Replacing a Rotork Actuator

Can you provide a link to the document that shows wiring for your new unit?

As you knew drwg no is 3000-550-04 pleas go to this link and download it

http://wiring.rotork.com/wiringdiagram/survey/form/

1) "As you knew"

Please be aware that neither nor anyone else on the forum know anything other than what you tell us.

2) from your post #2: drwg no is 3000-550-04
from your original post: DRWAING No 300-500-04

The link you provide shows a syntax/format XXXX-X-XXX incompatible with either of the numbers you have provided:

3) The listing of Rotork wiring diagrams starting with 3000 does not list anything similar to what you've posted.

4) It isn't clear what sort of communications you are dealing with, multichannel analog, discrete, or a digital communciations protocol. I was hoping to decipher that from your stated wiring, but I can not associate a wiring diagram with the actuator you have.

Existing actuator dwrg no is 200-520-01which not available at rotork web sit may be old version

New actuator dwrg no is 300-500-04

communication i deal with is Modbus communication

hope it clear

I use numbers, 1 or 2, for channels; not the letters A or B, because A and B are conventions used designate separate Modbus wires. And using numbers conforms with Rotork's documentation.

So assume (I still can't find wiring for your model Rotork) that
- ch 1 uses wiring terminals 27, 28
- ch 2 uses wiring terminals 22, 23

1) Do I understand your situation correctly?

- Ch 1 communicates OK. If Ch 1 wiring is disconnected from the Rotork's Ch 1 terminals, communication fails, indicating that fail-over-to-dual-channel-Modbus-communication is not functioning in some aspect.

- if Ch 1 wiring is connected to Rotork Ch 2, communication is established OK, indicating that the Rotork Modbus comm card works OK on both its channels 1 and 2.

- Ch 2 wiring (the wiring from control room master for ch 2) fails to communicate if it is connected to either Rotork channel 1 or 2.

I'm just not sure what this means
>To prove no problem at control room or field wiring actuator from another stream being used and tested okay

Does it mean that you uninstalled the first replacement Rotork acutator, installed a 2nd replacement actuator on the valve/damper and used the same field wiring 'as-is' ? What EXACTLY was tested and how?

Ignoring the 'other stream' test, my conclusion is that something is wrong between the control room Modbus master's ch 2 port and the ch 2 wiring at the first Rotork actuator.

It could be
- mislabeled ch 2 wires, A & B reversed
- Modbus master port for ch 2 is disabled in software/firmware
- bad ch 2 serial port drivers on the master
- bad ch 2 wiring connection somewhere along the link path
- bad ch 2 RS-232/485 converter at the master
- Ch 2 wiring break/open circuit somewhere along the path
- Ch 2 terminated accidentally or incorrectly somewhere along the serial link, (terminate only at the link ends)

Is this the only actuator on the link? Do other actuators perform properly on both channels?

Can you temporarily lift/remove Ch 1 wiring on another acuator to see if Ch 2 is active, working and functional?

Should termination be enabled on this actuator? Is at the end of a multi-drop link?
quote: "Linking the Terminator terminal to data line B completes the connection to place the resistor across the data lines." (Pg 17 pdf Publication S175E V2.4 Issue 07/04)

Apparently the dual highway option requires a jumper setting (page 20 of Publication S175E V2.4 Issue 07/04): Fig 12: Jumper Settings for Dual Highway Option, but I suspect that the jumpers are set properly since both channels work when provided Modbus commands over functioning cable, but I'm not a Rotork guy and I'm not sure what the jumpers enable or disable.

2) >The question is this type replacement for the existing type.

I can't help you on this.

Another things need to clarify to you, ch1 not 100% communicating i.e. its only send status of the valve to control room ,opening or closing the valve from control room cant perform

i.e. faile to do so

Ch2 can't send valve status to c/room nor command to valve for opening /closing

I'm just not sure what this means
>To prove no problem at control room or field wiring actuator from another stream being used and tested okay

Meaning to say I uninstalled the first replacement Rotork actuator and I brought same type of existing actuator (old version) and its working fine (Valve open and close remotely)

Is this the only actuator on the link? Do other actuators perform properly on both channels

Yes

If you did a "swap-test" and replaced the old actuator with an identical unit and the replacement works OK, then the Modbus communications between the control room and the actuator works on at least one of the two channels.

This 'swap-test' tells you that something is different between the new replacement unit and an identical 'old' actuator, right? Which is why you originally asked whether the replacement is the correct model to replace the existing acuator. Hmmm.

You say that certain functions on the replacement actuator work - "status" condition is properly read by the control room; but that other functions - commands to open or close, do not work.

Is Modbus the only communication between the actuator and control room? Are the status functions read by Modbus or are there additional discrete control or indicator points between the actuator and control room?

If Modbus is the only control wiring (no other discrete or analog wiring), then it is apparent that the replacement actuator works differently than the original.

It's possible that the Modbus registers or word format were changed from one generation actuator to another. I saw 2 Modbus manuals on the Rotork site, that might mean that there's two generations of Modbus.

I'm glad to help when I can on Modbus comm issues, but spec'ing replacement actuators or troubleshooting poorly spec'd devices is too much like day job work, which I'm not up for.

I suggest you contact whomever spec'd the replacement actuator and ask them what the differences are between your old and new actuators and why you're seeing the comm problems and what you can do to solve it.

And if that's a dead end, then try the Rotork support.