . be . the actuator will remain at the current position. .or . The first is a single contact.Type . The second is two contacts.INPUT . The actuator will travel toward Position Hi as long as the “Open” input is active.the .SIGNAL Some applications use a Contact Input signal rather than a 4 to 20 mA modulating signal to position the actuator. When the signal is not present.BOARD 3 .

Cont.12-1 Contact input board Using .1 . .X2 Troubleshooting and Repair Manual CONTACT .actuator . . LED “ON” when Signal is present MO = Open input TB3 ON = OPEN OFF = CLOSE 24-120 VAC/VDC D7 MO CONTACT INPUT BOARD ASSEMBLY NO.BOARD Assembly S97713 for Pulse Input CPU Assembly Photo 3.INPUT .move . S97713 TB6 Figure 3.not .will . – Verify the single contact is connected in one of the configurations shown below.12-1 1 Contact Signal Input – Using an Active Voltage Signal Or Troubleshooting – 06/10 89 .

1 Cont control will not operate the actuator in Local or Setup modes.present . 10mA TB3 LED “ON” when Signal is present MO = Open input D7 MO Jumper must be in place for Dry Contact operation CONTACT INPUT BOARD ASSEMBLY NO.PWR . If this operation is successful.PWR . apply a 20 mA signal between the OPEN–OPEN inputs. If a jumper is present.RTN . 90 REXA X2 Series TS&R Manual . Verify Actuator is in “Auto” mode. and the MO LED should illuminate. CAUTION: . S97713 TB6 Figure 3.12-2 1 Contact Signal Input – Using Relay and Bias Voltage from REXA Contact Input signal is NOT polarity sensitive. re-check the incoming signals from the DCS. Disconnect all wires from the DCS to the input board. Verify circuit board is seated properly on the CPU mating 24-pin connector.on . and .Vac . Using a handheld current device. – – – – – Verify Signal Type = 1 Cont in the INPUTS menu Verify the signal amplitude is 24 V or greater. Now remove the signal. The actuator should travel toward the position defined by parameter Position Lo.INPUT . The actuator should travel toward the position defined by parameter Position Hi.terminals . remove it.is .Troubleshooting CONTACT . Verify the inputs with a known good source.OUT .120 .the . not to exceed 120 V. .BOARD (06/10) ON/OFF RELAY MINIMUM CONTACT RATING 120 VAC.

not . and the actuator will not move.INPUT . the Contact In/Relay Out board must be replaced per TS&R . . – Verify the 2 signals are connected in one of the configurations shown below. 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. typical of solid state devices.signal .Cont.X2 Troubleshooting and Repair Manual CONTACT .Cont. .move .4 .1 . – If this leakage exceeds 1 mA.5.always . Are the LEDs on when no signal is applied? This indicates leakage current.when . Using . Using . .will . . The OFF state leakage current must be less than 1 mA.actuator . The input board is interpreting the input as active due to this leakage current.even .is .BOARD – If all the above do not solve the problem or the LED MO is not illuminating.no .actuator .applied .toward .E . S97713 TB4 TB6 Figure 13.Hi . coming from the control system.runs . a resistor must be added across the input signal terminals to bypass the current. Position .2-3 2 Contact Signal Input – Using an Active Voltage Signal Troubleshooting – 06/10 91 . LED’s “ON” when Signal is present MC = Close input MO = Open input CLOSE 24-120 VAC/VDC 24-120 VAC/VDC D8 MC D7 MO CONTACT INPUT BOARD ASSEMBLY NO.section .2 .

Verify Actuator is in “Auto” mode.INPUT . Verify the LED’s MC and MO illuminate when a signal is applied.2-4 2 Contact Signal Input – Using Relays & Bias Voltage from REXA Contact Input signal is NOT polarity sensitive. S97713 TB6 Figure 13. The input board is interpreting both inputs as active due to this leakage current. Diode clamps or RC snubber networks placed across mechanical relays and the 92 REXA X2 Series TS&R Manual . and the actuator will not move. not to exceed 120 V. 2 Cont control will not operate the actuator in Local or Setup modes. Verify the circuit board is seated properly on the CPU mating 24-pin connector.BOARD Or LED’s “ON” when Signal is present MC = Close input MO = Open input D8 (06/10) TB3 OPEN RELAY MC CLOSE RELAY D7 MO Jumper must be in place for Dry Contact operation CONTACT INPUT BOARD ASSEMBLY NO. The OFF state leakage current must be less than 1 mA. – – – – – Verify Signal Type = 2 Cont in the INPUTS menu Verify the signal amplitude is 24 V or greater.Troubleshooting CONTACT . Are both LEDs on when no signal is applied? This indicates current leakage—typical of solid state devices—coming from the control system.

is .present .actuator . CAUTION: . or the LEDs MC and MO are not illuminating.Position .OPEN .Vac .when .removed .2 .PWR . and the MC LED should illuminate. Verify the inputs with a known good source.INPUT .is .to . – If all the above do not solve the problem. Disconnect all wires from the DCS to the input board. Apply the signal between the OPEN–OPEN terminals. – – Verify CLOSE signal is not active Verify Signal Type = 2 Cont and not 1 Cont. a resistor must be added across the input signal terminals to bypass the current. Using a handheld current device.on . – If this leakage exceeds 1 mA.BOARD semiconductor junctions of solid state switches will pass some current in the OFF state. re-check the incoming signals from the DCS. Troubleshooting – 06/10 93 . Lo .terminals .Cont. .signal .4 . The actuator should travel toward the position defined by parameter Position Hi.moves . apply a 20 mA signal between the CLOSE–CLOSE inputs.OUT . .the .PWR . If a jumper is present. Using .E .120 . The actuator should travel toward the position defined by parameter Position Lo.X2 Troubleshooting and Repair Manual CONTACT . If this operation is successful.section . the Contact In/Relay Out board must be replaced per TS&R .RTN .5. and . remove it.

Troubleshooting DISPLAy . The pink stripe on the ribbon cable should be facing Pin 1 on connector P1 of the display interface board with latches securely locking the ribbon cable in place.Ribbon .PROBLEMS 3 . (See TS&R . The other end of the ribbon cable connecting to the display interface board should also be checked.PROBLEMS 3 .Connector The ribbon cable connecting the membrane switch assembly to the interface circuit board may be disconnected. . If these two conditions are not present. . A +5 Vdc should be present. the VFD display will have no read-out. the keypad display on the front of the enclosure will show the green power LED illuminated. the ribbon cable may be disconnected.DISPLAy . Measure dc voltage at terminal TB2 on CPU board. Power Board needs to be replaced.) – 94 REXA X2 Series TS&R Manual . Ribbon cable is disconnected – When the ribbon cable is connected.1 . Check that the ribbon cable is secured into CPU board connector P7 and the latches are closed so the cable can not pull out.13 . Before replacing CPU board.4 . (06/10) – Is power transmitting from CPU to the display? – When there is no power. Measure the dc voltage with a DMM between Pin 6 (+5 Vdc) and Pin 7 (Ground).E . and the green LED on the keypad will not be illuminated.3 to replace Power board. check +5 Vdc is present from Power Board.13 . section . if not. The pink stripe on the ribbon cable should be facing Pin 1 of connector P7. and the display should read SETUP.

(See TS&R . but the push buttons work on the display interface board.4 .E . Measure the dc voltage with a DMM between Pin 2 (+5 Vdc) and Pin 14 (Ground).E . +5 Vdc should be present.E .Control .4 to replace CPU board. If not.) Internal Display – 3 .PROBLEMS – On CPU connector P7.4 .2 . then the VFD needs to be replaced. but the VFD readout is not present.4 . disconnect the ribbon cable while powered.section . but still no display read-out: External Display – If the Green power LED is illuminated on the keypad display.X2 Troubleshooting and Repair Manual DISPLAy .section . The exposed gold plated pins of the connectors can be measured to check if power is being output from CPU to the display. then the VFD display needs to be replaced. (See TS&R . CPU board may need replacement. – If +5 Vdc power is present from above.11. – Troubleshooting – 06/10 95 . .Issues Trying to move the actuator in Local or Calibrate mode and the actuator will not move – – Ensure the keypad display green power LED is illuminated.section .13 .10). See TS&R . If +5 Vdc is present at TB2 on the CPU and at connector P7 and the display is still not functioning. Reset the Electronics by pushing SW1 on the CPU board. If the read-out is not present on the VFD display. Ensure that the Ribbon Cable (with blue connectors from the display interface to the keypad) has not come loose and is seated properly. then the ribbon cable should be replaced.

Pressure is not building because the valve stem is allowing fluid back into the system. If the valve stem is loose in the bonnet hole. reapply the cap adjustment but do not tighten.RELIEF . the pressure relief valve is performing as designed.7.14 .O to reset the pressure relief valve to its factory setting. order a pressure relief valve replacement kit. If the actuator does not build pressure.4 .PRESSURE .Troubleshooting PRESSSURE .Appendix .O to reset the pressure relief valve. – Place the pressure relief valve bonnet back into the pressure limiting cartridge cavity and refer to IOM .M . check for contaminants in the pressure relief valve cavity.VALVES 3 .Valve). Pressure . If the actuator continues to build pressure. – If the valve stem is tight/stuck in the bonnet hole.4 . The wrong color spring can provide more or less pressure for the application. NoTE: This process should be done to both pressure relief valves.M .7. – Refer to IOM .O).Appendix . unbolt the pressure relief valve bonnet from the power module (Refer to TS&R . 96 REXA X2 Series TS&R Manual . the following steps should be taken to rectify this problem: – Unscrew the adjustment cap on the pressure relief valve and check if the spring color is the correct color for the application (see . (06/10) If the spring in the pressure relief valve bonnet is correct. – Run the unit to see if the application is still building pressure on the pressure relief valve side that has been worked on. If the pressure relief valve continues to build too much pressure. .RELIEF . refer to TS&R .Appendix .IOM .Limiting .VALVES If the unit is creating more pressure than the application requires.

IOM to reset the pressure relief valve.VALVES – Reinstall as referenced in TS&R 4. Troubleshooting – 06/10 97 .M.RELIEF . and refer to Appendix .in .X2 Troubleshooting and Repair Manual PRESSURE .the .O .7.

one is electrical noise.section .Troubleshooting CONTROL . .CONTROL .Hunting . If the display is steady. Ensure that the DCS does not have a built-in “dither” signal on the control signal output.ISSUES 3 .1 .Signal If the actuator is in “auto” mode and the display is fluctuating greater than the deadband setting AND the motor is turning. (06/10) Electrical .– . If the actuator operates properly with the hand-held.Control . There are many different factors that may cause the actuator to hunt for position.Actuator . – – – – Ensure the Control Enclosure has a solid earth ground connection.ISSUES 3 . To determine if the control signal is unstable. the cause may be electrical noise on the incoming control signal. the Control Signal is noisy. .Electrical . (Refer to TS&R . Using a handheld current source. the DCS signal is noisy and should be checked.15 . This is referred to as “hunting” for position. try operating the actuator with the hand-held device. – 98 REXA X2 Series TS&R Manual . you can observe the incoming control signal by using the Up or Down arrows to view parameter “Control Sig”.Noise . The actuator will not stop moving around its target position. If the mA is fluctuating.4 . Ground the shield of the Control signal cable at the DCS end only. apply a 4 to 20 mA signal into the Control Signal input while observing the parameter Control Sig.E .the . This is found on some older control system/actuator combinations.) Ensure the control signal cable from the DCS is a shielded cable.Noise .1.15 .on .

NOT .ENTER.Signal If the actuator is in “auto” mode and the display is fluctuating greater than the deadband setting AND the motor is turning.section . the feedback signal from the actuator is noisy.1) Ensure the feedback signal cable from the actuator is a shielded cable. – – – – Place the actuator into setup mode. scroll down to parameter Position Lo. noise may not be the issue. Ensure that the Control Enclosure has a solid earth ground connection. To determine if the feedback signal is unstable.5%.the . Increase the deadband by 0. If this loop is noisy. This will exit parameter Position Lo and default back to its previous value. Press the “enter” button. DO .PRESS . Record the value for Position Lo. The “=” will flash. – – Troubleshooting – 06/10 99 .Actuator .4 .on . – Press the reset button on the upper right corner of the CPU.  If the display is fluctuating. The value for Position Lo will indicate the current position of the actuator. the cause may be electrical noise on the feedback signal from the actuator. (Refer to TS&R .E .ISSUES Electrical .Feedback . The feedback signal from the actuator is a 4 to 20 mA loop which tells the CPU the actuator position. the actuator may “hunt” to find the target position.X2 Troubleshooting and Repair Manual CONTROL .Noise . Access the “deadband” parameter in the Control menu. – – – – In the “Calibrate” menu. the problem is most likely noise. If not. Place actuator into “Auto” mode  Does the actuator stop hunting? If so. you can observe the actuator feedback signal in the “setup” mode.

The linear actuator uses a conductive plastic potentiometer with a 4 to 20 mA feedback board. and the rotary and drive actuators use a noncontacting device that transmits a 4 to 20 mA signal.Thrust . giving the appearance of a noisy signal. Having the Feedback cable in a tray or conduit with high voltage cable can cause the signal to be noisy due to induced voltage on the feedback signal from neighboring cables. The simplest way to ensure your actuator is producing the specified amount of torque / thrust is to observe the pressure gauges during 100 REXA X2 Series TS&R Manual .Torque .4 to troubleshoot feedback devices. driven by the motor. Ensure the Feedback cable is in a signal level tray or conduit. . That 2 000 psi pressure multiplied by the effective area of the cylinder equates to the output thrust / torque.3 . to pressurize either side of a double acting cylinder. Each X2 REXA standard power module is shipped from the factory with 2 pressure gauges. 3 . Refer to TS&R . This wire equalizes the ground potential at the control enclosure and actuator. it is possible that the actuator feedback device is faulty. and feedback and control signal noise have been ruled out. section .Actuator . thus eliminating possible current flow on the feedback cable shield./ . REXA Actuators and Drives are a self contained Electraulic™ device that utilizes a reversible hydraulic pump.ISSUES – – Ground the shield of the feedback signal cable at the control enclosure end only.15 . (06/10) –  Faulty Feedback Device? If the actuator is hunting or dithering for position. one to monitor each side of the cylinder.2 . Ensure the Green/Yellow ground wire in the module cable is terminated at both actuator and control enclosure. The feedback device may have a random spot within its stroke in which the feedback signal is intermittent.Troubleshooting CONTROL .requirements . The output thrust / torque of each cylinder is based on an internal pressure of 2 000 psi.

The REXA actuator is designed to operate on 2 000 psi internal oil pressure. If your REXA unit is operating above the 2 000 psi limit.section .5 . The gear pump will only produce as much pressure as needed to overcome the process forces.Actuator . the unit may build too much pressure and damage itself or the surrounding equipment. If the actuator stalls out or fails to produce over 2 000 psi then consult TS&R .3 .drifting . see the serial tag located on the electrical Troubleshooting – 06/10 101 .3 . .ISSUES operation. Every REXA X2 power module has adjustable pressure relief valves to protect the actuator from over-pressurizing. At 2 000 psi the cylinder is at its rated output. Actuator “drifts” away from applied load. To verify the cylinder output. If these relief valves are shut off or not operating properly.1. Each REXA unit has been designed to meet a specific application’s thrust or torque requirement. If your actuator is being “pushed” by the process. If the actuator is producing from 0 to 2 200 psi without producing a stall error then it is operating within specifications.X2 Troubleshooting and Repair Manual CONTROL . 3 .15 . you may have an undersized cylinder for your application. resolving this problem can be difficult and may require that the unit be removed from service.

Press Enter to access this setting. Actuator Identification. Connect the Red lead of the DMM to the LOOP OUT terminal. – – – If no pressure builds but motor is turning.4 .4-3 DMM display 102 REXA X2 Series TS&R Manual .section .2.15 .) If pressure builds but drifts down slowly.1 . Set the DMM to read milliamperes (mA). with the pressure gauges ON run the actuator in the direction of the load to see if internal pressure can be built.15.Position . the unit may have a leaking piston seal or problem with the flow matching valve. To calibrate the 4 mA zero. .15.Transmitter .4-1 Xmitter Low readout Photo 3. Please contact your local REXA representative if you believe your cylinder is undersized.Troubleshooting CONTROL .9 to 4.Calibration Xmitter Low {Transmitter Low} is the parameter to calibrate the Output zero of the 4 to 20 mA Position Transmitter. Refer to TS&R . If pressure builds but immediately drifts down.ISSUES or mechanical assembly. The acceptable range for Xmitter Lo is 3.15. The Value displayed on the REXA display corresponds to Digital bits.1 mA. Contact your REXA representative.14. for additional information. connect a DMM to the Position Transmitter Output on the CPU. Each increment or decrement of 4 bits will change the current output by one microamp (1 μA). If your actuator is correctly sized and still drifting away from the load. (06/10) 3 . check the pressure relief valve setting. check the Manual bypass and / or override solenoids.4-2 DMM connection Photo 3. Connect the black lead of the DMM to LOOP INT RTN terminal. Photo 3. (See TS&R section 3.

the output will change to the “Zero” or Lo Calibration value. Once the position transmitter calibration is complete. Changing the actuator span will cause the transmitter to automatically re-calibrate its output. Connect the black lead of the DMM to LOOP INT RTN terminal.15. Set the DMM to read milliamperes (mA). the output will change to the “Span” or Hi Calibration value.ISSUES NoTE: The Position Transmitter will output the mA signal that corresponds to the actuator's current position until the Enter button is pressed and the “ =” sign is flashing. When the “ =” sign is flashing. Xmitter Hi {Transmitter Hi} is the parameter to calibrate the Output span of the 4-20 mA Position Transmitter. Photo 3. When the “ =” sign is flashing. there is no need to re-calibrate the transmitter for changes in actuator span.4-5 DMM display NoTE: Xmitter Hi and Xmitter Lo values are not transmitted over the bus in Foundation Fieldbus units. Press Enter to access this setting. Connect the Red lead of the DMM to the LOOP OUT terminal.4-4 Xmitter Hi readout Photo 3. connect a DMM to the Position Transmitter Output on the CPU. To calibrate the 20 mA Span.X2 Troubleshooting and Repair Manual CONTROL . NoTE: The Position Transmitter will output the mA signal that corresponds to the current position of the actuator until the Enter button is pressed and the “ =” sign is flashing. The Value displayed on the REXA display corresponds to Digital bits. Each increment or decrement is steps of 4 bits and will change the current output by one micro-amp (1 μA). Troubleshooting – 06/10 103 .15.

be .Limit .Open .Switches . Refer to IOM .ISSUES 3 . D5 Photo 3.or .Closed? – No.the .Electrical .15 .15.Troubleshooting CONTROL .Normally . D4 LED. 1 A Can .6 .1 . The relay contact is “open” when power is off or the relay is not within the “active” range determined by actuator stroke.Switches The Electrical Sub-Assembly is equipped with two SPST 1 Form A PhotoMos relays that are configured as electronic limit switches. solid state devices with a Normally Open contact only.Limit .configured .Section . Normally . .5-1 Terminal Blaock TB5 Electrical limit switch rating = 200 Vac/Vdc.5 . Relay 1 and Relay 2.electrical . The relays close based on the value of parameters RELAY #1 and RELAY #2 in the OUTPUTS menu. 104 REXA X2 Series TS&R Manual . (06/10) Terminal Block TB5 with Relay 1 and Relay 2 Connections LED. The termination points for these relays are located on the CPU board assembly at TB5. The relays are SPST.8.

parameter .4 .below . but I do not have a closed contact. bring the actuator to within the active range of Relay #2 or adjust parameter Relay #2. replace the CPU Board according to TS&R .LED .E .the .actuator . bring the actuator to within the active range of Relay #1 or adjust parameter Relay #1. measure the resistance across the terminals at TB5 for Relay 1. Confirm the actuator is within the active range for Relay #1. but I do not have a closed contact.E .state .the . section .stroke .ISSUES Do . Relay .E .they .1 Ω or an open circuit.parameter . Using an ohmmeter.set .LED . RELAY 2 does not give a closed contact indication  Is .7 Ω but no greater than 1. replace the CPU Board according to section 4.X2 Troubleshooting and Repair Manual CONTROL . If the resistance is greater than 1.below .D4 . If RELAY 1 does not give a closed contact indication:  Is .off? – The leakage current in the “off” state should be no greater than 10 mA. section .  Is .#2? – If not. If No.stroke .D5 .leakage .value .4 .4.the . LED D5 is lit.4.4.1 Ω.the . current .the .solid . If it is greater. the relay is defective and the CPU should be replaced per TS&R .are .set .when .value . the relay is faulty and the CPU should be replaced per TS&R . Relay#1? – If no.relays .the . The “on” resistance of the relay should be approximately 0.actuator .in .section .the .lit? – – Troubleshooting – 06/10 105 .4 LED D4 is lit.have .E.lit? – –  Is . If No.4 .in .

Low . If the resistance is greater than 1. To prevent the unit from hitting the cylinder end during operation an electrical “cushion” is added.1 Ω or an open circuit. (06/10) – 3 . of the REXA cylinder is recorded in the CPU. disengage the driven device linkage slightly to allow the actuator more room to travel.section .15 .High/Too .4 . The actual physical mechanical travel.on .E . The “on” resistance of the relay should be approximately 0.display The display reads Too Low or Too Hi.4. and you cannot calibrate your high / low position. the relay is faulty and the CPU should be replaced per TS&R . 106 REXA X2 Series TS&R Manual . .1 Ω.Troubleshooting CONTROL .Too .6 . measure the resistance across the terminals at TB5 for Relay 2. contact your local REXA representative. Using an ohmmeter. If possible. – Back the actuator away from the cylinder end until the CPU allows the value to be set. If no changes can be made that will satisfy proper safe operation.ISSUES – Confirm the actuator is within the active range for Relay #2.7 Ω but no greater than 1.

– Ensure the Accumulator bottles are charged and the Shutoff valves are in their proper position. for proper setting when using Trip function to fail on loss of power. control signal or independent trip signal. Fuse F4 is for High-Speed solenoids. Check fuses on triple power supply board with DMM.on .4. Fuses F5.16 . It can be triggered by a loss of power.TRIP .No . Refer to IOM . and is not field reversible. .  If equipped with a REXA solenoid. and Fuse F3 is for – Troubleshooting – 06/10 107 . – Check software settings for Trip option and / or Accumulator option under Inputs menu.Fail . Modes of Operation and Control Parameters. 3 . The fail to end position is achieved by either the use of a coil spring or a pressurized accumulator bottle. .X2 Troubleshooting and Repair Manual TRIP .Appendix .16 . .of .4.section .direction The Fail direction is factory configured—based on information provided—to fail to either calibrated end. Refer to IOM . Accumulator Fail. F6 are for REXA spring fail solenoid.1 .section .2 .C.  If equipped with a high-speed solenoid.IOM .SIGNAL REXA actuators can be configured to fail to either end position or stay in its last position. section .6.loss . Refer to . Manual Override.Appendix .16 .trip . but not both. a bypass control toggle lever will be present on the power module.C . Ensure that the lever is in its ‘normal position’.C.SIGNAL 3 .power The actuator does not trip on loss of power reference.C . . ensure the solenoid override levers are both in Position A for normal actuator operation. Manual Override. 3 . Refer to IOM . Please contact your REXA representative.

Check fuses on triple power supply board with DMM. Refer to IOM . See TS&R . A blown fuse is an open circuit or will read infinity on the meter. Using a DMM.E . . Accumulator Fail.4 .control . See TS&R . If Analog control signal falls below 2. (06/10) 3 .section .3 .trip .signal The actuator doesn’t trip on loss of control signal. Refer to IOM .No .signal The actuator doesn’t trip on loss of trip signal reference – Check that the trip signal (24–120 Vac/Vdc) is wired to the correct terminals of the contact input board.17 to replace blown fuses on Triple Power Supply.C.16 . A blown fuse is an open circuit or will read infinity on the meter. a good fuse will measure close to zero Ohms or show continuity.16 .section .17 to replace blown fuses on Triple Power Supply.3. Refer to IOM . F6 are for REXA spring fail solenoid. Check that the Trip option and/or Accumulator option is enabled. and Fuse F3 is for Contact Input Board. Fuses F5.section .No .loss . Using a DMM. Failsafe Unit Operation.of . .Appendix .Appendix . Accumulator Fail. – 108 REXA X2 Series TS&R Manual . Ensure that any required jumpers are in place.loss .on .of .Troubleshooting TRIP . the actuator should move to fail safe position via motor.SIGNAL Contact Input Board.on .trip .C. a good fuse will measure close to zero Ohms or show continuity. Ensure the Accumulator bottles are charged and the Shutoff valves are in their proper position.5 mA. NoTE: Local and Remote Manual mode will override Failsafe position 3 .4 .M . Fuse F4 is for High-Speed solenoids.4 .E . – – Check that the Failsafe option is enabled.trip .

Accumulator Fail.  If equipped with a REXA solenoid.Appendix .SIGNAL  If equipped with high-speed solenoids. Manual Override. a bypass control toggle lever will be present on the power module.X2 Troubleshooting and Repair Manual TRIP .section .C . Refer to IOM . Ensure that the lever is in its ‘normal position’.section .4.C . – Ensure the Accumulator bottles are charged and the Shutoff valves are in their proper position. Manual Override. Refer to IOM . Refer to IOM .C.4. Troubleshooting – 06/10 109 . ensure the solenoid override levers are both in Position A for normal actuator operation.

The standard steel enclosure is rated NEMA 4 (protection against rain.17 .17 . The ¼ inch bolts used to hold the cover on should be torqued to 120 lb·in to ensure the proper pressure on the O-ring. .INGRESS 3 . Each of the entries ship from the factory with a stainless steel plug installed with sealant around the threads to eliminate the possible ingress of water. . (06/10) 3 . hose directed water and corrosion resistant). This cover incorporates an O-ring to form the seal against the environment. is also rated for outdoor use. water or other elements may cause damage to the motor or wire terminals.2 .WATER ./ . The Electrical Sub Assembly (ESA) of the REXA actuator. Each motor should be equipped with either a hand wheel or a motor cover on the back end of the motor. If a plug is removed and replaced with a conduit fitting both local and National Electrical Codes (NEC) must be complied with to ensure proper installation and sealing. although typically remote mounted from the MSA. snow and hose directed water). The MSA has multiple conduit entries.1 .17 .Electronics . The MSA is rated NEMA 4X (protection against rain. When properly installed your MSA should provide years of weather tight operation. snow. . The closing mechanism on the ESA is a single point quarter turn latch that requires the use of a tool for opening. If the back end of the motor is left unsealed.Module . When properly 110 REXA X2 Series TS&R Manual .Motor The Mechanical Sub Assembly (MSA) of the REXA Actuator is designed to thrive in the most hostile ambient environments.INGRESS 3 . The MSA also has a wire terminal cover that allows access to the module terminal strips. These items are equipped with an O-ring to make sure the motor is sealed from any elements.Troubleshooting WATER . When properly installed your ESA should give you years of weather tight operation.

drilled for the different entry points.INGRESS closed the cover is compressed against the gasket to form a seal against the environment. All electrical connections to the ESA should be made at the gland plate found at the bottom of the enclosure. The gland plate can be removed. Troubleshooting – 06/10 111 . and then re-installed with the gasket in place. When installing conduit fittings both local and National Electrical Code (NEC) must be complied witih to ensure proper installation and sealing.X2 Troubleshooting and Repair Manual WATER .

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" 4 . Electrical Repair 4 .is .E . The voltage drop along the wire that is part of the measurement circuit is impressed on the signal voltage thus causing the error. Because this current is variable.2 .E . .Ground .X2 Troubleshooting and Repair Manual 4. and signal lines are connected in such a way that circulating ground currents are able to flow through one or more signal conductors.1 .E .LOOPS 4 .E. . A grounded Electrical Repairs – 06/10 113 .1 .Loop? A Ground Loop can be present in a system when points nominated as Grounds are at different potentials. the measurement system would become dangerous. it cannot be "calibrated out.Anyway? Three reasons for grounding measurement systems: ● The first is safety.1 . .a .GROUND .1 .What . The resulting current that flows in the loop can be very large — in extreme cases hundreds of amps — but is more commonly less than 500 mA.Why . Should a high voltage accidentally come into contact with the measurement system. and there is more than one electrical path connecting these Grounds.Ground .

a .is . the system could be charged to high voltage levels by static electricity or insulation leakage. Eliminate . communications links with computers introduce additional grounds. Eliminate the loop. Use . The simplest and most effective method to avoid ground loop problems is to ensure the measurement system is connected to a single ground point. If the system were not grounded. However.1 . .Ground .a . the system's insulation would break down.Good .Electrical Repairs GROUND . preferably the measurement system end. If the ground voltage difference exceeds the rating the errors will be introduced.3 .LOOPS measurement system would cause a fuse to "open" thus rendering the system safe. to obtain the best possible thermal contact and response time. However. or electrical safety demands multiple grounds.Grounds .E .loop . . ● The second reason for grounding is to ensure the measuring system is operating within its operating voltage range.Solutions . this is not always possible as sensors must sometimes be grounded. For example.Differential . the shielding should be grounded at one end of the cable only. But there are solutions: 2 . a thermocouple may be welded to the object of interest — hence grounding the thermocouple.(or . If shielded wires are used. differential inputs are only as good as their common mode rating. 3 . At some point. ground current will flow through the shield and inductively induce noise into the signals wires (which should be twisted to minimize this 114 REXA X2 Series TS&R Manual . The use of differential inputs (as opposed to single ended inputs) is effective in overcoming ground loop errors as no current passes down the two measurement wires.Ground) 1 . .the . If grounded at both ends. possibly causing measurement errors in the process. . A third reason grounds may be introduced into a system is due to sensor needs. Shield . (06/10) ● 4 . Another example is the pH electrode — it is in electrical contact with the fluid being measured.Single .Inputs .

Isolation . The preferred grounding point is at the measuring device. 4 . Isolation .measuring . The simple rule still applies — a single ground is a good ground.(floating) .the .at . . Isolation . Also.output . In small systems a cost effective solution is to provide isolation at the measuring devices output interface such as RS232. . . extreme care must be taken against forgetful contact.device .measuring . Ethernet. 6 . If possible. Also.measuring .device . but remove ALL other grounds. isolation has its limitations — speed and accuracy are often sacrificed to contain the costs. 5 .LOOPS effect).device .the . but if used to isolate very high voltages. .the . This may need to include power supplies. Electrical Repairs – 06/10 115 .sensor . An unconventional but occasionally practical method of isolation in a small setup is to isolate the entire measuring device by allowing it to operate off batteries.the . it may be possible to use its ground as the system's ground. Sometimes you may have no choice where the ground may be placed (as with a grounded thermocouple grounded for good thermal contact and response time). 7 .X2 Troubleshooting and Repair Manual GROUND . Sometimes it is not possible to isolate the sensors or its wiring. Providing isolation at each of the measuring device's inputs is the best but most expensive solution. In these cases it is necessary to isolate at the measuring device by providing a fully isolated input for that sensor.input . The method can provide almost any level of isolation required. If there is only one such sensor in the system. USB or modem. Typically such isolation will double the equipment cost. electrically isolate all the wiring associated with the sensor from the area in which the sensor is installed. Isolation .of .at . it is possible that injecting the loop current into the shield connection points may cause errors in the measuring device or the sensor.at .

Potential .Causes .4 . .5 . control or pressure transmitter signal – High voltage measurement between Earth Ground and Neutral conductors at the control enclosure power input.and .REXA .LOOPS 4 .Ground .Ground . pressure transmitter) Earth ground connection between actuator and electronics Signs of ground loop problems: – Noisy/unstable feedback.E.Equipment ● ● ● Related to signal wires (Feedback.loops . 116 REXA X2 Series TS&R Manual .4 Ground Loop 4 .E .1 .Differences Understanding the cause of ground potential differences can be of some help in minimizing their impact on the measuring system and also in negating effects such as corrosion. .E .1.of .Electrical Repairs GROUND . Ground returns in electrical power systems Ground returns in marine power plants Lightning strike Galvanic corrosion prevention systems Inductively induced currents (06/10) ● ● ● ● ● Figure 4.1 . ● Electric trains and trams — Electric traction systems often use the tracks as a the return path for the current drawn from overhead power lines.

Every installation is different.ground . .E .fixes .1 .a .6 .What .loop? Typically. take it one step at a time Electrical Repairs – 06/10 117 .X2 Troubleshooting and Repair Manual GROUND .LOOPS 4 . a ground loop is fixed by cleaning up the interconnecting wiring to have: ● ● ● ● ● Shields terminated at ONE end of the cable only Shields connected to the backplane of the electronics enclosure AC Ground from the AC source brought to the control enclosure and actuator rather than ground to building steel only Good earth ground connections Trial and error… ground loops can be difficult to solve and require patience and thorough site evaluation.

SURE .THE .Electrical Repairs STANDARD .IS .ENCLOSURE 4 . Figures 4.BEFORE .CONTROL .UNIT . ANy .AND .2 .B/C-PUMP .COMPONENT . . DISCONNECTED .REPLACING .POWER . . IS .2-1&2 Standard and CSA B/C-Pump Control Enclosure 118 REXA X2 Series TS&R Manual .E .MAKE .E.AND .OFF .TURNED .COMPONENTS! (06/10) Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.REPLACEMENT . CAUTION: .CSA .

2-3&4 D-Pump Control Enclsure Electrical Repairs – 06/10 119 .X2 Troubleshooting and Repair Manual D-PUMP .CONTROL .E.ENCLOSURE Figures 4.

E.D-PUMP .ENCLOSURE (06/10) Figures 4.Electrical Repairs 1/2 .2-5&6 1/2D-Pump Control Enclsure 120 REXA X2 Series TS&R Manual .CONTROL .

CONTROL .E.X2 Troubleshooting and Repair Manual 2D-PUMP .ENCLOSURE Figures 4.2-7&8 2D-Pump Control Enclsure Electrical Repairs – 06/10 121 .

TURNED .SURE .E.COMPONENTS! (06/10) Figure 4.3 .POWER .THE .DISCONNECTED .MAKE . .AND .BEFORE .IS .E. REPLACING . OFF .Electrical Repairs POWER .IS .3-1 Stepper Power Supply Assembly Photo 4.ASSEMBLy 4 .ANy .POWER . CAUTION: .E .UNIT .ASSEMBLy .3-1 Power Supply Assembly (Stepper) 122 REXA X2 Series TS&R Manual . .SUPPLy .SUPPLy .

4 .E.section .E . 2. Figure 4.SUPPLy .E. Remove the AC power wires from the “Power In/Motor Power” terminal. Remove the CPU board per TS&R .3-2 Servo Power Supply Assembly 4 .REMOVAL .4 . Electrical Repairs – 06/10 123 .1-1 TB5 Power Supply 3.3 .E .1 . 1.3.1.X2 Troubleshooting and Repair Manual POWER . TB5. .ASSEMBLy Figure 4. TB1. Remove the wires from the green connector at the top left of the Power Supply.

3.ASSEMBLy (06/10) Figure 4.SUPPLy . TB3.1-2 TB1 Power Supply 4.3.E. Figures 4.4 TB3 “Motor In” Terminal 124 REXA X2 Series TS&R Manual . Remove any Motor wires that may be connected into the “Motor In” terminal.Electrical Repairs POWER .1-3.E.

E.1-6 TB2 & 3 Electrical Repairs – 06/10 125 .3.SUPPLy . Remove any Resolver wires that may be connected to the “Motor Resolver” terminal.3. 5. Figure 4.ASSEMBLy . Remove any wires that may be connected to TB2 and TB3. Figure 4. Note: All mounting hardware and wires that were removed will be required for the replacement of the power supply.X2 Troubleshooting and Repair Manual POWER .E. TB7.1-5 TB7 “Motor Resolver” terminal 6.

Make sure all wires have been removed from the power supply.E. (06/10) Figure 4.SUPPLy . the standoffs will require a ¼ nut driver for removal.1-7 Power Supply and “Standoffs” 126 REXA X2 Series TS&R Manual .625") used to secure the power supply. Remove the power supply from the control enclosure.75" with 6-32 x 0. Remove the Screws (6-32 x 0.25”) and Standoffs (6-32 x 1.Electrical Repairs POWER .ASSEMBLy 7.3.

3. Figure 4.E.2-2.5" standoffs mounted to the control enclosures panel.2 .E.3.REPLACEMENT 1. Install the replacement power supply using the 6-32 x 0.X2 Troubleshooting and Repair Manual POWER .3 TB3 motor cable wire connections Electrical Repairs – 06/10 127 . Reconnect the motor cable wires to the “Motor In” terminal on the power supply.625") that were removed from the old power supply. TB3. Use the Screws (6-32 x 0.25") and the Standoffs (6-32 x 1.2-1 Power Supply placement 2. Figure 4.E . .SUPPLy .3 .ASSEMBLy 4 .75" with 6-32 x 0.

TB1.E . Reconnect any wire that may have been connected to terminal TB2 and TB8. 4. 5.SUPPLy . Reconnect the AC power wires to the “Power In/Motor Power” terminals. (06/10) 128 REXA X2 Series TS&R Manual .4 .4 . Reconnect any Resolver wires to the “Motor Resolver” terminal TB7. Reconnect the DC power wires to TB5. Replace the CPU board per TS&R .2.Electrical Repairs POWER . 7.ASSEMBLy 3.section . 6.

E .CPU . OFF .IS . Figure 4. REPLACING .THE . .X2 Troubleshooting and Repair Manual CPU . .IS .4 CPU Assembly drawing Electrical Repairs – 06/10 129 .AND .BEFORE .DISCONNECTED .4 .E.POWER . CAUTION: .ANy .ASSEMBLy .UNIT .COMPONENTS! Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.SURE .ASSEMBLy 4 .TURNED .MAKE .

4.1-2 TB2 connections Figure 4.4.ASSEMBLy 4 . Location TB2.E.E.1-2 TB3.4.E .4 . Location P7.1-1 Ribbon connection Figure 4.1-3 TB3 connections 130 REXA X2 Series TS&R Manual .E. 3. Stepper Driver Wiring Photo 4.E. Remove the DC Power wires connected to the “Power In” connector. TB2 Ribbon Cable & Wire Connections 2.1-1 P7.Electrical Repairs CPU . . Remove any Stepper Driver Logic wiring connected to Location TB3 (Stepper Units Only).E. Photo 4.1 .4. (06/10) Photo 4.4. Remove the Ribbon Cable connected to the “To Display Interface” connector.Removal 1.

Figure 4. Remove any Servo Driver Logic wiring connected to the “Standard Motor” connector.E.X2 Troubleshooting and Repair Manual CPU . TB7 & TB8 Wire Connections Electrical Repairs – 06/10 131 . Remove the DC Power wires connected to Location TB8. 6. Location TB7 (Booster Units Only).ASSEMBLy 4. Remove any Booster Driver Logic wiring connected to the “Booster Motor” connector.1-3 TB6. Location TB6 (Servo Units Only).4. 5.

1-4 TB1 Connections Terminal 132 REXA X2 Series TS&R Manual . Make a note of all wires that are connected to Location TB1.4. write the location of each wire down if necessary.Electrical Repairs CPU .1-4 TB1 Wire Connections Photo 4. (06/10) Figure 4.4.E.E.ASSEMBLy 7. Remove all wires connected to TB1.

9.X2 Troubleshooting and Repair Manual CPU . This hardware will be required for installing the new CPU Board.1-5 Screw Location. CPU Board 10. Make a note any wires that may be connected to Locations TB4 & TB5.4. Electrical Repairs – 06/10 133 . write the location of each wire down if necessary. Remove the CPU.) that mount the CPU. Remove all wires connected to TB4 & TB5. Remove the 6-32 x 0. Figure 4.25" Phillips head screws (8 pcs.E.ASSEMBLy 8.

4.2-1 Screw Location.E .Electrical Repairs CPU . The Red Stripe on the Ribbon Cable should be oriented to Pin 1 at connector P7.E. Photo 4.4. Reconnect the Ribbon Cable to the “To Display Interface” connector.ASSEMBLy 4 .E. Location P7.Replacement 1. (06/10) Figure 4. CPU Board 2.4 . Install the replacement CPU Board to the Standoffs using the 6-32 x 0. .4.2-1 Ribbon Connector Figure 4.2-2 Cable to P7 and TB2 wire connections 134 REXA X2 Series TS&R Manual .E.2 .25" hardware removed from the old CPU Board.

4. 6.2-4 Connections to TB6.4.E. Reconnect any Stepper Driver Logic wiring that was connected to Location TB3 (Stepper Units Only). Reconnect any Servo Driver Logic wiring to the “Standard Motor” connector.4.E.2-3 TB3 connections drawing 5. 7. Figure 4. Location TB2. Reconnect the DC Power wires to Location TB8. 4. Location TB6 (Servo Units Only). Reconnect the DC Power wires to the “Power In” connector. Location TB7 (Booster Units Only). Reconnect any Booster Driver Logic wiring to the “Booster Motor” connector. Photo 4.2-2 DC Power Connections Photo 4.ASSEMBLy 3.E. TB7 & TB8 drawing Electrical Repairs – 06/10 135 .2-3 TB3 connections Figure 4.4.X2 Troubleshooting and Repair Manual CPU .E.

(06/10) Figure 4. Reconnect all wires that were removed from Location TB1.E.Electrical Repairs CPU .4.ASSEMBLy 8.2-5 CPU connections at TB1 136 REXA X2 Series TS&R Manual .

Photo 4.THE ./ .TURNED .UNIT .RELAy .OUT .5 Contact In/Relay out board drawing 4 .Removal 1. REPLACING .AND . .5 Contact Board Figure 4.BEFORE .E .5 . OFF .OUT .ANy .ASSEMBLy .5 .E./ .1-1 TB2 Contact Wires Figure 4.IN .RELAy . Photo 4.X2 Troubleshooting and Repair Manual CONTACT .1-1 TB2 wiring drawing drawing Electrical Repairs – 06/10 137 . .E.1 .ASSEMBLy 4 .SURE .CONTACT . .5.E.E .IN .E. CAUTION: .DISCONNECTED .COMPONENTS! Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.POWER .5 .IS .IS .MAKE . Remove the wires connected to location TB2.

5.OUT . Photo 4. make a note of their location as these jumpers will be required for the new board. (06/10) Figure 4. and note their location for later replacement.5.E. Remove any other wires that may be screwed into the contact boards terminals.5. TB1 & TB6./ .E.1-2 Jumper locations Figure 4.ASSEMBLy 2.IN .1-2 TB3. Remove any Jumpers installed at locations TB3.RELAy .Electrical Repairs CONTACT . TB1 & TB6 drawing 3.1-3 Jumper location drawing 138 REXA X2 Series TS&R Manual .E.

RELAy . Remove the 6-32 x 0. This hardware will be required for installing the replacement board. Figure 4. Unplug the 24-pin female connector on the contact board (location P1) from the 24-pin male connector on the CPU board (location P1).5.1-4 Screw location drawing 5.1-3 Board removal Electrical Repairs – 06/10 139 .IN .ASSEMBLy 4.25" Phillips head screws (6 pcs. Photo 4./ .5. Tag the board as defective and completely remove from the control enclosure.E.X2 Troubleshooting and Repair Manual CONTACT .) that secure the Contact board.E.OUT .

E.E. TB1 & TB6 locations 140 REXA X2 Series TS&R Manual .5.).2-2 TB3.25" Phillips head screws (6 pcs. Secure the replacement board to the mounting Standoffs using the 6-32 x 0.OUT . Be sure to line up connector P1 on the Contact board with connector P1 on the CPU. .IN .2-1 Screw placement drawing 2. TB1 & TB6.E. Figure 4.Electrical Repairs CONTACT . Replace any 2 Position Jumpers removed from locations TB3./ .2-1 Contact board placement Figure 4.2 .5.Replacement 1.ASSEMBLy 4 .RELAy . Refer to any notes taken during the removal process.5 .5.E . (06/10) Photo 4.

Figure 4.E.OUT .5.X2 Troubleshooting and Repair Manual CONTACT .5.5.2-3 TB2 connection drawing 4.IN .E. Refer to your notes and reconnect any additional wires that may have been installed to the Contact Board.ASSEMBLy 3. Reconnect the wires that were installed at location TB2.RELAy .2-4 Contact In/Relay out drawing Electrical Repairs – 06/10 141 . Photo 4.E./ .2-2 TB2 Wiring connections Figure 4.

MOTOR . Photo 4.MOTOR . CAUTION: .E.Electrical Repairs STD .STEPPER .COMPONENTS! (06/10) Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.DISCONNECTED .E.UNIT . Remove this hardware using a 1/8" Allen wrench.E.6.E.THE . Disconnect the AC Power connector (Left). This hardware will be required to install the replacement driver. .DRIVE .B/C .STEPPER . Photo 4.IS .TURNED .(STD .E .ANy . the Motor Power connector (Middle) and the Driver Logic connector (Right). . .B&C) 1.6 . Tag the driver as defective and completely remove from control enclosure.Removal .6.IS . Locate the four driver mounting screws and nylon washers on the top of the control enclosure.SURE . .BEFORE .6.1-1 Standard B/C power connections drawing 2.E .1-2 Motor Connectors Photo 4. .6.6.1-2 Mounting screw location 142 REXA X2 Series TS&R Manual . OFF .1-1 Stepper Motor Drive Figure 4.6 .E.1 . 4 .B&C) .MAKE .POWER .AND . REPLACING .1-3 Enclosure mounting screws Figure 4.(STD .DRIVER 4 .

Photo 4.B/C .Replacement .2-3 Stepper Motor Drive Figure 4.(STD . Mount the replacement driver to the top of the control enclosure using the four screws and nylon washers that were removed from the defective driver.DRIVER 4 .1-1 Standard B/C power connections drawing Electrical Repairs – 06/10 143 .B&C) 1.MOTOR .6. Photo 4. .STEPPER .6. .E.2-1 Thermal Coat Figure 4.X2 Troubleshooting and Repair Manual STD .2-2 Mounted Driver a.6.E.6.E.6 . 2.E .6.2-1 Mounting screw location Photo 4.2 .E. Motor Power (middle) and Driver Logic (right) connectors into the driver in their respective locations. Apply a thin layer of thermal coat to the back of the driver.E.) Plug the AC Power (left).

IS . Tag the driver as defective and completely remove from control enclosure. OFF . Locate the four driver mounting screws and nylon washers on the top of the control enclosure.TURNED .MAKE .UNIT . 1.Removal .MOTOR . Locate the B CSA Driver and disconnect the motor cable from location P1.E .STEPPER .IS . .7 . This hardware will be required to install the replacement driver.AND .B .E.POWER .STEPPER . Photo 4. CAUTION: .CSA . 144 REXA X2 Series TS&R Manual .DRIVER . 4 .1-1 CSA B stepper driver drawing 2.1 . .COMPONENTS! (06/10) Note: Assumed starting position is facing the upright electronic unit with the enclosure door open. CSA B stepper motor in enclosure Figure 4.E.BEFORE .7.ANy .DRIVE 4 .7 . . REPLACING .SURE .10.THE .DISCONNECTED . Remove this hardware using a 1/8" Allen wrench.Electrical Repairs CSA .B .E .

Figure 4.2 .STEPPER .7 . Apply a thin layer of thermal coat to the driver mounting plate.E. Electrical Repairs – 06/10 145 .X2 Troubleshooting and Repair Manual CSA .B .MOTOR .1-2 CSA B exterior mounting Figure 4.Replacement .2-1 Mounting diagram 3. . Mount the replacement driver to the top of the control enclosure using the four screws and nylon washers that were removed from the defective driver. 1. Reconnect the Motor cable to location P1 on the Driver.E .7.DRIVE Photo 4.E. 2.E.7.1-2 Mounting diagram 4 .7.

DRIVE (06/10) Figure 4.E.B .2-2 CSA B stepper driver drawing 146 REXA X2 Series TS&R Manual .7.MOTOR .Electrical Repairs CSA .STEPPER .

8.BEFORE .E.COMPONENTS! 4 . .TURNED .DRIVE .MAKE .POWER .STEPPER . Disconnect the power connector (Left).E . Photo 4.THE .8 .E.STEPPER .X2 Troubleshooting and Repair Manual CSA .DISCONNECTED . Photo 4.MOTOR . .8.MOTOR .C .ANy . CAUTION: . Tag the driver as defective and completely remove from control enclosure.UNIT .SURE . OFF .1-3 Mounting screws Figure 4.1-2 Cables disconnected Photo 4.1-2 Enclosure mounting drawing Electrical Repairs – 06/10 147 .CSA .E .IS .Removal .8. 1. Locate the four driver mounting screws and nylon washers on the top of the control enclosure.E.DRIVE 4 . This hardware will be required to install the replacement driver.8 .1-1 Power connections drawing 2. REPLACING . Remove this hardware using a 1/8" Allen wrench. .8.E.IS .1 .E.AND . the motor connector (Middle) and the logic connector (Right).8.1-1 Power connections Figure 4.C .

.2-2 Stepper motor attached to enclosure Figure 4.E. 2. Plug the AC Power (left).2-1 Enclosure mounting location 3.DRIVE 4 .8.2 . Photo 4. 1. Apply a thin layer of thermal coat to the bottom of the driver.E.E .E.Electrical Repairs CSA . Motor Power (middle) and Driver Logic (right) connectors into the Driver in their respective locations.8 .E.8.2-2 Cable connections Photo 4.E.C .8.MOTOR . (06/10) Photo 4.8.2-1 Therma coat Figure 4.8.2-3 Cables connected 148 REXA X2 Series TS&R Manual .Replacement .STEPPER . Mount the replacement driver to the top of the control enclosure using the four screws and nylon washers that were removed from the defective driver.

TURNED .D .MOTOR .POWER .X2 Troubleshooting and Repair Manual SERVO .9-1 Servo Motor Driver Electrical Repairs – 06/10 149 .MOTOR .MAKE .ANy . CAUTION: .SURE . .9-1 Servo Motor Driver Photo 4.DRIVE D .IS . .COMPONENTS! Note: Assumed starting position is facing the upright electronic unit with the enclosure door open. Figure 4.BEFORE .UNIT . REPLACING .9 .AND .THE . .DISCONNECTED .1/2 .IS .DRIVE 4 .E .E.SERVO . .E. OFF .

DRIVE 4 .1-1 Tie down bases 2.Removal 1.1 . (06/10) Photo 4.9. Cut away any wire ties that may be securing any cables to the tie down bases applied to the Servo Driver.1-2 Servo drive cable connections Figure 4. Unplug the “AC Input” connector.9.1-2 Servo drive cable connections 150 REXA X2 Series TS&R Manual .E.MOTOR .9 .9. . Disconnect the “Controller I/O” and “Resolver Feedback” cables by loosening the two thumb screws on each cable.Electrical Repairs SERVO . Unplug the “Motor Output” connector and remove the Green/ Shield wire from the ground Screw.E.E.1-1 Cable tie downs Figure 4. Photo 4.E .9.E.

1-3 Mounting screws Figure 4.9.50" Phillips head screws removed from the defective driver. Photo 4.9.9 . This hardware will be required to install the replacement drive.MOTOR .50" Philips head screws securing the Driver to the panel.1-3 Servo driver & panel drawing 4 . Tag the Driver as defective and completely remove from the control enclosure.DRIVE 3.E. Photo 4.E. Secure the replacement Driver to the panel using the 8-32 x 0. . Remove the four 8-32 x 0.E.Replacement 1.E.E .2-1 Servo driver & panel drawing Electrical Repairs – 06/10 151 .9.X2 Troubleshooting and Repair Manual SERVO .2-1 Screw placement Figure 4.9.2 .

E.MOTOR .2-2 Servo Motor Drive Connections Figure 4. (06/10) Photo 4. Plug in the “AC Input” connector. Plug in the “Motor Output” connector and secure the Green/Shield wire to the ground screw.E.DRIVE 2.Electrical Repairs SERVO .2-2 Servo Motor Drive Connections 152 REXA X2 Series TS&R Manual .9. Reconnect the “Resolver Feedback” and “Controller I/O” cables.9.

REPLACING .DISPLAy .COMPONENTS! Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.10. 3.ASSEMBLy .the . OFF . Disconnect the Ribbon Cable from the Display Interface connector P1.DISCONNECTED .Display: The External Display Assembly is mounted to the cover of the control enclosure.X2 Troubleshooting and Repair Manual EXTERNAL .of .BEFORE .MAKE .Removal .1-1 VFD Removal Drawing Photo 4.E. Tag the Display as defective and completely remove it from the cover of the control enclosure.VFD . CAUTION: .10 .10.External . Photo 4.10 .AND .E.1-1 Ribbon Cable Position Figure 4.10.E .* Photo 4.1 .IS .SURE .POWER .E . .IS . . 1.ANy .(EXTERNAL) .10 VFD Display 4 .TURNED .THE .E.VFD .1-2 Screw Removal Electrical Repairs – 06/10 153 .UNIT . . 2. Remove the 10 screws that secure the External Display to the enclosure’s cover.E.VFD .DISPLAy 4 .

VFD . .E.DISPLAy 4 .E.2-1 VFD Replacement Drawing Photo 4.of .2-1 Bezel & display (front view) Photo 4.E. Apply the gasket to the bezel then place thru the cut-out on the outside of the enclosure cover.E.assembly: 1. 2. The red stripe on the ribbon cable should be orientated to pin 1 on connector P1.the .2-3 Connected VFD Display 154 REXA X2 Series TS&R Manual .10.10 .2-2 Bezel & display (back view) Figure 4. (06/10) Photo 4.Replacement .10.10.E .Electrical Repairs EXTERNAL .2 . Connect the ribbon cable to the back of the display assembly location P1.10.display . Secure the Keypad mounting plate assembly to the bezel using the hardware provided.

E.BEFORE . Disconnect the ribbon cable from connector P1 of the Display Interface Board. .Display . 3.11.11.IS .11-2 Internal Display Interface 4 .11.of .AND .SURE .E.11-1 VFD Display Assembly Figure 4.X2 Troubleshooting and Repair Manual INTERNAL . CAUTION: .E.COMPONENTS! Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.E .Internal .11 .1-1 Ribbon Cable Photo 4.1 .25" screws used to secure the Display Interface Board.DISCONNECTED .11 .11-1 Internal VFD Display Assembly Drawing Photo 4. OFF .POWER . 2.VFD . Remove the six 6-32 x 0.THE . Tag this Board assembly as defective and completely remove from control enclosure. .1-2 Mounting Screws Figure 4.1-1 Internal VFD Removal Drawing Electrical Repairs – 06/10 155 .TURNED .Removal .IS . REPLACING .(INTERNAL) .UNIT .E.MAKE .* Photo 4. Photo 4. .E.E.E .VFD .the .DISPLAy .Assembly 1.DISPLAy 4 .ASSEMBLy .ANy .

The Bracket will be secured to three of the four Standoffs using the 6-32 x 0.the .2 .Display .Assembly: 1.375" standoffs to the Bracket in the 6 places shown below.375" screws. .1-3 VFD Removal Drawing 4 .DISPLAy 4 . Remove the Internal Display Mounting Bracket from the CPU Board by removing the three 6-32 x 0.E.11.Electrical Repairs INTERNAL . (06/10) Photo 4.2-1 VFD Replacement Drawing 156 REXA X2 Series TS&R Manual .Replacement .of .E .375" screws provided.11. Install the 6-32 x 0.1-3 Mounting Bracket Figure 4. Figure 4.E. Secure the Internal Display Mounting Bracket to the CPU Board.11. .VFD .11 .E.

X2 Troubleshooting and Repair Manual INTERNAL .2-4 VFD Replacement Drawing Electrical Repairs – 06/10 157 . Photo 4.2-2 Internal VFD Diplay Assembly Figure 4.DISPLAy 2.5625 standoffs into the front side of the Display Interface Board. Secure the VFD Display Board to the four standoffs installed on the Display Interface Board using the 6-32 x .25” screws provided.11. Install the 6-32 x . Photo 4.25" screws provided.12.E.VFD . secure the standoffs using 6-32 Hex Nuts in the 4 places shown below.11.2-1 Internal VFD Diplay Assembly Figure 4. Ensure the red stripe on the ribbon cable is orientated to Pin 1.11.2-2 VFD Replacement Drawing 3.E. Ensure that the 14 pin female connector on the VFD Display Board seats properly on the 14-pin male connector on the Display Interface Board. Reconnect the Ribbon Cable to connector P1 on the Display Interface Board. Secure the Display Interface Board to the six standoffs installed on the Mounting Bracket using 6-32 x 0.E.E.

REPLACING .SURGE .12.IS .1-3) 3. . Using a long length flat screwdriver. (Photo 4. Pull the screw driver downward to release the latch and the Suppressor should pop up off of the Din Rail.SUPPRESSOR .UNIT .SIGNAL .Removal .E.12.SURE . reach down into the enclosure and place the flat head into the release latch on the Suppressor. OFF . .ANy .12.1-3 Release Latch Photo 4.E .Control .E. (Photo 4.TURNED .12.12 .SUPPRESSOR 4 .SUPPRESSOR 4 .12 .4 .12.Surge .E.COMPONENTS! (06/10) Note: Assumed starting position is facing the upright electronic unit with the enclosure door open.POWER .E.12.E .AND .12 .12.1-4 Suppressor Released Photo 4.12.1 .E.1-2) 2. CAUTION: .1-1): 1.1-5 Suppressor Removed 158 REXA X2 Series TS&R Manual .Signal .E. (Photo 4.E.Electrical Repairs SURGE .12.E.BEFORE . Disconnect output wires from the Suppressor.MAKE .IS .2-1 Replacement Suppressor Photo 4. (Photo 4. You can now remove the Suppressor.1-4) 4.(Photo .E .DISCONNECTED . REPLACING .E.1-1 Signal Surge Suppressor Photo 4. .of .1-5) Photo 4.E.12.THE .SURGE .* CONTROL . Suppressor .1-2 output Wires Photo 4.

12.DP9.E.12. Replace the wires into their respective locations and screw them in. (STD .Replacement .3-3 Input wires Electrical Repairs – 06/10 159 .2D. Signal . .3 . Locate the replacement Suppressor.E. .SUPPRESSOR .3-3) Photo 4. .E.3-2) Photo 4.2 .E. Open the fuse holder to ensure that no power comes on while you are working on the unit.Surge .E.2-1) 2.1/2D.E .3-1 Fuse 3.12 . Make sure that the power to the unit is off.DP40) 4 .12.12 . (Photo 4. Place the Suppressor into position between the two end stops and snap it into place on the DIN Rail. .of .2-2 Position Suppressor Photo 4. (Photo 4.12. Locate the AC Power Surge Suppressor. The Control Signal Surge Suppressor is now replaced.2-2) 3.E .3-2 AC Power Surge Suppressor Photo 4.Surge . Photo 4.X2 Troubleshooting and Repair Manual SURGE .12.Suppressor: 1.Removal .the .3-1) 2.SUPPRESSOR 4 .12.E. .E.E.1-2) 4.of .E.12.E. .12.12. . (Photo 4.E.C.B.D.AC .12.2-3 Suppressor Replaced AC .Control . . (Photo 4.12. (Photo 4.Suppressor: 1. Unscrew the power input wires from the Surge Suppressor. (Photo 4. .SURGE . .

3-4) 5.12.Power .3-6 Release latch Photo 4.12.E.3-5 All power wires removed Photo 4.12.Replacement . Now all power wires are removed from the Surge Suppressor.E .Suppressor: 1.the .E. Unscrew the power output wires from the Surge Suppressor. (Photo 4.INTERFACE 4.12.3-4 output wires Photo 4. (Photo 4.AC .E. Remove the Surge Suppressor.12.E.3-7) (06/10) Photo 4.12 .E.41) 160 REXA X2 Series TS&R Manual . (Photo 4.4 .E. (Photo 4.of .Surge . Place a long.Electrical Repairs HART® .12.12.3-5) 6. 9. (Photo 4. . Push down and towards the Suppressor to release it from the Din Rail.E.3-7 Unit with AC Surge Suppressor removed 4 .12.3-6) 7. Locate the replacement Surge Suppressor. 8. The AC Power Surge Suppressor is now removed.12. narrow flat head screw driver in the release latch of the Surge Suppressor.E.E.

12. Close the fuse block (Photo 4. 6.3-1) and return power to the unit. Brown) (Photo 4.4-2 Input and output wires Electrical Repairs – 06/10 161 .12. The Surge Suppressor is now replaced. Screw the 3 power input wires back into the Surge Suppressor. If the unit powers up normally. the Surge Protector was successfully replaced. Screw the 3 power output wires into the Surge Suppressor. Photo 4. The power wires are now reconnected.E. (From left to right: Blue.12.4-1 AC Surge Suppressor Photo 4. 5. (From left to right: Blue.INTERFACE 2.E.X2 Troubleshooting and Repair Manual HART® .12.E.4-2) 4.E.12. Brown) (Photo 4.4-2) 3.E. Green (GND). Green (GND).

1-1 HART interface assembly Photo 4.4 .E. 3.Hart .13. .13. Remove the Control Signal wires from the board. OFF .1 .BEFORE .(S97695) . Remove the Phillips head mounting screws from the four corners of the Hart board and set aside for mounting the replacement.13.SURE .13.E.TURNED .DISCONNECTED .POWER .E.(See . 1.1-1) .Photo .REPLACING .13 .IS .Interface .E. CAUTION: .13.UNIT .E.ANy . (Photo 4.13.of .E .1-2) These wires are gray and gray/white and are screwed into the two terminals (CS.Electrical Repairs HART® .COMPONENTS! (06/10) 4 .AND .1-2 Control signal wires Photo 4. Assembly . ASSEMBLy . (Photo 4.13.& CS+) on top of the board.MAKE .INTERFACE . Unscrew these terminals and remove the wires.1-3 Terminals CS.1-5 Removal from standoffs and CPU pins 162 REXA X2 Series TS&R Manual .E .1-4) Photo 4. .E.THE .13. REPLACING .IS .1-4 Mounting screws Photo 4.13 .E.E.and CS+ 2.INTERFACE 4 .HART® . (Photo 4.Removal .E .the .1-3) Photo 4. .13 .

Interface .2-1) 2.13.INTERFACE 4. Place the gray/white wire under the ‘CS+’ terminal and turn the screw to clamp the wire in.E .2-2) 4.2-2 Hart board on standoffs 5. Secure the Hart board to the standoffs with the 4 screws set aside during removal.E.Hart .13.1-5) 3.Assembly: 1.X2 Troubleshooting and Repair Manual HART® .13. The Hart Interface Assembly is now removed.E.2-1 Hart interface board 4 . Locate the replacement board.13.E. 6.E.Replacement . Make sure that your replacement board has been pre-programmed before you install it. 5. Electrical Repairs – 06/10 163 . (Photo 4. (Photo 4.1-4) Photo 4.13.13. Place the gray wire under the ‘CS-’ terminal and turn the screw to clamp the wire in. (Photo 4.13 . The connector on the bottom of the board should match up perfectly with the pins on the CPU board. Reconnect the control signal wires. Lift the Hart board up to remove it from the standoffs and to disconnect it from the CPU pins. Firmly push the board down so that it rests on the 4 standoffs at the corners.E. (Photo 4.13.1-6 Hart interface board removed Photo 4.1-6) Photo 4.of . (Photo 4.the .2 .13. .E.E. Place the Hart board on top of the CPU board.13.E. Return power to the unit and check for proper functionality.E.1-5) It may be necessary to wiggle the board forward and back slightly while lifting in order to make its removal easier. (Photo 4.

Electrical Repairs
FOUNDATION .FIELDBUS
4 .E .14 . .REPLACING .FIELDBUS .ASSEMBLy
. CAUTION: . .MAKE .SURE .THE .UNIT .IS .TURNED . OFF .AND .POWER .IS .DISCONNECTED .BEFORE . REPLACING .ANy .COMPONENTS!

(06/10)

4 .E .14 .1 . .Removal .of .the .Foundation . Fieldbus .Assembly .(Photo .4 .E .14 .1-1)

Photo 4.E.14.1-2 Signal Wires

Photo 4.E.14.1-1 Foundation Fieldbus Assembly

1. Remove the signal wires coming from the Foundation Fieldbus that are screwed into the Signal Input terminal (unlabeled) (Photo 4.E.14.1-2). 2. Using a small flat-head screwdriver unscrew the wires from the terminal. 3. Unscrew the entire assembly from the CPU mounted standoffs setting aside the 4 Phillips-head screws to be used in the replacement. (Photo 4.E.14.1-3,4). 4. Slowly remove the assembly from the CPU by pulling upwards. 5. It may be necessary to wiggle the assembly up and down while pulling in order to ensure that the pins on the top of the CPU and the connector on the bottom of the assembly aren’t bent or damaged. (Photo 4.E.14.1-5).

Photo 4.E.14.1-3 Mounted Standoffs

Photo 4.E.14.1-4 Mounting Screws

Photo 4.E.14.1-5 CPU pins

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FOUNDATION .FIELDBUS
4 .E .14 .2 . .Replacement .of .the .Foundation . Fieldbus .Assembly .(Photo .4 .E .14 .2-1)

Photo 4.E.14.2-1 Foundation Fieldbus

1. Ensure that the power is off to the unit and the Foundation Fieldbus. 2. Carefully place the replacement assembly on top of the CPU and standoffs, being sure to properly line up the pins on the CPU and the connector on the bottom of the Fieldbus Assembly. (Photo 4.E.14.2-2) 3. Firmly press the assembly down so that it is seated atop the standoffs and is snugly fitted with the pins. 4. Mount the assembly to the standoffs. Using the 4 Phillipshead screws that had been set aside, screw them into the four corners of the assembly and into the threaded standoff holes. (Photo 4.E.14.2-3) 5. Connect the two signal wires. These wires are non-polar, so it makes no difference which wires you screw into which terminal as long as one wire goes into each terminal. (Photo 4.E.14.1-2) 6. Return power to the electronics unit and to the Foundation Fieldbus.
Photo 4.E.14.2-3 Threaded standoff holes

Photo 4.E.14.2-2 Pins

Electrical Repairs – 06/10

165

Electrical Repairs
EMI ./ .RFI .FILTER
4 .E .15 . .REPLACING .EMI ./ .RFI .FILTER

(06/10)

Photo 4.E.15 EMI/RFI Filter, bracket & wires

.

CAUTION: . .MAKE .SURE .THE .UNIT .IS .TURNED . OFF .AND .POWER .IS .DISCONNECTED .BEFORE . REPLACING .ANy .COMPONENTS!
Photo 4.E.15.1-3 Detached output wires

4 .E .15 .1 . .Removal .of .the .Filter:
1. Pull the fuse holder open to make sure that no power goes to the unit while it is being serviced. (Photo 4.E.15.1-1) 2. Locate the Filter and remove the power input wires to the Filter. Needle nose pliers may be needed to remove the connectors, as the connections are very secure. (Photo 4.E.15.1-2)

Photo 4.E.15.1-4 Bracket screw removal

Photo 4.E.15.1-1 open fuse holder

Photo 4.E.15.1-2 Detached input wires Photo 4.E.15.1-5 Bracket, filter removed

3. Remove the power output wired to the Filter. Again, use needle nose pliers if necessary. (Photo 4.E.15.1-3)

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EMI ./ .RFI .FILTER
4. Use a flat head screwdriver to remove the two screws that mount the Filter to the bracket. Set the screws aside for the replacement process. (Photo 4.E.15.1-4) 5. Remove the Filter. (Photo 4.E.15.1-5)

4 .E .15 .2 . .Replacement .of .the .Filter:
1. Use the mounting screws, mount the replacement Filter to the bracket. (Photo 4.E.15.1-4,5) 2. Reconnect the 3 power input wires to the right side of the filter. The Green/Yellow (GND) wire connects to the left pin, The Blue (Neutral) wire connects to the top right pin and the Brown (Line) wire connects to the bottom right pin. (Photo 4.E.15.2-1) 3. Give the wires a light tug to make sure the connections are secure.
Photo 4.E.15.2-1 Three power input wires

4. Reconnect the 2 power output wires to the left side of the filter. The Blue (Neutral) wire connects to the top pin and the Brown (Line) wire connects to the bottom pin. (Photo 4.E.15.2-2) 5. The filter replacement is complete (Photo 4.E.15.2-3); close the fuse holder (Photo 4.E.15.1-1) and return power to the unit. 6. If the unit starts up and initializes properly the replacement is complete.

Photo 4.E.15.2-2 Two power output wires

Photo 4.E.15.2-3 Complete Filter replacement

Electrical Repairs – 06/10

167

Electrical Repairs
REMOTE .MOUNTED .FEEDBACK .BOARD
4 .E .16 . .REPLACING .REMOTE . MOUNTED .FEEDBACK .BOARD

(06/10)

Photo 4.E.16 Feedback Board

.

CAUTION: . .MAKE .SURE .THE .UNIT .IS .TURNED . OFF .AND .POWER .IS .DISCONNECTED .BEFORE . REPLACING .ANy .COMPONENTS!

4 .E .16 .1 . .Removal .of .Feedback .Board
1. Using a small flat head screwdriver, remove the feedback wires (White, Red & Black) from the Feedback Board terminals TB1 & TB2. (Photo 4.E.16.1-1,2)

Photo 4.E.16.1-3 Feedback mounting screws Photo 4.E.16.1-1 Feedback wires at TB1 & TB2 Photo 4.E.16.1-2 Feedback Board wires removed

2. Locate and remove the 2 Phillips head screws used to mount the Feedback Board to the mounting plate. (Photo 4.E.16.1-3) 3. Set these screws aside, as they will be needed to mount the replacement Feedback Board. 4. Remove the Feedback Board from the mounting plate. (Photo 4.E.16.1-4)
Photo 4.E.16.1-4 Feedback mounting plate

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REMOTE .MOUNTED .FEEDBACK .BOARD
4 .E .16 .2 . .Replacement .of .Feedback .Board

Photo 4.E.16.2-1 Feedback Board

1. Using the screws that were previously set aside, mount the new Feedback Board to the mounting plate. (Photo 4.E.16.1-4) 2. Using the small flat head screwdriver, screw the wires into their respective locations. The wires from the CPU screw into Feedback Board terminal TB2 and the wires from the actuator screw into terminal TB1.
Note: The labels on the terminals dictate which wire goes to which terminal. (W-White, R-Red & B-Black) (Photo 4.E.16.2-2)

3. Power up the unit and check the display to make sure it does not read a feedback error (Fb bad). 4. The Feedback Board is now successfully replaced.

Photo 4.E.16-2 Feedback Board reconnected

Electrical Repairs – 06/10

169

2.E. both ends will be flat and it may be inserted either way.(SINGLE .1 .Electrical Repairs FUSES 4 .a . OFF .3 . 3.AND .17.17-3 3-phase 240+ Vac Photo 4.DOUBLE .ANy .1-1 open single pole Photo 4.POLE. 4) Note: The placement of the fuse(s) differs.BEFORE . POLE.TURNED . .E.MAKE . With a Ferraz Shawmut fuse holder the nipple end goes in first and the flat end is facing out.17.E.17.SURE .1-3 open 3-phase 4 .E. It may sometimes be necessary to use needle nose pliers or a similar tool to remove the fuse Photo 4. .17 . If the fuse in use is CE Approved. With a Bussman fuse holder the flat end of the fuse will go in first and the nipple end will be facing out.17.1-2 open double pole Photo 4. Locate and pull open the fuse holder to reveal the fuse(s) inside and note its placement in the holder.17-1 Single pole 120 Vac Photo 4.PHASE) (06/10) Photo 4.3.UNIT .E .THE .COMPONENTS! Photo 4.Fuse 1. .IS .4) 2.17 .E.E.1-4 open CE single pole 170 REXA X2 Series TS&R Manual .E.E.IS . REPLACING .FUSES . (Photos 4.POWER . .REPLACING .DISCONNECTED .of .1-1.E. 2.E. (Photos 4. Remove the fuse(s) from the fuse holder.17-2 Double pole 240 Vac Photo 4.1-1.Removal .17. CAUTION: . .17.17-4 CE approved Single pole 120 Vac .E .

17. 4 .1-1.2-2.E. If the unit powers up properly then the fuse replacement was successful and is now complete.2-3 Fuse placement Photo 4. Return power to the unit.17. Ensure that the replacement fuse(s) are of the same amperage and voltage rating. Close the fuse holder. Do not confuse the spent fuse with the functioning replacement fuse. 2 & 3.Fuse 1.X2 Troubleshooting and Repair Manual FUSES 3. 5. Locate and ensure that the amperage and voltage ratings are the same as the fuse that is being replaced. Photo 4.of . Note the amperage before discarding the spent fuse.a .17.) 4. (See Photo 4.2-2 Fuse insertion Photo 4.E.E.17.2 .E. Position the replacement fuse in the holder the same way that the previous fuse was installed.17.Replacement .E.2-4 Completed fuse replacement Electrical Repairs – 06/10 171 .17.E .E.2-1 Fuse Photo 4.) 3.17 . 2. . 3 & 4. (See Photo 4.

18.E.2-1 Switch assemebly 172 REXA X2 Series TS&R Manual . Finish unscrewing the bolt by hand. REPLACING .E . OFF .18.1-5 Switch label and bolt Photo 4.1-4) 4.18.AND .TURNED .18.18 .E.E.18.Electrical Repairs SWITCHES 4 . (Photo 4.SWITCH (06/10) Photo 4.COMPONENTS! 4 .1-2 open/off/Closed wiring Photo 4. (Photo 4.Switch 1.E.1-1) 2. CAUTION: .E . . (Photo 4.SURE . Open the enclosure door to access the wiring to the switch you wish to replace.1-3 Man/Auto wiring Photo 4.18 External switches Photo 4.18 .18.IS .DISCONNECTED .18.BEFORE . Photo 4.E.E.18.External .MAKE . Locate the correct switch and unscrew the wires from the back.1 . Remove the Switch.1-4 Switch bolt Photo 4.18.THE . Remove the bolt and the aluminum switch label.UNIT . .EXTERNAL .REPLACING .18.ANy . Close the enclosure door and loosen the large bolt— secures the switch to the control box—with an adjustable wrench.of .E.1-2 or 3 ) 3.1-5) 5.POWER .Removal . . “OFF/OPEN/CLOSE” is now on the left and “MAN/AUTO” is now on the right.E. (Photo 4.E.E.E.IS .1-1 Interior switch wiring .

Figure 4. N.C.18.C. N. N.18 . Photo 4.E.O.O. Front View P97630 Back View P97630 Front View P98144 Back View P98144 Figure 4.E.18. Place the switch inside of the notched hole in the enclosure door. Photo 4.18. N. 7.E.External .O.C. N.O. Using an adjustable wrench.2 . N. N.C. Wire the replacement switch as indicated in the Wiring Diagram.Switch 1.18. N.18. N.O. Place the bolt over the switch handle and hand tighten the bolt while lining up and straightening the switch and label.2-4 Manual /Auto wiring OPEN OFF CLOSE N. tighten the bolt just enough to lock the switch and label securely in place. Remove the bolt from the new switch assembly.E. Place the switch position label over the switch handle.2-4. MAN AUTO N. N.18.O.18.O.C. 6.E.E.1-5) 4. (Also see “OFF/OPEN/ CLOSE” Switch. N.18.18. (Photo 4.2-1) 2. (Photo 4. Power up the electronics and test each switch that was replaced to make sure that it is wired correctly and is operational.2-5 . (Photo 4. N.) 8.2-5 Switch wiring diagram Electrical Repairs – 06/10 173 .E.E.2-3 or “MAN /AUTO.X2 Troubleshooting and Repair Manual SWITCHES 4 . . N.E .C.Replacement .C.C.2-3 open/off/Closed wiring Photo 4. N. Open the enclosure door to access the switch wiring.2-2 Notched enclosure hole Photo 4.of .2-2) 3. NOTE: THERE IS A RED JUMPER WIRE INSTALLED BY THE VENDOR ON SWITCH P97630 THAT WILL NEED TO BE REMOVED.O.” Photo 4.E.E.18. 5.

.

Mechanical Repair ACCUMULATOR JUNCTION BOX 4 . .M .M.COMPONENT .X2 Troubleshooting and Repair Manual 4.1 .IDENTIFICATION CYLINDER COVER MOTOR Figure 4.M.1-1 REXA Linear Cylinder Component Identification Mechanical Repairs – 06/10 175 .

M.1-2 REXA Rotary Cylinder with Spring Fail MOTOR ROTARY Figure 4.M.Mechanical Repair (06/10) MOTOR ROTARY Figure 4.1-3 REXA Rotary Cylinder Fail in Place 176 REXA X2 Series TS&R Manual .

1-4 REXA Rotary Cylinder with Accumulator Package Mechanical Repair – 06/10 177 .X2 Troubleshooting and Repair Manual ROTARY MOTOR ACCUMULATOR JUNCTION BOX HIGH SPEED HIGH SPEED SOLENOID Figure 4.M.

. (06/10) 2 7" 16 Figure 4. To visually identify the size of the power module. see Figures 4. There are many different configurations of REXA Xpac actuators.21.OVERVIEW All REXA Xpac actuators consist of a motor. but in some cases there are multiple power modules on one actuator assembly. The details for identifying all REXA models by our labeling system can be found in the Section 1.M. Also. 2. The key identifying features are the shape and length of the motor.Mechanical Repair POWER .M.MODULE 4 . 3 & 4.1 of this manual. All REXA Power Modules have many common parts and repair procedures. Two characterizing features are the size and number of Power Modules.2 . a pumping system and a housing assembly referred to as the Power Module.2.M .2-1: B Power Module 178 REXA X2 Series TS&R Manual . please note that each actuator will have at least one power module.

X2 Troubleshooting and Repair Manual POWER .M.M.2-2: C Power Module 8 1" 2 Figure 4.2-3: ½ D Power Module Mechanical Repair – 06/10 179 .MODULE 5" Figure 4.

2-4: D Power Module NoTE: With the exception of pump and motor sizing. all REXA Power Modules share many of the same components encountered during a rebuild.M.MODULE (06/10) 7 98" Figure 4.Mechanical Repair POWER . 180 REXA X2 Series TS&R Manual . we will refer to rebuilding only one module in this guide. and point out the differences between different-sized Power Modules as needed. For this reason.

2.is .POWER . NoTE: On some modules the dual gauges on the module may not read zero.3. Repair of the power module will require removing the unit from service.must . (Refer to Figure 4. If the reservoir does not pull in it may be necessary to push it in.service .performed . .1.any .X2 Troubleshooting and Repair Manual POWER . It may be possible for certain repairs to be performed without removing the units from the installation site.Removal 1.loads . One way to do this is by turning the bypass counterclockwise. NoTE: Due to the large number of custom applications of REXA actuators this manual doesn’t show the exact steps to removing the power module but rather the general procedure that should be followed.MODULE 4 . Mechanical Repair – 06/10 181 .All . 4 .the . Extra hazards may result from this type of repair and are not covered in the scope of this manual.3 . but it is safe to proceed if they are both reading equal values.M .REMOVAL . Ensure that all pressure gauges read zero before disconnecting any pressure lines.external .before .3 .MODULE . 5. CAUTIoN: . 3. 4. NoTE: Tag and Lock-Out the unit for repair in accordance with local procedures. from . Consult the factory for further information. Disconnect the external conduit and wiring running to the power module.1 .be . .M .) The reservoir should pull in forcing out oil from the removed port. Ensure that power has been turned off to the unit.removed . An oil drain bin should be ready to catch any oil that may drain from disconnecting lines. .actuator . NoTE: Oil is under low pressure in the reservoir and will squirt out when reservoir plugs are removed. Disconnect either reservoir plug with the oil drain pan underneath.M.

7.M. Disconnect any external plumbing to the module.3. Place the module over the oil drain pan and remove the lower reservoir plug on the module.MODULE (06/10) Figure 4. this will allow the remaining oil to drain from the lower port. 8. This should allow you to completely remove the module for repair. 182 REXA X2 Series TS&R Manual . Remove the mounting screws from the module. Re-install the reservoir port plug. 9.1 Power Module 6.Mechanical Repair POWER . pressure and reservoir parts. Remove the upper reservoir plug on the module. 10.

3.Reservoir . .Spring .include: . Remove the retaining ring.Cover .REBUILD . .retaining . . Upper Reservoir/ Drain Port Reservoir Piston Indicator Assembly Reservoir Piston O-Ring Reservoir Spring Reservoir Cover Resevoir Scale Cover Seal Retaining Ring Cover O-Ring Lower Reservoir/ Drain Port Figure 4.Disassembly .removing . Mechanical Repair – 06/10 183 . 1.Required: .the .20 .Piston .(ALL . Use two 6-32 screws and thread them into the two tapped holes in the reservoir cover. 2.as . .compression.to .and . .when .M.Cover .4 . Kit .releases . CAUTION: .cover .O-ring .RESERVOIR . . . .under . Make sure actuator has been drained of oil and both drain plugs have been removed. NoTE: All B. pre-load .lb . CAUTION: . It may be necessary to tap in on the reservoir cover to allow the retaining ring to release. .M .Seal.4 .Seal . . 4.care . and . .this . ring . C.SIzE . Remove the reservoir scale.O-ring .M .1 . .Kit . 1/2D and D size modules share the same reservoir components and rebuild procedures.MODULES) Parts .Reservoir .spring .pre-loaded .4 Reservoir Rebuild 4 .X2 Troubleshooting and Repair Manual RESERVOIR 4 . .Use .

184 REXA X2 Series TS&R Manual . Remove the reservoir indicator piston assembly by pulling on the indicator. It is necessary to hold the reservoir spring compressed while installing the retaining ring. be cautious.4 . If they are deep enough to be felt. EXTERNAL Figure 4.M . 7.M .Mechanical Repair RESERVOIR 5.2 .4. Remove and discard the reservoir piston O-ring. 8. 4. Re-install the reservoir cover and retaining ring. 3. the reservoir has a spring load.and . . 5. 6. Clean all components in a solvent/parts washer to remove all dirt and contaminants. Clean out the reservoir cavity and be careful not to introduce any contaminants to the system. Remove the spring. Inspect reservoir bore for scratches. 6. replace power module body. While doing so.Inspection 1. 2.Re-Assembly 1. Pull the reservoir cover off using the two 6-32 screws. 2.3: Inner motor seal 7. Slide the new reservoir piston O-ring over reservoir piston indicator assembly. Fit the new cover seal into the reservoir cover groove.Cleaning . If a full rebuild is being performed proceed to the removal sections for the relevant motor before re-assembly.M. 4.4 . Slide reservoir assembly back into the reservoir cavity. Drop the reservoir spring over the indicator on the reservoir assembly. . Remove and discard the cover O-ring from the reservoir cover. 4 .3 . Remove and discard the cover seal from the reservoir cover. Install the new cover O-ring in the O-ring groove on the outside of the cover. (06/10) 4 . 3. Lubricate the two new O-rings and the new cover seal. NoTE: The O-ring side of the seal must face away from the module body.

and . Remove the four motor screws and four lock washers. NoTE: It may be necessary to lightly tap the sides of the motor with a rubber mallet to break the seal between the motor and module body.4 Motor Replacement 4 .motor . .M .5 .to .Required: .MODULE .1 .seals .Appropriate . EAL . Kit . . NoTE: All modules share similar motor mounting procedures and components.the . Mechanical Repair – 06/10 185 . Pull the motor straight out.MOTOR . Remove the four screws holding the wire cover on. Inner Motor Seal Motor Gasket Motor Motor Washers Wire Cover Outer Motor Seal Motor Wire Hole Motor Screws Figure 4.REPLACEMENT /S 4 .REPLACEMENT Parts . For simplicity the diagram below shows a B Module. .REPLACEMENT . .M . 2. 4.Kit .Motor .SEAL .5 .X2 Troubleshooting and Repair Manual MOTOR . Locate and disconnect the motor wires from the terminal block under wire cover.Seal . 5.motors .include . . Ensure the actuator has been drained of oil and top drain plug has been removed. . 3.2 .M.Disassembly 1.gasket . OR .

3. These three items can be thrown out after you have located the replacement parts in your rebuild kit. Place the gasket on the motor after installing sealant.M. 4.REPLACEMENT /S 6.3 Motor Seals 2. Peel off the motor gasket and remove both motor seals.Cleaning . Clean off the motor face and casting face. If a full rebuild is being performed proceed to the removal sections for the relevant power train before re-assembly. .M . Coat both new motor seals with petroleum jelly and insert as shown below into the module.5 . 5. Feed the wires into the motor wire hole on the module and slide the motor back into place.5 .and . Seal will not function properly if installed backwards. 186 REXA X2 Series TS&R Manual . and around the motor and mounting through-holes. Orientate the motor shaft so that it engages with the pump coupling in the module. .5.M . Turn the motor shaft back and forth to ensure it is aligned with the pump coupling. Apply sealant on boss of the motor area of the module. EAL . The motor should sit flush to the casting. Remove any remaining gasket material and sealant.3 .Mechanical Repair MOTOR . 4 . EXTERNAL Figure 4. . (06/10) 4 .2 .Re-Assembly 1. 2.Inspection 1.

screws . Apply blue Loctite® and install the four motor washers.before . 8.turning .X2 Troubleshooting and Repair Manual MOTOR . refer to Appendix P of the IOM.occur .or .the .shaft. 7.the .place .force . 6.mounting . .or . Torque the screws in place to 50 lb·in. .REPLACEMENT /S . motor .damage . . Reinstall the wire cover and torque the screws in place to 50 lb·in.will . For detailed wiring diagram. EAL . tighten .the . .in .Do . Mechanical Repair – 06/10 187 .not .motor . . CAUTION: . Re-wire the motor to match the wire colors.

Clean out any sealant that may be left.Disassembly .AND .Mechanical Repair FILL .M .OVERFILL .M .6 .M. Note: All B.VALVES 4 . C./ .2 . Screw both valves in place as shown above.M . 4 .6 . Fill Valve (06/10) Reservoir Overfill Valve Figure 4. .OVERFILL . .1 .6 . 1 2 Remove the reservoir overfill valve and the fill valve. 1 2 Coat the threads of the new overfill valve and the fill valve with thread sealant.VALVES . 1/2D and D size modules share the same external valves replacement procedures.FILL . 188 REXA X2 Series TS&R Manual .Re-Assembly . .6 External Valves 4 .

Mechanical Repair – 06/10 189 . Refer to Figure 4. Remove the valve bonnet (1) from the pressure relief cavity of the power module.Disassembly 1. remove the star washer (8) and the quad ring (7) from the power module side of the pressure relief. 4. 4 . Loosen the spring cap (5) by turning the cap lock nut (10) clockwise and remove both items. 2.M. .M . remove the valve stem (2) and O-ring (6). On the power module side.106 1 Valve Seat 1 2 8 7 12 11 9 6 1 4 3 10 5 FIGURE 4.X2 Troubleshooting and Repair Manual PRESSURE . Remove the spring (4) and the spring seat (3).PRESSURE .M.7 PRESSURE LIMITING VALVE NoTE: If the power module is still attached to the actuator system then make sure all pressure is relieved by turning the bypass counter clockwise. 3.M.VALVE Table 4.015 Qty 1 1 1 1 1 1 Item 7 8 9 10 11 12 Description Qty Quad Ring 1 Star Washer 1 Valve Seat Retainer 1 Cap Lock Nut 1 O-ring .VALVE 4 .7 . .List Item 1 2 3 4 5 6 Description Valve Bonnet Valve Stem Spring Seat Spring Spring Cap O-ring .7 Parts .M . Using a pick.LIMITING . Not doing so may result in damage to unit and or injury to self.LIMITING .1-1: Linear Cylinder Component Identification.1 .7 .

7 . Torque the valve bonnet (1) to 25 lb•in.and . remove the valve seat retainer (9). 2. Install the quad ring (7) and star washer (8) into the power module side of the valve bonnet (1). 6. Using a pick. (06/10) 4 .LIMITING . 3 4 5 Using an allen wrench.2 .Mechanical Repair PRESSURE . 7. Using an allen wrench.VALVE 5. .M . place the valve seat retainer (9) into the cavity and torque to 25 lb•in. Inspect for any metal files or gall marks in the pressure relief cavity 4 . Apply multi-purpose grease to the tip of the valve stem (2) and insert the valve stem (2) into the power module side of the valve bonnet (1).Cleaning . 2.Inspection 1.Re-assembly 1. remove the O-ring (11) inside the power module along with the valve seat (12).7 . The pressure relief O-rings (6 & 11) and quad ring (7) can be thrown out after you have located the replacement parts in your rebuild kit. Install the O-ring (6) onto valve bonnet (1) and insert the valve bonnet (1) into the power module. Clean out pressure relief cavity and be careful not to introduce any contaminants into the system 3. Install the valve seat (12) and O-ring (11) into the power module cavity. .3 . Insert the spring seat (3) and spring (4) inside the valve bonnet (1). Clean all components in a brake wash to remove dirt and contaminants.M . 6 7 NoTE: Refer to IOM Appendix O for adjustment range (psi) and spring color. 190 REXA X2 Series TS&R Manual . Install the cap lock nut (10) and spring cap (5) to the outside of the valve bonnet (1). Lubricate the new O-rings (6 & 11) and quad ring (7) before reinstalling.

1 . .Disassembly 1. 2.X2 Troubleshooting and Repair Manual DRIVE .Kit NoTE: All B.TRAIN .) Remove four screws holding wire cover on. . For spring fail units only: a.8 . 3.Required: .TRAIN 4 .M .REMOVAL . C.Module . Remove the four drive train mounting screws and lock washers.Rebuild . Disconnect two white solenoid wires.8 Drive Train 4 .DRIVE . Only the pump internals and coupling shafts are different. 1/2D and D size modules share the same rebuild procedures. Parts . . Mechanical Repair – 06/10 191 .) b. Pressure Gages Drive Train Mounting Screws Drive Train Drive Train Reservoir O-Ring Drive Train Pressure O-Rings Washers Solenoid Wire Hole Pump Coupling Solenoid O-Ring Wire Cover Figure 4. Ensure the oil has been drained from the module prior to disassembling the power train.M . Pull the power train assembly straight out.8 . 2.M.

) Feed solenoid wires into the module.) b.or . Apply blue Loctite® on the drive train screws and install the four lock washers. Clean out the inside of the module body.mounting .screws . (06/10) 4 . 3. Place a few dabs of petroleum jelly or grease over the O-ring to hold it in place.the .will . and D shafts can be installed either side first because they are symmetrical. Slide the power train assembly back into the module. There is no polarity. Align the pump shaft orientation to the coupling so they mate up during installation. Torque wire cover bolts to 50 lb·in.and .8 .train . . 2. It is best if the reservoir and the motor are completely removed and the body can be completely sprayed out with contact cleaner. wire cavity O-rings and drive train reservoir O-ring. tighten .place . Remove the pump coupling.8 .occur! 4.damage . .force .TRAIN 4.Inspection 1. The ½ D shaft will only go in one way.turning .the .before . .in . .M . so either wire can go to either solenoid terminal. CAUTION: . Check the fit of the shaft to the pump for correct orientation.Mechanical Repair DRIVE . The B.M . motor . Proceed with the drive train rebuild prior to assembly if performing a full rebuild. 4 .Re-Assembly 1. Reconnect both wires to the terminal strip under the wire cover.drive . Place the new O-rings into the O-ring grooves of the module. C.not . 2. It is necessary to rotate the motor shaft to allow the pump coupling to align properly. 5. Remove the drive train pressure O-rings. Torque screws in place to 190 lb·in. Drop the pump coupling shaft into the shaft hole in the module. . c.Cleaning .or . For spring fail only: a. 5.2 .3 . Reinstall wire cover.shaft.Do .the .) 192 REXA X2 Series TS&R Manual .

and .serviceable . Laying it on its output shaft will cause damage and it will need to be replaced.Module .opened .be .Rebuild .M . The .4 Drive Train Rebuild 4 . Place it driven shaft up. Figure 4.are . Mechanical Repair – 06/10 193 .Disassembly 1.8 .Rebuild Parts .5 .M. Remove the four 1/4-20 pump mounting bolts and lock washers. 1/2 D and D size modules share the same rebuild procedures. C.should .Required: .X2 Troubleshooting and Repair Manual DRIVE . or .8. pumps .never . Only the pump internals and coupling shafts are different. .not .8 . Separate the pump from the rest of the assembly.M .Drive .TRAIN 4 . Do not remove the #10-32 pump screws holding the pump together! 2. . Take extreme care to protect the drive shaft of the pump once it is unbolted.cleaned. .Train .Kit NoTE: All B.4 .

CAUTION: .the . . .balls . Torque the 4 screws in place to 100 lb·in. Place a few dabs of petroleum jelly over the O-ring to hold them in place.manifold . these .8. . match .Re-Assembly 1. Continue to the suction check valve replacement and manifold rebuild before reassembly if a full rebuild is being preformed. 5.and .check .4.Cleaning . Place new O-rings into the O-ring groove of the flow match valve face. Apply blue Loctite® on the flow match screws and install the 4 lock washers. between . Remove the four 1/4-20 flow match valve screws and lock washers.while .and . 2. Remove the four O-rings from the flow match valve face. . 3.lose . Remove both pump O-rings from the face of the flow match valve (FMV). 2. 4.separating .6 . Replace pump if the shaft will not turn or binding is felt.TRAIN 3.two .the . The gauges are on the top side along with the corner cutouts of the flow match valve. The outer surfaces of these components can be cleaned in solvent.M . Extreme care must be taken to ensure no contaminants enter the pump or flow match valve during cleaning. 3.not . Insert a check ball then a check spring into each hole on the flow match valve. Align the flow match valve to the manifold as shown in Figure 4.valve .careful .Be . 4 .faces .springs .from . . (06/10) 4 .There .to .Mechanical Repair DRIVE .Inspection 1.the .8 .flow .7 .M.M . 194 REXA X2 Series TS&R Manual .8 . . It should be free to turn with no binding felt. Turn the pump shaft 360°.components .are .

7. Mechanical Repair – 06/10 195 . Apply blue Loctite® on the pump screws and install the four lock washers.M. Torque the screws in place to 100 lb·in.7 Flow Match Valve Face 4.X2 Troubleshooting and Repair Manual DRIVE . Align the pump to the flow match valve as shown Figure 4.TRAIN Figure 4. Note the location of the pump driven shaft.8.8.M.

CHECK .CHECK .Kit NoTE: All B.M . .1 . The suction check cavity can be cleaned with brake wash but care must be taken not to introduce any contaminants into the valve.9 .9 . Install a new suction check O-ring into the groove on the suction check.VALVE 4 . . C. 2. Remove the suction check ball and the suction check spring from the flow match body.Disassembly 1. 1/2 D and D size modules share the same rebuild procedures.Check .M .9 . 4 . 2. 3.Inspection 1. Thread in the suction check valve and torque to 250 lb·in. (06/10) Figure 4.Mechanical Repair SUCTION . . Remove the suction check valve O-ring 3.2 . Unthread the suction check valve.Re-Assembly 1.M .Cleaning .Required: .Suction .3 .M.9 . 196 REXA X2 Series TS&R Manual . .9 Suction Check Valve 4 .SUCTION . Set a new suction ball onto the spring. .VALVE Parts . 4 . Slide the new suction check spring into the valve cavity of the flow match valve.M .and .Rebuild .

X2 Troubleshooting and Repair Manual MANIFOLD 4 . high temperature kits are available with different materials. 3. High temperature units also share the same procedure.1 . 1/2 D and D size modules share the same rebuild procedures.10 . . slow speed spring fail units are different. 2.M . Mechanical Repair – 06/10 197 . Remove the four face O-rings from the gauge manifold.Disassembly 1.REBUILD Parts .Kit NoTE: All B.10 .10 Manifold 4 . Unthread all three bypass plugs from the bypass plate. Remove the bypass plate. Unthread the six bypass plate screws.STANDARD . however.MANIFOLD .Rebuild .Required: .M .M. C. . 4. .Module . Figure 4. however.

10 .Cleaning .2 . Lubricate the O-rings with petroleum jelly. the plugs will keep this plate from mounting properly in the following steps.Mechanical Repair MANIFOLD 5. Repeat this for all three plugs. apply blue Loctite® on the bypass plate screws and install the washers.Inspection Clean the bypass plate and the gauge manifold with brake wash. . Use petroleum jelly or grease to hold the O-rings in place. Figure 4. (06/10) 4 . Install new bypass plug O-rings into the O-ring groove of the bypass plug. 4 . 4.10. Install the four face O-rings into the O-ring grooves of the gauge manifold.M . Torque to 50 lb·in. Remove the gauges—if they are being replaced—at this time. If the unit is a high temperature unit it will not have gauges installed…the ports will be plugged.3 o-ring Grooves 2. use a hex head screw driver and thread the plug until it bottoms into the plate. Be careful to avoid sliding the O-ring over the threads of the bypass plug. Ensure no contaminants are allowed to enter the ports of the gauge manifold. Align the bypass plate with the gauge manifold. Once the hex protrudes through the plate enough. NoTE: If this is not done. Thread the three bypass plugs into the bypass plate.M .and . 198 REXA X2 Series TS&R Manual .3 . which can cause damage to the O-ring.10 . . 3.M.Re-Assembly 1.

2. High temperature units also share the same procedure. cam guide. 1/2 D and D size modules share the same rebuild procedures.(Solenoid .M.11 Solenoid Cover 4 . Remove the cover mounting screws and washers. Tap out the Pivot Pin in order to remove the toggle assembly. .M . Remove the two toggle mounting screws and O-rings 4.11 . C. Mechanical Repair – 06/10 199 . however. 3.Required: .X2 Troubleshooting and Repair Manual SOLENOID 4 . plunger and plunger O-ring.Disassembly . Figure 4.SOLENOID Parts . 5. Remove the three face O-rings. spring washers and spring holder. Remove the solenoid cover and cover O-ring.Cover) 1.1 .Solenoid . . . 6.M . Remove the plunger return spring. high temperature kits are available with different materials.Kit NoTE: All B.11 .Rebuild .

3 .11 . Figure 4.Inspection .M. .Re-Assembly .11 .M.M . 3.Cover) Clean all components with brake wash. Place the spring assembly into the mounting block. Figure 4.3-2 Toggle Assembly 200 REXA X2 Series TS&R Manual .2 .(Solenoid .Cleaning .M .(Solenoid . Install the Cam guide over the springs and onto the spring holder as shown above. Locate the three new spring washers from the rebuild kit.3-1 Spring Washers 2. Note the “bow” location of the spring washers in the diagram.11.Cover) 1.11. (06/10) 4 . . installing the springs in the wrong orientation will cause the bypass not to function.Mechanical Repair SOLENOID 4 . Install them onto the spring holder as shown below.and . spring holder side first.

Align the toggle assembly as shown above into the mounting block. Press the new pivot pin in place. Continue onto the setup.3-4 Mounting Block 8. Insert the plunger assembly into the mounting block as shown below. Lubricate the new O-rings. Slide the plunger O-ring over the small diameter of the plunger. Figure 4.11.M. Coat the O-rings with petroleum jelly to hold them in place during assembly.3-3 Plunger 6. Slide the plunger return spring over the plunger as shown above and install the plunger adjustment screw into the bottom of the plunger until tight.4 .section .M. Place the three face O-rings into the O-ring grooves of the mounting block. note the location of the Lock-Out hole.12. TS&R . 5. Mechanical Repair – 06/10 201 . and down to the first shoulder as shown below. Figure 4. 7.11. 9.M .X2 Troubleshooting and Repair Manual SOLENOID 4.

so either wire can go to either solenoid terminal. Remove the solenoid plunger and the plunger O-ring.4 Solenoid Manifold NoTE: Mark position of solenoid wires on terminal strip. There is no polarity. Remove solenoid wire from terminal strip.Disassembly . 1. Locate and remove all four face O-rings and the plunger spring. 202 REXA X2 Series TS&R Manual .M.(Solenoid . .Manifold) Gauge (06/10) Gauge Manifold Face O-Ring Bypass Plug Bypass O-Ring Soleniod Plate Washer Solenoid Plate Screw Soleniod Plunger Solenoid Wire Plunger Spring Solenoid Nut Washer Plunger O-Ring Solenoid O-Ring Solenoid Solenoid Adjustment Screw Figure 4.Mechanical Repair SOLENOID 4 . 3.M . 4.11 .11. Ensure power is off. Remove the solenoid plate screws and the solenoid plate.4 . 2.

6-1 Bypass Plug 6. Install new bypass plug O-rings into the O-ring groove of the bypass plug. Remove the solenoid nuts.11 .5 .Cleaning .M . Coat the O-rings with petroleum jelly or grease to hold them in place. If the solenoid is being replaced remove the solenoid adjustment screw. Install the solenoid so that the two mounting studs slide through the O-ring holes. solenoid O-rings and the solenoid. Figure 4. 3. Repeat this for both plugs. Thread both bypass plugs into the solenoid plate. Be careful to avoid sliding the O-ring over the threads of the bypass plug which can cause damage to the O-ring.11. 4 .6 . Lubricate O-rings with petroleum jelly. 5.M. 4. Install the washers and solenoid nuts to hold the solenoid in place.X2 Troubleshooting and Repair Manual SOLENOID 5. 4 . . Unthread both bypass plugs from the solenoid plate.M . . 8. 6.Manifold) Clean all components with brake wash.(Solenoid . Place the solenoid O-rings into the grooves on the solenoid plate.and . Thread solenoid wires through solenoid manifold. Once the hex protrudes through the plate enough. Remove both bypass O-rings from the bypass plugs. 7.Inspection .(Solenoid . use a hex head screw driver and thread the plug in until it bottoms into Mechanical Repair – 06/10 203 . 2.Manifold) 1. Install the solenoid adjustment screw into the solenoid if a new solenoid is being installed.11 .Re-Assembly .

Slide the plunger spring over the solenoid plunger as shown below. (06/10) Figure 4. apply blue Loctite® on the solenoid plate screws and install the washers. 7.4. Feed solenoid wires through solenoid plate and engage manifold according to Figure 4. 10. 204 REXA X2 Series TS&R Manual . 8. Use petroleum jelly to hold the O-rings in place. Torque to 50 lb·in.M. If this is not done the plugs will keep this plate from mounting properly later in the following steps. Slide this O-ring over the solenoid plunger as shown below.Mechanical Repair SOLENOID the plate. Terminate accordingly. Feed solenoid wires through power module to heater cavity junction box. Install the four face O-rings into the O-ring grooves of the gauge manifold. Coat the plunger O-ring with petroleum jelly for lubrication. Insert the solenoid plunger assembly into the center hole of the solenoid plate.M.11.11. Making sure the plunger spring stays in place.6-2 Solenoid Manifold Plunger 9. It will slide in O-ring side first. align the solenoid plate to the gauge manifold.

The gap should measure . Re-apply power to the actuator. Press in on the solenoid plunger and measure the gap between the plunger and solenoid body using feeler gauges. The gap should measure 0. If this measurement is out of specification it will be necessary to remove the plunger and readjust the solenoid adjustment screw.12-2 Plunger 2. .12 . Remove plunger adjusting screw. The best way to measure the gap is to Mechanical Repair – 06/10 205 . Toggle the cover / latch assembly into the latched position shown below (the lever in the vertical position). aligning the notch in the cover with the solenoid wires. and replace screw.M.X2 Troubleshooting and Repair Manual SOLENOID 4 .SOLENOID .UP 1. apply blue Loctite®. Photo 4. place the cover/latch assembly over the solenoid. a. Figure 4. 4. With the solenoid energized.12-1 Cover/Latch Assembly 3.M.) Measure the gap between the bottom of the cover and the solenoid mounting plate.020 inches.SET .12-1 Plunger Gap Photo 4.M .015 inches.M.

Now insert the other .) NoTE: A Padlock with 3/16″ diameter shank may be used in place of the tethered pin to prevent unauthorized toggling of the lever.) Adjust the gap to .Mechanical Repair SOLENOID insert one .020 inches by removing the cover and turning the screw directly in the center of the cover cavity in or out until the desired gap is achieved. 206 REXA X2 Series TS&R Manual .12-3 Cover/Mounting Plate b.) e. Re-adjust as required to achieve the proper gap.) d.020 feeler gauge under the cover directly opposite the first gauge as shown below. Remove the cover and re-set the gap in step b.M. Reinstall the cover with the lever in the unlatched position.) Install the tethered pin to lock the handle in place. Place the lever in the unlatched position and attach the cover. (06/10) Photo 4. f.020 feeler gauge under one edge of the cover and press down on the cover directly over the gauge. c.

X2 Troubleshooting and Repair Manual SOLENOID 4 . . Solenoid must re-engage immediately upon power up. Manually latch the solenoid and turn power off. Remove power to trip the solenoid. Reapply power to the actuator and immediately stroke the unit fully against the spring. Observing the CPU display may test rotary units drift.) Remove the cover/latch assembly. except in the case of a B module Class 1 Division 2 which can take up to 10 seconds to begin moving.) Mechanical Repair – 06/10 207 . Back out the adjustment screw in the cover cavity ¼ turn and retest.M. Figure 4. c. No drift is to be allowed for 5 minutes.13 . Record current position.M .TESTING 1.13 Latching Cover VerIfIcatIon of ManUal latchIng operatIon b. Continue to adjust at ¼ turn intervals and retest as required until the re-latching of the solenoid is immediate.) In LOCAL mode stroke the actuator against the spring to the end of travel. SetUp of the open Stop a. If it does not. proceed to the next step for adjustment of the solenoid open travel stop. Stroke the unit against the spring until the end of stroke is reached.SOLENOID . 2. The actuator should begin to move immediately.

SPEED .Mechanical Repair HIGH . 13 14 15 16 17 18 19 20 21 22 23 24 25 Description Electrical connector O-ring Set screw Coil housing Coil Assembly Spring pads Socket head screws Valve body Seat assemblies Cage Guide Set screw Locking pad Figure 4.M.14-1 Solenoid Cut-away Figure 4.SOLENOID (06/10) Table 4.14-2 High SpeedSolenoid Layout 208 REXA X2 Series TS&R Manual .M. 1 2 3 4 5 6 7 8 9 10 11 12 Description Screws Set screw Spring pad Springs Armature O-ring Backup rings O-rings Poppet O-rings Backup rings Retainer ID No.14 Solenoid Cutaway ID No.M.

5 to 150 lb·in. Pressure transducer. Installation of Repair Kit Parts into existing solenoid valves is available.2 .Description . Regulated pressure source.SPEED .3 .SOLENOIDS . However. 4 . 2 When the solenoid coil is de-energized the NO port is connected to the COM port. Orient whole unit with solenoid below valve body when pulling two sections apart as there are loose parts within solenoid.M . .Valve 1.14 . and the NO port is closed.SPEED . audible adjustable. memory pointer. 2 amperes minimum. 2.1 . Remove four socket head screws (19) securing solenoid assembly to valve body (20). Sealing force on the NC seat is provided by springs within the solenoid assembly. .HIGH .Equipment .of .X2 Troubleshooting and Repair Manual HIGH .M . and the NC port is closed. 0 to 30 lb·in. 4 . Torque wrench. . the following information is provided. Torque wrench. 5. 0 to 3 000 psig. 4. 4 . The repair kit allows users of solenoid valve to update the subject valve to the latest configuration at their own discretion. 3.SOLENOID 4 . 2 position solenoid valve.M . Sealing force on the NO seat is provided by the energized solenoid coil. This section describes installation of Repair Kit Parts and subsequent testing on this solenoid valve. .M . Electric power supply to match solenoid voltage.Disassembly 1. Mechanical Repair – 06/10 209 . 0 to 3 000 psig clean air. dial style.14 . When the solenoid coil is energized the NC port is connected to the COM port. for those valve users choosing to perform their own installation.14 . Solenoid valve is a 3 way.14 . fast response.Requirement 1.

scratches.SOLENOID 2.and . Guide (23). O-rings (10). After completing above procedure. .Initial .14 . and backup rings (11) onto poppet (9) with the exception of one O-ring (10) used on seat assembly nearest threaded end of poppet. 4 . or other damage that can affect valve performance. Check inside valve body for possibility of an O-ring remaining.Assembly 1. 3. DO NOT wash solenoid assembly. Remove armature from poppet. 2. backup rings (7). Place this one O-ring into its final location within valve body (20). 4. 5.M . Do not remove set screw or locking pad (25) unless replacement is necessary. Hold armature while turning poppet counterclockwise utilizing slot in opposite end of poppet from armature. Clean metal valve components using commercial cleaning solvents or detergent solutions. Remove retainer (12). note relative distance between armature (5) and valve body for later use. O-rings are lightly lubricated with Monsanto MCS 352 or BAC 5001 or DAC ACO-DPM 5073.5 .Parts 1. Examine the bores in valve body (20) and guide (23) for nicks and scratches that can affect a-ring sealing. . Loosen set screw (24) 2 to 3 turns. Insert poppet and associated components into valve body. Using 3/8 hex wrench secure retainer (12). Tighten set screw (24) to secure retainer. O-rings (8).Cleaning . Assemble cage (22). 3.M . Visually inspect all metal parts for nicks.4 .Examination . Discard all items from valve for which replacement parts are included in the Repair Kit.Mechanical Repair HIGH . Torque retainer 8 to 10 lb·ft. (06/10) 4 . push against threaded end of poppet until components can be removed from valve body. 2. To remove internal valve components.14 . and remove.of .SPEED . 210 REXA X2 Series TS&R Manual . seat assemblies (21).

Cap COM port. NC port open to atmosphere. Energize solenoid coil via electrical connector pins A and B.X2 Troubleshooting and Repair Manual HIGH . Connect air pressure source to NO port NC port open to atmosphere. 6. 4 . 3. springs (4).14 . 2. place valve body assembly onto coil housing (16). . While aligning pin extending from coil assembly with hole in armature assembly.M . Valve operation shall be sharp and without hesitation.SPEED .Assembly 1. Increase air pressure at NO port to 3 000 psig. Cycle valve fifteen times minimum using 70% of the valves rated voltage.14 . step #2. Then turn Mechanical Repair – 06/10 211 . turn set screw (15) clockwise until solenoid pull-in voltage is 70% of rated voltage. and spring pads (18) into coil assembly (17).Tests 1.M . 4 . Turn poppet (9) counterclockwise until air just starts to flow from NC port.14. Using 5/64 hex wrench. Apply small amount of anti-seize compound to threads on poppet (9).Final . Thread armature assembly (5) onto poppet to approximate location of preceding section 4.6 . Pin must align with hole to avoid damage. Then turn poppet clockwise until air flow just ceases. Cap COM port.M. Using 5/64 hex wrench.and .SOLENOID 5. . Torque 55 to 57 lb·ft. Remove four screws (1) securing electrical connector (13).7 . Energize solenoid coil via electrical connector pins A and B. from electrical connector end. Secure coil housing (16) to valve body (20) (orientation optional) using four cap screws (19). DE•ENERGIzE COIL.Final .Adjustment . turn set screw (15) 3 to 4 turns counterclockwise. with approximately 24 Vdc. Assemble spring pad (3). 7. NC port open to atmosphere with muffler. Connect air pressure source to NO port. Raise connector sufficiently to access space beneath.3. Turn poppet an additional 1/8 to 1/4 turn clockwise. Turn poppet (9) counterclockwise until air just starts to flow from NC port. polarity optional.

4. Cap NC port. Starting at zero volts. Apply 4500 psig air to COM port for one (1) minute. Testing completed. 3. There shall be no signs of external leakage or damage. counterclockwise to lower voltage. Pull-In Voltage Test a. Remove pressure and voltage. NC port open to atmosphere with muffler. Energize solenoid coil with 24 Vdc. Leakage at NO port not to exceed 1 bubble in 2 minutes. Apply 3000 psig air to COM port.) b. Reduce pressure to zero. Solenoid coil de-energized. Leakage at NC port not to exceed 1 bubble in 2 minutes.SOLENOID poppet clockwise until air flow just ceases. gradually increase voltage to solenoid until valve actuates. Internal Leakage Test a. Energize solenoid coil with 24 Vdc. DE-ENERGIzE COIL. (06/10) 5. 2 Torque screws 8 to 10 inch-pounds. Turn poppet an additional 1/8 to 1/4 turn clockwise.Mechanical Repair HIGH . External Leakage and Proof Pressure Test a. Secure electrical connector (13) to coil housing (16) with four screws (1). turn set screw (15) until solenoid pull-in voltage is nearly 70% of rated voltage. 212 REXA X2 Series TS&R Manual . There shall be no signs of external leakage or damage.) 6.) 7. Apply 4500 psig air to COM port for one (1) minute. Turn clockwise to increase voltage.) b. Using 5/64 hex wrench.SPEED . Valve shall actuate at or below 70% of rated voltage. Apply 3000 psig air to COM port. Remove pressure and voltage. Solenoid coil de-energized. 2.) Cap NO port. Cap NO and NC ports. Apply 3000 psig air to COM port. Cap NO port. Cap NO and NC ports. Reduce pressure to zero.

Re-Assembly . .15 .2 . Screw hand wheel back onto the end of the motor.DRILLDRIVE 4 . Replace the O-ring.M.M . 1 2 3 Refer to Figure 4. . Figure 4.Required: .Kit .DRILL .15 Handwheel/Drilldrive 4 . Mechanical Repair – 06/10 213 . 4 . .15 .Wheel . 1 2 3 Replace the spring.DRIVE .Hand .15 and remove the hand wheel from the back end of the motor by unscrewing the housing.1 .WHEEL .M .HAND .Disassembly . Parts .15 ./ .X2 Troubleshooting and Repair Manual HANDWHEEL . Remove the O-ring./ .M .M. Remove the spring.

Remove any tubing connected to the hand pump and mounting plates. Refer to TS&R Appendix F for information on indicator clamping.M. 6.1 . (06/10) Photo 4. 1. Remove the mounting plate from the hand pump.Mechanical Repair MANUAL .HAND . 5.16 Manual Hand Pump 4 .PUMP .M .16 . Unscrew the bolts that connect the hand pump to the mounting plate. 4. .Removal .16 . Clamp the oil reservoir. 2. 214 REXA X2 Series TS&R Manual . If the gear pump or suction check valves fail. Open bypass and confirm that there is no internal pressure. . Place an oil drain pan under the hand pump. 3.PUMP 4 . Turn off power to the unit. The manual hydraulic pump needs only the cylinder side of the hydraulic circuit and the FMV check valves to be in working order.M .HAND . the manual hydraulic pump will still provide a means for manual operation.

HAND .Replacement 1. 5.PUMP 4 . Replace hand pump and mounting plate assembly to the original position. Attach the mounting plate to the new hand pump. 3. Mechanical Repair – 06/10 215 .16 . NoTE: It is not advisable to leave the lever in the piston assembly when the hydraulic pump is not in use.M . insert lever into the piston assembly and pump the handle up and down. 6. Unclamp oil reservoir and bleed the unit.2 .X2 Troubleshooting and Repair Manual MANUAL . 2. To reverse the direction of the pump either push in or pull out on the black knob located on the bottom of the pump. Re-attach the tubing to the hand pump. To operate the hand pump. . 4.

.M .M. Piston O-ring. Cylinder Body End Seal Piston Rod Piston Rod Extension Qty 2 2 2 2 2 2 1 1 216 REXA X2 Series TS&R Manual .List Item .COMMERCIAL . shank. Lipseal Type Tie Rod Tie Rod Nut Retainer Wiper Seal. Piston Backup Washer.M.LINEAR . The sizes range from 2 000 –10 000 lb greater than 6˝ stroke and greater than 10 000 lb with almost any stroke size required. Non-cushioned Cap. (06/10) Figure 4. There are two bushings with seals.CyLINDERS The cylinder consists of a double rod end through shaft cylinder. Gland Description Table 4. Gland Lipseal. piston disk.17 .CyLINDERS 4 . Qty No . Gland to Head Seal O-ring.17 Parts . piston seals and cylinder body.LINEAR . a wiper.17 Commercial Linear Cylinder Item . Ported. Ported Non-cushioned Gland Cylinder Body Piston Body.Mechanical Repair COMMERCIAL . Description 1 1 2 1 1 4 4 2 2 41 42 43 44 45 47 57 60 Lipseal. 1 7 14 15 17 19 23 27 40 Head. Gland Backup Washer. No .

1-1: Retainer Plate 2. .17. NoTE: Residual oil will drain at this point.of .17.and .1-2: Tools for gland removal and installation 6. Remove the cap assembly (7). Photo 4. Photo 4M. Repair of the cylinder will require removing the unit from service. Remove the fasteners holding the feedback arm to the cylinder shaft. Remove all plates. .discharging . 4.17.M.M . Remove tubing feeding the cylinder. 1.Replacement .17 . 60). Clamp the reservoir piston to prevent oil from discharging from power module when removing.oil .X2 Troubleshooting and Repair Manual COMMERCIAL .1-3: Parker tool for gland removal Photo 4M.aware . fasteners and legs as necessary to free the cylinder from the assembly. Remove the cylinder from the unit.17. the .17. 3. unprotected . 5. Remove the piston and piston rod assembly (57.While .ports .1 .Disassembly NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local procedures. Loosen and remove the four tie rod nuts (23).cylinder.disassembling .CyLINDERS 4 . .LINEAR .be . Remove the bronze gland (14) on the retainer plate (27) by unscrewing counter clockwise.1-5: Piston Rod Assembly Mechanical Repair – 06/10 217 .assembling . Seals .from . Remove the retainer plate (27).1-4: Cap/Head Assembly Photo 4M. Photo 4M. CAUTION: . 17. 7.

3. Slide the piston disk assembly to the end of the body to expose the seal groove with no seals. Ensure that the gland is installed only two turns.M. Remove the seals from the piston disk (17) and inspect the disk for wear and damage.2 . Tie rods may be left installed in the retainer.17 . NoTE: Lubricate all surfaces. Inspect the cylinder body (15) for wear and damage.Reassembly 1. 9. If required. install new wiper seal (40). Do not slide the piston disk assembly all the way out of the cylinder body.Mechanical Repair COMMERCIAL . Remove and discard the following O-rings: two glands to head seals (45) and two cylinder body end seals (47). Remove the seals (40.M .17.1-8: Piston disk with one set of seals into cylinder Photo 4.LINEAR . Slide the piston disk assembly (57. seals and O-rings prior to assembly. Replace as necessary.17. Replace as necessary. 10. Replace as necessary. 11. (06/10) Photo 4M. 4. gland lipseal (41) and gland backup washer (43) into the gland. 60) back into the cylinder body (15). 17. Remove the cylinder body (15). Install new cylinder body end seal O-ring (47) into head (1) and cap (7). Also install new gland to head seal (45). 12.17.CyLINDERS 8.1-7: Piston Disk Assembly Photo 4M. 60) into the cylinder body (14). Replace as necessary.1-6: Cylinder Body 4 .17. 41 & 43) from the glands (14) and inspect the gland for wear and damage. Slide the piston disk assembly (57. Photo 4M. Place one new set of piston lipseals (42) and back-up washer (44) on one side of the piston disk with the open end toward the shaft end. Inspect the O-ring seating surface for damage. Remove the head assembly (1). 6. 13. 2.1-9: Piston disk ready for second set of seals REXA X2 Series TS&R Manual 218 . 5. Install gland (14) to retainer (27). 17. Place the other new piston lipseal (42) and back-up washer (44) on the piston disk. install tie rods to retainer so that the tie rod ends are flush to the retainer. . With both glands.

17. Table 4.17. 17.1-10: Gland and Seals Photo 4M. 11.Rod Size Bore Size (lb·ft) 1. Thread the tie rod nuts onto the tie rods.1-12: Head/Cap Seals Mechanical Repair – 06/10 219 . 8. Slip the cylinder body (15) with piston disk assembly (57.LINEAR . 10.5" 2. tubing and feedback items.75" 3" 3" 3. Install retainer plate (27) to cap (7). Tighten gland (14) so that the top of the gland to the retainer is 0.17. Install unit to valve. Install cap (7) to cylinder body (15).1-11: Head/Cap Seals L2 000 L5 000 L10 000 L15 000 L20 000 L40 000 L60 000 L80 000 Photo 4M.5" 18 45 120 131 131 528 800 1 168 Photo 4M.17. 60) over the tie rods (19) and onto the head.5" 3.25" 4" 4" 6" 7" 8" 1" 1.CyLINDERS 7. Torque the tie rod nuts (23) in accordance with Table 4. 12.M. Install head (1) to retainer (27).X2 Troubleshooting and Repair Manual COMMERCIAL .75" 2" 2.25".M.2 ToRQUE (lb·ft) Cylinder Rod Tie . Install power module.2.5" 1. 9.17.

220 REXA X2 Series TS&R Manual .M .remove .18 .injury . . .LINEAR .Cylinder . Due to the large number of custom applications of REXA actuators this manual doesn’t show the exact steps to separate the power module but rather the general procedure that should be followed.Block .the . To identify the model/size of your cylinder reference the model number.LINEAR .18 .CAUTION: . Repair of the linear cylinder will require removing the unit from service. You can also confirm the output by measuring the shank diameter and reference the table below.CyLINDERS The current linear block cylinder line consists of five models. For more details on Model numbering refer to TS&R section 1. Clamp the reservoir indicator to prevent oil from draining out of the power module when disconnecting tubing.M . actuator .Procedure .in .1 .2.All . 2. 4″ and 6″. In some cases the power will be needed to remove these loads. The first digit will be an L signifying it is a linear stroke.on . .result . Shank Diameter 9/16″ 9/16″ 1″ 1-5/16″ Cylinder Size L500 L2 000 L4 000 L10 000 (06/10) 4 . . . These models can reach force outputs up to 10 000 lb.Mechanical Repair REXA . . Remove any external loads or springs attached to the unit before attempting any service.can . Be careful not to damage indicator. for .Removal .REXA .death .loads .1.properly .Failure .to .REXA .or . Each of these models comes in different stroke options typically 2″. The next three to five digits before the dash is the thrust output. 1.Cylinders NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local procedures.CyLINDERS 4 .

Remove the cylinder from its mounting. Remove the power module from the cylinder. Clean the module thoroughly.LINEAR .CyLINDERS 3.X2 Troubleshooting and Repair Manual REXA . It is important that no contaminants enter the internals of the actuator. 4. Mechanical Repair – 06/10 221 . 5.

M.2-A Parts List Item 1 2 3 4 5 6 7 8 9 Description Cylinder Body Bracket.150 #10 Lock Washer Anti-Vibration Tape Foam Qty 1 1 1 1 4 1 4 1 4 .18 .18 . . 222 REXA X2 Series TS&R Manual .2 . .Feedback .2-A .18.4 .Inch.Mechanical Repair L500 .Inch .Seal . Cylinder SHCS #10-32 × .000 .Cylinder .6 . .Rebuild .Removal .¾ .M.L2 .000 .1 .L500 . . For .2-A L500 & 2 000 Feedback Removal Table 4.Inch.M .Procedure .18.Units PARTS REQUIRED: .2 .Inch . (06/10) A .Stroke ..Cylinder .M .2-A and remove the 4 SHCS (14) and lock washers (16).Disassembly 1.and .and . 17 3 11 7 16 14 2 8 4 10 1 5 9 6 12 9 15 13 Figure 4.75 O-ring Viton .18.Kit . Refer to Figure 4.CyLINDERS 4 ..LINEAR . .M.L2 . Circuit Board Mounting Potentiometer Spring Washers #10-32 Shldr Scr Feedback Arm Hex Nut Std #4-40 (SS) Roll Pin (Spring SCR Pan HD SL #6-32NC Qty 1 1 1 2 1 1 1 1 4 Item 10 11 12 13 14 15 16 17 Description Anti-Rotation Rod Retaining Ring Circuit Board Assembly Cover. .

Remove the retaining ring (11). The O-ring can be thrown out once the replacement is identified from the rebuild kit. 7. unscrew the feedback arm (6). Screw in the anti rotation rod (10).. Apply the bottom of the potentiometer with anti-vibration foam (17) then slide the potentiometer (3) into the potentiometer (3) hole in the cylinder (1).L2 . Thread the hex nut (7) on.X2 Troubleshooting and Repair Manual L500 . Petroleum jelly can be used to prevent the O-ring from falling out. Remove the 2 SCR pan head screws (9) to remove the circuit board (12). 8. While holding the potentiometer (3) rod. 3. Disconnect all wires connected to the circuit board (12) 4. Align the 2 spring washers (4) to the end of the shank.2 .CyLINDERS 2.M . 2. Thread the potentiometer (3) into the feedback arm (6) over the spring washers (4). Install the shoulder screw (5). Record all termination points. Remove the shoulder screw (5) and hex nut (7). anti rotation rod (10). 3. Mechanical Repair – 06/10 223 .2-A . Snap the retaining ring (11) into the ring groove above the pot. Align the circuit board bracket (2) with its mounting hole on the cylinder and install the two SCR pan HD SL (9).. Ensure that the cable slides into its slot. Anytime the pot is removed you will need to adjust the pot height. 4. 6. . 4 . Screw the feedback arm (6) onto the potentiometer (3).LINEAR . Install a new O-ring (15) into the cover (13).18 . 7. 5. and the potentiometer (3). 5. Remove the 2 spring washers (4).Reassembly 1.000 . Remove the 2 SCR pan head screws (9) to remove the circuit board bracket (2) 6. Remove the feedback cover (13) and O-ring (15). Rewire all wires back to the circuit board (12). Proceed to bushing rebuild Section B to continue disassembly.

.assembling . the .oil .CyLINDERS 8.LINEAR .M.discharging .L2 .Bushing .cylinder.18.2-B L500 & 2 000 Bushing Rebuild Table 4.Rebuild 4 6 3 2 5 7 1 8 Figure 4.from . . Place the cylinder cover (13) with the O-ring (15) back over the cylinder and install the 4 SHCS (14) with washers (16).and . . unprotected . (06/10) B . .of .18.disassembling .000 . .2-B Parts List Item 1 2 3 4 5 6 7 8 Bushing Rod Wiper Rod Seal Bushing End Cover O-ring Viton ..M.Mechanical Repair L500 .026 SCR Flat HD Hex #4-40 Nylon Tipped Set Screw Description Cylinder Body Qty 1 2 2 2 2 2 8 4 CAUTION: .beware .While .ports . 224 REXA X2 Series TS&R Manual .

4 . Continue to section C to complete disassembly.and . 2.2-B . Install the new O-ring (6) into the O-ring groove on the outside of the bushing (2). 3. .2-B and remove the two set screws (8). 3.M . Use an allen wrench to remove the 4 SCR flat HD HEX (7) from the bushing end cover (5) and remove the rod seal (4). Install the new rod wiper (3) with the pointed edge out.2-B .M. 5.18 . Clean the bushings (2) in solvent and dry.Cleaning . The open side must face the cylinder body. Use a pick to remove the rod wiper (3) and O-ring (6).CyLINDER 4 .3 .18 .Reassembly 1. 4 . Lightly tap the opposite end of the shaft to force the bushing out. 3. (2).X2 Troubleshooting and Repair Manual L500 . Inspect the bushing (2) bore for damage. 2.1 . use a dead blow hammer or soft face mallet. If any visual marks can be felt in the bushing (2) bore then the bushing (2) will need to be replaced. Install the new rod seals (4) into the seal groove. 2.Inspection 1. NoTE: If there is a spacer sleeve on the piston rod it needs to be reassembled on the same side or damage and improper operation may result.Disassembly NoTE: To prevent damage.2-B . These items can be thrown out once the replacement parts are located from the rebuild kit. Repeat steps 1-5 on the opposite end.18.. Installing these backwards will cause the seals to fail.M .L2 . Using a spanner wrench. remove the bushing. 6. 1.000 .M . .2 . . Mechanical Repair – 06/10 225 . 4.18 . Refer to Figure 4.LINEAR .. Lubricate the O-ring (6) and seals (3 & 4) prior to installation.

Ensure the orientation of the output end. Tighten with spanner wrench.000 . Repeat steps 1. . Go back to the feedback reassembly in Section A to complete the rebuild.discharging .and .L2 .ports .7 for the opposite end of the cylinder.2-C Parts List Item 2 7 1 3 5 1 2 3 4 5 6 7 6 4 Shank Piston Split Ring Retainer Split Ring Retaing Ring O-ring Viton .18. .While . .from . Place the bushing end cover (5) back over the end of the bushing (2) and bolt the 4 hex head screws (7) back into the bushing (2). CAUTION: .disassembling .of .Mechanical Repair L500 . Table 4.oil . (06/10) C . Slide the piston assembly into the cylinder bore.beware .M.CyLINDER 4. 8. 226 REXA X2 Series TS&R Manual .18.Rebuild . 7.cylinder. .assembling . Place Loctite® onto the two set screws (4) and install into the cylinder body. the .Shank .2-C L500 & 2 000 Shank Rebuild . 6.. Turn the screws 1-¼ turns once you feel the screw contact the bushing (2).22 Description Piston Seal Qty 2 1 1 1 4 1 1 Figure 4. unprotected . Lightly tap the assembly in if necessary.. 10.LINEAR .M. Slide the bushing (2) into the cylinder body (1). 5. 9.

If burs are found replace the piston disk.. These three items can be thrown out once you have located the new replacements from your rebuild kit. Ensure no residue or contaminants remain. Refer to Figure 4. 4 . The second set of split rings (5) should now fall off.000 .M.X2 Troubleshooting and Repair Manual L500 ..2-C when ordering replacement parts.18 . 4.2 . Ensure any new cylinders have ball plugs installed before reassembly. Slide the split ring retainer (4) off exposing the first set of split rings (5). . 2.2-C and remove the retaining ring (6). split ring retainer (4).and .18. If the anodizing has worn through or any scuff marks can be felt replace the cylinder body. 2. Be very cautious not to get contaminants into the ports.1 .CyLINDER 4 . Inspect the bore for wear or scratches.LINEAR .M.18 .2-C . 3.Inspection 1. Inspect the piston disk (3) for any burs around the outer surface that would scratch into the cylinder bore.M . Clean the cylinder bore in brake wash and dry. Mechanical Repair – 06/10 227 . . Care must be taken not to scratch the shaft finish.Disassembly 1. If any contaminates get into the system they could cause drifting problems. 3. piston (3).2-C . 4. Reference Table 4. Clean the piston shaft (2).Cleaning . Remove the O-ring (7) from the piston shank (2) and both piston seals (1) from the piston disk (3). Inspect the piston shaft (2) for scratches.L2 . If you can detect scratches by running your finger nail around the shaft then the shaft will need to be replaced. split rings (5) and the retaining rings (6) in brake wash and dry.18.M . 5. Separate the split rings (5) and slide the piston disk (3) off.

Reassembly 1. 6. Install the second set of split rings (5) into the upper slot on the shank (2).18 ..2-C . (06/10) 3. 7.000 . O-ring groove is located between the two identical split ring grooves.L2 . 4. Slide the new piston seals (1) into the piston disk (3).Mechanical Repair L500 .CyLINDER 4 . Note: The split ring retainer can only go on one way and should set flush to the piston disk (3). 5.M . Slide the O-ring (7) into the O-ring groove of the shank (2). 8. Install one set of split rings (5) into the lower split ring slot of the shank (2).3 . Note: The O-ring side of the seals must face away from each other. . Lubricate the new piston seals (4). Go to the bushing rebuild reassembly Section B to continue the rebuild.LINEAR . Improper orientation will cause the seals to leak. Install the retaining ring (6). Lubricate the new O-ring. Slide the piston (3) on from the top insuring the counter bore fits over the split ring (5). 2. Slide the split ring retainer (4) over the second set of split rings (2). 228 REXA X2 Series TS&R Manual ..

Kit A . Circuit Board Mounting SBCHS ¼-20 O-ring Viton . .18. 13 12 5 6 4 14 3 2 17 11 10 15 1 7 8 9 16 Figure 4.STROKE . .156 L4.3-A Parts List Item 1 2 3 4 5 6 7 8 9 Description L4.AND .000 Cylinder Cover Spring Lock Washer Qty 1 1 1 2 1 1 1 1 4 Item 10 11 12 13 14 15 16 17 Description Spring Washers #10-32 Shldr Scr Circuit Board Assembly SCR Pan HD SL #6-32NC Hex Nut Std #4-40 (SS) Anti-Rotation Rod SHCS .000 . .000 .INCH .Seal .UNITS PARTS REQUIRED: . FOR .CyLINDER 4 .CyLINDER .Cylinder .M. . .X2 Troubleshooting and Repair Manual L4 .3 .18 .3-A L4 000 Feedback Removal Table 4.000 Cylinder Body Potentiometer Retaining Ring Feedback Takeoff Arm Bracket.25-20 Anti-Vibration Tape Foam Qty 1 1 1 1 4 1 4 1 Mechanical Repair – 06/10 229 .18.INCH . .¾ .M .4 .REBUILD .M.L4 .LINEAR .INCH.2 .PROCEDURE .Removal .Feedback .

CyLINDER 4 .3-A . Remove the 2 spring washers (10). Spin the feedback arm (4) over the spring washers (10) and line up the holes.M .000 . .3-A . anti-rotation rod (15) and the potentiometer (2). Align the circuit board bracket (5) at a 45° from the edge and install the SBHCS SS screw (6).3-A and remove the 4 ¼-20 screws (16) and the 4 lock washers (9).Disassembly 1 2 Refer to Figure 4. Screw in the anti-rotation rod (15). Screw the feedback arm (4) onto the potentiometer (2).18 .M. Remove the retaining ring (3). Remove the cylinder cover (8) and O-ring (7).18. Align the 2 spring washers (10) to the end of the shank. 2 3 4 5 230 REXA X2 Series TS&R Manual . Jump to bushing rebuild Section B to continue disassembly. While holding the potentiometer (2) rod. Snap the retaining ring (3) into the ring groove above the potentiometer (2).18 .Mechanical Repair L4 .Reassembly 1 Reapply anti-vibration tape foam (17) to the base of the potentiometer (2) and slide the potentiometer (2) into the potentiometer hole in the cylinder (1). unscrew the feedback arm (4). Thread the hex nut (14) on.1 . Disconnected all wires to the circuit board (12) and remove the 2 SCR pan head screws (13) to remove the circuit board (12) Remove the SBHCS ¼-20 (6) to remove the circuit board bracket (5) Remove the shoulder screw (11) and hex nut (14). Ensure the cable slides into its slot.2 . . Install the SH shoulder screw (11).M . The O-ring can be thrown out once the replacement is identified from the rebuild kit. (06/10) 3 4 5 6 7 4 .LINEAR .

X2 Troubleshooting and Repair Manual
L4 .000 .LINEAR .CyLINDER
6 Align the circuit board (12) with its mounting hole on the circuit board bracket (5) and install the 2 SCR pan head screw (13). Rewire all connecting wires to the circuit board (12). Install a new O-ring (7) into the cover (8). Petroleum jelly can be used to hold the O-ring from falling out. Install the 4 SHCS SS ¼-20 (16) and the 4 lock washers (9).

7 8 9

B . . .Bushing .Rebuild

6 5

2 1 4

3

Figure 4.M.18.3-B L4,000 Bushing Rebuild Table 4.M.18.3-B
Parts List
Item 1 2 3 4 5 6 Description L4 000 Cylinder Body O-ring Viton - 133 Rod Wiper Nylon Tipped Set Screw ¼-20 L4 000 Bushing Rod Seal Qty 1 2 2 4 2 2

Mechanical Repair – 06/10

231

Mechanical Repair
L4 .000 .LINEAR .CyLINDER
. CAUTION: . .While .assembling .and .disassembling .

(06/10)

the .cylinder, .beware .of .oil .discharging .from . unprotected .ports .

4 .M .18 .3-B .1 . .Disassembly
NoTE: To prevent damage, use a dead blow hammer or soft face mallet.

1. Stroke the cylinder by striking it with a dead blow hammer from end to end with the open SAE ports over an oil drain bucket. Read caution above. 2. Refer to Figure 4.M.18.3-B and remove the two set screws (4). 3. Use a spanner wrench to remove the bushing (5). 4. Lightly tap the opposite end of the shaft to force the bushing (5) out. 5. Use a pick to remove the rod wiper (3), O-ring (2) and the rod seal (6). These items can be thrown out once the replacement parts are located from the rebuild kit 6. Repeat steps 2-5 on the opposite end.
NoTE: If there is a spacer sleeve on the piston rod, it needs to be reassembled on the same side or damage and improper operation may result.

4 .M .18 .3-B .2 . .Cleaning .and .Inspection
1. Clean the bushings (5) in brake wash and dry. 2. Inspect the bushing (5) bore for damage. If any visual marks can be felt by touch in the bushing (5) bore then the bushing (5) will need to be replaced. 3. Continue to Section C to complete disassembly.

4 .M .18 .3-B .3 . .Reassembly
1. Lubricate the O-ring (2) and seals (3 & 6) prior to installation.

232

REXA X2 Series TS&R Manual

X2 Troubleshooting and Repair Manual
L4 .000 .LINEAR .CyLINDER
2. Install the new rod wiper (3) with the pointed edge out. Install the new O-ring (2) into the O-ring groove on the outside of the bushing (5). 3. Install the new rod seals (6) into the seal grooves. The O-ring side must face the cylinder body. Installing these backwards will cause the seals to fail. 4 5 6 Slide the bushing (5) into the cylinder body (1). Screw in the bushing (5) into the cylinder body (1) and tighten with spanner wrench. Use Loctite® on the 2 set screws (4) and install it into the cylinder body (1). Turn the screws 1 turn once you feel the nylon bottom contact the bushing retainer. Slide the piston assembly into the cylinder bore (observe the orientation of the output end). Repeat steps 1- 6 for the opposite end of the cylinder. See the feedback reassembly Section A to complete the rebuild.

7 8 9

C . . .Shank .Rebuild

Table 4.M.18.3-C
Parts List
Item 2 7 1 3 5 1 2 3 4 5 6 7 6 4 Shank Piston Split Ring Retainer Split Ring Retaing Ring O-ring Viton - 22 Description Piston Seal Qty 2 1 1 1 4 1 1

Figure 4.M.18.3-C L4 000 Shank Rebuild

Mechanical Repair – 06/10

233

Mechanical Repair
L4 .000 .LINEAR .CyLINDER
. CAUTION: . .While .assembling .and .disassembling . the .cylinder, .be .aware .of .oil .discharging .from . unprotected .ports .

(06/10)

4 .M .18 .3-C .1 . .Disassembly
1. Refer to Figure 4.M.18.3-C and remove the retaining ring (6). Care must be taken not to scratch the shaft finish. 2. Slide the split ring retainer (4) off exposing the first set of split rings (5). 3. Separate the split rings (5) and slide the piston disk (3) off. The second set of split rings (5) should now fall off. 4. Remove the O-ring (7) from the piston shank (2) and both piston seals (1) from the piston disk (3). These three items can be thrown out once you have located the new replacements from your rebuild kit.

4 .M .18 .3-C .2 . .Cleaning .and .Inspection
1. Clean the piston shaft (2), piston (3), split ring retainer (4), split rings (5) and the retaining rings (6) in solvent and dry. Ensure no residue or contaminants remain. 2. Inspect the piston shaft (2) for scratches. If you can detect scratches with your finger then the shaft (2) will need to be replaced. Reference Table 4.M.18.3-C when ordering replacement parts. 3. Inspect the piston disk (3) for any burs around the outer surface that would scratch into the cylinder bore. If burs are found replace the piston disk. 4. Clean the cylinder bore in brake wash and dry. Be very cautious not to get contaminants into the ports. If any contaminates get into the system they could cause drifting problems. 5. Inspect the bore for wear or scratches. If the anodizing has worn through or any scuff marks can be felt replace the cylinder body. Reference Figure 4.M.18.3-C. Ensure that any new cylinders have ball plugs installed before reassembly.

234

REXA X2 Series TS&R Manual

X2 Troubleshooting and Repair Manual
L4 .000 .LINEAR .CyLINDER
4 .M .18 .3-C .3 . .Reassembly
1. Lubricate all O-rings and seals prior to assembly. Slide the new O-ring (7) into the O-ring groove of the shank (2). 2. Slide the new piston seals (1) into the piston disk (3). Note the O-ring side of the seals must face away from each other. Improper orientation will cause the seals to leak. 3. Install one set of split rings (5) into the lower split ring slot of the shank (2). 4. Slide the piston (3) on from the top insuring the counter bore fits over the split ring (5). 5. Install the second set of split rings (5) into the upper slot on the shank (2). 6. Slide the split ring retainer (4) over the second set of split rings (5).
Note: The split ring retainer can only go on one way and should be flush to the piston disk (3).

7. Install the retaining ring (6). 8. Go to the bushing rebuild reassembly and feedback reassembly to complete the rebuild.

Mechanical Repair – 06/10

235

Mechanical Repair
L10 .000 .LINEAR .CyLINDER
4 .M .18 .4 . . .L10 .000 .CyLINDER .REBUILD .PROCEDURE . FOR .2 .INCH .AND .6 .INCH .STROKE .UNITS
PARTS REQUIRED: . .Cylinder .Seal .Kit

(06/10)

A . . .Feedback .Removal .

17 5 16

12

9 7

13 11 14 6

10

4 15 1

Figure 4.M.18.4-A L10 000 Feedback Removal

8

Table 4.M.18.4-A
2 3

Parts List
Item 1 2 3 4 5 6 7 8 9 Description Cylinder Body #10 Lock Washer SHCS #10-32 × .75 Potentiometer Bracket, Circuit Board Mounting Feedback Arm Anti-Rotation Rod O-ring Viton - 150 Cover, Cylinderr Qty 1 4 4 1 1 1 1 1 1 Item 10 11 12 13 14 15 16 17 Description Retaining Ring Hex Nut Std #4-40 (SS) BHCS SS 0.25 × 20 Spring Washers #10-32 Shldr Scr Anti-Vibration Tape Foam Circuit Board Assembly SCR Pan HD SL #6-32NC Qty 1 1 1 2 1 1 1 2

236

REXA X2 Series TS&R Manual

Remove the BHCS SS ¼-20 (12) screw from the circuit board bracket (5).4-A and remove the 4 SHCS ¼-20 screws (3) and lock washers (2). Ensure the cable slides into its slot. Screw in the anti-rotation rod (7).CyLINDER 4 . Mark termination points and disconnect all wires going to the circuit board (16).M .4-A . 6. 5. anti-rotation rod (7) and the potentiometer (4).4-A . 4. The O-ring can be thrown out once the replacement is identified from the rebuild kit.18. Snap the retaining ring (10) into the ring groove above the potentiometer (4). Remove the cover (9) and O-ring (8). 2.18 . Remove the shoulder screw (14) and hex nut (11). Remove the retaining ring (10). Apply anti-vibration tape foam (15) to the base of the potentiometer (4) and slide the potentiometer (4) into the potentiometer hole in the cylinder (1).X2 Troubleshooting and Repair Manual L10 . Refer to Figure 4. Remove the 2 pan head (17) to remove the circuit board (16). 4. Thread the hex nut (11) on.000 . Continue to bushing rebuild to continue disassembly. Spin the feedback arm (6) over the spring washers (13) and line up the holes.M .Reassembly 1. Align the 2 spring washers (13) to the end of the shank. Hold the potentiometer (4) rod and unscrew the feedback arm (6).Disassembly 1. 3. Screw the feedback arm (6) onto the potentiometer (4).LINEAR . 5.M.1 . 4 . . Align the circuit board bracket (5) at a 45° from the edge and install the BHCS SS screw (12). 3.2 . Install the SH shoulder screw (14). 2. Mechanical Repair – 06/10 237 . 7.18 . Remove the 2 spring washers (13). .

oil .of . Align the circuit board (16) with its mounting hole on the circuit board bracket (5) and install the 2 SCR pan head screw (17).029 Rod Buffer Qty 1 1 2 2 8 8 1 2 7 4 8 1 5 6 3 2 6 7 8 Figure 4.Disassembly NoTE: To prevent damage. .LINEAR .beware .1 .While . 4 . . Rewire all connecting wires to the circuit board (16). CAUTION: . Install a new O-ring (8) into the cover (9). .M.Rebuild Table 4.CyLINDER 6. 8.18.ports .Top .assembling .from . (06/10) B .4-B L10 000 Top Bushing Rebuild . . .000 .18.M.cylinder.discharging .18 .M .4-B Parts List Item 1 2 3 4 5 Description L10 000 Cylinder Body L10 000 Cylinder Bushing Rod Wiper SQB Rod Seal Lockwasher SHCS SS ¼-20 O-ring Viton .and . Install the 4 SHCS ¼-20 (3) and the 4 lock washers (2).disassembling . 7. Petroleum jelly can be used to prevent the O-ring from falling out. the .Mechanical Repair L10 .4-B .Bushing . unprotected . use a dead blow hammer or soft face mallet. 9. 238 REXA X2 Series TS&R Manual .

and the rod buffer seal (8). 3. Install the new rod wiper (3) with the pointed edge out. . . Use a pick to remove the rod wiper (3). Mechanical Repair – 06/10 239 . Ensure the screw holes line up. Install the four ¼-20 screws (6) and four lock washers (5).4-B . Refer to Figure 4. 3.2 . Inspect the bushing (2) bore for damage. After the end cap and shaft sections have been completed. 2. These items can be thrown out once the replacement parts are located from the rebuild kit.4-B and remove the four ¼-20 screws (6) and four lock washers (5).18 .M.M . 2. 4. Install the new SQB rod seal (4) and rod buffer (8) into the seal grooves. 2.Cleaning .18 . slide the bushing (2) over the shank and into place. Installing these backwards will cause the seals to fail.M . Clean the bushing (2) in brake wash and dry.LINEAR . Screw two of the ¼-20 screws (6) into the threaded holes of the bushing (2) to force it out.Reassembly 1. 3.X2 Troubleshooting and Repair Manual L10 .18. 4 . O-ring (7) the SQB rod seal (4). Install the new O-ring (7) into the O-ring groove on the outside of the bushing (2). Use blue Loctite on the screws and torque to 100 lb•in. Read caution above. The open side of the SQB rod seal (4) must face the cylinder body. 4.Inspection 1.and .4-B . 4 . Stroke the cylinder by striking it with a dead blow hammer from end to end with the open SAE ports over an oil drain bucket. Lubricate the O-ring and seals prior to installation. Continue to Section C to complete disassembly.000 . If any visual marks can be felt by touch in the bushing (2) bore then the bushing (2) will need to be replaced.3 .CyLINDER 1.

18 . unprotected .ports .1 .000 .discharging .cylinder.4-C End Cap Rebuild .4-C Parts List Item 1 2 3 4 5 6 7 8 9 Description L10 000 Cylinder Body L10 000 Cylinder Bottom Cylinder end Cap Rod Wiper SQB Rod Seal Lockwasher SHCS SS ½-13 O-ring Viton . 4 . . 6. .18.disassembling .M.from .Cap . output end goes in last. Slide the piston assembly into the cylinder bore.of . .18.and . Refer to Figure 4. .assembling .Disassembly 1.CyLINDER 5. 240 REXA X2 Series TS&R Manual .Mechanical Repair L10 .M.LINEAR .While .13 screws (6) and eight lock washers (5).End .beware . Lightly tap the assembly in if necessary.M .Rebuild Table 4. CAUTION: . Go back to the end cap rebuild reassembly in Section C to continue the rebuild. (06/10) C .M.047 Rod Buffer Qty 1 1 2 2 8 8 1 1 2 5 4 9 7 8 2 6 3 1 Figure 4.4-C and remove the eight ½ .4-C .oil . the . Note the orientation of the shank.18. .040 O-ring Viton .

Clean the end cap in brake wash and dry.3 . 2. Continue to the Piston Shank Rebuild in Section D before reassembly. NoTE: If there is a spacer sleeve on the piston rod.M . and SQB rod (4) and rod buffer (9) seals. reference the Shaft Rebuild in Section D for rebuild.M . Use 2 of the SHCS SS 1/2-20 screws (6) without washers to pull it back into place. 3. 5.000 . Install the new SQB rod (4) and rod buffer (9) seals into the seal grooves. Use Blue Loctite® on the screws and torque to 65 lb•ft. then the end cap (2) will need to be replaced. Inspect the end cap (2) for damage.18 . Install the eight ½ . These items can be thrown out once the replacement parts are located from the rebuild kit. The Shaft assembly should also come out. Slide the end cap (2) over the piston rod and back into the cylinder (1).and .2 .4-C . it needs to be reassembled on the same side or damage and improper operation may result.X2 Troubleshooting and Repair Manual L10 .CyLINDER NoTE: To prevent damage.Cleaning . Install the new O-rings (7 & 8) into the appropriate O-ring grooves. 2. 4 . Install the new rod wiper (3) with the pointed edge out. The open side of the SQB rod seal (4) must face the cylinder body.LINEAR .18 . use a dead blow hammer or soft face mallet. Use a pick to remove the rod wiper (3).Reassembly 1. Lightly tap on the opposite end of the shaft to drive the end cap (2) out. 3. 4 .Inspection 1. 2. . Mechanical Repair – 06/10 241 . Installing these backwards will cause the seals to fail. If any visual marks can be felt. 3. . 4. Lubricate O-rings and seals prior to installation.4-C . O-ring (7 & 8).13 screws (6) and eight lock washers (5).

.ports . unprotected .discharging .Shank .000 .1 . Separate the split rings (5) and slide the piston disk (3) off. Go to the Feedback Rebuild Reassembly in Section A to finish the rebuild. . .4-D L10 000 Shank Rebuild .M.Disassembly 1 Refer to Figure 4.assembling . 4 .M.disassembling . . .of .beware . The second set of split rings should now fall off.oil .While .LINEAR . Slide the split ring retainer (4) off exposing the first set of split rings (5).19 .and . These three items can be thrown out once you have located the new replacements from your rebuild kit.Rebuild Table 4. Remove the O-ring (7) from the shank (2) and both piston seals (1) from the piston disk (3).18. CAUTION: .18.M.4-D .CyLINDER 6.4-D and remove the retaining ring (6).Mechanical Repair L10 .from . (06/10) D . Care must be taken not to scratch the finish of the shank. 2 3 4 242 REXA X2 Series TS&R Manual .cylinder.22 Qty 2 1 1 1 4 1 1 6 4 Figure 4.4-D Parts List 2 7 1 3 5 Item 1 2 3 4 5 6 7 Description Piston Seal Shank Piston Split Ring Retainer Split Ring Retaing Ring O-ring Viton .M .18. the .

5. Ensure the new cylinder has ball plugs installed before reassembly. Be very cautious not to get contaminants into the ports. 3.000 . Slide the split ring retainer over (4) the second set of split rings (5).18 . Mechanical Repair – 06/10 243 . 5.3 . . piston (3).2 . If you can detect scratches by running your finger nail around the shaft (2) then the shaft (2) will need to be replaced.18 . split ring retainer (4). Lubricate the new O-ring. NoTE: The O-ring side of the seals must face away from each other. Ensure no residue or contaminants remain. Inspect the piston shaft (2) for scratches.M . replace the cylinder body. If burs are found replace the piston disk (3). Improper orientation will cause the seals to leak.Cleaning . Install the second set of split rings (5) into the upper slot on the shank (2). If the anodizing has worn through or any scuff marks can be felt. 4.M .Reassembly 1. Inspect the piston disk (3) for any burs around the outer surface that would scratch into the cylinder bore. 4 . .LINEAR . Clean the cylinder bore in brake wash and dry. 3. Inspect the bore for wear or scratches.4-D .and . Slide the piston (3) on from the top insuring the counter bore fits over the split ring (5).CyLINDER 4 .4-D .X2 Troubleshooting and Repair Manual L10 . Install one set of split rings (5) into the lower split ring slot of the shank (2). 4. Slide the new O-ring (7) into the O-ring groove of the shank (2). split rings (5) and the retaining rings (6) in solvent and dry. 2. Slide the new piston seals (1) into the piston disk (3).Inspection 1. Clean the piston shaft (2). 6. 2. If any contaminates get into the system they could cause drifting problems.

8. (06/10) 7. 244 REXA X2 Series TS&R Manual . 10 . top bushing rebuild reassembly and feedback reassembly to complete. Go to end cap rebuild reassembly.CyLINDER L NoTE: The split ring retainer can only go on one way and should set flush to the piston disk (3).000 . Install the retaining ring (6). Lubricate the new piston seals (1).Mechanical Repair .LINEAR . 9.

M. . the following steps should be used as a guide: Table 4. Item 5a applies to Viton O-rings only.M. Qty Single double rack rack Figure 4.CyLINDER The actuator consists of a pinion and one or two racks located within the housing. Pressurization of alternate cylinder port(s) result in shaft rotation.19 Parts List Item no. 2 4 15* Rack Bolt 16 Piston 2 4 17 Rack 1 2 18 Relief Valve 1 1 19 Locking Screw 1 1 20 Drive Screw 4 4 21 Name Plate 1 1 22 Bearing 2 2 23 Pinion 1 1 O-ring.19 . Rack Bolt 2 4 Back-up Ring.CyLINDER 4 .X2 Troubleshooting and Repair Manual ROTARy . 1* 2 3 4* 5* 5a* 6 7 8* 9* 10 11 12 13 14* description O-ring Pinion 2 2 Housing 1 1 Rack Bearing 1 2 Wear Ring 2 4 Piston Seal 2 4 Back-up Ring 2 4 Nylon Slug 2 4 Rack Bolt 2 4 O-ring Cylinder 2 4 O-ring end Cap 2 4 Tie Rod Nut 8 16 end Cap 2 4 Cylinder Tube 2 4 Tie Rod 8 16 O-ring. Item with an asterisk denote items supplied with seal kit 2. In the event that maintenance is required.19 Rotary Cylinder Mechanical Repair – 06/10 245 .M . Bearing 1 1 24* Retainer 25 Bearing Retainer 1 1 1. The gear chamber is filled with Moly grease containing a minimum Molybdenum Disulfide (MSO2) content of 3%.ROTARy .

Screw two threaded rods into the tapped holes in piston (16) and pull free from cylinder tube (12).O-Ring . . Replace end cap(s) (11) on cylinder tube (12) and assemble tie rod nuts (10) to tie rods (13). mounting.19.Cylinder . Remove the tie rod nuts/bolts (10) from the tie rods (13).& . of .CyLINDER 4 . 5.1-A-1 Tie rod nuts/bolts Photo 4.1.) Remove Rack bolt (7).Piston .Cap . 6.M . and motor/ pump assemblies as necessary to free the cylinder from the assembly. .19 .M. feedback. Clamp the actuators reservoir piston (some units may have external reservoirs) and remove the hydraulic tubing feeding the cylinder..M . 1. .1.(5) .. (06/10) 4 . Pull end cap (11) free from the cylinder tube (12).Seals .M. 3. Perform steps A1 and A2.000 lb·in: Photo 4.1 . check gauges before proceeding. Open the manual bypass to relieve internal pressure. Remove all fasteners. For models less than 50.M .(8) . Torque the tie rod nuts/bolts per the Torque Table. Repair of the rotary actuator will require removing the unit from service. .1-A-2 End cap o-ring 4 .Seals .& .Procedures NoTE: Tag-Out and Lock-Out the unit for repair in accordance with local procedures.B . Lubricate the seal and end cap with 5W-50 oil before re-installing.) b.1-B-1 Rack bolt .19. For 50 000 lb·in and greater models: a.Mechanical Repair ROTARy .Disassembly . 4.19 .and .19.Wear .19. 2.1-B-2 Cylinder tube 246 REXA X2 Series TS&R Manual . 3.Assembly .Inspection . Photo 4. Photo 4.Inspection . 7. Remove the actuator from the driven device. 9. (4).Replacement .M. . 2.19 . Inspect and/or replace end cap O-ring (9).M.A .of . 8.End .(9) 1.Rings .Replacement .and .

M. Failure . Replace end cap (11) and tie rod nuts (10). 3.retainer .Bearing .bolt . Slide piston (16) with piston seal and wear rings assembled onto it.Berfore . Place cylinder tube (12) over rack and press in housing (2).screw .damage .the .prevent .designed .19.match .1-B-4 Cylinder o-ring 9. Inspect and/or replace wear ring (4).rack . Inspect and/or replace pinion O-ring (1) located at the “front” or blind-side of the housing (2). .Replacement .loosen .19. .bolt . 4. . . CAUTION: .the . Remove the bearing retainer O-ring (24).vibrating .lock .operation . remove the bearing retainer (25) by turning counter-clockwise.beginning. 4. 5. 8. Remove Rack bolt (7). Photo 4.. Photo 4. . . .slug . Loosen lock screw (19). Replace rack bolt (7) and torque per the torque table.M.on . threads .X2 Troubleshooting and Repair Manual ROTARy .1-C-1 Match Marking 1.) Pull cylinder tube (12) free from housing (2).from .the .will .of .19: Torque. . torque per Table 4.M. .Retainer . Inspect piston (16) and replace piston seal (5).Inspection .if . .during .marks .that .Nylon .1-B-3 Piston 7. . CAUTION: . Ensure . .M .bearing .replace .19.make . Photo 4. Remove upper bearing (22). rack . required .to .19 . .1-C-2 Lock Screw Mechanical Repair – 06/10 247 . pinion (23) and lower bearing (22).is . (used on R2 500 lb·in and above actuators only).correct .and .C . 10. Inspect and/or replace cylinder O-ring (8). into the cylinder tube (12).it . Pinion . Photo 4. .O-Rings . 6.M.M.(6) . to .re-establishment . until it contacts the rack (17). 2.loose .to .) b.on .19.CyLINDER a.and .(7).1.of .is . Using a spanner wrench. 4 .timing . .enable .

. Apply Moly grease to bearing retainer threads (25) and reinstall into housing (2).of . 3. 8.1-C-5 Upper Bearing Photo 4.19 .000 Tie .Reassembly . and upper bearing. Perform C4 through C10. Rack . Locking .marks . correct . .M . 7. Perform steps C1 through C3.of . Inspect and/or replace bearing retainer O-ring (24)..M .Disassembly ..19: Torque.re-establish . .Rod . Push the rack (17) from either end to remove from housing.Mechanical Repair ROTARy .(10) Bolt .Torque . .match . Install and tighten locking screw per Table 4. Photo 4. 2.M .Make .timing .1. Reinstall lower bearing (22). .Cylinder 1.1-C-4 Bearing Retainer o-ring Table .19 .1-B-4 Cylinder o-ring 248 REXA X2 Series TS&R Manual . (25) (19) 15 30 100 250 500 2 4 4 15 15 Photo 4. (06/10) 4 . 9.(7) 6 15 30 130 525 3 15 40 130 360 Bearing . Torque bearing retainer (25) per the torque table.000/R20.1.M. pinion (23) making sure match marks line up.Cylinder 1. Nut . 2. . .19: .4 .000 R50.M. .19.M.M.19. CAUTION: .Complete . 6. Photo 4.(lb·ft) Size R600/R1200 R2500/R5000 R10.1-C-3 Bearing Retainer 4 .000 R200. Refill gear chamber with Moly Grease. Retainer .000/R100. Screw .19. Perform B4 through B10.to .M.CyLINDER 5.000/R400.19.D . Perform steps B1 through B3.E .

X2 Troubleshooting and Repair Manual ROTARy .A .1 . Tag-Out and Lock-Out the unit for repair in accordance with local procedures. . The potentiometer is coupled to the rotary cylinder by means of a spring clip and transmits the actuator position to the CPU. .20-2) Non-contacting potentiometer When removing the rotary feedback housing cover you will see the potentiometer mounted with a black cable coming out of the potentiometer housing and four wires (white. (Photo 4. (Photo 4.20 .. Put the electronics into the “SETUP” mode and under calibration. depending on which end of the travel. 4 .FEEDBACK 4 .FEEDBACK The rotary feedback assembly consists of a housing containing either a contacting or non-contacting potentiometer. brown. 4 .M .20-3) 4 .2 .20 .Contacting .20-3 Non-contactingPotentiometer Mechanical Repair – 06/10 249 . .M .Disassembly 1. take note of the CPU display when the actuator is in the failed position. green.M .M.20 . brown.2. either position may be selected.20-2 Contacting Potentiometer Any adjustments to the rotary potentiometer will require removing the unit from service. and a shield) going to a terminal block.M. If the actuator is somewhere in the middle.Potentiometer Photo 4. . If the actuator has a spring fail option. Photo 4. scroll down to either “PL” or “PH”.20-1 Feedback housing cover Contacting potentiometer When removing the rotary feedback housing cover you will see the potentiometer mounted with three wires (orange.M. and red) coming out of the potentiometer housing and going to a terminal block.Identification Photo 4.ROTARy .M .M.20 .M.

For calibration refer to IOM . 7. Reattach the potentiometer shaft to the shaft coupling and tighten the upper set screw. If no reading is present.20.2-2) 7. . 3.2.20 . Record the reading from the display before disconnecting power.M.20-1) 5.2-3) (06/10) Photo 4. (Photo 4.2-2 Potentiometer shaft coupling Photo 4. Reinstall the new potentiometer into position on the mounting plate and bolt the two screws to the mounting plate.6.M.20.20. Modes of Operation and Control Parameters. A record of this number has been recorded on the data sheet inside the electronics enclosure.20. 4.M. 6. Screw the feedback housing cover back on and tighten securely. (Photo 4.Mechanical Repair ROTARy . Rewire the three wires to the terminal strip as labeled. Disconnect the three wires coming from the potentiometer..2-3 Mounting plate screws 250 REXA X2 Series TS&R Manual .M.20. (Photo 4.M.FEEDBACK 2. Remove the two screws holding the potentiometer to the mounting plate and remove the old potentiometer. Reconnect incoming power to the unit.Reassembly 1. (Photo 4.20. 5.section .M. 3. Photo 4.M . 2.B . Disconnect the incoming power. then move the actuator to either the full open or full closed position.M. Loosen the upper set screw on the potentiometer shaft coupling.2-1) 6.2-1 Contacting Potentiometer 4 . 4. zip-tie the three wires to the post of the potentiometer mounting plate. Unscrew the cover of the feedback housing to expose the potentiometer.

If the actuator has a spring fail option.3-3 Mounting plate screws Mechanical Repair – 06/10 251 . Photo 4.3-1 Non-contactingPotentiometer 4 .20.Non . .3-2 Upper set screw 4 . If no reading is present.3 . Disconnect the incoming power. Loosen the upper set screw on the potentiometer shaft coupling. (Photo 4. Reinstall a new potentiometer on the mounting plate and bolt the two screws to the mounting plate.20 .M. (Photo 4.20-1) 5.20 . Record the reading from the display before disconnecting power.M . Put the electronics into the “SETUP” mode and under calibration. Tag-Out and Lock-Out the unit for repair in accordance with local procedures.3-B .20.3-3) Photo 4.20. take note of the CPU display when the actuator is in the failed position..20. Remove the two screws holding the potentiometer to the mounting plate and remove the old potentiometer. 2. . Photo 4.FEEDBACK 4 .3-1) 6. depending on which end of the travel. (Photo 4. Disconnect the four wires coming from the potentiometer.Potentiometer General Any adjustments to the rotary potentiometer will require removing the unit from service. A record of this number has been recorded on the data sheet inside the electronics enclosure. either position may be selected.M .20.3-2) 7.M. then move the actuator to either the full open or full closed position. If the actuator is somewhere in the middle. scroll down to either “PL” or “PH”.20. 4.M.Reassembly 1. Unscrew the cover of the feedback housing to expose the potentiometer.Contacting .M .M.M.3-A .M.M. .20 . (Photo 4.X2 Troubleshooting and Repair Manual ROTARy ..Disassembly 1. 3.

Mechanical Repair ROTARy . Non-Contacting .20.M. (Photo 4. depending on which end of the travel. For calibration refer to IOM .section .M . If the actuator is somewhere in the middle.M . General Any adjustments to the rotary potentiometer will require removing the unit from service. Rewire the three wires to the terminal strip as labeled.6. .M. . Reconnect incoming power to the unit.Potentiometer .20 .Disassembly 1. 3.4-A .with .4-2 Pan head screws 252 REXA X2 Series TS&R Manual . scroll down to either “PL” or “PH”.M. A record of this number has been recorded on the data sheet inside the electronics enclosure. 6. Modes of Operation and Control Parameters. If the actuator has a spring fail option.20-1) Photo 4. Record the reading from the display before disconnecting power. Put the electronics into the “SETUP” mode and under calibration. zip-tie the three wires to the post of the potentiometer mounting plate. If no reading is present then move the actuator to either the full open or full closed position.Contacting . 4.4-1 Feedback board wiring Photo 4. 5.20 .4 .Retrofitting . 7. 4. 4 .20. (06/10) 4 .FEEDBACK 2. Reattach the potentiometer shaft to the shaft coupling and tighten the upper set screw. Screw the feedback housing cover back on and tighten securely. Disconnect the incoming power.or . take note of the CPU display when the actuator is in the failed position. 2. Tag-Out and Lock-Out the unit for repair in accordance with local procedures. either position may be selected. 3. Unscrew the cover of the feedback housing to expose the potentiometer.

4-B1 . 4 .Potentiometer Refer to non .20 .4-3) 8. replace feedback board with the terminal strip as pictured.4-3 Upper set screw 4 . Mechanical Repair – 06/10 253 .Contacting . Disconnect all wires going to the feedback board.M.20. (Photo 4.4-2) 7. .20.Potentiometer Refer to contacting potentiometer reassembly.20.M.Reassembly 4 . (Photo 4.M.20.X2 Troubleshooting and Repair Manual ROTARy .4-B2 . (Photo 4. . Photo 4. Loosen the upper set screw on the potentiometer shaft coupling.20 .M.Non ..4-4 Mounting screws NoTE: During reassembly.20 .FEEDBACK 5.M .20.contacting potentiometer reassembly.4-B . NoTE: During reassembly.4-1) 6. (Photo 4. ..M .M.M .M.Contacting .20. replace feedback board with the terminal strip as pictured. Remove the two screws holding the potentiometer to the mounting plate and remove the old potentiometer.4-4) Photo 4. Remove the feedback board by unscrewing the two nylon pan head screws.

REXA Linear Cylinder Potentiometer The REXA block cylinder is equipped with a contacting potentiometer located inside the cylinder block. observe the color of the marker.FEEDBACK General Depending on the type of actuator application..21 . To determine whether the potentiometer is contacting or non-contacting. The contacting potentiometer uses a black marker which slides on the sensor track. each type is designated to a particular application. To determine whether the potentiometer is contacting or non-contacting.18.M . but in some 23-inch stroke or less applications a non-contacting potentiometer is utilized. observe the color of the marker.. Note.4 . Contacting Linear Potentiometer Typically. in some cases the steps maybe the same if retrofitting a contacting potentiometer to a non-contacting potentiometer.LINEAR . Non-contacting Linear potentiometer Non-contacting linear potentiometers are usually on applications that are over 23-inch stroke. (06/10) Identification .M . For the disassembly and reassembly of the REXA block cylinder refer to TS&R . The noncontacting potentiometer uses a yellow marker which slides on the sensor track. contacting linear potentiometers are on applications that have a 23-inch stroke or less.Mechanical Repair LINEAR .FEEDBACK 4 . there are three different types of linear potentiometers. 254 REXA X2 Series TS&R Manual . but some applications use a non-contacting potentiometer.

Linear . 8. Tag-Out and Lock-Out the unit for repair in accordance with local procedures. Record the reading from the display before disconnecting power.M .1-B .21 . If no reading is present.Contacting .21 . Unscrew the shoulder screw from the cylinder shaft. Unscrew the 2 SHCS and the set screw from the antivibration bracket and then remove the bracket. Detach the anti-rotation arm from the marker coupling. If the actuator is somewhere in the middle. A record of this number has been recorded on the data sheet inside the electronics enclosure. 5.FEEDBACK 4 . either position may be selected. Put the electronics into “SETUP” mode and under calibration. Mechanical Repair – 06/10 255 .21 . 3. . 6. scroll down to either “PL” or “PH”. 2. Attach the sensor track to the potentiometer bracket (wires should be on the top of the sensor) using the 2 sensor brackets and the 4 SHCS. . Attach the anti-rotation arm to the marker coupling. If the actuator has a spring fail option.X2 Troubleshooting and Repair Manual LINEAR . Disconnect all the wires attached to the feedback board. 4 . 7. depending on which end of the travel.Reassembly 1.Disassembly 1.M .1 . then move the actuator to either the full open or full closed position. Remove the sensor track by unscrewing the 4 SHCS from the 2 sensor brackets and removing the track from the potentiometer bracket. . take note of the CPU display when the actuator is in the failed position.Potentiometer General Any adjustments to the linear potentiometer will require removing the unit from service. 4. 4 . Remove the anti-rotation rod.1-A .M . 2.

then move the actuator to either the full open or full closed position. 5.Potentiometer/Retrofit General Any adjustments to the linear potentiometer will require removing the unit from service.6.. scroll down to either “PL” or “PH”. For calibration refer to IOM .21 . 2. Unscrew the 2 SHCS and the set screw from the antivibration bracket and then remove the bracket.M .Contacting . 7. either position may be selected. Disengage all the wires connecting to the feedback board. 4.2 . 4 .21 . If no reading is present. Reinsert the shoulder bolt and feedback spacer.Linear . 6. . A record of this number has been recorded on the data sheet inside the electronics enclosure. . Put the electronics into “SETUP” mode and under calibration. Modes of Operation and Control Parameters. Unscrew the 2 pan head screws and remove the feedback board. 4. depending on which end of the travel.FEEDBACK 3. Place the anti-vibration bracket back into position and screw in the 2 SHCS and set screw. 3.section . Tag-Out and Lock-Out the unit for repair in accordance with local procedures. 256 REXA X2 Series TS&R Manual . (06/10) 4 ..Non .Mechanical Repair LINEAR . Screw the anti-rotation rod back into position through the designated hole in the anti-rotation arm. If the actuator is somewhere in the middle. take note of the CPU display when the actuator is in the failed position.2-A . Rewire the sensor wires to the feedback board according to the wire schematic.M . Record the reading from the display before disconnecting power.Disassembly 1. If the actuator has a spring fail option.

4. 7. For calibration refer to . Modes of Operation and Control Parameters.X2 Troubleshooting and Repair Manual LINEAR .2-B . Remove the sensor track by unscrewing the 4 SHCS from the 2 sensor brackets and removing the track from the potentiometer bracket. 6. Remove the anti-rotation rod. 4 . Note the replacement retrofitting sensor. 5. Reinsert the shoulder bolt and feedback spacer. 6. Rewire the sensor wires to terminal strip as labeled or view wiring schematic. 2. 8. 8. Place the anti-vibration bracket back into position and screw in the 2 SHCS and set screw. the marker will be yellow.21 . Detach the anti-rotation arm from the marker coupling. Attach the sensor track to the potentiometer bracket (wires should be on the top of the sensor) using the 2 sensor brackets and the 4 SHCS.section . Unscrew the shoulder screw from the cylinder shaft.IOM .Reassembly 1.M . . 3. Mount the terminal strip in the location where the feedback board was mounted. Attach the anti-rotation arm to the marker coupling. 7. Mechanical Repair – 06/10 257 . Screw the anti-rotation rod back into position through the designated hole in the anti-rotation arm.FEEDBACK 5.6.

M.21.21.M. This can be done by sliding the magnet sensor down to the bottom of the sensor track.21.M .3-5 Sensor track & mounts 258 REXA X2 Series TS&R Manual . 2.Linear . Disconnect the non-contacting potentiometer wires from the terminal strip inside the junction box. 8.3-2 Terminal strip /wire connections Photo 4.21. Loosen the hex nut on the magnet sensor to disengage the coupling from the feedback tie rod (Photo 4.3-4).3-2) 5.Mechanical Repair LINEAR .21.21. Remove the cable from the junction box. 7.3-1).3-A .21.Disassembly 1. Unscrew the four 10-32 SHCS and lock washers and remove the sensor track mounts and track (Photo 4.3-1 Non-contacting potentiometer cover 4 .3-3).FEEDBACK 4 . 3.M. 6.3-3 Magnet sensor Photo 4. At the top of the sensor track. Run the actuator so that the cylinder is at its end stop.M.21.M .M. Unscrew the fourteen pan head screws to remove the two piece non-contacting potentiometer cover (Photo 4. remove the sensor tie rod guide by unscrewing the two 1/4-20 hex bolt and washers (Photo 4. Photo 4. . .-Contacting . .3-4 Sensor tie rod guide Photo 4.M.21.21 .3-5).M.M.21.21 .3 . Turn off power to the unit. 4. (Photo 4.Non .M.Potentiometer (06/10) Photo 4.M. Remove the magnet sensor from the sensor track.

.3-1. Use zip-ties to secure the cable. Once aligned. 6. 8.X2 Troubleshooting and Repair Manual LINEAR .21. Rewire the non-contacting potentiometer cables to the junction box as shown Photo 4.M.21. Mounting the sensor track onto the brackets. tighten the 10-32 SHCS on the brackets. Reinstall the sensor magnet by sliding the sensor magnet onto the sensor track with the coupling facing the feedback tie rod. reinstall the tie rod guide by installing the two hex head bolts and washers to clamp down the feedback tie rod guide to the sensor track. Three inches from the top of the sensor track.Reassembly 1. 7.21 . 5.21.M .M.M. Reinstall the two piece non-contacting sensor cover and reinstall the fourteen pan head screws as shown in Photo 4.3-6 and 7.3-2 or in wiring schematic.M. Reengage the magnet sensor coupling to the feedback tie rod and tighten the hex nut. Photo 4.FEEDBACK 4 .21. 3. Reinstall the four 10-32 SHCS and lock washer to the brackets for the sensor track. 2.3-6 Mechanical Repair – 06/10 259 . 4.3-B . Make sure there is a loop before any wire hole entries as shown in Photos 4.

M.FEEDBACK (06/10) Photo 4.21.Mechanical Repair LINEAR .3-7 260 REXA X2 Series TS&R Manual .

. Some valves are down seating and require a compression coupling.22-1 Downseating coupling Photo 4. NOTE: An arbor or hydraulic press will be required to disassemble the elastic coupling. Identification REXA offers two types of elastic couplings.M . One has an open frame construction. See Photo 4. The elastic coupling is attached to the actuator between the stem and the driven device.M.COUPLING General The elastic coupling is used to apply a controlled load at the seated position with linear (L series) actuators.M.M. The second type has a closed frame construction.X2 Troubleshooting and Repair Manual ELASTIC .22-2 Upseating couplling Mechanical Repair – 06/10 261 .22-2. See Photo 4. which is the downseating coupling. Photo 4. Ensure the press is in good working order and has sufficient force to handle the loads in the elastic couplings.22 .COUPLING 4 .221. Valves that are up seating require a tension coupling.ELASTIC .M. and is the upseating style.

1 NOTE: Repair of the elastic coupling will require removing the unit from service. Remove any external loads from the actuator.1 Parts List Item 1 2 3 4 5 6 7 Qty 10 1 1 1 1 1 1 Description Spring Washers Spring Stop Actuator Stem Adapter Load Pin #8-32 Set Screw Stroke Indicator Spacer (06/10) Figure 4.Spring . Remove the elastic coupling from the valve stem and actuator shaft by unthreading it from each end.Disassembly 1. Tag-Out and Lock-Out the unit for repair in accordance with local procedures.22 . (Downseating) .M .Type .M.Load .Compression .M. . 3. 4 .1-A .Elastic .Open . Remove the set screw (5) located in the thread hole of the actuator stem adapter (3).22. or removing the split clamp from the valve end.22. . 2.22 .M . The pressure gauges both should read zero. 262 REXA X2 Series TS&R Manual .Mechanical Repair ELASTIC .COUPLING 4 .Coupling Table 4.1 .

1-B . spring washer (1) stack and actuator stem adapter (3) over the spring stop (2).Reassembly 1. Insert the load pin (4) into the hole. 4 . Replace or modify components as necessary. Mechanical Repair – 06/10 263 . 7.22 . Slowly release the pressure on the coupling and note the arrangement of the spring washers (1). Reassemble by placing the stroke indicator (6). . 6. Push the load pin (4) out of the assembly. 5. 2. spacer (7). 3. Line up the spring stop (2) hole with the actuator stem adapter (3) slot. Slowly release the pressure on the spring washers (1).M .COUPLING 4. This removes the internal spring load from the load pin (4).X2 Troubleshooting and Repair Manual ELASTIC . 4. Compress the elastic coupling until the load pin (4) moves to the center of the hole in the actuator stem adapter (3). Compress the spring washers (1) until the hole and slot line up. Install the set screw using a thread lock. Make sure the flat on the pin is facing the set screw hole. 5.

Type .22 .M .M.M.Closed .Elastic .Mechanical Repair ELASTIC .COUPLING 4 .22.(Upseating) .2 . Load .22.2-1 Indicator pin Figure 4. . Photo 4.Coupling Table 4.M.22.2-2 Top plate against load 264 REXA X2 Series TS&R Manual .Spring .2 NOTE: Repair of the elastic coupling will require removing the unit from service.22.Hi Collar Travel Indicator Spring (06/10) Photo 4. Tag-Out and Lock-Out the unit for repair in accordance with local procedures.Tension .M.2 Parts List Item 1 2 3 4 5 6 7 8 9 10 Qty 1 1 1 1 8 1 8 8 1 1 Description Stem Adapter Upper Cap Stroke Indicator Disc Lower Cap Disc Spring Spacer Socket Hd Cap Screw Lockwasher .

4. Mechanical Repair – 06/10 265 . Use shims or provide the press base plate with proper clearance holes.22. Remove any external loads from the actuator. Slowly release the pressure on the coupling. Reassemble by placing the stroke indicator. spring washer stack.2-2 for reference.M. Remove bolts holding the coupling assembly together. Replace or modify components as necessary. Compress the elastic coupling until all the parts fit together then tighten the loading bolts in a start pattern.22 .X2 Troubleshooting and Repair Manual ELASTIC . Line up top plate with bolt holes in valve stem adaptor. or removing the split clamp from the valve end. .M . See Photo 2. stem adaptor.2-B . use tube stock to hold the top plate against the load. Place coupling in press. 4 .COUPLING 4 .M . Remove the top plate.2-A . 7. 6. Remove the elastic coupling from the valve stem and actuator shaft by unthreading it from each end. Please contact REXA for details if your coupling differs from the designs described above. 4. 2. 5. NOTE: Coupling design may differ on some models.Disassembly 1.22.M. cylindrical wall and note the arrangement of the spring washers. 3.22 . cylindrical wall and actuator stem adapter onto the valve step adapter. Also remove the seating indicator and spring which is under the stem adaptor. Have serial and model number ready before contacting the factory. . NOTE: Do not damage the indicator pin during this procedure. The both pressure gauges should read zero.2-1 for reference. indicator spring. 3. Install the set screw using a thread lock. 2. See Photo 4.Reassembly 1.

Photo 4. Caution: . 7. remove the bolts holding the SLC to the mounting plate.23 . 2. . Remove SLC feedback cover. remove hydraulic lines from the SLC. . .2 . 2. disconnect wires and conduit from the assembly. 4.Spring .CyLINDER The Seat Load Cylinder (SLC) is a hydraulic cushion that replaces the elastic coupling on larger REXA Actuators.M . Power the REXA unit down and follow local Lock-out/Tag-out procedures. While supporting the SLC assembly.23 . 266 REXA X2 Series TS&R Manual . .Disassembly 1. NoTE: Record the termination of the feedback wiring. shut off isolation valves on both hydraulic lines connecting the SLC. This procedure will take you through the removal.care .spring .M. Place the REXA actuator in the Set Up or Local mode.SEAT . . 3.when .lines .take . . 4 . Verify system pressure is relieved. disassembly and repair of the SLC. 4.LOAD .Mechanical Repair SEAT . 3. Holding the stem extension (5) still.CyLINDER 4 . remove jam nuts (8) relieving the spring pressure. NoTE: Record the spring pre-compression length before proceeding.and . Open manual bypass and pressure gauge isolation valves.M . 6.M .under . .Removal . removing . Remove shoulder bolts (19) from the spring button. Remove screws (16) holding spring tube (1) to cylinder assembly.LOAD . .1 .from .tension.23 Seat Load Cylinder 5.hydraulic .23 .Actuator 1.mechanical . Slide spring tube (1) off of the assembly. Leaving the isolation valves connected to the actuator. (06/10) 4 .

2 Parts List 3/8-16 THRU 8X Figure 4.LOAD . Table 4.X2 Troubleshooting and Repair Manual SEAT . Remove mounting plates (9) and adaptor port (10) from cylinder assembly. 6.M.2 SLC Mechanical Repair – 06/10 267 .CyLINDER 5. 6). Cover all open hydraulic ports and carefully grind weld away to remove extension from hydraulic cylinder.23. 7. The stem extension (5) has a tack weld holding the extension to the hydraulic cylinder.M. 4) and spring buttons (7. Some SLC assemblies have more than one spring. Remove coil spring (3.23.

23 .18 to repair the hydraulic cylinder assembly. Holding the cylinder stem (5) still.23 . Install spring tube (1) and tube mounting bolts (16). Thread stem extension (5) onto hydraulic cylinder stem.M. 4.4) and spring buttons (7. 268 REXA X2 Series TS&R Manual .5 . Replace mounting plates (9) and adaptor port (10) to cylinder assembly. 6. Re-install the SLC onto the mounting plate on the REXA unit. Tighten jam nuts (8) until the spring is compressed to the proper length.M . Refer to section 4. Close manual bypass and purge system of air. 2. (06/10) 4 . Install coil spring (3. Connect hydraulic lines.3 . .M . 5. 5. 2. 4. . Verify operation of the SLC system. thread jam nuts (8) onto the stem extension (5).23 . Adjust spring tension as needed. Use high grade thread locker to prevent the unthreading of shafts. System pressure at the seated position should be 2 000 psi. Install shoulder bolts (19) into the spring button. 4 .LOAD . connect conduit and feedback wiring.4 .Mechanical Repair SEAT . 3. 3. .CyLINDER 4 .6). 1.M . Replace SLC feedback cover.Re-Installation .Repair REXA SLC assemblies come in L2 000 and L4 000 cylinder sizes. 7.Reassembly 1. Use an anti-seize compound to prevent the assembly from galling.

M . .24.24 .M.1 .24 .PUMP 4 .X2 Troubleshooting and Repair Manual BOOSTER .PUMP 4 .BOOSTER .M .1 Booster Pump drawing (P40 shown) Mechanical Repair – 06/10 269 .Motor NoTE: P9 and P40 size modules share similar motor mounting procedures and components Figure 4. .

THE .SHAFT . Ensure that the power has been turned off from the unit. 4 . PLACE .THE .1 .A .1 Parts List (06/10) 4 . 5.DO .TIGHTEN . CAUTION: .PUMP Table 4.MOTOR . . DAMAGE .M. . Remove the four motor bolts and four lock washers.FORCE .OR .24. Ensure the actuator has been drained of oil and top drain plug has been removed.24 .SCREWS . Remove set screw from coupling (2).Disassembly 1.THE . .MOTOR . Disconnect as necessary any conduit and wires to the motor from the terminal block 3. Pull motor straight out.IN .24 .M .M .NOT . Orientate the motor shaft so that it engages with the pump coupling.Reassembly 1. 2.WILL .Mechanical Repair BOOSTER .1 .B .OR . . BEFORE . 6. 4.OCCUR! 270 REXA X2 Series TS&R Manual .MOUNTING .TURNING .

This will move the oil throughout the pump and manifold. Refer to IOM . 6. tighten adapters (19) and refill actuator with oil.Disassembly 1.24 .Pump 4 .X2 Troubleshooting and Repair Manual BOOSTER . NoTE: An oil drain bin should be ready to catch any oil that may drain from disconnecting lines. . Ensure the actuator has been drained of oil and top drain plug has been removed. Apply blue Loctite on motor bolts and install the four motor washers. Mechanical Repair – 06/10 271 . .M .A .2 .2 . Disconnect tubing from the pump. 4 .M . Replace set screw in coupling.24 .D . 2. Reconnect tubing. 3.2 . While supporting the pump. Remove two bolts (12) and two lock washers. Engage replacement pump with mounting bracket and coupling. 4. prime the pump by turning the coupling by hand approximately 5 rotations.24 . . Replace set screw in the coupling (2).B . 4. Remove pump. 5.M . Reconnect wires. 4. remove set screw from coupling (2). Confirm that all pressure gauges read zero before disconnecting any pressure lines. 2. 3. 4 . 3.for more information. Apply blue Loctite on pump screws and install the motor washers.PUMP 2.Reassembly 1. 5.Appendix . Before running motor.

3 . 4 .3 .A . While supporting the manifold.3 .PUMP 4 . This will move the oil throughout the pump and manifold.M . 3. Reconnect tubing. (06/10) 3. Confirm that all pressure gauges read zero before disconnecting any pressure lines 2. .24 .Mechanical Repair BOOSTER . Disconnect tubing from the manifold. .B .24 . turn the coupling by hand approximately 5 rotations. tighten adapters (19) and refill actuator with oil. Before running motor. Ensure the actuator has been drained of oil and top drain plug has been removed. 4. NoTE: An oil drain bin should be ready to catch any oil that may drain from disconnecting lines.M . remove four mounting bolts and take manifold off of mounting bracket. .24 .Manifold 4 . 272 REXA X2 Series TS&R Manual .Reassembly 1.M . 2. Secure the new manifold to the mounting bracket with the four mounting bolts.Disassembly 1.

repair . it .Care .fluid . NPT wire end of the transducer threads into the transducer wiring box shown below. NoTE: Ensure that the high pressure accumulator gauge located on the gauge block reads 0 psi before proceeding.500 .pressure .during .2 .M. Open the manual bypass by turning the “Bypass” hex counterclockwise on the power module’s front face.The . have .X2 Troubleshooting and Repair Manual TRANSDUCER 4 . 4 . .psi .Disassembly 1.up .to .of . The ¼" stainless steel tubing going to the transducer is the fluid side.1 .M . Transducer Transducer wiring box Figure 4.TRANSDUCER Identification Below is a typical installation of a pressure transducer on a REXA actuator.25 .REXA .25 Transducer CAUTION: .may . . .this . then the unit must be in its fail safe position and the accumulator in its trip state.be .M . . If the unit is an accumulator fail system.to .25 .must .connected . . The large.pressure . With the accumulator in the trip state this will drain the accumulator pressure to 0 psi.transducer . 2.taken . Mechanical Repair – 06/10 273 .

2. (06/10) 4 . 7. 4. Disconnect the ¼″ hydraulic fitting from the base of the transducer after placing an oil catch pan under the unit. section C. 3. Remove the cover from the transducer wiring box and disconnect both leads going to the transducer.25 . 4. Close the manual override levers on the accumulator solenoids for accumulator fail units only. Reconnect the ¼" hydraulic fitting to the base of the transducer. 5.P .4 for more details. .M . Re-wire the transducer into the transducer wiring box. Refer to Appendix .the . Refer to IOM Appendix C. 274 REXA X2 Series TS&R Manual .2 . Turn on electrical power to the unit. Thread the transducer into the transducer wiring box.of .Reassembly 1. 6.IOM for interconnect wiring diagrams. Re-install the transducer wiring box cover. 5.Mechanical Repair TRANSDUCER 3. Turn off electrical power to the unit. Unthread the transducer from the transducer wiring box. Apply thread sealant to the threads on both ends of the transducer.

that . There are some units that will not have hydraulic lines to both of these ports but both ports will be present if it is a reservoir. this .of . Following the hydraulic line from the bottle will lead you to a pressure gauge indicating the pressure in the accumulator bottle.BOTTLE Reservoir .ACCUMULATOR . The accumulator bottle can be identified by having only one hydraulic port located in the end cap as shown in Photo 4.reservoir . An accumulator fail actuator will have both an accumulator and a reservoir bottle.REXA .M.RESERVOIR .M .a . Depending on the system it may have one or two hydraulic lines coming off of the end cap.26-3. CAUTION: . .26 . These are typically painted black and there will be two hydraulic ports side by side on one end cap as shown in Photo 4. Photo 4.repair .psi .fluid .The . Any bottles having only one hydraulic port to the end cap is not a reservoir but is a high pressure fail safe accumulator. .The .typically . .is .pressure . pressure .may .typically .26-3 Hydraulic port Mechanical Repair – 06/10 275 .be . vessel . It is identified by the gray body and stainless indicator rod protruding out one end. psi .repair .must . pressure . The first type is a spring loaded piston cylinder.that .M.during .REXA .BOTTLE 4 .during .2 . ACCUMULATOR . .up .taken .26-2 Accumulator bottle Accumulator .M.have .EXTERNAL .Identification Photo 4.M.be .500 . .Care . Photo 4.X2 Troubleshooting and Repair Manual EXTERNAL .Identification REXA uses piston type accumulator bottles for all the accumulator fail units. The second type of reservoir is a low pressure accumulator bottle.M. .is ./ .pressure .26-1 Piston cylinder REXA uses two types of reservoir bottles depending on the oil volume required for the system.this .have .must . .accumulator .vessel .of . CAUTION: .60 .Care .AND .26-2.a .to .up .taken .RESERVOIR .to . .bottle .may . .fluid .

Disassembly: 1. The reservoir can now be safely removed.C.section . remove the REXA indicator clamp and open the ¼-turn valve on the purge kit.1 .IOM . . 7.section . For accumulator replacement – The bottle can now be safely removed. On most reservoir bottles there will be a ¼-turn isolation valve.BOTTLE 4 . Clamp the reservoir power module indicator. 4.1 ./ . Place an oil catch pan under the bleed kit port. NoTE: Ensure that the high pressure accumulator gauge located on the gauge block reads 0 psi before proceeding. Appendix .6 .Mechanical Repair EXTERNAL . Attach the REXA bleed kit to one of the open purge ports on the power module body. then the unit must be in the fail safe position and the accumulator fail in the trip state. This will allow the system oil to drain. 2.C .26 . Close this isolation valve so that the handle is perpendicular to the valve body.7 for port identification.M . Appendix . (06/10) 3. Close the manual override levers on the accumulator solenoids for accumulator fail units only. Refer to IOM . 9. With the accumulator in the trip state this will drain the accumulator pressure to 0 psi. 276 REXA X2 Series TS&R Manual .4 for more details.F for information on indicator clamping. open the reservoir ¼-turn valves. Open the manual bypass by turning the “Bypass” hex counterclockwise on the power module’s front face. 5. If the unit is an accumulator fail system. Refer to . 6. See TS&R . . Close off the ¼-turn valves going to the reservoir. continue on for reservoir replacement.ACCUMULATOR . 8.RESERVOIR .

ACCUMULATOR .2 . 3.X2 Troubleshooting and Repair Manual EXTERNAL . Mechanical Repair – 06/10 277 .RESERVOIR . 2. Open up all isolating ball valves 4.26 .BOTTLE 4 .6 of the IOM for re-filling the actuator. Replace appropriate bottle. Reference section 1.Reassembly: 1.M . . Remove the bleed assembly./ .

.

X2 Troubleshooting and Repair Manual Appendix A List of Recommended Tools REXA offers three tool kits which provide the needed tools to rebuild power modules. 8 pcs. The kit contains the following: Description Hex Key Set. 9 pcs.# .Kit The standard tool kit is contained in a rugged.Standard . 2 pcs. TK-2. TOOL-0001 TOOL-0002 TOOL-0003 TOOL-0004 TOOL-0005 TOOL-0007 TOOL-0008 TOOL-0009 TOOL-0010 TOOL-0011 TOOL-0012 TOOL-0013 TOOL-0014 TOOL-0015 TOOL-0016 TOOL-0017 TOOL-0018 TOOL-0019 Photo A-1 Tool kit (TK-2) Appendix A – 06/10 A . . Rubber Hammer Mag Lite 2D Flashlight Feeler Gauge Hacksaw with Blade Utility Knife Tool Case Qty 13 pcs 4 pcs. control enclosures and most cylinders: the Standard Tool Kit (TK-2). and the Bleed Kit with Oil Gun (TK-4). 1 1 1 1 1 1 Item . 1 1 3 pcs. high-visibility tool case which features convenient removable pallets and a combinatyion lock for optimal security. 2 pcs.the . Actuator Bleed Kit (K09275) and Oil Gun (S03082) are also available. 7 pcs. Ball End Pick Set Side Cutter/Needle Nose Pliers Stranded Wire Stripper/Cutter Tongue and Groove 12" Channellock Pliers Adjustable Wrench Set Retaining Ring Pliers Nut Driver Set Screw Driver Set Mini Screw Driver Set Combination Wrench Set Strap Wrench Set 2 lb. 2 pcs.Tool . the Tube Bending Kit (TK-3). 1 ea.1 .

# .Kit The bleed kit contains the following: Description Schrader Oil Gun Assembly Bleed Kit Qty 1 1 Item .the . .Kit The tubing kit contains the following: Description ¼" Tube Bender 3 Qty 1 1 1 1 Item . .2 REXA X2 Series TS&R Manual .Bending .the . S03082 K09275 Photo A-3 Bleed Kit (TK-4) A .Appendix A (06/10) TK-3.Bleed .Tube .# TOOL-0020 TOOL-0021 TOOL-0022 TOOL-0023 ⁄ 8" Tube Bender Tube Cutter Tube Deburring Tool Photo A-2 Tube Bending Kit (TK-#) TK-4.

. . No work will be performed without your authorization. B . Call REXA at (508) 584-1199 during regular business hours to get a Returned Materials Authorization Number (RMA#). REXA will determine the failure and cost to repair. .Repair .Street W .02379 Attn: . .Return .. 3. . Ship the actuator to: REXA 4 . A minimum charge for diagnostic evaluation will apply. .Bridgewater.1 .Procedure 1. Returns received without a valid RMA number are not accepted and are returned to sender.X2 Troubleshooting and Repair Manual Appendix B Returning the Actuator for Repair This section contains information on how to return a faulty actuator for repair or replacement. .1 .Dept . 2. Appendix B – 06/10 B . . Note: Do not attempt to return materials or other equipment without a valid RMA number.RMA# . . 4. . REXA is not responsible or liable for damage resulting from improper packaging or shipment.MA .Manley . .

2525 Commission/Installation Date (REXA use only) DATE: SERIAL # SECTIONS  THRU  MUST BE COMPLETED BEFORE AN RMA WILL BE ISSUED. and what actions were taken? Describe the operational conditions at the time.O. 6. Describe what failed…and how. MA 02379 Tel. 3. 4 Manley Street W.584.1199 Fax: 508.# KOSO AMERICA. 2. REP % BC . Electronics: supply voltage_________ Last error: ________ Fb bad _______ Cs bad _______ Stall _______  inside  outside Number of: ________ starts × 1k ______ strokes × 1k ______ Dir error _______ Drv fault _______ *Drive display location *Drive display ______  PROBLEM / FAILURE DESCRIPTION 1. Action Requested:  repair  troubleshoot / advise  refurbish Requested Return Date:______________ Prepared By:____________________________________ Representative:_______________________________________ Notes: 1. A miinimum 2 hour diagnostic charge will apply to all non-warranty evaluations. 2. How was the failure diagnosed? Have there been any recent site shutdown or restarts on the installation or associated equipment? Any normal or special maintenance procedures performed over the life of the unit? What was the reason and when (compared to failure date)? What application/function does the actuator perform? When did the issue first begin? What were the characteristics of this event. Before shipping the unit. 5. Completing this form will ensure a faster and less costly turn around.ELECTRAULIC™ ACTUATION RETURN MATERIALS AUTHORIZATION RETURN SHIPPING VIA: CUSTOMER P. Package the actuator properly and correctly to prevent damage during shipping. 7. make certain that the unit is properly cleaned to prevent injury to factory technicials while unpacking (due to hazardous substances on unit). turn arouond time and cost of order will increase. Bridgewater. 4. KOSO AMERICA is not responsible for damage during shipping. REXA RMA number must appear on all packages.584. Date Received Date Evaluated Date Scheduled  BILLING ADDRESS Company:______________________________________ Address:_______________________________________ _______________________________________________ _______________________________________________ Contact:_______________________________________ Tel:____________________ Fax:___________________ e-mail:_________________________________________  SHIPPING ADDRESS Company:_______________________________________ Address:________________________________________ ________________________________________________ ________________________________________________ Contact:________________________________________ Tel:____________________ Fax:____________________ e-mail:__________________________________________ ENVIRONMENTAL CONDITION: Ambient Temperature_________ Location: control signal__________  ITEM(S) BEING RETURNED  Actuator  Electronics  Other:____________________ Include photo of problem & installation. INC. 4. 8. If unit requires additional cleaning prior to receipt.: 508. Date and time of failure? (Give detailed description(s) to the following questions on a separate sheet of paper and attach to this form to ensure conclusive findings): 5. 3.

Electraulic Actuators & Drives REXA return materIalS authorIZatIon DATE: SERIAL # RETURN SHIPPING VIA: CUSTOMER P. 5. A MINIMUM 4 HOUR LABOR or 2 hour diagnostic charge will apply to all non-warranty repairs. Bridgewater. REXA RMA number must appear on all packages. turn around time and cost of repair will increase.O. MA 02379 Tel: 508•584•1199 Fax: 508•584•2525 WORK ORDER # (for REXA use only) SECTIONS THRU MUST BE COMPLETED BEFORE AN RMA WILL BE ISSUED. KOSO AMERICA is not responsible for damage during shipping. 4. 2.: ________________________________ Electronics: SUPPLY VOLTAGE __________ CONTROL SIGNAL Location: inside outside PROBLEM/FAILURE DESCRIPTION: ACTION REQUESTED: REPAIR TROUBLESHOOT/ADVISE REFURBISH REQUESTED RETURN DATE: _________________ PREPARED BY: _________________________ NOTES: REPRESENTATIVE: ________________________ 1. # Date Received v03 KOSO America 4 Manley Street W. PACKAGE THE ACTUATOR PROPERLY and correctly to prevent damage during shipping. COMPLETING this form will ensure a faster and less costly turn around on repair of the actuator. make certain that the unit is properly cleaned to prevent injury to factory technicians while unpacking (due to hazardous substances on unit). 3. REP % BC . If unit requires additional cleaning prior to repair. BEFORE SHIPPING the actuator. Date Evaluated Date Scheduled BILLING ADDRESS Company: ________________________________ Address: _________________________________ _________________________________________ _________________________________________ Contact: __________________________________ Tel: ________________ Fax: _______________ SHIPPING ADDRESS Company: ________________________________ Address: _________________________________ _________________________________________ _________________________________________ Contact: __________________________________ Tel: ________________ Fax: _______________ e-mail: ___________________________________ e-mail: ___________________________________ ITEM(S) BEING RETURNED ACTUATOR ELECTRONICS OTHER _________________ ENVIRONMENTAL CONDITION: Ambient Temperature _________ ___________ Model No.

.

. . . . . . . . . . . . . . . . . . . .P40 SERVO WITH ACCUMULATOR FAIL OPTION. . . . . . .8 D97904-. . . .1 . . . . . . . . . .X2 Troubleshooting and Repair Manual Appendix C Circuit Schematics D97904 — STEPPER WIRING DIAGRAM . . . . . . . . . . . . .P9 SERVO WITH ACCUMLATOR FAIL OPTION . . . . . . . . . . . . .C. . . . .C.C. . . . . . . .2 D97904-. . . . .10 D97904-2DACC — 2D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . . . . . . . . . . . . . . . . . . .13 Appendix C – 06/10 C . . . . . . . . . . .6 D97904-P40 — D. . . .C. . . . . . .7 D97904-STEPACCUM — STEPPER WITH ACCUMULATOR FAIL OPTION . . . .C. . . . . . . . . . . . . . . . . . . . . . . . . . . . .P40 SERVO WIRING DIAGRAM .9 D97904-DACCUM — D SERVO WITH ACCUMULATOR FAIL OPTION . . . . . . . . C. C. . . . . . . . . . .5 D97904-P9 — D. . . . . . .12 D97904-P40ACC — D. . . . . . . . . . . . . . . . .C. . . . . . . . . . .3 D97904-D — D SERVO WIRING DIAGRAM . . . . . . . . . . . . . .P9 SERVO WIRING DIAGRAM . . . . . . . . .5D — ½D SERVO WIRING DIAGRAM . .C. . . . . . . .4 D97904-2D — 2D SERVO WIRING DIAGRAM . . . . . . . . .C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 D97904-P9ACC — D. C. . . . . .5DACCUM — ½D SERVO WITH ACCUMLATOR FAIL OPTION. . C. . . .

2 D97904 .— .C.WIRING .DIAGRAM .STEPPER . .

WIRING .5D .D97904.SERVO .3 .— .DIAGRAM . C.½D ..

D .— .DIAGRAM .4 D97904-D .C.WIRING .SERVO .

D97904-2D .SERVO .5 .— .DIAGRAM C.WIRING .2D .

C.WIRING .6 D97904-P9 .P9 .SERVO .DIAGRAM .— .D.

D.P40 .— .SERVO .WIRING .D97904-P40 .DIAGRAM C.7 .

WITH .8 D97904-STEPACCUM .FAIL .STEPPER .— .ACCUMULATOR .OPTION .C.

SERVO ..ACCUMULATOR .OPTION C.FAIL .D97904.WITH .— .5DACCUM .½D .9 .

WITH .SERVO .OPTION .FAIL .D .10 D97904-DACCUM .C.ACCUMULATOR .— .

— .SERVO .WITH .11 .D97904-2DACC .2D .OPTION C.ACCUMULATOR .FAIL .

SERVO .OPTION .ACCUMULATOR .C.FAIL .D.WITH .12 D97904-P9ACC .P9 .— .

SERVO .D97904-P40ACC .FAIL .WITH .OPTION C.D.P40 .13 .— .ACCUMULATOR .

.

D. Blue with Blue Pair 4. Pull in a #16 AWG tinned copper drain wire under this tape. 1 twisted triad #16 AWG 19/29 Stranded Tinned Copper 4 Twisted pair.MODULE .SPECIFICATION CABLE TYPE: CONDUCTORS: CABLING: JACKET: FILLER: INSULATION: 4 Twisted pair. Flammability.5 – . O. LABELING: Label PVC jacket with company name and note (Repeat ever 1. Yellow with Yellow Triad RATINGS: Brown and Brown and Green/Yellow 600 volts -20 °C to +105 °C (-4 °F to +220 °F) Passes UL VW-1 flame test Voltage rating.X2 Troubleshooting and Repair Manual Appendix D Cable Specifications X2 . REXA P96191-X2 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIPMENT BY AT LEAST 1 METER APPROX.1 .0').CABLE . Green with Green/Black Pair 3. Red with Red/Black Pair 2. 0. 1 twisted triad. Gray PVC As required Color Coded PVC Pair 1.625" Appendix D – 06/10 D . wrap with an aluminum/mylar tape (foil side in). Temp rating.

Pull in same AWG tinned copper drain wire over this tape. Black Voltage rating. 0. Flammability. Temp rating.D. REXA P96192 ! ATTENTIoN ! – LoW VoLTAGE CABLE – MUST BE SEPARATED FRoM HIGH VoLTAGE CABLES AND HIGH VoLTAGE EQUIPMENT BY AT LEAST 1 METER APPROX.Appendix D (06/10) FEEDBACK . O.SPECIFICATIONS CABLE TYPE: CONDUCTORS: CABLING: JACKET: FILLER: INSULATION: 3 Conductor #18 AWG 16/30 Stranded Tinned Copper 3 Conductors together and wrap with an aluminum/mylar tape (foil side in). White 3. 600 volts -20 °C to +105 °C (-4 °F to +220 °F) Passes UL VW-1 flame test CHARACTERISTICS: LABELING: Label PVC jacket with company name and note (Repeat ever 1. Gray PVC As required Color Coded PVC 1.230 – .250" D .0').CABLE . Red 2.2 REXA X2 Series TS&R Manual .

3 . 600 volts -20 °C to +105 °C (-4 °F to +220 °F) Passes UL VW-1 flame test CHARACTERISTICS: LABELING: Label PVC jacket with company name and note (Repeat ever 1. 0.CABLE . Gray PVC As required Color Coded PVC Blue Blue Green/Yellow Voltage rating.275" Appendix D – 06/10 D . REXA P97981 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE SEPARATED FRoM HIGH SIGNAL LEVEL CABLES AND SENSITIVE EQUIPMENT BY AT LEAST 1 METER APPROX.SPECIFICATIONS CABLE TYPE: CONDUCTORS: CABLING: JACKET: FILLER: INSULATION: 3 Conductor #16 AWG 19/29 Stranded Tinned Copper 3 Conductors pulled in a PVC jacket.D.25 – . Flammability. O.0'). Temp rating.X2 Troubleshooting and Repair Manual SOLENOID .

Flammability.D. 600 volts -20 °C to +105 °C (-4 °F to +220 °F) Passes UL VW-1 flame test CHARACTERISTICS: LABELING: Label PVC jacket with company name and note (Repeat ever 1. REXA P97335 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIPMENT BY AT LEAST 1 METER APPROX.0'). 1 twisted triad #16 AWG 19/29 Stranded Tinned Copper 1 Twisted pair. Temp rating.CABLE . O.45" D . Blue with Blue/Black Triad Black and White and Green/Yellow Voltage rating.4 REXA X2 Series TS&R Manual .SPECIFICATIONS CABLE TYPE: CONDUCTORS: CABLING: JACKET: FILLER: INSULATION: 1 Twisted pair. 0. 1 twisted triad Gray PVC As required Color Coded PVC Pair 1.Appendix D (06/10) HEATER/SOLENOID .4 – 0.

Pull in a #14 (41/30) AWG tinned copper drain wire under this tape.SPECIFICATIONS CABLE TYPE: CONDUCTORS: CABLING: UL type TC (tray cable). 4 conductor. 0. 100% coverage. Orange 2.X2 Troubleshooting and Repair Manual D .PUMP . Blue 3. Green UL type TC Voltage rating.MOTOR . -20 °C to +90 °C (-4 °F to +195 °F) Flammability.5 . 600 volts Temp rating. O.60 – 0.D.61" JACKET: FILLER: INSULATION: CHARACTERISTICS: LABELING: Appendix D – 06/10 D . overall foil shield #14 AWG 41×30 Stranded Tinned Copper 4 Conductors together and wrap with an aluminum/polyester tape (foil side in).CABLE . Gray PVC As required Color Coded PVC / Nylon 1. REXA P96402-14 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIPMENT BY AT LEAST 1 METER APPROX.0'). Passes UL VW-1 flame test Sunlight resistant Direct burial Indoor/outdor use As required by UL for TC type cable Label PVC jacket with company name and note (Repeat ever 1.– . Gray 4.

Gray PVC. 300 volts -30 °C to +105 °C (-22 °F to +220 °F) Temp rating.42" LABELING: D . 100% coverage. twisted pairs. 0. 0. 20 AWG pairs stranded (7/28) tinned copper conductors. Foil Facing OUT with a 22 AWG (7/30) tinned copper DRAIN WIRE pulled over the tape Color Coded PVC. 0. Passes UL VW-1 flame test UL type PLTC Sunlight resistant Direct burial Indoor/outdor use UL File #…20 AWG TYPE PLTC 105 °C 300 V (UL) Label PVC jacket with company name and note. Flammability. 300 volt.016" WALL NOM. Colored PVC insulation.CABLE . 100% coverage. O.6 REXA X2 Series TS&R Manual . 105 °C (220 °F) 4 Twisted Pairs. REXA P98272 ! ATTENTIoN ! – LoW VoLTAGE CABLE – MUST BE SEPARATED FRoM HIGH VoLTAGE CABLES AND EQUIPMENT BY AT LEAST 1 METER APPROX. Indiviually shielded plus an overall foil shield (100% coverage). Foil Facing IN with a 22 AWG (7/30) tinned copper DRAIN WIRE pulled over the tape Outer SHEILDING: INSULATION: JACKET: FILLER: CHARACTERISTICS: ALULMINUM FOIL-Polyester TAPE.D.SPECIFICATIONS CABLE TYPE: Power Limited Tray Cable. As required Voltage rating. PVC Jacket #20 AWG 7/28 Stranded Tinned Copper Conductors. Min 2 twist/inch: Pair 1: Red paired with Black Pair 2: Green paired with Blue Pair 3: Brown paired with White Pair 4: Orange paired with Yellow CONDUCTORS: CABLING: Inner SHEILDING (per pair): ALULMINUM FOIL-Polyester TAPE.053" WALL NOM. PVC Insulation.40 – 0.Appendix D (06/10) RESOLVER .

Thickness Conductor diameter Tolerance: ASSEMBLY: Core Cabling: Filler: Lay direction: Binder: Shield 1 Shield: Drain Wire: 4/C Cable around filler Gray or White fibrillated polypropylene (center) Left Fleece tape (100% coverage.008" Orange.036 0. 37. 60-0600-34. 60-0875-02 0. (continued) Appendix D – 06/10 D . Apperance will worsen with addition of drain wire. 10-0100-14 Pics/Inch.7 . jacket thickness–0. Oil. Green Each conductor covered with clear nylon Clear Nylon. 35% min. PVC. 10-0100-253 PVC 105C. overlap) Aluminum/polyester (100% coverage. Gray.237 .X2 Troubleshooting and Repair Manual P40 . overlap. 4. Blue.25 #34.MOTOR . Ins.009" Shield 2 Type: Material: Required coverage: AWG: JACKET: Material type: Braid Ends.250 (+/-) .060 Note: outer jacket will show evidence of the underlying wire form. Ins. water & sunlight resistant. Thickness: Conductor diameter: Tolerance: Colors: Covering Insulation Type: Nom. foil facing outward) 10 AWG stranded tinned copper (in contact with foil and TC shield (0. 60-0600-34 0. 35% min.D.) Note: Drain wire may be parallel Cable.60 Gray PVC Tube Black. 48 90% minimum coverage Angle. Nom.CABLE .SPECIFICATIONS DESCRIPTION: CONDUCTORS: Wire Size & Type: Insulation Type: Nom.007 0. 8 Tinned copper carriers.120 O. 4/C 8 AWG shielded 8 AWG (7×24/30) tinned copper.

dimensional weight. Bulk Short Reels.Appendix D (06/10) Cable diameter: Tolerance: Print: Legend: Note: O.8 REXA X2 Series TS&R Manual . will increase by 0.D.120" on major diameterl 0. None Ratings: Tests misc.: Test 1: Test 2: Test 3: Approvals: D . Voltage rating of conductors is equivalent to SAB 08610804 (UL)/c(UL) 600v. cable not UL/CSA rated Continuity Put Ups. Wood Physical.028" Ink jet white REXA p/n P97882 ! ATTENTIoN ! – HIGH VoLTAGE CABLE – MUST BE SEPARATED FRoM SIGNAL LEVEL CABLES AND SENSITIVE EQUIPMENT BY AT LEAST 1 METER 105C. UL-AWM: 1000 V. 478 lb/mft UL/CSA.764 (+/-) .

X2 Troubleshooting and Repair Manual Appendix E Parameter Sheet Appendix E – 06/10 E .1 .

CALIBRATE
MAX HI SPEED SIGNAL TYPE DRIVE TYPE RELAY #1 MEM FAIL MEM FAIL

REXA "X2" DATA SHEET
SPEED/ACCEL INPUTS DRIVES OUTPUTS CURRENT STATS HISTORIC STATS

CONTROL

POSITION LOW

DEADBAND

POSITION HIGH

MIN MOD

GAIN

FAILSAFE

STALL TIME

RELAY #2

A/D FAIL

A/D FAIL

Appendix E – 06/10
HI ACCEL TRIP BOOST PUMP POS XMITTER DRIVE FAULT ACCEL BKPT ACCUMULATOR VERSION PRES BD PRES BD LO ACCEL RECHRG PRES SLC FB BAD SLC FB BAD 2 SPEED WARN PRES FB BAD FB BAD MAX LO SPEED MAX UP SPEED RECHRG TIME CS BAD CS BAD SPEED BKPT MAX DN SPEED ACCUM DIR DIRECTION DIRECTION MAX MAN SPEED ACCUM PRES STALL STALL SLC STOP SLC STOP STARTS (X1K) STROKES (X1K)

SIGNAL LOW

BUMPLESS

DRIVE FAULT

SIGNAL HIGH

SURGE BKPT

PULSE DUR

SEAT LD CYL

PULSE INC

FLOW CHAR

CUSTOMER:
STARTS (X1K)

APPL:
STROKES (X1K)

REXA MDL#

REXA SERIAL#

DATE:

LAST ERROR

E .3

SITE CONTACT:

PHONE: (

)

EMAIL:

COMMENTS:

X2 Troubleshooting and Repair Manual

Appendix F Field Service Memo

Appendix F – 06/10

F .1

Electraulic™ Actuators & Drives

Field Service Memo
KOSO AMERICA 4 Manley Street W. Bridgewater, MA 02379 Tel: 508.584.1199 Fax: 508.584.2525

Indicator Clamping
In the past it has been said that for simple maintenance procedures clamping of the aluminum X1 reservoir indicator is recommended to avoid draining of the actuator's oil. This is an acceptable procedure for the X1 power module because the reservoir indicator is aluminum, which will not corrode and also does not pass through any seals. An issue arises when this same procedure is performed on either an X2 power module or any REXA actuator (X1 or X2) with an external auxiliary reservoir. The X2 reservoir indicator should not be clamped as you can damage the stainless finish. The X2 reservoir indicator passes through a seal and damage to the indicators’ finish will result in the seal tearing while the indicator passes in and out. A tear in the indicator seal will allow water and other elements to enter the power module's electrical connection area. A similar issue exists with both X1 and X2 units which utilize an external auxiliary reservoir. The oil level indicator on an external reservoir is chrome plated and equally susceptible to damage. Once the finish on the indicator has been compromised there is a potential for corrosion. To avoid this we continue to recommend that these oil indicators not be clamped and that the oil be drained to complete maintenance and repairs. However, it is our understanding that certain simple procedures become far less time consuming if oil is not drained from the unit. For situations like this we recommend that all possible precautions be taken to ensure the integrity of the oil level indicators’ finish. A simple step must be taken to protect the oil level indicator. For this we recommend use of a rubber hosing to shield the indicator from the teeth of the clamping device. Please observe the photos below depicting this clamping procedure with a pair of vise grips. Following this procedure correctly will prevent the need to drain the oil during simple actuator maintenance or repair and will also adequately protect the finish of the indicator.

FSM/I-C - April 30, 2008

F .3

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